A163/A251/A252 SERVICE MANUAL

RICOH GROUP COMPANIES

PN: RCFM0740

A163/A251/A252
SERVICE MANUAL

RICOH GROUP COMPANIES

A163 FIELD SERVICE MANUAL

PN: RCFM0740

WARNING
The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property. or loss of warranty protection.
Ricoh Corporation

LEGEND
PRODUCT CODE A163 A251 A252 GESTETNER N/A N/A N/A COMPANY RICOH FW740 FW750 FW760 SAVIN N/A N/A N/A

DOCUMENTATION HISTORY
REV. NO. * 1 2 3 DATE 12/94 5/95 5/96 6/98 COMMENTS Original Printing Revised Pages Reprint A251/A252 Addition

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 and the peripherals 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. 6. The copier is not attached to the table. Pushing the copier too hard may cause it to drop onto the floor. While moving the copier, push the table. 7. When the main switch is turned on, the machine will suddenly start turnig to perform the developer initialization. Keep hands away from any mechanical and electrical components during this period.

HEALTH SAFETY CONDITIONS

1. Never operate the copier without the ozone filters installed. 2. Always replace the ozone filters with the specified ones at the specified intervals. 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. Caution: The RAM pack on the main control board has a lithium battery which can explode if replaced incorrectly. Replace the RAM pack only with an identical one. The manufacturer recommends replacing the entire RAM pack. Do not recharge or burn this battery. Used RAM packs 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 RAM packs in order to dispose of them later, do not put more than 100 RAM packs per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

Table of Contents
OVERALL MACHINE INFORMATION
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

COMPONENT LAYOUT AND DESCRIPTIONS

1. PAPER PATH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2. DRUM PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 3. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 2-4 4. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 5. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . 2-7

INSTALLATION
1. ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.1 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 1.2 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 1.3 POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1.4 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 1.5 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 1.6 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

SERVICE TABLES
1. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . 4-1
1.1 PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1.2 REGULAR PM PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

2. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

2.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 2.2 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

3. SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

3.1 SERVICE PROGRAM MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 3.1.1 Service Program Mode Access Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-8 3.1.2 Service Program Mode Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 3.2 INPUT/OUTPUT CHECK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 FSM i A163

Rev. 9/27/96 3.2.1 INPUT/OUTPUT CHECK MODE ACCESS PROCEDURE . . . . . . . . . . 4-27 3.2.2 INPUT CHECK MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 3.2.3 OUTPUT CHECK MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 3.3 POWER ON INITIAL SETTING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4. JAM CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4.1 ACCESS PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 4.2 JAM CODE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

5. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . 4-33 6. SERVICE REMARKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

6.1 DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 6.1.1 Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 6.2 CHARGE CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 6.3 OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 6.4 DEVELOPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 6.5 TRANSFER AND SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 6.6 CLEANING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 6.7 FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 6.7A PRESSURE ROLLER EVALUATION PROCEDURE . . . . . . . . . . . . . . . . . 4-38 6.8 ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 6.9 PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 6.10 ROLL FEEDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 6.11 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

REPLACEMENT AND ADJUSTMENT

1. EXTERIOR COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
1.1 LEFT SIDE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1.1.1 Left Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1.1.2 Left Lower Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1.2 RIGHT SIDE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1.2.1 Right Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1.2.2 Right Lower Front, Right Lower Middle, and Right Lower Rear Covers . . 5-1 1.3 REAR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1.3.1 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
2.1 ORIGINAL FEED UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 A163 ii FSM

2.2 EXPOSURE GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 2.3 EXPOSURE LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 2.4 FIBER OPTICS ARRAY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 2.5 LIGHT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

3. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
3.1 DEVELOPMENT UNIT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 3.2 DEVELOPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 3.3 TONER DENSITY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 5-9 3.4 PTL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 3.5 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 5-11 3.5.1 Bias Voltage for Image Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 3.5.2 Bias Voltage for Non-image Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

4. DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

4.1 DRUM UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 4.2 DRUM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 4.3 CLEANING BLADE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

4.4 CHARGE CORONA UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 4.5 CHARGE CORONA WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 4.6 PICK-OFF PAWL UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 4.7 GRID VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 4.8 DRUM CURRENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 4.8.1 Charge Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 4.8.2 Transfer Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 4.8.3 Separation Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5. FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.1 FUSING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.2 HOT ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.3 PRESSURE ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 5.4 PRESSURE ROLLER THERMISTOR REPLACEMENT . . . . . . . . . . . . . . . . 5-30 5.5 PRESSURE ROLLER STRIPPER UNIT REPLACEMENT . . . . . . . . . . . . . . 5-30 5.6 HOT ROLLER STRIPPER UNIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . 5-30 5.7 HOT ROLLER THERMISTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 5-31 5.8 FUSING THERMOFUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 5.9 FUSING TEMPERATURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

6. T & S CORONA UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

FSM iii A163

6.1 T & S CORONA UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 6.2 TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT . . . . . . 5-34 6.2.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 6.2.2 Separation Corona Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 6.2.3 Transfer Corona Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

7. OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
7.1 OZONE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 7.2 ANTICONDENSATION HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . 5-37

8. COPY QUALITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

8.1 LIGHT SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 8.2 IMAGE BIAS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 8.3 TONER DENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 8.4 REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

TROUBLESHOOTING
1. COPY QUALITY TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 6-1
1.1 LOW IMAGE DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 1.2 UNEVEN COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 1.3 DIRTY BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 1.4 BLACK LINE OR BAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 1.5 ENTIRELY BLANK COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 1.6 PAPER CREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

2. SERVICE CALL CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

2.1 SC Code E-1: Exposure Lamp Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 2.2 SC Code E-2: Fusing Thermofuse Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 2.3 SC Code E-3: Hot Roller Thermistor Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 2.4 SC Code E-4: Hot Roller Thermistor Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 2.5 SC Code E-5: Pressure Roller Thermistor Open . . . . . . . . . . . . . . . . . . . . . . . 6-8 2.6 SC Code E-6: Pressure Roller Thermistor Short . . . . . . . . . . . . . . . . . . . . . . . 6-9 2.7 SC Code E-7: Fusing Overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 2.8 SC Code E-8: Fusing Warm-up Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 2.9 SC Code E-9: Toner Density Sensor Abnormal . . . . . . . . . . . . . . . . . . . . . . . 6-10 2.10 SC Code E-10: Main Motor Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 2.11 SC Code E-11: Toner Density Sensor adjustment Error . . . . . . . . . . . . . . . 6-11

A163

iv

FSM

3. BLOWN FUSE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

3.1 POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

ROLL FEEDER
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 2. MECHANICAL COMPONENT AND DRIVE LAYOUT . . . . . . . . . 7-2 3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . 7-3 4. MECHANICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
4.1 BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 4.2 CUTTER UNIT OPENING AND CLOSING MECHANISM . . . . . . . . . . . . . . . 7-6 4.3 CUTTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

5. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

5.1 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 5.2 BLOWN FUSE CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

6. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 7. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 7-16

7.1 EXTERIOR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 7.1.1 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 7.1.2 Left and Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 7.2 CUTTER UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 7.3 PAPER FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 7.4 PAPER FEED MOTOR TIMING BELT TENSION ADJUSTMENT . . . . . . . . 7-19 7.5 CUT LENGTH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 7.5.1 Preset Cut : Adjustment standards: 3 mm (for length shorter than 420 mm) 5 mm (for 420 to 1189 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 7.6 ROLL FEED PAPER SKEW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 7-21

FSM

A163

OVERALL MACHINE INFORMATION

Rev. 12/22/95

1. SPECIFICATIONS
Configuration: Copy Process: Original Feed: Original Size: Copy Size: Copying Speed: First Copy: Warm-up Time: Multi-Copy: Automatic Reset: Photoconductor: Drum Charge: Reproduction Ratio: Exposure System: Table top Electrostatic transfer system Sheet feed Maximum: 914 x 2,000 (36" x 80")mm Minimum: A4 (81/2" x 11") lengthwise Same as "Original Size" 3 cpm (A1/D sideways) 24 seconds (A1/D sideways) Within 5 minutes (Room temperature 23oC) 1 to 1 only 2 minutes after copying is finished (can be set to 1, 3, 4, or 5 minutes or to no auto reset) Organic photoconductor drum Single-wire with grid plate (Negative Charge) 1 : 1 (0.5%) Slit exposure via fiber optic array Fluorescent lamp (26 W) Dual-component dry toner system (Type 410, 2 bags) Cartridge system (750g toner/cartridge) 1,860 A1 or D copies per cartridge (6% original) Negative Direct toner density detection by induction sensor Development bias control + exposure control Dual wire ac corona and pick-off pawls Cleaning blade

Exposure Lamp: Development: Toner Replenishment: Toner Consumption: Development Bias: Toner Density Control: Image Density Adjustment: Paper Separation: Cleaning:

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Paper Feeding: Image Fusing: Fusing Lamp: Self-diagnostic Codes: Power Source:

Manual feed (roll feeder optional) Heat and pressure type, teflon (upper) and silicone rubber (lower) rollers Nichrome wire lamp (115 V: 1,100 W, 230 V: 1,100 W) 11 codes, displayed in copy counter 115 V/60 Hz....15 A 220 V/50 Hz....7 A 230 V/50Hz.....7 A 240 V/50 Hz....7 A Maximum: Warm-up: Ready: Copy cycle: 1.4 kW 1.2 kW 0.04 to 1.2 kW 1.3 kW

Power Consumption:

Dimensions (W x D x H): Weight:

1,080 x 570 x 490 mm 42.1" x 22.2" x 19.1" 76 kg, 167.4 lb

Optional Equipment and Machine Configuration Configuration Optional equipment Roll feeder (A571) Roll cutting rail (A570) Side guides (A569) Additional equipment Table (A714) ---

Main frame A163 copier

Other Optional Equipment

Paper Spool Drum anti-condensation heater

Specifications are subject to change without notice.

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COMPONENT LAYOUT AND DESCRIPTION

1. PAPER PATH

D E A

A: Original Path B: Paper from the manual feed C: Paper from the roller feed D: Paper exit E: Original Path from Rear Feeder

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2. DRUM PROCESSES
2

1 8

1. Charge In the dark the charge corona unit applies a negative charge to the drum. The grid wire ensures the charge is applied uniformly. The charge remains on the surface of the drum because the photoconductive drum has a high electrical resistance in the dark. 2. Exposure High intensity light from a fluorescent lamp is reflected from the moving original through the fiber optic array. The charge on the drum surface is dissipated in direct proportion to the intensity of the reflected light, thus producing an electric latent image on the drum surface.

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3. Development The magnetic developer brush on the development roller comes in contact with the latent image on the drum surface. Toner particles are electrostatically attracted to the negatively charged latent image areas. 4. Pre-Transfer Lamp The pre-transfer lamp (PTL) illuminates the drum prior to image transfer. This reduces the attraction between the toner and the drum, thus making image transfer easier. 5. Image Transfer Copy paper is fed to the drum surface, at the exact timing, to align the copy paper and the developed image on the drum surface. Then a strong negative charge is applied to the back side of the paper. The negative charge pulls the toner particles from the drum surface onto the paper. 6. Paper Separation A strong ac corona discharge is applied to the back side of the copy paper, reducing the charge on the paper and breaking the electrostatic attraction between the paper and the drum. Then, the stiffness of the copy paper causes it to separate from the drum. The pick-off pawls help to separate paper which has low stiffness. 7. Cleaning The cleaning blade, which is angled against drum rotation (counter blade system), removes any toner remaining on the drum surface. 8. Quenching The light from the quenching lamp electrically neutralizes the surface of the drum.

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3. MECHANICAL COMPONENT LAYOUT

22 21

23 24 25

20 19 18 17 16 15 4 5 6 7 8 9 10 14 11

13 12

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1. 1st Original Feed Roller 2. 1st Press Rollers 3. Copy Tray 4. Exit Rollers 5. Fusing Exit Rollers 6. Hot Roller 7. Pressure Roller 8. Gas Spring 9. OPC Drum 10. T/S Corona Unit 11. Main Drive Unit 12. Table 13. Paper Spool

14. Roll Feeder 15. Paper Registration Rollers 16. Development Unit 17. Toner Cartridge 18. Manual Feed Table 19. Charge Corona Unit 20. 2nd Original Feed Roller 21. Original Table 22. 2nd Press Rollers 23. Exposure Lamp 24. Fiber Optic Array 25. Cleaning Blade

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4. DRIVE LAYOU T

11

12 13

15 14

16

10

5 6

1. Original Feed Roller Pulley 2. Original Feed Roller One Way Pully 3. Development Unit 4. Development Unit Relay Gear 5. Development Drive Chain 6. Paper Registration Roller Clutch 7. Drum Drive Relay Gear 8. Main Motor

9. Fusing Drive Chain 10. Exit Unit Drive Belt 11. Hot Roller Drive Gear 12. Fusing Drive Sprocket/Gear 13. Toner Collection Coil Drive Gear 14. Drum Drive Gear 15. Original Feed Drive Pulley 16. Original Feed Drive Belt

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5. ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper) index numbers. Name Motors Main Exhaust Fan Function Drives all mechanical components except the fans. (DC Motor) Removes the ozone built up around the drum section to the ozone filter. (DC Motor) Index. No.

32 5

Magnetic Clutches Registration Toner Suppl y Solenoids Pick-off Paw l Switches Main Original & Paper Feed Safety Fusing Exit Safety Sensors Door Open Toner Densit y Original Registration Light Entrance Fee d Indicates "Door Open" in the operation panel and prohibits the key operation. Detects the density of toner in the developer. Detects when the original lead edge passes at the front of the exposure glass. Detects the intensity of the exposure lamp output. Detects when copy paper is inserted (jam detector). 29 26 4 27 Supplies power to the copier. Cuts ac power when the original or paper feed unit is opened. Cuts ac power when the fusing exit unit is opened. 17 18 12 Moves the pick-off pawls against the drum. 6 Drives the registration rollers. Turns on to supply toner to the development unit. 30 31

24

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Name Registration Exit

Function Detects when copy paper arrives at the registration rollers (jam detector). Detects jams through the fusing exit unit.

Index. No. 25 7

Printed Circuit Boards Main PSU AC Drive FL Regulator Operation Panel Lamps Exposure Fusing Pre-Transfer (PTL) Quenching (QL) Provides light to reflect the originals image onto the drum (fluorescent lamp). Provides heat to the fusing unit. Reduces the charge on the drum surface prior to image transfer. Neutralizes any charge remaining on the drum surface after cleaning. 2 3 20 1 Controls all copier functions both directly and through other PCBs. Converts the ac voltage to dc voltage. Provides ac power to the fusing lamp and PSU. Stabilizes power to the exposure lamp. Control the operation panel display. 22 21 15 23 10

Power Packs Charge/Bias/Grid Provides high voltage power for the charge Power Pack corona, charge grid, and development bias. Transfer/ Separation Thermistors Hot Roller Pressure Rolle r Monitors the hot rollers surface temperature. Monitors the pressure rollers surface temperature. 8 11 Provides high voltage power for the transfer corona and separation. 19 16

Thermofuses Fusing Protects against fusing overheat. 9

Heaters
FSM 2-8 A163

Name Function Anticondensatio n Keeps moisture from forming inside the copier (option). Others Total Counter Circuit Breaker (Europe, Asia)/ Fuse (U.S.A.) Keeps track of the total length of copies made (Europe) or the total copies made (U.S.A.). Guards against voltage surges in the input power.

Index. No. 13

28

14

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INSTALLATION

1. ENVIRONMENT
1. Temperature Range: 2. Humidity Range: 3. Ambient Illumination: 4. Ventilation: 15oC to 30 oC (59 oF to 86 oF) 20% to 80% RH Less than 1,500 Lux (do not expose to direct sunlight). Minimum space 20 m 3 Room air should turn over at least 30 m3/hr/person. Less than 0.15 mg/m 3 (4 x 10 -3 oz/yd 3)

5. Ambient Dust:

6. If the installation place is air-conditioned or heated, place the machine as follows: a) Where it will not be subjected to sudden temperature changes from low to high, or vice versa. b) Where it will not be directly exposed to cool air from an air conditioner in the summer. c) Where it will be directly exposed to reflected heat from a space heater in the winter. 7. Avoid placing the machine in an area filled with corrosive gases. 8. Avoid any area higher than 2,000 m (6,500 ft) above sea level. 9. Place the machine on a strong and level base. 10. Avoid any area where the machine may be subjected to frequent strong vibration.

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1.1 MINIMUM SPACE REQUIREMENTS

Back 600 mm

Left 600 mm Front 1000 mm

Right 600 mm

1. Front: 2. Back: 3. Right: 4. Left:

1,000 mm (39 in) 600 mm (24 in) 600 mm (24 in) 600 mm (24 in)

1.2 MACHINE LEVEL

1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level Make sure that the machine is level using a carpenters level.

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1.3 POWER SOURCE

1. Input Voltage Level: 115 V/60 Hz More than 15 A (for U.S.A. version) 220 V/230 V/240 V/50 Hz More than 7 A (for European version) 2. Permissible Voltage Fluctuation: 3. Do not set anything on the power cord. NOTE: a) Make sure the plug is firmly inserted in the outlet. b) Avoid multi-wiring.
10%

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1.4 INSTALLATION PROCEDURE

Copier Check the accessories and their quantities according to the following list: Guide Wire ............................................................ . 2 pcs Copy Tray .............................................................. . 1 pc Copy Guide ........................................................... . 1 pc

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[D]

[B]

[E] [C]

[E]

[A]

1. Lower the feet [A] so that the table does not move while the copier is being installed on the table. 2. Place the copier [B] on the table [C] (Place the copier feet [D] into the table holes [E]). Warning: The copier is not attached to the table. Pushing the copier too hard may cause it to drop onto the floor. While moving the copier, push the table.

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Rev. 5/95

[A]

[C]

[B]

[D] [E] 3. Open the paper path section [A] and remove two strips of shipping tape [B]. 4. Remove the right upper cover [C] (2 screws). 5. Remove the drum protection sheet [D], and remove the screw [E] to apply cleaning blade pressure to the drum. Remove paper from transport section. Close the paper path section.

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Rev. 5/95

[A]

[E] [C] [B]

[D]

6. Open the original feed unit [A], manual feed table [B], and toner supply cover [C]. Remove a sheet [D] covering the developer entrance. Pour 1 kg of the developer [E] into the development unit evenly across its width as shown, then close all doors. 7. Plug in the power supply cord and turn on the main switch.

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Rev. 5/95

[D]

[B]

[A]

[C]

[E] NOTE: If the fusing temperature is lower than 60 C when the main switch is turned on, the main motor will rotate. In this case, it is not necessary to access the SP mode when loading the second Kg of developer (in step 11). Turn off the main switch to stop the main motor after the developer is loaded from the development entrance. 8. Press the following keys on the operation panel: Clear Mode key [A] + key [B] + key Clear/Stop key [C] 9. Press the Clear/Stop key again for longer than 3 seconds. The wrench and toner end indicators will blink (SP INPUT/OUTPUT mode). 10. Select 23 using the + key [D] and press the RF Select key [E]. The main motor will rotate. 11. Press the RF Select key to stop the main motor after the developer is loaded from the development entrance. Pour in another kg of developer into the development unit evenly across its width (Total: 2 Kg). Press the Clear Modes/Stand by key 3 times to leave the SP mode.

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Rev. 5/95

[C]

[B]

[A]

[D]

[E]

[F]

12. Press the following keys on the operation panel: Clear key [A] + key [B] --key [C] Clear/Stop key [D] 13. Press the Clear/Stop key again for longer than 3 seconds. The roll paper end and call service indicators will blink (SP mode). 14. Select 36 using the + and - keys. Enter "1" by pressing the following keys. Function Select key [E] + key RF Select key [F] Five minutes later, the copier will automatically return to the normal operating mode from SP mode. (New developer initialization)

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[A]

[B]

[C]

15. Install the toner cartridge [A] as shown. 16. Remove the sealing tape [B] from the cartridge and turn the knob [C] until it stops.

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[A] [C] [B]

17. Attach the guide wires [A] to the copy tray [B]. 18. Install the copy tray [B] and copy guide [C]. 19. Reinstall all the covers. 20. Check the copy quality and copier operation.

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1.5 INSTALLATION PROCEDURE

Table Check the accessories and their quantities according to the following list: Top Plate ................................................................ 1 Left Side Plat e ........................................................ 1 Right Side Plat e ..................................................... 1 Middle Plate ........................................................... 1 Rear Cover ............................................................. 1 Screws with Spring Washer - M4x 8 ...................... . 14

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[E]

[D] [H]

[C]

[A] [G] [E]

[C] [A] [A] A, B [F] [A]

[D] [B]

[A]

NOTE: To ensure grounding, paint has been removed from the surfaces around the screw holes [A] (only from the surfaces where the two components meet) and from the surface around the screw hole [B] at the inside of the left plate. 1. Temporarily install the top plate [C], left [D], and right side plate [E] (6 screws). 2. Turn the table up-side down in the direction of A. 3. Install the middle plate [F] and rear cover [G] (4 screws each). 4. Tighten all the screws until the spring washers [H] of screws are flattened. 5. Flip the table the correct way.

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1.6 INSTALLATION PROCEDURE

Roll Cutting Rail Check the accessories and their quantities according to the following list: Cutter Guide .......................................................... . 1 pc Cutter Knife ........................................................... . 1 pc Roll Paper Ar m ...................................................... . 2 pcs Roll Paper Shaf t .................................................... . 1 pc Roll Shaft Holde r ................................................... . 2 pcs Roll Flange ............................................................ . 2 pcs

[A]

[B] [A] [B]

1. Remove the small caps [A] from the lower front cover. 2. Attach the roll shaft holders [B] as shown.

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[J] [G] [K]

[A]

[C] [E] [B] [H] [A] [G]

[D] [C] [F]

[H] [I]

[I]

3. Attach the roll paper arms [A] to the cutter guide [B]. (Install each arm pin [C] into each cutter guide hole [D]. Position the cutter guide pin [E] in the lower slot of the roll paper arm [F].) 4. Install the cutter guide on the roll shaft holder [G]. 5. Slide the roll paper shaft [H] into the roll paper. 6. Fit the roll flanges [I] onto the roll paper shaft (both ends). 7. Push the roll flanges [I] inside to fix the roll paper position. 8. Set the roll paper shaft on the roll shaft holder. 9. Set the paper between the cutter guide stay [J] and slide shafts [K]. 10. Check the roll cutting rail operation.

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SERVICE TABLES

1.
1.1

PREVENTIVE MAINTENANCE SCHEDULE

PM TABLE
Symbol key: I=Inspect L=Lubricate R=Replace A=Adjust C=Clean
EM 2.1KM (3.6K) ( 4.3KM 6.4KM 8.6KM (7.2K) (10.8K) (14.4K) ) A1 sideways/D size 10.8KM (18K)

Notes

A. Original Feed 1 First original feed roller 2 Second original feed roller 3 1st and 2nd press rollers 4 Original table B. Optics 1 Fiber optics array 2 Exposure lamp I C

C C C C I C

C C C C I C

Alcohol Alcohol

Alcohol Alcohol Clean with lens paper if necessary Clean using water if necessary Water or alcohol Alcohol Replace at 20K (A1 sideways/ D size) Clean using a dry cloth if necessary Clean using a dry cloth if necessary Clean at 60K (A1 sideways/ D size)

3 Exposure glass 4 Reflection plate C. Development 1 Developer

C C

C C

C C

C C

C C

C C

2 Cartridge holder 3 Entrance seal

4 Development filter

D. Around drum 1 Corona wires 2 Grid wires 3 Charge corona end blocks and casing 4 Pre-transfer lamp C C C C C C C C C C C Clean using blower brush if necessary R C Dry cloth Dry cloth Dry cloth

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EM

2.1KM (3.6K) ( C C C

4.3KM 6.4KM 8.6KM (7.2K) (10.8K) (14.4K) ) A1 sideways/D size C C C C C C C C C

10.8KM (18K)

Notes Dry cloth Dry cloth

5 T/S corona wires 6 T/S corona end blocks and casing 7 Pick-off pawls 8 Quenching Lamp E. Cleaning 1 Cleaning blade

R C C

Dry cloth Clean using blower brush if necessary Replace at 20K (A1 sideways/ D size) Replace if damaged Empty used toner

I 2 Cleaning seal 3 Toner tank

I I

I I

I I

I I

I I

F. Paper Feed 1 Registration roller 2 Paper feed guide plate 3 Manual feed table G. Fusing 1 Hot roller

C C C

C C C

C C C

C C C

C C C

Water Water Water

2 Pressure roller

3 Thermistors 4 Hot roller strippers 5 Pressure roller stripper 6 Entrance guide plate

C C C C C C C

7 Exit turn guide

Replace at 48K (A1 sideways/ D size) Replace at 60K (A1 sideways/ D size) Clean using suitable solvent Clean using suitable solvent Clean using suitable solvent Clean using suitable solvent if necessary Clean using alcohol

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EM

2.1KM (3.6K) (

4.3KM 6.4KM 8.6KM (7.2K) (10.8K) (14.4K) ) A1 sideways/D size

10.8KM (18K)

Notes Clean using suitable solvent if necessary

8 Exit guide plate

Others 1 Chain I 2 Gears I 3 Ozone filter F. Roll Feeder 1 Feed Roller R I R I R I R I R I I I I Lubricate with G501 if necessary Lubricate with G501 if necessary

Alcohol

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1.2

REGULAR PM PROCEDUR E

1. Make a copy

Make a copy of OS-A1 chart.

2. Original Feed (every 3.6K)

Clean the original table using alcohol. Inspect the 1st and 2nd press rollers. If they are dirty, clean them using alcohol.

Original Feed (every 7.2K)

1. Clean the first and second original feed rollers using alcohol. 2. Clean the first and second press rollers using alcohol.

3. Optics (every 3.6K)

1. Clean the reflection plate using alcohol.

2. Clean the exposure glass using water. 3. Clean the exposure lamp using water if necessary. 4. Clean the fiber optics array using lens paper if necessary.

4. Around Drum (every 3.6K)

NOTE: After removing the drum, wrap it in clear sheets of paper to protect it. 1. Clean the charge corona wire, T& S corona wires and grid wires using a dry cloth. (Do not expand the corona wires.) 2. Clean the T/S corona end blocks, casing using a dry cloth. 3. Clean the pick-off pawls using a dry cloth. 4. Clean the pre-transfer lamp if it is dirty. 5. Clean the quenching lamp if it is dirty.

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Around Drum (every 7.2K)

Clean the charge corona end blocks and casing.

Around Drum (every 18K)

Replace the charge corona wires and T/S corona wires.

5. Cleaning Unit (every 3.6K)

1. Inspect the cleaning blade. Replace it, if it is damaged. 2. Inspect the cleaning seal. Replace it, if it is damaged.

Cleaning Unit (every 20K)

Replace the cleaning blade.

6. Development Unit (every 3.6K)

1. Clean the cartridge holder using a dry cloth if it is dirty. 2. Clean the entrance seal using a dry cloth if it is dirty.

Development Unit (every 30K)

Replace the developer.

Development Unit (every 60K)

Clean the development filter.

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7. Paper Feed (every 3.6K)

1. Clean the registration roller using water.

2. Clean the paper feed guide plates using water. 3. Clean the manual table using water.

8. Fusing Unit (every 3.6K)

Clean the small separation rollers using suitable solvent.

Fusing Unit (every 6.4K)

1. Clean the fusing thermistors using suitable solvent. 2. Clean the hot roller strippers using suitable solvent.

Fusing Unit (every 48K)

Replace the hot roller.

9. Others (every 3.6K)

1. Inspect the drive chain. Lubricate using G501 if necessary. 2. Inspect the drive gears. Lubricate using G501 if necessary. 3. Replace the ozone filter.

10. Roll Feeder (every 3.6K)

1. Clean the feed roller using alcohol.

11. Copy Quality.

1. Check the copy quality. 2. Perform the light sensor adjustment.

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2.
2.1

SERVICE TABLES
TEST POINTS
Function VAA (+24V) Vcc (+5V) GND Toner density sensor (CN104-A10) Light sensor output (CN104-B1)

Main Board
Number TP101 TP102 TP103 TP104 TP105

Charge/Bias/Grid Power Pack

Number TP1 TP2 Function Development Bias Voltage Grid Voltage

2.2

VARIABLE RESISTORS
Function Charge Corona Voltage

Charge/Bias/Grid Power Pack

Number VR1

Caution: VR1 should not be changed in the field. Charge corona can be adjusted using SP #--10.

T&S Power Pack

Number Function VRT Transfer Corona Voltage VRD (DC) Separation Corona Voltage (DC) VRD (AC) Separation Corona Voltage (AC)

Caution: VRT, VRD (DC), and VRD (AC) should not be changed in the field. They can be adjusted using SP # --12 to --17.

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3.
3.1

SERVICE TOOLS
SERVICE PROGRAM MODE

The service program (SP) mode is used to check electrical data, change mode or adjustment values. 3.1.1 Service Program Mode Access Procedure How to access the SP mode for service representatives (All service program modes can be accessed with this procedure.) Press the following keys in sequence. key is pressed, hold it down for more than 3 indicators blink).

The second time that th e seconds (until th e and

How to access the SP mode for customers and sales representatives modes 1 to 35 are accessible by a customer with this procedure.) Press and key then hold dow n indicators blink).

(SP

key more than 3 seconds (until the

How to leave the SP mode Press the following keys in sequence

or turn off the main switch. NOTE: Each of the above procedure must be finished within 20 seconds. How to select the program number The program number can be selected by th e and keys. The selected program number is displayed in the lead edge erase indicator (the two digit indicator beside th e mark). To select the program number quickly, hold dow n or key.

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How to change settings 1. Access the SP mode and select the program number. 2. Press the key to select the paper length indicator (the four digit indicator beside th e mark). 3. The present setting is displayed in the paper length indicator. 4. Select the setting using th e key to enter the selected setting. 5. Leave the SP mode. How to read data 1. Access the SP mode and select the program number. 2. Press the key and select the paper length indicator (the four digit indicator beside th e mark). 3. Press the 4. Press key, then the paper length indicator shows the data. key again to stop displaying the data. and keys, then press the

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3.1.2 Service Program Mode Table 1: A "*" before the mode number means that the mode can be accessed by custormers or sales representative. 2: In the data colum, the default value is printed in bold letters. The default settings for several items depend on the machine destination (refer to page 4-26.).

Mode No. Fusing Temperature 1 (Normal) *1

Function Selects the fusing temperature for plain paper.

*2

Fusing Temperature 2 (High) Fusing Temperature 3 (Low) Copy Count Up/Down Beeper On/Off

*3

*4

Data 0: Mode 1 1: Mode 2 2: Mode 3 3: Mode 4 4: Mode 5 5: Mode 6 6: Mode 7 Selects the fusing temperature for translucent 0: Mode 5 paper. 1: Mode 6 2: Mode 7 3: Mode 8 Selects the fusing temperature for translucent 0: Mode 2 film. 1: Mode 3 2: Mode 4 3: Mode 5 Selects the copy count amount up or down. 0: Up 1: Down Selects if the beeper sounds or not. 0: On 1: Off 2: Only when the edge margin or paper length is changed continuously, the beeper is off. 0: 2 minutes 1: 1 minute 2: 3 minutes 3: 4 minutes 4: 5 minutes

*5

*6

Paper Feed Out Waiting Time Setting

Selects the time to when the paper is automatically fed out after it has been set on the manual table, or after the Roll Feed Select key is pressed.

*7

Manual Feed Start Selects the time to when the registration 0: 2 seconds Time Setting roller starts rotating after the entrance sensor 1: 0.7 second detects the paper leading edge. 2: 1 second 3: 3 seconds 4: 4 seconds 5: 5 seconds

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Rev. 1/26/96 Mode No. Function Data Count up/down at To change the leading edge margin (print Leading Edge every: Increase/Decrease number) increase/decrease speed, the 0: 0.1 second customer holds down the + or -- key. Then, Speed Setting *8 1: 0.50 second after a few 0.25 second intervals (See SP 2: 0.25 second mode 12), the speed begins to change. SP 3: 0.05 second mode 8 determines the rate of speed 4: 0.02 second increase/decrease. Auto Reset Time Selects the time to return to the initial setting. 0: 2 minutes 1: 1 minutes Setting 2: 3 minutes *9 3: 4 minutes 4: 5 minutes 5: No auto reset Auto Energy The machine goes into energy saver mode at 0: No *10 Saver Mode auto reset time. 1: Auto Energy Saver Mode Screen Message Setting *11 Selects one of the options indicated on the display in the energy saver mode. 0: None 1: Pre-HEAt 2: HEllo i lovE yoU 3: 0 1 2 3 4 5 6 7 8 9 4: SLEEPinG 5: HAvE A Good dAy. 0: 3 intervals 1: 1 intervals 2: 2 intervals 3: 10 intervals

Leading Edge Increase/Decrease *12 Adjustment Preliminary Interval 13 14 Not Used Not Used Auto Off 15 16 to 19 Not Used

The leading edge margin (print number, paper length) increase/decrease speed starts to change several 0.25 second intervals after the customer starts the adjustment procedure. This SP mode adjusts the number of 0.25 second intervals.

Auto off time can be selected

1 ~ 120 minutes (1 minute per step) Default: 30 minutes

Paper Length Count Up/Down *20 Setting Paper Length Up/Down Speed Setting *21

Selects if the paper length is in count down or 0: Down up when the preset cut key is pressed. (Long Short) 1: Up (Short Long) To change the paper length increase/decrease speed, the customer holds down the + or -- key. Then, after a few 0.25 second intervals (See SP mode 12), the speed begins to change. SP mode 21 determines the rate of speed increase/decrease. Selects the fixed paper size pattern chosen when the "Preset Cut" key is pressed. 0: 0.10 second 1: 0.5 second 2: 0.25 second 3: 0.05 second 4: 0.02 second 5: 0.01 second Refer to page 4-25.

*22

Fixed Paper Size Pattern Setting

Optional Paper *23 Size Setting to *32

Up to 10 different paper size can be stored UdEF: Undefined from 23 to 32. If "19" is selected in SP No. 22, this data is used as fixed paper size when the "Preset Cut" key is pressed.

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Rev. 12/22/95 Mode No. Optional Paper Size Setting Function Data UdEF: Undefined Up to 10 different paper size can be stored from 23 to 32. If "19" is selected in SP No. 22, this data is used as fixed paper size when the "Preset Cut" key is pressed.

*23 to *32 33 to 34 *35

Not Used

All Indicators On

Turns on all the indicators on the operation panel when the Roll Feed Select key is pressed. Carries out the new developer initialization for 5 minutes. The machine counts down the remaining time on the display. After the initialization, the machine automatically adjusts the toner sensor output to 4.0 0.1V. During the toner sensor adjustment, "Adj" is displayed. When the adjustment is completed, the machine automatically returns to normal operating mode.

0: No 1: All indicators on If the initialization is canceled before returning to the normal operating mode, do it again from the beginning. If the machine fails to adjust the toner sensor output, "E=11" is indicated. 0: Release SC 1: SC condition

New Developer Initialization

36

37 38 39 40

Not Used Release Fusing Unit Service Call Not Used Roll Feeder Identification Roll Feeder Speed Setting (Factory Use) Roll Feeder Cutting Length Adjustment (300 mm, Plain Paper) Roll Feeder Cutting Length Adjustment (300 mm, Translucent Paper) Roll Feeder Cutting Length Adjustment (300 mm, translucent Film) Identify the roll feeder installation. 0: No 1: Roll Feeder Installed 0: Standard --50 0 50 Faster Slower 0: Standard --9.9 0 9.9 mm Longer Shorter Recovers from the fusing unit SC condition. After it has been recovered, the machine returns to its initial (power on) condition.

41

To adjust the paper feed speed of the roll feeder. To adjust the cutting length of 300 mm in the plain paper mode.

42

To adjust the cutting length of 300 mm in the translucent paper mode.

43

To adjust the cutting length of 300 mm in the translucent film mode.

44

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46

Mode No. Roll Feeder Cutting Length Adjustment (1100 mm, Plain Paper) Roll Feeder Cutting Length Adjustment (1100 mm, translucent Paper)

Function To adjust the cutting length of 1100 mm in the plain paper mode.

Data 0: Standard --50.00 50.0 mm Longer Shorter

To adjust the cutting length of 1100 mm in the translucent paper mode.

47

48

Roll Feeder To adjust the cutting length of 1100 mm in Cutting Length the translucent film mode. Adjustment (1100 mm, Translucent Film) Not Used Main Motor Speed To change the main motor speed. Adjustment

49

50

Toner End Detection Setting

Determines the possible number of copies (when A1 paper is used) after the toner near end condition. Determines the total copy length before the toner overflow indicator lights.

Used Toner

51

Used Toner Counter 52

Indicates the copy length after clearing the used toner counter. This counter is automatically cleared if the clear mode key is pressed after turning off and on the main switch in the full toner condition.

0: Standard --9 0 11 Slower Faster If the main motor speed is incorrect, PJ56 or PJ57 will be indicated when a long copy is made. In these cases this adjustment is required. 0: 27 sheets 1: 9 sheets 2: 18 sheets 3: 36 sheets 0: 1220 1: 610 2: 915 3: 1000 4: 1464 5: 1830 6: 2000 7: 2440 8: No overflow indication 9: 10m (Should be used for test) tF=XX,XXX (Beeper)

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Mode No. Used Toner Counter Clear

53

54

Developer Warm-up Setting

Data 0: Full toner condition is not detected 1: Full toner condition is detected. To clear the counter, input "0" even if "0" is already indicated. Determines the warm-up time to increase the 0: 1 minute Q/M of the developer. This warm-up is done 1: 2 minute 2: 3 minute if the fusing temperature is lower than 6 0 C 3: None when the main switch is turned on. Determines the maximum paper length. Note: If paper longer than 2000 mm is used, skew copy, poor fusing, crease copy original damage might occur. (In mm mode) 0: 2000 mm 1: 3600 mm 2: 5200 mm 3: 6800 mm 4: 8400 mm 5: 9999 mm (In inch mode) 0: 80.0 inch 1: 160.0 inch 2: 240.0 inch 3: 320.0 inch 4: 400.0 inch 5: 480.0 inch 0: 99 sheets 1: 10 sheets 2: 20 sheets 3: 30 sheets 4: 40 sheets 5: 50 sheets 6: 67 sheets 7: 70 sheets 8: 80 sheets 9: 90 sheets

Function Clear used toner counter.

Paper Length Limit Setting

55

Copy Number Limit Setting

Determines the maximum copy number.

56

57 to 58 59

Not Used

Misfeed Special Recovery Mode Fixed Paper Length Special Mode

60

While the Emergency Stop key is held down, the main motor and the registration clutch are energized. Each time + /-- key is pressed while holding the Preset Cut key down, the length selected in SP mode 61 is increased/reduced from the preset paper size.

0: No 1: Misfeed Special Recovery Mode 0: Normal 1: Fixed Paper Length Special Mode

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Mode No. Fixed Paper Length Special Mode

Function Selects the interval of each step for SP60.

Data (In mm mode) 0: 100 mm 1: 50 mm 2: 60 mm 3: 120 mm 4: 200 mm 5: 240 mm 6: 250 mm 7: 500 mm 8: 600 mm (In inch mode) 0: 10.0 inch 1: 5.0 inch 2: 6.0 inch 3: 12.0 inch 4: 20.0 inch 5: 24.0 inch 6: 25.0 inch 7: 50.0 inch 8: 60.0 inch

61

Special Toner Supply Mode 62

In the energy saver mode, 10% toner supply 0: No is done while the "Emergency Stop" key is 1: Special Toner pressed. Toner sensor voltage is displayed Supply Mode on the "Paper Length" indicator. If the voltage is lower than 1V, toner is not supplied. Selects the indication speed on the display. 0: 300 ms/letter 1: 100 ms/letter 2: 200 ms/letter 3: 400 ms/letter 4: 500 ms/letter Example: vEr_1994_06_06_01 Year Date

63

Not Used SP Mode Display Speed Setting

64

ROM Version Display 65

Indicates the ROM version.

Month Internal Use Only RAM Abnormal Condition Check 66 Displays the total number of abnormal conditions of the back-up RAM. A number is added if an abnormal RAM condition is detected when the machine is powered on.

67 to 69

Not Used

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Mode No. Total Copy Length/Number Display 70 to 75

Function Displays the total copy length/number according to the following units. SP70 = Yard SP71 = meter SP72 = 100 inches SP73 = 50 inches SP74 = A1 length (594 mm) SP75 = sheet (any size)

Data SP70: t0 = XXX,XXX SP71: t1=XXX,XXX SP72: t2=XXX,XXX SP73: t3=XXX,XXX SP74: t4=XXX,XXX SP75: t5=XXX,XXX

OPC Counter 76

Developer Counter Display 77

Displays the total length of copied paper after do = XX,XXX the OPC drum is installed. This counter should be cleared when the OPC drum is replaced. (SP #--1) Displays the total length [m] of copied paper dE = XX,XXX This counter is after the new developer is poured. automatically cleared when the new developer initialization is done. dt = XX,XXX This counter is automatically cleared when the new toner cartridge is installed. Indicates the present toner sensor level. dL = ab -- -- c a: Toner density setting n, H, L b: TS level 0~5 c: Copy number step 0: ~30m 1: ~60m 3: ~90m 4: ~120m 5: ~150m 6: 150m ~ Displays the total number of paper misfeeds J = XXX by location. Misfeed location codes displayed Jt = Total Jam in each SP number are as follows: SP80: Jt, J90, J98, J99 SP81: J01, J02, J03, J04 SP82: J20, J21, J22, J23 SP83: J30, J31, J32 SP84: J40, J41, J42, J43 SP85: J56, J57, J58, J59 Displays the total length of copied paper [m] after a new toner cartridge is installed.

Toner Counter Display 78

Toner Supply Level Indication

79

Number of Misfeeds by Location 80 to 85

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Mode No. Misfeed Record Display

Function Displays the locations of the last five misfeeds one after the other.

86

Data J1 = XX (Last jam) J2 = XX (1 before the last jam) J3 = XX (2 before the last jam) J4 = XX (3 before the last jam) J5 = XX (4 before the last jam) Beeper (XX = Jam Location)

87 to 89 90 to 92

Not Used

Number of Service Calls by Location

E = XXX Displays the total number of service calls (SC) by location. SC codes displayed in each Et = Total SCs SP number are as follows: SP90: Et, E1, E9, E10, E11 SP91: E2, E3, E4, E5 SP92: E6, E7, E8 Displays the last five service calls one after the other. E1 = XX (The last error code) E2 = XX (1 before the last error code) E3 = XX (2 before the last error code) E4 = XX (3 before the last error code) E5 = XX (4 before the last error code) Beeper (XX= Error Code)

Service Call Records

93

94 to 99

Not Used

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Mode No. RAM Clear

--1

Function Data Clears selected data items form the RAM. To 0: Not Used 1: Copy Number clear the memory, input the number of the Counter item you want to delete, then press the (The memory for key. SP75) Note: 2: Copy Length If all the memory is cleared (if a number from Counter 20 to 28 is selected), reinput the factory (SP70 to 74) settings that are shown on the decal attached 3: OPC Counter inside the upper right cover. (SP76) Please refer to page 4-26 to know the default 4: Developer settings for each destination. (When No. 10 Counter to 26 is selected.) (SP77)(*Note1) 5: Toner Counter (SP78) 6: Counter for toner density step.(*Note2) 7: Clear data No.1 to 9 and 53. 8: SC Counter (SP90 to 93) 9: Jam Counter (SP80 to 86) 10: Not Used

* Note: 1 This counter is not used for the toner density step control (described on page 2-16). * Note: 2 For the toner density step control, this counter counts down from 150 (m) to 0 (m) after the developer initialization. When the developer initialization is done, this counter to 150 and after 150m of copies, the counter stays at 0. If this counter is cleared, the counter is set to 0.

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Mode No.

Function

Data 11: Change the setting to the U.S.A. version 12: Not Used 13: Not Used 14: Not Used 15: Not Used 16: Not Used 17: Factory use 18: Not Used

--1

19: Not Used 20: Not Used 21: Clear all the memories and change the setting to the U.S.A version 22: Not Used 23: Not Used 24: Not Used 25: Not Used 26: Not Used

--1

--2

--3 --4 --5

27: Factory use 28: Clear all the memories Total Counter Unit Selects the unit in which the total counter 0: 1 yard Setting counts up by. 1: 1 m 2: 100 inches 3: 50 inches 4: A1 length (594 mm) 5. Sheet (Any size) Inch/mm Selects the unit in which the edge margin and 0: mm Exchange paper length is indicated by. 1: Inch Not Used Registration Adjusts the paper registration. 0: Standard Adjustment --9.9 0 9.9 mm Advance Delay

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Mode No. Light Sensor Adjustment --6

--7

Hot Roller Temperature Adjustment Pressure Roller Temperature Adjustment Hot Roller/ Pressure Roller Temperature Display

Function Change the light sensor setting. Turn on and off the exposure lamp using the Copy Media key. Tracing paper: ON Film: OFF Change the hot roller temperature setting.

Data 50: Standard 0 50 99 Darker Lighter

--8

Change the pressure roller temperature setting. Displays the hot roller temperature and pressure roller temperature. Even if the SP mode is canceled when the temperature is displayed, the temperature is continuously displayed during stand-by condition or copy cycle. To release this condition, turn the main switch off and on.

0: Standard --9 0 9C Decrease Increase 0: Standard --9 0 9C Decrease Increase Fu = XXX

Pr = XXX Fu: Hot roller temperature Pr: Pressure roller temperature If the hot roller temperature is lower than 10 0 C

--9

(pressure roller temperature is lower than 50C), "LLL" is indicated. If the hot roller temperature is higher than 210C (pressure roller temperature is higher than 18 0C), "HHH" is indicated. Drum Charge Setting Determines the drum charge voltage. In this mode, the charge corona can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF 200: Standard 150 200 249 Low High

--10

Copy Grid Settin g Determines the copy grid voltage. In this mode, the grid voltage can be turned on and off using the Copy Media key. --11 Translucent paper = ON Translucent Film = OFF Transfer Corona Voltage Setting --12 Determines the transfer corona voltage. In this mode, the transfer corona can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF

9: Standard 0 9 15 Low High

80: Standard 40 80 120 Low High

Transfer Voltage at Paper Trailing Edge Setting --13

Determines the transfer corona voltage at the 120: Standard paper trailing edge. 40 120 249 In this mode, the transfer corona can be Low High turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF

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Mode No. Separation AC Voltage Setting --14

Function Determines the AC separation corona voltage. In this mode, the separation corona can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Determines the AC separation corona voltage at the paper leading edge. In this mode, the separation corona can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Determines the DC separation corona voltage. In this mode, the separation corona can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF

Data 170: Standard 130 170 220 Low High

Separation AC Voltage at the Paper Leading --15 Edge Setting

190: Standard 130 190 220 Low High

Separation DC Voltage Setting

200: Standard 0 200 249 Low High

--16

Separation DC Voltage at the Paper Leading --17 Edge Setting

Determines the DC separation corona voltage at the paper leading edge. In this mode, the separation corona can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF

200: Standard 0 200 249 Low High

--18 Not Used to --19 Bias Voltage for the Image Area Setting --20

Determines the development bias voltage for the image area. In this mode, the bias voltage can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Determines the development bias voltage for the non-image area. In this mode, the bias voltage can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF

3: Standard 038 Low High

Bias Voltage for Non-image Area Setting --21

4: Standard 048 Low High

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Mode No. Toner Density Setting

Function Data Selects the toner density setting. The toner 0: Standard density changes according to the copy length 1: Low after the developer is replaced. 2: High Copy length (A1 size) ~ 30 m (~50 sheets) ~ 60 m (~100 sheets) ~ 90 m (~150 sheets) ~ 120 m (~200 sheets) ~ 150 m (~250 sheets) Std. Low High

4.25V 4.35V 4.00V 4.00V 4.30V 3.50V 3.50V 4.25V 3.00V 3.00V 3.75V 2.50V 2.50V 3.25V 2.00V

--22

23 to 24

Not Used

Toner Density Sensor Voltage Setting --30

Toner Sensor --31 Voltage Display (Last Copy)

Changes the toner density sensor voltage. Normally, the value is automatically adjusted when the new developer initialization (SP36) is done. In this mode, PTL, main motor, QL and the bias voltage for non-image area can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Displays the toner sensor output voltage for the last copy.

80: Standard 50 80 120 Low High

A = X,XX (Beeper)

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Mode No. Toner Sensor Voltage Display (Real Time)

--32

Function Displays the real time toner sensor output voltage. In this mode, the PTL, main motor, QL and the bias voltage for non-image areas can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Even if the SP mode is canceled when the voltage is displayed, the voltage is displayed during the stand-by condition or copy cycling (the toner sensor output voltage, paper length and copy counter are displayed one after the other). To release this condition, turn the main switch off and on.

Data A = X,XX A = Toner Sensor Voltage During the stand-by condition, and copy cycling the following data is displayed. A=X,XX LE=X,XXX CO=XX (Beeper) LE = Paper Length (ex. 297 mm: LE=0.297 12 inch: LE=0.120) CO=Copy counter

--33 Not Used to --44 Forced Ready Condition --50 (Factory Use) --51 Lamp Off Mode Goes to "Ready" condition ignoring the fusing 0: Normal 1: Forced Ready temperature. This mode cannot be used Condition during the development idling. Fluorescent lamp does not turn on during the copy cycle. Ignores jam detections except for initial jams. The setting automatically returns to "0" when the main switch is turned off. The machine caries out copy operation without an original. This mode can be used if the optional roll feeder is installed and selected paper length is more than 594mm. The machine starts operation when the roll feed select key is pressed, and stops when the Emergency Stop key is pressed. 0: Normal 1: Lamp off 0: Normal 1: No Misfeed Detection 0: Normal 1: Next Paper is fed when the fusing exit sensor is deactivated. 2~250: Next paper is fed (X-1) seconds after the fusing exit sensor is deactivated. X = Input Number

No Misfeed --52 Detection Mode Free Run Mode

--53

--54 Not Used to --59 Fluorescent Lamp Counts the time when the exposure sensor is 0~250: The total time Abnormal Time more than 1 V higher than the target value. (seconds) that the --60 Check 1 lamp voltage is more than 1 volt higher than the target value.

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Mode No. Function Data Fluorescent Lamp Counts the time when the fluorescent lamp is 0~250: The total time Abnormal Time in full power during the copy cycle. (seconds) that the --61 Check 2 fluorescent lamp is at full power. --62 Not Used --63 Factory Use Only 0: NO Manual Feed Beeper sounds if a sheet is set on the 1: Manual Feed --64 Attention Mode 1 manual feed table before the "Set Paper" Attention Mode 1 indicator lights. Manual Feed Beeper sounds when the manual table is 0: NO --65 Attention Mode 2 ready to accept the next sheet. 1: Manual Feed Attention Mode 2 Partial copy Enable to make "+" margin in the partial copy 0: NO Leading Edge mode, ("--" margin cannot be made.) 1: "+" margin can be --66 Margin made in the part copy mode Toner Full Supply In the Special Toner Supply mode (SP62), if 0: NO Mode the "clear/stop" key is pressed while the 1: Toner Full Supply --67 "Emergency Stop" key is pressed, 100%, Mode toner supply is done. Combine Originals Normally the copy process stops at the 0: Normal Mode trailing edge of paper or original which ever 1: Combine comes first. If this mode is selected, copy Originals Mode --68 process continues to the paper trailing edge even if the original trailing edge comes first. Using this mode, several originals can be combined on copy sheet.

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Fixed Paper Size Pattern Data (SP No.22)

In mm Mode 0: 1189, 841, 594, 420, 297 1: 2000, 1189, 841, 594, 420, 297, 245 2: 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 245 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1189, 841, 594, 420, 297, 245 2000, 1800, 1456, 1189, 1030, 841, 728, 594, 515, 420, 364, 297, 245 2000, 1500, 1230, 880, 625, 450, 330, 245 1456, 1030, 728, 515, 364, 257 2000, 1456, 1030, 728 515, 364, 257, 245 2000, 1500, 1189, 1100, 841, 594, 420, 300, 297, 245 2000, 1456, 1200, 1189, 1091, 1085, 1030, 1016, 1000, 939, 900, 880, 841, 813, 788, 765, 762, 758, 728, 679, 636, 625, 594, 591,546, 515, 508, 420,364, 297, 257 2000, 1800, 1600, 1400, 1200, 1000, 800, 600, 400, 245 2000, 1750, 1500, 1250, 1000, 750, 500, 245 2000, 1950, 1900, 1850, 1800, 1750, 1700, 1650, 1600, 1550, 1500, 1450, 1400, 1350, 1300, 1250, 1200, 1150, 1100, 1050, 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 245 2000, 1800, 1500, 1189, 1100, 1050, 1000, 950, 900, 841, 800, 750, 700, 650, 594, 550, 500, 420, 297, 245 2000, 1800, 1456, 1200, 1189, 1085, 1030, 900, 880, 841, 765, 728, 625, 594, 515, 420, 364, 297, 245 2000, 1800, 1500, 1200, 1189, 594, 245 2000, 1800, 1500, 1200, 1000, 841, 420, 245 2000, 1800, 1500, 1220, 1189, 915, 841, 610, 594, 458, 420, 305, 297, 245 2000, 1800, 1500, 1189, 1118, 864, 841, 594, 559, 432, 420, 297, 280, 245 The data stored in SP23 to 32

13: 14: 15: 16: 17: 18: 19:

In inch Mode 0: 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 48.0, 36.0, 24.0, 18.0, 12.0 44.0, 34.0, 22.0, 17.0, 11.0 80.0, 72.0, 64.0, 48.0, 36.0, 24.0, 18.0, 12.0, 9.6 80.0, 72.0, 64.0, 44.0, 34.0, 22.0, 17.0, 11.0, 9.6 80.0, 72.0, 64.0, 48.0, 44.0, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0, 9.6 80.0, 70.0, 60.0, 50.0, 40.0, 30.0, 20.0, 10.0, 9.6 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 45.0, 40.0, 35.0, 30.0, 25.0, 20.0, 15.0, 10.0, 9.6 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 48.0, 36.0, 24.0, 18.0, 12.0, 9.6 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 44.0, 34.0, 22.0, 17.0, 11.0, 9.6 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 48.0, 44.0, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0, 9.6 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 47.5, 45.0, 42.5, 40.0, 37.5, 35.0, 32.5, 30.0, 27.5, 25.0, 22.5, 20.0, 17.5, 15.0, 12.5, 10.0, 9.6 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 48.0, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0, 9.6 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 48.0, 36.0, 24.0, 18.0, 12.0, 9.6 4-25 A163

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13: 14:

80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 44.0, 34.0, 22.0, 17.0, 11.0, 9.6 80.0, 78.0, 76.0, 74.0, 72.0, 70.0, 68.0, 66.0, 64.0, 62.0, 60.0, 58.0, 56.0, 54.0, 52.0, 50.0, 48.0, 46.0, 44.0, 42.0, 40.0, 38.0, 36.0, 34.0, 32.0, 30.0, 28.0, 26.0, 24.0, 22.0, 20.0, 18.0, 16.0, 14.0, 12.0, 10.0, 9,6 80.0, 72.0, 60.0, 48.0, 36.0, 24.0, 12.0, 9.6 80.0, 78.0, 72.0, 66.0, 60.0, 50.0, 54.0, 48.0, 42.0, 36.0, 30.0, 24.0, 18.0, 12.0, 9.6 80.0, 78.0, 75.0, 72.0, 69.0, 66.0, 63.0, 60.0, 57.0, 54.0, 51.0, 48.0, 45.0, 42.0, 39.0, 36.0, 33.0, 30.0, 27.0, 24.0, 21.0, 18.0, 15.0, 12.0, 9.6 80.0, 72.0, 64.0, 57.3, 48.0, 46.8, 40.6, 36.0, 34.0, 33.1, 28.7, 24.0, 23.4, 22.0, 20.3, 18.0, 17.0, 16.6, 14.4, 12.0, 11.7, 11.0, 10.1, 9.6 The data stored in SP23 to 32

15: 16: 17: 18: 19:

Default Settings (SP # --1)

SP. No. #1 #2 #3 #4 #5 #6 #8 #9 #10 #20 #21 #22 #--2 #--3 U.S.A. 2 0 1 0 2 0 0 0 0 1 0 0 5 1

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3.2

INPUT/OUTPUT CHECK MODE

The input check mode allows you to check the current status of electrical components (such as sensors, switches, etc.) from the operation panel. The output check mode allows you to turn the individual electrical components (such as motors, solenoids, etc.) ON/OFF from the operation panel. 3.2.1 INPUT/OUTPUT CHECK MODE ACCESS PROCEDURE How to access the output check mode Press the following keys in sequence.

The second time that th e seconds (until th e and

key is pressed, hold it down for more than 3 indicators blink).

How to leave the input/output check mode Press the following keys in sequence.

or turn off the main switch. NOTE: Each of the above procedures must be finished within 20 seconds.

How to select the program number The program number can be selected by pressing the To select an input check mode, press the To select an output check mode, press th e key. key. and keys.

The selected number is displayed on the lead edge erase indicator (the two digit indicator beside th e mark). To select the program number quickly, hold down th e or key.

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Rev. 5/95

3.2.2 INPUT CHECK MODE TABLE The on/off status of the selected electrical component is displayed on the paper length indicator ("ON" or "OFF" is displayed.). If a program number not used is selected, "NOT" is displayed.
Program No. --1 --2 --3 --4 --5 Sensor/Switch /Signal Registration Sensor Exit Sensor Original Registration Sensor Entrance Sensor

Main Motor LOC Signal (Status is "ON" when the main motor is normally rotating.) Door Switch (Status is "ON" when the --6 door is open.) --7 to --9 Not Used --10 R/F Leading Edge Sensor --11 --12 --13 --14 Roll Feeder Door Switch Right Cutter Switch Left Cutter Switch Paper End Sensor

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3.2.3 OUTPUT CHECK MODE TABLE Press the key to turn on the selected electrical component. The status of the component is displayed on the paper length indicator. To turn off the component, press th e
Program No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 to 19 20 21 22 23 Electrical Component Main Motor Toner Supply Clutch Pick off solenoid Registration Clutch Total Counter Pre-transfer Lamp Quenching Lamp Fusing Lamp Exposure Lamp (100% duty ratio) Exposure Lamp (selected ID level) Main Charge Corona Grid Voltage Transfer Charge Corona Not Used Separation Charge Corona Not Used Bias Voltage for the Image Area Bias Voltage for the Non-image Area Main Charge Corona + Grid Voltage

key again.

Main Motor + PTL + Bias Voltage for the Non-image Area + Quenching Lamp 24 to 25 Not Used 26 Roll Feeder Dehumidity Heaters 27 Roll Feeder Cutter Moto r *Note 28 Roller Feeder Paper Feed Motor

NOTE: The cutter unit continuously moves between the left and right cutter switches. The number of the movement (0~9999) is displayed on the paper length indicator.

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3.3

POWER ON INITIAL SETTING MODE

The initial setting, when the main switch is turned on, can be changed in this mode. The procedure is as follows: 1. Turn on the main switch while holding the Emergencey stop key down and indicators blink). 2. Input the operation panel setting that the customer requires (paper size, image density, etc.). 3. Turn off the main switch. The setting, just before the main switch is turned off, is memorized as the power on initial setting. It appears again when the main switch is turned on.

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4.

JAM CODE LIST

When a document (original) jam or paper jam occurs, the cause of the jam is displayed by using the following jam code.

4.1

ACCESS PROCEDURE

1. When a document jam or paper jam occurs, press and hold the Clear/Stop key. 2. Read the jam code.

4.2
Code PJ01 PJ02 PJ03 PJ04 PJ05 PJ20 PJ21 PJ22 PJ23 PJ30 PJ31 PJ32 PJ40 PJ41 PJ42 PJ43 PJ56 PJ57 PJ58 PJ59

JAM CODE TABLE

Cause of Jam Initial misfeed at the registration sensor. Initial misfeed at the exit sensor. Initial misfeed at the original registration sensor. Initial misfeed at the entrance sensor. Initial misfeed at the leading edge sensor of the roll feeder. Registration sensor OFF check at the paper leading edge. Registration sensor ON check at the paper leading edge. Registration sensor OFF check at the paper trailing edge. Registration sensor ON check at the paper trailing edge. Exit sensor OFF check at the paper leading edge. Exit sensor ON check at the paper leading edge. Exit sensor OFF check at the paper trailing edge. Leading edge sensor ON check at the paper leading edge. Leading edge sensor OFF check at the paper leading edge. Paper cutter failure. Door open during the roll feeding. Leading edge sensor ON check at the paper trailing edge. Leading edge sensor OFF check at the paper trailing edge. Entrance sensor ON during the roll feeding. Registration sensor ON check at the paper leading edge (in roll feeding). SP Mode No. SP81 (Initial Jams)

SP82 (Manual Feed and Registration Jams)

SP83 (Jams at Fusing Unit) SP84 (Roll Feeder Jams)

SP85 (Roll Feeder Jams)

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Code PJ90 PJ98 PJ99

Cause of Jam Roll feeder. motor does not turn off after paper is fed 500 mm more than the maximum paper length. Registration sensor does not turn off after paper is fed 2500 mm. Original registration sensor does not turn off after paper is fed 2500 mm.

SP Mode No. SP80 (Others)

NOTE: To display total jam number, access SP mode No. 80.

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5.
No. 1 2 3 4 5 6 7 8

SPECIAL TOOLS AND LUBRICANTS

DESCRIPTION Digital Multimeter Deluxe Test Lead Accessory Kit Grease -- Mobil Temp.78 Grease-G501 Current Measuring Drum Test Chart OS-A1 (2 sheets/set) Spring Hook Setting Powder PART NO. 54209507 54209508 54479078 52039501 A0239520 A0239504 54199653 54429101 REMARKS BECKMAN RMS3030 BECKMAN DL241 400 g/can

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6.
6.1

SERVICE REMARKS
DRUM UNIT

6.1.1 Drum The organic photoconductor drum is comparatively more sensitive to light and ammonia gas than a selenium drum. 1. Never expose the drum to direct sunlight. 2. Never expose the drum to direct light of more than 1,000 Lux for more than a minute. 3. Never touch the drum surface with bare hands. When the drum surface is touched with a finger or becomes dirty, wipe with a dry cloth or clean with wet cotton. Wipe with a dry cloth after cleaning with wet cotton. 4. Never use alcohol to clean the drum; alcohol dissolves the drum surface. 5. Store the drum in a cool, dry place away from heat. 6. Take care not to scratch the drum as the drum layer is thin and is easily damaged. 7. Never expose the drum to corrosive gases such as ammonia gas. 8. Always keep the drum in the protective sheet when inserting or pulling the drum unit out of the copier to avoid exposing it to bright light or direct sunlight. This will protect the drum from light fatigue. 9. Before removing the drum, place a sheet of paper under the drum to catch any falling toner. 10. Dispose of used drums according to local regulations. 11. Perform the light sensor adjustment when a new drum is installed. 12. Hold both ends of the drum unit to carry it. 13. Be careful not to scratch the drum with the pick-off pawls when removing or reinstalling the drum. 14. When installing and/or removing the pick-off pawl unit, do not press too strongly. Otherwise, the drum unit may deform.

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15. When the drum unit is removed from the copier, do not close the paper path section if possible. Otherwise, the gas springs at both sides open the paper path section forcibly if the paper path section is released. If you close the paper path section, take care not to injure yourself by opening the paper path section. Also, releasing only one side of the paper path section deform the copier machine, which may cause paper jam and copy image problem. Release both levers together while holding the paper path section to open the paper path section slowly. 16. The drum unit is heavy. Take care not to injure yourself by dropping the drum unit when removing and installing it.

6.2

CHARGE CORONA

1. The wire can also be cleaned with a blower brush. If the wire is cleaned with a dry cloth, make sure that the wire does not become stretched. Do not use sand paper or a solvent. 2. Do not touch the corona wire and the grid wires with oily hands. Oil stains may cause uneven image density on copies. 3. Make sure that the corona wire is correctly positioned and that there is no foreign material (iron filings, etc.) on the casing. 4. Clean the grid wires with a dry cloth. 5. When reinstalling the charge corona unit, make sure that the 2 connectors (C for the charge corona, G for the grid bias) are set properly. 6. Make sure that the grid wires are correctly placed on the eight slots, are all straight, and not crossed. 7. Do not expand and bend the corona wires and grid wires. 8. Make sure that the wire junction is positioned inside the right endblock.

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6.3

OPTICS

1. Clean the exposure glass with water or alcohol. 2. Clean the fiber optics array with lens paper or silicone cloth. 3. Make sure that the exposure glass is under the rear original guide plate when reassembling. 4. Make sure that the direction of the aperture of the exposure lamp is towards the fiber optics array side (rear side) when reassembling. 5. When reassembling, be careful not to damage the right side of the fiber optics array by touching the optics side plate.

6.4

DEVELOPMENT

1. Be careful not to nick or scratch the development roller. 2. Clean the drive gears after removing used developer. 3. Initial conditioning (SP#36) is necessary when the developer is replaced. 4. Dispose of used developer according to local regulations. 5. Do not loosen the painted screws which determine the development doctor blade height and do not push the doctor blade too hard, otherwise the doctor gap may change. 6. Be careful not to bend the bias terminal. 7. When the development unit is removed from the copier, do not close the paper path section if possible. Otherwise, the gas springs at both sides open the paper path section forcibly if the paper path section is released. If you close the paper path section, be careful not to injure yourself when opening the paper path section. Also, releasing only one side of the paper path section deform the copier machine, which may cause paper jam and copy image problem. Release both levers together while holding the paper path section to open the paper path section slowly. 8. The development unit is heavy. Take care not to injure yourself by dropping the development unit when removing and installing it. 9. During the developer initialization, do not turn off the main switch, or do not open the original feed unit or the paper path section, or do not unplug the copier power cord. If these conditions happen, do the developer initialization again, the toner density sensor cannot be adjusted.

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6.5

TRANSFER AND SEPARATION

1. Clean the corona wires with a blower brush. If the wires are cleaned with a dry cloth, make sure that the wire does not become stretched. 2. When adjusting the corona current, always use the drum current measuring drum. 3. Make sure that the T & S corona unit is set correctly by pressing it down when reinstalling. 4. Handle the new wire by the ends only. Oil from your hands may cause uneven charge on the drum. 5. Do not expand and bend the corona wires. 6. Do not rub the corona wires with rough material (sand paper,... etc.) as this will damage the corona wire. 7. Do not use any solvent to clean the wire as this will cause uneven charge on the drum.

6.6

CLEANING UNIT

1. Be careful not to damage the edge of the cleaning blade. 2. Dispose of used toner according to local regulations. 3. Do not press the cleaning blade too hard. Otherwise, the drum unit may deform. 4. When installing or replacing the cleaning blade, release the pressure several times manually, and then hold down the cleaning blade gently along its entire length ensure that the cleaning blade contacts the drum. Otherwise, cleaning failure may occur. 5. When replacing the cleaning blade, apply setting powder on the edge of the cleaning blade. 6. Empty the toner collection bottle every service call and clear the memory counter SP#52 for used toner overflow detection by SP#53. Do not perform SP#53 without emptying the toner collection bottle. If "FULL" is indicated in the copy counter, SP#52 can also be reset to 0 by pressing the Clear Modes/Standby key after opening and closing the paper path section. Instruct customers to deal with the toner collection bottle if the "FULL" condition is indicated.

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Rev. 9/27/96

6.7 FUSING UNIT

1. Be careful not to damage the edges of the hot roller strippers and tension springs. 2. Do not touch the fusing lamp with bare hands. 3. Make sure that the fusing lamp does not touch the hot roller. 4. Be careful not to damage the hot roller thermistor and pressure roller thermistor when removing and reinstalling hot roller or the pressure roller. 5. The fusing unit is heavy. Take care not to injure yourself by dropping the fusing unit when removing and installing it.

6.7A

PRESSURE ROLLER EVALUATION PROCEDURE

The following procedure is a method to determine whether the pressure roller should be replaced. 1. Access Sp mode with the steps below. In order, press Clear Modes (C) key, Plus (+) key, Minus (-) key, Clear/Stop key, press and hold the Clear/Stop key again for longer than 3 seconds. 2. Select Lamp Off Mode with the steps below. a) Confirm that "Lead Margin" indicators lights. If "Lead Margin" indicator does not light, press Function Select key until it lights. b) Select "-51" by pressing Minus key. ("-51" is the number to select Lamp Off Mode.) c) Press Function Select key until "Paper Length" indicator lights. d) Select "1" by pressing Plus key. ("1" is the number to set Lamp Off Mode.) e) Press RF Select key to set Lamp Off Mode. 3. To prevent a paper misfeed create a lead edge margin with the steps below. a) Press Function Select key until "Lead Margin" indicator lights. b) Continue to press Plus key until "99 mm" or "4.0 inches" (max. value) is indicated. 4. Make a copy using a less fusible kind of paper like film, translucent paper or thicker plain paper with vertical grain direction. Note: Before making a copy, set the fusing temperature setting to the mode which is one step lower than the proper setting for the particular kind of paper. For example, if the proper setting is Mode 3, select Mode 2 for this test. Refer to TSB No. FW740-010 for more information regarding the proper settings for particular types of paper and the adjustment procedure for non-listed papers.
4-38 FSM

A163

Rev. 9/27/96

5. Scrape some black areas on the copy using a cotton cloth approximately 5 times. 6. Check whether the toner is peeled off on the areas that correspond with the scraped parts of the pressure roller. If white lines and/or bands appear, the pressure roller should be replaced with a new one. 7. Before turning the main switch "OFF" to reset the SP mode, reset "Lamp Off Mode", "Lead Margin" and "Fusing Temperature Setting" back to the original settings.

6.8 ORIGINAL FEED

1. Do not touch the original feed rollers, original registration rollers, platen roller and press rollers with bare hands. 2. Clean the white plate with water or alcohol.

6.9 PAPER FEED

Service Tables A163

1. Do not touch the manual feed rollers and registration rollers with bare hands. 2. A worn out registration roller causes paper to crease. It should be replaced.

6.10 ROLL FEEDER

1. The copier is not attached to the table and roll feeder is attached to the table and copier. Do not lift the copier from the table, otherwise roll feeder unit is deformed. 2. When the copier and roll feeder is moved, loosen the screws for angle bracket and spacer and retighten them for absorb floor distortion.

6.11 OTHERS
1. When replacing the main board, if the RAM on the old main board is still usable, remove and place it on the new main board. Then, install the new main board in the copier. 2. After installing the new main board with a new RAM, clear the RAM memory. (Do not clear RAM memory if you have placed the old RAM on the new main board.) 3. Take care not to damage the mylars on the rear feed table during servicing. 4. When replacing a sensor, do not overtighten the screws. This may damage the sensor.

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REPLACEMENT AND ADJUSTMENT

1.

EXTERIOR COVERS
[A] [C] [B] [J] [I] [H] [G] [D] [E] [F]

1.1

LEFT SIDE COVER REMOVAL

1.1.1 Left Upper Cover 1. Remove the left upper cover [A] (2 screws). 1.1.2 Left Lower Cover 1. Open the paper path section [B]. 2. Remove the left lower cover [C] (2 screws).

1.2

RIGHT SIDE COVER REMOVAL

1.2.1 Right Upper Cover 1. Remove the right upper cover [D] (2 screws). 1.2.2 Right Lower Front, Right Lower Middle, and Right Lower Rear Covers 1. Open the paper path section. 2. Remove the right lower cover [E] (2 screws), right lower middle cover [F], and toner collection bottle [G]. 3. Remove the right lower rear cover [H] (1 screw).

1.3

REAR COVER REMOVAL

1.3.1 Rear Cover 1. Remove the rear cover [I] (2 screws). NOTE: When re-installing the rear cover, push in the rear cover hooking portion [J] over the copier bottom plate as shown.

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2.

OPTICS
[C] [A] [D]

[B]

[E]

[G]

[F]

2.1

ORIGINAL FEED UNIT REMOVAL

1. Remove the left and right upper covers. 2. Remove the copy tray [A]. 3. Push the projections [B] into the holes [C] of the rear side of the original feed unit as shown and remove the operation panel [D] (2 connectors). 4. Open the original feed unit [E] and unhook the stoppers [F] at both ends. 5. Turn the original feed unit and two bushings [G] at both ends 1/4 of a turn and remove.

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[F] [C]

[C]

[B]

[E]

[D]

[A]

2.2

EXPOSURE GLASS REMOVAL

1. Remove the original feed unit. 2. Remove the exposure glass bracket [A] (2 screws). 3. Remove the rear original guide plate [B] (2 screws). 4. Remove the exposure glass [C] by sliding it out to the right side and lifting up the left side as shown. NOTE: Make sure that the exposure glass is under the rear original guide plate when reassembling.

2.3

EXPOSURE LAMP REMOVAL

1. Remove the exposure glass. 2. Remove the front original guide plate [D] (2 screws). NOTE: If the exposure lamp is too tight to be turned, remove one side of the exposure lamp socket (1 screw) and remove the exposure lamp. 3. Turn the exposure lamp [E] 1/4 of a turn and remove. NOTE: Make sure that the direction of the aperture [F] of the exposure lamp is towards the fiber optics array side (rear side).

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2.4

FIBER OPTICS ARRAY REMOVAL

[C]

[B]

[D] [A]

1. Follow the steps from 1 to 3 of the exposure lamp removal. 2. Remove the original registration sensor bracket [A] (1 screw). 3. Lift up the fiber optics array [B] and remove it from the left side by sliding it out to the right side as shown. NOTE: When reassembling, be careful not to damage the right side [C] of the fiber optics array by touching the optics side plate [D].

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2.5

LIGHT SENSOR REPLACEMENT

Rev. 5/95

[A]

1. Remove the exposure lamp. 2. Replace the light sensor [A] (1 screw, 1 connector). 3. Perform light sensor adjustment. See page 5-39

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3.
3.1

DEVELOPMENT
DEVELOPMENT UNIT REMOVAL

[B]

[A] [C]

1. Remove the left and right upper cover. 2. Open the paper path section and original feed unit. 3. Remove the toner supply cover [A]. 4. Remove the manual entrance feed cover [B] (2 pins). 5. Remove the paper feed driven unit [C] (2 screws and 1 connector).

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[A] [B] [A]

[A] [B] [A] [E]

[C]

[D] [F] [G] [F]

6. Remove the 4 shoulder screws [A] and 2 screws [B] fixing the development unit. 7. Disconnect the 14p connector [C] and remove it out of the cutout [D]. 8. Remove the development unit [E].

CAUTION: Do not loosen the painted screws [F] which determine the development doctor blade height and do not push the doctor blade [G] too strongly, otherwise the doctor gap may change.

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3.2

DEVELOPER REMOVAL
[B] [C]

[A]

[D]

NOTE: Be careful not to bend the bias terminal. 1. Remove the development unit and place it on a large sheet of paper [A] as shown. 2. Remove the toner supply unit casing [B] (2 pins) and development filter [C] and bracket [C] and clean them. 3. Stand up the development unit as shown (the drive section of the unit is the upper side). 4. Turn the paddle roller knob [D] clockwise. The developer will fall out onto the paper. 5. Repeat step 4 until all of the developer has been dumped out. 6. Clean the development unit prior to reassembling. Especially, clean the right end of the unit.

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3.3

TONER DENSITY SENSOR REPLACEMENT

[C]

[E]

[D] [B]

[A]

1. Remove the development unit. 2. Disconnect the harness connector [A] and take the harness from the 2 clamps [B]. 3. Remove the 2 screws [C] of the toner density sensor holder. 4. Pull out the harness from the toner density sensor side until the relay connector [D] appears. 5. Replace the toner density sensor [E] (2 screws and 1 connector).

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3.4

PTL REPLACEMENT

[B] [A]

1. Remove the paper feed driven unit (follow the steps from 1 to 5 of the development unit removal). 2. Remove the PTL assembly [A] (4 screws, 3 connectors, and 4 clamps [B]).

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3.5

DEVELOPMENT BIAS VOLTAGE ADJUSTMENT

NOTE: This adjustment is required when the charge/bias/grid power pack is replaced. Preparation: 1. Turn off the main switch, and remove the rear cover. 2. Connect the ground terminal of the multimeter to the machine ground, and connect the voltage terminal to TP1 on the charge/bias/grid power pack. 3. Set the multimeter range to dc 1500 V. 4. Turn on the main switch. 3.5.1 Bias Voltage for Image Area ADJUSTMENT STANDARD: dc --180 10 V . 1. Access SP mode and select No. --20. 2. Press the key to turn on the bias voltage.

3. Check the multimeter. If the voltage is not that of the standard voltage, press the keys. 4. If the voltage is within that of the standard voltage, press th e key. key and then change the voltage usin g and

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3.5.2 Bias Voltage for Non-image Area ADJUSTMENT STANDARD: dc --200 10V 1. Access SP mode and select No. --21. 2. Press the key to turn on the bias voltage.

3. Check the multimeter. If the voltage is not that of the standard voltage, press the keys. 4. If the voltage is within the standard, press th e key. key and then change the voltage usin g and

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4.
4.1

DRUM UNIT
DRUM UNIT REMOVAL

[A]

[B] [A]

[F]

[C] [D] [E]

1. Remove the development unit. 2. Remove the 2 screws [A] at both ends. 3. Remove the timing belt [B] and disconnect the harness connector [C]. 4. Remove the drum unit [D]. 5. Place the drum unit on the flat floor. NOTE: (1) When reinstalling the drum unit, hook the drum unit guides [E] on the pins [F] of the copier side plates. (2) Hold both ends of the drum unit to carry it.

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Rev. 5/95

4.2

DRUM REPLACEMENT
[E] [F] [C] [D] [B]

[B] [A]

1. Remove the drum unit. 2. Remove the pulley [A] (1 C-ring). 3. Remove the 2 bearing holders [B] (2 screws each). NOTE: Be careful not to scratch the drum with the pick-off pawls when removing or reinstalling the drum. 4. Remove the drum [C] with the drum shaft. 5. Loosen the drum knob [D] by turning it counter clockwise as shown. 6. Remove the drum flange [E]. 7. Replace the drum with new one. NOTE: when reinstalling the gear [F], make sure that the direction of the projection of the gear is on the drum side.

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Rev. 5/95

4.3

CLEANING BLADE REPLACEMEN T

[E [A] [B]

[D] [C] [F]

1. Remove the drum unit. 2. Remove the charge corona unit (Pg 5-16) 3 Remove the quenching lamp unit [A]. 4. Remove the pressure spring [B] and bushing [C]. 5. Slide the cleaning blade [D] to the left side and remove it from the right side. NOTE: 1. Do not press the cleaning blade too strongly. Otherwise, the drum unit may deform. 2. When installing or replacing the cleaning blade, release the pressure [E] several times manually, and then hold down the cleaning blade gently along its entire length to ensure that the cleaning blade contacts the drum. Even if the drum is installed already, this action [F] can be taken through the rear side from where the rear feed table assembly is removed (follow steps 1 to 3 of the ozone filter replacement). 3. When replacing the cleaning blade, apply setting powder on the edge of the cleaning blade.

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4.4

CHARGE CORONA UNIT REMOVAL

[A]

[A]

[B]

1. Remove the drum unit. 2. Remove the ground springs [A]. 3. Remove the charge corona unit [B] (2 connectors). NOTE: When reinstalling the charge corona unit, make sure that the 2 connectors (C for the charge corona, G for the grid bias) are set properly.

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4.5

CHARGE CORONA WIRE REPLACEMENT

[E]

[B] [A] [C]

[B]

[D] 1. Remove the charge corona unit. 2. Remove the 4 grid wires [A] (4 springs). 3. Remove the endblock covers [B]. 4. Replace the corona wire [C] (1 spring). NOTE: (1) Make sure that the grid wires are correctly placed on the eight slots [D], are all straight, and not crossed. (2) Handle the new wire by the ends only. Oil from your hands may cause uneven charge on the drum. (3) Do not expand and bend the corona wires and grid wires. (4) Do not rub the corona wires with rough material (sand paper,... etc.) as this will damage the corona wire. (5) Do not use any solvent to clean the wire as this will cause uneven charge on the drum. (6) Make sure that the wire junction [E] is positioned inside the right endblock.

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4.6

PICK-OFF PAWL UNIT REMOVAL

[A]

[B]

1. Remove the drum unit and place it as shown. 2. Remove the pressure spring [A] and pick-off pawl unit [B] (2 screws and 1 connector). NOTE: When installing and/or removing the pick-off pawl unit, do not press too strongly. Otherwise, the drum unit may deform.

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4.7

GRID VOLTAGE ADJUSTMENT

Rev. 2/7/96

ADJUSTMENT STANDARD: dc --940 10V.

NOTE: This adjustment is required when the charge/bias/grid power pack is replaced. 1. Turn off the main switch and remove the rear cover. 2. Connect the ground terminal of the multimeter to the machine ground, and connect the voltage terminal to TP2 on the charge/bias/grid power pack. 3. Set the multimeter range to dc 1500 V. 4. Turn on the main switch. 5. Access SP mode and select No. --11. 6. Press the key to turn on the grid voltage.

7. Check the multimeter. If the voltage is not that of the standard voltage, press the keys. 8. If the voltage is within that of the standard voltage, press the key. key and then change the voltage using and

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4.8

DRUM CURRENT ADJUSTMENT

NOTE: a) The drum currents vary with environmental conditions such as humidity and atmospheric pressure. Generally it is not necessary to adjust the drum currents because they have already been adjusted for a wide range of environments at the factory. b) Drum current adjustment is necessary whenever the power packs are replaced: adjustment may also be necessary to correct problems with paper separation, incomplete toner transfer, or image density. c) Make sure that the main switch is turned off when you change the range on the digital multimeter. If it is not, the multimeter may be damaged. d) There are variable resistors to change the charge currents, but they should not be changed. The drum currents should be adjusted by changing SP mode setting. Preporation 1. Remove the developer unit. 2. Remove the drum unit. 3. Remove the OPC drum from the drum unit, and install the current measurement drum [A] instead of the OPC drum.

[A]

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4. Install the drum unit [B] on the machine.

[B]

CAUTION: Be careful not to turn on the main motor. If the main motor accidentally turns on, some parts around the drum may be damaged.

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4.8.1 Charge Current Adjustment

ADJUSTMENT STANDARD: dc --1000 20 A WARNING: Make sure that the machine is unplugged before connecting the multimeter on the charge/bias/grid power pack. Pay extreme attention when connecting the multimeter. The potential of the charge corona terminal become s --5kV. 1. Connect all the terminals of the current measurement drum to the machine ground. 2. Disconnect the charge corona terminal of the charge/bias/grid power pack. 3. Connect the multimeter as shown in the illustration. 4. Set the multimeter range at dc 2 mA. 5. Plug in the machine and turn on the main switch. 6. Access SP mode and select No. --10. 7. Press the key to turn on the charge corona.

8. Check the multimeter. If the voltage is not that of the standard voltage, press the key and then change the voltage usin g keys so that the charge current is dc --1000 20 A. 9. If the voltage is within that of the standard voltage, press th e key. and

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4.8.2 Transfer Current Adjustment

ADJUSTMENT STANDARD: dc --100 5 A (Leading edge to 20 mm from the trailing edge) dc --150 5 A (20 mm trailing edge) 1 Connect the multimeter as shown above. 2. Set the multimeter range at dc 200 A. 3. Plug in the machine and turn on the main switch. 4. Access SP mode and select No. --12. 5. Press the key to turn on the transfer corona. key and then change the keys so that the transfer current is dc

6. Check the multimeter. Press th e voltage usin g --100 5 A. and

7. If the voltage is within that of the standard voltage, press th e 8. Select SP mode No. --13. 9. Press the key to turn on the transfer corona. key and then change the

key.

10. Check the multimeter. Press th e voltage usin g --150 5 A. and

keys so that the transfer current is dc

11. If the voltage is within that of the standard voltage, press th e

key.

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4.8.3 Separation Current Adjustment

ADJUSTMENT STANDARD: ac 250 10 A (Normal Paper) ac 350 10 A (Film and leading edge of translucent paper) dc --20 2.5 A 1. Connect the multimeter as shown above. 2. Set the multimeter range at ac 2 mA. 3. Plug in the machine and turn on the main switch. 4. Access SP mode and select No. --14. 5. Press the key to turn on the separation corona. key and then change the current

6. Check the multimeter. Press th e using 10 A. and

keys so that the ac separation current is ac 250

7. If the voltage is within that of the standard voltage, press th e 8. Select SP mode No. --15 9. Press the key to turn on the separation corona.

key.

10. Check the multimeter. Press th e using 10 A. and

key and then change the current

keys so that the ac separation current is ac 350

11. If the voltage is within that of the standard voltage, press th e

key.

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12. Set the multimeter range at dc 200 A. 13. Select SP mode No. --16. 14. Press the key to turn on the separation corona.

Rev. 5/95

15. Check the multimeter. Press th e using 2.5 A. and

key and then change the current

keys so that the dc separation current is dc --20

16. If the voltage is within that of the standard voltage, press th e 17. Select SP mode No. --17. 18. Press the key to turn on the separation corona.

key.

19. Check the multimeter. Press th e using 2.5 A. and

key and then change the current

keys so that the dc separation current is dc --20

20. If the voltage is within that of the standard voltage, press th e

key.

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5.
5.1

FUSING
FUSING UNIT REMOVAL
[H] [H] [I]

[E] [B]

[F]

[C]

[D]

[A]

[F]

[B] 1. Remove the copier rear cover.

[G]

2. Open the exit cover [A] and remove the shoulder screws [B] at both ends. 3. Disconnect the connector [C] and flex the hinge arms [D] of the exit cover slightly to the outside of the exit unit shafts and remove. 4. Turn the exit unit 1/4 of a turn to the front side (rear view) and remove it by pulling out. NOTE: When reinstalling the exit unit, set the right hinge [F] between the two pulleys [G] and raise the left hinge [H] using tape [I].

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[F]

[E] [G]

[C]

[D] [C]

[B]

[A]

5. Disconnect the connectors [A]. 6. Remove the screw [B] fixing the safety switch bracket. 7. Remove the 2 screws [C]. 8. While pressing down the fusing pressure release bar [D], pull out the fusing unit. NOTE: While pressing down the fusing pressure release bar [D], set the fusing unit on the guides [E] and align the cuts [F] to the side plates [G] at both ends when reinstalling the fusing unit.

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Rev. 5/95

5.2

HOT ROLLER REPLACEMENT

[B] [F] [B]

[C] [D]

[C] [E]

[G]

[J]

[K]

[I] [A]

[G]

[A] [J] [I]

[H]

NOTE: Be careful not to damage the hot roller thermistor when removing and reinstalling the hot roller. 1. Remove the fusing unit. 2. Remove the pressure springs [A]. 3. Remove the fusing lamp brackets [B] and cushions [C] (1 screw each). 4. Remove the fusing lamp [D] from the left side as shown (1 connector [E], rear view). 5. Remove the 2 C-rings [G], 1 gear [H], 2 bushings [I], and 2 bearings [J]). 6. Slide the hot roller [K] to the right side and remove it from the left side.

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5.3

PRESSURE ROLLER REPLACEMENT

[H] [D] [G]

Rev. 5/95

[C] [E] [B] [F] [A] [I]

[I] [J]

CAUTION: 1) Do not touch the hot roller or pressure roller while they are hot. 2) Be careful not to damage the hot roller thermistor [A] and pressure roller thermistor [B] when removing and reinstalling the pressure roller. 1. Remove the hot roller. 2. Push the projection [C] of the fusing entrance guide stopper and remove the fusing entrance guide [D]. 3. Remove the pressure roller stripper unit [E] (4 screws). 4. Lift up the pressure roller (access the pressure roller from the cut [F] of the frame), slide out the pressure roller shaft [G] to the left, then remove the pressure roller [H]. 5. Replace the pressure roller (2 stoppers [I] and 1 shaft [J]). NOTE: When reinstalling pressure roller, set the right pressure roller stopper and push the pressure roller shaft to the right from the left, and set the left pressure roller stopper [ ].

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[A] [B]

[C]

5.4

PRESSURE ROLLER THERMISTOR REPLACEMENT

1. Follow step 1 to 5 of the fusing unit removal. 2. Remove the pressure roller thermistor [A] (1 screw).

5.5

PRESSURE ROLLER STRIPPER UNIT REPLACEMENT

1. Follow step 1 to 5 of the fusing unit removal. 2. Remove the pressure roller stripper unit [B] (4 screws).

5.6

HOT ROLLER STRIPPER UNIT REPLACEMENT

1. Follow step 1 to 4 of the fusing unit removal. 2. Remove the hot roller stripper unit [C] (2 screws).

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[A] [E] [D] [E] [E] [G] [C] [B]

[A] [F] [G]

5.7

HOT ROLLER THERMISTOR REPLACEMENT

1. Remove the fusing unit. 2. Remove the 4 screws [A] of the fusing stay. 3. Disconnect the thermofuse connector [B] from the fusing lamp harness 4. Remove the hot roller thermistor [D] (1 screw and 1 spring, 7 clamps [E]). [C].

5.8

FUSING THERMOFUSE REPLACEMENT

1. Follow step 1 to 3 of the hot roller thermistor replacement. 2. Remove the fusing thermofuse [F] (1 screw and 4 clamps [G]).

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5.9

FUSING TEMPERATURE ADJUSTMENT

[A] [B]

Caution: When the main switch is turned on, the machine will suddenly start to drive the fusing section. Keep your hands away from any mechanical and electrical components during this period. This procedure is required only when the hot roller thermistor is replaced. Adjustment standard: Mode 1 (155 C), Mode 2 (160 C), Mode 3 (165 C), Mode 4 (170 C), Mode 5 (180 C), Mode 6 (190 C), Mode 7 (196 C) 1. Turn off the main switch. 2. Remove the copier rear cover. 3. Remove the pressure roller thermistor screw and hang the thermistor by the harness. 4. Actuate the fusing exit safety switch [A]. 5. Turn on the main switch, select the normal fusing temperature mode, and wait for longer than 10 minutes. 6. Using a digital thermometer and probe [B], measure the temperature at the middle of the hot roller. 7. If the actual temperature is different from the value for the mode being used (use SP#1 to find out the current mode), adjust the temperature using SP#-7. 8. Repeat steps 5 to 7 and confirm the temperature. 9. Reassemble the machine.

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6.
6.1

T & S CORONA UNIT

T & S CORONA UNIT REMOVAL

[A] [B]

[C]

[C]

[D] 1. Open the paper path section [A] and take out the T & S corona unit [B] (2 connectors [C]). NOTE: 1) Make sure that the T & S corona unit is set correctly by pressing it down when reinstalling. 2) Remove the connector cover [D] (1screw) for connecting the 2 connectors.

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6.2

TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT

[A]

[B]

[I] [C] [B] [H] [F] [E]

[H]

[D]

[G] NOTE: (1) Handle the new wire by the ends only. Oil from your hands may cause uneven charging of the drum. (2) Do not stretch or bend the corona wires. (3) Do not rub the corona wires with rough material (sand paper, etc.) as this will damage the corona wire. (4) Do not use any solvent to clean the wire as this will cause uneven charging of the drum. 6.2.1 Preparation 1. Remove the T & S corona unit. 2. Remove the paper guides [A] and endblock covers [B].

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6.2.2 Separation Corona Wire Replacement 1. Remove the separation corona wire [C]. 2. Hook the new separation corona wire on the terminal [D] of the right endblock. NOTE: Make sure that the wire junction [E] is positioned inside the right endblock. 3. Hook the other side of the separation corona wire on the spring hook [F] (special tool: 54199653). While pushing the spring [G] in the direction of the arrow, hook the separation corona wire on the spring. 4. Set the wire on the slots [H]. 6.2.3 Transfer Corona Wire Replacement 1. Remove the transfer corona wire [I]. 2. Install the new transfer corona wire.

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7.
7.1

OTHERS
OZONE FILTER REPLACEMENT

[H] [G] [F]

[A]

[E] [I] [D]

[B]

[I]

[C] NOTE: Take care not to damage the mylars [A] on the rear feed table. 1. Open the fusing exit cover [B] and exit unit [C]. 2. Remove the copy tray [D]. 3. Remove the rear feed table assembly [E] (2 screws and 1 connector). 4. Unhook the blower duct [F] and remove. 5. Unhook the fan support plate [G] and remove. 6. Replace the ozone filter [H]. NOTE: When reinstalling the rear feed table assembly, fix the 2 screws [I] while pushing the assembly.

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7.2

ANTICONDENSATION HEATER INSTALLATION

[C]

[A]

[B] [C]

1. Remove the rear cover of the machine (2 screws). 2. Remove the T&S corona unit. 3. Install the anticondensation heater [A] (3 screws). 4. Put the harness of the heater into the cutout [B] of the frame. 5. Connect the connector of the heater [C] with the one beside the ac drive board.

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Rev. 5/95

8.

COPY QUALITY ADJUSTMENT

-- General Informatio n -Image density is affected by the following factors: (1) Light Intensity (2) Bias Voltage (3) Toner Density (4) Grid Voltage (5) Charge Corona Current The items listed above must be kept in balance to maintain correct image density. In the field, image density should be adjusted first by changing the light intensity. (Adjust the light sensor voltage.) If results are unsatisfactory, the bias voltage can be changed. Also, if requested by the customer, the overall image density can be changed by changing the toner density. Normally, this should be kept at the normal position (factory setting). The grid voltage and charge corona current are carefully adjusted at the factory. Any adjustment out of the adjustment standards will result in over toning, toner scattering, dirty background, or light image density problems. The grid voltage and charge corona current adjustment should be done only when replacing the Charge/Bias/Grid power pack, or to correct certain problems with image density after checking all other possible causes.

NOTE: Adjusting grid voltage will not affect toner supply amount, but will affect the amount of charge reaching the drum. Exposing the the drum to light will not disipate all residual voltage resulting in overtoning and background.

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8.1

LIGHT SENSOR ADJUSTMENT

1. Every Call When: 2. When replacing the following part Exposure lamp Drum Purpose: Adjustment Standard: Perform: How: Light sensor RAM on the main board

To maintain the correct light intensity. Level 2 (10%) of the 9 step gray scale on the OS-A1 chart should be slightly visible when the 4th manual image density level is selected. Change SP #-6 setting. Change the light sensor voltage.

1. Turn off the main switch. 2. Clean the following parts:

Item No. (1) (2) (3) Section Optics (Exposure glass, fiber optics array) Corona wires (charge, transfer and separation) and casing. PTL Method Damp cotton and dry soft cloth Dry cloth Dry cloth or blower brush

3. Remove the middle right cover. 4. Make several copies at manual image density level 4 with OS-A1 chart. 5. Confirm that level 2 (10%) of the 9 step gray scale is slightly visible on the copy. If the copy image density is not correct, proceed with the following step. 6. Change SP #-6 setting in the SP mode. If the image density is too dark: Increase SP #-6 setting. If the image density is too light: Decrease SP #-6 setting. 7. Confirm that image density is within the adjustment standard.

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8.2

IMAGE BIAS ADJUSTMENT

1. The image is blurred even though the image density in black solid areas is acceptable. When: 2. Dirty background, where the problem is not caused by excess toner and cannot be solved by adjusting the light sensor voltage. To improve the copy image. SP #-20 Change the development bias voltage for image density control by SP #-20.

Purpose: Perform: How:

SP #-20

3 Standard 038 Darker Lighter

1. Make a copy after adjusting the light intensity. 2. If the image is blurred: Decrease bias voltage by one step and readjust light intensity. If the background is dirty: Increase bias voltage by one step and readjust light intensity.

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8.3

TONER DENSITY ADJUSTMENT

When: Purpose: Perform: How:

Customer wants to change the overall image density of the copies. To change toner concentration inside development unit. SP #-22 Change the toner density setting by SP #-22

NOTE: The toner density can also be adjusted using SP #-30 (toner density sensor voltage setting). To return SP #-30 to the initial value, take memo when the value is changed.

8.4

REGISTRATION ADJUSTMENT

When: Purpose: Adjustment Standard: Perform: How:

Registration is not within the adjustment standard. To maintain proper registration. 0 3 mm (0 0.12") SP #-5 Change the registration roller start timing by SP #-5.

1. Make several copies by using the manual feed or roll feeder and check the registration. 2. Adjust the registration using SP #-5 if the registration is not within the adjustment standard.

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TROUBLESHOOTING

1. COPY QUALITY TROUBLESHOOTING

1.1 LOW IMAGE DENSITY
Is the used paper moist or extremely dry? No Yes Replace the paper. Is the toner sensor voltage within the no toner supply level (level 0) ? (Refer to Page 2-16.) Yes No Is there sufficient toner in the cartridge? Yes No Replace the toner cartridge. Is the toner supply clutch energized? Yes No Check the main board and the toner supply clutch. Does the toner sensor voltage decrease in the special toner supply mode (SP#62)? Yes No Check the toner supply mechanism. The amount of toner used exceeds the toner supply amount. Supply toner until the toner sensor voltage reaches the target value. Is the solid black copy dark enough? (Make a solid black copy using SP # -51.) Yes No Does the image density recover (without dirty background) after forcing supply of toner using SP#62? Yes No Check the charge corona, transfer corona and development bias. Check the toner sensor and main board. Check the light sensor, FL regulator and main board.

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1.2 UNEVEN COPY IMAGE

Make a solid black copy using SP # --51. Is the image density even? Yes No Is the developer level in the development unit? Yes No

Check and correct the machine level. Clean the charge corona wire, grid wire, and transfer corona wire. Check if they are correctl set y on the slots of the end blocks. Clean the optics. If the problem is not fixed, replace the exposure lamp.

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1.3 DIRTY BACKGROUND

Clean the optics and check the copy image. No good Change the light sensor setting to a lighter position using SP # --6. No good Is the bias voltage correct? Yes No

Adjust the bias voltage. Is the toner sensor voltage much lower than the threshold between level 0 and 1? (Check using SP #--32 referring to Page 2-16.) No Yes Check the main board and toner supply clutch. Is the image density of solid areas high? No Yes Check the toner sensor. Make several blank copies. Is the background still dirty? Yes No

Check the cleaning blade. Are the grid voltage and the charge corona current correct? Yes No

Adjust the grid voltage and/or the charge corona current. Replace the drum.

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1.4 BLACK LINE OR BAND

Vertical line or band? Yes No Does the black line appear at 251 mm intervals? No Yes Clean or replace the drum. If a black band appears 250 mm from the leading edge, turn the main switch off and on . If the problem is not fixed, check the T& S corona leakage .*NOTE Check the part of the following items that corresponds to the position of the vertical line or band.

Charge corona wire Grid wires Light path (Exposure lamp, fiber optics array, exposure glass) Cleaning blade Development unit Drum

NOTE:

If the separation corona leakage is detected, the separation corona will be turned off. This condition will not be reset until the main switch is turned off and on. If the separation corona does not turn on, a black band appears 250 mm from the paper leading edge.

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1.5 ENTIRELY BLANK COPY

Is the used paper moist? No Yes Replace the paper. Are the terminals of the charge corona unit and the T& S corona unit connected properly? Yes No

Set the terminals properly. Is the charge corona wire or the T & S corona wire broken? No Yes Replace the broken part. Are the charge corona and transfer corona applied? Yes No

Check the main board, charge/bias/grid power pack, and T & S power pack. Does leakage occur in the T & S endblocks? No Yes Replace the defective parts. Are the development drive gears broken? No Yes Replace the broken gears. Check the drum drive mechanism.

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1.6 PAPER CREASING

Is the used paper moist? No Yes Change the paper. Is the paper feed direction the same as the paper fiber direction? No Yes Change the paper transport direction, if possible .(NOTE 1.) Decrease the fusing temperature using SP mode #1 to #3 . (NOTE 2.)

NOTE:

1. If there is rib shape creasing, the paper feed direction should be the same as the paper fiber direction. 2. After decreasing the fusing temperature, check if the image is completely fused on the paper.

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2. SERVICE CALL CONDITION

When a service call condition occurs, the Call Service indicato r and service call codes are displayed. When the service call conditions E2, E3, E4, E5, E6, E7, and E8 conditions occur, for safety reason they cannot be cleared by turning the main switch off and on. Accessing SP38 and changing the date from "1" to "0" must be done to clear these service call conditions.

2.1 SC Code E-1: Exposure Lamp Abnormal

-DefinitionThe light sensor voltage is less than 0.4 volts for 10 seconds. <Points to check> Exposure lamp Light sensor FL regulator (CN402-1,2,4, and 5, CN401-1, -2, -4) Main board (CN106-A3, and CN104-B1, -B2, -A29 -A30)

2.2 SC Code E-2: Fusing Thermofuse Open

-DefinitionThe temperature detected by the hot roller thermistor does not reach 100 C within 4 minutes and 30 seconds after the main switch is turned on. <Point to check> Fusing thermofuse Hot roller thermistor AC drive board (T202-2, RA201-T4) Main board (CN106-A2, A4, B12, B14, B15)

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2.3 SC Code E-3: Hot Roller Thermistor Open

-DefinitionThe temperature detected by the hot roller thermistor does not reach 50 C within 3 minutes after the main switch is turned on. <Point to check> Hot roller thermistor AC drive board ( T202-2, RA201-T4) Fusing thermofuse Main board (CN106-A2, -A5, -B11, -B14, -B15)

2.4 SC Code E-4: Hot Roller Thermistor Short

-DefinitionThe resistance of the the hot roller thermistor is less than 0.11 K . <Point to check> Hot roller thermistor Main board (CN106-A2, -A5, -B11, -B14, -B15)

2.5 SC Code E-5: Pressure Roller Thermistor Open

-DefinitionThe resistance of the pressure roller thermistor is more than 0.53 M . <Point to check> Pressure roller thermistor Main board (CN106-A2, -A4, -B12, -B14, -B15)

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2.6 SC Code E-6: Pressure Roller Thermistor Short

-DefinitionThe resistance of the pressure roller thermistor is less than 0.55 K . <Point to check> Pressure roller thermistor Main board (CN106-A2, -A5, -B11, -B14, -B15)

2.7 SC Code E-7: Fusing Overheat

-DefinitionThe temperature detected by the hot roller thermistor becomes higher than 250 C <Point to check> Hot roller thermistor Fusing thermofuse AC drive board (T202-2, RA201-T4) Main board (CN106-A2, -B14, -B15)

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2.8 SC Code E-8: Fusing Warm-up Error

-DefinitionThe temperature detected by the hot roller thermistor does not reach the target ready temperature within 12 minutes after main switch is turned on. <Point to check> Hot roller thermistor Fusing lamp Fusing thermofuse AC drive board (T202-2, RA201-T4) Main board (CN106-A2, -A5, -B11, -B14, -B15) AC harness

2.9 SC Code E-9: Toner Density Sensor Abnormal

-DefinitionThe toner density sensor voltage is less than 0.5 volts or more than 4.5 volts. NOTE: This condition is not detected until 251 copies since initializing developer.

<Point to check> Toner density sensor Flow of the developer at the toner density sensor area Main board (CN104-A10, -A11, -B20, -B21)

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2.10 SC Code E-10: Main Motor Abnormal

-DefinitionThe main board does not receive a signal from the main motor for 2 seconds while the main motor is on. <Point to check> Main motor Mechanical interference of the main motor drive Main board (CN106-A12, -A13)

2.11 SC Code E-11: Toner Density Sensor adjustment Error

-DefinitionThe toner density sensor voltage cannot be adjusted to its standard value (4.1 0.1 volts) during the new developer initialization. NOTE: If clearing the SC condition, the previous data of SP#-30 is still used until its next initialization.

<Point to check> Toner density sensor Developer Flow of the developer at the toner density sensor area Main board (CN104-A10, -A11, -B20, -B21)

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Rev. 5/95

3. BLOWN FUSE TABLE

3.1 POWER SUPPLY UNIT
Europe version
Fuse No. FU1 FU2 FU3 FU4 Specification 250V 4A 250V 6.3A 250V 6.3A 250V 6.3A Symptom No power. No indication. Beeper sounds. E=10 is indicated. Not used.

USA version
Fuse No. FU1 FU2 FU3 FU4 Specification 125V 8A 250V 5A 250V 5A 250V 5A Symptom No power. No indication. Beeper sounds. E=10 is indicated. Not used.

FU5 125V 1A Counte r No symptoms

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ROLL FEEDER

1. SPECIFICATIONS
Roll Paper Size: Width: 210 mm to 914 mm, 8 1/2" to 36" Length: 150 meters Diameter: Less than 170 mm --Preset Cut: 1189 mm, 841 mm, 594 mm, 420 mm, 297 mm 48", 36", 24", 18", 12" 46", 34", 22", 17", 11" Up to 10 extra preset cut length can be specified by SP23 ~ 32. --Selected Length Cut: 245 mm to 2000 mm (1 mm per step) 9.6" to 80" (0.1" per step) Within 0.80 second 50 mm/s 1 to 99 Microprocessor +24 volts and +5 volts from the copier Maximum 110 W 1,080 mm x 475 mm x 295 mm 42.71" x 18.70" x 11.61" 29 kg, 63.8 lb

Cut Size:

Cutting Time: Paper Transport Velocity: Repeat Quantity: Control: Power Source: Power Consumption: Dimensions (W x D x H): Weight:

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2. MECHANICAL COMPONENT AND DRIVE LAYOUT

4 3 2 1 5

8 5

1. Paper Feed Motor 2. Idle Pulley 3. Timing Belt 4. Cutter Motor

5. Paper Feed Rollers 6. Paper Roll Spool 7. Paper Roll 8. Cutter Unit

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3. ELECTRICAL COMPONENT DESCRIPTIONS

The index numbers refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper).
Name Motors Paper Feed Cutter Switches Door Left Cutter Right Cutter Function Drives all mechanical components except the cutter unit (DC Stepper Motor). Drives the cutter (DC Reversible Motor). Index No. 32 39

Indicates "Door Open" on the operation panel and disables the key operation. Detects whether or not the cutter is at the left home position. Detects whether or not the cutter is at the right home position.

38 40 33

Sensors Paper End Leading Edge Humidity

Detects when the roll paper runs out. Misfeed detector. Also detects the leading edge of the paper to start the paper length pulse count. Detects humidity and turns on the RF antihumidity heaters while copying is not being done (if the humidity is higher than 45%).

35 42 34

Printed Circuit Board RF Control Controls all roll cutter unit functions in accordance with copier CPU. Others Upper RF Antihumidity Heater Lower RF Antihumidity Heater

37

Removes humidity from the roll paper Removes humidity from the roll paper

41 36

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A163

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4. MECHANICAL OPERATION
4.1 BASIC OPERATIO N

[D] [C]

[A]

[B]

The paper feed rollers [A], which are turned by the paper feed motor, feed paper from the paper roll [B] through the cutter unit [C] to the paper leading edge sensor [D] according to the signal from the copier. When the paper feed motor starts, the copier CPU starts measuring the length of the paper. (The paper length is measured by counting the number of steps as the paper feed motor [stepper motor] turns.)

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Rev. 5/95

[C]

[B] [A]

[D]

After the leading edge of the paper reaches the exit rollers [A], the paper is directed to the copier registration roller [B]. The registration roller stops rotating after the registration sensor [C] detects the leading edge of the copy paper. The copy paper is fed to the registration roller and stops to wait for the original. At the appropriate timing after the original registration sensor is activated by the original, the registration roller and roll paper feed motor start to rotate. The copy paper starts to be fed again. Just before the cut length of copy paper is fed, the speed of the roll paper feed motor is doubled. A paper buckle forms at the trailing edge of the copy paper. When the paper reaches the proper length, paper feed motor stops and the cutter unit cuts the paper. During the time that paper feed motor has stopped, the registration roller continues to feed the copy paper forward. The paper is cut during the time it takes for the paper buckle to be pulled straight. This allows for a neat cut. When the selected cut length is between 245 mm and 309 mm, the roll cutter unit cuts the paper after the first rotation of the roll paper feed roller [D], as the paper reaches the selected length before the registration roller starts to rotate again. After the registration roller stops rotating, the roll paper feed motor continues to rotate and a paper buckle forms at the trailing edge of the paper. When the selected cut length is between 309 mm and 410 mm, the roll cutter unit cuts the paper after the second rotation of the roll paper feed roller. The paper buckle forms after the first rotation of the roll paper feed motor, because the paper feed roller is still rotating after the registration roller has stopped. The registration roller brake ensures that the very stiff types of paper will not rotate the registration rollers when the paper buckles while it is stopped at these rollers.

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4.2 CUTTER UNIT OPENING AND CLOSING MECHANISM

[B] [A]

[D] [C] The gear [A] from the paper feed motor disengages from the cutter unit gears [B] when the roll cutter unit is unlocked from the lower position and lifted up. At this time, the cutter unit is locked at the upper position by the lock lever [C], and the wheel [D] on the right side can be rotated manually to position the leading edge of the roll paper.

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4.3 CUTTER OPERATION

[C]

[B]

[C]

[A]

The cutter unit uses a sliding rotary cutting blade [A] which is pulled past a fixed blade by a drive wire. The rotary cutting blade allows the cutter unit to cut paper in both directions. There are home position switches [B] at both ends of the cutter unit. The cutter motor turns off, stopping the cutting action, when the rotary cutting blade knob plate [C] turns off one of these switches.

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5. SERVICE TABLES
5.1 TEST POINTS
Function GND VA (24 V) VC (5 V) TP No. TP903 TP901 TP902

5.2 BLOWN FUSE CONDITION

Component F901 (250V/1.0A) Unit RF Main board Symptom The AC line for the R/F antihumidity heaters is cut. The heaters are not turned on.

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6. INSTALLATION PROCEDURE
Roll Feeder (A571) CAUTION: Unplug the copier power cord before starting the following procedure. Check the accessories and their quantities according to the following list: Harness Cove r ........................................................................... . 2 pcs Angle Bracke t ............................................................................. . 1 pc Spacer ........................................................................................ . 1 pc Small Cap.................................................................................... . 1 pc Screws - M4x 8 ........................................................................... . 8 pcs Screws with Spring Washer - M4x 8 ............................................ . 2 pcs

NOTE: When the Roll Feeder is installed on the copier, the table (A714) is required.

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[A]

[D] [C]

[C] [H] [E] [G]

[C]

[H] [B]

[F]

1. Lower the feet [A] so that the table does not move while the roll feeder is being installed on the table and the copier. NOTE: Do not place the roll feeder unit [B] onto the floor roughly, to prevent the left and right covers from being damaged. 2. Remove the shipping tapes [C] and shipping cushions [D]. 3. Remove the left and right covers [E and F] (3 screws each). 4. Remove the front cover [G] (2 screws) and lower the front cover arms [H] to the down position.

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[A] [E]

[B] [F]

[C]

[D]

[G] 5. Open the copier paper path section and remove the copier left lower cover [A] (2 screws), lower right front cover [B] (2 screws), lower right middle cover [C], toner collection bottle [D], and rear cover [E] (2 screws). 6. Remove the small caps [F] from the copier rear cover using cutting pliers. 7. Remove the table rear cover [G] (4 screws).

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[A]

[D] [C]

[B]

NOTE: Take care not to drop the manual feed table when removing the bracket [A]. 8. Remove the lower front cover [B] (2 screws), reinforcement plate [C] (1 screw), bracket [A] (4 screws) (which is changed by the harness), and the manual feed table [D].

[C]

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[A]

[B]

[D] [E] [F]

9. Mount the roll feeder unit on the copier (hook the mounting arms [A] on both sides into the mounting rail [B]). NOTE: Lift the unit by holding the plate [C] just under the size marks. 10. Install the angle bracket [D] and spacer [E] (4 screws). 11. Install the small cap [F] (2 screws).

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[A] [H] [I] [G] [C] [D]

[J]

[A]

[B] [F] [E] NOTE: To ensure grounding, tighten the screws for the ground wire until the spring washers [A] are flattened. 12. Secure the grounding wire [B] (1 screw with spring washer) to the inside of the table. 13. Run the roll feeder harness [C] and roll feeder heater harness [D] through the holes in the table rear cover (right [E] and left [F]) 14. Connect the roll feeder harness to the copier main board {2 connectors [G] and 1 grounding wire [H] (1 screw with spring washer)}. 15. Connect the roll feeder heater harness connector [I] to the copier ac drive board connector. 16. Install the harness covers [J] (1 screw each). 17. Reinstall Manual Feed Table 18. Reattach all the covers and manual feed table excluding the roll feeder right cover.

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[C]

[B]

[A]

[E]

[F]
Length Temperature NORMAL HIGH (VELLUM) LOW (FILM)

[D]

300 XX XX XX

PRG. No. 42 43 44

1100 XX XX XX

PRG. No. 45 46 47

18. Plug in the power supply cord and turn on the main switch. 19. Press the following keys on the operation panel: Clear Modes key [A] + key [B] - key [C] Clear/Stop key [D] 20. Press the Clear/Stop key again and hold it down for longer than 3 seconds. The roll paper end and call service indicators will blink (SP mode). 21. Select 40 using the + and - keys. Enter "1" by pressing the following keys. Function Select key [E] + key RF Select key [F]. 22. Input values into SP modes 42 to 47 in accordance with the decal that is attached to the right side plate. 23. Press the Clear Modes key 3 times to leave the SP mode. 24. Reattach the roll feeder right cover. 25. Check the roll feeder operation.
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7. REPLACEMENT AND ADJUSTMENT

7.1 EXTERIOR COVER REMOVAL
7.1.1 Front Cover Removal

[A] [C]

[C] [B]

1. Remove the front cover [A] (2 screws). NOTE: If the screw holes for the front cover become worn by the screws, extra holes are provided next to the original screw holes. 7.1.2 Left and Right Cover NOTE: Be careful not to drop and damage the lower front cover [B]. 1. Remove the left and right covers [C and D] (3 screws each). NOTE: When reattaching the left and/or right covers, unlock and lift the cutter unit for easier assembly.

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7.2 CUTTER UNIT REMOVAL

[C]

[D]

[A] [B]

[A] 1. Remove the roll feeder left and right covers. 2. Remove the 4 screws [A] of the cutter unit. 3. Take out the cutter unit [B] (1 connector [C]). NOTE: When reinstalling the cutter unit, attach the cutter unit cover [D] with the cutter unit.

A163

7-18

FSM

7.3 PAPER FEED ROLLER REPLACEMENT

[A]

[B]

[C]

[I] [H]

[D]

[E]

[H] [G]

[E]

[F]

1. Remove the cutter unit. 2. Unlock and lift the paper feed roller unit [A] using the release lever [B]. 3. Remove the release lock lever [B] (2 screws). 4. Remove the feed roller guide plate [C] (6 screws). 5. Replace the paper feed roller [D] (2 allen screws [E], 1 gear [F], 1 snap ring [G], 2 bushings [H], and 1 retaining ring [I]).

FSM

7-19

A163

7.4 PAPER FEED MOTOR TIMING BELT TENSION ADJUSTMENT

[A]

[B]

If the timing belt tension for the paper feed motor is not correct, the paper cut length varies for each copy paper. Readjust the timing belt tension for the paper feed if this occurs. 1. Remove the small cap [A] (2 screws). 2. Loosen the screw [B] and re-tighten it.

A163

7-20

FSM

7.5 CUT LENGTH ADJUSTMENT

Rev. 5/95

The cut length adjustment should be done when the roll feeder is installed to correct cutting errors. The cut error correction data is determined in the factory without the copier installed. The cut length varies depending on the copier on which it is installed and/or paper type used. If required, adjust the cut length as follows: NOTE: The cut length should be measured 10 minutes or later after copying because the fusing unit dries the paper and reduces its length temporarily. 7.5.1 Preset Cut : Adjustment standards : 3 mm (for length shorter than 420 mm) 5 mm (for 420 to 1189 mm) NOTE: There are three settings of the cut length depending on the temperature mode. They are set in the factory to match a standard paper type. [Normal (SP#42, 45), High (SP#43, 46), Low (SP#44, 47)]. 1. Make 5 copy samples of A0 lengthwise (1189) and A3 sideways (297) in the preset cut mode. 2. Measure the difference of the length between the each copy sample and preset cut length (1189 and 297). Then, calculate the average difference. 3. Input the average value using SP modes #42 to 47 so that the cut length is within the adjustment standards. Example: 1. Current SP data #42....0 Copy sample length = 297 -- 4 Set SP mode #42...4.0 2. Current SP data #42....0 Copy sample length = 297 -- 4 Set SP mode #42...+ 4.0 4. Make A0 lengthwise and A3 sideways copies using preset cut mode and check their length. 5. Repeat steps 2 to 4 if necessary.

FSM

7-21

A163

7.6 ROLL FEED PAPER SKEW ADJUSTMENT

[B] [A]

[C] [E]

[E]

[D] 1. Mark a line [A] on the exposure glass [B]. 2. Make 594 x 1189 mm copies from the roll feeder unit. NOTE: 594 mm wide paper is easier to adjust than 841 mm wide paper. 3. Measure the lengths [C] and [D]. 4. Loosen the 2 screws [E] which determine the paper spool height. 5. If C > D, lower the right side of the paper spool. If C < D, do the opposite. 6. Make another copy. Check the lengths [C] and [D]. 7. Repeat steps 4 to 6 if necessary. NOTE: If the 10 or more copies are made continuously, the nip band width of the fusing unit may change. For correct adjustment, do this procedure at least 10 minutes after a continuous copy run of 10 or more.

A163

7-22

FSM

A251/A252 Service Manual

The A251/A252 machines are based on the A163 copier. Only the differences from the base copier are described in the following pages. Therefore, this documentation should be treated as an insert version of the base copiers service manual. It should always be utilized together with the base copiers service manual.

TABLE OF CONTENTS
1. OVERALL MACHINE INFORMATION ......................................... 1-1
1.1 SPECIFICATIONS..................................................................................... 1-1 1.2 PAPER PATH ............................................................................................ 1-3 1.4 MECHANICAL COMPONENT ................................................................... 1-4 1.5 DRIVE LAYOUT ........................................................................................ 1-6 1.6 ELECTRICAL COMPONENT DESCRIPTIONS ........................................ 1-7

2. DETAILED SECTION DESCRIPTIONS........................................ 2-1

2.1 DRUM ........................................................................................................ 2-1
2.1.2 DRUM DRIVE.............................................................................................................. 2-1

2.3 EXPOSURE............................................................................................... 2-2

2.3.2 PAPER AND ORIGINAL FEED (A252 ONLY) ............................................................ 2-2

2.4 DEVELOPMENT........................................................................................ 2-4

2.4.2 TONER DENSITY CONTROL..................................................................................... 2-4

2.8 FUSING AND PAPER EXIT ...................................................................... 2-5

2.8.1 OVERVIEW (A252 COPIER) ...................................................................................... 2-5

3. INSTALLATION............................................................................ 3-1
3.1 INSTALLATION REQUIREMENTS ........................................................... 3-1
3.1.1 ENVIRONMENT .......................................................................................................... 3-1 3.1.2 MINIMUM SPACE REQUIREMENTS ......................................................................... 3-2 3.1.3 MACHINE LEVEL........................................................................................................ 3-2 3.1.4 POWER SOURCE ...................................................................................................... 3-3

3.2 INSTALLATION PROCEDURES ............................................................... 3-4

3.2.1 COPIER....................................................................................................................... 3-4 3.2.2 TABLE (A836) ........................................................................................................... 3-12 3.2.3 COPY TRAY (A836-10)............................................................................................. 3-14 3.2.4 ROLLER FEEDER (A571)......................................................................................... 3-18

4. SERVICE TABLES ....................................................................... 4-1

4.3 SERVICE TOOLS...................................................................................... 4-1
4.3.1 SERVICE PROGRAM MODE ..................................................................................... 4-1 4.3.2 INPUT/OUTPUT CHECK MODE ................................................................................ 4-9

4.4 JAM CODE LIST...................................................................................... 4-11

4.4.2 JAM CODE TABLE.................................................................................................... 4-11

4.6 SERVICE REMARKS .............................................................................. 4-15

4.6.12 AC DRIVE BOARD.................................................................................................. 4-15

5. REPLACEMENT AND ADJUSTMENT ......................................... 5-1

5.2 OPTICS ..................................................................................................... 5-1
5.2.1 ORIGINAL FEED UNIT REMOVAL (A252 ONLY) ...................................................... 5-1 5.2.2 EXPOSURE GLASS REMOVAL (A252 ONLY) .......................................................... 5-2 5.2.3 FIBER OPTICS ARRAY REMOVAL (A252 ONLY) ..................................................... 5-2 5.2.4 EXPOSURE LAMP REMOVAL ................................................................................... 5-3 5.2.5 LIGHT SENSOR REPLACEMENT (A252 ONLY) ....................................................... 5-4 5.2.6 SYNCHRO-CUT LENGTH ADJUSTMENT (A252 ONLY) .......................................... 5-5

5.4 DRUM UNIT............................................................................................... 5-6

5.4.1 DRUM UNIT REMOVAL.............................................................................................. 5-6

TOC

A251/A252

5.5 FUSING ..................................................................................................... 5-7

5.5.1 FUSING UNIT REMOVAL........................................................................................... 5-7

5.6 T & S CORONA UNIT................................................................................ 5-9

6.5.1 TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT......................... 5-9

5.8 COPY QUALITY ADJUSTMENT ............................................................. 5-11

5.8.4 REGISTRATION ADJUSTMENT .............................................................................. 5-11

6. TROUBLESHOOTING.................................................................. 6-1
6.2 SERVICE CALL CONDITIION................................................................... 6-1
6.2.12 SC CODE E-14: ZERO CROSS SIGNAL DETECTION ABNORMAL ...................... 6-1 6.2.13 SC CODE E-15: MAIN SWITCH ABNORMAL (U.S.A. VERSION ONLY) ................ 6-1

6.3 BLOWN FUSE TABLE .............................................................................. 6-2

6.3.1 POWER SUPPLY UNIT .............................................................................................. 6-2

A251/A252

ii

TOC

 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 and the peripherals 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. 6. The copier is not attached to the table. Pushing the copier too hard may cause it to drop onto the floor. While moving the copier, push the table. 7. When the main switch is turned on, the machine will suddenly start turning to perform the developer initialization. Keep hands away from any mechanical and electrical components during this period.

HEALTH SAFETY CONDITIONS

1. Never operate the copier without the ozone filters installed. 2. Always replace the ozone filters with the specified ones at the specified intervals. 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. Caution: The RAM pack on the main control board has a lithium battery which can explode if replaced incorrectly. Replace the RAM pack only with an identical one. The manufacturer recommends replacing the entire RAM pack. Do not recharge or burn this battery. Used RAM packs 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 RAM packs in order to dispose of them later, do not put more than 100 RAM packs per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

A251/A252 OVERALL MACHINE INFORMATION

TAB POSITION 8

TAB POSITION 7

TAB POSITION 6

A251/A252 TROUBLESHOOTING

TAB POSITION 5

A251/A252 REPLACEMENTS AND ADJUSTMENT

TAB POSITION 4

A251/A252 SERVICE TABLES

TAB POSITION 3

A251/A252 INSTALLATION

TAB POSITION 2

A251/A252 DETAILED SECTION DESCRIPTIONS

TAB POSITION 1

A163, A251, A252, A174 COMPARISON CHART

THE FOLLOWING LIST DEFINES THE DIFFERENCES BETWEEN THE A163, A251, A252 and A174 WIDE FORMAT COPIERS. A163 Table Top 3 cpm 24 seconds 5 minutes No Manual Feed, (roll feed optional) No Ni-chrome Wire Lamp 11 codes, displayed in copy counter A251 Table Top 3 cpm 24 seconds 5 minutes No Manual Feed, (roll feed optional) Semi-auto synchro Cut Ni-chrome Wire Lamp 13 codes, displayed in copy counter Same as A163 1 motor, 1 fan A163 A163 A163 A163 No A163 140 V, 26 W A163 Main Motor 14 steps No A163 A163 A163 A163 A163 A163 1 Exhaust A252 Table Top 3 cpm 30 seconds 5 minutes 1 10 copies Manual Feed, (roll feed optional) Full Auto Synchro Cut Ni-chrome Wire Lamp 13 codes, displayed in copy counter Similar to A163, different in original feed area 2 motors, 1 fan A163 A163 A163 A163 No A163 140 V, 26 W A163 Main Motor 14 steps No A163 A163 A163 A163 A163 A163 1 Exhaust A174 Console 7.5 cpm 18 seconds 6 minutes 1 10 copies Manual Feed, 2 Roll Feeds (3rd roll feed optional) Full Auto Synchro Cut Halogen Lamp 18 codes, displayed in copy counter Similar to A163 7 motors, 2 vacuum, 1 fan Similar to A163 Similar to A163 Similar to A163 Similar to A163 Yes Similar to A163 125 V, 37 W Similar to A163 Separate Dev. Motor 26 steps Yes Similar to A163 Similar to A163 Similar to A163 Similar to A163 Similar to A163 Separate Fusing Motor 2 Vacuum, 1 Exhaust

Configuration Copy Speed First Copy Warm-up Time Multiple Copy Paper Feed Syncronized Cut Mode Fusing Lamp Self Diagnostic Codes Mechanical Component Layout Drive Layout Drum Area Drum Drive Charge Charge Corona Circuit Auto. Charge Wire Cleaning Exposure Exposure Lamp Development Development Drive Manual Image Density (ID) Auto Image Density Control Toner Density Control Toner Supply Transfer and Separation Cleaning / Quenching Fusing and Paper Exit Fusing Drive Fans

1 motor, 1 fan A163 A163 A163 A163 No A163 140 V, 26 W A163 Main Motor 14 steps No A163 A163 A163 A163 A163 A163 1 Exhaust

OVERALL INFORMATION

SPECIFICATIONS

1.1 SPECIFICATIONS
Configuration: Copy Process: Original Feed: Original Size: Copy Size: Copying Speed: First Copy: Warm-up Time: Multi-Copy: Automatic Reset: Photoconductor: Drum Charge: Reproduction Ratio: Exposure System: Exposure Lamp: Development: Toner Replenishment: Toner Consumption: Development Bias: Toner Density Control: Image Density Adjustment: Paper Separation: Cleaning: Paper Feeding: Image Fusing: Fusing Lamp: Self-diagnostic Codes: Table top Electrostatic transfer system Sheet feed Maximum: 914 x 2,000 (36" x 80")mm Minimum: A4 (81/2" x 11") lengthwise Same as Original Size 3 cpm (A1/D sideways) 24 seconds (A1/D sideways): A251 copier 30 seconds (A1/D sideways): A252 copier Within 5 minutes (Room temperature 23C) 1 to 1 only (A251 copier), 1 to 10 (A252 copier) 2 minutes after copying is finished (can be set to 1, 3, 4, or 5 minutes or to no auto reset) Organic photoconductor drum Single-wire with grid plate (Negative Charge) 1 : 1 (0.5%) Slit exposure via fiber optic array Fluorescent lamp (26 W) Dual-component dry toner system Cartridge system (750 g toner/cartridge) 1,860 A1 or D copies per cartridge (6% original) Negative Direct toner density detection by induction sensor Development bias control + exposure control Dual wire ac corona and pick-off pawls Cleaning blade Manual feed (roll feeder optional) Heat and pressure type, teflon (upper) and silicone rubber (lower) rollers Nichrome wire lamp (115 V: 1,100 W, 230 V: 1,100 W) 13 codes, displayed in copy counter

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1-1

A251/A252

Overall Information

1. OVERALL MACHINE INFORMATION

SPECIFICATIONS

Power Source:

115 V/60 Hz ..... 15 A 220 V/50 Hz ..... 7 A 230 V/50 Hz ..... 7 A 240 V/50 Hz ..... 7 A Maximum: 1.4 kW Warm-up: 1.2 kW Ready: 0.04 to 1.2 kW Copy cycle: 1.4 kW A251: 1,080 x 570 x 490 mm 42.1" x 22.2" x 19.1" A252: 1,080 x 623 x 480 mm 42.1" x 24.6" x 18.9" A251: 79 kg, 174.0 lb A252: 80 kg, 176.2 lb

Power Consumption:

Dimensions (W x D x H):

Weight:

Optional Equipment and Machine Configuration

Configuration Main frame Optional equipment Roll feeder (A571-06, 07) A251 copier Roll cutting rail (A570-06) Side guides (A569-06) Roll feeder (A571-06, 07) A252 copier Copy tray (A836-10) Side guide (A569-06) Additional equipment Table (A714-05) Table (A836-00) Table (A836-00)

NOTE: 1) Roll cutting rail cannot be installed on the A252 copier. 2) Key counter cannot be installed on these copiers. Other Optional Equipment Paper Spool Drum anti-condensation heater Specifications are subject to change without notice.

A251/A252

1-2

SM

PAPER PATH

- A251 copier -

- A252 copier -

E A E A B D F D

B C

A252V500.PCX

A252V504.WMF

A: Original Path (A251 copier) B: Paper from the manual feed C: Paper from the roller feed D: Paper exit E: Original Path from Rear Feeder F: Original Path (A252 copier): Switching back

SM

1-3

A251/A252

Overall Information

1.2 PAPER PATH

MECHANICAL COMPONENT

1.4 MECHANICAL COMPONENT

3 21 22 23 24 25 1 20 19 18 17 16 15 7 8 9 14 13 12 10 11 5 6 4 2

A252V502.PCX

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

1st Original Feed Roller 1st Press Rollers Copy Tray Exit Rollers Fusing Exit Rollers Hot Roller Pressure Roller Gas Spring OPC Drum T/S Corona Unit Main Drive Unit Table Paper Spool

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Roll Feeder Paper Registration Rollers Development Unit Toner Cartridge Manual Feed Table Charge Corona Unit 2nd Original Feed Roller Original Table 2nd Original Press Roller Exposure Lamp Fiber Optic Array Cleaning Blade

A251/A252

1-4

SM

MECHANICAL COMPONENT

28 31 29

32 30

26

27

A252V505.WMF

26. 27. 28. 29.

Original Guide Rear Copy Tray (Option Copy Tray) Original Feed Motor Original Entrance Roller

30. Original Rear Roller 31. Original Entrance Press Roller 32. Original Rear Press Roller

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1-5

A251/A252

Overall Information

DRIVE LAYOUT

1.5 DRIVE LAYOUT

11 12 13 14 15 16 1 2 3

10 4 5 6

9
A252V503.WMF

7 - A252 copier only 17 19

18
A252V501.WMF

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Original Feed Roller Pulley Original Feed Roller One Way Pulley Development Unit Development Unit Relay Gear Development Drive Chain Paper Registration Roller Clutch Drum Drive Relay Gear Main Motor Fusing Drive Chain Exit Unit Drive Belt

11. 12. 13. 14. 15. 16. 17. 18. 19.

Hot Roller Drive Gear Fusing Drive Sprocket/Gear Toner Collection Coil Drive Gear Drum Drive Gear Original Feed Drive Pulley Original Feed Drive Belt Original Feed Motor Original Rear Roller Pulley Original Entrance Roller Pulley

A251/A252

1-6

SM

ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper) index numbers.
Name Motors Main Function Drives all mechanical components except the original feed section (A252only) and the fans. (DC Motor) Removes the ozone built up around the drum section to the ozone filter. (DC Motor) Drives the original feed section. (DC motor) Index. No.

32 5 45

Exhaust Fan Original Feed (A252 only) Magnetic Clutches Registration Toner Supply Solenoids Pick-off Pawl Switches Main Original & Paper Feed Safety Fusing Exit Safety

Drives the registration rollers. Turns on to supply toner to the development unit.

30 31

Moves the pick-off pawls against the drum.

Supplies power to the copier. Cuts AC power when the original or paper feed unit is opened. Cuts AC power when the fusing exit unit is opened.

17 18 12

Sensors Door Open Toner Density Original Registration Light Entrance Feed Registration Exit Original Entrance (A252 only) Original Rear (A252 only) Exit Cover Open

Indicates Door Open in the operation panel and prohibits the key operation. Detects the density of toner in the developer. Detects when the original lead edge passes at the front of the exposure glass. Detects the intensity of the exposure lamp output. Detects when copy paper is inserted (jam detector). Detects when copy paper arrives at the registration rollers (jam detector). Detects jams through the fusing exit unit. Detects the original length and the original jam. Detects the original jam. Indicates Door Open in the operation panel and prohibits the key operation.

29 26 4 27 24 25 7 43 44 47

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1-7

A251/A252

Overall Information

1.6 ELECTRICAL COMPONENT DESCRIPTIONS

ELECTRICAL COMPONENT DESCRIPTIONS Name Function Printed Circuit Boards Main Controls all copier functions both directly and through other PCBs. PSU Converts the AC voltage to DC voltage. AC Drive Provides AC power to the fusing lamp and PSU. FL Regulator Stabilizes power to the exposure lamp. Operation Panel Control the operation panel display. Original Feed Drive Controls the rotation of the original feed motor. (A252 only) Lamps Exposure Fusing Pre-Transfer (PTL) Quenching (QL) Index. No. 22 21 15 23 10 46

Provides light to reflect the originals image onto the drum (fluorescent lamp). Provides heat to the fusing unit. Reduces the charge on the drum surface prior to image transfer. Neutralizes any charge remaining on the drum surface after cleaning.

2 3 20 1

Power Packs Charge/Bias/ Grid Power Pack Transfer/Separation

Provides high voltage power for the charge corona, charge grid, and development bias. Provides high voltage power for the transfer corona and separation.

19 16

Thermistors Hot Roller Pressure Roller

Monitors the hot rollers surface temperature. Monitors the pressure rollers surface temperature.

8 11

Thermofuses Fusing Heaters Anticondensation

Protects against fusing overheat.

Keeps moisture from forming inside the copier (option).

13

Others Total Counter Circuit Breaker (Europe, Asia)/ Fuse (U.S.A.)

Keeps track of the total length of copies made (Europe) or the total copies made (U.S.A.). Guards against voltage surges in the input power.

28 14

A251/A252

1-8

SM

DETAILED DESCRIPTIONS

DRUM

2. DETAILED SECTION DESCRIPTIONS

2.1 DRUM
2.1.2 DRUM DRIVE
Detailed Descriptions

[I] [H] [G] [D] [F] [E] [B] [C]

A252D502.WMF

[A]

- A252 copier only [K]

[J]
A252D503.WMF

The OPC drum [A] is 80 millimeters in diameter and 970 millimeters long. It turns constantly when the main motor [B] is on. When the main motor turns on, the drive is transmitted to the drum as follows: main motor drive gear [C] idle gears [D] drum drive gear [E] drum flange [F] drum When the drum knob is tightened, the right flange presses firmly against the drum so that the drum is held tightly between the flanges. The drum and flanges turn together when the main motor is on. At this time, the drive is also transmitted to the original feed rollers [G] through the original feed drive pulley [H] and belt [I] (A251 copier). The original feed rollers [J] (original entrance and rear rollers) for the A252 copier are driven by the original feed motor [K].

SM

2-1

A251/A252

EXPOSURE

2.3 EXPOSURE
2.3.2 PAPER AND ORIGINAL FEED (A252 ONLY)
[D]

[J]

[B] [C] [G] [H]

26 mm

[K] [F] [I]

15 mm

J: Original Rear Roller K: Original Rear Sensor [E]

[A]

A252D500.WMF

A252D501.WMF

In this machine (A252 copier), first, the leading edge [A] of the original is inserted into the original table and the original is delivered to the appropriate start position. Then the original is switched back while it is being scanned. Therefore, the original is scanned from the trailing edge to the leading edge. When an original is placed on the original table, it activates the original entrance sensor [B]. The main motor starts rotating and the quenching lamp, development bias, and PTL begin. Then, the exposure lamp turns on. To ensure correct original feeding (especially for a thin original), the original is returned toward the operator side (300 ms) before the original feed. Thus the original will be fed evenly by each roller on the original entrance roller [C]. 4 seconds after the original entrance sensor is activated, the original feed motor starts rotating 200 mm/s to turn the original entrance rollers [C] and the original rear rollers [J]. The original is delivered to the original feed start position [D]. The 4 second delay allows time for the operator to align the trailing edge (non-operator side) against the first set of the rollers (to prevent skewing).

A251/A252

2-2

SM

EXPOSURE

When the original entrance sensor is turned off by the trailing edge [E] of the original, the roll paper feed motor turns on and paper feeding starts. When the trailing edge of the original reaches the original feed start position (26 mm ahead of the original registration sensor [F]), the original feed motor stops to wait for the copy paper. The registration clutch is activated after paper feed begins. The copy paper is fed to the registration roller [G] and the registration clutch turns off when the copy paper reaches 15 mm ahead of the registration sensor [H]. The voltage is applied to the charge corona. At the appropriate time the original feed motor rotates 50 mm/s in opposite direction and the original is delivered to the exposure glass. The registration clutch and roll paper feed motor turn on again after the trailing edge of the original passes the original entrance sensor. The paper feed resumes and the copy paper is transported to the drum [I]. To measure the original length for synchro-cutting, the copier CPU measures the time from when the original registration sensor detects the leading edge of the original until the original entrance sensor detects the trailing edge of the original (delivering the original to appropriate start position). The copy paper length is measured by counting the number of steps as the roll paper feed motor (stepper motor) turns. Just before the cut length of the copy paper is fed, the speed of the roll paper feed motor is doubled. A paper buckle forms at the trailing edge of the copy paper. When the copy paper is fed out to the appropriate length, the roll paper feed motor stops and the cutter unit cuts the paper. When making duplicate copies, at the appropriate time after the trailing edge of the original passes at the original registration sensor, the rotation of the original feed motor changes in the opposite direction and the speed of the original feed motor changes to 200 mm/s. The roll paper feed motor starts again. The original is delivered to the original feed start position and roll paper feed starts again. The above process is repeated. After all the duplicates have been made, the original is stopped and caught by the original entrance roller (original hold mode: SP16). If the original hold mode is canceled by SP16, the original is fed out without being caught in the original entrance roller. During this procedure the original rear sensor [K] determines the end of the original. When the original hold mode is selected, the original is fed out when the  key is pressed.

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2-3

A251/A252

Detailed Descriptions

DEVELOPMENT

2.4 DEVELOPMENT
2.4.2 TONER DENSITY CONTROL
Recovery from Toner End Condition
After replacing the toner cartridge (opening and closing the original feed unit), the main motor rotates the development unit for 60 seconds. During this period, toner is supplied at 100% of the supply amount until TS level reaches 3. Then, the main motor rotates the development unit for another 30 seconds. Then copies can be made. If the TS level does not reach 3 after rotation of the development unit, the CPU stops the machine and displays the toner end condition. This prevents the operator from resetting the toner end condition by simply opening and closing original feed unit.

A251/A252

2-4

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FUSING AND PAPER EXIT

2.8 FUSING AND PAPER EXIT

2.8.1 OVERVIEW (A252 COPIER)
The copy paper is delivered to the lower paper exit.
Detailed Descriptions

The location of the fusing exit sensor is different from the A163 and A251 copier. Except for this difference, the A252 copier is identical to the with A251 and A163 copiers. Please refer to A163 copier service manual for details.

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2-5

A251/A252

INSTALLATION

INSTALLATION REQUIREMENTS

3. INSTALLATION
3.1 INSTALLATION REQUIREMENTS
3.1.1 ENVIRONMENT
1. Temperature Range: 2. Humidity Range: 3. Ambient Illumination: 4. Ventilation: 5. Ambient Dust: 15C to 30C (59F to 86F) 20% to 80% RH Less than 1,500 lux (do not expose to direct sunlight).
Installation

Minimum space 20 m3 Room air should turn over at least 30 m3/hr/person. Less than 0.15 mg/m3 (4 x 10-3 oz/yd3)

6. If the installation place is air-conditioned or heated, place the machine as follows: a) Where it will not be subjected to sudden temperature changes from low to high, or vice versa. b) Where it will not be directly exposed to cool air from an air conditioner in the summer. c) Where it will not be directly exposed to reflected heat from a space heater in the winter. 7. Avoid placing the machine in an area filled with corrosive gases. 8. Avoid any area higher than 2,000 m (6,500 ft) above sea level. 9. Place the machine on a strong and level base. 10. Avoid any area where the machine may be subjected to frequent strong vibration.

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3-1

A251/A252

INSTALLATION REQUIREMENTS

3.1.2 MINIMUM SPACE REQUIREMENTS

Back 600 mm

Left 600 mm

Right 600 mm

Back 1,000 mm

A252I505.WMF

1. Front: 1,000 mm (39 in) 2. Back: 3. Right: 4. Left: 600 mm (24 in) 600 mm (24 in) 600 mm (24 in)

3.1.3 MACHINE LEVEL

1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level

Make sure that the machine is level using a carpenters level.

A251/A252

3-2

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INSTALLATION REQUIREMENTS

3.1.4 POWER SOURCE

1. Input Voltage Level: 120 V, 60 Hz More than 15 A (for U.S.A. version) 220 ~ 240 V, 50/60 Hz More than 7 A (for European version) 2. Permissible Voltage Fluctuation: 10%

3. Do not set anything on the power cord.

Installation

NOTE: 1) Make sure the plug is firmly inserted in the outlet. 2) Avoid multi-wiring.

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3-3

A251/A252

INSTALLATION PROCEDURE

3.2 INSTALLATION PROCEDURE

3.2.1 COPIER
Accessory Check
Check the accessories and their quantities according to the following list:

- A252 copier Original Guide ......................................................................... 6 pcs Operating Instruction Holder ................................................... 1 pc

- A251 copier Guide Wire .............................................................................. 2 pcs Copy Tray ............................................................................... 1 pc Copy Guide ............................................................................. 1 pc Operating Instruction Holder ................................................... 1 pc

A251/A252

3-4

SM

INSTALLATION PROCEDURE

[D]

[B]

[E] [C]

[E]

[A]
A252I500.WMF

1. Lower the feet [A] so that the table does not move while the copier is being installed on the table. 2. Place the copier [B] on the table [C] (Place the copier feet [D] into the table holes [E]).

WARNING
The copier is not attached to the table. Pushing the copier too hard may cause it to drop onto the floor. While moving the copier, push the table.

SM

3-5

A251/A252

Installation

INSTALLATION PROCEDURE

[A] [B] [G]

A252I501.WMF

[C]
A252I510.WMF

[E] [D]

[F] [E] 3. Open the paper path section [A]. 4. Remove the right upper cover [B] (2 screws). 5. Remove the drum protection sheet [C] and remove the screw [D] to apply cleaning blade pressure to the drum. 6. Open the fusing exit section. Remove the two strips of shipping tape [E] and protection sheet [F]. 7. Remove two strips of shipping tape [G]. (Close the paper path section and fusing exit section.)
A252I502.WMF

A251/A252

3-6

SM

INSTALLATION PROCEDURE

[B] [A]
Installation
A252I511.WMF

[F] [D] [C]

A252I503.WMF

[E]
A252I504.WMF

8. Remove two shipping cushions [A]. 9. Open the original feed unit [B], manual feed table [C], and toner supply cover [D]. Remove a sheet [E] covering the developer entrance. Pour 1 kg of the developer [F] into the development unit evenly across its width as shown. NOTE: Close the paper path section while opening the toner supply cover. Otherwise, the toner supply cover will drop. 10. Plug in the power supply cord and turn on the main switch.

SM

3-7

A251/A252

INSTALLATION PROCEDURE

[A]

[C]

[D]

[B]

[E]

A252I508.WMF

NOTE: If the fusing temperature is lower than 60C when the main switch is turned on, the main motor will rotate. In this case, it is not necessary to access the SP mode to load the total 2kg of developer (Steps 11 to 14). Turn off the main switch to stop the main motor after the developer is loaded from the development entrance. Then, pour in another kg of developer. 11. Press the following keys on the operation panel: Clear Mode key [A] + key [B] + key Clear/Stop key [C] 12. Press the Clear/Stop key again for longer than 3 seconds. The wrench and toner end indicators will blink (SP INPUT/OUTPUT mode). 13. Select 23 using the + key and key [D] and press the RF Select key [E]. The main motor will rotate. 14. Press the RF Select key to stop the main motor after the developer is loaded from the development entrance. Pour in another kg of developer into the development unit evenly across its width (Total: 2 kg). Press the Clear Modes/Stand by key 3 times to leave the SP mode.

A251/A252

3-8

SM

INSTALLATION PROCEDURE

[A]

[E]

[C]

[B]

[F]

A252I508.WMF

15. Press the following keys on the operation panel: Clear key [A] + key [B] key [C] Clear/Stop key [D] 16. Press the Clear/Stop key again for longer than 3 seconds. The roll paper end and call service indicators will blink (SP mode). 17. Select 36 using the + and keys. Enter 1 by pressing the following keys. Function Select key [E] + key RF Select key [F] Five minutes later, the copier will automatically return to the normal operating mode from SP mode.

SM

3-9

A251/A252

Installation

[D]

INSTALLATION PROCEDURE

[A]

[B]

[C]
A252I507.WMF

18. Install the toner cartridge [A] as shown. 19. Remove the sealing tape [B] from the cartridge and turn the knob [C] until it stops.

A251/A252

3-10

SM

INSTALLATION PROCEDURE

[A] [B]

[D] [C]

A252I506.WMF

A252I509.WMF

A252 copier only (step 20)

20. Install the original guides [A].

A251 copier only (step 21 and 22)

21. Attach the guide wires [B] to the copy tray [C]. 22. Install the copy tray [C] and copy guide [D]. 23. Reinstall all the covers. 24. Check the copy quality and copier operation.

SM

3-11

A251/A252

Installation

INSTALLATION PROCEDURE

3.2.2 TABLE (A836)

Accessory Check
Check the accessories and their quantities according to the following list: Top Plate ............................................................................... 1 Left Side Plate ........................................................................ 1 Right Side Plate ..................................................................... 1 Middle Plate ........................................................................... 1 Rear Cover ............................................................................. 1 Screws with Spring Washer - M4 x 8 ..................................... 14

A251/A252

3-12

SM

INSTALLATION PROCEDURE

[A] [G] [A] [C] [F] [A] A, B [B] [D] [I] [J]
A836I501.WMF

[E]

[A]

[A] [D]

[E]

[H]

[C]
A836I500.WMF

NOTE: To ensure grounding, paint has been removed from the surfaces around the screw holes [A] (only from the surfaces where the two components meet) and from the surface around the screw hole [B] at the inside of the left plate. 1. Temporarily install the top plate [C], left [D], and right side plate [E] (6 screws). 2. Turn the table up-side down in the direction of A. 3. Install the middle plate [F] and rear cover [G] (4 screws each). NOTE: If the optional copy tray is installed after copier installation, install the front copy tray stay [I] and rear copy tray stay [J] after step 3. 4. Tighten all the screws until the spring washers [H] of screws are flattened. 5. Put the table the correction way up.

SM

3-13

A251/A252

Installation

INSTALLATION PROCEDURE

3.2.3 COPY TRAY (A836-10)

Accessory Check
Check the accessories and their quantities against the following list: Front Copy Tray Stay.............................................................. 1 Rear Copy Tray Stay .............................................................. 1 Copy Tray Support.................................................................. 1 Copy Tray Guide..................................................................... 2 Copy Tray Sheet ..................................................................... 3 Nylon Clamp ........................................................................... 1 Rear Copy Tray....................................................................... 3 Copy Tray Stopper.................................................................. 2 Screw...................................................................................... 13 Rear Copy Tray Sheet - Short................................................. 2 Rear Copy Tray Sheet - Center .............................................. 1 NOTE: The copy tray is an option for the A252 copier. When the copy tray is installed on the copier, the table (A836-00) is required.

A251/A252

3-14

SM

INSTALLATION PROCEDURE

[B] [A]
A836I501.WMF

[C]

[D]

A836I502.WMF

1. Install the front copy tray stay [A] and rear copy tray stay [B] (4 screws each). NOTE: This step should be done during the table installation when the table and the copy tray are installed at the same time. Refer to the table installation procedure. If the copy tray is installed after the copier installation, remove the roll feeder and copier from the table, then loosen the screws of the table, then do step 1. 2. Install the copy tray guides [C] (1screw each). 3. Install the copy tray support [D] (2 truss screws).

SM

3-15

A251/A252

Installation

INSTALLATION PROCEDURE

[C]

[A]

[D] [A]
A836I503.WMF

[C]

[B]

[F] [G]

[E] [E] [D]

A836I504.WMF

4. Adhere the copy tray sheets with rubber [A] to the middle plate [B] of the table so that the copy tray sheets are positioned between the screw holes [C] on the rear copy tray stay [D] as shown in the illustration. 5. Hook the rear copy trays [E] onto the rear copy tray stay [D]. 6. Secure the copier power supply cord [F] to prevent the cord from interfering with the paper path (1 nylon clamp [G] and 1 screw).

A251/A252

3-16

SM

INSTALLATION PROCEDURE

[D]

A836I505.WMF

265 5 mm

[D]

265 5 mm

[C]

A836I506.WMF

[A]

[B]

[A]

[B]
A836I508.WMF

7. Adhere the rear copy tray sheet - center (long) [A] and the two rear copy tray sheets - short [B] onto the exit cover as shown. 8. Adhere the copy tray stoppers [C] to the front side of the table middle plate [D].

SM

3-17

A251/A252

Installation

[C]

INSTALLATION PROCEDURE

3.2.4 ROLL FEEDER (A571)

CAUTION
Unplug the copier power cord before starting the following procedure.

Accessory Check
Check the accessories and their quantities according to the following list: Harness Cover ....................................................................... 2 pcs Angle Bracket ......................................................................... 1 pc Spacer ................................................................................... 1 pc Small Cap ............................................................................... 1 pc Screws - M4 x 8 ..................................................................... 8 pcs Screws with Spring Washer - M4 x 8 ...................................... 2 pcs Washer (220 ~ 240 V versions only) ....................................... 2 pcs Ground Plate (220 ~ 240 V versions only) .............................. 2 pcs Screws with Spring Washer - M4 x 8 for Ground Plate (220 ~ 240 V versions only) .................................................... 2 pcs NOTE: When the Roll Feeder is installed on the copier, the table (A714 or A836) is required.

A251/A252

3-18

SM

INSTALLATION PROCEDURE

[D]

[A]

A571I500.WMF

[C]

[C]

[H] [E]

[G]

[C]

A571I501.WMF

[H] [B] [F]

A571I502.WMF

1. Lower the feet [A] so that the table does not move while the roll feeder is being installed on the table and the copier. NOTE: Do not place the roll feeder unit [B] onto the floor roughly, to prevent the left and right covers from being damaged. 2. Remove the shipping tapes [C] and shipping cushions [D]. 3. Remove the left and right covers [E and F] (3 screws each). 4. Remove the front cover [G] (2 screws) and lower the front cover arms [H] to the down position.

SM

3-19

A251/A252

Installation

INSTALLATION PROCEDURE

[A]

[E]

[D] [C] [B]

A571I503.WMF

[F]

A571I504.WMF

[G]
A571I505.WMF

5. Open the copier paper path section and remove the copier left lower cover [A] (2 screws), lower right front cover [B] (2 screws), lower right middle cover [C], toner collection bottle [D], and rear cover [E] (2 screws). 6. Remove the small caps [F] from the copier rear cover using cutting pliers. 7. Remove the table rear cover [G] (4 screws).

A251/A252

3-20

SM

INSTALLATION PROCEDURE

[A] [B] [D] [C]

A571I506.WMF

NOTE: Take care not to drop the manual feed table when removing the bracket [A]. 8. Remove the lower front cover [B] (2 screws), reinforcement plate [C] (1 screw), bracket [A] (4 screws) (which is changed by the harness), and the manual feed table [D].

SM

3-21

A251/A252

Installation

INSTALLATION PROCEDURE

[A] [B]

[D] [E] [F]

A571I507.WMF

[C]

A571I508.WMF

9. Mount the roll feeder unit on the copier (hook the mounting arms [A] on both sides into the mounting rail [B]). NOTE: Lift the unit by holding the plate [C] just under the size marks. 10. Install the angle bracket [D] and spacer [E] (4 screws). 11. Install the small cap [F] (2 screws).

A251/A252

3-22

SM

INSTALLATION PROCEDURE

[I]

[G]

- A251 copier -

[G] [C]

[C] [D] [L] [H] [F]

[N]

A571I512.WMF

[A] [J]
A571I513.WMF

[M] [B] [E]

A571I510.WMF

NOTE: To ensure grounding, tighten the screws for the ground wire until the spring washers [A] are flattened. 12. Secure the grounding wire [B] (1 screw with spring washer) to the inside of the table. 13. Run the roll feeder harness [C] and roll feeder heater harness [D] through the holes in the table rear cover (right [E] and left [F]). NOTE: There are two versions of the ferrite core [N] for the roll feeder harness. One is gray and the other is white. When installing the gray core version on the A252 copier, unwind one loop, as shown.

For A252 copier

14. Connect the roll feeder harness to the copier main board and original feed motor drive board [K] {2 connectors [G] and 1 grounding wire [H] (1 screw with spring washer)}.

For A251 copier

14. Connect the roll feeder harness to the copier main board {2 connectors [G] and 1 grounding wire [H] (1 screw with spring washer)}. 15. Connect the roll feeder heater harness connector [I] to the copier ac drive board connector. 16. 220 ~ 240 V versions only Install the ground plates [L, M] (1 screw with spring washer and 1 washer each). 17. Install the harness covers [J] (1 screw each). 18. Reattach all the covers and manual feed table excluding the roll feeder right cover.
SM 3-23 A251/A252

Installation

[N]

[K]

[A]

INSTALLATION PROCEDURE

[A]

[D]

[E]

[C]

[B]

[F]
PRG. NO. 42 43 44

A571I514.WMF

Length Temperature NORMAL HIGH (VELLUM) LOW (FILM)

300 XX XX XX

1100 XX XX XX

PRG. NO. 45 46 47

19. Plug in the power supply cord and turn on the main switch. 20. Press the following keys on the operation panel: Clear Modes key [A] + key [B] key [C] Clear/Stop key [D] 21. Press the Clear/Stop key again and hold it down for longer than 3 seconds. The roll paper end and call service indicators will blink (SP mode). 22. Select 40 using the + and - keys. Enter 1 by pressing the following keys. Function Select key [E] + key RF Select key [F]. 23. Input values into SP modes 42 to 47 in accordance with the decal that is attached to stuck on the right side plate. 24. Press the Clear Modes key 3 times to leave the SP mode. 25. Reattach the roll feeder right cover. 26. Check the roll feeder operation.

A251/A252

3-24

SM

SERVICE TABLES

SERVICE TOOLS

4. SERVICE TABLES
4.3 SERVICE TOOLS
4.3.1 SERVICE PROGRAM MODE
All items except for the following are common with the A163 copier. Please refer to the A163 copier service manual.

Service Program Mode Table

Data 0: 2 minutes 1:1 minute 2: 2 minutes 3: 4 minutes 4: 5 minutes 0: 2 minutes Original Feed Out Select the time to when the original is automatically fed out after it has been set on 1:1 minute Waiting Time 2: 2 minutes the original table in the manual feed mode. Setting 3: 4 minutes (A252 copier only) 4: 5 minutes 5: No auto feed out Original Feed Start Selects the time to when the original feed 0: 1 second Time Setting roller starts rotating after the original 1: 2 seconds entrance sensor or original rear sensor for 2: 3 seconds the rear feed is actuated (A252 copier only). 3: 4 seconds 4: 5 seconds 5: 6 seconds 6: 7 seconds Auto Shut-off Time Determines the auto shut-off time. 1 30 240 Setting (120 V machines only) 0: No Original Hold After original scanning is finished, the 1: Original Hold mode Mode original exit roller stops before completely feeding out the original. This is to prevent the original from dropping onto the floor after scanning. key is The original is fed out when the pressed or when the next original is inserted A252 copier only). Length Size Adjusts the speed of the original feed motor -1.0 (shorter) 0.0 Magnification (A252 copier only). 1.0 (longer) The setting can be changed by the key operation. Semi-synchro Cut Selects whether the roll paper cut key must 0: Pressing the roll paper cut key Original Scanning be pressed at the appropriate time when the trailing edge of the original passes the Semi- 1: Inserting the original Mode synchro cut mark, or whether the original again must be inserted again after the original is scanned and the length is measured (A251 copier only). Mode No. Paper Feed Out Waiting Time Setting Function Refer to the A163 service manual for details. The paper from the roll feeder is fed out only when the roll feeder is attached to the A251 copier.

*6

*13

*14

*15

*16

*17

*18

SM

4-1

A251/A252

Service Tables

SERVICE TOOLS
Mode No. Function Synchro-cut Adjusts the cut length in the semi-synchro Length Adjustment cut mode (A251 copier). Adjusts the cut length in the synchro cut, *19 preset cut, and variable cut modes (A252 copier). The setting can be changed by a key operation. Fixed Paper Size 42.0 size is added to the following modes Pattern Setting in the inch mode: Refer to the A163 copier manual and page 4-13 of this manual for *22 details. 0, 1, 2, 3, 4, 7, 8, 9, 11, 12, 13, and 18 *33 Not Used Semi-synchro-cut Adjusts the cut length in the semi-synchro 48 Length Adjustment cut mode (A251 copier only). Data -25 (Shorter) 0 25 (Longer) 1 mm/step

49

56

57 58

67

69

80

81

Main Motor Speed (Jam code numbers have been changed Adjustment from those used in the A163 copier.) If the main motor speed is incorrect, rJ98 or rJ99 will be indicated when a long copy is made. In these cases this adjustment is required. Copy Number Determines the maximum copy number. The 0: 99 sheets (A251) 1: 10 sheets (A252) default settings for the A251 and A252 Limit Setting 2: 20 sheets copiers are different. 3: 30 sheets 4: 40 sheets 5: 50 sheets 6: 60 sheets 7: 70 sheets 8: 80 sheets 9: 90 sheets Not Used 0: 1,200 mm/48 inch Repeat Copy Determines the maximum copy length for Length Limit 1: The maximum paper repeat copy (A252 copier only). length determined by Setting SP55. dc = X,XXX Machine Displays the total time (hours) of the Operation Counter machine operation (total time of the motor rotation). SP69: t6 =XXX,XXX Total Copy Length Displays the total copy length by feet. /Number Display (Feet) dnF = XX (total number Displays the total number of developer Developer of developer initializations (SP36). Also displays the Initialization initializations) developer counter (SP77) at the last Number Counter Hde = XX,XXX developer initialization. (developer counter at the last developer initialization dtE = XX Toner End Displays the total number of toner end Hdt = XX,XXX Number Counter conditions (dtE). Also, displays the toner counter (SP78) at the last toner end condition (Hdt).

-10 (Shorter) 0 10 (Longer) 0.1 %/step 0: Standard -9 0 11

A251/A252

4-2

SM

SERVICE TOOLS
Mode No. Toner Near End Counter Function Displays the total number of toner near end conditions (dtn). Also, displays the toner counter (SP78) at the last toner end condition (Hdt). Data dtn = XX Hdt = XX,XXX

82 83 84

Not Used Not Used Number of Misfeeds by Location

Displays the total number of originals in the paper length indicator and paper misfeeds by location in the leading edge indicator.

85

90

Number of Service Displays the total number of service calls (SC) in the paper length indicator and SC Call by Location codes by location in the leading edge indicator. Service Call Displays the last five service calls one after Records the other.

Jt = X,XXX (Total Jam) J1 J8 (initial jam) J10 J45 (original jam) J51 J72 (copy paper jam) J80 J99 (roll feeder paper jam) Et = X,XXX (total SCs) E1 E15 (each SC) E1 = XX (The last SC code) E2 = XX (1 before the last SC code) E3 = XX (2 before the last SC code E4 = XX (3 before the last SC code E5 = XX (4 before the last SC code Beeper (XX = SC code)

91

92 93

Not Used Not Used

SM

4-3

A251/A252

Service Tables

SERVICE TOOLS
Mode No. RAM Clear Function Clears selected data items from the RAM. To clear the memory, input the number of the item you want to delete, then press the key. Note: If all the memory is cleared (if a number from 20 to 28 is selected), reinput the factory settings that are shown on the decal attached inside the upper right cover. Please refer to page 4-14 for the default settings for each destination. (When No. 10 to 26 is selected.) Data 0: Not Used 1: Machine Operation (The memory for SP67) 2: Copy Length Counter (SP69 to 75) 3: OPC Counter (SP76) 4: Developer Counter (*Note1) (SP77) / Developer Initialization Number (SP80) 5: Toner Counter (SP78) /Toner End Number (SP81)/Toner Near End Number (SP82) 6: Counter for toner (*Note2) density step. 7: Clear data No.1 to 9 and 53. 8: SC Counter (SP90 to 91) 9: Jam Counter (SP85 to 86) 10: Change the settings to the Japan version

-1

*Note1: This counter is not used for the toner density step control (described on page 2-16 in the A163 manual). *Note2: For the toner density step control, this counter counts down from 150 (m) to 0 (m) after the developer initialization. When the developer initialization is done, this counter is set to 150 and after 150 m of copies, the counter stays at 0. If this counter is cleared, the counter is set to 0.

A251/A252

4-4

SM

SERVICE TOOLS
Mode No. Function Data 11: Change the settings to the U.S.A. version 12: Change the settings to the Europe version 13: Change the settings to the Asia version 14: Charge the settings to the Hoechst version 15: Change the settings to the Regma version 16: Change the settings to the K+E version 17: Factory use 18: Not Used 19: Not Used 20: Clear all the memory and change the settings to the Japanese version 21: Clear all the memory and change the settings to the U.S.A. version 22: Clear all the memory and change the settings to the Europe version 23: Clear all the memory and change the settings to the Asia version 24: Clear all the memory and change the settings to the Hoechst version 25: Clear all the memory and change the settings to the Regma version 26: Clear all the memory and change the settings to the K+E version 27: Factory use 28: Not Used 29: Not Used 30: Clear all the memory

-1

SM

4-5

A251/A252

Service Tables

SERVICE TOOLS
Mode No. Total Counter Unit Setting -2 Function Selects the unit in which the total counter counts up by. Data 0: 1 yard 1: 1 m 2: 100 inches 3: 50 inches 4: A1 length (594 mm) 5: Sheet (Any size) 6: 1 foot 0: Standard 9.9 0 9.9 mm Advance Delay 0: 60 s 1: 70 s 2: 80 s 3: 90 s -50 (Faster) 0 50 (Slower) 0.025 %/step -100 10 100 (Shorter) (Longer) 2.5% +2.5%

-5

Registration Adjustment

Adjusts the paper registration.

Toner Supply Periods in Toner -23 End Condition Original Feed -24 Motor Speed Adjustment -27 Factory Use Only Length Size Magnification Compensation on Leading Edge -28

Selects the periods for supplying toner after clearing the toner end condition.

Adjusts the speed of the original feed motor (A252 copier only).

Registration Adjustment for the Rear Feed -29

Synchro-cut Length Auto Adjustment (297 mm)

-35

The fusing rollers speed is slightly higher than the drum speed. The speed of the copy paper transport will slightly increase after the leading edge of the copy paper enters the fusing unit. To compensate for this, the speed of the original feed motor is corrected from the leading edge to 183 mm (A252 copier only). Adjust the paper registration for the rear original feed (A252 only). If the setting of SP#-74 is 1, this setting is used for the paper registration for the front original feed as well as the rear original feed. In this case, this adjustment is added to the SP#-5 adjustment. Adjusts the original cut length in Synchro Cut mode at 297 mm (standard length). Insert the 297 mm length original five times (this number displayed on the copy number indicator can be changed : 1 to 10). If the actual original length is different from the standard length, input the following value in the cut length indicator before inserting the original: Actual Length - Standard Length Then the machine automatically calculates the correction value. The data is overwritten on SP#-38.

0: Standard 9.9 0 9.9 mm Advance Delay

-9.9 0 9.9 1 step = 0.1 mm

A251/A252

4-6

SM

SERVICE TOOLS
Mode No. Synchro-cut Length Auto Adjustment (1,189 mm) Function Data Adjusts the original cut length in Synchro -50 0 50 Cut mode at 1189 mm. 1 step = 0.1 mm Insert the 1189 mm length original five times (this number displayed on the copy number indicator can be changed : 1 to 10). If the actual original length is different from the standard length, input the following value in the cut length indicator before inserting the original: Actual Length - Standard Length Then the machine automatically calculates the correction value. The data is overwritten on SP#-39. -37 Not Used Synchro-cut Length Manual -38 Adjustment (297 mm) Synchro-cut Length Manual -39 Adjustment (1,189 mm) Light Sensor Voltage Display (Factory use) -9.9 0 9.9 1 step = 0.1 mm (This value is over written when SP#-35 is performed.) Adjusts the synchro cut length when a 1,189 -50.0 0 50 mm original is used. Increasing the number 1 step = 0.1 mm will shorten the paper cut length. (This value is over written when SP#-36 is performed.) Fd = X,XX Displays the real time light sensor output Fd = Light Sensor voltage. Voltage In this mode, the PTL, main motor, QL and the bias voltage for non-image areas can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Even if the SP mode is canceled, the voltage is displayed during the stand-by condition or copy cycling. To release this condition, turn the main switch off and on. 0: Normal Normally, an original cannot be inserted from the rear side in Synchro-cut mode. If 1 1: Synchro-cut Rear is selected in this mode, an original can be Feed Mode inserted from the rear side even if Synchrocut mode is selected. This mode cannot be used with the trailing edge margin function. In this mode, the copy will be 194 mm longer than the original (A252 copier only). Adjusts the synchro cut length when a 297 mm original is used. Increasing the number will shorten the paper cut length.

-36

-62

Synchro-cut Rear Feed Mode -70

SM

4-7

A251/A252

Service Tables

SERVICE TOOLS
Mode No. Cut Length Display Mode Function In semi-synchro cut mode, the machine stores the 1st original cut length and displays it in the paper length counter. In this case, the paper cut mode will be automatically changed to the Preset/Variable cut mode. It is not necessary to press the cut key at the trailing edge of the original from the 2nd copy paper. Before the 2nd original is inserted in the original table, the cut length in the cut length counter can be changed with the +/ keys within the range of the semi-synchro cut (410 mm ~ 2,000, 16.5' ~ 80.0'). Selects the speed of the original feed motor in returning original mode. A slower speed may be effective for the thinner original. Selects the Roll Feeder start timing, just after the original entrance sensor detects the trailing edge of the original, or just after the original entrance sensor detects the insertion of the original. The setting change from 0 to 1 makes the first copy faster and 1 to 1 CPM increases. If the emergency stop key is pressed while the original is being transported to the scanning start position from the original insertion, it is necessary to check for paper left between the copier and roll feeder. Whichever setting is selected, the first copy and 1 to 1 CPM are within specification. Select whether the original is transported from the original table to the scanning start position directly, or whether the original is returned to the scanning start position after the trailing edge of the original passes through the original registration sensor (A252 copier only). The default setting (= 0) is effective for usage of curled originals. If the setting is changed from 0 to 1, perform the synchro-cut length auto adjustment (SP#-35, #-36). Determines how the machine recovers when the fusing temperature becomes lower than the target value during repeat copy operation when selecting mode 8 (highest temperature mode) (A252 copier only). Data 0: Non-Length Display 1: Length Display

-71

Original Feed -72 Motor Returning Speed Setting Roll Feeder Start Timing

0: 200 mm/s 1: 150 mm/s 2: 100 mm/s 0: Trailing edge is detected. 1: Original insertion

-73

Original Transport Mode

-74

0: Original is transported directly to the start position. 1: Original is returned to the start position after the original passes through the original registration sensor.

Fusing Temperature Recovery Setting

-75

0: No recovery (The machine simply continues copying, ignoring the fusing temperature.) 1: Stops copying and feeds out the original. 2: Stops copying but the original is not fed out. Copying starts again after the fusing temperature recovers.

A251/A252

4-8

SM

SERVICE TOOLS

4.3.2 INPUT/OUTPUT CHECK MODE

Input Check Mode Table
The on/off status of the selected electrical component is displayed in the paper length indicator (ON or OFF is displayed). If a program number not used is selected, NOT is displayed.
Program No. -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -16 Sensor/Switch/Signal Registration Sensor Exit Sensor Original Registration Sensor Entrance Sensor Main Motor LOC Signal (Status is ON when the main motor is normally rotating.) Door Switch (Status is ON when the door is open.) Original Entrance Sensor (A252 copier only) Original Rear Sensor (A252 copier only) Not Used R/F Leading Edge Sensor Roll Feeder Door Switch Right Cutter Switch Left Cutter Switch Paper End Sensor Exit Cover Open (Status is ON when the door is open.)

SM

4-9

A251/A252

Service Tables

SERVICE TOOLS

Output Check Mode Table

Press the Bypass Select key to turn on the selected electrical component. The status of the component is displayed in the paper length indicator. To turn off the component, press the Bypass Select key again.
Program No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 to 19 20 21 22 23 24 25 26 27 28 Electrical Component Main Motor Toner Supply Clutch Pick off solenoid Registration Clutch Total Counter Pre-transfer Lamp Quenching Lamp Fusing Lamp Exposure Lamp (100% duty ratio) Exposure Lamp (selected ID level) Main Charge Corona Grid Voltage Transfer Charge Corona Not Used Separation Charge Corona Not Used Bias Voltage for the Image Area Bias Voltage for the Non-image Area Main Charge Corona + Grid Voltage Main Motor + PTL + Bias Voltage for the Non-image Area + Quenching Lamp Original Feed Motor (Forward) (A252 copier only) Original Feed Motor (Reverse) (A252 copier only) Roll Feeder Dehumidity Heaters Roll Feeder Cutter Motor *Note Roll Feeder Paper Feed Motor Original Feed Motor (Forward and Reverse) (A252 copier only) Note

30

34

Main Switch OFF (Energy Star)

Original feed motor operation changes every time the roll feed key is pressed. 1st time: Forward 2nd time: Stop 3rd time: Reverse 4th time: Stop Turn off the main switch.

NOTE: The cutter unit continuously moves between the left and right cutter switches. The number of the movements (0 ~ 9999) is displayed in the paper length indicator.

A251/A252

4-10

SM

JAM CODE LIST

4.4 JAM CODE LIST

4.4.2 JAM CODE TABLE
Code dJ01 dJ02 dJ03 dJ05 dJ06 dJ07 dJ08 dJ10 dJ11 dJ17 dJ18 dJ21 dJ22 dJ23 dJ25 dJ26 dJ27 dJ28 dJ32 dJ33 dJ35 dJ36 dJ40 dJ41 dJ42 dJ43 Cause of Jam Initial misfeed at the original entrance sensor. Initial misfeed at the original registration sensor. Initial misfeed at the original rear sensor. Initial misfeed at the entrance sensor. Initial misfeed at the registration sensor. Initial misfeed at the exit sensor. Initial misfeed at the leading edge sensor of the roll feeder. Original entrance sensor OFF check during the original scanning process. Original entrance sensor ON check during the original scanning process. Original entrance sensor OFF check during the original returning process. Original entrance sensor ON check during the original returning process. Original registration sensor leading edge ON check during the original scanning process. Original registration sensor trailing edge OFF check during the original scanning process. Original registration sensor trailing edge ON check during the original scanning process. Original registration sensor leading edge OFF check during the original returning process. Original registration sensor leading edge ON check during the original returning process. Original registration sensor trailing edge OFF check during the original returning process. Original registration sensor trailing edge ON check during the original returning process. Original rear sensor trailing edge OFF check during the original scanning process. Original rear sensor trailing edge ON check during the original scanning process. Original rear sensor leading edge OFF check during the original returning process. Original rear sensor leading edge ON check during the original returning process. Emergency stop key pressed Original registration sensor OFF condition during the original scanning process. Original rear sensor OFF condition during the original returning process. Original rear sensor ON condition when clearing the original hold mode by pressing the key. Remarks A252 only A252 only

A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only A252 only
Service Tables

A252 only A252 only A252 only

SM

4-11

A251/A252

JAM CODE LIST Code dJ45 pJ51 pJ52 pJ53 pJ55 pJ60 pJ61 pJ62 pJ63 pJ70 pJ71 pJ72 rJ80 rJ81 rJ90 rJ91 rJ95 rJ98 rJ99 Cause of Jam Original registration sensor does not turn off after paper is fed 2,500 mm. Registration sensor OFF condition is detected just after starting the copy process. Registration sensor OFF condition is detected before starting the roll feeder again. Entrance sensor ON condition is detected during roll feeding. Registration sensor does not turn off after paper is fed 2,500 mm. Registration sensor OFF check at the paper leading edge. Registration sensor ON check at the paper leading edge. Registration sensor OFF check at the paper trailing edge. Registration sensor ON check at the paper trailing edge. Exit sensor OFF check at the paper leading edge. Exit sensor ON check at the paper leading edge. Exit sensor OFF check at the paper trailing edge. Leading edge sensor OFF check at the paper leading edge. Leading edge sensor ON check at the paper leading edge. Paper cutter failure Door open during roll feeding Roll feeder. Motor does not turn off after paper is fed 500 mm more than the maximum paper length. Leading edge sensor ON check at the paper trailing edge during roll feeding. Leading edge sensor OFF check at the paper trailing edge during roll feeding. Remarks

A251 only

A251/A252

4-12

SM

JAM CODE LIST

Fixed Paper Size Pattern Data (SP No. 22)

In mm Mode 0: 1189, 841, 594, 420, 297 1: 2000, 1189, 841, 594, 420, 297, 245 2: 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 245 3: 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1189, 841, 594, 420, 297, 245 4: 2000, 1800, 1456, 1189, 1030, 841, 728, 594, 515, 420, 364, 297, 245 5: 2000, 1500, 1230, 880, 625, 450, 330, 245 6: 1456, 1030, 728, 515, 364, 257 7: 2000, 1456, 1030, 728 515, 364, 257, 245 8: 2000, 1500, 1189, 1100, 841, 594, 420, 300, 297, 245 9: 2000, 1456, 1200, 1189, 1091, 1085, 1030, 1016, 1000, 939, 900, 880, 841, 813, 788, 765, 762, 758, 728, 679, 636, 625, 594, 591,546, 515, 508, 420,364, 297, 257 10: 2000, 1800, 1600, 1400, 1200, 1000, 800, 600, 400, 245 11: 2000, 1750, 1500, 1250, 1000, 750, 500, 245 12: 2000, 1950, 1900, 1850, 1800, 1750, 1700, 1650, 1600, 1550, 1500, 1450, 1400, 1350, 1300, 1250, 1200, 1150, 1100, 1050, 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 245 13: 2000, 1800, 1500, 1189, 1100, 1050, 1000, 950, 900, 841, 800, 750, 700, 650, 594, 550, 500, 420, 297, 245 14: 2000, 1800, 1456, 1200, 1189, 1085, 1030, 900, 880, 841, 765, 728, 625, 594, 515, 420, 364, 297, 245 15: 2000, 1800, 1500, 1200, 1189, 594, 245 16: 2000, 1800, 1500, 1200, 1000, 841, 420, 245 17: 2000, 1800, 1500, 1220, 1189, 915, 841, 610, 594, 458, 420, 305, 297, 245 18: 2000, 1800, 1500, 1189, 1118, 864, 841, 594, 559, 432, 420, 297, 280, 245 19: The data stored in SP23 to 32 In inch Mode 0: 48.0, 42.0, 36.0, 24.0, 18.0, 12.0 1: 44.0, 42.0, 34.0, 22.0, 17.0, 11.0 2: 80.0, 72.0, 64.0, 48.0, 42.0, 36.0, 24.0, 18.0, 12.0, 9.6 3: 80.0, 72.0, 64.0, 44.0, 42.0, 34.0, 22.0, 17.0, 11.0, 9.6 4: 80.0, 72.0, 64.0, 48.0, 44.0, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0, 9.6 5: 80.0, 70.0, 60.0, 50.0, 40.0, 30.0, 20.0, 10.0, 9.6 6: 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 45.0, 40.0, 35.0, 30.0, 25.0, 20.0, 15.0, 10.0, 9.6 7: 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 48.0, 42.0, 36.0, 24.0, 18.0, 12.0, 9.6 8: 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 44.0, 42.0, 34.0, 22.0, 17.0, 11.0, 9.6 9: 80.0, 75.0, 70.0, 65.0, 60.0, 55.0, 50.0, 48.0, 44.0, 42.0, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0, 9.6 10: 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 47.5, 45.0, 42.5, 40.0, 37.5, 35.0, 32.5, 30.0, 27.5, 25.0, 22.5, 20.0, 17.5, 15.0, 12.5, 10.0, 9.6 11: 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 48.0, 42.0, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0, 9.6

SM

4-13

A251/A252

Service Tables

JAM CODE LIST 12: 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 48.0, 42.0, 36.0, 24.0, 18.0, 12.0, 9.6 13: 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 44.0, 42.0, 34.0, 22.0, 17.0, 11.0, 9.6 14: 80.0, 78.0, 76.0, 74.0, 72.0, 70.0, 68.0, 66.0, 64.0, 62.0, 60.0, 58.0, 56.0, 54.0, 52.0, 50.0, 48.0, 46.0, 44.0, 42.0, 40.0, 38.0, 36.0, 34.0, 32.0, 30.0, 28.0, 26.0, 24.0, 22.0, 20.0, 18.0, 16.0, 14.0, 12.0, 10.0, 9,6 15: 80.0, 72.0, 60.0, 48.0, 36.0, 24.0, 12.0, 9.6 16: 80.0, 78.0, 72.0, 66.0, 60.0, 50.0, 54.0, 48.0, 42.0, 36.0, 30.0, 24.0, 18.0, 12.0, 9.6 17: 80.0, 78.0, 75.0, 72.0, 69.0, 66.0, 63.0, 60.0, 57.0, 54.0, 51.0, 48.0, 45.0, 42.0, 39.0, 36.0, 33.0, 30.0, 27.0, 24.0, 21.0, 18.0, 15.0, 12.0, 9.6 18: 80.0, 72.0, 64.0, 57.3, 48.0, 46.8, 42.0, 40.6, 36.0, 34.0, 33.1, 28.7, 24.0, 23.4, 22.0, 20.3, 18.0, 17.0, 16.6, 14.4, 12.0, 11.7, 11.0, 10.1, 9.6 19: The data stored in SP23 to 32

Default Settings for Each Destination (SP#-1)

SP. No. #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #13 #14 #15 #17 #19 #20 #21 #22 #-2 #-3 Japan 1 0 1 0 2 0 0 0 0 0 0 0 30 0.0 0.0 0 0 0 1 0 U.S.A. 2 0 1 0 2 0 0 0 0 0 0 0 30 0.0 0.0 1 0 0 6 1 Europe 2 0 1 0 2 0 0 0 0 0 0 0 0.0 0.0 0 0 0 1 0 Asia 2 0 1 0 2 0 0 0 0 0 0 0 0.0 0.0 0 0 0 1 0 Regma/Ozalid 2 0 1 1 2 0 0 0 0 0 0 0 0.0 0.0 0 0 0 1 0 K+E 2 0 1 0 2 0 0 0 0 0 0 0 30 0.0 0.0 1 0 0 6 1

#13, #14, #17: A252 only

A251/A252

4-14

SM

SERVICE REMARKS

4.6 SERVICE REMARKS

4.6.12 AC DRIVE BOARD

Noise Filter

AC Drive Board TB202 TB201

A252M500.WMF

Service Remark for 220 240 V Version

Make sure that the harnesses are connected to the noise filter and ac drive board as shown correctly 1. Set the power supply cord hot line (brown wire) connector to terminal 1 on the noise filter. 2. Set the power supply cord neutral line (blue wire) connector to terminal 2 on the noise filter. 3. Set the noise filter harness hot line (black wire) yellow connector to terminal 3 on the noise filter. 4. Set the noise filter harness neutral line (white wire) white connector to terminal 4 on the noise filter 5. Set the noise filter harness hot line (black wire) yellow connector to TB201 on ac drive board. 6. Set the noise filter harness neutral line (white wire) white connector to TB202 on ac drive board.

SM

4-15

A251/A252

Service Tables

SERVICE REMARKS

AC Drive Board TB202 TB201

A252M500.WMF

Service Remarks for 120 V Version

Make sure that the harness is connected to the ac drive board as shown correctly 1. Set the power supply cord harness hot line (black wire) yellow connector to TB201 on ac drive board. 2. Set the power supply cord harness neutral line (white wire) white connector to TB202 on ac drive board.

A251/A252

4-16

SM

REPLACEMENT AND ADJUSTMENT

OPTICS

5. REPLACEMENT AND ADJUSTMENT

5.2 OPTICS
[A] [D] [C]

[B]

[E]

A252R500.WMF

[G] [F]

A252R501.WMF

5.2.1 ORIGINAL FEED UNIT REMOVAL (A252 ONLY)

1. Remove the left and right upper covers. 2. Remove the upper original guide [A]. 3. Push the projections [B] into the holes [C] of the rear side of the original feed unit as shown and remove the operation panel [D] (1 screw and 2 connectors). 4. Open the original feed unit [E] and unhook the stoppers [F] at both ends. 5. Turn the original feed unit and two bushings [G] at both ends 1/4 of a turn and remove.

SM

5-1

A251/A252

Replacement Adjustment

OPTICS

[D] [B] [G]

[C]

[F] [H] [B] [C] [E] [I] [J]

A252R510.WMF

[A]

[K]

A252R502.WMF

5.2.2 EXPOSURE GLASS REMOVAL (A252 ONLY)

1. Remove the original feed unit. 2. Remove the exposure glass bracket [A] (1 screw). 3. Remove the exposure glass stoppers [B] (2 screws). 4. Remove the exposure glass [C] by sliding it out to the right side and lifting up the left side as shown. NOTE: Make sure that the edge cut side [D] of the exposure glass is towards the upper side when reassembling.

5.2.3 FIBER OPTICS ARRAY REMOVAL (A252 ONLY)

1. Remove the exposure glass. 2. Open the toner supply cover [E] and remove the front original guide plate [F] (1 screw). 3. Remove the rear original guide plate [G] (4 screws and 1 pin [H]). 4. Lift up the fiber optics array [I] and remove it from the left side by sliding it out to the right side as shown. NOTE: When reassembling, be careful not to damage the right side [J] of the fiber optics array by touching the optics side plate [K].
A251/A252 5-2 SM

OPTICS

5.2.4 EXPOSURE LAMP REMOVAL

[B] [A]

[A]

A252R511.WMF

2. Turn the exposure lamp [A] 1/4 of a turn and remove. NOTE: Make sure that the direction of the aperture [B] of the exposure lamp is towards the fiber optics array side (rear side).

SM

5-3

A251/A252

Replacement Adjustment

1. Remove the fiber optics array. NOTE: If the exposure lamp is too tight to be turned, remove one side of the exposure lamp socket (1 screw) and remove the exposure lamp.

OPTICS

5.2.5 LIGHT SENSOR REPLACEMENT (A252 ONLY)

[A]

A252R503.WMF

1. Follow the steps from 1 to 2 of the fiber optics array removal. 2. Replace the light sensor [A] (1 screw, 1 connector).

A251/A252

5-4

SM

OPTICS

5.2.6 SYNCHRO-CUT LENGTH ADJUSTMENT (A252 ONLY)

This adjustment should be carried out when the original registration and/or original entrance sensor is replaced. 1. Measure the actual length of A3 (297) and A0 (1189) originals. 2. Access SP#-35 (synchro-cut length auto adjustment, 297 mm) and input the difference between the measured length and 297 mm. 3. Press the RF Select key. The copy quantity indicator blinks. Input the test copy number (default: 5). 4. Press the RF Select key. 5. Place the measured original (A3) on the original feed table. If the original is not placed correctly (placed diagonally), by pressing the  key once, this step can be canceled only one time. Otherwise, carry out this procedure from the beginning. 6. Repeat step 5 until the number in the blinking copy quantity indicator is 0. 7. Press the RF Select key. 8. Access SP#-36 (synchro-cut length auto adjustment, 1,189 mm) and carry out the adjustment in the same way as for the 297 mm adjustment.
Replacement Adjustment

SM

5-5

A251/A252

DRUM UNIT

5.4 DRUM UNIT

5.4.1 DRUM UNIT REMOVAL

[A] [B] [B] [A] [F]

[E] [C]
A252R504.WMF

[D]

A252R505.WMF

1. Remove the development unit. 2. Remove the 2 screws [A] at both ends. 3. Remove the timing belt [B] (A251 copier)/grounding plate spring [B] (A252 copier) and disconnect the harness connector [C]. 4. Remove the drum unit [D]. 5. Place the drum unit on the flat floor. NOTE: 1) When reinstalling the drum unit, hook the drum unit guides [E] on the pins [F] of the copier side plates. 2) Hold both ends of the drum unit to carry it.

A251/A252

5-6

SM

FUSING

5.5 FUSING
5.5.1 FUSING UNIT REMOVAL
[J] [K] [H]

[G] [I] [C]

[B]

[D]

[F] [E] [C] [B]

A252R509.WMF

NOTE: Close the paper path section to remove and reinstall the fusing unit. 1. Remove the copier rear cover. 2. Open the exit cover [A] and remove the shoulder screws [B] at both ends. Remove the screws [C] for the grounding wires. 3. Disconnect the connector [D], remove the screw [E], and flex the hinge arms [F] of the exit cover slightly to the outside of the exit unit shafts and remove. 4. Turn the exit unit [G] 1/4 of a turn to the front side (rear view) and remove it by pulling out. NOTE: When reinstalling the exit unit, set the right hinge [H] between the two pulleys [I] and raise the left hinge [J] using tape [K].

SM

5-7

A251/A252

Replacement Adjustment

[A]

FUSING

[B] [A]

[G]

[F]

[H]

A252R507.WMF

[C] [E]

[C]

A252R508.WMF

[D]
A252R506.WMF

5. Disconnect the connectors [A]. 6. Remove the screw [B] fixing the safety switch bracket. 7. 220 ~ 240 V version only: Remove the 2 screws [C] and bronze plate [D] (2 screws). 8. While pressing down the fusing pressure release bar [E], pull out the fusing unit. NOTE: When reinstalling the fusing unit, press down the fusing pressure release bar [E], set the fusing unit on the guides [F] and align the cuts [G] to the side plates [H] at both ends.
A251/A252 5-8 SM

T & S CORONA UNIT

5.6 T & S CORONA UNIT

5.6.1 TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT
[A] [B]

[H]

[C] [B]

[E] [F] [G]

[G]

[D]

A252R512.WMF

NOTE: 1) Handle the new wire by the ends only. Oil from your hands may cause uneven charging of the drum. 2) Do not stretch or bend the corona wires. 3) Do not rub the corona wires with rough material (sand paper, etc.) as this will damage the corona wire. 4) Do not use any solvent to clean the wire as this will cause uneven charging of the drum.

Preparation
1. Remove the T & S corona unit. 2. Remove the paper guides [A] and endblock covers [B].

SM

5-9

A251/A252

Replacement Adjustment

T & S CORONA UNIT

Separation Corona Wire Replacement

1. Remove the separation corona wire [C]. 2. Hook one end of the new separation corona wire on the terminal [D] of the right endblock. 3. Hook the center part of the separation corona wire on the spring [E] of the left endblock. 4. Set the wire on the slots [F]. 5. While pushing the spring in the direction of the arrow, hook the other end [G] of the separation corona wire on the terminal of the right endblock. 6. Make sure the wire is set on the slots [F].

Transfer Corona Wire Replacement

1. Remove the transfer corona wire [H]. 2. Install the new transfer corona wire.

A251/A252

5-10

SM

COPY QUALITY ADJUSTMENT

5.8 COPY QUALITY ADJUSTMENT

5.8.4 REGISTRATION ADJUSTMENT
When: Purpose: Adjustment Standard: Perform: How: Registration is not within the adjustment standard. To maintain proper registration. 0 3 mm (0 0.12") SP#-5, SP#-27 (A252 rear original feed) Change the registration roller start timing by SP#-5 and/or SP#-27

1. Make several copies by using the manual feed or roll feeder and check the registration. 2. Adjust the registration using SP#-5 and/or SP#-27 if the registration is not within the adjustment standard.

SM

5-11

A251/A252

Replacement Adjustment

TROUBLESHOOTING

SERVICE CALL CONDITION

6. TROUBLESHOOTING
6.2 SERVICE CALL CONDITION
The following service conditions are newly added as the A251 and A252 copiers. For other SC conditions, refer to the A163 copier for details. To clear SC E-15, access SP38 and change the data from 1 to 0.

6.2.12 SC CODE E-14: ZERO CROSS SIGNAL DETECTION ABNORMAL

- Definition The zero cross signal is not detected within 0.5 second after the main switch is turned on. - Points to check Main board AC Drive board

6.2.13 SC CODE E-15: MAIN SWITCH ABNORMAL (U.S.A. VERSION ONLY)

- Definition The main switch does not turn off within 0.45 second after sending reset signal. - Points to check Main switch Main board
Troubleshooting

SM

6-1

A251/A252

BLOWN FUSE TABLE

6.3 BLOWN FUSE TABLE

6.3.1 POWER SUPPLY UNIT
Europe Version
Fuse No. FU301 FU302 FU303 FU304 Specification 250 V 5A 250 V 6.3 A 250 V 6.3 A 250 V 6.3 A Symptom No power. Flourescent lamp does not light. Black copy. No indication. Beeper sound. E = 10 is indicated.

U.S.A. Version
Fuse No. FU301 FU302 FU303 FU304 Specification 125 V 8A 125 V 6.3 A 125 V 6.3 A 125 V 6.3 A Symptom No power. Flourescent lamp does not light. Black copy. No indication. Beeper sound. E = 10 is indicated.

AC Drive Board
Fuse No. FU201 CB201 Specification 250 V 15 A (U.S.A. version only) 250 V 8 A (Europe version only) Symptom No power. No power.

A251/A252

6-2

SM

TECHNICAL SERVICE BULLETINS

BULLETIN NUMBER: 740-001 APPLICABLE MODEL: FW740

05/12/95

SUBJECT: PARTS CATALOG UPDATES GENERAL:

The following Parts Updates are being issued for all FW740 Parts Catalogs. This information should be incorporated into all existing FW740 Parts Catalog documentation.

UPDATE NO. 1 -

SPRING HOOK - The old style Spring Hook (54199653) is no longer produced. However, the two new style Spring Hooks (shown below) have been made available as replacement options.
Spring Hook - SS-22

Spring Hook - SS-21 OLD NEW

REFERENCE OLD PART NO. NEW PART NO. 54199653 A1639504 A1639505 * DENOTES NEW ITEM DESCRIPTION Spring Hook Spring Hook - SS-22 Spring Hook - SS-21 QTY 1 1 1 PAGE 45 45 45 ITEM 6 6 10*

Operating Sheet

UPDATE NO. 2 -

OPERATING SHEET - Please add the Operating Sheet to your Parts Catalog as indicated below.

REFERENCE PART NUMBER A1631385 * DENOTES NEW ITEM DESCRIPTION Operating Sheet QTY 1 PAGE 7 ITEM 27*

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 002

10/11/95

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: GENERAL:

GROUNDING PLATE SPRING AND BUSHINGS

To ensure grounding of the Lower Entrance Guide, the Grounding Plate Spring has been replaced by the Grounding Wire as shown below. Also, the material of the Exit Unit Bushing has been changed. This information should be incorporated into all existing FW740 Parts Catalog documentation. 12. PAPER EXIT SECTION 1 13. PAPER EXIT SECTION 2 (A163)
The material of this bushing has been changed.

MECHANICAL ELECTRICAL

The material of this bushing has been changed.

PAPER PATH

Grounding Plate Spring

Grounding Wire

REFERENCE OLD PART NO. NEW PART NO. A1634464 A1635640 08053385 50530447 DESCRIPTION Grounding Plate Spring Grounding Wire Bushing - 6mm Bushing - 6mm 2 2 1 31 103
PARTS

QTY

INT

PAGE

ITEM
FSM

29

UNITS AFFECTED:
All FW740 copiers manufactured after Serial Number A3844120069 will have the new style Grounding Wire and Exit Unit Bushings installed during production.

INTERCHANGEABILITY CHART:
0 1 3/S
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines. 2 NEW machines. OLD parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines. NEW parts can be used in OLD and NEW machines. 3 NEW parts CAN NOT be used in OLD machines. OLD parts CAN NOT be used in NEW machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually. OTHER

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 003

12/22/95

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: FIELD SERVICE MANUAL - INSERT GENERAL:

The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 2 sets of replacement pages.

MECHANICAL

PAGES:
The revised areas have been highlighted by an arrow 1-1 4-11

Developer Type Addition of SP Mode 15

Additional Information Additional Information

ELECTRICAL PAPER PATH FSM PARTS OTHER

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 004

1/26/96

APPLICABLE MODEL: FW740

COPY QUALITY

SUBJECT: ENERGY STAR MODIFICATION (DETAILS) GENERAL:

To conserve energy, the copier automatically turns "OFF" 30 minutes after the last copy job has been completed. The details of the machine operation are as follows:

MECHANICAL

AUTO OFF MODE

To automatically turn "OFF" the copier, a new type of Main Switch with an incorporated coil is used. The connector layout is shown below.
Main Switch

ELECTRICAL

AC Harness Relay

PAPER PATH

Upper DC Harness

FSM

Lower DC Harness

SP MODE

New software (ROM A1635208) provides an additional SP Mode to adjust the Auto Off Timer. Replace page 4-11 of the Field Service Manual with the updated page provided with this package.

PARTS

Mode No. 15

Function Auto off time can be selected

Settings 1~ 120 minutes (1 minute per step) Default : 30 minutes

OTHER

The Auto Off time can also be selected by the customer. Refer to page 3 of this bulletin for the procedure.

Continued...

Tech Service Bulletin No. FW740-004 Page 2 of 4

The Auto Off mode is prohibited during the following conditions:

* * * *

The roll feeder is operating A sheet of paper is set on the feed table A Jam or SC indicator is "ON" The Toner End indicator is "ON" or the Used Toner Bottle is full

NOTE:

When you use a new style Main Board (modified for Energy Star) in a non-Energy Star machine, remove the ROM (A1635208) from the new Main Board and install ROM (A1639506) in its place. Also, when you replace the RAM Board, please clear all memory (SP1-21) and input the factory data referring to the Field Service Manual.

NOTE:

For part numbers, refer to Tech Service Bulletin No. FW740-005

INSTRUCTION SHEET

An additional explanation sheet has been added to the operating instructions. Please make copies of the following two pages and add them to the operating instructions that were shipped with the copier.

Continued...

Tech Service Bulletin No. FW740-004 Page 3 of 4

Continued...

Tech Service Bulletin No. FW740-004 Page 4 of 4

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 005

1/26/96

APPLICABLE MODEL: FW740

COPY QUALITY

SUBJECT: PARTS CATALOG UPDATES GENERAL:

To meet Energy Star requirements, the following parts have been changed.
Main Switch Relay AC Harness Relay (new part)

MECHANICAL ELECTRICAL

Lower DC Harness Upper DC Harness

PAPER PATH

NOTE:

For more information regarding Energy Star Office Equipment, refer to Publications Bulletin #PUB-066. REFERENCE

OLD PART NO. NEW PART NO. A1631095 12041545 A1631257 A1635600 A1635605 A1635608 A1635206 A1635200 A1631100 12042421 A1631256 A1635702 A1635704 A1635706 A1635208 A1635230 12081392 A1638637 * DENOTES NEW ITEM

DESCRIPTION Right Latch Bracket Main SW Lower Right Front Cover - 115V AC Harness Lower DC Harness Upper DC Harness ROM (IC - AM27C010-120DC) Main Board Relay Operating Instructions - Energy Star

QTY 11 11 11 11 11 11 11 11 01 01

INT 3/S 3/S 3/S 3/S 3/S 3/S 3/S 3/S

PAGE 35 35 7 35 35 35 39 35 35 43

ITEM 23 118 15 3 5 4 1 7 119* 6*

FSM

PARTS OTHER

UNITS AFFECTED:
All FW740 copiers manufactured after Serial Number A3845070122 will have the parts listed above installed during production.

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 005 REISSUE

03/20/96

APPLICABLE MODEL: FW740

COPY QUALITY

SUBJECT: PARTS CATALOG UPDATES GENERAL:

To meet Energy Star requirements, the following parts have been changed.
Main Switch Relay AC Harness Relay (new part)

MECHANICAL ELECTRICAL

Lower DC Harness Upper DC Harness

PAPER PATH

NOTE:

For more information regarding Energy Star Office Equipment, refer to Publications Bulletin #PUB-066. REFERENCE

OLD PART NO. NEW PART NO. A1631095 12041545 A1631257 A1635600 A1635605 A1635608 A1635206 A1635200 A1631100 12042421 A1631256 A1635702 A1635704 A1635706 A1635208 A1635230 12081392 A1638637 * DENOTES NEW ITEM

DESCRIPTION Right Latch Bracket Main SW Lower Right Front Cover - 115V AC Harness Lower DC Harness Upper DC Harness ROM (IC - AM27C010-120DC) Main Board Relay Operating Instructions - Energy Star

QTY 11 11 11 11 11 11 11 11 01 01

INT 3/S 3/S 3/S 3/S 3/S 3/S 3/S 3/S

PAGE 35 35 7 35 35 35 39 35 35 43

ITEM 23 118 15 3 5 4 1 7 119* 6*

FSM

PARTS OTHER

UNITS AFFECTED:
All FW740 copiers manufactured after Serial Number A3845070122 will have the parts listed above installed during production.

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 006

2/7/96

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: FIELD SERVICE MANUAL - INSERT GENERAL:

The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 2 sets of replacement pages.

MECHANICAL

PAGES:
The revised areas have been highlighted by an arrow 5-19

ELECTRICAL

Updated Information

PAPER PATH FSM PARTS OTHER

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 007

02/21/96

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: PARTS CATALOG UPDATES GENERAL:

The following Parts Updates are being issued for all FW740 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation.

MECHANICAL

UPDATE NO. 1 -

T & S CORONA CASING - To meet CE Mark Standards, the following parts have been changed.
ELECTRICAL

REFERENCE OLD PART NO. NEW PART NO. AD023113 A1635450 A1632254 A1635440 A1633867 A1634120 A1635636 A1635200 A1633130 A1635455 A1632257 A1635439 A1633869 A1634121 A1635637 A1635230 DESCRIPTION T & S Corona Casing Quenching Lamp Grounding Spring Plate Pre - Transfer Lamp - 24V 7.2W T & S Corona Guide Plate Fusing Lower Stay Separation Power Pack Harness Main Control Board QTY 11 11 11 11 11 11 11 11 INT 0 0 0 0 0 0 0 0 PAGE 25 23 37 15 17 27 35 35 40 ITEM 9 38

PAPER PATH

26 1 9 28 14

FSM

7 *

UNITS AFFECTED:
All FW740 copiers manufactured after Serial Number A3845070122 will have the new style T & S Corona Casing, etc... installed during production.
PARTS

INTERCHANGEABILITY CHART:
0 1 3/S
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines. 2 NEW machines. OLD parts can be used in OLD and NEW machines. NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines. 3 OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or previously modified, use the new part numbers individually. OTHER

Continued...

Tech Service Bulletin No. FW740 - 007 Page 2 of 2

UPDATE NO. 2 -

PARTS CATALOG CORRECTION - Add Spacer (A1634355) to your Parts Catalog as indicated below.

Fusing Entrance Guide Plate

20 mm

25 mm

Spacer - Fusing Entrance

REFERENCE PART NUMBER A163 4355 DESCRIPTION Spacer - Fusing Entrance QTY 01 PAGE 27 ITEM 39

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 008

03/20/96

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: ORIGINAL STOPPERS GENERAL:

Rubber tubes have been added on the both right and left original stoppers to ensure that the original stoppers are being held in position. This information should be incorporated into all existing FW740 Parts Catalog documentation.

MECHANICAL

Left Original Stopper

ELECTRICAL

Rubber Tubes

Right Original Stopper PAPER PATH FSM

REFERENCE PART NUMBER AA161118 * DENOTES NEW ITEM DESCRIPTION Tube - 3 x 4.5 x 3 QTY 02 PAGE 7 ITEM 28*

PARTS

UNITS AFFECTED:
Not available at time of publication.

OTHER

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 009

09/27/96

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: GENERAL:

PARTS CATALOG ADDITIONS

The following Parts Catalog additions are being issued for all FW740 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation.
MECHANICAL

Page 14
Philips Pan Head Screw

Photointeruptor

ELECTRICAL PAPER PATH FSM PARTS

REFERENCE NEW PART NO. AW020012 DESCRIPTION Photointeruptor QTY 1 1 PAGE 15 15 ITEM 13* 130*

03130100B Philips Pan Head Screw - M3 X 10 * DENOTES NEW ITEM

OTHER

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 010

09/27/96

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: GENERAL:

FUSING TEMPERATURE ADJUSTMENT PROCEDURE

To achieve optimal copy quality, it may be necessary to adjust the fusing temperature based on the type of copy paper used and the specific environmental conditions in which the machine is located. The tables below demonstrate how to adjust the fusing temperature to compensate for these factors.

MECHANICAL

Environmental conditions:

L/L ------ 15C, 20%RH M/M ---- 23C, 65%RH H/H ----- 30C, 80%RH

ELECTRICAL

1. Plain Paper Paper T6200/T6000 Azon Bond Azon Recycled Bond M/M H/H L/L M/M H/H Regma 61gr L/L Regma 75-80gr M/M H/H

Environ L/L Mode 8 Mode 7 Mode 6 Mode 5 Mode 4 Mode 3 O Mode 2 Mode 1

M/M H/H L/L

M/M H/H L/L

PAPER PATH

O O O

O O O O O

O O O

O O O
FSM

Paper Regma 90gr Regma 110gr Ozalid EF-Weiss Environ L/L M/M H/H L/L M/M H/H L/L M/M H/H Mode 8 Mode 7 O O O Mode 6 O O Mode 5 O Mode 4 Mode 3 O Mode 2 O Mode 1 O

PARTS OTHER

Continued...

Tech Service Bulletin No. FW740 - 010 Page 2 of 2

2. Vellum Paper TA-70 Environ L/L M/M H/H Mode 8 Mode 7 Mode 6 O Mode 5 O O Mode 4 Mode 3 Mode 2 Mode 1 Azon Vellum L/L M/M H/H Erazable Vellum Regma 91gr L/L M/M H/H L/L M/M H/H O O O O O O

3. Film Paper Azon Film 3mil M/M H/H Azon Film 4mil L/L M/M H/H Regma Film 3mil Regma Film 4mil Hoechst Film 4mil L/L M/M H/H L/L M/M H/H L/L M/M H/H

Environ L/L Mode 8 Mode 7 Mode 6 Mode 5 Mode 4 Mode 3 O Mode 2 Mode 1

O O O

O O O O

FOR NON-LISTED PAPERS :

The following is the procedure to determine the best Fusing Temperature Setting for each type of paper. The best setting is said to be the highest position before creasing begins to appear. 1. Set the Fusing Temperature Setting to the maximum mode for the type of paper, such as Plain Paper, Vellum, or Film using SP #1, SP #2 or SP #3. Plain Paper: Vellum: Film: Mode 7 (SP #1) Mode 8 (SP #2) Mode 5 (SP #3)

2. Make 3 white copies with the largest size of the paper available in the vertical grain direction. White copy is the worst case for creasing. 3. Check whether creasing appears on any of the copies. 4. If creasing appears, lower the Fusing Temperature Setting by 1 and repeat Steps # 2~4.

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 011

09/27/96

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: GENERAL:

PRESSURE ROLLER EVALUATION PROCEDURE

The following procedure is a method to determine whether the pressure roller should be replaced.
MECHANICAL

1. Access SP mode with the steps below. In order, press Clear Modes (C) key, Plus (+) key, Minus (-) key, Clear/Stop key, press and hold the Clear/Stop key again for longer than 3 seconds. 2. Select Lamp Off Mode with the steps below. a) Confirm that "Lead Margin" indicator lights. If "Lead Margin" indicator does not light, press Function Select key until it lights. b) Select "-51" by pressing Minus key. ("-51" is the number to select Lamp Off Mode.) c) Press Function Select key until "Paper Length" indicator lights. d) Select "1" by pressing Plus key. ("1" is the number to set Lamp Off Mode.) e) Press RF Select key to set Lamp Off Mode. 3. To prevent a paper misfeed, create a lead edge margin with the steps below. a) Press Function Select key until "Lead Margin" indicator lights. b) Continue to press Plus key until "99 mm" or "4.0 inches" (max. value) is indicated. 4. Make a copy using a less fusible kind of paper like film, translucent paper or thicker plain paper with vertical grain direction. Note: Before making a copy, set the fusing temperature setting to the mode which is one step lower than the proper setting for the particular kind of paper. For example, if the proper setting is Mode 3, select Mode 2 for this test. Refer to TSB No. FW740-010 for more information regarding the proper settings for particular types of paper and the adjustment procedure for non-listed papers.

ELECTRICAL PAPER PATH FSM

5. Scrape some black areas on the copy using a cotton cloth approximately 5 times. 6. Check whether the toner is peeled off on the areas that correspond with the scraped parts of the pressure roller. If white lines and/or bands appear, the pressure roller should be replaced with a new one. 7. Before turning the main switch "OFF" to reset the SP mode, reset "Lamp Off Mode", "Lead Margin" and "Fusing Temperature Setting" back to the original settings.

PARTS

FIELD SERVICE MANUAL - INSERT

The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 1 set of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow 4-38

OTHER

Additional Information

Pressure Roller Evaluation Procedure

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 012

10/15/96

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: GENERAL:

PHOTOINTERUPTOR

The Photointeruptor shown below is missing from the Parts Catalog. This information should be added to all existing FW740 Parts Catalog documentation.

MECHANICAL ELECTRICAL PAPER PATH

14 9

FSM

REFERENCE PART NUMBER AW020024 DESCRIPTION Photointeruptor QTY 1 PAGE 15 ITEM 14

PARTS OTHER

TECHNICAL SERVICE BULLETIN

CUSTOMER SERVICE GROUP

BULLETIN NUMBER:

FW740 - 013

01/16/97

APPLICABLE MODEL: FW740

COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: GENERAL:

PARTS CATALOG UPDATES

The following Parts Updates are being issued for all FW740 Parts Catalogs. The following information should be incorporated into all existing Parts Catalog documentation.

MECHANICAL

UPDATE NO. 1 -

PRESSURE ROLLER STRIPPER - To prevent the Pressure Roller from being damaged, the following modifications have been made.

1. The material of the Strippers has been changed from metal to a Teflon-coated resin to decrease the friction level on the Pressure Roller.
ELECTRICAL

2. Springs have been added to press the Strippers against the Pressure Roller. 3. A Stopper Guide Plate has been added to prevent the Pressure Roller from contacting the Paper Exit Cover when it is bent. NOTE: The proper fusing temperature setting for each type of throughput material is very important to keep the Fusing and Pressure Rollers in good condition for as long as possible. Please refer to Tech Service Bulletin No. 010. Please also refer to Tech Service Bulletin No. 011 regarding how to judge whether the Pressure Roller is still usable or not. 40
31 43 42 41

FSM PARTS

INTERCHANGEABILITY CHART:
0 1 3/S
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines. 2 NEW machines. OLD parts can be used in OLD and NEW machines. NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines. 3 OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or previously modified, use the new part numbers individually.

OTHER

Continued...

Tech Service Bulletin No. FW740 - 013 Page 2 of 2

REFERENCE OLD PART NO. NEW PART NO. A1634171 A1634175 A1744155 AE044020 AA066285 A1634176 * DENOTES NEW ITEM DESCRIPTION Pressure Roller Stripper Pressure Roller Stripper Assy Stopper Guide - Paper Exit Pressure Roller Stripper Stripper Spring Stripper Stay Bracket QTY 10 01 01 0 16 0 16 01 INT 1 1 1 PAGE 27 27 27 27 27 27 ITEM 31 31 40* 41* 42* 43*

UNITS AFFECTED:
All FW740 copiers manufactured after Serial Number A3846060120 will have the new Pressure Roller Strippers installed during production.

UPDATE NO. 2 -

ORIGINAL FEED TABLE ASSEMBLY - As per field request, the Original Feed Table Assembly has been registered as a service part.

29

REFERENCE PART NUMBER A1636111 A1636113 * DENOTES NEW ITEM DESCRIPTION Original Feed Table - LT Original Feed Table - A4 QTY 1 1 PAGE 9 9 ITEM 29* 29*

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NLfFMfMK
COPY QUALITY

Note: This copy intended as master of original for reproduction of additional bulletins.

SUBJECT: GENERAL:

T/S CORONA UNIT

A part number has been assigned to the T/S Corona Unit. This information should be incorporated into all existing FW740 Parts Catalog documentation.

MECHANICAL

REFERENCE NEW PART NO. A1633849 A1633850 DESCRIPTION T/S Corona Unit (EU) T/S Corona Unit (NA) QTY 1 1 PAGE 25 25 ITEM * *

ELECTRICAL

PAPER PATH

FSM

PARTS

OTHER

       

   
   

 
0 D -1 -B. B 0 T



  7 

 
7

SUBJECT: BLANK COPIES

Note: This copy intended as master of original for reproduction of additional bulletins.

COPY QUALITY

SYMPTOM:
Intermittent blank copies, partially blank copies or blank copies.

POSSIBLE CAUSES:
1. 2. 3. 4. Arcing from Charge Corona. Arcing from the High Voltage Leads / Receptacles. No voltage output from the C, G, B Power Pack. Fuse 3 Open.

Y
MECHANICAL

SOLUTION:
Inspect the following parts for proper operation and/or signs of arching. Replace the parts as necessary. 1. 2. 3. 4. 5. 6. Relay Receptacle - Charge Corona (AD021113). Charge Corona Receptacle (AD021114). Charge Corona Assembly (A1632050). Power Pack - C, G, B (AZ320079). Power Supply (AZ230056). Fuse 3 on Power Supply.

Y
ELECTRICAL

NOTE: Inspect Grid Wire routing (see illustration below). Ensure that wire junctions are positioned as shown and staggered. If the wires cross or touch each other, arcing or copy quality problems may occur.

PAPER PATH

Y
SM

T
PARTS

Y
OTHER

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %440-'%&0)#13()0U ####+)78)82)6#h#2f% ####6-'3,#g#*;KHN ####7%:-2#h#2f% %EJG#g#gNNE NHfFMfML
The chart listed below shows the Last Bulletin Number issued for the A163 series. Bulletin Cross Reference Ricoh Group Companies Last Bulletin No. Gestetner N/A Ricoh 015 Savin N/A

SUBJECT: SYMPTOM:

SPRING REPLACEMENT CHARGE CORONA UNIT

PARTS

Note: This copy is intended as a master original for reproduction of additional bulletins.

Difficulty when replacing Charge Corona Wires.

CAUSE:
The angle of the opening on the Spring is only 45, and this makes it difficult to attach the spring. Also the notch in the Right End Block made it difficult to attach the Spring from above.

SOLUTION:
The angle on the opening of the Spring has been changed from 45 to 90 so the Spring can be replaced with less pulling. Also the length of the notch in the Right End Block has been changed from 4 mm to 2.9 mm so the spring end with a diameter of 3 mm can be hooked from above. See the Before and After figures below.
B e fo r e A fte r

45

90

B e fo r e
4 .0 m m

A fte r
2 .9 m m

GENERAL:
The following parts corrections are being issued for all A163 Parts Catalogs. OLD PART NO. AA060124 AD022336 NEW PART NO. AA060749 AD022348 DESCRIPTION Spring Right End Block- Charge QTY 5 1 INT 0 0 REFERENCE PAGE ITEM 23 9 23 14

Continued
RICOH GROUP COMPANIES

Tech Service Bulletin No. A163 001 Page 2 of 2

UNITS AFFECTED:
All copiers manufactured after the Serial Number listed below will have new style parts installed during production. MODEL NAME Gestetner N/A Ricoh FW740 Savin N/A SERIAL NUMBER N/A A3847050073 N/A

INTERCHANGEABILITY CHART:
0 1 3/S
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines. 2 NEW machines. OLD parts can be used in OLD and NEW machines. NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines. 3 OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or units previously modified, use the new individual part numbers.

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %440-'%&0)#13()0U ####+)78)82)6#h#2f% ####6-'3,#h#*;KHN ####7%:-2#h#2f% SUBJECT: GENERAL:
The following parts updates are being issued for all A163 Parts Catalog.

%EJGg#NNF

NIfEIfML

UPDATED ENERGY STAR REQUIREMENTS

FIRMWARE

Note: This copy is intended as a master original for reproduction of additional bulletins.

UPDATE 1:

OPERATING INSTRUCTIONS The Operating Instructions have been changed to announce changes concerning Energy Star (115V). REFERENCE PAGE ITEM 43 6

OLD PART NO. A1638637

NEW PART NO. A1638647

DESCRIPTION Operating Instructions Energy Star (115V)

QTY 1

INT 3

UPDATE 2:

AUTO SHUT-OFF TIME Auto Shut-Off Time has been changed from 1 to 120 minutes to 1 to 240 minutes. The change has been made to SP Mode 15. See Table below. Old Data 1 to 120 Minutes (1 Minute per step) Default: 30 Minutes New Data 1 to 240 Minutes (1 Minute per step) Default: 30 Minutes REFERENCE PAGE ITEM 39 1 35 7

15

Mode No. Auto Shut-Off Time Setting (115 V)

PART NO. A1635208 A1635230

DESCRIPTION ROM Main Board

OLD SUFFIX No Suffix A

NEW SUFFIX A B

QTY 1 1

The Main Board ROM revision A (file name 740A1A.EXE) can be downloaded through the Ricoh Technical Services BBS. NOTE: For more information about the Ricoh Technical Services BBS, order the Guide to Operation (P/N BBS00001) through normal NSPC channels.

INTERCHANGEABILITY CHART:
0 1 3/S
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines. 2 NEW machines. OLD parts can be used in OLD and NEW machines. NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines. 3 OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or units previously modified, use the new individual part numbers.

RICOH GROUP COMPANIES

#'328630#23T#FLI

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %440-'%&0)#13()0U ####+)78)82)6#h#2f% ####6-'3,#h#*;KHN ####7%:-2#h#2f% SUBJECT: SMALL CAP
PARTS

%EJG#g#NNG

NKfFFfML

Note: This copy is intended as a master original for reproduction of additional bulletins.

GENERAL:
The part number for the Small Cap (A163 RIC/NRG)/(A251/A252) was incorrect. The following part correction is being issued for all A571 Parts Catalog Sections.

OLD PART NO. A5717479

NEW PART NO. A5717497

DESCRIPTION Small Cap (A163 RIC/NRG)/(A251/A252)

QTY 1

REFERENCE PAGE ITEM 3 19

RICOH GROUP COMPANIES

CONTROL NO. 296


    U    U     h f   h
KHNfKINfKJN    h f SUBJECT:

  

  
EEfEMfML

EJGf FIEf FIF g NNH

INSTALLATION CHECK GROUNDING WIRES n

PAPER PATH

Note: This copy is intended as a master original for reproduction of additional bulletins.

SYMPTOM:
Paper jams at the Registration Roller.

CAUSE:
The ground wire is positioned behind the Main Board on the Roll Feeder. NOTE: This can result in an electrical short.

n
ELECTRICAL

SOLUTION:
Ensure that both Ground Wires are attached. (See Illustration Below)

NOTE-1: To ensure grounding, tighten the screws for the ground wires until the spring washers [A] are flattened NOTE-2: Ensure that both wires are connected before powering up the copier. Attach the Long Wire [C] to the copier.

Attach the Short Wire [B] to the stand.

RICOH GROUP COMPANIES

CONTROL NO. 316

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %IKE#g#NNE NMfEEfML
The chart listed below shows the Last Bulletin Number issued for the A571 series. Bulletin Cross Reference Ricoh Group Companies Last Bulletin No. Gestetner NA Ricoh 5000 Savin NA

%440-'%&0)#13()0U ####+)78)82)6#h#2f% ####6-'3,#h#6300#*))()6#(14#*;KHN ####7%:-2#h#2f% SUBJECT: GENERAL: SMALL CAP

Note: This copy is intended as a master original for reproduction of additional bulletins.

PARTS

The following part correction is being issued for the A571 Parts Section.

OLD PART NO. A5717479

NEW PART NO. A5717497

DESCRIPTION Small Cap (A163 RIC/NRG)(A251/A252)

QTY 1

REFERENCE PAGE ITEM 3 19

RICOH GROUP COMPANIES

CONTROL NO. 304


    U

  

  
EEfNJfML

LGJ g NNE

   U     h f   h    (14

KJN    h f SUBJECT: GENERAL:
The following parts updates are being issued for all A836 Parts Catalog Section.

REAR COPY TRAY n

Note: This copy is intended as a master original for reproduction of additional bulletins.

PARTS

OLD PART NO. A8364465 A8364468 A1744493

NEW PART NO. A86364469

DESCRIPTION Rear Copy Tray Small (760S) Rear Copy Tray Sheet Center Copy Tray Sheet

QTY 6 10 20

REFERENCE PAGE ITEM 3 16 3 19 3 20

RICOH GROUP COMPANIES

CONTROL NO. 314