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FT2012/2212 Service Manual (Skylark)

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1. 21 20 19 18 17 16 15 14 A184V500 wmf 1 2nd Mirror 13 Relay Rollers 2 1st Mirror 14 Paper Feed Roller 3 Exposure Lamp 15 Toner Bottle Holder 4 Quenching Lamp 16 Registration Rollers 5 Charge Corona Unit 17 Transfer Corona Unit 6 6th Mirror 18 Drum 7 Lens 19 Cleaning Blade 8 Erase Lamp 20 Pressure Roller 9 Development Roller 21 Hot Roller 10 4th Mirror 22 Exit Rollers 11 5th Mirror 23 Copy Tray 12 By pass Feed Table 24 3rd Mirror 4 July 1996 ELECTRICAL COMPONENT DESCRIPTIONS 4 ELECTRICAL COMPONENT DESCRIPTIONS i Sz Refer to the electrical component layout and the point to point diagram on the RBS waterproof paper in the pocket for symbols and index numbers og Symbol Name Function Index No Motors Main Motor Drives all the main unit components except M1 23 for the optics unit and fans Exhaust Fan Motor Removes heat from around the fusing unit M2 and blows the ozone built up around the 6 charge corona unit to the ozone filter M3 Scanner Drive Motor Drives the scanners 1st and 2nd 10 Lens and Mirror Motor Moves the lens and 4th 5th mirror positions M4 A184 machines only in accordance with the selected 11 magnification Optics Cooling Fan Prevents build up of hot air in the optics M5 Motor 220 240 V cavity 18 machines only Clutches CL1 T
2. A184D504 wmf During the copy cycle an image of the original is reflected onto the drum surface through the optics assembly as follows Light path Exposure Lamp A Original First Mirror B gt Second Mirror C gt Third Mirror D Lens E gt Fourth Mirror F Fifth Mirror G Sixth Mirror H Drum I This copier has five metric version or four inch version standard reproduction ratios A184 copier only and a zoom function The operator can also change the reproduction ratio in one percent steps from 70 to 141 One stepper motor is used to change the positions of the lens and 4th 5th mirrors to enlarge reduce the image across the page Changes in reproduction ratio down the page are achieved by changing the scanner speed A184 copier only The CPU monitors the temperature around the optics through a thermistor which is located on the scanner frame When the temperature reaches 35 C the optics cooling fan J 230 V machines only starts rotating to draw cool air into the optics cavity The fan operates until the temperature drops below 32 C However 120 V machines are not equipped with a cooling fan For all models the machine will stop if the optics cavity overheats to a certain temperature See Troubleshooting for details In this case the Start key turns red Additionally a thermofuse on the 1st scanner provides back up over
3. Auto Shut Off Selects the Automatic Shut Off mode 0 Yes 77 Energy Star The copier automatically shuts itself off at the auto 1 No Selection shut off time selected SP14 Factory Factory use only BAG ae cctined Initialization Data Factory use only 82 hod Communication Total Copy Displays the total electrical copy counter Counter The counter is displayed as shown in the example Display below To view the next two digits press the Darker key For example The total copy count is 1087 Manual ID Indicator Copy Counter 88 Wom LG Mow ala The mechanical total counter and the electrical total counter may not always display the same value because of initial differences in the counter values 4 19 PROGRAM MODES 4 July 1996 Mode No Function Settings Factory Data Factory use only 90 jand Counter Clear Optics Cooling Not used Keep the default setting 0 No 91 Fan Operation 1 Yes 120 V NA machines only Imaging Unit For testing purposes only Selects whether the 0 Yes Initialization Imaging Unit initialization procedure is performed 1 No Selection when a new Imaging Unit is installed Set this mode to 1 when you wish to check the 92 copier condition with a new Imaging Unit without the settings being changed by the Imaging Unit initialization procedure After using this mode do not forget to change the
4. A184D503 2 wmf The main board supplies 24 volts to the high voltage supply board at CN1 1 When the Start key is pressed the CPU starts sending the bias trigger pulses to CN1 4 This energizes the development bias circuit within the high voltage supply board which applies a high negative voltage to the development roller The development bias is applied whenever the drum is rotating 2 20 4 July 1996 TONER SUPPLY 6 TONER SUPPLY 6 1 TONER SUPPLY MECHANISM C Detailed n c e Q Z S N m A184D512 wmf When the toner bottle A is set and the lever B is pushed down the chuck C pulls out the cap D and the toner bottle is opened While the TD toner density sensor detects enough toner in the developer the toner supply clutch E is off and the main motor drive is not transmitted to the gear F When the TD sensor detects a low toner condition the toner supply clutch is energized and the drive is transmitted to the gear G through idle gears The gear G drives the toner bottle gear H and the toner bottle rotates in the direction of the arrow The toner bottle has a spiral groove that helps move toner to the toner bottle opening I Then the toner is carried up to the opening J of the toner bottle holder by the rotating fins K to be supplied into the development unit 2 21 TONER SUPPLY 4 July 1996 6 2 TONER DENSITY DETECTION A A184D511 2 wmf A toner den
5. 2 Always cover the imaging unit with sheets of paper when the upper unit is opened 3 Never use alcohol to clean the drum alcohol dissolves the drum surface 4 Take care not to scratch the drum as the photoconductive layer is thin and is easily damaged 5 Never expose the drum to corrosive gases such as ammonia gas 6 When placing the imaging unit onto the copier do not push it down forcibely This unit is set only to put it on the guide plate The imaging unit is shaky if you push it this is not a problem 4 1 SERVICE REMARKS 4 July 1996 7 Do not touch the charge corona wire and the grid plate with bare hands Oil stains may cause uneven image density on copies 8 Clean the charge corona wire by sliding the wire cleaning tool from right to left 9 Clean the charge grid with a blower brush not with a cloth 10 Be careful not to damage the edge of the cleaning blade 11 After installing a new cleaning blade be sure to apply setting powder evenly on the surface and edge of the blade 1 3 OPTICS 1 Clean the exposure glass with glass cleaner and a dry cloth to reduce the amount of static electricity on the glass surface Only use a clean soft cloth to clean the mirrors and reflectors Only use a blower brush to clean the 6th mirror and the lens Do not touch the following parts with bare hands a Reflectors b Exposure Lamp c Mirrors and Lens Do not change the cutout po
6. PAPER FEED 4 July 1996 4 2 PAPER FEED ROLLER REMOVAL A184R518 wmf 1 Open the upper unit Remove the imaging unit See Imaging Unit Removal Remove the paper feed tray Remove the paper feed clutch A See Paper Feed Clutch Removal Remove the securing spring plate B O a fF W N Slide the paper feed roller assembly C to the rear side then pull down to remove it arrow direction NOTE Do not touch the roller with bare hands Reinstallation 1 Set the paper feed roller assembly so that the flat side of the semicircular feed rollers faces down 2 Slide the paper feed roller assembly to the front side until it clicks 6 16 4 July 1996 PAPER FEED 4 3 REGISTRATION SOLENOID REPLACEMENT F A184R819 wmf NOTE When replacing the registration solenoid A the plunger spring B should be replaced 1 Open the upper unit Remove the imaging unit See Imaging Unit Removal c o E 2 3 lt c o Q S Q oc Remove the paper feed tray Remove the harness cover C 2 screws Disconnect the connector D Remove the registration solenoid cover E 2 screws Remove the stopper F oN Oa KR WwW LD Replace the registration solenoid and the plunger spring NOTE 1 When reinstalling the registration solenoid make sure that the harness side of the solenoid is facing upwards 2 When reinstalling the
7. NOTE Move the 1st scanner by holding the scanner belt B Handling the 1st scanner will deform the frame 3 Disconnect the connectors C and D and the clamps 4 Remove the 1st scanner 2 screws E c o E 2 3 lt c o Q S Q oc Reinstallation 1 Set the 1st scanner with 2 screws E Do not fully tighten the screws 2 Slide the 1st scanner to the home position and insert the two positioning pins F NOTE Scanner positioning pins are available as a service part P N A184 9501 See the parts catalog 3 Connect the two connectors G and H and secure the harness to the clamps 4 Tighten the two screws E to secure the 1st scanner 5 Install the exposure glass and exterior covers Then check the image quality OPTICS 4 July 1996 2 2 2ND MIRROR REPLACEMENT A184R505 wmf _ Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Slide the 1st scanner about 200 mm from the home position NOTE Move the 1st scanner by holding the scanner belt Handling the 1st scanner will deform the frame 3 Remove the spring plate A securing the 2nd mirror B 4 Slide the 2nd mirror and remove the spring plate C 5 Remove the 2nd mirror Reinstallation 1 Cut off both ends of the protection sheet covering the new 2nd mirror 2 Put the ends of the 2nd mirror into the cutouts in the 2nd sca
8. 6 4 TONER END CONDITION 6 4 1 Toner Near End If the CPU detects toner supply level 6 VT VTs 4S 5 five times consecutively the toner end indicator blinks and the machine goes to the toner near end condition In this condition the toner supply clutch is energized for 16t seconds for every copy If a toner sensor voltage lower than VTS 4S 5 is detected twice consecutively during the copy cycle the machine recovers from the toner near end condition As explained before t depends on SP31 N 35 Xs o Ss E nag Q If the toner sensor voltage does not recover from level 6 during the copy cycle the main motor continuously rotates after the copy job is finished and the toner supply clutch is energized intermittently for T seconds T can be changed using SP23 The CPU monitors the TD sensor voltage during this T seconds If the toner sensor voltage returns to level 5 or less in this period the machine recovers from the toner near end condition and the main motor stops 6 4 2 Toner End If TD sensor level 6 is detected the machine supplies toner for T seconds after the copy job is finished During this T seconds if the CPU detects TD sensor level 7 VT VTs S three times consecutively a toner end condition is detected and copier operation is disabled If the toner sensor voltage stays in level 6 during the T seconds the machine keeps the toner near end condition and 50 more copies can be made After 50 copies the t
9. NOTE 1 Do not touch the drum surface with bare hands 2 Do not expose the drum to direct sunlight 6 Remove the paper A from the inside of the copier this paper contains the installation procedure for the imaging unit 7 Fit the imaging unit onto both hinges B as shown Then set the unit on the guide plate as shown 8 Pull out horizontally and remove the tape C inside the imaging unit as shown INSTALLATION 4 July 1996 A1841512 wmf A1841513 wmf A1841514 wmf 9 Shake the toner bottle A well 5 or 6 times 10 Remove the black cap B from the toner bottle NOTE Remove the black cap carefully so as not to spill any toner 11 Open the lever C and put the cap side of the toner bottle under the lever 12 Push the other side of the toner bottle in until it locks in position 13 Close the lever C 14 Close the top unit 4 July 1996 INSTALLATION A1841502 wmf A1841511 wmf A1841507 wmf 15 Take out the paper cassette from the clear wrapper and remove the tape stuck on the center of the cassette Then remove the two pieces of cardboard beside the side guides 16 Change the end plate A for the paper size the customer requests 17 Load paper and set the paper cassette in the machine 18 Paste the Error Code decal B next to the exposure glass if needed 19 Put the cord clamp C in the hole that is opposite side of the entrance of the cord if necessary 20 Insert the power plug
10. Perform SP90 Factory Data and Counter Clear Check the continuity between the TD sensor harness and CN106 on the main control board Are they properly connected No Connect the connector firmly Is the TD sensor circuit open Yes Replace the imaging unit 7 20 4 July 1996 COPY QUALITY Check the continuity of connection between the imaging unit and the main copier Are they connected properly No Replace the latch connector Check the electrical continuity of the harness from the main control board to the TD sensor Are they connected properly No Replace the harness Replace the imaging unit 7 21 oa Dz 30 22 Eo COPY QUALITY 4 July 1996 1 18 OPTICS OVERHEAT PROTECTION Problem The Start key turns red during copying No SC code is indicated Definition The optics thermistor has detected a high temperature condition as shown below Copying is disabled until the temperature drops to the starting temperature 120 V machine without fan 230 V machine with fan Stopping temp 40 C 43 C Starting temp 37 C 40 C Possible Case e Optics thermistor short circuit e Excessive continuous copy jobs Action Is the optics thermistor short circuited Yes Replace the thermistor Check if the customer has run excessive continuous copy jobs No Replace the main board Notify the customer
11. Possible Causes 1 Defective sensor 2 Mechanical or electrical malfunction Action 1 Initial misfeed Check which sensor registration sensor or exit sensor is defective Replace the defective sensor If no sensors are defective replace the main board Action 2 Misfeed during copy cycle If the Add Paper indicator turns on after the Start key is pressed check whether the paper tray has run out of paper or not Yes Load paper into the paper tray Set the Misfeed Detection OFF mode SP6 to on and make a copy to see whether a misfeed occurs Misfeed No misfeed o 25 530 E Lt Check which sensor registration sensor or exit sensor is defective If sensors are not defective replace the main board Check whether a mechanical or electrical malfunction occurs Replace the defective parts 7 19 COPY QUALITY 4 July 1996 1 17 ABNORMAL CONDITION IN TONER DENSITY DETECTION Problem The Auto ID indicator or the selected manual ID level blinks No SC Code is indicated Definition If the detected TD sensor output goes below 0 2 volts or SP90 Factory Data and Counter Clear has not been performed at the factory Possible Causes e Defective TD sensor e Defective main control board e Loose connector e Poor connection between the imaging unit and the main copier Action Is ita brand new machine Yes Enter SP92 and check the setting
12. Press the Start key to perform this mode Sensor Manual ID Level Indication Display Condition 8 Registration ID Level 1 ON Paper Present Exit ID Level 2 ON Paper Present ID Level 3 TEE Scanner HP ID Level 4 ON Home Position Lens Mirror ID Level 5 ON Actuator inside HP sensor A184 copier only Output Check Use to turn on individual electrical components Enter the desired number given in the following table Press the Start key to turn on the electrical component Press the C S key to turn off the electrical component peepee Electrical Component Note Main Motor Quenching 1 Lamp Exhaust Fan Motor High Speed Charge Corona Transfer Dev bias is the 2 Corona Development standard voltage for Bias Voltage manual ID level 3 9 without corrections 3 Erase Lamp All LEDs on 4 Toner Supply Clutch 5 Registration Solenoid 6 Paper Feed Clutch Main Switch Main switch will turn 7 off when performed 8 Optics Cooling Fan Exposure Lamp Optics Standard voltage for 9 Cooling Fan manual ID level 3 without corrections 10 Exhaust Fan Motor High Speed 4 11 PROGRAM MODES 4 July 1996 Mode No Function Settings Scanner Free Starts a scanner free run 10 Run Press the Start key to start the free run Press
13. 1 5 VERTICAL BLACK LINES Problem Thin black lines appear on the copy Possible Causes 1 Scratched cleaning blade 2 Dirty or scratched exposure glass or dirty or scratched mirrors A184T505 wmf 3 Scratched or dirty drum 4 Scratched hot roller Action Do the black lines shift when a reduction copy is made Yes Clean or replace the exposure glass or mirrors After cleaning the optics perform the necessary SP modes in order see Section 4 Service Remarks for details Is the edge of the cleaning blade scratched Yes Replace the cleaning blade Is the hot roller scratched Yes o ss 30 J Eo Check whether black lines appear on the copy by stopping the copy paper in the transport section If no black lines appear replace the hot roller Check whether the drum is scratched or toner is built up on the drum Replace the imaging unit if necessary COPY QUALITY 4 July 1996 1 6 VERTICAL WHITE LINES OR BANDS 1 DULL OR BLURRED Problem Dull or blurred white lines appear on the copy Possible Causes 1 Dirty or deteriorated charge corona wire A184T506 wmf 2 Dirty or deformed grid plate 3 Damp or deformed inlet seal on the development unit Action Are the charge corona wires or grid plate dirty Yes Clean the charge corona wires or grid plate Is the grid plate or the charge corona wire detoriorated or deformed Yes Replace the
14. ADS mode is disabled and notch 3 is used for the center setting of the manual ID level The base exposure lamp voltage also varies depending on the manual ID level as shown 2 17 DEVELOPMENT 4 July 1996 Adjustment factor for manual ID level 5 SP36 The base bias voltage at manual ID level 5 can be changed using SP36 as follows Image Density SP36 Setting Base Bias et oe for Level 5 Normal 0 40 Lighter 1 80 Lightest 2 120 Default setting 0 5 4 2 Base Bias Voltage Factor In Automatic Image Density ADS Mode In ADS mode the base exposure lamp voltage is fixed at Vo this value is determined by SP48 Image density is controlled by changing only the base bias voltage The base bias voltage for ADS mode depends on the background image density of the original which is measured by the ADS sensor See page 2 8 for more information about the ADS sensor The CPU checks the voltage output from the automatic ID circuit This circuit has a peak hold function The peak hold voltage corresponds to the maximum reflectivity of the original The CPU then determines the proper base bias level with reference to the peak hold voltage The table below shows the relationship between the original background density ADS voltage ratio and the base bias voltage ADS Voltage Ratio 0 Base Bias Voltage 80 to 100 light 200 V 75 to 79 240
15. Drives the exposure lamp fusing lamp and PCB4 Supply Board main motor Rectifies 30 Vac and 8 Vac input 19 and outputs 5 Vdc and 24 Vdc PCB5 Operation Panel Informs the CPU of the selected modes and 13 Board displays the situation on the panel Lamps L1 Exposure Lamp Applies high intensity light to the original for exposure L2 Fusing Lamp Provides heat to the hot roller 22 L3 Quenching Lamp QL Neutralizes any charge remaining on the 17 drum surface after cleaning Erase Lamp Discharges the drum outside of the image L4 area Provides leading trailing edge and 16 side erases Others co Total Counter except Keeps track of the total number of copies 12 for 17 machines made THI Optics Thermistor Monitors the temperature around the 3 exposure lamp for overheat protection TH2 Fusing Thermistor Monitors the fusing temperature 21 TF1 Exposure Lamp Provide back up overheat protection around 4 Thermofuse the exposure lamp TF2 Fusing Thermofuse Provide back up overheat protection in the 20 fusing unit TR Transformer Steps down the wall voltage to 30 Vac and 8 31 Vac 1 8 SECTION 2 DETAILED DESCRIPTIONS 4 July 1996 DRUM 1 DRUM 1 1 OPC DRUM CHARACTERISTICS The OPC Organic Photoconductor Drum used in this copier is small in diameter 30 mm ensuring good paper separation An OPC drum has the characteristics of 1 Being able to accept a high negative electrical charge in the dark The elect
16. English 10 17 22 26 29 57 machines Imaging Unit Paper Feed Tray Error Code Decal English c oO 2 2 Operating Instructions Spanish 17 22 26 57 machines Operating Instructions German 26 machines Operating Instructions French 26 machines Operating Instructions Italian 26 machines Operating Instructions Portuguese 57 machines Model Name Decal 10 22 machines NECR English 57 machines NECR Multi language 27 29 machines Warranty Card 17 machines User Registration Card 17 machines INSTALLATION 4 July 1996 2 2 INSTALLATION PROCEDURE A1841500 wmf A1841503 wmf A1841501 wmf A1841506 wmf 1 Remove the tape securing the platen cover copy tray and power cord 2 Open the platen cover and remove the two scanner locking pins A from both sides of the exposure glass NOTE Save the lock pins for future shipping use 3 Take off the tape covering the screw and remove the knob screw B and red tag C as shown NOTE Save the knob screw for future shipping use 4 Open the top unit and remove the 4th 5th mirror lock tool D NOTE Save the shipping retainer for future shipping use 4 July 1996 INSTALLATION B B A1841508 wmf c oO S 2 A1841509 wmf A1841510 wmf 5 Take out the imaging unit from the cardboard box Then remove the protective sheet and the tape fixing the lever
17. FUSING THERMISTOR TH2 AsO NO Ave 2 6LENO alo as TSINO HL HASN NI lt ICoT TeTNO anolol PTsrNo yosnas Lixalas 4 IP z SriNo oals S6 AST Cava Je zm zannop Arava LAOA e STN azina LNOA D olano PUT PZLINO SLENO EXIT SENSOR ADS SENSOR S1 valvel Z 70INO SOL MAIN CONTROL BOARD REGISTRATION Ano 10s isioaulr2 al gt O gt z91N5 P DNI HL NOS valvel Pz gorNo TI z OPTICS THERMISTOR LNO Nowo Al gt Orsons Lin p rzlva LA valve 2 601NO ZINoP lt re A MOTNV4 LSNYXI TOTAL COUNTER EU ONLY oa O z lt EXAUST FAN MOTOR CLUTCH Q Lu Lu ire oc Ww a lt a ino 10 aaaalr2 A D O60 SVA Is NYOS SVA Ip NYOS Z v0LNO SVA le NYOS SVA Iz NYOS SVA l NYOS LNO 1D YANO T POIND SVA l0 NYOS TONER SUPPLY CLUTCH d 93S 6 93S vAlbal Q 1 93S wasvuatrz ADO oo 3038 p 93S 293S q93S e gaS WAlrz Q C6E0IND Luasvualre A p 2 EONO Ake 9 YSSVHAl e A S YASVHAlre A p YASVHAlbe A YASVUAlre A z YaSVUal e A l yasvYalrz A 0 YaSVHal e A ERASE LAMP 2 CN404 1 CN404 2 CN404 3 CN404 7 CN404 8 OPERATION PANEL 24VX CN403 1 24V X CN405 3 GND x CN403 24V X CN405 2 PGND X CN405 4 PGND X CN405 5 GNDX CN403 4 NA EU gt lt M MOTOR ONA CN405 1 FUSING LAMP ER
18. Image Density Normal Lighter Darker Lighter Darker Lightest Darkest SP36 Image Bias Adjustment at ID level 5 Setting 0 1 2 Bias Voltage Change 40 V 80 V 120 V Image Density of ID Level 1 Normal Lighter Lightest c o E N 3 lt f o E o S Q oc 7 3 TONER DENSITY ADJUSTMENT When The customer wants to change the overall image density of the copies Purpose To change the toner concentration inside the development unit Method SP38 How it works Changes the toner supply threshold As a result toner density increases 6 37 COPY QUALITY ADJUSTMENT 4 July 1996 7 4 GRID VOLTAGE ADJUSTMENT A184R543 wmf ADJUSTMENT STANDARD Adjusting VR SP Mode DC 850 15 V VRG SP9 2 NOTE Normally each High Voltage Supply Board spare part is adjusted in the factory before shipment This adjustment is not required when the board is replaced A WARNING Very high voltage is applied from the high voltage supply unit terminals Pay extreme attention when adjusting the grid voltage Make sure that the machine is unplugged before connecting the multimeter 1 Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Set the multimeter range to dc 1500 V and connect the m
19. Stripper Pawls C C C R Suitable solvent 5 1 gt 5 gt i ou S c s gt PREVENTIVE MAINTENANCE SCHEDULE 4 July 1996 EM 30k 60k 90k 120k Notes Suitable solvent Fusing Entrance and Exit Guide Plates Fusing Thermistor C C C C Suitable solvent Others ADS A Adjust when the lamp voltage is changed Exit and Registration Sensors Bearings 5 2 4 July 1996 PREVENTIVE MAINTENANCE SCHEDULE 1 2 REGULAR PM PROCEDURE mp Every 30 k Every 60k 1 Make a copy Change the setting of SP19 from 0 to 1 Then make a copy of your test chart at manual image density level 3 _ 2 Optics every 30 k Clean the reflector and 1st to 5th mirrors with a silicone cloth N Clean the 6th mirror and lens with a blower brush 3 Clean the exposure glass with a soft cloth dampened with alcohol or water 4 Clear the platen cover sheet with a soft cloth dampened with water g Lubricate the scanner guide rod with Launa oil D Lubricate the scanner guide rail and the 4th 5th mirror guide rail with G501 0 o 2c Eg oO DE 2 o amp _ 3 Around the drum Clean the corona wires and the transfer guide every 30 k plate using the cleaning tool 2 Clean the end blocks and casings with a blower brush or dry cloth 3 Clean the
20. 0 8 Interval voltage SP48 is increased by 1 step atthe set copy Default 0 count interval SP Setting Exposure Lamp Note 0 1 step 1500 copies Default 1 1 step 1000 copies 2 1 step 2000 copies 62 3 1 step 500 copies 4 1 step 2500 copies 5 1 step 250 copies 6 1 step 3000 copies 7 1 step 4000 copies 8 No Correction 1 step of the lamp voltage equals 0 5 V for N American and 1 0 V for European machines Forced Toner Forces the toner bottle to supply toner to the 0 6 seconds Supply development unit 1 3 seconds 63 This mode starts when the Start key is pressed and stops automatically after the selected time Use this mode to achieve standard image density when copy quality problems indicate low toner 64 VR Correction Sets the VR correction value Default 0 Value Keep this at the default setting 66 Imaging Unit Factory use only Check Mode TD Sensor Displays the TD sensor initial setting output 0 02 V per 67 Initial Output The Manual Image Density indicator is used to step Display display the first digit 4 18 4 July 1996 PROGRAM MODES Mode No Function Settings Imaging Unit Shows the total number of copies made by the Counter Imaging Unit installed in the machine Display The counter is displayed as shown in the example below To view the next two digits press the Darker key For example The copy count is 21548 Manual ID Indicator Copy Counter MK Jili Mom iSl Mom HE
21. 2 3 lt c o Q S Q oc 4 Disconnect the connector CN119 B from the main board 5 Remove the quenching lamp C 2 screws NOTE When reinstalling make sure that the quenching lamp is secured firmly by the hook D 6 29 OTHERS 4 July 1996 6 7 OZONE FILTER REPLACEMENT C A184R546 wmf 1 Open the upper unit 2 Move the lever A in the direction of the arrow while pulling down on the tape edge B as shown 3 Replace the ozone filter C 6 30 4 July 1996 OTHERS 6 8 AC DRIVE DC POWER SUPPLY BOARD TRANSFORMER REPLACEMENT B A184R545 wmf NOTE Check the fuses on the board before determining that the ac drive dc power supply board is defective 1 Turn off the main switch and unplug the machine c o E 2 3 lt 2 Remove the fusing unit See Fusing Unit Removal c o Q S Q oc 3 Remove the exit cover A 2 screws and 1 harness clamp 4 Replace the ac drive dc power supply board B 3 screws and all connectors or the transformer C 4 screws and 2 connectors 6 31 OTHERS 4 July 1996 6 9 MAIN CONTROL BOARD REPLACEMENT A184R544 wmf 1 Turn off the main switch and unplug the machine 2 Remove the upper cover See Exterior Cover Exposure Glass Removal 3 Remove the main control board A 4 screws and all connectors
22. 4 Remove the EEPROM B from the old main board and install it on the new board 6 32 4 July 1996 COPY QUALITY ADJUSTMENT 7 COPY QUALITY ADJUSTMENT Image density is affected by the following factors 1 Light Intensity 2 Development Bias Voltage 3 Toner Density 4 Grid Voltage Drum Current The items listed above must be kept in balance to maintain the correct image density In the field image density should be adjusted first by changing the exposure lamp voltage If the results are unsatisfactory the development bias voltage can be changed Also if requested by the customer the overall image density can be changed by changing the toner density However the effects of adjusting this are small compared to adjusting the exposure lamp and development bias voltages The grid voltage and drum current are carefully adjusted at the factory Any adjustment out of standard will result in overtoning toner scattering dirty background or light image density problems The grid voltage and charge corona current adjustment should be done to correct certain problems with image density after checking the other possible causes 6 33 c o Q S Q oc c o E N T lt COPY QUALITY ADJUSTMENT 4 July 1996 7 1 LIGHT INTENSITY ADJUSTMENT 7 1 1 Base Exposure Lamp Voltage Adjustment When Every call Purpose To maintain the correct light intensity Adjustme
23. 7 10 4 July 1996 COPY QUALITY 1 9 JITTER Problem Jitter appears on the copy Possible Causes 1 Drum not turning smoothly 2 Scanner not moving smoothly Action Does the jitter interval change when a reduction copy is made Yes No Check drum drive mechanisms such as the drum drive gears and drum pulleys No Good Reinstall them correctly or replace the defective parts Are the scanner drive belts correctly installed Yes No Reinstall them correctly or replace the defective parts Does the voltage at CN300 2 through 5 on the main board stay at 24 volts when the Start key is pressed 24 volts Not 24 volts oa Dz 30 E Eo Replace the scanner motor or check the scanner drive Replace the main board 7 11 COPY QUALITY 4 July 1996 1 10 BLACK SPOTS ON THE COPY IMAGE Problem The grid voltage is not applied correctly e Poor contact between the charge corona casing and grid plate e Main control board defective e High voltage supply board CT B G defective A184T509 wmf Action Is there good electrical contact between the charge corona casing and the grid plate No Repair the poor contact or replace the charge corona unit if needed Check the voltage at CN123 3 on the main board Not 0 volts Replace the main control board Replace the high voltage supply board CT B G 7 12 4 July 1996 COPY QUALITY 1 11 SKEWED OPTICAL COPY IMAGE
24. Adjustment When 1 The customer requires the image density to be either darker or lighter 2 The customer requires a darker image when manual ID level 1 is selected Purpose To get proper image density Method SP34 for case 1 and SP35 for case 2 How it works Changes the ac drive board output voltage NOTE SP34 and SP35 settings can be changed by customers SP34 Image Density Adjustment Setting 0 1 2 3 4 5 6 Bias Voltage Exposure Lamp 7 p Change 0 0 0 3 steps 3 steps 7 steps 7 steps Image Density Normal Light Dark Lighter Darker Lightest Darkest SP35 Image Adjustment at ID level 1 Setting 0 1 2 Exposure Lamp Change 6 steps 8 steps 10 steps Image Density of ID Level 1 Normal Darker Darkest c o E n 3 lt c o Q S Q oc 6 35 COPY QUALITY ADJUSTMENT 4 July 1996 7 2 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT 7 2 1 Base Bias Voltage Adjustment A184R540 wmf ADJUSTMENT STANDARD Adjusting VR SP Mode DC 200 4V VRB SP9 2 NOTE Normally each High Voltage Supply Board spare part is adjusted in the factory before shipment This adjustment is not required when the board is replaced Z WARNING Very high voltage is applied from the hi
25. LOW installing a new imaging unit During CN106 3 normal usage the Manual Image Density or the ADS indicators start blinking Exit Sensor S6 Stays HIGH The Paper Misfeed indicator lights CN115 2 when a copy is made Stays LOW The Paper Misfeed indicator stays on CN115 2 when the main switch is turned on 3 2 SWITCHES Component Condition Symptom Main Switch SW1 OPEN The copier does not turn on SHORT The copier does not turn off Interlock Switch SW2 OPEN The copier does not turn on SHORT The copier does not turn off when the upper unit is opened 7 28 4 July 1996 4 BLOWN FUSE CONDITIONS BLOWN FUSE CONDITIONS USER CODES FUSE Rating 120 V 230 V Symptom when turning on the Main Switch AC Drive DC Power Supply Board F1 10 A 125 V T5 A 250 V No response F2 8 A 125 V T6 3 A 250 V E22 lights F3 2 A 125 V T2 A 250 V No response U code Contents na Blinking Imaging unit life near end condition na Lit Imaging unit life end condition i ci Imaging unit not installed IIJ Lit Developer not installed CEA Dz 30 E Eo 7 29 COPIER ELCTRICAL COMPONENT LAYOUT A184S500 wmf A184S501 wmf Description Index No P to P Location Exposure Lamp L1 1 B4
26. POSITION ERROR 2 Definition The scanner home position sensor s output remains HIGH actuated for 4 0 seconds after the main switch is turned on or the output remains HIGH actuated for 0 3 second after the scanner starts Possible Causes e Defective home position sensor e Defective scanner drive motor e Defective main control board e Defective ac drive dc power supply board e Defective scanner drive circuit e F2 onthe ac drive dc power supply board open blown fuse CODE 28 LENS MIRROR HOME POSITION ERROR 1 A184 COPIER ONLY Definition The lens mirror home position sensor s output remains LOW de actuated for 10 seconds after the unit moves to the home position o Dz 30 Pg Eo Possible Causes e Defective lens mirror home position sensor e Defective lens mirror drive motor e Defective main control board e Defective lens mirror drive mechanism 7 25 SERVICE CALL CONDITIONS 4 July 1996 CODE 29 LENS MIRROR HOME POSITION ERROR 2 A184 COPIER ONLY Definition The lens home position sensor s output remains HIGH actuated for 10 seconds after the unit leaves the home position Possible Causes e Defective lens mirror home position sensor e Defective lens mirror drive motor e Defective main control board e Defective lens mirror drive mechanism CODE 40 OPTICS THERMISTOR ERROR Definition The optics thermistor is open Possible Cause e Defective optics thermistor
27. V 70 to 74 280 V 60 to 69 320 V 29 to 59 360 V 0 to 28 dark 380 V ADS Output Voltage a VADso Total VL Correction Steps so far Reproduction Correction Steps x 0 5 VADSo ADS Reference Voltage 2 18 4 July 1996 DEVELOPMENT 5 4 3 Image Density Adjustment Factor Using SP 34 the base bias voltage and the exposure lamp data can be increased or decreased for both ADS mode and all manual ID levels as follows m SP34 Setting Setting Dev Bias Exposure Lamp He 0 Normal 0 0 ae 1 Light 40 V 0 a a 2 Dark 40 V 0 a 3 Lighter 40 V 3 steps 4 Darker 40 V 3 steps 5 Lightest 40 V 7 steps 6 Darkest 40 V 7 steps Default setting 0 5 4 4 Drum Residual Voltage VR Correction Factor During the drum s life drum residual voltage VR will gradually increase To compensate for this the bias voltage is increased by 10 V every 5 k copies The VR correction is done up to 20 k copies The VR correction will not change after 20 k copies 2 19 DEVELOPMENT 5 5 DEVELOPMENT BIAS CIRCUIT 4 July 1996 CN123 4 CN1 1 24V 9 GND CN123 3 CN1 2 A DC DC Inverter CN123 2 CN1 3 CT Trigger CN123 1 CN1 4 DC DC B PWM Inverter 3 MQ e a B Drum e Zener Diode TT High Voltage Supply Board CT B G at O T e Le 620 V v To Drum GND
28. access procedure but all the UP mode functions can be accessed from the SP mode To be able to reset a service call E5 condition using SP mode the SP mode can be accessed while the error condition exists The error code will not be displayed in the copy counter during these conditions 2 Operation To access these program modes a certain key must be held down while turning on the main switch After accessing select the required mode number and perform the necessary procedures needed for that function It is possible to move on to the next required mode without exiting each time To leave from these modes turn the main switch off on 3 Display To achieve the same operation for the two models A183 and A184 the Magnification Ratio display the Zoom key and the Zoom key are not used To display and to distinguish various conditions using the copy counter the appearance of the copy counter and the dot e which appears in the top left corner of the Copy Counter is different When the Copy Counter is blinking and the dot is lit the machine is ready to accept a program mode number The program mode number is displayed when you input it When the Copy Counter stops blinking and the dot starts blinking the machine is ready to accept an adjustment value and it may be displaying the current adjustment value PROGRAM MODES 4 July 1996 4 Notes 1 With the exception of SP57 all copies made inside the program modes ar
29. and the Darker key at the same time To avoid resetting the memory by mistake the memory is reset only when the Lighter key and the Darker key are pressed at the same time 4 20 4 July 1996 PROGRAM MODES 2 6 CLEAR ALL MEMORY PROCEDURE A CAUTION The Clear All Memory procedure SP99 resets all the correction data for copy process control and all the software counters and returns all modes and adjustments to the default settings Normally this SP mode should not be performed This procedure is required only when replacing the EEPROM or when the copier malfunctions due to a damaged EEPROM 1 Enter SP99 2 Enter 1 3 Press the Darker key and the Lighter key at the same time NOTE To avoid resetting the memory by mistake the memory is reset only when the Darker key and the Lighter key are pressed at the same time 4 Turn the main switch off and on Recovering the machine after a memory reset A CAUTION If SP99 is performed all the software counters for process control and the TD sensor initial setting data are reset As a result the old drum and the old developer cannot be used any more Otherwise dirty background and or toner scattering will appear on copies sooner or later because proper process control will not be applied to the drum After doing SP99 execute the following procedure to return the machine to its normal operating condition 1 Clean the optics a
30. and turn the main switch on NOTE When the main switch is turned on the machine automatically starts developer initialization EUELA SECTION 4 SERVICE TABLES 4 July 1996 SERVICE REMARKS 1 SERVICE REMARKS 1 1 GENERAL CAUTIONS 1 To prevent physical injury keep hands away from the mechanical drive components when the main switch is on especially during the warm up cycle If the Start key is pressed before the copier finishes the warm up cycle the Start indicator starts blinking and the copier starts making copies as soon as the warm up cycle is completed 2 Before disassembling or assembling any parts of the copier make sure that the power cord is unplugged 3 To avoid possible injury or machine damage always hold the upper unit firmly with your other hand when opening the upper unit 4 Keep all the shipping retainers for future shipping use 1 2 IMAGING UNIT 1 Always make sure of the following when removing the imaging unit from the copier e Do not touch the drum surface with bare hands When the drum surface is touched with fingers or becomes dirty wipe it with a dry cloth e Place the imaging unit on a clean and level place Take care not to scratch the drum from under the unit as there is no cover to protect it e Cover the imaging unit with sheets of paper to prevent the drum from being exposed to light e Do not turn the imaging unit upside down Toner and developer may fall out from the unit
31. charge corona unit Replace the imaging unit 4 July 1996 COPY QUALITY 1 7 VERTICAL WHITE LINES OR BANDS 2 THIN DISTINCT Problem Vertical white lines appear on the copy Possible Causes 1 Paper dust on the edge of the cleaning blade 2 Scratched drum 3 Scratched hot roller n Action Remove the cleaning blade Clean and inspect the edge of the blade Is the edge of the cleaning blade deformed Replace the cleaning blade Make a copy and stop the machine when the paper reaches the transport section Do white lines appear on the copy Replace the imaging unit Replace the hot roller if it is scratched CEA Dz 30 22 Eo COPY QUALITY 4 July 1996 1 8 HORIZONTAL BLACK WHITE LINES Problem Black or white lines perpendicular to the paper feed direction appear on the copy image Possible Causes 1 Drum or hot roller is scratched If black lines appear at 94 2 mm intervals the cause is a scratched drum scratched hot roller or toner build up A184T508 wmf 2 Toner adheres to the drum surface Due to insufficient cleaning foreign matter may accumulate on the blade causing toner to stick to the drum surface when the drum stops Action Is the drum scratched Yes Replace the drum Is the hot roller scratched Yes Replace the hot roller If toner adheres to the drum surface clean the drum with water Also clean or replace the cleaning blade
32. exposure glass and exterior covers Then check the image quality OPTICS 4 July 1996 2 4 LENS AND 4TH 5TH MIRROR POSITION ADJUSTMENT A184 model only A184R509 wmf 1 Remove the exterior covers and the exposure glass See Exterior Cover Exposure Glass Removal 2 Remove the lens cover A 1 screw 3 Insert the two positioning pins B If the pins cannot be inserted loosen the screw C and adjust the lens unit position NOTE 1 Use the timing belt D to move the lens unit 2 Scanner positioning pins are available as a service part P N A184 9501 See the parts catalog 4 July 1996 OPTICS 2 5 4TH MIRROR REMOVAL A184R510 wmf c o E 2 3 lt c o Q S 2 Q oc 1 Remove the exterior covers See Exterior Cover Exposure Glass Removal 2 Remove the support plate A 2 screws 3 Remove the lens cover B 1 screw 4 Remove the 4th mirror bracket C 1 spring and 1 screw 5 Remove the 4th mirror D Refer to steps 3 to 5 of 2nd Mirror Removal NOTE When reinstalling the screw E do not tighten it strongly Otherwise the frame will bend OPTICS 4 July 1996 2 6 5TH MIRROR REMOVAL A184R508 2 wmf A184R512 wmf A184R513 wmf 1 Remove the exterior covers See Exterior Cover Exposure Glass Removal 2 Remove the support plate A 2 screws 3 Remove the lens cover B 1 screw 4 Remove the lens unit base C 5 sc
33. motor A drive is transmitted to the hot roller B through idle gears The hot roller always rotates while the main motor rotates While the upper unit is open the pressure roller C is not in contact with the hot roller This enables easy misfed paper removal at the fusing area When the upper unit is closed the pressure roller is pushed up by the arms D The two springs E apply the proper fusing pressure between the hot roller and the pressure roller IMAGE FUSING 4 July 1996 11 3 FUSING LAMP CONTROL The CPU monitors the temperature of the hot roller surface using a thermistor The fusing lamp is turned on and off to keep the hot roller surface at the target temperature The target temperature depends on the machine condition as follows 1 minute Room Temp Fusing ON Lamp OFF i Y Time i Copy End Ready Copy Start Start key pressed A184D528 wmt Machine Condition Fusing Lamp Remarks ON OFF Threshold After the main switch is turned After the fusing temperature on until one minute has past 185 C reaches 170 C ready after the fusing temperature temperature the fusing lamp is reaches 170 C kept on until it reaches 185 C After the above time period When the Start key is pressed the 150 C red indicator blinks and copying starts after the fusing temperature reaches 170 C During copying 185 C After copying is finished 150 C 2 40 4 July 1996 IMAGE FU
34. oa Dz 530 E Eo COPY QUALITY 4 July 1996 Action Are the charge and transfer corona units correctly installed No Install the charge and transfer corona units correctly Are the charge and transfer corona wires broken Yes Replace the corona wires Is leakage occurring in the endblocks or receptacles No Yes Replace the defective parts Are the imaging unit drive gears worn or broken Replace the drive gears Check CN123 2 Charge Transfer trigger line 1 If the signal stays HIGH after the Start key is pressed replace the main board 2 If the charge or transfer corona does not turn on even if the signal changes to LOW replace the high voltage supply board If there is no problem with the signal lines replace the imaging unit if the sensitivity does not recover even when the drum is not exposed to light 4 July 1996 COPY QUALITY 1 2 DIRTY BACKGROUND Problem 1 Dirty background at image density level 4 manual setting 2 When newspapers are copied the background is dirty even at level 5 3 ADS copies have a dirty background Possible Causes 1 Dirty optics 2 Toner scattering e High toner density e The inlet seal of the development unit is stripped off e User SP mode setting error 3 The exposure lamp is not bright enough This may be caused by deterioration of the exposure lamp or low lamp voltage 4 In ADS mode light reflected from the original is
35. of the 1st scanner belt clamper A on the belt B 3 Set the 1st scanner at the home position and insert the two positioning pins C NOTE Scanner positioning pins are available as a service part P N A184 9501 See the parts catalog 4 Loosen the screw D securing the 1st scanner belt clamper c o E 2 3 lt c o Q S Q oc 5 Move the 1st scanner timing belt to change the optical distance between the 1st scanner and the 2nd scanner 6 Reinstall the exterior covers and make a copy to check the image quality 7 If the focus is still no good repeat steps 1 to 5 6 43 SECTION 7 TROUBLESHOOTING 4 July 1996 COPY QUALITY 1 COPY QUALITY 1 1 BLANK COPY WHITE COPY Problem White or almost white copy Possible Causes 1 Charge is not applied A184T503 wmf e High voltage supply board charge or grid failure e Poor contact of metal plates e Broken charge corona wire e Leak in insulator or endblock 2 Copy image is not transferred to the paper e High voltage supply board transfer failure e Poor contact of metal plates e Broken transfer corona wire e Leak in the insulator or endblocks 3 Poor drum sensitivity e The drum was exposed to fluorescent light or direct sunlight for a long period of time e The drum was exposed to ammonia gas or corrosive fumes for a long period of time 4 The imaging unit does not rotate e Broken drive gear 7 1
36. readjust the light intensity and the ADS voltage Does the toner supply clutch turn even though there is sufficient toner in the development unit Yes Check the voltage at CN104 1 on the main board 24 volts 0 volts 7 14 4 July 1996 COPY QUALITY 24 volts 0 volts Replace the main board Replace the toner supply clutch Is SP30 Toner Supply Mode Selection set to the default value No Change the value to the default setting 0 Is the grid voltage correct No Readjust the grid voltage Check the related SP mode settings SP 23 24 25 26 30 31 32 34 35 36 38 48 53 54 and 62 Change the settings to lean towards the lighter side oa Dz 30 22 Eo 7 15 COPY QUALITY 4 July 1996 1 13 TONER DENSITY TOO LOW Problem 1 Light copy 2 Carrier on the copy 3 Light spots appear in black solid areas Possible Causes 1 The toner supply clutch does not rotate 2 SP30 Toner Supply Mode Selection has been changed from the default setting 3 The main control board is defective 4 The charge corona current is too high 5 Some SP or UP modes have been changed that would lead to this problem 6 TD sensor defective Action Has an abnormal TD sensor condition occur No Yes See the Abnormal Condition in Toner Density Detection section Does the toner supply clutch rotate No Check the voltage at CN104 1 on the main b
37. setting back to YES If the setting was not changed before the SP mode was closed the ID indicator will blink VL Correction Resets the exposure lamp data and counter for the VL 10 No Reset correction To clear enter 1 and press the Lighter 1 Yes 95 key and the Darker key at the same time Before performing this mode clean the optics parts After performing this mode do SP48 then SP56 See page 4 2 for details Toner End The Toner End condition is canceled forcibly 96 Force Cancel By pressing the Lighter key to enter this SP mode the toner end condition is canceled Service Call Resets a service call E5 condition 97 ES Condition Turn the main switch off and on to check if the service Reset call condition is reset Total Counter Clears the total electrical counter 0 No Clear Normally this SP mode should not be performed 1 Yes To clear enter 1 and press the Lighter key and the 98 Darker key at the same time To avoid resetting the counter by mistake the counter is reset only when the Lighter key and the Darker key are pressed at the same time Clear All Clears all counters and returns all modes to the 0 No Memory default settings See the Clear All Memory Procedure 1 Yes in this section for more details Normally this SP mode should not be performed This SP mode is required only when replacing the 99 EEPROM or when the copier malfunctions due to a damaged EEPROM To clear enter 1 and press the Lighter key
38. the C S key to stop the free run All Indicators Turns on all the indicators on the operation panel for 11 ON 30 seconds It will turn off automatically after 30 seconds To turn off the indicators press the Lighter key Auto Shut Off Selects the auto shut off time in 5 minute steps 0 5 min Time Setting The copier main switch is shut off automatically after 1 10 min 14 the selected auto shut off time if SP77 is at 0 2 15 min 3 20 min 4 25 min 5 30 min Auto Reset Selects an auto reset time of 1 or 3 minutes or 0 1 min 15 Time Setting cancels this mode 1 3 min 2 None Count Selects count up or count down 0 Up Up Down The default setting depends on the setting of SP3 1 Down 16 Selection The setting can be changed after SP3 is set but if the setting of SP3 is changed again the SP16 setting will also change accordingly Function of Specifies whether the center notch of the manual 0 ADS Manual ID density indicator is used as the ADS function or as 1 Manual ID Level 3 the manual ID level 3 Level 3 This mode is used to perform the light intensity 19 adjustment of the copy quality adjustment Always change the setting to 1 at this time in order to achieve the center of the manual image density level to adjust the standard copy quality Do not forget to change it back to 0 after adjustment A4 Lengthwise Selects the trailing edge erase timing to A4 0 LT Erase Selection lengthwise on a machine in which the setting
39. to the lens motor Drive from the lens amp mirror motor is also transmitted to the 4th 5th mirror drive cam E As the lens unit position is changed the cam rotates to change the 4th 5th mirror F position to provide proper the focal distance between the lens and the drum OPTICS 4 July 1996 3 4 AUTOMATIC IMAGE DENSITY SENSOR A184D525 wmf A184D529 wmf The auto ID sensor A a photodiode is mounted on the upper front frame The sensor cover has a hole in it to allow light to fall directly onto the sensor Sampling starts 6 millimeters from the leading edge of the original and continues for 11 5 millimeters from the leading edge of original in full size mode These lengths a and b will vary depending on the selected reproduction ratio A184 copier only The lengths a and b for each reproduction ratio are calculated as follows 6mm 11 5 mm Reproduction Ratio ae Reproduction Ratio es The photosensor circuit converts the light intensity to a voltage The detected voltage is amplified and sent to the main board If less light is reflected from the original the image is darker the sensor outputs a lower voltage The CPU compares the maximum detected voltage with the standard voltage and compensates the copy image density by changing the development bias voltage 4 July 1996 OPTICS 3 5 EXPOSURE LAMP VOLTAGE CONTROL The main board controls the exposure lamp voltage through the ac drive dc power supp
40. your finger until it locks in position 4 July 1996 EXTERIOR 1 3 EXTERIOR COVER EXPOSURE GLASS REMOVAL A184R501 wmf 1 Remove the operation panel A 1 screw and 2 connectors side cover B and the platen cover 2 Remove the upper cover C 4 screws 3 Remove the exposure glass D c o E 2 EA lt c o Q S Q oc NOTE When removing or reinstalling the upper cover take care not to hook the harness onto the projections inside the cover EXTERIOR 4 July 1996 1 4 UPPER UNIT STOPPER RELEASE A184R502 wmf 1 Remove the upper cover See Exterior Cover Exposure Glass Removal Remove the exposure glass Release the stopper and open the upper unit A Remove the snap ring B and remove the pin C to release the arm D a A OO PD While holding the upper unit remove the snap ring E and release the arm F from the pin NOTE If the upper unit is opened more than 90 degrees the exterior cover of the lower unit might be damaged 6 To keep the position of the upper unit fix the arm D to position G with the pin and snap ring removed in step 4 4 July 1996 OPTICS 2 OPTICS 2 1 1ST SCANNER REMOVAL A184R503 wmf A184R504 wmf 1 Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Slide the 1st scanner A about 100 mm towards the direction of the arrow
41. 0 4 July 1996 FUSING 5 4 FUSING EXIT PAWL REPLACEMENT D j o D A184R524 wmf 2 ko lt x c o Q S Q oc 1 Release the upper unit stopper See Upper Unit Stopper Release 2 Remove the fusing upper unit A 4 screws and 2 connectors 3 Remove the fusing exit guide B 2 screws 4 Remove the fusing exit pawl bracket C 2 screws 5 Replace the fusing exit pawls D 1 spring each 6 21 FUSING 4 July 1996 5 5 HOT ROLLER REPLACEMENT A184R521 wmf A184R525 wmf Release the upper unit stopper See Fusing Unit Removal Remove the fusing upper unit A 4 screws and 2 connectors Remove the fusing lamp See Fusing Lamp Replacement Remove the fusing exit guide B 2 screws Remove the fusing exit pawl bracket C 2 screws O oa fF WwW N Remove the front D and rear E C rings Then replace the hot roller F NOTE 1 The shape of the left C ring D is different from the right C ring E The ends of the left C ring are bent as shown 2 When reinstalling the exit pawls be careful not to scratch the hot roller surface 3 When reinstalling the fusing exit guide be careful not to damage the exit sensor 4 Do not touch the hot roller surface with bare hands 6 22 4 July 1996 FUSING 5 6 FUSING THERMISTOR REPLACEMENT A184R526 wmf 1 Remove the fusing exit
42. 1 Be careful not to damage the drum surface 2 Do not touch the drum surface with bare hands 3 After removing the imaging unit from the main body cover the unit with sheets of paper to prevent the drum from being exposed 4 July 1996 IMAGING UNIT 3 2 CHARGE CORONA UNIT REMOVAL A184R516 wmf 1 Remove the imaging unit See Imaging Unit Removal 2 Remove the charge corona unit A 1 screw NOTE When removing the charge corona unit be careful not to scratch the drum surface 6 13 c o o S Q oc c o E EA lt IMAGING UNIT 4 July 1996 3 3 CLEANING BLADE REPLACEMENT A184R535 wmf 1 Remove the imaging unit See Imaging Unit Removal 2 Remove the charge corona unit See Charge Corona Unit Removal 3 Replace the cleaning blade A 2 screws NOTE 1 When removing the cleaning blade be careful not to scratch the drum surface 2 When installing a new cleaning blade apply setting powder on the edge of the cleaning blade 6 14 4 July 1996 PAPER FEED 4 PAPER FEED 4 1 PAPER FEED CLUTCH REPLACEMENT A184R517 wmf 1 Open the upper unit 2 Remove the imaging unit See Imaging Unit Removal c o E 2 3 lt c o o iS Q oc 3 Replace the paper feed clutch A 1 connector 1 snap ring and a spring NOTE When reinstalling a new clutch engage the notch B with the stopper C
43. 2 or 3 is selected in SP30 Detect Supply mode is used If 4 is selected Fixed Supply mode is used Note that when 2 3 or 4 is selected the machine will not perform the toner near end detection Normally SP30 should always be kept at the default setting The following pages describes in detail of each toner supply mode settings 6 3 2 Detect Supply Mode In Detect Supply mode the CPU monitors the TD sensor voltage which depends on the toner to carrier ratio in the developer As the toner in the developer is consumed the TD sensor output voltage increases The TD sensor voltage is compared with the standard voltage known as the Target Toner Sensor Voltage and toner is supplied when the TD sensor output is higher than this target voltage The machine has two ways of calculating the target toner sensor voltage the method used depends on SP30 The toner supply amount can also be changed using SP31 or 32 2 23 N 35 Xs O Ss E nag m TONER SUPPLY 4 July 1996 1 Target Toner Sensor Voltage Method 1 Normally if O or 2 is selected in SP30 the voltage is determined by the following factors Target Toner Sensor Voltage VTs Initial Developer Setting Voltage VTo Toner Density Adjustment Factor a Initial Developer Setting Voltage VTo This voltage is adjusted to 1 9 0 1 V during the developer initialization refer to section 6 2 b Toner Density Adjustment Factor The target toner den
44. 20 seconds after the main switch is turned on e The temperature change detected by the thermistor is more than 20 C within any one second after the 20 seconds warm up time after the main switch is turned on To clear this error refer to note 3 at the beginning of this chapter o2 25 530 J Eo Possible Causes e Thermistor open e Defective main control board e Defective ac drive dc power supply board e Fusing lamp open e Poor thermistor connection 7 27 ELECTRICAL COMPONENT DEFECTS 4 July 1996 3 ELECTRICAL COMPONENT DEFECTS 3 1 SENSORS Component Condition Symptom ADS Sensor S1 Stays HIGH The image density will be abnormal CN112 3 Dirty background Stays LOW The image density will be abnormal CN112 3 Light copies Registration Sensor S2 Stays HIGH The Add Paper indicator lights when a CN108 2 copy is made Stays LOW The Paper Misfeed indicator lights CN108 2 when a copy is made Lens and Mirror H P Sensor Stays HIGH Service code E29 is displayed S3 CN113 2 A184 machines only Stays LOW Service code E28 is displayed CN113 2 Scanner H P Sensor S4 Stays HIGH Service code E22 is displayed CN110 2 Stays LOW Service code E21 is displayed CN110 2 Toner Density Sensor S5 Stays HIGH The toner near end condition will not be CN106 3 cleared even if new toner is added User code Lic is displayed when Stays
45. 49 Temperature copying Default 185 C Adjustment 175 to 195 C in 1C steps 4 16 4 July 1996 PROGRAM MODES Mode No Function Settings Exposure Displays the current exposure lamp voltage 0 225 V Lamp Voltage For 120V machines the actual applied Display voltage displayed value 2 51 The exposure lamp turns on for 10 seconds when this mode is selected Do not repeat more than 5 times to avoid overheating the optics cavity The Manual Image Density indicator is used to display the first digit Fusing Displays the fusing temperature detected by the Temperature fusing thermistor Display t Press the Start key to monitor the temperature during es the normal copy cycle The Manual Image Density indicator is used to display the first digit TD Sensor If the setting of SP30 Toner Supply Mode Selection 1 200 Target Control lis 1 or 3 this value is used for the TD sensor target Default 97 53 Voltage voltage 0 02 V per Adjustment step TD Sensor When the TD Sensor initial setting is performed this 0 255 Gain mode is adjusted automatically Default 153 54 Adjustment Normally this value should not be changed ae V per step TD Sensor Displays the TD sensor output voltage 0 02 V per Output Display Press the Start key to monitor the output voltage step t during the normal copy cycle 55 The output voltage will display 0 when this mode is ac
46. 8xt 5 Vts S 2 lt VT lt V ts 45 5 13xt 6 Near End Level VT 2 Vts 45 5 16xt 7 Toner End Level VT gt V1s S 16xt The toner supply time step t can be changed using SP31 t SP31 setting x 0 1 second Default 1 0 1 second S TD Sensor Sensitivity SP24 In the toner supply level 6 and 7 after a copy job is finished the main motor continuously rotates and the toner supply clutch is energized intermittently for T seconds repeatedly 2 seconds on and 2 seconds off during this T second interval The interval T can be changed using SP23 Method 2 If 2 or 3 is selected in SP30 a fixed amount of toner is supplied when the TD sensor voltage becomes higher than the target toner sensor voltage The amount of toner can be selected using SP32 SP32 Setting Toner Supply Clutch On Time Corresponding image area ratio seconds 0 0 3 3 5 1 0 6 7 2 1 2 15 3 2 4 30 4 3 6 45 5 4 8 60 Stays on until the TD sensor 6 voltage becomes lower than the target voltage 7 0 No toner supply 0 Example Set SP32 to 2 if the customer s originals are typically 15 black 2 25 TONER SUPPLY 4 July 1996 6 3 3 Fixed Supply Mode If 4 is selected in SP30 the TD sensor is not used for toner supply control A fixed amount of toner is supplied at every copy cycle The toner supply amount is determined by the SP32 setting 6 3 4 TD Sensor
47. AK TAA mim F T403 hd hd Fut 1402 Ac Drive DC Power CY Supply Board AC Power Source A184D519 wmf The main board monitors the fusing temperature through a thermistor It uses the zero cross signal generated by the ac drive dc power supply board to control the applied power accurately Normally the voltage applied to the lamp is the full duty cycle of the ac waveform However through SP29 fusing power can be set to phase control mode Phase control is used only if the customer has a problem with electrical noise or interference 2 42 4 July 1996 IMAGE FUSING 11 4 2 On Off Control When the main switch is turned on the main board starts to output a trigger pulse which has the same timing as the zero cross signal to the ac drive dc power supply board This trigger pulse allows maximum ac power to be applied to the fusing lamp When the operating temperature is reached the CPU stops outputting the trigger pulse the trigger stays HIGH and the fusing lamp turns off Detailed 11 4 3 Phase Control Mode AC Power A _ a Zero Cross JL I JL JL TM TI Trigger Low Temp iT ef fy ff jf ff Fusing Lamp Power Arey eu Trigger High Temp ao a al a Fusing Lamp Power 6 A184D526 wmf n c e Q ro N m The main board sends the fusing lamp trigger pulse LOW active to the ac drive dc power supply board which provides ac power to the fusing
48. ASE LAMP EXPOSE LAMP T Z Y LLNO 24v OFF ZERO CROSS gt a C lt I vz 01 NY4 NOS valiz Q 9 921NO_1 PZI vel ZINO Z tzio vz tzio vz tzio vz L PVLENO OPTICS COOLING FAN MOTOR L2 al al vi vi AC DRIVE DC POWER SUPPLY BOARD FUSING LAMP LINDYID SAYA Fe amy dWV71 SNISNA L L LObL MOTOR A184 ONLY 5 VC 24VA 0 PGND O lt I w 24 C T TRG lt I 40 0 5 B PWM LENS amp MIRROR 02 9 CN123 4 CN123 3 CN123 2 0N123 1 CN S TRANSFORMER TR Zz FUSING THERMOFUSE TF1 CNSC CN301 8 CN301 9 O Z 20bNO LINOUIO SAIC TONO T div7 SHNSOdx3 24y QONI PGND CN1 2 c T TRG OON13 62 aD Kd bm K2 B PWM OCNT4_ SCANNER M R F SCANNER DRIVE BOARD PONPI EXPOSURE LAMP L1 EXPOSURE LAMP THERMOFUSE TF1 SW2 S 00ENO F 00ENDY lt r20 lt vzla lt pz0 lt vel 00ENO Z 00END lt pz o lt vzla L 00ENO b to DRUM GND INTERLOCK SW BOARD CT B G A SCANNER DRIVE MOTOR HIGH VOLTAGE SUPPLY AC POWER CORD MAIN SW SW1
49. At high temperature and high humidity or at low temperature and low humidity store paper in a plastic bag This is especially important to decrease the amount of curls or waves that would lead to paper misfeeds SERVICE REMARKS 4 July 1996 1 7 OTHERS 1 When replacing the main board remove the EEPROM IC106 from the old main board and place it on the new main board Then install the new main board in the copier After installing a new main board with a new EEPROM IC106 the Clear All Memory SP99 procedure must be performed Do not perform SP99 if you have placed the old EEPROM on the new main board Never perform SP99 Clear All Memory except for the following two cases a When the copier malfunctions due to a damaged EEPROM b When replacing the EEPROM Whenever SP99 Clear All Memory is performed the imaging unit must be replaced with a new one Otherwise copy quality might be seriously affected Tighten securely the screws used for grounding the following PCBs when reinstalling them e Main Control Board e Scanner Drive Board e AC Drive DC Power Supply Board e High Voltage Supply Board CT B G 4 July 1996 PROGRAM MODES 2 PROGRAM MODES 2 1 BASIC OPERATION 1 Component This copier is equipped with two program modes One is the Service Program SP Mode for factory and field technician usage and the other is the User Program UP mode for user usage Both program modes have a different
50. Check and Toner Supply Timing During every copy cycle the TD sensor voltage is monitored for three seconds after the machine starts developing the image on the drum The CPU checks the voltage every 40 ms and stores the second highest voltage of every 250 ms period Then the stored voltages during the three seconds are averaged and the average is used as the TD sensor value for the copy The toner supply clutch on time for detect supply mode using TD sensor output depends on this value If the machine determines that toner needs to be added the toner supply clutch turns on just after the trailing edge of the copy paper passes the transfer corona unit If the copy paper is shorter than A4 LT size the clutch is energized for 3 seconds after the machine starts developing the latent image 6 3 5 Abnormal Condition in Toner Density Detection If the calculated value of the TD sensor goes below 0 2 volts the CPU determines that the toner density detection is abnormal The CPU changes from the detect supply mode to the fixed supply mode At the same time either the Auto ID indicator or the selected manual ID level starts blinking and the machine can be operated Under this condition the machine will not perform the toner end detection If the value recovers above 0 2 volts or the main switch is turned off and on this condition is canceled and the toner density detection will recover to the previous settings 2 26 4 July 1996 TONER SUPPLY
51. D which adsorbs ozone O3 generated by the charge corona is located beside the exhaust fan The ozone filter decreases in efficiency over time as it adsorbs ozone The ozone filter should be replaced every 30 k copies N 35 Xs O S E nag Q CHARGE 4 July 1996 2 2 CHARGE CORONA CIRCUIT CN123 4 CN1 1 24 V ii CN123 3 CN1 2 DC DC GND Inverter ae CN123 2 CN1 3 CT Trigger 9 G B Drume CN123 1 CN1 4 DC DC T i B PWM Inverter oe we e ATT v High Voltage Supply To Drum GND Board CT B G A184D503 wmf The main board supplies 24 V to the high voltage supply board at CN123 4 as the power source After the Start key is pressed the CPU drops CN123 2 from 24 V to 0 V This activates the charge corona circuit which applies a high negative voltage of approximately 5 k volts to the charge corona wire The corona wire then generates a negative corona charge The grid plate limits the charge voltage to ensure that the charge does not fluctuate and that an even charge is applied to the entire drum surface The grid plate is connected to ground through a zener diode in the high voltage supply unit The grid plate drains any charge in excess of 850 V which is discharged to the ground through the zener diode 4 July 1996 OPTICS 3 OPTICS 3 1 OVERVIEW C B A E F
52. IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1 Before disassembling or assembling any parts of the copier make sure that the power cord is unplugged 2 The wall outlet should be near the copier and easily accessible 3 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 4 The inside and the metal parts of the fusing unit become extremely hot while the copier is operating Be careful to avoid touching those components with your bare hands HEALTH SAFETY CONDITIONS 1 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 must be maintained by a customer service representative who has completed the training course on the model SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1 Do not incinerate toner cartridges or used toner Toner dust may ignite suddenly when exposed to open flame 2 Dispose of imaging units in accordance with local regulations These are non toxic supplies 3 Dispose of replaced parts in accordance with local regulations SECTION 1 OVERALL MACHINE INFORMATION 4 July 1996 SPECIFICATIONS 1 SPECIFICATIONS _5 oT Conf
53. July 1996 DEVELOPMENT 5 2 DRIVE MECHANISM Detailed n c e Q ro N m A184D510 wmf When the main motor A turns on the drive is transmitted to the development roller gear B through idle gears The rotation of the development roller gear is transmitted to the agitator gears C through idle gears 2 15 DEVELOPMENT 4 July 1996 5 3 CROSS MIXING D A184D511 wmf A cross mixing mechanism is used to keep the toner and developer evenly mixed It also helps agitate the developer to prevent developer clumps from forming and helps create the triboelectric charge Two agitators helical coils A and B are used for the cross mixing The 1st agitator A moves the developer from left to right The toner supplied from the cutout in the toner cartridge holder is mixed with the developer by the 1st agitator The 2nd agitator B rotates in the opposite direction and moves the developer back from right to left In this way the developer is evenly distributed in the development unit The magnets in the development roller C attract the developer and the development roller sleeve rotates to carry the developer to the drum The doctor blade D trims the developer on the development roller to the desired thickness 2 16 4 July 1996 DEVELOPMENT 5 4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL The image density is controlled by changing two items the amount of bias voltage applied to the developm
54. N123 1 CN1 4 DC DC A B PWM Inverter oe we e ATT i v High Voltage Supply To Drum GND Board CT B G A184D503 3 wmf The terminal which applies high negative voltage to the transfer corona is the same as the terminal for the charge corona So when the CPU drops CN123 2 from 24 V to 0 V both the transfer corona and charge corona are applied to the drum at the same time To apply the proper transfer current to the drum the transfer corona casing is connected to ground through a varistor This keeps the potential of the casing at 620 volts to prevent excess corona current from flowing into the casing 2 29 DRUM CLEANING 4 July 1996 8 DRUM CLEANING 8 1 OVERVIEW A184D514 wmf A counter blade system is used for drum cleaning The cleaning blade A scrapes off any toner remaining on the drum after the image is transferred to the paper The removed toner is transported into the developer to be recycled 2 30 4 July 1996 DRUM CLEANING 8 2 TONER RECYCLING MECHANISM A N 35 Xs o S E nag Q B A184D515 wmf The toner removed from the drum falls onto the toner collection coil A The drum gear rotation is directly transmitted to the gear of the toner collection coil As the coil rotates the toner moves from left to right to be transported to the toner recycling belt B The paddles of the belt which is driven by the toner collection coil shaft transports the toner into
55. NCE 4 July 1996 1 PREVENTIVE MAINTENANCE SCHEDULE 1 1 PM TABLE PREVENTIVE MAINTENANCE SCHEDULE NOTE The amounts mentioned as the PM interval indicate the number of copies Symbol key L Lubricate R Replace C Clean Inspect A Adjust EM 30k 60k 90k 120k Notes Optics Reflector C C C C Silicone cloth 1st to 5th Mirrors C C C C Silicone cloth 6th Mirror C C C C Blower brush Lens C C C C Blower brush Exposure Glass C C C C C Soft cloth dampened with alcohol or water Platen Cover Sheet C C C C C Soft cloth dampened with water Scanner Guide Rod L L L L Launa oil Scanner Guide Rail L L L L G501 4th 5th Mirror Guide Rod L G501 Lubricate if necessary 4th 5th Mirror Guide Rail L L L L G501 Around Drum Transfer Corona Unit C C R C R Cleaning tool Transfer Guide Plate C C C C C Cleaning tool End Blocks and Casings C C C C Blower brush or dry cloth Erase Lamp C C C C Blower brush or dry cloth QL C C C C Blower brush or dry cloth Paper Feed Pick up Roller C C C R C Soft cloth dampened with water Bottom Plate Pad C C C C Soft cloth dampened with water Relay Roller C C C c C Soft cloth dampened with water Registration Roller C C c C C Soft cloth dampened with water Paper Feed Guide C C C C Soft cloth dampened with water Fusing Hot Roller R R Pressure Roller R R
56. Problem The copy image is skewed parallelogram shape IMAGE The sides of the copy image are straight but the leading and trailing edges are skewed This differs from skewing originating in the paper path A184T510 wmf Possible Causes 1 The 4th 5th mirror assembly is not parallel with the 1st and 2nd scanners 2 The mirrors are in the wrong position Action Is each mirror positioned correctly on its scanner and on the 4th 5th mirror assembly Yes No Reposition the mirror correctly If the spring plates are defective replace them Readjust the height of 4th 5th mirror assembly by turning the adjusting screw oa Dz 30 22 Eo 7 13 COPY QUALITY 4 July 1996 1 12 TONER DENSITY TOO HIGH Problem 1 Dirty background appears on the copy 2 The image density of black solid areas is too high Possible Causes 1 The toner supply clutch keeps on turning continuously 2 SP30 Toner Supply Mode Selection has changed from the default setting 3 The main control board is defective 4 The charge corona current is too low 5 Some SP or UP modes have been changed that would lead to this problem 6 TD sensor defective Action Has an abnormal TD sensor condition occurred Yes See the Abnormal Condition in Toner Density Detection section Clean the optics section and the area around the drum Clear the VL correction with SP95 Make a few sky shot copies and then
57. REGISTRATION 4 July 1996 10 4 BY PASS FEED C B A A184D522 wmf If a sheet of paper is inserted in the by pass feed table A the registration sensor B is actuated and the machine goes to by pass feed mode 500 milliseconds after the registration sensor is actuated the main motor turns on for 222 milliseconds to drive the relay roller C to catch the leading edge of the paper After the Start key is pressed the main motor starts again to transport the paper to the registration roller D The registration solenoid is energized 1912 milliseconds after the main motor started rotating 2 36 4 July 1996 PAPER FEED AND REGISTRATION 10 56 PAPER FEED AND MISFEED DETECTION TIMING second I Start Key o I N Vf 5 c Main Motor TE 9 2 It z5 i oe Paper Feed l 5 Clutch rt D 9 I 1 5 m D Registration oI 5 7 A Sensor er CED Paper Length Detection T OFF Check T gt Registration ON Check 2 7 3 2 3h 1 Solenoid E 57 Io 10 3 Exit Sensor I l ON Check sh 2 34 3 A184D527 wmf The registration sensor and the exit sensor are used for misfeed detection If the CPU detects a misfeed the Check Paper Path or the Add Paper indicator turns on When the main switch is turned on the CPU checks these sensors for initial misfeed During the copy cycle the CPU performs four kinds of misfeed detection Checks whether the registration sensor is actuated within 1 5
58. SING When the main switch is turned on the CPU turns on the fusing lamp When the fusing thermistor detects 170 C the machine enters the ready condition After the ready temperature is detected the CPU keeps the fusing temperature at 185 C for one minute then the target temperature is changed to 150 C When the Start key is pressed if the fusing temperature is higher than 170 C the machine starts copying immediately If the temperature is lower the fusing lamp is turned on and the red start indicator blinks Copying starts after the fusing temperature reaches 170 C and the fusing temperature is controlled at 185 C during copying Detailed n c e Q X S N m After copying is finished the fusing temperature is controlled at 150 C To prevent any copy quality problem caused by exposure lamp intensity fluctuation the fusing lamp does not turn on while the exposure lamp is on even if the fusing temperature drops below 185 C 2 41 IMAGE FUSING 4 July 1996 11 4 FUSING LAMP CONTROL CIRCUIT 11 4 1 Overview CN121 11 F Fusing a CN121 10 L 5V es CN121 8 7 TE SAN CN404 2 408 ae Ce V Fusing Lamp Trigger Pulse y NAY poe 24 V T407 N404 3 pesoto CN121 7 c sos as Main Board 1406 tas Main Switch Interlock REN e T404 Switch X Alh D
59. Scanner H P Sensor S4 2 G1 Optics Thermistor TH1 3 E1 Exposure Lamp Thermofuse TF 1 4 B4 Main Control Board PCB1 5 E3 Exhaust Fan Motor M2 6 D1 High Voltage Supply Board CT B G PCB3 7 A3 Lens and Mirror H P Sensor 8 G1 A184 machines only S3 Scanner Drive Board PCB2 9 A3 Scanner Drive Motor M3 10 A1 Lens and Mirror Motor A184 machines only M4 11 C4 Total Counter except for 17 machines CO 12 E4 Operation Panel Board PCB5 13 D1 Toner Density TD Sensor S5 14 F6 ADS Sensor S1 15 E1 Erase Lamp L4 16 C4 D4 Quenching Lamp QL L3 17 F1 Optics Cooling Fan Motor 18 C1 220 240 V machines only M5 AC Drive DC Power Supply Board PCB4 19 C6 Fusing Thermofuse TF2 20 B5 Fusing Thermistor TH2 21 F6 Fusing Lamp L2 22 C5 Main Motor M1 23 E7 Paper Feed Clutch CL2 24 D6 Toner Supply Clutch CL1 25 D6 Registration Sensor S2 26 F1 Registration Solenoid SOL1 27 E6 Main Switch SW1 28 A7 Interlock Switch SW2 29 A7 Exit Sensor S6 30 F6 Transformer TR 31 B8 Start Key Main Motor Quenching Lamp Paper Feed Clutch Registration Sensor Registration Solenoid Scanner Drive Motor ADS Detection Exposure Lamp Erase Lamp Development Bias Charge Transfer Corona TD Sensor Detection Toner Supply Clutch Exit Sensor Total Counter For the 1st copy cycle the CPU determines the copy paper to be the maximum LG paper size except for the erase m
60. ber Description Q ty A184 9501 Scanner Positioning Pin 2 pcs set 1 5214 9500 Test Chart OS A4 10 pcs set 1 5442 9103 Launa Oll 1 5203 9501 Silicone Grease G 510 1 5420 9507 Digital Multimeter 1 5442 9101 Setting Powder 1 0 o 2S Eg oO DE a o amp 5 5 SECTION 6 REPLACEMENT AND ADJUSTMENT 4 July 1996 EXTERIOR 1 EXTERIOR a OPERATION PANEL POSITION CHANGE A184R500 wmf 1 Remove the operation panel A 1 screw and 2 connectors 2 Connect the 2 connectors B and C f o E n Pk lt f o E S Q oc 3 Remove the side cover D 1 screw 4 Install the side cover D at the other position 1 screw 5 Connect the two connectors of the operation panel then set the operation panel and secure it with the screw removed in step 1 6 1 EXTERIOR 4 July 1996 1 2 PLATEN COVER POSITION CHANGE A184R537 wmf A184R538 wmf 1 Hold the platen cover A as shown and pull it in the direction of the arrow 2 Remove the two caps B from the main body Then fix the caps over the slots where the platen cover was set 3 Put one of the hinges C into one of the openings in the copier Then fix the hinge to the platen cover and lean the cover back until it clicks 4 Attach the other hinge to the platen cover Hold the platen cover and lower the hinge into the opening Then push the hinge into the opening with
61. c 82 to 84 a b 85 to 141 a 4 4 TRAILING EDGE ERASE This minimizes toner consumption The entire line of LEDs turns on after the trailing edge of the latent image has passed 10 mm from the erase lamp The length of the latent image is determined by the paper length which is checked by the registration sensor The LEDs stay on to erase the leading edge of the latent image in the next copy cycle After the final copy the erase lamps turn off at the same time as the main motor 2 13 DEVELOPMENT 4 July 1996 5 DEVELOPMENT 5 1 OVERVIEW A184D509 wmf When the main motor turns on the development roller A and two agitators B and C start turning There are permanent magnets in the development roller which attract the developer which is about 50 um in diameter to the roller The turning sleeve of the development roller carries the developer past the doctor blade D which trims the developer to the desired thickness The development roller sleeve continues to turn carrying the developer to the drum E When the developer brush contacts the drum surface the negatively charged areas of the drum surface attract and hold the positively charged toner In this way the latent image is developed The development roller is given a suitable negative bias for preventing toner from being attracted to the non image areas on the drum which may have a residual negative charge The bias also controls image density 2 14 4
62. cessed after turning on the main switch without making any copies The Manual Image Density indicator is used to display the first digit ADS Adjusts the ADS reference voltage Reference After adjusting the light intensity SP48 place 5 Voltage sheets of A4 LT white paper on the exposure glass gg Adjustment and select this mode Adjust the ADS voltage to 2 5 0 2 V using VR100 on the main control board The Manual Image Density indicator is used to display the first digit See Replacement and Adjustment Copy Quality Adjustment for details ADS Output Displays the ADS output voltage Voltage Display Press the Start key to monitor the output voltage t during the normal copy cycle 57 For only this SP mode the copies are made with the ADS mode other SP modes use the manual ID level 3 The Manual Image Density indicator is used to display the first digit 4 17 PROGRAM MODES 4 July 1996 Mode No Function Settings Optics Displays the optics temperature detected by the 59 Temperature optics thermistor Display t Press the Start key to monitor the temperature during the normal copy cycle Drum Potential Factory use only 60 Measurement With Paper Drum Potential Factory use only 61 Measurement Without Paper VL Correction Sets the interval for VL correction The exposure lamp
63. de changes the OFF time Near End 0 1 second per step range 0 to 4 seconds Recovery Normally this value should not be changed Fusing Selects the fusing temperature control mode 0 ON OFF 29 Temperature After selecting the control mode and turning the main control Control i 7 ic 1 Phase oniro switch off on the fusing temperature control mode is Selection changed control 4 13 PROGRAM MODES 4 July 1996 Mode No Function Settings Toner Supply Mode Selection 30 Selects the toner supply system Normally this value should not be changed SP Setting Note Toner Supply System Detect supply mode using Default 0 the initial TD sensor setting Detect supply mode using 1 the target TD sensor voltage set with SP53 Detect supply mode fixed 2 amount using the initial TD sensor setting Detect supply mode fixed amount using the target TD sensor voltage set with SP53 Use only in abnormal TD sensor conditions Fixed supply mode See SP31 SP32 for the toner supply amount Default 0 Toner Supply Amount TD Sensor 31 Mode Determines how much toner is supplied in detect supply mode Select the base unit for toner supply time from 0 1 s to 5 0 s in 0 1 s steps The multiple of this unit that is used depends on current TD sensor output See Detailed Descriptions Toner Supply Contr
64. drum surface via the optics assembly The charge on the drum surface is dissipated in direct proportion to the intensity of the reflected light thus producing an electrical latent image on the drum surface ERASE The erase lamp illuminates the area of the charged drum surface that will not be used for the copy image The resistance of the drum in the illuminated areas drops and the charge on those areas dissipates DEVELOPMENT Positively charged toner is attached to the negatively charged areas of the drum thus developing the latent image The positive triboelectric charge is caused by friction between the carrier and toner particles IMAGE TRANSFER Paper is fed to the drum surface at the proper time so as to align the copy paper and the developed image on the drum surface Then a strong negative charge is applied to the back side of the copy paper producing an electrical force which pulls the toner particles from the drum surface to the copy paper At the same time the copy paper is electrically attracted to the drum surface CLEANING The cleaning blade scrapes the toner off the drum The collected toner is recycled QUENCHING Light from the quenching lamp electrically neutralizes the drum surface a i SE 2 gt og MECHANICAL COMPONENT LAYOUT 4 July 1996 3 MECHANICAL COMPONENT LAYOUT
65. e Defective main control board e CN111 on the main control board is not correctly connected CODE 52 FUSING ERROR 1 Definition The temperature detected by the thermistor does not reach 160 C within 45 seconds after the main switch is turned on To clear this error refer to note 3 at the beginning of this chapter Possible Causes e Defective fusing thermistor e Fusing lamp open e Defective ac drive dc power supply board e Defective main control board e CN121 on the main control board or CN404 on the ac drive dc power supply board is not correctly connected 7 26 4 July 1996 SERVICE CALL CONDITIONS CODE 53 FUSING ERROR 2 Definition The temperature detected by the thermistor becomes higher than 230 C for more than 3 0 seconds To clear this error refer to note 3 at the beginning of this chapter Possible Causes e Thermistor short e Defective ac drive dc power supply board e Defective main control board e Fusing harness shorted e Triac short CODE 54 FUSING ERROR 3 Definition The temperature detected by the thermistor does not rise for more than 15 C within 15 seconds after the fusing lamp is turned on during stand by To clear this error refer to note 3 at the beginning of this chapter Possible Causes e Poor thermistor connection e Defective thermistor CODE 55 FUSING ERROR 4 Definition e The temperature value output by the thermistor does not change at all after
66. e made with ID level 3 center value 2 Since the Darker Lighter keys are used during the program modes image density cannot be changed using the Darker Lighter keys while in the program modes 3 Since the Copy Counter is used to display the adjustment values and data the copy counter can not be displayed 2 2 SP MODE 1 Service Program Mode Access Procedure 1 Turn off the main switch 2 While pressing the Darker key and the Clear Stop key together turn on the main switch 3 A dot will appear in the top left corner of the Copy Counter 4 Release the Darker key and the Clear Stop key and within 5 seconds press the Lighter key if not pressed within 5 seconds the machine will return to the copy mode The copier is ready to accept the program number NOTE To access the UP mode turn on the main switch while pressing the Clear Stop key 2 How to Select the Program Number 1 By using the Increase or Decrease Quantity or keys enter the required program number At this point the Copy Counter will be blinking and the dot e will be lit 2 When the Lighter key is pressed the number which is currently blinking in the Copy Counter will be entered as the selected program number 4 July 1996 PROGRAM MODES 3 Changing the Value of an SP Mode 1 Enter the desired value or setting using the Increase or Decrease Quantity or key For some modes since the Copy Counter has only 2 digits the f
67. echanism COPIER TIMING CHART 2 3 3 1 5 8 7 2 7 7 8 0 10 3 11 4 Second io l 1 Io 1 I 1 0 5 1 1 oo lo Io I o Io l 12 3 I I 12 7 l I i i l 15 3 ce be eS Note 1 A4 2 repeat copies 2 100 3 ADS mode 4 Paper Tray A183 A184 May 24 1996 POINT TO POINT DIAGRAM A183 184 COPIER gnal Signal Direction Active High Active Low y 1 Symbol Table UPPER SIDE LOWER SIDE 5 gt AC Line Pulse Si NO YOLOW W AAO NO Ave Q5 SSOHD OHAZ ZIINO E LZLNO 4 E ash Is OA NO AYAH WW OP IZIND OD NI d H YANNVOS p B 0TINO P oul dnvisi0 lt sI gt Q ONS Ts porna g ONS oul aasnals A lP OS Ave 04 vN S4 SENSOR SCANNER H P aN9 NO HOLOWW aN9d Ave v 02LNO 021NO 0cLNO L OZLNO ASi EEHNO LNOA e eeunoyp gt NI d H NOV aNd Ololano L ELLNO S3 H P SENSOR A184 ONLY AY798 HYLS ADYANA VAltz O g gorND AVTaY HYLS ADHANAlPZ A gt O Z90INo LENS amp MIRROR to MAIN SW DRUM GND 130 Odo GN9I0 O g S 90INO 130 dols A O e g0rN5 Q MSA eson ii aNolol HOSN3S 1 QF90rND aN9 L A s A l1si93 NI HOSNIS 1 lt Q E90INI INOA Ololano 4NOO HOsNas 1 8 2l gt O s g0rN5 OPC SENSOR DETECT w o we S2 TD S5 REGIST SENSOR jN jN oO DRAWER CONNECTOR a
68. ent roller sleeve and the amount of voltage applied to the exposure lamp Applying a bias voltage to the development sleeve reduces the potential between the development roller and the drum thereby reducing the amount of toner transferred As the bias voltage becomes greater the copy becomes lighter N 35 Xs O Ss E nag Q The method of control depends on whether the image density is manually selected or auto image density is used The development bias voltage applied to the development roller sleeve has the following factors Development bias voltage Base bias voltage factor Manual ID level 5 SP 36 Image density adjustment factor SP34 Drum residual voltage VR correction factor The base bias voltage for non image areas between copies is 200 volts The above correction factors are also applied NOTE SP34 Image Density Adjustment is applied for both ADS and manual ID modes SP36 is for manual ID level 5 only 5 4 1 Base Bias Voltage Factor In Manual Image Density Mode Manual ID Level 1 2 ADS 3 4 5 Base Bias Voltage 240 Volts 200 200 200 200 SP36 Base Exposure Vo 6 steps Lamp Voltage SP35 Vo 6 steps Vo Vo 3 steps Vo 7 steps Volts Vo Depends on the setting of SP48 The base voltage applied at each ID level is shown in the above table Normally notch 3 is used for the ADS mode If SP mode 19 is changed from 0 to 1
69. erase lamp with a blower brush or Replace the dry cloth corona wires 4 Clean the quenching lamp with a blower brush every 60 k or dry cloth PREVENTIVE MAINTENANCE SCHEDULE 4 Paper Feed every 30 k 5 Fusing Unit every 30 k Fusing Unit every 60 k 6 Others every 30 k 7 Copy Quality 4 July 1996 1 Clean the pick up rollers with a soft cloth dampened with water Replace at every 90 k 2 Clean the bottom plate pad with a soft cloth dampened with water 3 Clean the relay roller and the registration roller with a soft cloth dampened with water 4 Clean the paper feed guide with a soft cloth dampened with water 1 Clean the stripper pawls with a suitable solvent Replace at every 120 k 2 Clean the fusing entrance and exit guide plates with a suitable solvent 3 Clean the fusing thermistor with a suitable solvent 1 Replace the hot roller N Replace the pressure roller 1 Replace the ozone filter 2 Inspect the exit and registration sensors 3 Inspect the bearings 1 Reset the VL correction SP95 2 Make a copy of a test chart at manual image density level 3 Perform the light intensity adjustment SP48 if necessary 3 Return the setting of SP19 from 1 to 0 4 Perform the ADS reference voltage adjustment SP56 4 July 1996 SPECIAL TOOLS AND LUBRICANTS 2 SPECIAL TOOLS AND LUBRICANTS Part Num
70. ets 8 5 x 14 10 sheets 50 sheets OHP 1 sheet 120 V 60 Hz More than 10 A for North America 220 240 V 50 Hz More than 6 A for Europe 220 V 50 Hz More than 6 A for Asia 220 V 60 Hz More than 6 A for Middle East Asia 110 V 60 Hz More than 10 A for Taiwan 127 V 60 Hz More than 10 A for Middle East Maximum 0 9 kW Copy cycle condition 0 5 kW Warm up condiiton 0 6 kW Stand by condition 0 1 kW Width Depth Height 400 mm 550 mm 220 mm copier 15 8 21 7 8 7 Sound pressure level the measurements are made according to ISO 7779 at the operator position Less than 55 dB Sound power level the measurements are made according to ISO 7779 Stand by condition Less than 40 dB Copy cycle condition Less than 63 dB Less than 18 kg 39 7 Ib 4 July 1996 SPECIFICATIONS MEMO 2 m SE 2 gt OL COPY PROCESS AROUND THE DRUM 4 July 1996 2 COPY PROCESS AROUND THE DRUM A184V501 wmf 4 July 1996 COPY PROCESS AROUND THE DRUM oh DRUM CHARGE In the dark the charge corona unit gives a uniform negative charge to the organic photoconductive OPC drum The charge remains on the surface of the drum because the OPC drum has a high electrical resistance in the dark EXPOSURE An image of the original is reflected to the
71. gh voltage supply unit terminals Pay extreme attention when adjusting the bias voltage Make sure that the machine is unplugged before connecting the multimeter 1 Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Set the multimeter range to dc 1500 V and connect the multimeter leads as shown 3 Close the upper unit 4 Turn on the development bias using SP9 2 5 Adjust the development bias voltage by turning VRB on the high voltage supply unit 6 36 4 July 1996 COPY QUALITY ADJUSTMENT 7 2 2 SP Bias Settings When 1 The image is blurred in ADS mode even though the image density in black solid areas is acceptable 2 Dirty background in ADS mode The problem is not caused by excess toner and cannot be solved by adjusting the light intensity 3 The customer requires a lighter image when manual ID level 5 is selected Purpose To get the proper image density Method VRB on the high voltage supply board SP34 for cases 1 and 2 SP36 for case 3 How it works Changes the bias voltage while the image area on the drum is being developed NOTE SP34 and SP36 settings can be changed by customers SP34 Image Density Adjustment Setting 0 1 2 3 4 5 6 Bias Voltage Change V 0 40 40 40 40 40 40 Exposure Lamp Change 0 0 0 3 steps 3 steps 7 steps 7 steps
72. heat protection It opens when the temperature reaches 128 C and cuts ac power to the exposure lamp N 35 Xs 2 s E nag Q OPTICS 4 July 1996 3 2 SCANNER DRIVE A184D505 wmf A stepper motor A is used to drive the scanners The first scanner B which consists of the exposure lamp and the first mirror is connected to the first scanner belt C The second scanner D which consists of the second and third mirrors is connected to the second scanner belt E Both the scanners move along the guide rail F The pulley G drives both the first and second scanner belts The 2nd scanner moves at half the speed of the first scanner This maintains the focal distance between the original and the lens during scanning The scanner home position is detected by the home position sensor H The scanner return position is determined by counting the scanner motor drive pulses 4 July 1996 OPTICS 3 3 LENS AND 4TH 5TH MIRROR DRIVE A184 copier only N 35 Xs o S E nag Q A184D506 wmf Drive from the lens amp mirror motor A is transmitted to the timing belt B on which the lens unit C is clamped The lens position is changed to provide the proper optical distance between the lens and the drum surface corresponding to the selected reproduction ratio The home position of the lens is detected by the home position sensor D The main board keeps track of the lens position based on the number of pulses sent
73. horizontal magnification Adjustment Less than 0 5 difference between original and copy Standard Method SP44 0 2 step 31 steps How it works Changes the lens home position 6 41 COPY QUALITY ADJUSTMENT 7 9 REGISTRATION ADJUSTMENT When Registration is not within the adjustment standard Purpose To maintain proper registration Adjustment Paper tray 0 2 0mm Standard By pass feed 023 Method SP42 0 5 mm step 15 steps How it works Changes the registration solenoid on timing 1 Place a 150 mm scale perpendicular to the left scale on the exposure glass 2 Adjust the registration using SP42 Make copies and check the registration 7 10 ERASE MARGIN ADJUSTMENT When The leading edge margin is not within the adjustment standard Purpose To maintain the correct leading erase margin Adjustment 2 5 2 0 mm Standard Method SP41 0 5 mm step 15 steps How it works Changes the erase lamp on period 1 Place a 150 mm scale perpendicular to the left scale on the exposure glass 2 Adjust the leading edge erase margin using SP41 Make copies and check the registration 6 42 4 July 1996 COPY QUALITY ADJUSTMENT 7 11 FOCUS ADJUSTMENT B Al A184R541 wmf s Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Mark the position
74. iguration Desk Top QE OL Copy Process Dry electrostatic transfer system Originals Sheet Book Original Size Maximum A4 8 5 x 14 A183 copier B4 10 x 14 A184 copier Copy Paper Size Paper tray feed A4 8 5 x 11 8 5 x 13 8 5 x 14 Bypass feed Maximum A4 8 5 x 14 Minimum A5 5 5 x 8 5 Copy Paper Weight Paper tray feed 64 to 86 g m 17 to 23 Ib Bypass feed 60 to 105 g m2 16 to 27 Ib Reproduction Ratios Metric Version Inch Version UNTER model ONIY Enlargement o 129 Full Size 100 100 93 93 Reduction 82 85 71 78 Zoom A184 model only From 70 to 141 in 1 steps Copying Speed 12 copies minute A4 8 5 x 11 Warm up Time Less than 30 seconds at 23 C First Copy Time Less than 9 seconds A4 8 5 x 11 Copy Number Input Up Down key 1 to 50 Manual Image Density 4 steps can also be set to 5 steps Selection Automatic Reset 1 minute standard setting can also be set to 3 minutes or no auto reset Paper Capacity Paper Tray 250 sheets A4 8 5 x 11 80 g m2 20 Ib 100 sheets 8 5 x 14 80 g m2 20 Ib Bypass feed entrance 1 sheet Toner Replenishment Bottle exchange 91 g bottle 1 1 SPECIFICATIONS Copy Tray Capacity Power Source Power Consumption Dimensions Noise Emissions Weight 4 July 1996 Copy tray inthe Copy tray in the closed position open position A4 8 5 x 11 20 sheets 50 she
75. in motor rotation is transmitted to the paper feed clutch gear A The rotation of the paper feed clutch gear is transmitted to the relay roller gear B through an idle gear After the Start key is pressed the solenoid C of the paper feed clutch is energized to release the stopper D and the rotation of the relay roller gear is transmitted to the feed roller shaft E The solenoid stays on for 250 milliseconds and then turns off The feed rollers stop when they complete one rotation Before the feed rollers stop the leading edge of the paper is caught by the relay rollers F 2 34 4 July 1996 PAPER FEED AND REGISTRATION 10 3 REGISTRATION MECHANISM N 35 Xs O S E nag Q A184D524 wmf The relay rollers always rotate while the main motor rotates They transport the paper to the registration roller A The registration roller is also driven by the main motor through idle gears There is a paper stopper B between the relay roller and the registration roller After the leading edge of the paper reaches the stopper a small buckle is made between the relay roller and the registration roller 2 7 seconds after the paper feed clutch is turned on the registration solenoid C is energized to release the stopper synchronizing the paper feeding with the image on the drum After 0 5 second the registration solenoid is de energized The registration sensor detects paper length and paper end 2 35 PAPER FEED AND
76. ion is air conditioned or heated do not place the machine a Where it will not be subjected to sudden temperature changes b Where it will not be directly exposed to cool air from an air conditioner c Where it will not be directly exposed to heat from a heater 7 Do not place the machine where it will be exposed to corrosive gasses 8 Do not install the machine at any location over 2 000 m 6 500 feet above sea level 9 Place the copier on a strong and level base 10 Do not place the machine where it may be subjected to strong vibrations 1 2 MACHINE LEVEL 1 Front to back Within 3 mm 0 12 of level 2 Right to left Within 3 mm 0 12 of level 3 1 INSTALLATION REQUIREMENTS 1 3 MINIMUM SPACE REQUIREMENTS 4 July 1996 Place the copier near the power source providing clearance as shown 40 cm 15 6 A1841516 wmf 1 4 POWER REQUIREMENTS 1 Input voltage level 120 V 60 Hz More than 10 A 220 240 V 50 60 Hz More than6A 2 Permissible voltage 10 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 4 July 1996 INSTALLATION 2 INSTALLATION 2 1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list 1 2 3 4 5 6 7 8 9 0 r 11 12 13 14 15 Error Code Decal Multi language 10 22 26 27 machines Operating Instructions
77. irst digit is displayed in the Manual Image Density indicator as shown below 00 09D QUOD QUUD Sfl se 00 00D A184M500 wmf NOTE After changing the value setting the previous value setting can be recalled again if the Clear Stop key is pressed at this point 2 When the Lighter key is pressed the number which is currently displayed in the Copy Counter will be entered as the new value or setting and will be stored in memory 3 The copier is ready to accept the new program number Repeat from step 1 or leave SP mode by turning the main switch off on PROGRAM MODES 4 July 1996 2 3 SP MODE QUICK REFERENCE TABLE gi E Function a Function 3 Destination Setting 48 Light Intensity Adjustment 4 Forced Start 49 Fusing Temperature Adjustment 5 ae Run with Exposure Lamp 51 Exposure Lamp Voltage Display 6 Misfeed Detection Off 52 Fusing Temperature Display 7 Free Run 53 TD Sensor Target Control Voltage Adjustment 8 Input Check 54 TD Sensor Gain Adjustment 9 Output Check 55 TD Sensor Output Display 10 Scanner Free Run 56 ADS Reference Voltage Adjustment 11 All Indicators On 57 ADS Output Voltage Display 14 Auto Shut Off Time Setting 59 Optics Temperature Display Auto Reset Time Setting Drum Potential Measurement 15 60 With Paper 16 Count Up Down Selection 61 Drum Potential Measurement Without Paper 19 Functio
78. lamp at the falling edge of each trigger pulse The trigger pulse goes HIGH when the main board receives the zero cross signal The amount of time that power is applied to the fusing lamp depends on the temperature of the hot roller The trigger pulse LOW part is wider C1 and power is supplied for longer D1 when the hot roller temperature is lower It is narrower C2 and power is supplied for a shorter time D2 when the hot roller is near the operating temperature 2 43 IMAGE FUSING 4 July 1996 11 4 4 Overheat Protection There is an overheat protection circuit in the main board If the hot roller temperature reaches 230 C the resistance of the thermistor between CN121 10 and CN121 11 becomes too low If the main board detects this condition E 53 lights on the operation panel and power to the fusing lamp is cut Even if the thermistor overheat protection fails the thermofuse opens when it reaches 169 C removing power from the fusing lamp 2 44 SECTION 3 INSTALLATION 4 July 1996 INSTALLATION REQUIREMENTS 1 INSTALLATION REQUIREMENTS 1 1 ENVIRONMENT 1 Temperature Range 10 C to 30 C 50 F to 87 2 Humidity Range 15 to 90 RH 3 Ambient Illumination Less than 1 500 lux Do not exposure to direct sunlight 4 Ventilation Minimum space 20 m8 Room air should turn over at least 3 times per m hour S SS 5 Ambient Dust Less than 0 15 mg m3 4 x 10 3 oz yd E 6 If the place of installat
79. lative to the base exposure lamp voltage Vo in SP48 1 step of the lamp voltage equals 0 5 V for 120 V NA and 1 0 V for 230 V EU machines Image Adjusts the image density at ID level 1 by changing 0 Normal Adjustment at the exposure lamp voltage 1 Darker ID Level 1 t 2 Darkest SP Setting Setting ey Note 0 Normal 6 steps Default 35 1 Darker 8 steps 2 Darkest 10 steps This setting specifies the change relative to the base exposure lamp voltage Vo SP48 1 step of the lamp voltage equals 0 5 V for 120 V NA and 1 0 V for 230 V EU machines Image Bias Adjusts the development bias voltage used at ID level 0 Normal Adjustment at 5 1 Lighter 36 ID Level 5 t 0 Bias 40 V 2 Lightest 1 Bias 80 V 2 Bias 120 V Toner Density Adjusts copy quality by changing the toner 0 Normal Adjustment t concentration inside the development unit 1 Darker 38 2 Lighter 3 Darkest 4 Lightest Lead Edge Adjusts the lead edge erase margin 0 15 Erase Margin 9 5 mm per step 4 0 mm to 3 5 mm Default 8 41 Adjustment t See Replacement and Adjustment Copy Quality 2 5 mm from Adjustment for details the leading edge 4 15 PROGRAM MODES 4 July 1996 Mode No Function Settings Registration Adjusts the registration 0 15 42 Adiustment t 0 5 mm per step 4 0 mm to 3 5 mm See Default 8 Replace
80. ly board The exposure lamp voltage is determined by the following factors Lamp Voltage Base Lamp Voltage Setting SP48 iage Density Adjustment Factor SP34 Manual Image Density Setting Factor SP35 VL So iauied Factor SP62 e T Ratio Correction Factor Detailed n c e Q ro N m 1 Base Lamp Voltage Setting The lamp voltage is determined by the SP48 setting Base Lamp Voltage SP48 setting x 0 5 120 V machines SP48 setting x 1 0 230 V machines The default setting is 137 68 5 V 120 V machines 128 128 V 230 V machines The current lamp voltage can be viewed with SP 51 2 Image Density Adjustment Factor SP34 Depending on the SP34 setting the development bias and the exposure lamp data are increased or decreased for both ADS and manual ID modes SP34 Setting Setting Dev Bias Exposure Lamp 0 Normal 0 0 1 Light 40 V 0 2 Dark 40 V 0 3 Lighter 40 V 3 steps 4 Darker 40 V 3 steps 5 Lightest 40 V 7 steps 6 Darkest 40 V 7 steps OPTICS 4 July 1996 3 Manual Image Density Setting Factor Depending on the manual image density setting on the operation panel the exposure lamp voltage is changed as shown in the table below Darker Lighter Manual ID Level 1 2 ADS 3 4 5 Base Development f E 240 Bias Voltage Volts ee 200 200 ene SP36 Manual Image Vo 6 steps Se
81. ment and Adjustment Copy Quality Adjustment for details Vertical Adjusts magnification in the paper travel direction by 0 31 43 Magnification changing the scanner speed Default 16 Adjustment t 9 2 per step 3 2 to 3 0 See Replacement and Adjustment Copy Quality Adjustment for details Horizontal Adjusts magnification perpendicular to the direction of 10 31 Magnification paper travel by changing the home position of the Default 16 44 Adjustment lens and mirrors A184 copier 9 2 per step 3 2 to 3 0 See Replacement only t and Adjustment Copy Quality Adjustment for details Light Intensity Adjusts the exposure lamp voltage 120 V Adjustment t Machines 2 Lamp Voltage V 100 194 SPS etting 790 V NA Version 230V EU Version Default 137 100 50 0 100 101 50 5 101 230 V 102 51 0 102 Machines i i 100 180 iso J50 Default 128 J J 180 90 0 180 Max J 48 193 96 5 194 97 0 Max Before performing this mode clean the optics and clear the VL correction SP95 Open SP34 and return the setting to the normal value if it has been changed Then adjust the light intensity using an OS A4 Test Chart with the platen cover placed over it After adjusting the light intensity adjust the ADS Reference Voltage Adjustment SP56 See Replacement and Adjustment Copy Quality for details on how to do this adjustment Fusing Adjusts the control temperature of the hot roller during 1175 195 C
82. n of Manual ID Level 3 62 VL Correction Interval 21 A4 Lengthwise Erase Selection 63 Forced Toner Supply 23 Total Toner Supply On Time 64 VR Correction Value During Toner Near End Condition 24 TD Sensor Sensitivity Setting 66 Imaging Unit Check Mode 25 Toner Supply ON Time During 67 TD Sensor Initial Output Display Toner Near End Recovery Toner Supply OFF Time During Imaging Unit Counter Display 26 69 Toner Near End Recovery 29 Fusing Temperature Control 77 Auto Shut Off Energy Star Selection Selection 30 Toner Supply Mode Selection 81 Factory Initialization 34 Toner Supply Amount 82 Data Communication TD Sensor Mode 32 Toner Supply Amount 88 Total Copy Counter Display Fixed Supply Mode 34 Image Density Adjustment 90 Factory Data and Counter Clear 35 Image Adjustment at ID Level 1 91 Optics Cooling Fan Operation 120 V NA machines only 36 Image Bias Adjustment at ID 92 Imaging Unit Initialization Level 5 Selection 38 Toner Density Adjustment 95 VL Correction Reset N Lead Edge Erase Margin Toner End Force Cancel 41 96 Adjustment 42 Registration Adjustment 97 Service Call E5 Reset 43 Vertical Magnification Adjustment 98 Total Counter Clear P Horizontal Magnification Clear All Memory 44 99 Adjustment Items Listed On The Factory Setting Data Sheet 4 8 4 July 1996 PROGRAM MODES 2 4 UP MODE AND SP MODE CROSS REFERENCE TABLE UP Mode No SP Mode No Func
83. nd inside the copier if necessary 2 Install a new imaging unit and turn on the main switch The machine will perform the TD sensor initial setting automatically 3 Refer to the SP MODE FACTORY SETTING DATA sheet located behind the sub operation panel cover and enter the data that were stored in the following SP modes at the factory e SP41 Lead Edge Erase Margin e SP42 Registration Adjustment e SP43 Vertical Magnification Adjustment e SP44 Horizontal Magnification Adjustment e SP48 Light Intensity Adjustment 4 21 PROGRAM MODES 4 July 1996 4 Open SP3 Destination Setting and enter the setting according to the customer s environment 5 Check the copy quality and the paper path and do any necessary adjustment see Replacement and Adjustment Copy Quality Adjustments 4 22 4 July 1996 SERVICE TABLES 3 SERVICE TABLES 3 1 TEST POINTS Main Control Board Number Label Monitored Signal TP101 T OUT Toner density sensor output 3 2 VARIABLE RESISTORS Number Location Function VR100 Main Control Board Change the ADS voltage 2 5 0 2 volts VRT High Voltage Supply Board CT B G Change the charge and transfer corona voltage VRB High Voltage Supply Board CT B G Changes the standard development bias voltage VRG High Voltage Supply Board CT B G Changes the charge grid voltage 4 23 SECTION 5 PREVENTIVE MAINTENA
84. new plunger spring make sure not to stretch it by more than 21 0 mm 6 17 FUSING 4 July 1996 5 FUSING 5 1 FUSING UNIT REMOVAL A184R520 wmf 1 Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Release the upper unit stopper See Upper Unit Stopper Release 3 Remove the fusing unit A 4 screws and 3 connectors a C 6 18 4 July 1996 FUSING 5 2 PRESSURE ROLLER REPLACEMENT A184R521 wmf A184R522 wmf 3 T lt x c o o S Q oc NOTE When reinstalling make sure both right and left fusing arms are positioned correctly as shown above 1 Release the upper unit stopper See Upper Unit Stopper Release 2 Remove the fusing upper unit A 4 screws 3 Remove the pressure roller B with the two bearings C 4 Replace the pressure roller NOTE Do not touch the pressure roller surface with bare hands 6 19 FUSING 4 July 1996 5 3 FUSING LAMP REPLACEMENT B A184R523 wmf 1 Open the upper unit 2 Remove the front and rear lamp holders A and B 1 screw each 3 Disconnect the three connectors and replace the fusing lamp C NOTE 1 Do not touch the fusing lamp with bare hands 2 When installing a new fusing lamp set the fusing lamp connectors correctly as shown in the illustration 3 Make sure that both fusing lamp insulators are properly set in the holders 6 2
85. nner bracket NOTE Make sure that the reflecting surface faces the lens 3 While holding the mirror set one spring plate C Then set the other spring plate A NOTE 1 Make sure that the notches D in the spring plates are correctly set at position E 2 Do not touch the reflecting surface with bare hands 4 July 1996 OPTICS 2 3 3RD MIRROR REPLACEMENT A184R506 wmf A184R507 wmf 1 Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Slide the 1st scanner about 200 mm from the home position NOTE Move the 1st scanner by holding the scanner belt Handling the 1st scanner will deform the frame 3 Remove the 1st scanner See 1st Scanner Removal 4 Remove the 2nd scanner A 2 screws C 5 Remove the 3rd mirror B Refer to steps 3 to 5 of 2nd Mirror Removal Reinstallation c o E 2 3 lt 1 Install the 3rd mirror on the 2nd scanner unit Refer to Reinstallation of 2nd Mirror Replacement f o E Q S Q oc 2 Put back the two screws C Do not fully tighten the screws 3 Slide the 2nd scanner unit to the home position and insert the two positioning pins D NOTE Scanner positioning pins are available as a service part P N A184 9501 See the parts catalog 4 Tighten the 2 screws to fix the 2nd scanner position 5 Install the 1st scanner Refer to 1st Scanner Removal 6 Install the
86. nt Level 2 of the gray scale on the OS A4 chart should be just visible on the Standard copy when the 3rd manual image density level is selected Method SP48 How it works Changes the ac drive board output voltage 1 Unplug the power cord 2 Clean the following parts Item No Section Method 1 Optics mirrors lens reflectors exposure Damp cotton silicone cloth and glass blower brush 2 Corona wires and casings charge transfer Wire Cleaning tool Casing Blower brush 3 Quenching lamp erase lamp Dry cloth 3 Reset the VL correction using SP95 NOTE SP95 should be reset every time the optics are cleaned 4 Open SP34 and return the setting to the normal value if it has been changed 5 Place an OS A4 chart on the exposure glass Place the platen cover over the chart and make a full size copy at manual image density level 3 center 6 Check if level 2 of the gray scale is just visible on the copy If the image density is not correct proceed to the following steps 7 Enter the lamp voltage adjustment mode SP48 8 Change the setting with the or key as follows If the copy image is too dark Increase the value If the copy image is too light Decrease the value 9 Confirm that the image density is within the adjustment standard 10 Perform the ADS adjustment SP56 6 34 4 July 1996 COPY QUALITY ADJUSTMENT 7 1 2 SP Image Density
87. oard 24 volts 0 volts Replace the toner supply clutch Replace the main control board Go to A 7 16 4 July 1996 COPY QUALITY Is SP30 Toner Supply Mode Selection set to the default value Change the value to the default setting 0 Go to A Is the grid voltage correct Readjust the grid voltage Clean the optics section and around the imaging unit Perform the necessary SP modes in order SP95 48 and 56 7 17 oa Dz 530 E Eo COPY QUALITY 4 July 1996 1 14 UNFUSED COPY IMAGE Problem Solid images rub off easily Possible Causes 1 The fusing temperature is too low 2 The thermistor is malfunctioning Action Increase the fusing temperature using SP49 No good Check the thermistor If the thermistor is malfunctioning replace it 1 15 CREASING PAPER AFTER FUSING Problem The copy paper is creased Possible Causes 1 The fusing temperature is too high 2 The thermistor is malfunctioning Action Decrease the fusing temperature using SP49 No good Check the thermistor If the thermistor is malfunctioning replace it 7 18 4 July 1996 COPY QUALITY 1 16 PAPER MISFEED Problem 1 The Check Paper Path indicator turns on when the main switch is turned on even if there is no paper in the copier 2 The Check Paper Path or Add Paper indicator always turns on at the same location when copies are made
88. of SP3 11 A4 21 Destination Setting is set to 1 inch Set this to 1 for customers that takes copies of A4 paper occasionally without changing the magnification ratio Total Toner Selects the toner supply clutch on time performed 0 5s Supply On after every copy job under the toner near end 1 10s 23 Time During condition 2 15s Toner 3 20s Near End 4 25s Condition 5 30 s 4 12 4 July 1996 PROGRAM MODES Mode No Function Settings TD Sensor Adjusts the sensitivity of the TD sensor Default 8 Sensitivity Setting SP Setting Sensitivity Viwt Note 0 0 1 0 05 2 0 10 L L 0 05 per step 7 0 35 8 0 40 Default 24 9 0 45 10 0 50 11 0 55 L 0 05 per step 19 0 95 20 1 00 The toner supply clutch on time and or the toner density are changed by this setting See Detailed Descriptions Toner Supply Control for more details Toner Supply The ON OFF movement of the toner supply clutch is 0 40 ON Time changed after the TD sensor voltage level recovers to Default 7 25 During Toner _level 6 or less This mode changes the ON time Near End 0 1 second per step range 0 to 4 seconds Recovery Normally this value should not be changed Toner Supply The ON OFF movement of the toner supply clutch is 0 40 OFF Time changed after the TD sensor voltage level recovers to Default 33 26 During Toner level 6 or less This mo
89. ol for more details 1 50 Default 1 0 1 s Toner Supply Amount Fixed Supply Mode 32 Determines how much toner is supplied in fixed supply mode and in detect supply fixed amount mode For example if the user normally makes copies of A4 originals that are about 7 black select the 7 setting for best results SP Setting Note Ratio Supply Time 0 3 5 0 3s Default 7 0 0 6 s 15 1 28 30 2 458 45 3 6 s 60 4 8 s Continuous supply m co NIO AJA OJN 0 0 No toner supply 0 7 Default 0 See Detailed Descriptions Toner Supply Control for more details 4 14 4 July 1996 PROGRAM MODES Mode No Function Settings Image Density Selects the image density level in ADS and manual ID 10 Normal Adjustment t mode 1 Light The development bias and the exposure lamp data 2 Dark are increased or decreased This adjustment affects 3 Lighter ADS mode and all manual ID settings 4 Darker 5 Lightest SP Setting Setting Dev Bias Exposure Lamp 6 Darkest 0 Normal 0 0 1 Light 40 V 0 34 2 Dark 40 V 0 3 Lighter 40 V 3 steps 4 Darker 40 V 3 steps 5 Lightest 40 V 7 steps 6 Darkest 40 V 7 steps The exposure lamp setting specifies the change re
90. oner Supply Clutch Transfers main motor drive to the toner bottle 25 gear CL2 Paper Feed Clutch Transfers main motor drive to the paper feed 24 roller Switches SW1 _ Main Switch Supplies power to the copier 28 SW2 Interlock Switch Cuts all power when the upper unit is opened 29 Sensors S1 ADS Sensor Detects the background density of the 15 original s2 Registration Sensor Detects paper end conditions Checks if 26 paper is set on the by pass feed table Lens and Mirror Informs the CPU when the lens and 4th 5th 3 H P Sensor mirror assembly are at the home position full 8 A184 machines only size position S4 Scanner H P Sensor Informs the CPU when the 1st scanner is at 2 the home position Toner Density TD Detects the ratio of toner to carrier in the Sp Sensor developer 14 S6 Exit Sensor Detects misfeeds 30 Solenoid SOL 1 Registration Solenoid Releases the stopper synchronizing the 27 paper feed timing with the original scan 1 7 ELECTRICAL COMPONENT DESCRIPTIONS 4 July 1996 Symbol Name Function Index No Printed Circuit Boards PCB1 Main Control Board _ Controls all copier functions 5 PCB2 Scanner Drive Board Controls the scanner drive motor 9 PCB3 High Voltage Supply Provides high voltage for the charge corona 7 Board CT B G transfer corona and development bias AC Drive DC Power
91. oner end indicator lights and copying is disabled 6 4 3 Toner End Recovery If the main switch is turned off and on or the upper unit is opened and closed during a toner end condition the main motor turns on and the toner supply clutch is intermittently energized If the TD sensor voltage does not recover from level 7 within 40 seconds the machine stops keeping the toner end condition If the TD sensor voltage level recovers to level 6 or less in this period the toner supply clutch on time is reduced and the main motor continuously rotates for 40 seconds to evenly distribute toner inside the development unit The on off timing of the clutch is set using SP25 and 26 These settings should not be changed 2 27 IMAGE TRANSFER 4 July 1996 7 IMAGE TRANSFER 7 1 OVERALL A A184D513 wmf A high negative voltage approximately 6 kV is applied to the transfer corona wire A and the corona wire generates negative ions These negative ions are applied to the back side of the copy paper This negative charge forces the paper against the drum and attracts the positively charged toner onto the paper 2 28 4 July 1996 IMAGE TRANSFER 7 2 TRANSFER CORONA CIRCUIT CN123 4 CN1 1 24 V ii v g nome ayp 4 CN123 3 CN1 2 Bove 3 MQ os nverter oe CN123 2 CN1 3 0o CT Trigger 9 G nag foe B Drum e C
92. ose the upper unit Turn on the charge and transfer corona using SP9 2 Adjust the drum current by turning VRCT on the high voltage supply board Perform the Grid Voltage Adjustment after changing the drum current 6 40 4 July 1996 COPY QUALITY ADJUSTMENT 7 6 ADS ADJUSTMENT When 1 After light intensity is changed 2 Image density in ADS mode is too light or too dark Purpose To maintain correct ADS mode operation Adjustment ADS Voltage 2 5 0 2 V Standard Method SP56 and VR101 on the main board How it works The bias voltage thresholds which correspond to image density will all change 1 Place 5 sheets of A4 paper on the exposure glass 2 Access SP56 and press the Start key The ADS sensor output is displayed 3 If the voltage is out of standard adjust by turning VR101 on the main board 7 7 VERTICAL MAGNIFICATION ADJUSTMENT When The vertical magnification is not within the adjustment standard Purpose To maintain proper vertical magnification Adjustment Less than 0 5 difference between original and copy Standard Method SP43 0 2 step 31 steps How it works Changes the scanner speed compensation SS gE On 5 Qao 7 8 HORIZONTAL MAGNIFICATION ADJUSTMENT A184 only Fas When The horizontal magnification is not within the adjustment standard Purpose To maintain proper
93. ot reached the required value yet Perform this mode using blank originals only Free Run with A free run is performed without exposure This mode Exposure can be performed before the fusing unit reaches the Lamp Off t ready temperature Press the Start key to start the free run Press the 5 C S key to stop the free run This mode is performed with the normal copy process for LG paper size without the paper feed clutch exposure lamp and total counter increment Normally use SP7 to save toner Misfeed Copies are made without misfeed detection by the Detection Off t registration and exit sensors Press the Start key to make a copy It stops when reaching the set count or when the C S key is 6 pressed Use this mode to check whether the paper misfeed was caused by a sensor malfunction The total counter increments when copies are made in this mode 4 10 4 July 1996 PROGRAM MODES Mode No Function Settings Free Run Performs a free run with the exposure lamp on Press the Start key to start the free run Press the C S key to stop the free run 7 This mode is performed with the normal copy process for LG paper size without the paper feed clutch and total counter increment Before starting close the platen cover to minimize toner consumption Input Check t The Manual Image Density indicator is used to display the input data from the sensors while making a normal copy
94. ove the main drive unit C 2 connectors and 5 screws NOTE When reinstalling set the main drive unit so that the spring plate D is on the main motor bracket 6 25 OTHERS 4 July 1996 6 3 MAIN MOTOR REMOVAL A184R531 wmf 1 Remove the main drive unit See Main Drive Unit Removal 2 Remove the main motor A 4 screws 6 26 4 July 1996 OTHERS 6 4 TONER SUPPLY CLUTCH REMOVAL A184R532 wmf 1 Remove the main drive unit See Main Drive Unit Removal 2 Remove the brackets A and B 6 screws and 1 spring NOTE Be careful not to drop the gears 3 Remove the toner supply clutch C NOTE When reinstalling the clutch engage the pin D with the stopper E as shown 6 27 c o Q S Q oc c o E 2 3 lt OTHERS 4 July 1996 6 5 ERASE LAMP REMOVAL A C A184R533 wmf 1 Remove the exterior covers and the exposure glass See Exterior Cover Exposure Glass Removal 2 Open the upper unit 3 Remove the harness clamper A 1 screw 4 Disconnect the connector CN103 B from the main board 5 Remove the erase lamp C 2 screws 6 28 4 July 1996 OTHERS 6 6 QUENCHING LAMP REMOVAL A184R534 wmf 1 Remove the exterior covers and the exposure glass See Exterior Cover Exposure Glass Removal 2 Open the upper unit 3 Remove the harness clamper A 1 screw c o E
95. pawl bracket 2 screws Follow to steps 1 to 4 of Fusing Exit Pawl Replacement 2 Replace the fusing thermistor A 1 screw 5 7 FUSING THERMOFUSE REPLACEMENT A184R527 wmf 1 Remove the fusing unit See Fusing Unit Removal 2 Remove the hot roller A See Hot Roller Replacement 3 Remove the fusing thermofuse B 2 screws 6 23 c o Q S Q oc c o E n 3 lt OTHERS 4 July 1996 6 OTHERS 6 1 TRANSFER CORONA UNIT REMOVAL B A184R528 wmf 1 Remove the imaging unit See Imaging Unit Removal 2 Push down both ends of the transfer corona unit A Then release the front and rear hooks B 3 Remove the transfer corona unit 6 24 4 July 1996 OTHERS 6 2 MAIN DRIVE UNIT REMOVAL A184R530 wmf as Remove the exterior covers See Exterior Cover Exposure Glass Removal c o E 2 3 lt f o Q S Q oc Release the upper unit stopper See Upper Unit Stopper Release Remove the imaging unit See Imaging Unit Removal Remove the fusing unit See Fusing Unit Removal Remove the transfer corona unit See Transfer Corona Unit Removal O a A WwW N Turn the front and rear bearings of the relay roller in the direction of the arrows A Then remove the relay roller B NOTE When reinstalling the relay roller turn each bearing until it clicks 7 Rem
96. position of the reflectors 3 Dirty corona wires or grid 4 Uneven height of the charge corona wire Action Does the uneven image area shift when a reduction copy is made Yes Is the optics section dirty Yes Clean the optics and perform the necessary SP modes in order see Section 4 Service Remarks for details The cutout position of the 1st scanner reflectors should not be changed Replace the 1st scanner unit Is the erase lamp or quenching lamp dirty Yes Clean the erase lamp or quenching lamp Are the corona wires or grid plate dirty Yes oa Dz 30 22 Eo Clean the corona wires grid plate and casings Replace the charge corona unit COPY QUALITY 4 July 1996 1 4 VERTICAL BLACK BANDS Problem Vertical black bands appear on the copy Possible Causes 1 Dirty optics 2 Dust between the cleaning blade and drum A184T504 wmf 3 Edge of the cleaning blade deformed 4 Deformed inlet seal on the development unit Action Do the black bands shift when a reduction copy is made Yes Check and clean the optics section After cleaning the optics perform the necessary SP modes in order see Section 4 Service Remarks for details Remove the cleaning blade and clean the edge of the cleaning blade Then check if the edge of the cleaning blade is deformed or not Yes Replace the cleaning blade Replace the imaging unit 4 July 1996 COPY QUALITY
97. rews and 2 connectors NOTE 1 Do not touch the mirror surface or lens with bare hands 2 Place the lens unit base on a soft cloth so as not to damage the 6th mirror 5 Turn the lens unit base upside down Then remove the 5th mirror D Refer to steps 3 to 5 of 2nd Mirror Removal NOTE Before turning the lens unit base over confirm that the lens unit is in the home position Otherwise the lens unit will drop 6 10 4 July 1996 OPTICS 2 7 LENS AND MIRROR MOTOR REMOVAL A184R508 3 wmf A184R511 2 wmf A184R512 2 wmf A184R539 wmf 1 Remove the exterior covers See Exterior Cover Exposure Glass Removal c o E 2 3 lt f o Q S Q oc 2 Remove the support plate A 2 screws 3 Remove the lens cover B 1 screw 4 Remove the lens unit base C 5 screws and 2 connectors NOTE 1 Do not touch the mirror surface or lens with bare hands 2 Place the lens unit base on a soft cloth so as not to damage the 6th mirror 5 Turn the lens unit base upside down Then remove the lens and mirror motor D 2 screws NOTE Before turning the lens unit base over confirm that the lens unit is in the home position Otherwise the lens unit will drop 6 11 IMAGING UNIT 4 July 1996 3 IMAGING UNIT 3 1 IMAGING UNIT REMOVAL A184R515 wmf 1 Open the upper unit 2 Pull up the imaging unit A releasing the projections B from the hooks C NOTE
98. rical resistance of a photoconductor is high in the absence of light N 35 Xs O S E nag Q 2 Dissipating the electrical charge when exposed to light Exposure to light greatly increases the conductivity of a photoconductor 3 Dissipating an amount of charge in direct proportion to the intensity of the light That is where stronger light is directed to the photoconductor surface a smaller voltage remains on the drum 4 Being less sensitive to changes in temperature when compared to selenium F type drums 5 During the drums life drum residual voltage gradually increases and the photoconductive surface becomes worn Therefore some compensation for these characteristics is required 2 1 DRUM 4 July 1996 1 2 DRIVE MECHANISM A184D500 wmf The drum A is driven by the main motor B through idle gears 2 2 4 July 1996 CHARGE 2 CHARGE 2 1 OVERVIEW ie i af B A184D501 wmf A184D502 wmf This copier uses a single wire scorotron to charge the drum The corona wire A generates a corona of negative ions when the high voltage supply unit applies a negative voltage The stainless steel grid plate B ensures that the drum coating receives a uniform negative charge as it rotates past the corona unit The exhaust fan C causes a flow of air through the charge corona section This prevents an uneven build up of negative ions that can cause uneven image density An ozone filter
99. ro cross signal within 2 0 seconds or the interval between zero cross signals is more than 2 0 seconds Possible Causes e Defective main control board e Defective ac drive dc power supply board e Zero cross line open e CN121 on the main control board or CN404 on the ac drive dc power supply board is not correctly connected CODE 14 ZERO CROSS SIGNAL ERROR 2 Definition The detected current is not 50 or 60 Hz Possible Causes e Defective main control board e Defective ac drive dc power supply board e Zero cross line open e CN121 on the main control board or CN404 on the ac drive dc power supply board is not correctly connected e Power line not stable CODE 15 ZERO CROSS SIGNAL ERROR 3 Definition The detected current is 50 Hz on a 60 Hz machine or SP3 Destination Setting error Possible Causes e Wrong power line connection e SP3 is set to 0 e SP3 input error 7 24 4 July 1996 SERVICE CALL CONDITIONS CODE 21 SCANNER HOME POSITION ERROR 1 Definition The scanner home position sensor s output remains LOW de actuated for 10 seconds after the main switch is turned on or the output remains LOW de actuated after the scanner returns during the copy process Possible Causes e Defective home position sensor e Defective scanner drive motor e Defective main control board e Defective ac drive dc power supply board e Defective scanner drive circuit CODE 22 SCANNER HOME
100. seconds after the Start key is pressed Since this machine has no indicator or sensor to detect paper end the PE indicator is lit in the paper end condition as well 84 1 Checks whether the copy paper has passed through the registration sensor 5 7 seconds after the Start key is pressed 84 2 Checks whether the exit sensor is actuated within 5 7 seconds after the Start key is pressed 84 3 Checks whether the copy paper has passed through the exit sensor 10 3 seconds after the Start key is pressed 2 37 IMAGE FUSING 4 July 1996 11 IMAGE FUSING 11 1 OVERVIEW E l A184D520 wmf After the image is transferred the copy paper enters the fusing unit The image is fused to the copy paper by the process of heat and pressure through the use of a hot roller A and pressure roller B The CPU monitors the hot roller temperature through a thermistor C which is in contact with the hot roller surface A thermofuse D protects the fusing unit from overheating The hot roller strippers E separate the copy paper from the hot roller and direct it to the exit rollers The exit sensor F monitors the progress of the copy paper through the fusing unit and acts as a misfeed detector The exit rollers drive the copy paper to the copy tray 2 38 4 July 1996 IMAGE FUSING 11 2 FUSING DRIVE MECHANISM N 35 Xs O S E nag Q a A184D521 wmf c a P i a L E ls SS felt A184D523 wmf The main
101. sition of the reflectors as they are adjusted at the factory Always replace the 1st scanner unit as an assembly as the matching of each set of exposure lamp and reflectors is performed at the factory Whenever cleaning the optics all the following actions must be done in order a Optics cleaning b SP95 VL Correction Reset c SP48 Light Intensity Adjustment see the SP mode table for details d SP56 ADS Reference Voltage Adjustment see the SP mode table for details 4 July 1996 SERVICE REMARKS 1 4 TRANSFER CORONA 1 Clean the corona wire by sliding the wire cleaning tool from right to left 1 5 FUSING UNIT 1 Be careful not to damage the edges of the hot roller strippers or their tension springs 2 Do not touch the fusing lamp with bare hands 3 Make sure that both fusing lamp insulators are properly set in the holders 4 The two C rings securing the hot roller are not interchangeable Make sure to place them properly when reinstalling For more details see section 6 Replacements and Adjustments 1 6 PAPER FEED 1 Do not touch the feed rollers with bare hands 2 The side fences and the end fence of the paper tray should be positioned correctly so that they securely hold the paper Otherwise paper misfeeds may occur Also when using 81 2 x 14 paper make sure that the trailing edges of the paper are under the two guides of the cassette 3 Avoid storing paper for a long time
102. sity can be changed by customers or service engineers using SP mode 38 or user tool No 4 User Tool 4 Toner Densit SP SS Sating Setting Toner Density Adjustment Factor B 0 0 Normal 0 1 1 Higher S x 1 2 2 2 Lower S x 1 2 3 Highest S 4 Lowest S S TD Sensor Sensitivity SP24 Default Normal The sensor sensitivity is stored in SP24 TD Sensor Sensitivity S V wt Change of TD sensor output V Change of toner density wt SP24 setting x 0 05 V Default SP24 8 Method 2 If 1 or 3 is selected in SP30 the setting of SP53 is used as the target toner sensor voltage In this case the target toner sensor voltage is determined by the following formula Target Toner Sensor Voltage SP53 setting x 0 02 V Default 97 1 94 V 2 24 4 July 1996 TONER SUPPLY 2 Toner Supply Amount Method 1 Normally if O or 1 is selected in SP30 the toner supply amount is determined by the difference between the TD sensor voltage VT and the target toner sensor voltage VTs The following table shows the relationship between the sensor output and the toner supply clutch on time foreach copy E Toner Supply Level TD Sensor Voltage Level Vt Toner Supply Clutch On Time SE 1 Vis lt VT lt VTs 5 16 t 39 2 Vts 8 16 lt VT lt VTS S 8 2xt 3 Vis S 8 lt VT lt VTS S 4 4xt 4 Vis S 4 lt VT lt Vts S 2
103. sity sensor TD sensor A is used for toner density control The TD sensor is located under the 1st agitator B The developer being conveyed by the 1st agitator passes over the top of the sensor As the toner in the developer is consumed during development the toner to carrier ratio changes resulting in a change in the magnetic permeability of the developer This in turn is converted to a corresponding voltage The CPU monitors the voltage to control the toner supply mechanism When a new imaging unit is installed the machine starts idling for developer initialization During the developer initialization the CPU adjusts the TD sensor control voltage so that the TD sensor outputs 1 9 0 1 volts for the toner to carrier ratio of new developer 4 0 by weight This voltage is used as the standard TD sensor voltage 2 22 4 July 1996 6 3 TONER SUPPLY CONTROL 6 3 1 Modes Available TONER SUPPLY SP30 Toner Supply Target Toner Toner Supply Toner Near End Setting Mode Sensor Voltage Amount Detection Detect Supply Depends on the Depends on the 0 Mode initial TD sensor TD sensor output O setting 1 Depends on SP53 Depends on the O TD sensor output Depends on the Fixed 2 initial TD sensor X setting 3 Depends on SP53 Fixed X 4 Fixed Supply Mode None Fixed X Default setting 0 Depending on the SP30 setting Detect Supply mode or Fixed Supply mode is selected If 0 1
104. that the machine may stop when excessive continuous copy jobs are performed 7 22 4 July 1996 SERVICE CALL CONDITIONS 2 SERVICE CALL CONDITIONS NOTE 1 E codes are displayed in the copy counter The E and the code number are displayed alternatively 2 To clear the service call condition turn the main switch off and on 3 When E5 service call conditions occur for safety reasons they cannot be cleared by turning the main switch off on The following procedure must be performed to clear these service call conditions 1 Turn on the main switch 2 Enter SP mode 97 3 Turn the main switch off and on CODE 11 EXPOSURE LAMP ERROR 1 Definition e The feedback signal becomes higher than 4 0 volts rms for 1 0 second when the exposure lamp is on e The feedback signal becomes higher than 1 0 volt rms for 1 0 second when the exposure lamp is off Possible Causes e Triac short circuit e Exposure lamp open e Thermofuse open CODE 12 EXPOSURE LAMP ERROR 2 Definition e The feedback signal falls below 0 5 volt rms for 1 0 second when the exposure lamp is on e The exposure lamp stays on for longer than 25 seconds Possible Causes e Defective ac drive dc power supply board e Defective main control board e Defective power supply circuit CEA Dz 30 E Eo 7 23 SERVICE CALL CONDITIONS 4 July 1996 CODE 13 ZERO CROSS SIGNAL ERROR 1 Definition The CPU does not receive the ze
105. the developer and the toner is recycled 2 31 QUENCHING 4 July 1996 9 QUENCHING A S A184D507 2 wmf In preparation for the next copy cycle light from the quenching lamp QL A which is installed in the upper unit neutralizes any charge remaining on the drum LEDs are used for quenching and the lamp is turned on whenever the main motor rotates 2 32 4 July 1996 PAPER FEED AND REGISTRATION 10 PAPER FEED AND REGISTRATION 10 1 OVERVIEW C D E Detailed n c e Q Z re n 3 m Eo E YO a Z 4 2 WRG J lee Bu eee Re A Lae A A184D516 wmf This copier has one paper feed station and a by pass feed table The paper feed station uses a paper tray A which can hold 250 sheets The by pass feed table B can hold 1 sheet The paper tray uses two semicircular feed rollers C and a corner separator The semicircular feed rollers make one rotation to drive the top sheet of the paper stack to the relay rollers D The paper tray has two corner separators which allow only one sheet to feed They also serve to hold the paper stack If a sheet of paper is set on the by pass feed table the registration sensor E is actuated and the machine goes to by pass feed mode 2 33 PAPER FEED AND REGISTRATION 4 July 1996 10 2 PAPER FEED MECHANISM D yo EE F A184D518 wmf Through several gears ma
106. tion 1 34 Image Density Adjustment 2 35 Image Adjustment at ID Level 1 3 36 Image Bias Adjustment at ID Level 5 4 38 Toner Density Adjustment 5 14 Auto Shut Off Time Setting 6 15 Auto Reset Time Setting 7 16 Count Up Down Selection 8 88 Total Copy Counter Display 9 69 Imaging Unit Counter Display 10 62 VL Correction Interval 4 9 PROGRAM MODES 4 July 1996 2 5 SERVICE PROGRAM MODE TABLE 1 In the Function column comments extra information are in italics 2 In the Settings column the default value is printed in bold letters 3 If there is a t mark in the Mode No column copies can be made within this SP Mode Mode No Function Settings Destination The setting can be changed depending on the paper Default 0 Setting size being used Copy Count No Measurement Note SP16 Setting 0 oo Factory setting for 120 V copiers i 2 Metric UP Factory setting for 230 V copiers 1 Inch UP This mode does not have any relationship to the electrical power supply The erase and magnification ratio mechanism is changed For example by changing this mode North American inch size machines can use metric size paper for normal usage Forced Start Selects whether forced start is on or off Copy quality and paper transport are not guaranteed 4 If forced start is switched on the copier enters the ready condition even if the fusing temperature has n
107. tion Ratio Reproduction Ratio Correction Factor A 70 to 72 4 steps 3 73 to 78 2 steps ae 79 to 119 0 a a 120 to 129 4 steps fm 130 to 141 8 steps 2 11 ERASE 4 July 1996 4 ERASE 4 1 OVERVIEW A184D507 wmf abcdefg h gfedcb a A184D508 wmf The erase lamp A which is installed in the upper unit consists of a single row of LEDs extended across the full width of the drum The erase lamp has the following functions leading edge erase side erase A184 copier only and trail edge erase 2 12 4 July 1996 ERASE 4 2 LEAD EDGE ERASE The entire line of LEDs turn on when the main motor turns on They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum Lead Edge Erase Margin This prevents the shadow of the original edge from being developed on the copy At this point side erase starts A184 copier only The width of the leading erase margin can be adjusted using SP41 N 35 Xs 2 S E nag Q 4 3 SIDE ERASE A184 COPIER ONLY Based on the reproduction ratio the LEDs turn on in blocks labeled a h on the previous page This reduces toner consumption and drum cleaning load The CPU determines which blocks to turn on based on the selected reproduction ratio as follows Reproduction Ratio Blocks ON 70 to 72 a g 73 and 74 a f 75 to 77 a e 78 and 79 a d 80 and 81 a
108. too intense 5 The ADS optical fiber is cut or bent 6 The development bias is grounded Action Make a copy in reduction mode at manual image density level 4 Is the non image area dirty No Is the optics section dirty Yes o 25 530 22 Eo Clean the optics and perform the necessary SP modes in order see Section 4 Service Remarks for details COPY QUALITY 4 July 1996 Yes No Is the exposure lamp light intensity too weak due to deterioration Replace the 1st scanner unit Is the signal at CN123 1 LOW after the Start key is pressed No bias voltage is applied to the development roller Replace the high voltage supply board CT B G Replace the main board Is the cleaning blade worn Replace the cleaning blade Are the erase lamp and or quenching lamp dirty Clean the erase lamp quenching lamp as required If toner scattering occurs see Toner Density Too High If dirty background occurs only in ADS mode do the following If the ADS voltage is not within 0 2 volts of the standard voltage 2 5 V readjust the ADS voltage If the signal at CN112 3 stays HIGH check the harness and sensor and replace any defective parts If the signal at CN112 2 stays LOW replace the main board 4 July 1996 COPY QUALITY 1 3 UNEVEN IMAGE DENSITY Problem Uneven image density appears on the copies Possible Cause 1 Dirty optics 2 Uneven cutout
109. tting Factor Vo 3 steps Vo Vo 3 steps Vo 7 steps SP35 Volts VO Base lamp voltage setting SP48 1 step 0 5 V 120 V machines or 1 0 V 230 V machines The manual setting factor for ID level 1 can be changed using SP35 SP35 Setting Image Adjustment at ID Level 1 0 6 steps 1 8 steps 2 10 steps 4 VL Correction Factor The light intensity may decrease because of dust accumulated on the optics parts Additionally the drum sensitivity gradually decreases during the drum s life This may cause dirty background on copies To compensate this VL correction is done The exposure lamp voltage is increased by 1 0 V 230 V machines or 0 5 V 120 V machines at the set copy count interval The table below shows the relationship between the SP setting and the interval SP62 Setting VL Correction Interval 0 1 step 1500 copies 1 step 1000 copies 1 step 2000 copies 1 step 500 copies 1 step 2500 copies 1 step 250 copies 1 step 3000 copies 1 step 4000 copies No Correction Default setting 0 COIN JAIA J 2 10 4 July 1996 OPTICS 5 Reproduction Ratio Correction Factor The exposure lamp voltage is increased depending on the selected magnification ratio in order to compensate for the change in concentration of light on the drum Magnifica
110. ultimeter leads as shown 3 Close the upper unit 4 Turn on the charge and transfer corona using SP9 2 5 Adjust the grid voltage by turning VRG on the high voltage supply unit 6 38 4 July 1996 COPY QUALITY ADJUSTMENT 7 5 DRUM CURRENT ADJUSTMENT B A184R542 wmf ADJUSTMENT STANDARD Adjusting VR SP Mode DC 750 2 uA VTCT SP9 2 NOTE Normally each High Voltage Supply Board spare part is adjusted in the factory before shipment This adjustment is not required when the board is replaced A WARNING Very high voltage is applied from the high voltage supply unit c o E 2 3 lt terminals Pay extreme attention when adjusting the drum current Make sure that the machine is unplugged before connecting the multimeter f o E Q S Q oc 1 Remove the upper cover and the exposure glass See Exterior Cover Exposure Glass Removal 2 Disconnect the connector from the CT corona current terminal A Then connect the ground terminal of the multimeter to the connector B and connect the other terminal to the CT terminal of the high voltage supply board as shown in the illustration NOTE Make sure that the connector B is not in contact with the CT terminal A 6 39 COPY QUALITY ADJUSTMENT 4 July 1996 N O oO A O Set the multimeter range to dc 2 mA Connect the operation panel connectors Cl

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