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1. Transportation/Installation
• When transporting the copier, move it by the casters while lifting the stoppers.
The copier is quite heavy and weighs approximately 230 kg (507 lb); therefore, pay full attention
when handling it.
2. Installation
• Be sure to use a dedicated outlet with AC 115V/15A (220V, 230V, 240V/10A) or more for the
power source.
• The copier must be grounded for safety.
Never ground it to a gas pipe or a water pipe.
• Select a suitable place for installation.
Avoid excessive heat, high humidity, dust, vibration and direct sunlight.
Also provide proper ventilation as the copier emits a slight amount of ozone.
• To insure adequate working space for copying operations, keep a minimum clearance of 80 cm
(32") on the left, 80 cm (32") on the right and 10 cm (4") in the rear.
3. Service of Machines
• Basically, be sure to turn the main switch off and unplug the power cord during service.
• Be sure not to touch high temperature sections such as the exposure lamp, the fuser unit, the
damp heater and their periphery.
• Be sure not to touch high-voltages sections such as the chargers and the high-voltage transformer.
• Be sure not to touch rotating/operating sections such as gears, belts, pulleys,etc.
• When servicing the machines with the main switch turned on, be sure not to touch live sections
such as the lamp terminal etc.
• Use suitable measuring instruments and tools.
5. Notice Labels
• Be sure to check the rating plate and the notice labels such as "Unplug the power cord during
service" ,"Hot area" ,etc. to see if there is any dirt on their surface or if they are properly stuck to
the copier during servicing.
7. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise
noted in this manual or other related documents. Be careful not to reassemble small parts such as
screws, washers, pins, E-rings, toothed washers in the wrong places.
8. Basically, the machine should not be operated with any parts removed or disassembled.
1.1 Specifications
1.2 Accessories
1.3 Options
1.4 System List
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
When either the CLEAR PAPER( )or CALL SERVICE( ) symbol appears,press the CLEAR/
STOP and "8"keys simuitaneously and the corresponding error code will be displayed.To clear the
error code,turn off the power.
PWA-F-LGC-154/155 installed.
Be sure to cut it when replacing the PC boards.
VR2
stack guide unit.
PWA-F-PFC-154/155
Plus terminal of the tester Minus COM terminal of the tester Adjustment value VR
VR Function
R19
R40
R39
VR1
VR3
ë ë ë
VR2 For adjustment of the PFP middle aligning value.
VR3 For adjustment of the PFP upper aligning value.
JP25
(TP-SG)
Note: The independent operation mode is performed as in the following procedure;set the DIP switch 1
to its ON position and turn on the power.Select the menu of the independent operation mode and
then open and close the jam release cover or the ADF cover.
Note: To access the desired diagnostic mode,turn on the power switch while pressing the appropriate
keys.
<Procedure>
•All-LEDs-lit mode(01):
Power On
"02" "07"
"01" (With ADF) "03/04" "05" "08"
*2
"C"
In the "03" or "04" test mode, the following input signal conditions can be checked by pressing the
appropriate keys.
<Procedure>
0 3 → PRINT → EXP → Digital key → PWR OFF →0 9
↑
PWR (To clear)
Note: 03 →With initialization before test mode is entered
(
04 →Without initialization
ORIGINAL COPY
A4
(LD)
• means that when the particular key is pressed and the
A3
(LG) condition shown exists,the LED will light.(Input signal is "H" level)
B4 • means that the LED does not light if the condition shown
(LT)
exists.(Input signal is "L"level)
A5
(ST)
UNIVERSAL
(OTHER)
In the "03"or"04"test mode,the folloeing output signal conditions can be checked by entering appropiate
codes.
Group3
RGT3-CLT ON 73 OFF ADF-BELT-MOT(CW)
RGT4-CLT 84 ADF-CLU ON/OFF
65 DEV-FAN ON 75 OFF ADF-BELT-MOT(CCW)
67 BTM-FAN HIGH 77 LOW 85 ADF-FEED-MOT(CCW) ON/OFF
68 CH-FAN ADF-BELT-MOT(CW)
ON 78 OFF
HTR-FAN ADF-CLU
86 STP-SOL
*3 20 SCN-MOT FLP-SOL ON/OFF
21 LNS-MOT ADF-CLU
22 MRR-MOT BRKE
23 CLN-MOT
24 DCM-MOT
Group2
*1 The feed motor will rotate in the direction appropriate for the cassette loaded at the time of the output signal
check.
*2 For FD2~4-CLT and RGT2~4-CLT,the clutch appro priate for the cassette loaded at the time of the output signal
check will be driven.
*3 The scanning motor will run at the correct speed for the reproduction ratio selected(and displayed)at the time of
the output signal check.
*4 The tray motor moves the tray up when the PRINT key is pressed once,and is turned off when the tray-up switch
is turned on.When the PRINT key is pressed a second time,it moves the tray down and is turned off when the
tray-down switch is turned on.
*5 The length guide motor performs initalisation when the PRINT key is pressed once.When the PRINT key is
pressed a second time, it moves the paper length guide to the widest setting position and then is turned off.When
the PRINT key is pressed a third time,it moves the paper length guide in for a narrow setting and is turned off
when the length guide home switch is turned on.
*6 The width guide motor widens the paper width guide when the PRINT key is pressed once and is turned off when
the width guide home switch is turned on.When the PRINT key is pressed a second time,it narrows the paper
width guide until the A4-R size position and then is turned off.When the PRINT key is pressed a third time,it,widens
the guide until the A3 size position and is turned off.
*7 For TR2 to 4-MOT,the motor appropriate for the cassette loaded at the time of output signal check is chosen.When
the PRINT key is pressed once, the motor moves the tray up and is turned off when TUP2 to 4-SW is turned
on.When the PRINT key is pressed a second time,it moves the tray down and is turned off after a set time lag.
*8 The exposure lamp stays on for 5 sec.and then goes off automatically.
Group(2)
0 3 / 0 4 ↓ ↓→ PRINT Operation → C/S → Test mode standby
→ Code →
PWR (one-way) → 0 9 → Warm-up
Group(3)
Test mode
0 3 / 0 4 Operation Operation → C/S → standby
↓→ Code ↓→ PRINT → → PRINT →
PWR (ON) (OFF) → 0 9 → Warm-up
In this mode,the following adjustment items can be corrected or changed(see the Adjustment Code
List for "05"Mode). To access this code,turn on the power while pressing the "0"and"5"keys.
Adjustment item Code Keys to adjust with keys to store with Remarks
Auto-toner sensor 0 Zoom keys INTERRUPT See 2.6 for details.
Exposure 1~10 Digital keys/ INTERRUPT See 2.7 for details.
14~17 ZOOM keys
*Automatic adjustment 49 Not needed Not needed See 2.7 for details.
for exposure
HVT output 38~40,41,44 ZOOM keys INTERRUPT See 2.10 for details.
Registration 53~58 Digotsl keys INTERRUPT See 2.8.5 for details.
Other adjustment Except for Digital keys INTERRUPT Refer to Adjustment
above codes code list
<Procedure>
0 5
↓ → Code → PRINT → ADJUST → INT → E/S →0 9
PWR ↑
Memory set Test copy Exit
∗ 0 5
→ 49 → PRINT → Automatic adjustment →0 9
PWR for automatic exposure
Exit
9 Allowable exposure step 0~255 128 The larger the value,the lighter the light range.
range(light)
10 Allowable exposure step 0~255 128 The smaller the value,the darker the dark range.
range(dark)
14 Manual photo exposure 0~255 128 •The larger the value,the lighter the image.
(100%) •The adjustment sequence must be 14→15→16→17.
15 Manual photo exposure 0~255 128
(154%)
16 Manual photo exposure 0~255 128
(50%)
17 Manual photo exposure 0~255 128
(200%)
20 Aligning roller speed 0~15 10 Each time the numerical value is increased by "1",the
adjustment reproduction ratio in the movement direction increases
by approximately 0.15%.
Range;-1.17%(reduction)to +1.05%(enlargement)
21 Drum speed adjustment 0~15 12 Each time the numerical value is increased by"1",the
reproduction ratio in the movement direction increases
by approximately 0.10.
Range:-0.77%(reduction)to +0.69%(enlargement)
22 Heat roller speed adjustment 0~15 8 Each time the numerical value is increased by"1",the
heat roller motor speed increases by 0.06%.
Range:-0.75%(reduction)to +0.71%(enlargement)
25 Leading edge of image shift 0~15 8 Each time the numerical value is increased by "1",the
(100%) image shift moves 0.5mm toward the trailing edge of
the paper without changing the position of the image
26 Leading edge of image shift 0~15 8 relative to the paper.
(200%)
27 Leading edge of image shift 0~15 8
(50%)
28 PFP motor speed 0~15 8 Motor ratings can be adjusted by the following ranges:
0:-1.19% 1:-1.03%
2:-0.88% 3:-0.73%
---------- ----------
---------- 13:+0.76%
14:+0.91% 15:+1.06%
*The initial value means the one that is set by the BC-RAM initialize program, and does not mean the one set at the
factory before shipment.
39 High-voltage transformer 0~255 128 The larger the value,the higher the output.
(transfer)output
40 High-voltage transformer 0~255 128 The larger the value,the higher the output.
(separation/developer bias)
output
41 Pre-transfer discharger 0~255 128 The larger the value, the higher the output.
transformer output
42 Main charger output 0~255 205 When the numerical value is increased, the output
(photo mode) increases
44 Separation DC output 0~255 185 The lager the value, the higher the separation DC
welghted output.
45 LCD contrast adjustment 0~255 150 The larger the value, the brighter the LCD panel.
57 Registration(PFP/100%) 0~15 8
58 Registration(ADD/100%) 0~15 8
60 Lens position(100%) 0~99 50 Each time the numerical value is increased by "1",the
lens moves approximately 0.2mm toward the
enlargement direction.
61 Mirror position(100%) 0~99 50 Each time the numerical value is increased by "1",the
lens moves approximately 0.1mm toward the
enlargement direction.
<Procedure>
0 8
↓ → Code → PRINT → Ste/change → INT → 0 9
PWR a value
Memorize Clear
4 Auto sort mode 0~3 0 The sort mode is selected automatically when the
original is placed on the ADF.
0: Deactivated
1: Staple sort
2: Sort
3: Group
5 Automatic duplex mode 0~3 0/1** The duplex mode is selected automatically when the
original is placed on the ADF.
0: Deactivated
1: (single-sided to dual-sided) is selected
2: (dual-sided to dual-sided) is selected
3: (dual-sided to single-sided) or (single-sided to dual-
sided) is selected according to the message.
6 Setting temperature of the 0~15 0 0:200°C 1:197°C 2:199°C 3:200°C 4:202°C 5:204°C
heat-roller surface 6:206°C 7:208°C 8:210°C 9:212°C 10:214°C 11:216°C
12:218°C 13:221°C 14:223°C 15:224°C
∗Never set to a value of 8 or more.
10 Timer mode 0~10 3 If there is no control panel operation during the ready
status for a certain length of time as shown below,the
copy-mode automatic resetting function is performed.
Resetting operation start time is:
1: 15 sec.,2: 30 sec.,3: 45 sec.,4: 60 sec.,-----
10: 150 sec.
0: Deactivates the copy-mode automatic resetting.
11 Auto power saving 0~12 0/3** Auto power saving operates n minutes after ready status
is reached.The functions are:
0: Deactivated
1: After 5 minutes
2: After 10 minutes
n: After n ×5 minutes
19 Sort mode selection 0~3 0 The mode selected when power is turned ON
0: Non sort
1: Staple sort
2: Sort
3: Group
COSMOS
OK Skip Cancel
76/7560 S/H
2.6 Auto-Toner Sensor Adjustment
At the initial machine setup or when the developer material is replaced,the auto-toner sensor needs
to be adjusted.
<Key Operation>
<Display, Supplementary Explanation>
0 5
TEST MODE A 100% A
POWER
↓
: Enter code
0
ò
developer, drum, etc.) Numerical value corresponding
to auto-toner adjusting value
ò Stops changing
↓
↓
XXX ZZZ
ADJUST MODE 100%
↓
ZOOM Adjust so that "XXX" on the display panel is within the
permissible range only when outside of range 245 to 255.
XXX ZZZ
ZOOM UP key Increases Increases
ZOOM DOWN key Decreases Decreases
* Auto-toner sensor output range: 2.45 to 2.55V
↓
INT
(developer, drum, TEST MODE A 100% A
etc. stop)
↓
0 9 : Cancel adjustment
mode.
76/7560 S/H
2.7 Exposure Adjustment
At the initial machine set-up or when the light distribution is adjusted, the exposure needs to be
adjusted. Adjustment must be also performed in accordance with any special request of the user.
Adjustment order
Manual photo
Light gradataion Dark gradation exposure Manual photo exposure
→ → → →
154% →50%→ 200%
C1 100%
100% 100%
(9) (10) (14) (15) (16) (17)
Note: In the dotted-line squares are the adjustment to be performed according to any special request of the user.
Adjust the above items by following the procedures below using the operation keys while comparing
adjustment values stored to memory for each item and copies made under those conditions.
0 5
TEST MODE A 100% A
POWER ↑
∗→ ↓
·Code becomes "ZZZ"according to the entire
code.
DEGITAL KEYS ·The order of above adjustment is fixed.
code # XXX
1,5,11 100 Newly entered adjustment values (default: YYY)
2,6,12 154 ·To darken: value smaller than YYY
↓ 3,7,13 50 ·To lighten: value larger than YYY
4,8,14 200
ZOOM : Adjustment 9,10 Any value
[numerical keys] Adjustment of variable step exposure (codes #9 and 10) are
not related with the copy reproduction ratio.
↓
ENERGY SAVER : Output test chart COPYING 100% A
*1: You can make only single-sided copies. (You cannot make dual-
sided copies.)
→ To readjust, go to∗ *2: Test copies can be made immediately after starting the test mode.
When outputing this test chart, match to the desired reproduction
ratio and exposure conditions for adjustment.
↓
: Cancel adjustment
0 9 mode.
76/7560 S/H
2) Automatic exposure adjustment
• Adjust manual exposure (100%), and then carry out automatic exposure adjustment.
• Place a blank sheet of A3 paper on the original glass, and close the ADF with the original aligned
against the original scale.
• After completing the above preparations, follow the procedure below to automatically adjust.
<Key Operation>
<Display, Supplementary Explanation>
0 5 TEST MODE A 100% A
POWER
↓
49 : Enter code Adjustment values for the
reproduction ratio displayed
at XXX are displayed.
↓
: Start of automatic YYY
PRINT adjustment ADJUST MODE XXX%
↓
: Cancel adjustment
0 9 mode.
76/7560 S/H
2.8 Adjustment of Drum/Aligning Roller/Heat Roller Speed,Aligning Value,Registration,Leading
Edge of Edge Erasing,Trailing Edge of Edge Erasing,Leading Edge of Image Shift, Editing
Position,Leading-Edge Void and Trailing-Edge Void.
<Adjustment procedure>
Aligning roller
Drum speed Heat roller speed Aligning value
→
speed
→ → LCF Manual PFP ADD
→
→ → →
(21) (20) (22) (80) (81) (82) (83)
Leading edge of edge erasing Leading edge of Editing position Leading edge void
Registration
→
Trailing edge of edge erasing
→
image shift
100% 200% 50%
→ 100% 200% 50%
→ Trailing edge void
→ → → →
(53) ~ (58) (30) ~ (31) (25) (26) (27) (32) (33) (34) (35)→(36)
(Note) In the dotted-line squares are the items which normally do not require adjustment.
Follow the procedure below to adjust each of the adjustment value so that the measured values
obtained from the test chart satisfy the specifications. Immediately after starting test mode "05",
only single-sided test charts (normal copies) can be output with the ENERGY SAVER key.
0 5
TEST MODE A 100% A
POWER
∗→ ↓ Adjustment value stored
Copy mode key : Set the copy mode using the to BC-RAM
paper size, original size and Selected code #
cassette keys.
↓ YYY ZZ
ADJUST MODE XXX%
DEGITAL KEYS
Preset copy reproduction ratio
Adjustment Code Adjustment Item
PRINT 20~22,30~34 Edge erasing, Aligning value,
80~84 etc
53~58 Registration
(100%)
25~27 Leading edge of image shift
35 Leading edge void
↓
: Enter adjustment 36 Trailing edge void
DEGITAL KEYS value
↓
: Value ZZZ is stored in New adjustment value displayed
INTERRUPT place of value YYY.
YYY ZZZ
ADJUST MODE XXX%
↓
ENERGY SAVER : Output test chart TEST MODE A 100% A
→ To readjust, go to ∗
COPYING 100% A
↓ *1: You can make only single-sided copies. (You cannot make dual-
: Cancel adjustment sided copies.)
0 9
mode. *2: Test copies can be made immediately after starting the test mode.
When outputing this test chart, match to the desired reproduction
ratio and exposure conditions for adjustment.
COSMOS
OK Skip Cancel
76/7560 S/H
2.9 Automatic Adjustment of Remaining Paper Quantity
(1) Before automatic adjustment, prepare following the instructions in the following table.
(2) Set the PFP cassettes in the copier, and mount the LCF. Then, close the LCF door.
(3) Follow the procedure below to carry out automatic adjustment.
0 5
POWER TEST MODE A 100% A
↓
DEGIAL KEYS : Enter code.
↓
PRINT : Automatic adjustment starts. The paper selection LED flashes during automatic
adjustment.
* Automatic adjustment does not start if a cassette or LCF is not properly in place, or the
LCF door is open.
Paper selection
display
Note: Before carrying out automatic adjustment by code 69, the user must set the paper (type and size)
in actual use in the PFP and LCF.
(+)terminal
Black cable
(-)COM terminal
Digital tester
POWER
∗→
↓
0 : Enter code Currently stored adjustment value
Newly entered adjustment value
↓ ↓ (default:XXX)
→
XXX YYY ZZ
↓ ADJUST MODE 100% Selected code #
PRINT
↓
: Adjust so that display voltage of the digital
ZOOM tester satisfies the values in the following table.
Digital tester
Adjustment code Item (adjustment standard voltage value)
39 Transfer DC -78~ -88mV
RMS AC 133~ 151mV
40 Separation
AVG AC 127~ 144mV
41 Pre-transfer DC 40~ 56mV
↓
INT Value YYY is stored in place of value XXX.
→ To readjust, go to ∗
↓
: Cancel adjustment
0 9 mode.
↓ ↓
XX YYY ZZ
PRINT ADJUST MODE 100%
↓
ZOOM
Main Charger Adjust by the ZOOM key so that the digital tester display
voltage is within the range -780 to -800V.
Separation DC Check that XXX is 185.
If XXX is not 185, adjust the ZOOM key so that YYY is
185.
↓
INT Value YYY is stored in place of value XXX.
∗
→ To read just, go to .
↓
0 9 : Cancel adjustment mode.
(+)terminal
Small Large
Digital tester
VR(Vdc) VR1 for developer bias
(Blue) adjstment(White)
↓
(adjustment) Make sure that the voltage is 200 VDC+2V using the digital tester.
Turn VR1 if adjustment is required.
↓
INT : End
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
76/7560 S/H
2.27.2 PFP paper size
When shipped, the 7650/7550 is set for A4-R/LT-R in the upper cassetle,A3/LG in the middle
cassetle, and A4/LD in the lower cassetle. However,use the following procedure to change the size
if requested to do so by the user.
Mechanical change
(1) Pull out the cassetle to be changed, take out the stopper screw(1 screw each for feed and exit sides)
and then remove the cassette from the copier.
Exit side
Feed side
Stopper screw
Stopper screw
Fig. 6.2-3
76/7560 S/H
Electrical Changes
•The electrical settings must be changed according to the procedure below when mechanical changes
have been made.
•After changing the electrical settings, select the cassette that has been changed using the
CASSETTE key, and make sure that the LED for the set paper size lights.
↑
PRINT XX XX YY
SYSTEM MODE 100%
Setting value of selected cassette
Paper Size Setting Value Paper Size Setting Value
A5-R 1 Insert sheet 8
B5,ST-R 2 Cover 9
LT 3 FOLIO,COMP 10
A4 4 LG 11
B5-R 5 B4 12
LT-R 6 LD 13
↓
A4-R 7 A3 14
DEGITAL KEYS
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
Note: For inspection and maintenance of the PFP, remove the PFP upper aligning unit and the
PFP feed units from the copier
(A) Cleaning with alcohol (V) Vacuoline (100)Every 100,000 copies Customer's
(L) Launa 40 (200) Every 200,000 copies name
(P) Cleaning with heat roller
(400) Every
cleaner(RC60) Application Same thereafter Machine
Cleaning with soft pad, No.
(SI) Silicone Oil ( ) Replace in event of
cloth, or cleaner deformation or other Inspector
(W) White grease(Molycoat)
(vacuum cleaner) (M) Molytherm damage
97 :W
74 75 74 76 75 74 76 75 76 77 77
65/5560 PERIODIC
89 90
86 92 85 87 91
Explanation of items in the "REMARKS" column of the Periodic Inspection Check List
*1 Main blade
If poor cleaning occurs due to the adhesion of paper dust, etc. before the specified number of copies
for replacement have been reached, the edge of the blade has been damaged.
Replace the blade if necessary,while change fur brush siwuitaneously.
*2 Recovery blade
If the edge of the blade is damaged, replace the blade regardiess of the number of copies made so
far.
*3 Separation claw
If any abnormal condition (e.g. coating wear) is observed on the tip of separation claw and ifthe mark
of the separation claw is observed on the copy image, replace the claw regardless of the number of
copies made so far.
Clean the tip of the claw by lightly wiping with a dry cloth. In addition, be sure to apply patting powder
(lubricant) to the separation claw after cleaning the claw and when replacing the claw or drum.
*4 Drum
Refer to section 5.2 "Inspection and Cleaning of the OPC Drum".
*5 Air filter
If the air filter is dirty, replace it.
*6 Charger wire and case
Clearn the charger case and the charger wire with a cloth which should be soaked in water and then
squeezed tightly.
*7 Developer material
After replacing the developer material, be sure to adjust the auto-toner sensor.
*8 Upper and lower heat rollers
Refer to section 5.4 "Checking and Cleaning of the Upper and Lower Heat Rollers".
79 :W
Mixer shaft
Coat the entire periphery of the mixer shaft with
grease (Alvania No.2) and assemble the bearing.
Oiling Cycle
Number Item to Lubricate Tyre of oil
Number of coples ×1000
7-1 Used toner-transport auger drive section (front, White grease 200
rear)
41 Toner hopper drive worm gear White grease 200
49 Paper-feed system drive gears (tooth faces) White grease 200
50 GCB bushings and plastic bushings Launa 40 200
64 Heat roller and cleaning rollers drive gears Silicone oil 200
65 Cleaning roller bushings Siliconeoil 200
71 GCB bushings and plastic bushings Launa 40 200
72 ADD drive gears (tooth faces) White grease 200
73-2 Decurler bushings Laua 40 200
73-3 Decurler gear White grease 200
79 Tray drive worm wheels and gears (tooth faces) White grease 200
80 PFP drive gears (tooth faces) White grease 200
81 GCB bushing and plastic bushings Launa 40 200
93 Gears White grease 200
94 Worm and worm wheel White grease 200
95 Worm shaft Launa 40 200
96 Wire pulley shaft Launa 40 200
97 Slit for the elevator tray White grease 200
98 Clamshell lock section White grease 200
* The number is the same as that in the Periodic Inspection Check List.
Notes:
1) Do not apply oil to the rollers,belt and belt pulley.
t5 e3 w2 !0
10 !3
13!6
16
q1
!5
15
!7
17
o9
i8
u7
r4 12 !4
y6 !2 14x2 11 14
!1!4
[Items of a Kit]
COSMOS
OK Skip Cancel
COSMOS
OK Skip Cancel
COSMOS
OK Cancel