Ricoh C249 Service Manual
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Ricoh C249 Service Manual

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Table of Contents

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C249/C264

SERVICE MANUAL

001780MIU

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Summary of Contents for Ricoh C249

  • Page 1: Service Manual

    C249/C264 SERVICE MANUAL 001780MIU...
  • Page 5 C249/C264 SERVICE MANUAL 001780MIU...
  • Page 7 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
  • Page 9 Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained uncertified users utilizing...
  • Page 11 LEGEND PRODUCT CODE COMPANY GESTETNER LANIER RICOH SAVIN C249 CP244 LDD145 JP4500 3560DNP C264 CP6244 LDD245 DX4542 3270DNP DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 10/2003 Original Printing 09/2006 C264 Addition...

  • Page 13: Table Of Contents

    Rev. 04/2004 C249/C264 TABLE OF CONTENTS INSTALLATION 1. INSTALLATION................1-1 1.1 INSTALLATION REQUIREMENTS ............1-1 1.1.1 OPTIMUM ENVIRONMENTAL CONDITION........1-1 1.1.2 ENVIRONMENTS TO AVOID............1-1 1.1.3 POWER CONNECTION ..............1-1 1.1.4 MACHINE ACCESS .................1-2 1.2 INSTALLATION PROCEDURE ..............1-3 1.2.1 MAIN UNIT ..................1-3 1.2.2 BEFORE BEGINNING MACHINE OPERATION ......1-9 1.2.3 PLATEN COVER INSTALLATION (OPTION) ........1-10...
  • Page 14 4.1 ERROR CODES..................4-1 4.2 ELECTRICAL COMPONENT DEFECTS ..........4-3 4.2.1 SENSORS ..................4-3 4.2.2 SWITCHES..................4-5 4.2.3 LINES ....................4-5 4.3 FUSE, LED, VR, DIP-SW, AND TP TABLES ..........4-6 4.3.1 BLOWN FUSE CONDITIONS ............4-6 4.3.2 LED’S ....................4-6 4.3.3 VR’S ....................4-6 4.3.4 DIP SWITCHES................4-7 C249/C264...
  • Page 15 5.7.1 SP TABLE ..................5-11 5.7.2 SP6-40: INK DETECTION ADJUSTMENT ........5-14 5.7.3 IMAGE ADJUSTMENT (SP6-10, -21, -5, -3, AND -1).....5-14 5.7.4 SP6-31: SBU CALIBRATION ............5-17 5.7.5 SP6-32 TO 37: MTF FILTER ............5-17 5.7.6 SP6-20: REGISTRATION BUCKLE (NOT USED)......5-18 5.7.7 SP6-60: MASTER RETURNING VALUE........5-18 C249/C264...
  • Page 16 6.4.4 MASTER BUFFER MECHANISM...........6-21 6.4.5 DETECTION OF MASTER IN THE LOWER MASTER TRAY..6-22 6.4.6 DUCT PLATE MECHANISM ............6-23 6.4.7 MASTER FEED MECHANISM ............6-25 6.4.8 CLAMPER AND TENSION ROLLER MECHANISM.......6-26 6.4.9 MASTER PUSH MYLAR ..............6-27 6.4.10 2ND DRUM MASTER SENSOR...........6-28 C249/C264...
  • Page 17 6.9.5 PAPER FEED JAM (A JAM LOCATION INDICATOR) ....6-60 6.9.6 PAPER DELIVERY JAM (C JAM LOCATION INDICATOR)...6-61 SPECIFICATIONS SPECIFICATIONS................7-1 1. GENERAL SPECIFICATIONS..............7-1 C264 SEE SECTION C264 FOR DETAILED TABLE OF CONTENTS DOCUMENT FEEDER C600 SEE SECTION C600 FOR DETAILED TABLE OF CONTENTS C249/C264...
  • Page 18 PRINTER SCANNER C624 SEE SECTION C624 FOR DETAILED TABLE OF CONTENTS C249/C264...
  • Page 19 INSTALLATION C249 DOCUMENT FEEDER C600 PREVENTIVE MAINTENANCE C249 PRINTER/CONTROLLER C624 REPLACEMENT AND ADJUSTMENT C249 TROUBLESHOOTING C249 SERVICE TABLES C249 DETAILED DESCRIPTIONS C249 SPECIFICATIONS C249 C264...

  • Page 21: Installation

    INSTALLATION...

  • Page 23: Installation Requirements

    1. Securely connect the power cord to a power source. 2. Make sure that the wall outlet is near the machine and easily accessible. 3. Make sure the plug is firmly inserted in the outlet. 4. Avoid multi-wiring. 5. Do not pinch the power cord. C249...

  • Page 24: Machine Access

    INSTALLATION REQUIREMENTS 1.1.4 MACHINE ACCESS Place the machine near a power source, providing clearance as shown below. C249I000.WMF C249...

  • Page 25: Installation Procedure

    Accessory Check C249I019.WMF Make sure that you have all the accessories listed below: Description Q'ty 1. Master Spool................2 2. Operating Instructions..............1 3. NECR (Ricoh version only) ............1 4. Model Name Plates (C249-22, and -52 only)......1 set C249...
  • Page 26 Secure the machine on the table with the 2 screws [A] provided. This prevents the machine from falling from the table when the platen cover is open. Lock the casters of the table as shown [B], to prevent the machine from moving (e.g. when the drum is set). C249...
  • Page 27 INSTALLATION PROCEDURE C249I908.WMF C249I907.WMF C249I020.WMF C249I909.WMF 2. Remove the filament tape and string securing the covers and units as shown above. C249...
  • Page 28 C249I030.WMF 5. Install the master roll as shown to the right. C249I032.WMF 6. Insert the leading edge of the master roll under the platen roller. The arrows [B] indicate the correct position of the master leading edge. C249I910.WMF C249...
  • Page 29 9. Open the door, and insert a new ink cartridge [D]. C249I034.WMF 10. Open the paper table, and load a stack of paper. 11. Make sure that the side plates [E] touch the paper gently. Shift the lock lever [F] in the direction of the arrow. C249I028.WMF C249...
  • Page 30 15. Make sure that the wall outlet is near the machine and easily accessible. 16. Turn on the main switch [H]. 17. Press the “Economy mode” key while holding down the “0” key, to supply ink inside the drum. 18. Make some test copies. C249I026.WMF C249...

  • Page 31: Before Beginning Machine Operation

    NOTE: If they are not removed: Paper jams or blank images may occur, due to the lack of pressure on the Press Roller. The tape may stick to the drum screen or Press Roller. C249...

  • Page 32: Platen Cover Installation (Option)

    1.2.3 PLATEN COVER INSTALLATION (OPTION) Accessory Check Check the quantity and condition of the accessories in the box against the following list: Description Q'ty 1. Stepped Screw................2 Installation Procedure C249I001.WMF 1. Install the platen cover [A] (2 screws). C249 1-10...

  • Page 33: Adf Installation (Option)

    6. Decal - Scale - mm ..............1 7. Decal - Scale - inch..............1 8. Scale Guide ................1 9. Stabilizer Bracket............... 2 10. Thumbscrew ................4 11. Caution Label................1 Installation Procedure C249I002.WMF 1. Remove the strips of tape. 1-11 C249...
  • Page 34 5. Install the two stud screws [F]. 6. Mount the DF by aligning the holes [G] in the DF with the stud screws, then slide the DF to the front as shown. 7. Secure the DF unit with two screws [H]. C249 1-12...
  • Page 35 10. Plug in the power cord, then turn the main switch on. 11. Make a full size copy using the ADF. Then check to make sure the side-to-side and leading edge registrations are correct. If they are not, adjust their values (do the adjustment procedures in section 5.7.3). 1-13 C249...
  • Page 36 1. Attach the two stabilizer brackets [A] to the back of the table using the thumbscrews (4 screws). 2. Attach the caution label [B], as shown. CAUTION This procedure must be done to prevent the machine from falling backwards when the ADF is open. C249 1-14...

  • Page 37: Tape Marker (Option)

    C226 only) ..............2 4. Auxiliary Bracket (C226 only)..........1 5. Auxiliary Bracket (C238, C247, and C249 only)....1 6. Screw M4 x 8 (C226, C238, C247 and C249 only) ....2 7. Lock Washer (C226 only) ............ 1 8. Lock Washer................ 1 9.
  • Page 38 INSTALLATION PROCEDURE Rev.04/2004 Installation Procedure - For C238, C247 and C249 - C249I994.WMF C249I536.WMF 1. Turn off the main switch and unplug the power cord. 2. Remove the paper delivery plate (4 screws). 3. Cut the cap [A] off the rear cover of the main body with pliers, then connect the tape marker cable to the main body.
  • Page 39 NOTE: 1) Tighten the knob screws with a screwdriver to prevent them from coming loose. 2) Install the lock washer [C] (accessories) with the lower of the two knob screws. 6. Reinstall the paper delivery plate and paper delivery table. 7. Refer to "Common Steps". 1-17 C249...
  • Page 40 NOTE: Install the lock washer [C] (accessories) with the nut. Tape Marker: 6. Install the tape marker on the auxiliary bracket with two M4 x 8 screws [E] (accessories). 7. Install the lock washer [F] (accessories) with one of the two screws. 8. Refer to "Common Steps". C249 1-18...
  • Page 41 3. Refer to “Common Steps”. — For Model C228 and the models on which the new Paper Delivery Table is installed — Use the two holes in the tape marker bracket [C] as shown below. C238I504.PCX 1-19 C249...
  • Page 42 (accessories) in the two inner holes of the tape marker bracket. NOTE: 1) Install the lock washer [B] (accessory) with the lower of the two knob screws.. 2) Tighten the knob screws with a screwdriver to prevent them from coming loose 3. Refer to “Common Steps”. C249 1-20...
  • Page 43 [B] to the main body, and install the connector cover [C] using one of the rear cover securing screws. (For C238, C247 and C249, this has already been done.) C238I518.PCX 2. Open the tape marker cover [D]. Then,...

  • Page 44: Optional Drums

    NOTE: The color drum indicator (or A4 drum indicator) on the operation panel stays lit when a drum is mounted in the machine. 8. Remove the ink cartridge cap. 9. Insert the ink cartridge in the ink holder. C249 1-22...

  • Page 45: Preventive Maintenance

    PREVENTIVE MAINTENANCE...

  • Page 47: Maintenance Table

    (SAE #20) Friction Pad Damp Cloth Press Roller Alcohol Table Fulcrum Motor Oil Shafts [B] (SAE #20) Table Racks [C] Grease (Alvania Paper Delivery Transport Belts Paper End Sensor Dry Cloth Registration/Exit Dry Cloth Sensors Registration Roller Dry Cloth C249...
  • Page 48 In/Outside of Drum Alcohol Ink Nozzle Alcohol Black Patch [G] Dry Cloth Others Main Drive Timing ! 3.8.9 Belt Tension Printing Pressure Grease Spring Hooks [F] (Alvania Press Roller Release Lever Position ADF (Option) DF Feed Rollers Dry Cloth C249...

  • Page 49: Replacement And Adjustment

    REPLACEMENT AND ADJUSTMENT...

  • Page 51: General Caution

    GENERAL CAUTION 3. REPLACEMENT AND ADJUSTMENT Only items that were changed or newly added to the C249 model are described. 3.1 GENERAL CAUTION  CAUTION Turn off the main power switch and unplug the machine before attempting any of the procedures in this section.

  • Page 52: Covers / Boards

    COVERS / BOARDS 3.3 COVERS / BOARDS 3.3.1 FRONT COVER / PANEL C238R006.WMF [A]: Front door ( x 4) [B]: Front cover ( x 6) [C]: Upper right cover ( x 2) [D]: Operation panel ( x 4,  x 1) C249...

  • Page 53: Rear Covers

    [A]: MPU ( x 17,  x 6, 9 clamps) CAUTION: Move the RAM [B] from the old board to the new one, so that the SP mode settings will be transferred to the new board. Adjust the master end sensor (! 3.6.10) after installing the new MPU. C249...

  • Page 54: Psu

    • Master eject unit (! 3.5.1) [A]: PSU ( x 5,  x 2, 2 clamps) CAUTION: When the PSU is replaced, the thermal head voltage returns to the default. Adjust the thermal head voltage (! 3.6.6) after installing the new board. C249...

  • Page 55: Scanner

    C238R038.WMF 3.4.2 SBU AND LAMP STABILIZER / SCANNER MOTOR • Left scale, Upper scale, Exposure glass (! 3.4.1) • Upper right cover (! 3.2.1) [A]: SBU cover ( x 4) C238R039.WMF [B]: SBU ( x 1,  x 5) C249...

  • Page 56: Scanner H.p. Sensor / Platen Cover Sensor

    • Left scale, Upper scale, Exposure glass (! 3.4.1) • Operation panel (! 3.3.1) • Rear upper cover (! 3.3.2) [A]: Platen cover sensor ( x 1) [B]: Left stay ( x 1) [C]: Scanner H.P. sensor ( x 1) C238R043.WMF C249...

  • Page 57: Exposure Lamp (Xenon Lamp)

    [B]: Rear frame ( x 1,  x 2) [C]: Front frame ( x 5) C238R045.WMF [D]: Exposure lamp ( x 1) NOTE: After installing the lamp, press the lamp holder [E] up to the original position so that it can hold the lamp properly. C249...

  • Page 58: Scanner Wires

    5. Wind the end of the new wire with the ring as shown ( , and & 6. Connect the tension spring to the wire tension bracket ( 7. Wind the new scanner wire for the other side as well. C249...
  • Page 59 10. Secure the scanner drive pulley [G] (1 Allen screw). 11. Remove the scanner positioning pins [I] (P/N: #A0069104). 12. Slide the scanner to the left and right several times, then set the scanner positioning pins to check the clamp position and wire tension bracket position again. C249...

  • Page 60: Image Adjustment

    SP6-06: Scanning speed - ADF ↓ SP6-03: Scanning start position - platen (! 5.7.3) SP6-04: Scanning start position - ADF ↓ SP6-01: Main scan position - platen (! 5.7.3) SP6-02: Main scan position - ADF ↓ SP6-31: SBU calibration (! 5.7.4) C249 3-10...

  • Page 61: Master Eject

    MASTER EJECT 3.5 MASTER EJECT 3.5.1 MASTER EJECT UNIT C249R001.WMF [A]: Master eject unit ( x 1,  x 2, 1 clamp) 3-11 C249...

  • Page 62: Master Feed

    2. Select SP5-74 (T/H driving motor - up), then press the enter (#) key and turn off the main switch. NOTE: 1) The thermal head is released, after about 2 seconds. (There is almost no sound of operation.) 2) The thermal head does not separate, unless it releases as mentioned above. C249 3-12...
  • Page 63 • Master making unit (! 3.6.1) • Open the platen roller unit [1]. [A]: T/H upper cover ( x 2) [B]: T/H side cover ( x 1) C249R122.WMF • Close the platen roller unit [1]. [C]: Thermal head ( x 2) 3-13 C249...
  • Page 64 1. Turn the thermal head clockwise and remove a nail ( 2. Turn the thermal head counterclockwise, and remove a nail ( 3. Remove the thermal head slowly. NOTE: If you cannot access SP modes, open the master making unit and loosen the 2 screws [D]. C249R110.WMF C249 3-14...
  • Page 65 2) While fitting the tops of the springs [A] over the protrusions on the underside of the thermal head. 3) Make sure that all protrusions are properly fitted into the springs. CAUTION: Adjust the thermal head voltage (! 3.6.6) after installing the new thermal head. 3-15 C249...

  • Page 66: Duct Plate Hp Sensor / Duct Plate Motor

    • Master making unit (! 3.6.1) [A]: Rear cover ( x 2) [B]: Duct plate HP sensor ( x 1,  x 1) [C]: Rear rail bracket ( x 2) [D]: Duct plate motor ( x 1,  x 2) C249 3-16...

  • Page 67: Cutter Unit

    3.6.5 THERMAL HEAD DRIVING UNIT C249R105.WMF • Thermal head (! 3.6.2) • Rear cover (! 3.3.2) • Cutter unit (! 3.6.4) [A]: Anti-Static roller ( x 2) [B]: Thermal head driving unit ( x 2,  x 2) 3-17 C249...

  • Page 68: Thermal Head Voltage Adjustment

    Stop key if you cannot finish the adjustment quickly. A beeper sounds while the power is being supplied. 6. Measure the voltage, and turn VR1 so that the value becomes between “+0” and “-0.1” volts from the value on the thermal head decal. C249 3-18...

  • Page 69: Duct Jam Sensor Adjustment

    NOTE: When the value of the voltage does not become the standard value, adjust the threshold level of the duct jam sensor. (SP6-52 : Duct jam sensor voltage) Standard Value Standard Value Threshold level (SP6-52) Master being Master nothing 0.5 ±0.1V Above 2.0V 2.0V 3-19 C249...

  • Page 70: Master Edge Sensor Adjustment

    NOTE: When the value of the voltage does not become the standard value, adjust the threshold level of the master edge sensor. (SP6-51 : Master edge sensor voltage) Standard Value Standard Value Threshold level (SP6-51) Master being Master nothing 2.0 ±0.1V 2.8V Above 3.3V C249 3-20...
  • Page 71 NOTE: When the value of the voltage does not become the standard value, adjust the threshold level of the 2nd drum master sensor. (SP6-53 : 2nd drum master sensor voltage) Standard Value Standard Value Threshold level (SP6-53) Master being Master nothing 2.0 ±0.1V 1.0V Below 0.8V 3-21 C249...

  • Page 72: Master End Sensor Adjustment

    NOTE: When the value of the voltage does not become the standard value, adjust the threshold level of the master end sensor. (SP6-50 : Master end sensor voltage) Standard Value Standard Value Threshold level (SP6-50) Master being Master nothing 2.0 ±0.1V Below 1.8V 1.9V C249 3-22...

  • Page 73: Paper Feed

    3.7.1 PICK-UP ROLLER / PAPER FEED ROLLER / FRICTION PAD C249R115.WMF • Lower the paper table. [A]: Pick-up roller ( x 1) [B]: Paper guide ( x 1) [C]: Feed roller ( x 1) [D]: Friction pad [E]: 3-23 C249...

  • Page 74: Paper Separation Pressure Adjustment

    Adjust the paper separation pressure by loosening and moving the adjusting screw [A] up or down. Moving up the screw ⇒ Increases the paper separation pressure Moving down the screw ⇒ Decreases the paper separation pressure Tighten the screw after the adjustment. C238R031.WMF C249 3-24...

  • Page 75: Paper Width Detection Board

    • Lower the paper table. [A]: Paper table ( x 1,  x 2) [B]: Table cover ( x 5, 3 washers) [C]: Sensor cover ( x 2) [D]: Paper width detection board ( x 1,  x 1) 3-25 C249...

  • Page 76: Printing

    • Remove the drum. [A]: Press roller ( x 1) The bearings on the rear and front differ. During installation, ensure that the bearing with the stopper [B] is positioned towards the rear of the machine. C249 3-26...

  • Page 77: Press Roller Release Lever Adjustment

    [C] and the press roller lock lever [D] (rear side). It should be between 0.7 and 1.2 mm. 3. If it is not correct, adjust the position of the press roller lock lever after loosening the two screws [E]. 4. Repeat steps 2 and 3 for the front side. 3-27 C249...
  • Page 78 Standard: Within 17 ± 0.2 mm C249R127.WMF 1. Adjust the distance [A] to 17 ± 0.2 mm by turning the adjusting bolt [B]. 2. Repeat the same procedure for the printing pressure spring at the non- operation side. C249 3-28...
  • Page 79 • Remove the drum C238R054.WMF 1. Remove the drum upper bracket ( x 4). 2. Release the stopper [A], then rotate the drum until the master clamper faces top. 3. Remove the cloth screen [B] ( x 4). 3-29 C249...
  • Page 80 [C]. Adjust the stay so that it is parallel to the master clamper, then tighten the screws. • Make sure that the cloth screen is not wrinkled while spreading it around the drum. C249 3-30...

  • Page 81: Clamper / Metal Screen

    2) Use a cloth dampened with water to clean the inside of the clamping plate [C]. Never use alcohol or other solvents. The clamping force of the magnet will be weakened. [D]: Tape (do not lose it) [E]: Metal screen ( x 12) 3-31 C249...
  • Page 82 (The two holes [A] on the trailing side are round holes and the other holes are long holes, to allow for the removal of the slack.) • Do not scratch the cloth screen or metal screen. C249 3-32...

  • Page 83: Ink Pump Adjustment

    2. Loosen the two screws securing the holder [E]. (Do not remove the holder.) 3. Push the plunger [F] until it reaches the bottom. NOTE: The end of the plunger [F] must not stick out from the holder [E]. 3-33 C249...
  • Page 84 5. If the motion is stiff, loosen the pump screws [G] and adjust the pump position. 6. After tightening, repeat step 4 and step 3. C238R017.WMF 7. Re-tighten the two screws [H]. 8. Check that the piston motion is smooth. 9. Reinstall the E-ring [C]. C249 3-34...

  • Page 85: Ink Roller Unit / Ink Roller One-Way Clutch

    [B]: Front stay ( x 2,  x 3) [C]: Front flange C238R023.WMF [D]: Rear stay ( x 2) [E]: Rear stoppers ( x 1) [F]: Ring [G]: Rear flange C238R060.WMF [H]: Ink roller unit [I]: Ink roller one-way clutch C238R033.WMF 3-35 C249...

  • Page 86: Doctor Roller Gap Adjustment

    2. If the gap is out of the standard, loosen the screw [B] and adjust the gap by turning the cam bushing [C] for the front and for the rear. NOTE: Make sure to repeat the adjustment for both ends of the rollers. C249 3-36...

  • Page 87: Ink Detection Adjustment

    • MPU (! 3.3.3) 1. Loosen the screws [A], [B], and [C]. 2. Move the tension roller [D] to the right with a screwdriver [E] as shown. 3. Tighten the screws [A], [B], and [C]. 4. Remove the screwdriver. C238R032.WMF 3-37 C249...

  • Page 88: Ink Idling Motor /Ink Idling Roller Hp Sensor

    3.9.10 INK IDLING MOTOR /INK IDLING ROLLER HP SENSOR C249R106.WMF • Cloth Screen (! 3.9.2) • Clamper / Metal Screen (! 3.9.3) [A]: Ink idling roller HP sensor ( x 1,  x 1) [B]: Ink idling motor ( x 1,  x 2) C249 3-38...

  • Page 89: Exit Pawl Adjustment

    It should be 0.80 ± 0.15 mm. 3. If the clearance is not correct, adjust the clearance by turning the bolt [F]. 4. Reposition the bracket [C] and tighten the screws [A] and [B]. 5. Do the timing adjustment (see the next page). 3-39 C249...
  • Page 90 5. Re-tighten the two screws while pushing the cam follower against the cam face. Make sure that the gap [F] is 0 or less than 0.5 mm. NOTE: Do not push the cam followers too strongly against the cam. 6. Re-position the bracket [D] and tighten the screws [B] and [C]. C249 3-40...

  • Page 91: Paper Delivery

    3.10.2 DELIVERY BELT / PAPER EXIT SENSOR C238R035.WMF • Paper delivery unit (! 3.10.1) [A]: Paper guide ( x 2) [B]: Delivery belts [C]: Vacuum fan motor ( x 1,  x 4) C238R036.WMF [D]: Paper exit sensor ( x 1) 3-41 C249...

  • Page 92: Exit Pawl Adjustment

    It should be 1.15 ± 0.15 mm. 8. If the clearance is not correct, adjust the clearance by turning the bolt [F]. 9. Reposition the bracket [C] and tighten the screws [A] and [B]. 10. Do the timing adjustment (see the next page). C249 3-42...
  • Page 93 11. Re-tighten the two screws while pushing the cam follower against the cam face. Make sure that the gap [F] is 0 or less than 0.5 mm. NOTE: Do not push the cam followers too strongly against the cam. 12. Re-position the bracket [D] and tighten the screws [B] and [C]. 3-43 C249...

  • Page 94: Air Pump Adjustment

    2. Check whether the hole [B] in the pump drive gear is aligned with the hole [C] in the air pump unit bracket. 3. If the alignment is incorrect, remove the air pump unit and re-position the gear. C249 3-44...

  • Page 95: Special Tools

    SPECIAL TOOLS 3.11 SPECIAL TOOLS The following are the special tools used for service. Description Part number Note ! 3.4.5 Scanner positioning pins (4 pins as a set) A006 9104 ! 5.9.2 Flash memory card A230 9352 ! 5.9.3 3-45 C249...
  • Page 97 TROUBLESHOOTING...

  • Page 99: Troubleshooting

    Signal transmission error (from the operation panel board) occurred in the MPU. E-16 Paper Feed Control error Signal transmission error (from the paper feed control section) occurred in the MPU. E-17 Drum Thermistor Open Thermistor connector The thermistor output voltage is over 4.9 volts. Thermistor C249...
  • Page 100 The machine detects a failure in the MPU ASIC. E-47 Thermal head driving error Thermal head HP sensor The thermal head HP sensor does not change status Thermal head driving within 4.0 seconds after the thermal head driving motor motor on signal is generated. C249...

  • Page 101: Electrical Component Defects

    The paper table goes down below the sensor, Shorted and E-02 is displayed. Platen Cover Sensor The master is made normally, even if the Open platen cover is open. The image is treated using center/edge erase Shorted mode. Scanner HP Sensor Open E-13 is displayed. Shorted C249...
  • Page 102 E-01 is displayed. Open E-42 is displayed. Duct plate HP sensor Shorted E-42 is displayed. Open The “D” jam indicator is lit. Master Edge Sensor Shorted The “D” jam indicator is lit. C249...

  • Page 103: Switches

    E-47 is displayed, and the output mode in SP mode does not turn anything on except the main motor. +24v (CN111-1) E-13 is displayed, and SP5-13, 14, 15 (master eject motor/pressure plate motor output mode) does not turn the motor on. C249...

  • Page 104: Fuse, Led, Vr, Dip-Sw, And Tp Tables

    ! 3.6.7) VR102 Adjusts the duct jam sensor ( ! 3.6.8) VR103 Adjusts the master edge sensor ( ! 3.6.9) VR104 Adjusts the 2 drum master sensor ( Function ! 3.6.6) Adjusts the thermal head voltage. ( Not used. C249...

  • Page 105: Dip Switches

    TP102 Measures the duct jam sensor voltage. ( ! 3.4.7) TP103 Measures the master edge sensor voltage. ( ! 3.6.9) TP104 Measures the 2 drum master sensor voltage. ( Function !3.6.6) TP701 Measures the thermal head voltage. ( TP702 C249...

  • Page 106: Others

    Non-feed jam Feed pressure is weak. Feed pressure is set as thick paper. (! O/I Operation - Printing on thick or thin) Separation pressure is set as weak. (! 6.7.3) C249...
  • Page 107 128g/m difficult feed by normal Feed pressure Thin paper Normal paper Thick paper (Lever) (weak) (Normal) (strong) Separation Strong Normal Weak Pressure (Scale) NOTE: Adjust feed pressure at first. If it does not improve, then adjust the separation pressure. C249...

  • Page 108: Paper Ejection Errors

    Cause Solution Master feed Suction becomes weaker Pull out the master feed tray, and as pieces of Master remove the broken of Master enter into duct and pieces. (D jam) vacuum fan. (! O/I Troubleshooting - Clearing Misfeeds) C249 4-10...

  • Page 109: Master Delivery Errors

    (! 3.8.4 ) Leak ink from The doctor gap in the Adjust the doctor gap. (! 3.7.2) end of drum. drum is too wide. Drum cannot be The bearing of drum Attach the spacer. set properly. drive part comes off. 4-11 C249...

  • Page 110: Poor Image

    (! 1.2.1) striped pattern. caused the ink supply to decrease. Part of image is Foreign materials may Remove foreign materials from the not shown have stuck on the surface. surface of the screen. C249 4-12...

  • Page 111: Others

    A harness snapped and Check if there is snapping harness caused a short circuit. or short circuit. Unplug the machine. Then plug it back in again. Unknown Caution: Record the settings before clearing memory. Clear the memory with SP7 4-13 C249...

  • Page 112: User Instructions

    " (Insert the master too mark when master is set. deep.) D jam Exit pawl of clamper When master is taken off, exit pawl clamper should not be on the master clamper. C249T905.WMF C249 4-14...
  • Page 113 OTHERS C249T906.WMF 4-15 C249...
  • Page 115 SERVICE TABLES...

  • Page 117: Service Tables

    Entering SP Mode 1. Key in the following sequence.  →  →  →  →  • Hold the  key down for longer than 3 seconds. Leaving SP Mode Press the  key one or more times. C249...

  • Page 118: How To Select A Program Number

    4. Press the Enter key or the OK key to store the displayed setting. 5. Follow the “Change Adjustment Values or Modes” procedure below. NOTE: To cancel the SP mode, press the Clear Modes/Energy Saver key [G] or the Cancel key [H]. C249...

  • Page 119: Main Menu No.1: Copy Data

    1-161 Key counter setting check 5.2.2 SP1-70: MAIN FIRMWARE PARTS NUMBER Displays the main firmware parts number and the suffix. 5.2.3 SP1-80: ERROR CODE HISTORY Displays the latest 40 records of the SC codes. Use the  keys to view the records. C249...

  • Page 120: Main Menu No.2: Basic Settings

    0 to 50% 2-50 T/H swinging mode ( Off/On Not used 2-51 T/H swinging quantity (Not ±1 to 5mm ⇒ used) 2-95 Paper Table Standby Position Off/On ( 5.3.11) 2-60 Bold letter mode Off/On ( 5.3.10) Make master without printing 5.3.11) C249...

  • Page 121: Sp2-7: Chinese Display Setting (China Model Only)

    5.3.2 SP2-7: CHINESE DISPLAY SETTING (CHINA MODEL ONLY) To change the warning message when you made a mistake of installing different masters in the machine depends on the selling company. 0: Ricoh master type 1: Gestetner master type 5.3.3 SP2-32: INK SUPPLY AFTER TRIAL9 Ink is detected and supplied after the trial print when this SP is on.

  • Page 122: Sp2-36: Ink Idling Roller Setting

    Procedure: 1) Access the SP2-100 (Make master without printing). Then press “OK”. 2) Press the “Start” key while holding down the “#”key. C249...

  • Page 123: Main Menu No.3: System Settings

    Input the year, the month / date, and the time in that order. Press the Enter key between each one. Input the last two digits of the present year (two-digit number). ↓# Input the present month (two-digit number). ↓# Input the present date (two-digit number). ↓# C249...

  • Page 124: Sp3-4: Input Installation Date

    Input installation date in that order. Press the Enter key between each one. Input the last two digits of the present year (two-digit number). ↓# Input the present month (two-digit number). ↓# Input the present date (two-digit number). ↓# Example: 2003/January/27th ↓# ↓# ↓OK C249...

  • Page 125: Main Menu No.4: Input Mode

    4-36 Paper width signal 1 4-37 Paper width signal 2 4-38 Paper width signal 3 4-39 Paper width signal 4 4-40 Paper width signal 5 4-41 Registration sensor 4-42 Feed start timing sensor 4-43 2nd feed timing sensor 4-44 Paper exit sensor C249...

  • Page 126: Main Menu No.5: Output Mode

    5-37 Paper feed motor: 105 rpm 5-38 Paper feed motor: 120 rpm 5-100 All indicators on the panel 5-39 Registration motor: 15 rpm 5-40 Registration motor: 30 rpm 5-41 Registration motor: 60 rpm 5-42 Registration motor: 75 rpm C249 5-10...

  • Page 127: Main Menu No.6: Adjustment

    6-73 90 rpm pressure: low temp 1 to 5 (! 6.6.1) 6-74 105 rpm pressure: low temp 1 to 5 (! 6.6.1) 6-75 120 rpm pressure: low temp 1 to 5 (! 6.6.1) 6-76 Trial pressure: normal temp 1 to 5 (! 6.6.1) 5-11 C249...
  • Page 128 6-132 Paper Regist: A4 drum 15 (Not used) -40 to 40 6-133 Paper Regist: A4 drum 30 (Not used) -40 to 40 6-134 Paper Regist: A4 drum 45 (Not used) -40 to 40 6-135 Paper Regist: A4 drum 60 (Not used) -40 to 40 C249 5-12...
  • Page 129 6-160 Paper front bulge: A4: 75 (Not used) -90 to 8 6-161 Paper front bulge: A4: 90 (Not used) -90 to 8 6-162 Paper front bulge: A4: 105 (Not used) -90 to 8 6-163 Paper front bulge: A4: 120 (Not used) -90 to 8 5-13 C249...

  • Page 130: Sp6-40: Ink Detection Adjustment

    When correcting errors made when printing with the controller, use only the first two procedures. When correcting errors made when printing with scanned originals, do all six adjustments in the given order. This adjustment is required every time the RAM on the MPU has been replaced. C249 5-14...
  • Page 131 4. If it is not, access SP6-21, input the difference and press the Enter key. Example: If the value is 7 mm, 7 - 8 = -1.0 5. Repeat the procedure to make sure that the gap is correct. 5-15 C249...
  • Page 132 3. Access SP6-01, input the gap value and press the Enter key. (If you input a positive value, the image moves towards the operation side.) 4. Repeat the procedure to make sure that there is no difference. 5. Make a copy in ADF mode and repeat the process using SP6-02. C249 5-16...

  • Page 133: Sp6-31: Sbu Calibration

    Sharpens image, however moiré can become more apparent. Refer to the following table for the relationship between this SP mode value and filter strength (the relationship is not linear). Value Strength of Filter X 1/2 X 1/4 X 1/8 X 1/16 X 1/32 5-17 C249...

  • Page 134: Sp6-20: Registration Buckle (Not Used)

    Bigger number: increases feeding Smaller number: decreases feeding One memory: 0.1mm 5.7.8 SP6-64: MASTER PUSHING VALUE (NOT USED) This adjusts the pressure between the master push Mylar and the drum. Bigger number: increases the pressure Smaller number: decreases the pressure C249 5-18...

  • Page 135: Sp6-100 To 107: Paper Registration - Each Speed

    2nd print: 45 rpm 3rd print: 60 rpm 4th print: 75 rpm 5th print: 90 rpm 6th print: 105 rpm print: 120 rpm 5. The distance between the leading edge and first line should be 8mm, as shown below. C249S905.WMF 5-19 C249...

  • Page 136: Sp6-116 To 123: Paper Middle Buckle (Not Used)

    5.7.10 SP6-116 TO 123: PAPER MIDDLE BUCKLE (NOT USED) Adjusts doubled [A] or blurred [B] images (e.g. bold lines, text) for each printing speed (15,30, 60, 75, 90, 105, 120 rpm), by changing SP settings. 200 mm 50 mm C249S906.WMF C249 5-20...
  • Page 137 6 copies expect for 2nd print. Trail print: 30 rpm 1st print : 45 rpm 2nd print: 45 rpm 3rd print: 60 rpm 4th print: 75 rpm 5th print: 90 rpm 6th print: 105 rpm print: 120 rpm 5-21 C249...

  • Page 138: Sp6-124 To 131: Paper Front Buckle (Not Used)

    8. Return SP2-34 (Slow starting mode) to the value it was at before the adjustment. 5.7.11 SP6-124 TO 131: PAPER FRONT BUCKLE (NOT USED) Adjusts doubled [A] or blurred [B] images (e.g. bold lines, text) for each printing speed (15,30, 60, 75, 90, 105, 120 rpm), by changing SP settings. C249S911.WMF C249 5-22...
  • Page 139 6 copies expect for 2nd print. Trail print: 30 rpm 1st print : 45 rpm 2nd print: 45 rpm 3rd print: 60 rpm 4th print: 75 rpm 5th print: 90 rpm 6th print: 105 rpm print: 120 rpm 5-23 C249...
  • Page 140 Higher values ([C]): Blurred images improve, doubled images tend to be more noticeable. Lower values ([D]): Doubled images improve, blurred images tend to be more noticeable. 7. Perform the adjustment again where necessary. 8. Return SP2-34 (Slow starting mode) to the value it was at before the adjustment. C249 5-24...

  • Page 141: Main Menu No.7: Memory Clear

    7-4 Jam/Error data clear Hold 0 & push # to clear 5.8.2 SP7-1: FACTORY SETTINGS CLEAR This resets all SP settings except for the following SP numbers. • SP2-20: Destination settings • SP3-01: Present time • SP6-All: Adjustments 5-25 C249...

  • Page 142: Main Menu No.8: System Test

    7. Access SP8-1 and press the OK key. Press the “Enter(#)” key. 8. Press the Enter key. (It takes about 2.0 minutes to complete.) 9. Check that the “Completed” is displayed. 10. Turn off the main switch, and remove the flash memory card. C249 5-26...

  • Page 143: Sp8-2: Upload Main Firmware

    1. Access SP8-22 and press the OK key. 2. Exit the SP mode and enter the number of times that you want to repeat the paper feed cycle. 3. Press the Print key. 4. To exit this mode, turn off the main switch. 5-27 C249...

  • Page 144: Sp8-18: Temporary Security

    “Security Mode”. You cannot clear “Security Mode” by turning OFF the main switch. The job will not occur when you set a new original and press the “START” key. C249 5-28...
  • Page 145 DETAILED DESCRIPTIONS...

  • Page 147: Detailed Section Descriptions

    21. Paper delivery table 9. Thermal head 22. Air knife fan motors 10. Paper separation roller 23. Master eject rollers 11. Paper feed roller 24. Master eject box 12. Paper table 25. 2nd scanner 13. Registration rollers 26. 1st scanner C249...

  • Page 148: Electrical Component Layout

    MECHANISM OVERVIEW 6.1.2 ELECTRICAL COMPONENT LAYOUT C249D939.WMF C249D064 WMF C249...
  • Page 149 MECHANISM OVERVIEW C249D940.WMF C249D941.WMF C249...
  • Page 150 Provides suction to guide the master into the duct. Thermal head driving motor Raises and lowers the thermal head. Blower fan motor Provides air to separate the master. Ink idling motor Presses or releases the idling roller against the drum screen. C249...
  • Page 151 Detects when a master remains in the duct. Thermal head HP sensor Detects when the thermal head is at the home position. Master edge sensor Detects the leading edge of the master. Ink idling roller HP sensor Detects when the idling roller is at home position. C249...
  • Page 152 Keeps track of the total number of copies. Master Counter Keeps track of the total number of masters made. Others Component Function Thermal Head Burns the image onto the master. Exposure Lamp (Xenon Lamp) Applies light to the original for exposure. C249...

  • Page 153: Drive Layout

    7. Paper feed motor 2. Clamper motor 8. Master feed motor 3. Paper delivery motor 9. Scanner motor 4. Main motor 10. Thermal head driving motor 5. Registration motor 11. Duct plate motor 6. Table motor 12. Printing pressure motor C249...

  • Page 154: Master Eject Unit

    The pressure plate [D] then compresses the used masters in the eject box. • The capacity is 50 used masters (under normal conditions) • The master eject process is skipped when the drum master sensor [E] detects no master on the drum. C249...

  • Page 155: Master Clamper Opening Mechanism

    4) The drum guide catches the drum at the master eject position while the master clamper is being opened. When the clamper motor turns on in reverse to close the clamper, the drum guide also disengages the pin and the drum can turn. C249...

  • Page 156: Master Eject Roller Mechanism

    4. When the drum reaches the master feed position, the master eject and drum motors stop. The master feed position is 121 encoder pulses (43 degrees) after the feed start timing sensor is actuated. 5. During this process, the master eject sensor [E] detects master eject jams. (! 6.10.1) C249 6-10...
  • Page 157 3. If the pressure plate limit sensor is not actuated within 4.5 seconds after the pressure plate motor rotates, the Full Master Eject Box indicator lights. 4. The idle gear has a clutch [E] to prevent motor overload. 6-11 C249...

  • Page 158: Scanner Unit

    • Light reflected off the original is directed onto a CCD via the mirrors and the lens. • The main-scan resolution is 600 dpi, because the CCD is 600 dpi. This model always reduces the amount of scanned data to 400 dpi. (! 6.3.6) • The sub-scan resolution is 400 dpi. C249 6-12...

  • Page 159: Board Layout

    • The CCD line has 7,450 pixels and the resolution is 600 dpi (23.6 lines/mm). • The A/D converter in the SBU transforms the analog signals into 8-bit digital signals. The MPU carries out the following processes on the image data: Auto shading ↓ Filtering (MTF, SMOOTHING) ↓ Magnification ↓ Binary processing 6-13 C249...

  • Page 160: Auto Background Correction

    • The processing for main-scan enlargement/reduction is the same as in the previous digital machines • The thermal head is 400 dpi, but the CCD is 600 dpi. Therefore, this model always reduces the amount of scanned data by half before printing. C249 6-14...

  • Page 161: Binary Processing

    With this function, the scanner scans at 400 dpi in the sub-scan direction by reducing the scanner motor speed, then the master making unit writes at 400 dpi in the master feed direction by reducing the master feed motor speed. Therefore, the resolution in the paper feed direction is 400 dpi. 6-15 C249...

  • Page 162: Thermal Head

    The CPU detects an abnormal ID signal from the thermal Thermal head head energy control pulse. E-40 Thermal Head ID error Thermal head The CPU detects an abnormal ID signal from the thermal head. Thermal head connector disconnected C249 6-16...
  • Page 163 • Connect and disconnect the connectors carefully. Keep them horizontal and firmly reconnect them. • Adjust the voltage supplied to match the specified value for the thermal head. 6-17 C249...

  • Page 164: Master Feed

    The thermal head [B] makes an image on the master. ↓ Clamper [C] opens. (The drum is at the master feed position.) ↓ The clamper clamps the master. At this time, the cutter [D] cuts the master. ↓ The master is wrapped around the drum [E]. C249 6-18...

  • Page 165: Auto Adjustable Master Set

    The master feed motor feeds the master until the master edge sensor detect the master. (3) ↓ The duct plate moves from the open position to the middle position [D]. (4) ↓ The duct fan motors and the blower fan motor turn off. (4) 6-19 C249...

  • Page 166: Thermal Head Driving Mechanism

    Thermal head HP sensor [F] has two stop positions: • Platen roller apply position • Platen roller release position The actuator disk [G] interrupts the thermal head HP sensor [F] when the thermal head base [D] is released from the platen roller [E]. C249 6-20...

  • Page 167: Master Buffer Mechanism

    The stored master is fed out from the duct when the drum reaches the master making position after the used master has been ejected. The blower fan motor [C] provides air to separate the master in the master buffer duct. 6-21 C249...

  • Page 168: Detection Of Master In The Lower Master Tray

    • The duct jam sensor [A] detects whether there is a master in the lower master tray or not. • When the duct jam sensor detects master, the “D” jam indicator comes. If this happens, open the lower master tray [B] and remove the misfed master. C249D065.WMFF C249 6-22...

  • Page 169: Duct Plate Mechanism

    • The duct plate middle position ( • The duct plate open position ( • The master push mylar apply position ( The actuator disk [E] interrupts the duct plate HP sensor [D] when the duct plate opens. 6-23 C249...
  • Page 170 (5). The master push mylar prevents air pockets and distributes the ink through the master as the master is wrapped around the drum. ↓ The cutter [F] cuts the master after the master is wrapped around the drum (6). C249 6-24...

  • Page 171: Master Feed Mechanism

    5. The master feed motor continues to feed the master until master making has completed. Then the master feed motor turns off, and cutting is done. 6. Springs press the thermal head against the platen roller. 6-25 C249...

  • Page 172: Clamper And Tension Roller Mechanism

    When the clamper opens, it pushes the tension roller arms [I] and moves the tension roller away from the guide plate to allow the master to be fed into the master clamper. C249 6-26...

  • Page 173: Master Push Mylar

    The master push mylar contacts with the master on the drum to distribute ink through the master. C249D012.WMF • The 2nd drum master [D] sensor prevents the master push mylar from contacting the drum when there is no master on the drum. 6-27 C249...

  • Page 174: Nd Drum Master Sensor

    [B]: Black patch on the screen [C]: Black patch on the clamper • The 2nd drum master sensor prevents contact with the master push mylar from contacting the drum when there is no master on the drum. C249D013.WMF C249 6-28...

  • Page 175: Cutter Mechanism

    The leading edge of the master that was cut remains at the cutting position, ready to make the next master. 6.4.12 MASTER SET COVER SENSOR C238D020.WMF [A]: Master set cover sensor [B]: Master set cover • If the cover is closed properly, the release button [C] rises. 6-29 C249...

  • Page 176: Re-Cutting Mechanism

    5.0 seconds after the main motor turns on by master cut miss, the cutter tries to cut the master again. The cutter cuts the master a second time, and the jam indicator lights. If the cutter does not cut the master the second time, the E- 06(Main Motor error) indicators lights. C249 6-30...

  • Page 177: Drum

    2) The main motor speed and the drum stop positions are controlled by the monitoring the motor encoder. 3) The ink pump, which is outside the drum, supplies ink from the ink cartridge to the drum through the drum shaft. 6-31 C249...

  • Page 178: Drum Drive Mechanism

    • Second feed timing sensor [F] (jam detection) • Paper exit timing sensor [G] (jam detection) 4) The drum has two stop positions: • Master eject (home) position • Master feed position (feed start timing sensor + 121 pulses (43 degrees)) C249 6-32...

  • Page 179: Ink Supply Mechanism

    Supplies ink from the ink cartridge to the ink roller via the pump, the shaft, the tube, and the ink distributor pipes [C]. Ink drops through 4 openings [D] in the ink distributor onto the ink roller. NOTE: The ink pump is outside the drum in this model. 6-33 C249...

  • Page 180: Ink Roller Mechanism

    This happens when the press roller [F], under the drum, moves up to press the drum screen and the master against the ink roller. (!: Digital Duplicators – Ink Supply Control) C249 6-34...

  • Page 181: Ink Supply Control

    “0” key, the drum turns for 60 seconds to supply ink inside the drum. 4) The ink roller blades [D] on both ends of the ink roller scrape off the built-up ink on the ends of the ink roller. 6-35 C249...

  • Page 182: Drum Idling Mechanism

    The idling roller motor [A] turns to press the drum idling roller against the inner surface of the drum screen [E]. The actuator disk [F] interrupts the idling roller HP sensor [G] when the drum idling roller is in contact with the drum screen. C249 6-36...
  • Page 183 Because of this, the master eject process can be skipped when a new master is being made, if no master is detected on the drum. • The drum master sensor uses the black patch [C] on the clamper for jam detection. (!6.7.3) 6-37 C249...

  • Page 184: Paper Feed

    The registration rollers [D] feed the paper. ↓ The print is made. NOTE: 1) A dedicated stepper motor (paper feed motor) controls the feed roller and the pick-up roller. 2) A dedicated stepper motor (registration motor) controls the registration roller. C249 6-38...

  • Page 185: Paper Feed Mechanism

    3) The guides [G] help to feed paper that is not perfectly flat. 4) Paper feed start timing depends on the selected printing speed: see the Timing Charts. 6-39 C249...

  • Page 186: Paper Feed/Separation Pressure Mechanism

    • By loosening then moving the screw [D] up or down, the spring [E], which applies pressure to the friction pad block [F], moves up or down. • The default position of the screw [D] is at the next to highest position. C249 6-40...

  • Page 187: Registration Roller Mechanism

    • When the high point of the cam [E] on the drum drive gear reaches the cam follower [F], the shaft [G] rotates clockwise (as seen from the operation side) to release the upper registration roller [D] from the lower registration roller. 6-41 C249...

  • Page 188: Printing Pressure Mechanism

    6.6.6 RE-FEEDING MECHANISM • If the registration sensor detects a non-feed, the machine tries again. However, if the machine detects a non-feed the second time, the jam indicator lights. C249 6-42...
  • Page 189 Printing Pressure 2 4th Print (105 rpm) Printing Pressure 5 Printing Pressure 4 Printing Pressure 3 5th Print (120 rpm) Printing Pressure 5 Printing Pressure 5 Printing Pressure 5 Bigger number: increases the pressure Smaller number: decreases the pressure 6-43 C249...

  • Page 190: Paper Table Mechanism

    Paper end detection • The paper end sensor [G] under the paper table detects when the paper on the table runs out. Paper size detection [H]: Paper length sensor [I]: Paper width detection board C249 6-44...
  • Page 191 These are especially useful when thin paper is used. • The user can install the friction pads if they are using thin paper. 6-45 C249...

  • Page 192: Paper Delivery

    Rotates the transport belts [D]. NOTE: 1) The vacuum fan motor inside the unit holds the paper against the belts [D] C238D048.WMF to deliver the paper to the exit table. 2) The motor rotation speed depends on the selected print speed. C249 6-46...

  • Page 193: Paper Separation From The Drum

    When the gear [A] rotates, it drives the piston [B] back and forth. • The piston moves forward and pushes a jet of air out through the nozzle [C]. This jet of air helps to separate the paper from the drum. C238D016.WMF 6-47 C249...

  • Page 194: Exit Pawl Drive Mechanism

    [D] and held in the lower position. Therefore, after printing finishes, the cam follower is out of contact with the cam, and the exit pawl moves away from the drum to its normal position. C238D060.WMF C249 6-48...

  • Page 195: Timing Chart

    TIMING CHART 6.8 TIMING CHART 6.8.1 MASTER EJECT / MASTER FEED C249D900.WMF 6-49 C249...
  • Page 196 TIMING CHART C249 6-50...

  • Page 197: Master Wrapping

    TIMING CHART 6.8.2 MASTER WRAPPING C249D901.WMF 6-51 C249...
  • Page 198 TIMING CHART C249 6-52...

  • Page 199: Printing

    TIMING CHART 6.8.3 PRINTING C249D902.WMF 6-53 C249...
  • Page 200 TIMING CHART C249 6-54...

  • Page 201: Jam Detection

    (pressure plate at lower limit), the B, E jam indicator lights. Just after turning on the main switch Jam check timing: Just after the main switch has been turned on. Check: If the master eject sensor is on (master detected), the B, E jam indicator lights. 6-55 C249...

  • Page 202: Df Jam (P Jam Location Indicator)

    Turning on the main switch/closing the DF cover Jam check timing: Just after turning the main switch on, and when the DF cover is closed. Check: If the DF registration sensor detects an original, the P jam indicator lights. C249 6-56...

  • Page 203: Master Feed Jam (D Jam Location Indicator)

    When the cutter motor reverses to the cutter reach home position, the D jam indicator lights. When the cutter motor reverses, the cutter does not reach home position, the E- 01 (Cutter error) indicators lights. 6-57 C249...
  • Page 204 To even off the leading edge of the master roll after the edge has been unevenly cut, such as after a master misfeed jam (D-jam). NOTE: The following procedure cannot be performed if a misfeed or SC error condition has not been cleared. C249 6-58...
  • Page 205 The machine will then trim the leading edge. After this is completed, a beep will sound and the operation panel will display, “Pull out lower master tray or master tray and remove the cut master.” 4. Open the lower master tray [D] and remove the trimmed portion [E]. 6-59 C249...

  • Page 206: Drum Jam (B Jam Location Indicator)

    Check: If after the paper feed motor has fed 310 pulses, the re-feeding function starts. The paper feed motor re-starts, and if the registration sensor doesn’t detect paper again after 310 pulses, the A jam location indicator lights. C249 6-60...

  • Page 207: Paper Delivery Jam (C Jam Location Indicator)

    Drum: 360 degrees = 1020 pulses Jam check timing: Just after the main switch is turned on, or when drum rotation has finished. Check: When the paper exit sensor detects paper, the C jam location indicator lights. 6-61 C249...
  • Page 209 SPECIFICATIONS...

  • Page 211: General Specifications

    3 enlargements and 4 reductions A3 version DLT version 141% 155% Enlargement 122% 129% 115% 121% Full Size 100% 100% Reduction Zoom: 50% to 200%, in 1% steps Power Source: America 120 V, 60 Hz Europe, Asia 220 – 240 V, 50/60 Hz C249...
  • Page 212 Tables opened: 1360 x 700 x 640 mm (53.6" x 27.6" x 25.2") NOTE: Measurement Conditions 1) Without the ADF 2) Without the table Weight: America, Europe, Asia (Except for Chinese Version) 85 kg (187.4 lb) China 87 kg (191.8 lb) (Excluding ADF, platen cover, ink, and master) C249...
  • Page 213 10% to 95% RH Recommended maximum storage period: One year after production date Note: Avoid locations exposed to direct sunlight. Ink Type: 600 ml cartridge type Available colors: Black, Red, Blue, Green, Brown, Purple, Yellow, Navy, Maroon, Orange, Teal, and Gray C249...
  • Page 214 Note: Avoid locations exposed to direct sunlight. • Platen cover Optional Equipment: • Automatic document feeder • Color drum • A4 black drum • Tape marker (dispenser) • Key Counter • PC Controller (EarlGray-Lt) Note: China model is equipped a standard PC Controller (UC5). C249...
  • Page 215 C264...
  • Page 217 Rev. 10/2006 C264 TABLE OF CONTENTS 1. INSTALLATION................1-1 1.1 INSTALLATION REQUIREMENTS ............1-1 1.1.1 OPTIMUM ENVIRONMENTAL CONDITION........1-1 1.1.2 ENVIRONMENTS TO AVOID............1-1 1.1.3 POWER CONNECTION ..............1-1 1.1.4 MACHINE ACCESS .................1-2 1.1.5 POWER SOCKETS FOR PERIPHERALS ........1-3 1.2 INSTALLATION PROCEDURE ..............1-4 1.2.1 MAIN UNIT ..................1-4 Accessory Check ..................1-4 Installation Procedure ................1-5 1.2.2 PLATEN COVER INSTALLATION (OPTION) ........1-11...
  • Page 218 3.3.4 EXPOSURE LAMP (XENON LAMP) ..........3-7 3.3.5 SCANNER WIRES ................3-8 Installation.....................3-8 3.3.6 IMAGE ADJUSTMENT ..............3-10 3.4 MASTER EJECT ..................3-11 3.4.1 MASTER EJECT UNIT ..............3-11 3.5 MASTER FEED ..................3-12 3.5.1 MASTER MAKING UNIT ..............3-12 3.5.2 THERMAL HEAD................3-12 Installation...................3-15 3.5.3 DUCT PLATE HP SENSOR / DUCT PLATE MOTOR....3-16 3.5.4 CUTTER UNIT................3-17 3.5.5 THERMAL HEAD DRIVING UNIT ..........3-17 3.5.6 DUCT JAM SENSOR ADJUSTMENT ..........3-18...
  • Page 219 3.11 OTHERS....................3-45 3.11.1 SOUND-PROOFING CUSHIONS..........3-45 Paper feed left, Paper feed right ............3-45 Paper exit....................3-46 Master eject unit cover................3-46 Base....................3-47 4. TROUBLESHOOTING ..............4-1 4.1 ERROR CODES..................4-1 4.2 ELECTRICAL COMPONENT DEFECTS ..........4-3 4.2.1 SENSORS ..................4-3 4.2.2 SWITCHES..................4-5 4.2.3 POWER SUPPLIES................4-5 4.3 FUSE, LED, VR, DIP-SW, AND TP TABLES ..........4-6 4.3.1 BLOWN FUSE CONDITIONS ............4-6 Main motor board..................4-6 PSU ......................4-6...
  • Page 220 5.3 MAIN MENU NO.2: BASIC SETTINGS .............5-4 5.3.1 SP TABLE ..................5-4 5.3.2 SP2-6 IMAGE POSITION DISPLAY ..........5-5 5.3.3 SP2-7: CHINESE DISPLAY SETTING (CHINA MODEL ONLY) ..5-5 5.3.4 SP2-28, 2-29, 2-38: IDLING AFTER PRINTING.......5-5 5.3.5 SP2-32: INK SUPPLY AFTER TRIAL..........5-5 5.3.6 SP2-33: RE-FEEDING SETTING .............5-6 5.3.7 SP2-34: SLOW STARTING MODE ..........5-6 5.3.8 SP2-35: PRINTING PRESSURE ADJUSTMENT ......5-6 5.3.9 SP2-36: INK IDLING ROLLER SETTING .........5-6...
  • Page 221 5.9.3 SP8-2: UPLOAD MAIN FIRMWARE..........5-31 5.9.4 SP8-10: TEST PATTERNS ............5-31 5.9.5 SP 8-18 - TEMPORARY SECURITY OFF........5-31 5.9.6 SP8-21: PAPER FEED TEST (15 RPM).........5-32 5.9.7 SP8-22: FREE RUN PAPER FEED (15 RPM) .......5-32 5.9.8 SP8-23: 30-45-60 RPM PRINT MODE ...........5-32 6.
  • Page 222 6.5.4 MASTER BUFFER MECHANISM...........6-19 6.5.5 DETECTION OF A MASTER IN THE LOWER MASTER TRAY ..6-20 6.5.6 DUCT PLATE MECHANISM ............6-21 Mechanism ..................6-21 Procedure ...................6-22 6.5.7 MASTER FEED MECHANISM ............6-23 Mechanism ..................6-23 Procedure ...................6-23 6.5.8 CLAMPER AND TENSION ROLLER MECHANISM.......6-24 Mechanism ..................6-24 Procedure ...................6-24 6.5.9 MASTER PUSH MYLAR ..............6-25 Mechanism ..................6-25...
  • Page 223 Paper size detection ................6-44 Table side fences and side-to-side shift..........6-45 6.8 PAPER DELIVERY..................6-46 6.8.1 OVERVIEW ..................6-46 Procedure ...................6-46 6.8.2 PAPER DELIVERY UNIT DRIVE MECHANISM......6-47 Mechanism ..................6-47 6.8.3 PAPER SEPARATION FROM THE DRUM ........6-48 Air knife....................6-48 Exit pawl air pump................6-48 6.8.4 EXIT PAWL DRIVE MECHANISM..........6-49 6.8.5 PAPER DELIVERY TABLE MECHANISM........6-50 6.8.6 ADJUSTABLE BUFFER FINS ............6-51 6.9 AUTO OFF MODE...................6-52...

  • Page 225: Important Safety Notices

    IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the power cord is unplugged. 2. The wall outlet should be near the printer 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.
  • Page 226 SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Dispose of replaced parts in accordance with local regulations. 2. Used ink and masters should be disposed of in an environmentally safe manner and in accordance with local regulations. 3. When keeping used lithium batteries (from the main processing units) in order to dispose of them later, do not store more than 100 batteries (from the main processing units) per sealed box.

  • Page 227: Installation

    INSTALLATION REQUIREMENTS 1. INSTALLATION 1.1 INSTALLATION REQUIREMENTS Carefully select the installation location. Environmental conditions greatly affect machine performance. 1.1.1 OPTIMUM ENVIRONMENTAL CONDITION 1. Temperature ⎯10 to 30 °C (50 to 86 °F) 2. Humidity ⎯20 to 90 % RH 3. Install the machine on a strong and level base. The machine must be level within 5 mm (0.2") both front to rear and left to right.

  • Page 228: Machine Access

    INSTALLATION REQUIREMENTS 1.1.4 MACHINE ACCESS Place the machine near a power source, providing clearance as shown below. This machine has a paper delivery table with buffer fins, so the width of the paper delivery table is changed from 136 cm (previous model) to 137 cm (this model). More than 10cm Paper Paper...

  • Page 229: Power Sockets For Peripherals

    INSTALLATION REQUIREMENTS 1.1.5 POWER SOCKETS FOR PERIPHERALS CAUTION Rating Voltage for Peripherals Make sure to plug the cables into the correct sockets. “Rating Voltage of Output Connector for Accessory: Max. DC 24 V” TAPE DISPENSER “Rating Voltage of Output Connector for Accessory: Max.

  • Page 230: Installation Procedure

    INSTALLATION PROCEDURE 1.2 INSTALLATION PROCEDURE 1.2.1 MAIN UNIT Accessory Check Make sure that you have all the accessories listed below: Description Q'ty 1. Master Spool................. 2 2. Carrying Handle Stoppers............. 4 3. Operating Instructions (sheet) (Excluding C264-53) ..............1 4. Operating Instructions (CD-ROM) (C264-53 only)................
  • Page 231 INSTALLATION PROCEDURE Installation Procedure 1. Unpack the box. When installing the optional table, mount the machine as shown (there are 2 screws [A] packed with the table). CAUTION Only lift with the carrying handles on the bottom corners of the machine. Secure the machine on the table with the 2 screws [A] provided.
  • Page 232 INSTALLATION PROCEDURE 2. Push the carrying handles [C] into the machine, and attach the carrying handle stoppers [D]. 3. Remove the filament tape and string securing the covers and units as shown above. C264 C264...
  • Page 233 INSTALLATION PROCEDURE 4. Remove the front tape [E], the tag [F], and the rear tape [G]. NOTE: To remove the rear tape, pull the portion shown in the diagram toward the front of the machine. 5. Pull out the master making unit, and take out the accessory bag [H].

  • Page 234: Installation Procedure

    INSTALLATION PROCEDURE 7. Install the master roll as shown above. 8. Insert the leading edge of the master roll under the platen roller. The arrows [I] indicate the correct position of the master leading edge. 9. Close the cover [J] using both hands. C264 C264...
  • Page 235 INSTALLATION PROCEDURE 10. Set the master-making unit. 11. Open the door, and insert a new ink cartridge [K]. 12. Open the paper table, and load a stack of paper. 13. Make sure that the side plates [L] touch the paper gently. Shift the lock lever [M] in the direction of the arrow.
  • Page 236 INSTALLATION PROCEDURE 16. Firmly insert the power plug in the outlet. 17. Make sure that the wall outlet is near the machine and easily accessible. 18. Turn on the main switch [O]. 19. Press the “Economy mode” key while holding down the “0” key, to supply ink inside the drum.

  • Page 237: Platen Cover Installation (Option)

    INSTALLATION PROCEDURE 1.2.2 PLATEN COVER INSTALLATION (OPTION) Accessory Check Check the quantity and condition of the accessories in the box against the following list: Description Q'ty 1. Stepped Screw................2 Installation Procedure 1. Install the platen cover [A] (2 screws). 1-11 C264...

  • Page 238: Adf Installation (Option)

    INSTALLATION PROCEDURE 1.2.3 ADF INSTALLATION (OPTION) Accessory Check Check the quantity and condition of the accessories in the box against the following list: Description Q'ty 1. Stepped Screw ................. 2 2. Screws ..................3 3. Screwdriver................1 4. DF Exposure Glass..............1 5.
  • Page 239 INSTALLATION PROCEDURE Installation Procedure 1. Remove the strips of tape. 1-13 C264...

  • Page 240: Installation Procedure

    INSTALLATION PROCEDURE 2. Remove the left scale [A] (2 screws). 3. Place the DF exposure glass [B] on the glass holder. NOTE: When installing the DF exposure glass, make sure that the white point [C] is positioned at the lower front side, as shown. 4.
  • Page 241 INSTALLATION PROCEDURE 8. Connect the cables [I] and [J] to the main body. 9. Attach the scale decal [K] as shown. 10. Plug in the power cord, then turn the main switch on. 11. Make a full size copy using the ADF. Then check to make sure the side-to-side and leading edge registrations are correct.

  • Page 242: Adf Stabilizer Installation

    INSTALLATION PROCEDURE ADF stabilizer installation 1. Attach the two stabilizer brackets [A] to the back of the table using the thumbscrews (4 screws). 2. Attach the caution label [B], as shown. CAUTION This procedure must be done to prevent the machine from falling backwards when the ADF is open.

  • Page 243: Tape Dispenser Type 20 (Option)

    5. Auxiliary Bracket (For C238, C247 and C249)....1 6. Auxiliary Bracket (For C264 only) ........1 7. Screw M4 x 8 (For C226, C238, C247, C249, C264 and C267) .................. 4 8. Lock Washer (For C226 only) ..........1 9.

  • Page 244: Installation Procedure

    INSTALLATION PROCEDURE Installation Procedure - For C264 – C256I902.WMF 1. Turn off the main switch and unplug the power cord. 2. Remove the paper delivery plate (4 screws). 3. Cut off the cover [A] in the rear cover, as shown. 4.
  • Page 245 INSTALLATION PROCEDURE 9. Open the tape dispenser cover [I]. Then, insert the leading edge of the tape into the tape entrance until it stops as shown in the illustration [J]. NOTE: Be sure that the tape is installed in the proper direction. If it is not, the tape marker will not work correctly.

  • Page 246: Optional Drums

    INSTALLATION PROCEDURE 1.2.5 OPTIONAL DRUMS There are two types of optional drum units: A3 Size: Color drum A4 Size: Black drum (Black ink only) 1. Remove the protective sheet [A] and the lock [B] from the drum unit. 2. Remove the tape securing the ink holder. 3.

  • Page 247: Interface Board Type 45 (Option)

    INSTALLATION PROCEDURE 1.2.6 INTERFACE BOARD TYPE 45 (OPTION) Accessory check Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Interface Board ................1 2. Interface Cable ................1 3. Printer Controller Unit Case ............1 4.
  • Page 248 INSTALLATION PROCEDURE Installation procedure 1. Attach the three brackets [A], [B], [C] ( x 6) 2. Remove the rear covers [D], [E] and I/F connector cover [F] ( x 10). C264 1-22 C264...
  • Page 249 INSTALLATION PROCEDURE 3. Connect CN101 [G] on the interface board to CN117 [H] on the MPU ( x 2). 4. Clamp the interface cable [I] at the positions shown. 5. Connect the short end of the interface cable [J] (4-pin connector) to the main harness [K] (narrow 4-pin connector).
  • Page 250 INSTALLATION PROCEDURE 8. Attach the core [O] to the interface cable [I]. 9. Attach the cable clamp [P] to the printer controller unit case [Q] ( x 2). 10. Attach the printer controller unit case [Q] to the machine ( x 4).

  • Page 251: Printer Unit Vc-20 (Option)

    INSTALLATION PROCEDURE Rev. 10/2006 ⇒ 1.2.7 PRINTER UNIT VC-20 (OPTION) IMPORTANT: The Interface Board Type 45 (option) ( 1.2.6) is necessary to install the Printer Unit VC-20 (option). Accessory Check Make sure that you have all the accessories listed below. C264I910.WMF Description Q’ty...
  • Page 252 INSTALLATION PROCEDURE Rev. 10/2006 Installation Procedure CAUTION To avoid serious injury, do not connect the power plug to the machine until you are instructed to do so. C264I901.WMF 1. Attach the three brackets [A], [B], [C] ( x 6). C264I902.WMF 2.
  • Page 253 INSTALLATION PROCEDURE Rev. 10/2006 C264I001.WMF 3. Connect CN101 [G] on the interface board to CN117 [H] on the MPU ( x 2). 4. Clamp the interface cable [I] at the positions shown. 5. Connect the short end of the interface cable [J] (4-pin connector) to the main harness [K] (narrow 4-pin connector).
  • Page 254 INSTALLATION PROCEDURE Rev. 10/2006 C264I002.WMF 8. Attach the core [O] to the interface cable [I]. 9. Attach the cable clamp [P] to the printer controller unit case [Q] ( x 2). 10. Attach the printer controller unit case [Q] to the machine ( x 4). 11.

  • Page 255: Preventive Maintenance

    MAINTENANCE TABLE 2. PREVENTIVE MAINTENANCE 2.1 MAINTENANCE TABLE The following items should be maintained periodically. There are two sets of intervals - one based on time and the other based on print count. For maintenance items with entries in both of them, use whichever comes first. C: Clean, R: Replace, L: Lubricate, A: Adjust Interval Time...
  • Page 256 MAINTENANCE TABLE Interval Time Print Counter NOTE Item 1M 1.2M 2M 2.4M 3M Drum and Ink Supply Cloth Screen Ink Roller One-way 3.8.6 Clutch Drum Drive Gears Grease and Cam [D] (Alvania Ink Pump Gears [E] Motor Oil (SAE #20) In/Outside of Drum Alcohol Ink Nozzle...

  • Page 257: Replacement And Adjustment

    GENERAL CAUTION 3. REPLACEMENT AND ADJUSTMENT 3.1 GENERAL CAUTION CAUTION Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. NOTE: This manual uses several symbols. The meaning of those symbols are as follows: : See or Refer to : screw...

  • Page 258: Print Key / Master Making Key

    COVERS / BOARDS [A]: Rear left cover ( x 5) [B]: Rear right cover ( x 3) [C]: Upper left cover ( x 2) [D]: Rear upper cover 3.2.3 PRINT KEY / MASTER MAKING KEY [E]: Key Cover [F]: Print start key [G]: Master making key C264...

  • Page 259: Mpu

    COVERS / BOARDS 3.2.4 MPU • Rear left cover, Rear right cover ( 3.2.2) [A]: MPU ( x 17, x 6, 9 clamps) CAUTION: Move the RAM [B] from the old board to the new one, so that the SP mode settings will be transferred to the new board.

  • Page 260: Scanner

    SCANNER 3.3 SCANNER 3.3.1 EXPOSURE GLASS / SCALES [A]: Left scale ( x 2) [B]: Upper scale ( x 3) [C]: Exposure glass 3.3.2 SBU AND LAMP STABILIZER / SCANNER MOTOR • Left scale, Upper scale, Exposure glass ( 3.3.1) •...
  • Page 261 SCANNER [B]: SBU ( x 1, x 5) [C]: Lamp stabilizer ( x 2, x 5) C264...
  • Page 262 SCANNER [D]: Scanner motor ( x 2, 1 spring) 3.3.3 SCANNER H.P. SENSOR / PLATEN COVER SENSOR • Left scale, Upper scale, Exposure glass ( 3.3.1) • Operation panel ( 3.2.1) • Rear upper cover ( 3.2.2) [A]: Platen cover sensor ( x 1) [B]: Left stay ( x 1)

  • Page 263: Exposure Lamp (Xenon Lamp)

    SCANNER 3.3.4 EXPOSURE LAMP (XENON LAMP) • Move the first scanner next to the opening in the frame. • Exposure glass ( 3.3.1) • [1]: Left stay ( 3.3.3) [A]: Platen base ( x 1, x 5) [B]: Rear frame ( x 1, x 2) [C]: Front frame (...

  • Page 264: Scanner Wires

    SCANNER 3.3.5 SCANNER WIRES • Move the first scanner next to the opening in the frame. • Exposure glass ( 3.3.1) • SBU cover ( 3.3.2) • Left stay ( 3.3.3) 1. First scanner ([1]: 2 pins) NOTE: The drawings show only the front side. Repeat to remove components on the other side.
  • Page 265 SCANNER C249R047.WMF 8. Secure the first scanner with the pins [E]. 9. Tighten the screw securing the tension bracket [F]. 10. Secure the scanner drive pulley [G] (1 Allen screw). 11. Remove the scanner positioning pins [H] (P/N: #A0069104). 12. Slide the scanner to the left and right several times, then set the scanner positioning pins to check the clamp position and wire tension bracket position again.

  • Page 266: Image Adjustment

    SCANNER 3.3.6 IMAGE ADJUSTMENT Purpose: To adjust the image position on prints by changing the SP settings. Adjust the following in the order given below. SP6-10: Master writing speed ( 5.7.3) ↓ SP6-21: Paper registration position ( 5.7.3) ↓ SP6-05: Scanning speed - platen ( 5.7.3) SP6-06: Scanning speed - ADF ↓...

  • Page 267: Master Eject

    MASTER EJECT 3.4 MASTER EJECT 3.4.1 MASTER EJECT UNIT [A]: Master eject unit ( x 1, x 2, 1 clamp) 3-11 C264...

  • Page 268: Master Making Unit

    MASTER FEED 3.5 MASTER FEED 3.5.1 MASTER MAKING UNIT [A]: Master making unit ( x 2) 3.5.2 THERMAL HEAD 1. Connect the power plug. Then turn on the main switch to access SP mode. 2. Select SP5-74 (T/H driving motor - up), then press the enter (#) key and turn off the main switch.
  • Page 269 MASTER FEED 3. Remove the master making unit ( 3.4.1) 4. Open the platen roller unit [1]. 5. Remove the following: [A]: T/H upper cover ( x 2) [B]: T/H side cover ( x 1) 6. Close the platen roller unit [1]. 7.
  • Page 270 MASTER FEED 8. Turn the thermal head clockwise and remove a tab ( ). 9. Turn the thermal head counterclockwise, and remove a tab ( ). 10. Remove the thermal head slowly. NOTE: If you cannot access SP modes, open the master making unit and loosen the 2 screws [D].

  • Page 271: Installation

    MASTER FEED Installation 1. Insert the tabs ( ) at the operation side and the middle. 2. Turn the thermal head counterclockwise and insert the tab ( ) at the front. 3. Turn the thermal head clockwise and insert the tab ( ) at the non-operation side.

  • Page 272: Duct Plate Hp Sensor / Duct Plate Motor

    MASTER FEED 3.5.3 DUCT PLATE HP SENSOR / DUCT PLATE MOTOR • Master making unit ( 3.4.1) [A]: Rear cover ( x 2) [B]: Duct plate HP sensor ( x 1, x 1) [C]: Rear rail bracket ( x 2) [D]: Duct plate motor ( x 1, x 2)

  • Page 273: Cutter Unit

    MASTER FEED 3.5.4 CUTTER UNIT [A]: Cutter unit ( x 1, x 1) 3.5.5 THERMAL HEAD DRIVING UNIT • Thermal head ( 3.5.2) • Rear cover ( 3.2.2) • Cutter unit ( 3.5.4) [A]: Anti-static roller ( x 2) [B]: Thermal head driving unit ( x 2, x 2) 3-17...

  • Page 274: Duct Jam Sensor Adjustment

    MASTER FEED 3.5.6 DUCT JAM SENSOR ADJUSTMENT Ensures that the sensor detects when a master remains in the duct. Standard: 0.5 volts (within “+0.1” and “-0.1”volts) Tools: Circuit tester • Rear cover ( 3.2.2) 1. Check if a master remains in the duct. If a master remains in the duct, remove the master from the duct.

  • Page 275: Master Edge Sensor Adjustment

    MASTER FEED 3.5.7 MASTER EDGE SENSOR ADJUSTMENT Ensures that the sensor detects the leading edge of the master. Standard: 2.0 volts (within “+0.1” and “-0.1”volts) Tools: Circuit tester • Rear cover ( 3.2.2) 1. Connect the terminals of a circuit tester to TP103 and a grounded place (e.g. iron base) 2.

  • Page 276: 2Nd Drum Master Sensor Adjustment

    MASTER FEED Standard Value Standard Value Threshold level (SP6-51) Master present Master not present 2.0 ±0.1V 2.8V Above 3.3V 3.5.8 2ND DRUM MASTER SENSOR ADJUSTMENT Ensures that the sensor detects if there is a master on the drum. Standard: 2.0 volts (within “+0.1” and “-0.1”volts) Tools: Circuit tester •...

  • Page 277: Master End Sensor Adjustment

    MASTER FEED NOTE: When the voltage cannot be adjusted to the standard value, adjust the threshold level of the 2nd drum master sensor. (SP6-53: 2nd drum master sensor voltage) Standard Value Standard Value Threshold level (SP6-53) Master present Master not present 2.0 ±0.1V 1.0V Below 0.8V...
  • Page 278 MASTER FEED NOTE: Please refer to the following table for the standard voltages. If the voltage cannot be adjusted to the standard value, do not change the threshold level using SP6-50. Standard value When set a new roll End mark only Master end (4 layers of master (master present) on the core)

  • Page 279: Thermal Head Voltage Adjustment

    MASTER FEED 3.5.10 THERMAL HEAD VOLTAGE ADJUSTMENT CAUTION This adjustment is always required when the thermal head or PSU has been replaced. Purpose: To maintain master making quality and extend the lifetime of the thermal head. Standard: Refer to the voltage value (X) printed on the thermal head. The value varies from one thermal head to another.

  • Page 280: Paper Feed

    PAPER FEED 3.6 PAPER FEED 3.6.1 PICK-UP ROLLER / PAPER FEED ROLLER / FRICTION PAD • Lower the paper table. [A]: Pick-up roller ( x 1) [B]: Paper guide ( x 1) [C]: Feed roller ( x 1) [D]: Friction pad 3.6.2 PAPER SEPARATION PRESSURE ADJUSTMENT Purpose: To ensure that the friction pad exerts sufficient pressure for smooth printing paper separation.

  • Page 281: Paper Width Detection Board

    PAPER FEED 3.6.3 PAPER WIDTH DETECTION BOARD • Lower the paper table. [A]: Paper table ( x 1, x 2) [B]: Table cover ( x 5, 3 washers) [C]: Sensor cover ( x 2) [D]: Paper width detection board ( x 1, x 1) 3-25...

  • Page 282: Printing

    PRINTING 3.7 PRINTING 3.7.1 PRESS ROLLER CAUTION Take care to avoid possible injury. If the printing pressure release arms disengage, the press roller will be pulled upwards suddenly. • Remove the drum. [A]: Press roller ( x 1) The bearings on the rear and front differ. During installation, ensure that the bearing with the stopper [B] is positioned towards the rear of the machine.

  • Page 283: Press Roller Release Lever Adjustment

    PRINTING 3.7.2 PRESS ROLLER RELEASE LEVER ADJUSTMENT Purpose: To maintain the correct clearance between the press roller arms and press roller lock levers. This ensures that the press roller is correctly released and pressed against the drum when the press roller release solenoid is energized. Standard: 0.7 to 1.2 mm Tools: A thickness gauge •...

  • Page 284: Printing Pressure Adjustment

    PRINTING 3. If it is not correct, adjust the position of the press roller lock lever after loosening the two screws [E]. 4. Repeat steps 2 and 3 for the front side. 3.7.3 PRINTING PRESSURE ADJUSTMENT Improves print results without decreasing the run length. Standard: Within 17 ±...

  • Page 285: Drum

    DRUM 3.8 DRUM 3.8.1 PREPARATION Before attempting any of the procedures in this section, wipe off the ink around the ink roller. To do this, set SP2-10 (ink detection) to OFF, and feed paper until ink ends. After finishing the required procedures in this section, do not forget to return SP2- 10 to the default (ink detection on).

  • Page 286: Installation

    DRUM Installation • Do not scratch the cloth screen or metal screen. • Properly insert the edge of the belt cloth [A] on the cloth screen under the mylar [B] on the metal screen, as shown above. Otherwise, ink will leak from the trailing edge of the master on the drum during a long printing run.

  • Page 287: Clamper / Metal Screen

    DRUM • Make sure that the cloth screen is not wrinkled while spreading it around the drum. 3.8.3 CLAMPER / METAL SCREEN • Remove the drum Cloth screen ( 3.8.2) [A]: Clamper lever (1 hexagon screw) [B]: Clamper - open the clamping plate [C], then remove the clamper. NOTE: 1) Do not allow ink to get on the inside of the clamping plate [C].

  • Page 288: Installation

    DRUM Installation • Make sure that the correct end of the metal screen is overlapping. (The right side overlaps, as viewed from the non-operation side, as shown above.) • The 4 screws holding the drum master clamper are longer than the 12 screws holding the metal screen, although they are similar in appearance.

  • Page 289: Mylar Seal

    DRUM 3.8.4 MYLAR SEAL A3 drum A4 drum [A]: -0.5 to 0.5 mm [B]: 5.6 to 7.2 mm Attach the mylar seal at the attachment position on the metal screen as shown above. NOTE: Clean the attachment position using isopropyl alcohol. 3-33 C264...

  • Page 290: Ink Pump Adjustment

    DRUM 3.8.5 INK PUMP ADJUSTMENT Purpose: To ensure the smooth operation of the ink pump plunger by properly positioning its holder. • Remove the drum [A]: Lower pump cover ( x 2) [B]: Upper pump cover ( x 3) 1. Remove the E-ring [C] to free the plunger from the pump drive slider [D]. 2.
  • Page 291 DRUM 4. Check that the piston motion is smooth. 5. If the motion is stiff, loosen the pump screws [G] and adjust the pump position. 6. After tightening, repeat step 4 and step 3. 7. Re-tighten the two screws [H]. 8.

  • Page 292: Ink Roller Unit / Ink Roller One-Way Clutch

    DRUM 3.8.6 INK ROLLER UNIT / INK ROLLER ONE-WAY CLUTCH • Metal screen ( 3.8.3) • Pump covers ( 3.8.5) [A]: Board cover ( x 2) [B]: Front stay ( x 2, x 3) [C]: Front flange [D]: Rear stay ( x 2) [E]: Rear stoppers ( x 1)

  • Page 293: Idling Roller Motor / Idling Roller Hp Sensor

    DRUM [H]: Ink roller unit [I]: Ink roller one-way clutch 3.8.7 IDLING ROLLER MOTOR / IDLING ROLLER HP SENSOR • Cloth Screen ( 3.8.2) • Clamper / Metal Screen ( 3.8.3) 3-37 C264...

  • Page 294: Doctor Roller Gap Adjustment

    DRUM [A]: Idling roller HP sensor ( x 1, x 1) [B]: Idling roller motor ( x 1, x 2) 3.8.8 DOCTOR ROLLER GAP ADJUSTMENT Controls ink thickness around the ink roller. Standard: 0.07 mm gauge passes, 0.09 mm gauge does not. Tools: Thickness gauge CAUTION: Normally, the doctor roller gap is not adjusted or changed.

  • Page 295: Ink Detection Adjustment

    DRUM 3.8.9 INK DETECTION ADJUSTMENT Purpose: To ensure that the CPU detects a no-ink condition. CAUTION: Before attempting this procedure, wipe off the ink around the ink roller. To do this, set SP2-10 (ink detection) to OFF, and feed paper until ink ends.

  • Page 296: Main Drive Timing Belt Adjustment

    DRUM 3.8.11 MAIN DRIVE TIMING BELT ADJUSTMENT Purpose: After the timing belt is replaced, correct belt tension must be applied. • Rear covers ( 3.2.2) • MPU ( 3.2.4) 1. Loosen the screws [A], [B], and [C]. 2. Move the tension roller [D] to the right with a screwdriver [E] as shown. 3.

  • Page 297: Paper Delivery

    PAPER DELIVERY 3.9 PAPER DELIVERY 3.9.1 PAPER DELIVERY UNIT [A]: Paper delivery cover ( x 4) [B]: Paper delivery unit ( x 3, x 2) 3.9.2 FAN MOTOR, EXIT SENSOR • Paper delivery unit ( 3.9.1) [A]: Paper guide ( x 2) [B]: Delivery belts [C]: Vacuum fan motor (...

  • Page 298: Exit Pawl Adjustment

    PAPER DELIVERY 3.9.3 EXIT PAWL ADJUSTMENT Ensures that the exit pawls can move out of the way of the drum master clamper while the drum is rotating. Timing adjustment • Front cover ( 3.2.1) • Rear covers ( 3.2.2) NOTE: When releasing the stoppers from the brackets, note that the press roller goes up quickly.

  • Page 299: Clearance Adjustment

    PAPER DELIVERY Clearance adjustment • Do this after the timing adjustment. Standard: Within 0.80 ± 0.15 mm • Front cover ( 3.2.1) 1. Release the stopper at the operation side [A] from the pressure arm [B]. NOTE: Slide the stopper [A] to the left, and then lift the pressure arm [B]. 2.

  • Page 300: Air Pump Adjustment

    PAPER DELIVERY 3.9.4 AIR PUMP ADJUSTMENT Purpose: To ensure that the exit pawl produces a jet of air at the proper time. • Rear covers ( 3.2.2) 1. Check the recess in the drum drive gear meets the positioning hole [A] in the bracket, as shown.

  • Page 301: Chocks

    PAPER DELIVERY 3.9.5 CHOCKS [C]: Do not remove [C]: Do not remove [C]: Do not remove [C]: Do not remove [A]: Chocks ( x 2) [B]: Buffer fin bracket ( x 2 [C]) – Normally, do not disassemble parts [B] to [E] in the field.

  • Page 302: Special Tools

    SPECIAL TOOLS 3.10 SPECIAL TOOLS The following are the special tools used for service. Description Part number Note Scanner positioning pins (4 pins as a set) A006 9104 3.3.5 Flash memory card A230 9352 5.9.2 5.9.3 3.11 OTHERS 3.11.1 SOUND-PROOFING CUSHIONS The following are the attachment positions of the soundproofing cushions.

  • Page 303: Paper Exit

    OTHERS Paper exit [C]: 0.0 mm Master eject unit cover Master eject cover ( x 4) [D]: 0.0mm to 2.0mm 3-47 C264...

  • Page 304: Base

    OTHERS Base Paper delivery cover ( x 4) ( : 3.9.1) Short side Long side NOTE: Insert the soundproofing cushion from the paper delivery side, and push it towards the inside of the machine. The cushion has a short side and a long side, as shown above. Insert the cushion from the short side, and secure the cushion inside the machine at [E].

  • Page 305: Troubleshooting

    ERROR CODES 4. TROUBLESHOOTING 4.1 ERROR CODES Symptom Possible cause E-00 Clamper error Clamper drive The MPU cannot detect the clamper position sensor Clamper sensors signal (open or closed) within 3.0 seconds after the Clamper motor clamper motor turns on. E-01 Cutter error Cutter drive...
  • Page 306 ERROR CODES 24 February 2006 Symptom Possible cause E-22 Feed Timing Sensor error Drum sensors Feeler The 2 feed timing sensor does not activate before the paper exit timing sensor activates. E-23 Master Eject Position Sensor (Drum HP) error Drum sensors The master eject position sensor does not activate Feeler before the feed start timing sensor activates.

  • Page 307: Electrical Component Defects

    ELECTRICAL COMPONENT DEFECTS 4.2 ELECTRICAL COMPONENT DEFECTS 4.2.1 SENSORS Component Condition Symptom Master Eject Position (HP) Open E-23 is displayed whenever the drum rotates. Sensor Shorted Paper Exit Timing Sensor Open E-21 is displayed whenever the drum rotates. Shorted Feed Start Timing Sensor Open E-24 is displayed whenever the drum rotates.
  • Page 308 ELECTRICAL COMPONENT DEFECTS 24 February 2006 Component Condition Symptom Master Set Cover Sensor The “D” jam indicator is lit or E-01 is displayed Open whenever the cover isn’t placed correctly. Shorted The “open cover” and “D” indicators are lit. Master End Sensor Master making can start even if there is no White master roll, but the “D”...

  • Page 309: Switches

    ELECTRICAL COMPONENT DEFECTS 4.2.2 SWITCHES Component Condition Symptom Door Safety Switch Open The “open cover” indicator is lit. The “open cover” indicator is not lit even if the Shorted door is opened. Main Switch Open The machine does not turn on. Shorted The machine does not turn off.

  • Page 310: Fuse, Led, Vr, Dip-Sw, And Tp Tables

    FUSE, LED, VR, DIP-SW, AND TP TABLES 24 February 2006 4.3 FUSE, LED, VR, DIP-SW, AND TP TABLES 4.3.1 BLOWN FUSE CONDITIONS Main motor board Rate Symptom Fuse 10.0 A The “close the covers” indicator is lit. Rate Symptom FU700 6.3 A The machine does not turn on.

  • Page 311: Ink Detection Board

    FUSE, LED, VR, DIP-SW, AND TP TABLES Ink detection board Function 5.7.2) Adjusts the ink detection. ( 4.3.4 DIP SWITCHES Ink detection board Normal drum Color drum A4 black drum 4.3.5 TEST POINTS Function 3.5.9) TP101 Measures the master end sensor voltage. ( 3.5.6) TP102 Measures the duct jam sensor voltage.

  • Page 312: Others

    OTHERS 24 February 2006 4.4 OTHERS Discussed in accordance with C238/C249/C264 O/I: Operation Instruction S/M: Service Manual 4.4.1 PAPER FEED PROBLEMS Model Problem Cause Solution C264 Paper feed jam Dust build-up affects Clean the registration sensor with a operation of the dry cloth.
  • Page 313 C249 correct. S/M 5.7.3) C238 C249/C264: Adjust SP6-100 to 107 (paper registration - each speed) C238: Adjust SP6-23 (paper registration - each speed) RTB# RC238008a) C238: SP6-33 (paper registration - each speed, when image shifts...

  • Page 314: Feed Pressure/Separation Pressure Adjustment

    NOTE: Adjust feed pressure at first. If it does not improve, then adjust the separation pressure. 4.4.2 PAPER EJECTION PROBLEMS Model Problem Cause Solution C249 Non-feed jam The suction of the Attach the air reduction sheet at the (Thin paper) vacuum fan. (MB #MC238010) vacuum fan is too strong C238 at paper delivery unit.

  • Page 315: Master Feed Problems

    C264 Master feed Suction becomes weaker Pull out the master feed tray, and as pieces of master remove the broken pieces of C249 master. enter into the duct and (D jam) the vacuum fan. ( O/I Troubleshooting - Clearing Misfeeds)

  • Page 316: Poor Image

    The position of Adjust SP6-21 (paper registration registration registration is not right. position). ( S/M 5.7.3) C249 C249/C264: Adjust SP6-100 to 107 C238 (paper registration - each speed) C238: Adjust SP6-23 (paper registration - each speed) RTB# RC238008a) C238: SP6-33 (paper registration -...
  • Page 317 Ink is on the The edge of the paper Scotch tape is stuck on the broken paper’s leading tears the master. parts of the master. C249 edge. C238 * Envelopes, thick paper and others, which have sharp edges, tend to tear the master easily.

  • Page 318: Others

    24 February 2006 4.4.6 OTHERS Model Problem Cause Solution C249 Paper size The paper tray harness C249: Replace the paper tray misdetection is damaged. harness. C238 MB# MC249012) RTB#RC249012) C238: Replace the paper feed tray harness, paper size sensor stay and pad plate harness.

  • Page 319: User Instructions

    Cause Solution C264 B jam Incorrect master Do not insert the master too far into installation the machine. The leading edge of C249 the master must be fed until the (Inserted the master too C238 mark. far.) C264 D jam...

  • Page 320: Flow Charts

    OTHERS 24 February 2006 4.4.8 FLOW CHARTS C264 4-16...
  • Page 321 OTHERS 4-17 C264...

  • Page 323: Service Tables

    USING SERVICE PROGRAM MODES 5. SERVICE TABLES NOTE: The Service Program Mode is for use by service representatives only so that they can properly maintain product quality. If this mode is used by anyone other than service representatives for any reason, data might be deleted or settings might be changed.

  • Page 324: How To Select A Program Number

    USING SERVICE PROGRAM MODES 5.1.2 HOW TO SELECT A PROGRAM NUMBER 1. Using the number keys [A] or the keys [B] or the zoom keys [C], enter the desired main menu number (listed below), then press the Enter key [D] or the OK key [E].

  • Page 325: Main Menu No.1: Copy Data

    MAIN MENU NO.1: COPY DATA 5.2 MAIN MENU NO.1: COPY DATA 5.2.1 SP TABLE Menu Items Function Total master counter 1-20 Total print counter 1-50 D - master clamp jam 6.12 1-51 E - master eject jam 6.12 1-52 E - master compressing jam 6.12 1-53 A - paper non-feed jam 6.12...

  • Page 326: Main Menu No.2: Basic Settings

    MAIN MENU NO.2: BASIC SETTINGS 5.3 MAIN MENU NO.2: BASIC SETTINGS 5.3.1 SP TABLE Menu Items Default Settings Default print speed 1 to 5 Default image position -15.0mm to +15.0mm Destination code 264-XX Not used 0 to 2 Image position display 0:Slow 1:Normal 2:Fast ( 5.3.2) 0 to 1 (...

  • Page 327: Sp2-6 Image Position Display

    5.3.3 SP2-7: CHINESE DISPLAY SETTING (CHINA MODEL ONLY) To change the warning message after you have made a mistake to set different masters in the machine depends on the selling company. 0: Ricoh master type 1: Gestetner master type 5.3.4 SP2-28, 2-29, 2-38: IDLING AFTER PRINTING Ensures that the first print has sufficient ink density if the machine was not used for a long time.

  • Page 328: Sp2-33: Re-Feeding Setting

    MAIN MENU NO.2: BASIC SETTINGS 5.3.6 SP2-33: RE-FEEDING SETTING When the machine performs re-feeding, the paper registration position can be up to 5mm out of range. If this position is not acceptable to the customer, change this SP mode to “OFF”. ON: Re-feeding is on (factory setting).

  • Page 329: Sp2-41, 2-42: Thermal Head Energy Control

    MAIN MENU NO.2: BASIC SETTINGS 5.3.10 SP2-41, 2-42: THERMAL HEAD ENERGY CONTROL 2-41: The default is 7%. This means that during normal printing mode, the thermal head energy is 93% of the maximum possible (100 – 7). 2-42: The default is 10%. This means that in economy printing mode, the thermal head energy is reduced by another 10%.

  • Page 330: Main Menu No.3: System Settings

    MAIN MENU NO.3: SYSTEM SETTINGS 5.4 MAIN MENU NO.3: SYSTEM SETTINGS 5.4.1 SP TABLE Menu Items Default Settings 3-1 Input the present time 5.4.2 3-2 Input Tel number 3-3 Input serial number 3-4 Input installation date 5.4.3 3-10 Key counter setting No/Yes 5.4.2 SP3-1: INPUT THE PRESENT TIME Input the year, the month / date, and the time in that order.

  • Page 331: Sp3-4: Input Installation Date

    MAIN MENU NO.3: SYSTEM SETTINGS 5.4.3 SP3-4: INPUT INSTALLATION DATE Input the installation date as shown below. Press the Enter key between each one. Input the last two digits of the present year (two-digit number). ↓# Input the present month (two-digit number). ↓# Input the present date (two-digit number).

  • Page 332: Main Menu No.4: Input Mode

    MAIN MENU NO.4: INPUT MODE 5.5 MAIN MENU NO.4: INPUT MODE 5.5.1 SP TABLE Menu Items Menu Items 4-1 Scanner HP sensor 4-50 Door safety switch 4-2 Platen cover sensor 4-60 ADF connecting signal 4-9 Thermal head HP sensor 4-61 ADF cover sensor 4-10 Master making unit set switch 4-62 ADF registration sensor 4-11 Master set cover sensor...

  • Page 333: Main Menu No.5: Output Mode

    MAIN MENU NO.5: OUTPUT MODE 5.6 MAIN MENU NO.5: OUTPUT MODE 5.6.1 SP TABLE Menu Items Menu Items 5-1 Exposure lamp (xenon lamp) 5-43 Registration motor: 90 rpm 5-2 Scanner motor - scan 5-44 Registration motor: 105 rpm 5-3 Scanner motor - return 5-45 Registration motor: 120 rpm 5-4 Scanner to HP 5-46 Air knife fan motors...

  • Page 334: Sp Table

    MAIN MENU NO.6: ADJUSTMENT 5.7 MAIN MENU NO.6: ADJUSTMENT 5.7.1 SP TABLE Menu Items Default Settings 6-1 Main-scan position - platen -5.0 to 2.0 mm ( 5.7.3) 6-2 Main-scan position - ADF -5.0 to 5.0 mm ( 5.7.3) 6-3 Scan start position - platen -2.0 to 5.0 mm ( 5.7.3) 6-4 Scan start position - ADF...

  • Page 335: Main Menu No.6: Adjustment

    MAIN MENU NO.6: ADJUSTMENT Menu Items Default Settings 6-77 60rpm pressure: normal temp 1 to 5 ( 6.7.5) 6-78 75rpm pressure: normal temp 1 to 5 ( 6.7.5) 6-79 90rpm pressure: normal temp 1 to 5 ( 6.7.5) 6-80 105rpm pressure: normal temp 1 to 5 ( 6.7.5) 6-81 120rpm pressure: normal temp...
  • Page 336 MAIN MENU NO.6: ADJUSTMENT Menu Items Default Settings 6-136 Paper Regist: A4 drum 75 (Not used) -40 to 40 6-137 Paper Regist: A4 drum 90 (Not used) -40 to 40 6-138 Paper Regist: A4 drum 105 (Not used) -40 to 40 6-139 Paper Regist: A4 drum 120 (Not used) -40 to 40 6-140 Paper Regist: skip: A4: 15 (Not used)

  • Page 337: Sp6-40: Ink Detection Adjustment

    MAIN MENU NO.6: ADJUSTMENT 5.7.2 SP6-40: INK DETECTION ADJUSTMENT Ensures that the CPU detects a no ink condition. CAUTION: Before attempting this procedure, wipe off the ink around the ink roller. To do this, set SP2-10 (ink detection) to OFF, and feed paper until ink ends.

  • Page 338: Image Adjustment (Sp6-10, -21, -5, -3, And -1)

    MAIN MENU NO.6: ADJUSTMENT 5.7.3 IMAGE ADJUSTMENT (SP6-10, -21, -5, -3, AND -1) Adjusts the image position on prints by changing the SP settings. Adjust the following in the given order. SP6-10: Master writing speed ↓ SP6-21: Paper registration position ↓...
  • Page 339 MAIN MENU NO.6: ADJUSTMENT SP6-10: Master writing speed 1. Input SP8-10 (Test patterns) and enter “6”, then press the Start key. 2. Exit the SP mode, then print 10 copies at 90 rpm (speed 3). Use the 10th print for the adjustment. 3.
  • Page 340 MAIN MENU NO.6: ADJUSTMENT SP6-05: Scanning speed - platen SP6-06: Scanning speed - ADF 1. Make copies of the test pattern printed during the previous adjustments ( previous page), in platen mode at 90 rpm (speed 3). Use the 10th print for the adjustment.

  • Page 341: Sp6-32 To 37: Mtf Filter

    MAIN MENU NO.6: ADJUSTMENT 5.7.4 SP6-31: SBU CALIBRATION Do this after one of the following is replaced: • RAM on the MPU • White plate located behind the original scale . Do it at the end of the image adjustment procedure ( 5.7.3) 1.

  • Page 342: Sp6-20: Registration Buckle (Not Used)

    MAIN MENU NO.6: ADJUSTMENT 5.7.6 SP6-20: REGISTRATION BUCKLE (NOT USED) Adjusts the paper skew and the paper registration slippage. [A]: Increase the value The occurrence of paper skew will be reduced, but the paper is more likely to slip and the registration position may be incorrect. [B]: Decrease the value The paper registration position is more likely to be correct.

  • Page 343: Sp6-100 To 107: Paper Registration - Each Speed

    MAIN MENU NO.6: ADJUSTMENT 5.7.9 SP6-100 TO 107: PAPER REGISTRATION - EACH SPEED The following procedure allows the image position to be adjusted for each speed (15, 30, 60, 90 and 120 rpm) NOTE: If you want to adjust the image position for all speeds at the same time, use SP6-21 (Paper registration position).
  • Page 344 MAIN MENU NO.6: ADJUSTMENT 6. If this distance is not 8 mm, access SP6-101 to 107 and then input a value to adjust the distance (range: -40 to 40, step: 1) for each of 6 copy samples. To adjust the distance for 30 cpm, use SP 6-101. To adjust the distance for 45 cpm, use SP 6-102.

  • Page 345: Sp6-116 To 123: Paper Middle Buckle (Not Used)

    MAIN MENU NO.6: ADJUSTMENT 5.7.10 SP6-116 TO 123: PAPER MIDDLE BUCKLE (NOT USED) Adjusts doubled [A] or blurred [B] images (e.g. bold lines, text) for each printing speed (15, 30, 60, 75, 90, 105, 120 rpm), by changing SP settings. 200mm 50mm 5-23...
  • Page 346 MAIN MENU NO.6: ADJUSTMENT 1. Set SP2-34 (Slow starting mode) to a value of “30 rpm” (print from 30rpm). 2. Set SP8-10 (Test patterns) to a value of “6”, then press the Start key. 3. Access SP4-91 (Ink temperature), then check the ink temperature. 4.
  • Page 347 MAIN MENU NO.6: ADJUSTMENT 5. Check the area from the leading edge to about 50 to 200mm down for any doubled or blurred images. 6. If any are present, access SP6-117 to 123 and then input a value to adjust the doubled or blurred images (range: -100 to 100, step: 1) for each of 6 copies samples To adjust the distance for 30 cpm, use SP 6-117.

  • Page 348: Sp6-124 To 131: Paper Front Buckle (Not Used)

    MAIN MENU NO.6: ADJUSTMENT 5.7.11 SP6-124 TO 131: PAPER FRONT BUCKLE (NOT USED) Adjusts doubled [A] or blurred [B] images (e.g. bold lines, text) for each printing speed (15, 30, 60, 75, 90, 105, 120 rpm), by changing SP settings. 1.
  • Page 349 MAIN MENU NO.6: ADJUSTMENT 2. Set SP8-10 (Test patterns) to a value of “6”, then press the Start key. 3. Access SP4-91 (Ink temperature), then check the ink temperature. 4. Make 6 copies at speed 5 (finishing with 120 rpm). Perform the adjustment below for all 6 copies.

  • Page 350: Main Menu No.7: Memory Clear

    MAIN MENU NO.7: MEMORY CLEAR 5.8 MAIN MENU NO.7: MEMORY CLEAR 5.8.1 SP TABLE Menu Items Default Settings 7-1 Factory settings clear Hold 0 & push # to clear ( 5.8.2) 7-3 Total counter clear Hold 0& push # to clear 7-4 Jam/Error data clear Hold 0 &...

  • Page 351: Main Menu No.8: System Test

    MAIN MENU NO.8: SYSTEM TEST 5.9 MAIN MENU NO.8: SYSTEM TEST 5.9.1 SP TABLE Menu Items Default Settings 8-1 Download main firmware Start with # key ( 5.9.2) 8-2 Upload main firmware Start with # key ( 5.9.3) Test patterns Pattern 6 (1-9) A4 start 8-10 with # (...

  • Page 352: Sp8-2: Upload Main Firmware

    MAIN MENU NO.8: SYSTEM TEST 5.9.3 SP8-2: UPLOAD MAIN FIRMWARE Writes firmware to a flash memory card (P/N’ #A2309352) from the machine. 1. Refer to steps 3 to 5 of section 5.9.2. 2. Connect the power cord, then turn on the main switch while holding the Clear modes key.

  • Page 353: Sp8-21: Paper Feed Test (15 Rpm)

    MAIN MENU NO.8: SYSTEM TEST “Security Mode” is used to prevent others from accessing the master on the drum and making prints of confidential documents. When you set “Security Mode”: • You cannot press the “Proof” key or the “Print” key while the previous master is on the drum •...

  • Page 355: Detailed Section Descriptions

    MECHANISM OVERVIEW 6. DETAILED SECTION DESCRIPTIONS 6.1 MECHANISM OVERVIEW 6.1.1 COMPONENT LAYOUT 2 3 4 19 18 17 16 15 1. Lens 14. Doctor roller 2. CCD and SBU 15. Ink roller 3. Blower fan motor 16. Press roller 4. Tension roller 17.

  • Page 356: Electrical Component Layout

    MECHANISM OVERVIEW 6.1.2 ELECTRICAL COMPONENT LAYOUT C267...
  • Page 357 MECHANISM OVERVIEW C264...
  • Page 358 MECHANISM OVERVIEW C267...

  • Page 359: Boards

    MECHANISM OVERVIEW Boards Component Function Main Processing Unit (MPU) Controls all machine functions, both directly and through other boards. Lamp Stabilizer This supplies power to the exposure lamp. Power Supply Unit (PSU) Provides dc power to the machine. Operation Panel Boards These boards control the operation panel.

  • Page 360: Sensors

    MECHANISM OVERVIEW Sensors Component Function Master Eject Position (Drum Detects when the drum is at the master eject HP) Sensor position. Paper Exit Timing Sensor Determines the paper exit misfeed check timing. Feed Start Timing Sensor Determines the paper feed start timing. Master Eject Sensor Detects used master misfeeds.

  • Page 361: Switches

    MECHANISM OVERVIEW Switches Component Function Table Lowering Switch Lowers the paper table. Door Safety Switch Checks whether the front door is properly closed. Main Switch Turns the power on or off. Master Making Unit Set Switch Checks if the master making unit is installed. Eject Box Set Switch Checks if the master eject box is installed.

  • Page 362: Drive Layout

    MECHANISM OVERVIEW 6.1.3 DRIVE LAYOUT 1. Pressure plate motor 7. Paper feed motor 2. Clamper motor 8. Master feed motor 3. Paper delivery motor 9. Scanner motor 4. Main motor 10. Thermal head driving motor 5. Registration motor 11. Duct plate motor 6.

  • Page 363: Master Eject Unit

    MASTER EJECT UNIT 6.2 MASTER EJECT UNIT 6.2.1 OVERVIEW Overview The master eject unit removes the used master from the drum. ( : Digital Duplicators – Duplicating Process – Master Ejecting) Procedure The drum turns to the master eject position. Then the clamper [A] opens. ↓...

  • Page 364: Master Clamper Opening Mecheanism

    MASTER EJECT UNIT 6.2.2 MASTER CLAMPER OPENING MECHEANISM Clamper Mechanism Clamper motor [A] - opens the clamper at the master eject position ↓ Gears [B] ↓ Link [C] ↓ Drum guide [D] - moves and engages the pin on the rear flange of the drum ↓...

  • Page 365: Master Eject Roller Mechanism

    MASTER EJECT UNIT 6.2.3 MASTER EJECT ROLLER MECHANISM Mechanism Master eject motor [A] ↓ Belt [B] ↓ Gears [C] ↓ Master eject rollers [D] – the upper roller has paddles ↓ Pick up the master and feed it into the master eject box Procedure 1.

  • Page 366: Mechanism

    MASTER EJECT UNIT 6.2.4 PRESSURE PLATE MECHANISM Mechanism Pressure plate motor [A] ↓ Gears [B] ↓ Pressure plate rotates ↓ Compresses the masters Procedure 1. After the master has been ejected and the drum is stopped at the master feed position, the pressure plate motor turns until the actuator on the pressure plate actuates the limit sensor [D].
  • Page 367 SCANNER UNIT SCANNER UNIT 6.3.1 OVERVIEW [J]: Exposure lamp [J]: Charge coupled device (CCD) [J]: First mirror [J]: Second mirror [J]: Third mirror [J]: Lens • The exposure lamp is a xenon lamp (DC 24V). • Light reflected off the original is directed onto a CCD via the mirrors and the lens. •...

  • Page 368: Image Processing

    IMAGE PROCESSING 6.4 IMAGE PROCESSING 6.4.1 OVERVIEW • The CCD line has 7,450 pixels and the resolution is 600 dpi (23.6 lines/mm). • The A/D converter in the SBU transforms the analog signals into 8-bit digital signals. The MPU carries out the following processes on the image data: Auto shading ↓...

  • Page 369: Mtf Filter

    IMAGE PROCESSING 6.4.2 MTF FILTER • The MTF filter is used in all modes (Letter, Letter/Photo, Photo, and Tint). • This model has SP mode adjustments (SP 6-32 to 6-37, see section 5.7.5). 6.4.3 SMOOTHING FILTER • The Smoothing filter is used in Photo mode only. •...

  • Page 370: Thermal Head

    IMAGE PROCESSING 6.4.5 THERMAL HEAD Specifications Length: 292.6 mm Number of thermal head elements: 4068 dots Density of thermal head elements: 400 dpi Thermal head control The thermal head contains heating elements at a density of 400 dpi. The thermal heating elements melt the over-coating and polyester film layers of the master, in accordance with the image signal for each pixel.

  • Page 371: Master Feed

    MASTER FEED MASTER FEED 6.5.1 OVERVIEW The master feed unit makes an image on the master and feeds the master to the drum. Procedure The machine feeds the master from the master roll [A]. ↓ The thermal head [B] makes an image on the master. The master is fed into the master buffer duct [C].

  • Page 372: Procedure

    MASTER FEED 6.5.2 AUTO ADJUSTABLE MASTER SET (2-1) (2-2) When the customer installs a master roll in the master making unit, the machine automatically adjusts the position of the leading edge of the master. Procedure The duct plate moves to the open position [A] from the middle position. (1) ↓...

  • Page 373: Thermal Head Driving Mechanism

    MASTER FEED 6.5.3 THERMAL HEAD DRIVING MECHANISM Mechanism Thermal head driving motor [A] ↓ Gears [B] ↓ Thermal head release cam [C] ↓ Thermal head base [D] is released from the platen roller [E]. Thermal head HP sensor [F] has two stop positions: •...

  • Page 374: Master Buffer Mechanism

    MASTER FEED 6.5.4 MASTER BUFFER MECHANISM The master is stored in the master buffer duct [A] by the three master vacuum fans [B] after the thermal head transfers the image to it. The stored master is fed out from the duct when the drum reaches the master making position after the master has ejected.

  • Page 375: Detection Of A Master In The Lower Master Tray

    MASTER FEED 6.5.5 DETECTION OF A MASTER IN THE LOWER MASTER TRAY [J]: Duct jam sensor • The duct jam sensor [A] detects whether there is a master in the lower master tray or not. • When the duct jam sensor detects a master, the “D” jam indicator comes on. If this happens, open the lower master tray [B] and remove the misfed master.

  • Page 376: Duct Plate Mechanism

    MASTER FEED 6.5.6 DUCT PLATE MECHANISM Mechanism Duct plate motor [A] ↓ Gears [B] ↓ The duct plate [C] moves The duct plate motor HP sensor [D] has four stop positions: • The duct plate close position ( ) • The duct plate middle position ( ) •...
  • Page 377 MASTER FEED Procedure The duct plate [A] is in the middle position before printing. (1) ↓ The duct plate moves to the close position when the master is fed until the master tension roller [B] catches the leading edge of the master. (2) ↓...

  • Page 378: Procedure

    MASTER FEED 6.5.7 MASTER FEED MECHANISM Mechanism Master feed motor [A] (stepper motor) ↓ Gears [B] ↓ Platen roller [C], master feed roller [D] ↓ Feeds the master (The thermal head makes an image on the master.) Procedure 1. After the old master has been ejected, the drum stops at the master feed position and the master clamper opens, ready to clamp the new master.

  • Page 379: Procedure

    MASTER FEED 6.5.8 CLAMPER AND TENSION ROLLER MECHANISM Mechanism Clamper motor [A] ↓ Gears [B] ↓ Link [C] ↓ Drum guide [D] ↓ Lifts the lever [E], engages and locks the drum pin [F], and opens the clamper plate [G]. ↓...

  • Page 380: Mechanism

    MASTER FEED 6.5.9 MASTER PUSH MYLAR Mechanism Duct plate motor [A] ↓ Gears [B] ↓ The master push mylar [C] pushes the master against the drum. This is done to distribute ink through the master. • The 2nd drum master [D] sensor prevents contact between the master push mylar and the drum when there is no master on the drum.

  • Page 381: Detection Of Masters On The Drum

    MASTER FEED 6.5.10 DETECTION OF MASTERS ON THE DRUM [J]: Drum master sensor [J]: Black patch on the screen [J]: Black patch on the clamper • The drum master sensor [A] detects whether there is a master on the drum. •...

  • Page 382: 2Nd Drum Master Sensor

    MASTER FEED 6.5.11 2ND DRUM MASTER SENSOR Mechanism The 2nd drum master sensor [A] detects the black patch on the screen [B] when there is no master on the drum. The 2nd drum master sensor detects the black patch on the clamper [C] when there is no master on the drum.

  • Page 383: Cutter Mechanism

    MASTER FEED 6.5.12 CUTTER MECHANISM [A]: Cutter motor [B]: Cutter HP sensor • When the cutter starts, the drum is stopped at the master eject position (drum HP). • The cutter moves backwards and forwards. While the cutter travels towards the rear (non-operation side), it cuts the master.

  • Page 384: Master Set Cover

    MASTER FEED 6.5.14 MASTER SET COVER [A]: Master set cover sensor [B]: Master set cover • If the cover is closed properly, the release button [C] rises. C267 6-30...

  • Page 385: Drum

    DRUM 6.6 DRUM 6.6.1 OVERVIEW • The drum idling roller [C] ensures that the first print has sufficient ink density if the machine was not used for a long time. Procedure Ink is supplied inside the drum, through the drum shaft. ↓...

  • Page 386: Drum Drive Mechanism

    DRUM 6.6.2 DRUM DRIVE MECHANISM Mechanism Main motor [A] (dc motor) ↓ Belt [B] ↓ Gears [C] ↓ The drum rotates. NOTE: 1) The main motor encoder sends pulses to the main motor control board (1020 pulses = 360 degrees). 2) The CPU on the board monitors the pulses and controls the drum speed and stop positions.

  • Page 387: Ink Supply Mechanism

    DRUM 6.6.3 INK SUPPLY MECHANISM Gears [C] Mechanism Ink pump motor [A] ↓ Gears [B] ↓ Gear rotation converted into piston motion. ↓ Supplies ink from the ink cartridge to the ink roller via the pump, the shaft, the tube, and the ink distributor pipes [C].

  • Page 388: Ink Roller Mechanism

    DRUM 6.6.4 INK ROLLER MECHANISM Mechanism Main motor ↓ Gears [A] ↓ Ink roller [B] rotates ↓ Gears [C] ↓ Doctor roller [D] rotates ↓ The doctor roller squeezes the ink on the ink roller to produce an even thickness of ink on the ink roller.

  • Page 389: Drum Idling Mechanism

    DRUM 6.6.5 DRUM IDLING MECHANISM Mechanism Idling roller motor [A] ↓ Gears [B] ↓ Cam [C] ↓ Drum idling roller [D] rotates ↓ The drum idling roller puts the ink onto the screen and master before and after printing. This ensures that the first print has sufficient ink density even if the machine was not used for a long time.

  • Page 390: Detection Of Masters On The Drum

    DRUM NOTE: 1) User Tools 4-11 can change the number of rotations for each of these conditions. 2) The drum rotation speed during idling is fixed at 30 rpm. Period/ Less than 2 Over 24 2 to 4 hours 4 to 24 hours hours hours Temperature...

  • Page 391: Ink Supply Control

    DRUM 6.6.7 INK SUPPLY CONTROL Mechanism When the ink level is low, the pins [A] do not touch the ink. ↓ The ink pump motor ( 6.6.3) keeps the ink level normal by supplying ink when the level is low. NOTE: 1) The ink detection pins [A] detect the capacitance between the ink roller [B] and doctor roller [C].

  • Page 392: Drum Home Position Detection

    DRUM 6.6.8 DRUM HOME POSITION DETECTION LEDs are added to inform the operator when the drum is at the exact home position and can be pulled out. The drum home position sensor monitors the drum home position. The green LED [A] turns on when the drum is at the home position. The red LED [B] turns on when the drum is not at the home position.

  • Page 393: Paper Feed

    PAPER FEED 6.7 PAPER FEED 6.7.1 OVERVIEW This mechanism feeds blank copy paper into the printer. ( : Handling Paper – Paper Feed – Paper Feed Methods – Friction Pad) Mechanism The paper table is lifted. ↓ The pick-up roller [A] picks up a sheet of paper. ↓...

  • Page 394: Mechanism

    PAPER FEED 6.7.2 PAPER FEED MECHANISM Mechanism Paper feed motor [A] ↓ Belt [B] ↓ Turns the feed roller [C] ↓ Belt [D] ↓ Turns the pick up roller [E] NOTE: 1) The machine uses a friction pad [F] and feed roller system. ( Handling Paper –...

  • Page 395: Paper Feed / Separation Pressure Mechanism

    PAPER FEED 6.7.3 PAPER FEED / SEPARATION PRESSURE MECHANISM [J]: Normal position [J]: Thick paper position [J]: Thin paper position • The user can change the pick-up roller pressure by changing the position of the pressure adjustment lever. • If paper feed jams frequently occur, the lever should be moved to the left or the right to adjust the pressure.

  • Page 396: Registration Roller Mechanism

    PAPER FEED 6.7.4 REGISTRATION ROLLER MECHANISM Registration Roller Drive Registration motor [A] ↓ Belt [B] ↓ Turns the lower registration roller [C] NOTE: 1) The CPU controls the registration roller start timing to synchronize the printer paper with the image on the master on the drum. 2) The motor speed depends on the selected printing speed.

  • Page 397: Registration Roller Up/Down Mechanism

    PAPER FEED Registration Roller Up/Down Mechanism • After the printing paper is caught between the drum and the press roller, the registration motor stops and the upper registration roller [D] is released from the lower registration roller. This is to prevent interference from the registration rollers while the drum and press roller transport the paper.
  • Page 398 PAPER FEED 6.7.5 AUTO ADJUSTABLE PRINTING PRESSURE MECHANISM The printing pressure motor [A], the printing pressure sensor [B], and the printing pressure springs [C] were added to the press roller to control the image density for each printing speed or temperature. The printing pressure depends on temperature and printing speed, as shown in the following table.

  • Page 399: Paper Table Mechanism

    PAPER FEED 6.7.7 PAPER TABLE MECHANISM Table lifting/lowering Table motor [A] (dc motor) ↓ Gear [B] ↓ Racks [C] ↓ Lifting or lowering the paper table [D]. NOTE: 1) When the paper height sensor [E] is actuated, the top of the paper stack contacts the pick-up roller [F], lifting it up.
  • Page 400 PAPER FEED Table side fences and side-to-side shift • The paper table shift dial [A] shifts the image across the page. If the dial is turned, the whole paper table moves towards one side or the other. • The side fences move together due to a rack and pinion mechanism. There is a lock lever [B] to hold the side fences in position.

  • Page 401: Paper Delivery

    PAPER DELIVERY 6.8 PAPER DELIVERY 6.8.1 OVERVIEW Procedure The exit pawl [A] and the air knife [B] separate the paper from the drum. ↓ The paper is fed to the exit table [C] by the paper delivery unit [D]. The paper exit sensor [E] is used for jam detection. ( 6.12.6) 6-47 C264...

  • Page 402: Paper Delivery Unit Drive Mechanism

    PAPER DELIVERY 6.8.2 PAPER DELIVERY UNIT DRIVE MECHANISM Mechanism Paper delivery motor [A] ↓ Belt [B] ↓ Shaft [C] ↓ Rotates the transport belts [D]. NOTE: 1) The vacuum fan motor inside the unit holds the paper against the belts [D] to deliver the paper to the exit table.

  • Page 403: Paper Separation From The Drum

    PAPER DELIVERY 6.8.3 PAPER SEPARATION FROM THE DRUM Air knife • The air from the air knife fan motors [A] separates the paper from the drum. • The air knife fan motors start blowing air when the print start key is pressed or when master cutting is finished.

  • Page 404: Exit Pawl Drive Mechanism

    PAPER DELIVERY 6.8.4 EXIT PAWL DRIVE MECHANISM • During printing, the distance between the exit pawl [A] and the drum is very small, to prevent paper wrap jams. However, when the master clamper [B] approaches the exit pawl (as the drum turns), the pawl must be moved away from the drum to prevent it from being damaged by the master clamper.

  • Page 405: Paper Delivery Table Mechanism

    PAPER DELIVERY 6.8.5 PAPER DELIVERY TABLE MECHANISM The paper delivery table consists of the rear side fence, front side fence, and end fence. The angle of the small paper guide [A] on each side fence can be changed by pulling the small paper guide. The small guides help to stack the paper more evenly on the table.

  • Page 406: Adjustable Buffer Fins

    6.8.6 ADJUSTABLE BUFFER FINS The printed paper bends upwards easily. This causes uneven stacking and ink stains on the back of the paper on the delivery table. The buffer fins [A] on the paper delivery table lift the edges of the paper, to prevent this problem. When the paper is fed to the delivery table, these plates catch the edges of the paper, and the paper falls in an inverted “U”...

  • Page 407: Auto Off Mode

    AUTO OFF MODE 6.9 AUTO OFF MODE To meet environmental concerns, this machine has energy saving mode and auto off mode. • Energy saver mode: The machine goes into a low-power mode. • Auto off mode: The main switch will be turned off automatically by a solenoid. Energy saver mode Saving at the set time...

  • Page 408: Sound-Proofing Cushions

    SOUND-PROOFING CUSHIONS 6.10 SOUND-PROOFING CUSHIONS Soundproofing cushions were added to further reduce the level of noise during printing. C267 6-54...

  • Page 409: Timing Chart

    TIMING CHART 6.11 TIMING CHART 6.11.1 MASTER EJECTION 6-55 C264...
  • Page 410 TIMING CHART C267 6-56...

  • Page 411: Master Wrapping

    TIMING CHART 6.11.2 MASTER WRAPPING 6-57 C264...
  • Page 412 TIMING CHART C267 6-58...

  • Page 413: Printing

    TIMING CHART 6.11.3 PRINTING 6-59 C264...
  • Page 414 TIMING CHART C267 6-60...

  • Page 415: Jam Detection

    JAM DETECTION 6.12 JAM DETECTION 6.12.1 MASTER EJECT JAM (B JAM LOCATION INDICATOR) Picking up the used master from the drum 1.0 s Main motor (30 rpm) Clamper Open Open Close Close Master eject motor 0.1 s Master eject sensor Check 2 Check 1 Jam check timing: When the clamper open sensor is on (clamper open).

  • Page 416: Df Jam (P Jam Location Indicator)

    JAM DETECTION 6.12.2 DF JAM (P JAM LOCATION INDICATOR) Feeding in the original Start to scan DF registration sensor DF motor Original length + 80 mm DF feed clutch 5.0 s Check 1 Check 2 Jam check timing: When an original is placed in the DF. Check 1: If the DF motor has operated for 5.0 seconds since the start key was pressed, and the DF registration sensor still doesn’t detect the original, the P jam indicator lights.

  • Page 417: Master Feed Jam (D Jam Location Indicator)

    JAM DETECTION 6.12.3 MASTER FEED JAM (D JAM LOCATION INDICATOR) Cutting the master (master not cut) Master making Main motor Cutter HP sensor Cutter motor Re-cutting Drum master sensor Master not cut Check Black patch on the clamper Jam check timing: When the master is clamped in the clamper and cutting is taking place.

  • Page 418: Clamping The Master

    JAM DETECTION Clamping the master Master making 21 degrees Main motor Master eject position sensor Drum master sensor Check Jam check timing: When the master is wrapping around the drum. Check: When the drum has turned 21 degrees since the master eject position sensor turns on (drum at master eject position), if the drum master sensor doesn’t detect a master, then the D jam indicator lights.

  • Page 419: Drum Jam (B Jam Location Indicator)

    JAM DETECTION 6.12.4 DRUM JAM (B JAM LOCATION INDICATOR) Wrapping jam Master eject position sensor (HP) Paper exit sensor 80 degrees Check Jam check timing: When printing. Check : When the drum has turned 80 degrees since the master eject position sensor turned on (drum reached master eject position), and the paper exit sensor still doesn’t detect the paper, then the B jam indicator lights.

  • Page 420: Paper Delivery Jam (C Jam Location Indicator)

    JAM DETECTION 6.12.6 PAPER DELIVERY JAM (C JAM LOCATION INDICATOR) Paper delivery Paper exit timing sensor Paper exit sensor Check Jam check timing: When printing. Check: When the paper exit-timing sensor turns on (drum at paper exit timing position), if the paper exit sensor detects paper, the C jam location indicator lights.

  • Page 421: Specifications

    7 SPECIFICATIONS 7 SPECIFICATIONS 1. GENERAL SPECIFICATIONS Configuration: Stand-alone Master Process: Digital with 400 dpi thermal head Scanning (Pixel Density): 400 dpi Originals: Sheet/Book Printing process: Fully automatic one-drum stencil system Original Size: Maximum 300.0 x 432 mm / 11.8" x 17.0" Copy Paper Size: Maximum 297 x 432 mm / 11.6"...
  • Page 422 7 SPECIFICATIONS Noise Emission Operating Position Sound Sound Power Level Power Level Standby: Not more than 45 dB (A) Not more than 31 dB (A) Copying 60 rpm: Not more than 73 dB (A) Not more than 59 dB (A) Copying 90 rpm: Not more than 76 dB (A) Not more than 62 dB (A)
  • Page 423 7 SPECIFICATIONS Master Process Time: Less than 24 seconds (A4 copying) Less than 29 seconds (A3 copying) NOTE: Measurement Conditions 1) 100%size Paper Table Capacity: 1,000 sheets (80 g/m , 20 lb) Paper Delivery Table 1,000 sheets (80 g/m , 20 lb) Capacity: Leading Edge Margin: 5 ±...
  • Page 424 7 SPECIFICATIONS Ink Storage Conditions: Temperature: -5 °C to 40 °C (Optimal conditions: 15 °C to 25 °C) Humidity: 10% to 95% RH (Optimal conditions: 20% to 70% RH) Recommended maximum storage period: 18 months after production date Note: Avoid locations exposed to direct sunlight. •...
  • Page 425 DOCUMENT FEEDER C600...
  • Page 427 DOCUMENT FEEDER C600 TABLE OF CONTENTS 1. OVERALL INFORMATION .............. 1 1.1 SPECIFICATIONS..................1 1.2 MECHANICAL COMPONENT LAYOUT ............2 1.3 ELECTRICAL COMPONENT LAYOUT............3 1.4 ELECTRICAL COMPONENT DESCRIPTION..........4 1.5 DRIVE LAYOUT ................... 5 2. DETAILED SECTION DESCRIPTIONS........... 6 2.1 ORIGINAL SIZE DETECTION..............

  • Page 429: Overall Information

    SPECIFICATIONS 1. OVERALL INFORMATION 1.1 SPECIFICATIONS Original Size: Standard Size (Single-sided Mode only): A3 to A5, DLT to HLT Non-standard Size (Single-sided Mode only): Max. width 297 mm Min. width 105 mm Max. length 1,260 mm Min. length 128 mm Original Weight: 40 ~ 128 g/m (10 ~ 34 lbs.)

  • Page 430: Mechanical Component Layout

    MECHANICAL COMPONENT LAYOUT 1.2 MECHANICAL COMPONENT LAYOUT C600V101.WMF 1. Separation roller 6. Original exit roller 2. Original feed belt 7. 2nd transport roller 3. Pick-up roller 8. Original exposure guide 4. Original entrance guide 9. 1st transport roller 5. Original table C600...

  • Page 431: Electrical Component Layout

    ELECTRICAL COMPONENT LAYOUT 1.3 ELECTRICAL COMPONENT LAYOUT C600V102.WMF 1. DF feed clutch 8. Original length sensor 1 2. Feed cover open sensor 9. DF transport motor 3. Original width sensor 10. Stamp solenoid 4. DF pick-up solenoid 11. Original set sensor 5.

  • Page 432: Electrical Component Description

    ELECTRICAL COMPONENT DESCRIPTION 1.4 ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Motors DF Transport Drives the transport and exit rollers Sensors DF Open Informs the CPU of the DF when the DF is opened and closed (for platen mode). Registration Detects the leading edge of the original to determine when to turn off the DF transport...

  • Page 433: Drive Layout

    DRIVE LAYOUT 1.5 DRIVE LAYOUT C600V103.WMF 1. DF feed clutch 5. 1st transport roller 2. DF transport motor 6. Separation roller 3. 2nd transport roller 7. Original feed belt 4. Exit roller 8. Pick-up roller C600...

  • Page 434: Detailed Section Descriptions

    ORIGINAL SIZE DETECTION 2. DETAILED SECTION DESCRIPTIONS 2.1 ORIGINAL SIZE DETECTION C600D104.WMF The DF has one width sensor [A] to detect the original width and two original length sensors (-1 [B] and -2 [C]) to detect the original length. The DF detects the original size through the combination of inputs from those sensors as shown in the table on the next page.
  • Page 435 ORIGINAL SIZE DETECTION Original Original Length 1 Length 2 A3 L (297 x 420) — — — " B4 L (257 x 364) — — — " A4 L (210 x 297) — — — — " A4 S (297 x 210) "...

  • Page 436: Pick-Up And Separation

    PICK-UP AND SEPARATION 2.2 PICK-UP AND SEPARATION C600D105.WMF C600D106.WMF When the print key is pressed, the DF pick-up solenoid [A] turns on and the entrance guide [B] lifts up the originals to the pick-up roller [C]. At the same time, the DF feed clutch [D] turns on.

  • Page 437: Original Transport And Exit Mechanism

    ORIGINAL TRANSPORT AND EXIT MECHANISM 2.3 ORIGINAL TRANSPORT AND EXIT MECHANISM C600D107.WMF When the leading edge of the original reaches the registration sensor [A], the DF transport motors turn off. After a short time the DF transport motors turn on again. The original is fed past the DF exposure glass [B], where it is scanned.

  • Page 438: Overall Electrical Circuit

    OVERALL ELECTRICAL CIRCUIT 2.4 OVERALL ELECTRICAL CIRCUIT Main Transport Processing DF Drive Board Unit Motor Driver DF Connection Sensors Clutch Solenoids C600D509.WMF The C235 directly controls the DF pick-up solenoid, stamp solenoid, and DF feed clutch through the DF drive board. The sensor signals are directly sent to the copier through the DF drive board.

  • Page 439: Replacement And Adjustment

    FEED UNIT REMOVAL 3. REPLACEMENT AND ADJUSTMENT 3.1 FEED UNIT REMOVAL C600R102.WMF 1. Open the DF feed cover [A]. 2. Slide the feed unit [B] in the direction of the arrow, then remove it. 3.2 SEPARATION ROLLER REPLACEMENT C600R105.WMF 1. Remove the feed unit. 2.

  • Page 440: Pick-Up Roller Replacement

    PICK-UP ROLLER REPLACEMENT 3.3 PICK-UP ROLLER REPLACEMENT C600R103.WMF 1. Remove the feed unit. 2. Remove the snap ring [A]. 3. Replace the pick-up roller [B]. 3.4 FEED BELT REPLACEMENT C600R104.WMF 1. Remove the feed unit. 2. Remove the E-ring [A], bearing [B], washers [C], and spring [D]. 3.

  • Page 441: Original Set Sensor Replacement

    ORIGINAL SET SENSOR REPLACEMENT 3.5 ORIGINAL SET SENSOR REPLACEMENT C600R106.WMF 1. Remove the DF feed cover. 2. While releasing the front and rear stoppers [A], open the transport guide [B]. 3. Replace the original set sensor [C]. C600...

  • Page 442: Original Width/Length/Trailing Edge Sensor Replacement

    ORIGINAL WIDTH/LENGTH/TRAILING EDGE SENSOR REPLACEMENT 3.6 ORIGINAL WIDTH/LENGTH/TRAILING EDGE SENSOR REPLACEMENT C600R107.WMF C600R108.WMF C600R113.WMF 1. Open the original table. 2. Remove the original guide [A] (3 screws). 3. Replace the following sensors: • Original length sensor 1 [B] • Original length sensor 2 [C] •...

  • Page 443: Original Exit Tray/Front Cover/Rear Cover Removal

    ORIGINAL EXIT TRAY/FRONT COVER/REAR COVER REMOVAL 3.7 ORIGINAL EXIT TRAY/FRONT COVER/REAR COVER REMOVAL C600R101.WMF 1. Open the DF feed cover. 2. Open the original table. 3. Remove the front cover [A] (2 screws). 4. Remove the rear cover [B] (2 screws). 5.

  • Page 444: Feed Clutch/Pick-Up Sol/Transport Motor Replacement

    FEED CLUTCH/PICK-UP SOL/TRANSPORT MOTOR REPLACEMENT 3.9 FEED CLUTCH/PICK-UP SOL/TRANSPORT MOTOR REPLACEMENT C600R109.WMF 1. Remove the rear cover (2 screws). - Feed Clutch - 2. Replace the feed clutch [A] (1 E-ring and 1 connector). - Pick-up Solenoid - 3. Replace the pick-up solenoid [B] (3 screws and 1 connector). - Transport Motor - 4.

  • Page 445: Df Feed Cover Removal

    DF FEED COVER REMOVAL 3.10 DF FEED COVER REMOVAL C600R110.WMF 1. Remove the front cover (2 screws) and the rear cover (2 screws). 2. Remove the turn guide [A] (2 screws [B]). 3. Remove the DF feed cover [C] (2 screws [D]). 3.11 REGISTRATION SENSOR REPLACEMENT C600R111.WMF 1.
  • Page 447 PRINTER CONTROLLER C624 SERVICE MANUAL/PARTS CATALOG...
  • Page 449 Trademarks ® ® ® Microsoft , Windows , and MS-DOS are registered trademarks of Microsoft Corporation in the United States and /or other countries. ® Ethernet is a registered trademark of Xerox Corporation. Other product names used herein are for identification purposes only and may be trademarks of their respective companies.
  • Page 451 4.2.1 HOW TO ENTER THE SP MODE ............. 21 Entering Controller SP mode ..............21 4.2.2 SP MODE TABLE................21 9 Printer Controller (For model #C249)..........21 9 Printer Controller (For models #C239/C244) ........22 SP9-1/ SP9-1-1 (HEX Dump Print) ............23 SP9-2 to -3/ SP9-1-2 to -3 (Service Summary 1 Print, Service Summary 2 Print) ....................
  • Page 452 5.1 OVERVIEW ....................28 5.2 MACHINE LAYOUT..................29 6. SPECIFICATIONS................31 1. GENERAL SPECIFICATIONS..............31 2. SOFTWARE ACCESSORIES ..............31 2.1 PRINTER DRIVERS ................31 UTILITY SOFTWARE................. 31 PARTS CATALOG AND LIST ............33 FOR MODELS #C239/C244................33 FOR MODEL #C249..................34 C624...

  • Page 453: Hardware Installation

    *The power cable is black and orange 6. Bracket (For model #C249)............3 7. I/F Board - MPU side (For model #C249) ........1 8. I/F Board - controller side (For model #C249) ......1 9. Core (For models #C239/C244)............ 1 10.

  • Page 454: Printer Controller Unit Installation

    HARDWARE INSTALLATION 1.1.2 PRINTER CONTROLLER UNIT INSTALLATION Open the printer controller unit cover [A]. Then remove the video I/F board [B] from the package. Then attach the printer controller unit cover ( x 4). C624I916.WMF C624I918.WMF C624...

  • Page 455: For Model #C249

    HARDWARE INSTALLATION For model #C249 1. Attach three brackets [A] [B] [C] ( x 6). 2. Attach the I/F Board - controller side [D] ( x 2). C624I003.WMF 3. Remove the rear covers [E] [F] ( x 8). 4. Remove the I/F connector cover [G] ( x 2).
  • Page 456 HARDWARE INSTALLATION 5. Attach the video I/F board [H] ( x 2). 6. Attach the I/F Board - MPU side [I] ( x 2). C624I006.WMF 7. Remove the I/F cable bracket [J] ( x 2). NOTE: You do not need the I/F cable bracket [J]. C624I008.WMF C624...
  • Page 457 HARDWARE INSTALLATION 8. Attach two power cables [K] [L]. Then clamp the power cable. C624I004.WMF 9. Install the printer controller unit [M] ( x 4). C624I005.WMF NOTE: After installing the printer controller unit, make sure that the board and the cable are securely connected.

  • Page 458: For Models #C239/C244

    HARDWARE INSTALLATION For models #C239/C244 1. Attach three brackets [A] [B] [C] ( x 6). C624I902.WMF 2. Remove the rear cover [D] ( x 6). 3. Remove the I/F connector cover [E] ( x 2). C624I007.WMF C624...
  • Page 459 HARDWARE INSTALLATION 4. Attach the video I/F board [F], and power cable [G]. C624I903.WMF NOTE: 1) Install two cable clamps [H]. Then clamp the power cable. 2) Attach the core [I] to the power cable. 5. Install the printer controller unit [J] ( x 4). C624I904.WMF NOTE: After installing the printer controller unit, make sure that the board and the cable are securely connected.

  • Page 460: Parameter Settings

    1.2 PARAMETER SETTINGS After installing the printer controller, change the User Tools settings according to your environment. Press the User Tools key, then select Set [6 Online Paramet's] (For model #C249) [7 Set O/L Paramet's] (For models #C239/C244) MENU SETTINGS FUNCTION Set auto-O/L def.
  • Page 461 PARAMETER SETTINGS MENU SETTINGS FUNCTION I/O Timeout 15 sec *30 sec 60 sec 180 sec 300 sec I/O Buffer 16 KB You must turn the power off and then on for the changes to take 32 KB effect. 64 KB 128 KB 256 KB *512 KB...

  • Page 462: Utility Software Setup

    UTILITY SOFTWARE SETUP 1.3 UTILITY SOFTWARE SETUP One of the following utilities is required to monitor and set up the NIB. The utilities are on the Drivers and Utilities CD-ROM. 1.3.1 SMARTDEVICEMONITOR FOR ADMIN 1. Install SmartDeviceMonitor for admin from the CD-ROM. 2.

  • Page 463: Setting Up The Nib For Various Networks

    SETTING UP THE NIB FOR VARIOUS NETWORKS 1.4 SETTING UP THE NIB FOR VARIOUS NETWORKS This section gives a summary of how to set up the NIB in various network environments. NOTE: It is not recommended that service technicians program network and protocol parameters.

  • Page 464: Possible Problems With Dhcp Parameter Settings

    SETTING UP THE NIB FOR VARIOUS NETWORKS Possible Problems with DHCP Parameter Settings 1. IP address conflicts with an another host If the IP address conflicts with another host, the NIB does not show any errors. However, the NIB cannot receive any print jobs, because the IP protocol is disabled automatically at startup.

  • Page 465: Netware Networks

    SETTING UP THE NIB FOR VARIOUS NETWORKS 1.4.3 NETWARE NETWORKS The following parameters are required for NetWare networks. NOVELL 2.X/3.X/4.X/5.X NOVELL 4.X/5.X PARAMETER BINDERY NETWORK NDS NETWORK Protocol (Default = Enabled) Operation Mode (Print Server or Remote (Print Server or Remote (Default = Print Server) Printer) Printer)

  • Page 466: Replacement And Adjustment

    Then install the NVRAM on the new board. 2) If the controller does not start up after a firmware update, try to download the firmware again. If that does not work, you may need to replace the controller board. For model #C249 [A]: Rear cover C624R000.WMF C624...
  • Page 467 CONTROLLER [B]: Controller cover ( x 4) [C]: NIB ( x 2) [D]: Upper ground plate ( x 1) C624R001.WMF [E]: Lower ground plate ( x 2) [F]: Controller board ( x 6) C624R002.WMF • Remove the optional components and the NVRAM from the controller. Then install them on the new controller.

  • Page 468: For Models #C239/C244

    CONTROLLER For models #C239/C244 [A]: Rear cover C624R502.WMF [B]: Controller cover ( x 4) C624R503.WMF C624...
  • Page 469 CONTROLLER [C]: NIB ( x 2) [D]: Controller board ( x 6) C624R005.WMF • Remove the optional components and the NVRAM from the controller. Then install them on the new controller. • Print the configuration page ([User Tools] – [7 Set O/L Paramet's] – [3 List/Test Print] –...

  • Page 470: Nib

    Tools, SmartDeviceMonitor for Admin, and Web Status Monitor. 2) If you replace the NIB with a NIB from another machine, access SP9- 32 (NIB NVRAM) (For model #C249)/ SP9-2-3 (NIB NVRAM) (For models #C239/C244) to initialize all the data (machine information) in the NIB NVRAM.

  • Page 471: Troubleshooting

    ERROR MESSAGE 3. TROUBLESHOOTING 3.1 ERROR MESSAGE MESSAGE DESCRIPTION REQUIRED ACTION Controller Communication Abnormal communication Examine the connectors between the controller and and cable connections. Error the engine. Replace the controller board, cable, Video I/F Board, and/or MPU of the engine.

  • Page 472: Nib Led Indications

    NIB LED INDICATIONS 3.2 NIB LED INDICATIONS LED1 LED2 LED3 C624T000.WMF DESCRIPTION LED1 Operating status Ready Not ready LED2 Topology 100BaseTX 10BaseT LED3 Link status Link success Link failure NOTE: Push switch [A] on the NIB for 2 seconds/ 5 seconds and the machine will make the status sheet/ system log sheet.

  • Page 473: Service Tables

    Entering Controller SP mode →→→→ (Hold for more than 3 seconds.) Select “9 Printer Controller”. The Printer Controller SP mode main menu appears. 4.2.2 SP MODE TABLE 9 Printer Controller (For model #C249) MENU DEFAULT SETTINGS HEX Dump Print Disable...

  • Page 474: Printer Controller (For Models #C239/C244)

    SERVICE PROGRAM MODE OVERVIEW 9 Printer Controller (For models #C239/C244) DISPLAY MENU DEFAULT SETTINGS Test HEX Dump Print Disable Disable/Enable Service Summary 1 Print – – Service Summary 2 Print – – Parallel Loop-Back Test – – Self-diagnostic Mode – –...

  • Page 475: Sp9-1/ Sp9-1-1 (Hex Dump Print)

    SERVICE PROGRAM MODE OVERVIEW SP9-1/ SP9-1-1 (HEX Dump Print) This prints Hex Dump data using the controller. NOTE: The Hex Dump Print is not used. SP9-2 to -3/ SP9-1-2 to -3 (Service Summary 1 Print, Service Summary 2 Print) This prints a summary of all the controller settings. 1.

  • Page 476: Sp9-4/ Sp9-1-4 (Parallel Loop-Back Test)

    SERVICE PROGRAM MODE OVERVIEW SP9-4/ SP9-1-4 (Parallel Loop-Back Test) This tests the standard IEEE 1284 parallel interface using a loop-back connector. The loop-back connector (P/#: G0219350) is required for this test. NOTE: Do not use the loop-back connector with P/#: G0109350. This loop-back connector causes a timeout error.

  • Page 477: Sp9-32/ Sp9-2-3 (Nib Nvram )

    SERVICE PROGRAM MODE OVERVIEW SP9-32/ SP9-2-3 (NIB NVRAM ) This initializes all the data (Information of “Network Setup” in the configuration page) in the NIB NVRAM. SP9-40/ SP9-3-1 (Load Program-System) This upgrades the system data (firmware) for the controller. (! 4.2.3) SP9-50/ SP9-3-2 (Load Program-NIB) This upgrades the network interface board.

  • Page 478: Load Program (Sp9-40 To -50/ Sp9-3)

    This procedure is for upgrading the system firmware for the controller and the network interface board.  CAUTION Do not turn off the machine while downloading the firmware. For model #C249 C624S004.WMF For models #C239/C244 C624S009.WMF 1. Before downloading new firmware, print the configuration page.

  • Page 479: Error Recovery

    8. Turn on the machine, and print the configuration page [User Tools] – [6 Online Paramet's] – [3 List/Test Print] – [System Print]. (For model #C249) [User Tools] – [7 Set O/L Paramet's] – [3 List/Test Print] – [System Print].

  • Page 480: Detailed Section Descriptions

    OVERVIEW 5. DETAILED SECTION DESCRIPTIONS 5.1 OVERVIEW For model #C249 C624D005.WMF For models #C239/C244 C624D006.WMF C624...

  • Page 481: Machine Layout

    For connecting the IC card for firmware upgrades IEEE1284 I/F CN509 IEEE1284 parallel To the host computer interface 5.2 MACHINE LAYOUT For model #C249 C624D007.WMF REF. COMPONENT Printer Controller Board I/F Board - controller side Network Interface Board I/F Board - MPU side...
  • Page 482 MACHINE LAYOUT For models #C239/C244 C624D004.WMF REF. COMPONENT Printer Controller Board Video Interface Board Network Interface Board C624...
  • Page 483 C624 PARTS CATALOG...
  • Page 485 PARTS CATALOG AND LIST PARTS CATALOG AND LIST FOR MODELS #C239/C244 C624C502.WMF Index Q’ty Per Part No. Description Assembly C613 5645 Shading Plate G038 5826 IC Card Cover G038 5813 Connector Cover C607 5651 Left Stand C607 5150 Video I/F Board C607 5201 Controller Power Cable C607 5652...
  • Page 486 PARTS CATALOG AND LIST FOR MODEL #C249 C624C501.WMF Index Q’ty Per Part No. Description Assembly C624 5120 I/F Board – MPU side C607 5150 Video I/F Board C624 5202 DC power Supply Harness C624 1382 Upper Foot C624 1381 Left Foot C624 5130 I/F Board –...

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