Ricoh JP5800 Service Manual
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Ricoh JP5800 Service Manual

Ricoh JP5800 Service Manual

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SERVICE MANUAL
(Machine code: C232)
C232V500.WMF

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Summary of Contents for Ricoh JP5800

  • Page 1 SERVICE MANUAL (Machine code: C232) C232V500.WMF...
  • Page 2 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 3 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 4: Table Of Contents

    TABLE OF CONTENTS 1. OVERALL INFORMATION............1-1 1.1 ESSENTIAL DIFFERENCES BETWEEN C232 AND C229 MODELS..1-1 1.2 SPECIFICATIONS ..................1-2 1.3 GUIDE TO COMPONENTS AND THEIR FUNCTIONS......1-6 1.3.1 MACHINE EXTERIOR..............1-6 1.4 MACHINE INTERIOR ................1-7 1.5 OPERATION PANEL ................. 1-9 1.5.1 KEYS ....................
  • Page 5 2.4 DRUM HOME POSITION DETECTION........... 2-14 2.5 TIMING CHART ..................2-15 2.6 ERROR DETECTION ................2-19 2.6.1 PAPER FEED ERROR DETECTION IN THE PAPER BANK ..2-19 3. INSTALLATION................3-1 3.1 INSTALLATION REQUIREMENTS............3-1 3.1.1 REQUIRED ENVIRONMENTAL CONDITIONS........ 3-1 3.1.2 ENVIRONMENTS TO AVOID............3-1 3.1.3 POWER CONNECTION ..............
  • Page 6 6.2 PRINTING SECTION................6-10 6.2.1 TORQUE LIMITER ................. 6-10 6.2.2 FEED START SENSORS AND FEED ENCODER ......6-16 6.3 PAPER FEED SECTION (MAIN BODY)..........6-18 6.3.1TIMING BELT TENSION ADJUSTMENT FOR THE REGISTRATION MOTOR..........6-18 6.3.2TIMING BELT TENSION ADJUSTMENT FOR THE PAPER TABLE FEED MOTOR........6-19 6.3.3 PAPER FEED LENGTH ADJUSTMENT ........

  • Page 7: Overall Information

    1 March, 2000 ESSENTIAL DIFFERENCES BETWEEN C232 AND C229 MODELS 1. OVERALL INFORMATION 1.1 ESSENTIAL DIFFERENCES BETWEEN C232 AND C229 MODELS Item Remarks Thermal Head, Thermal Some related parts are also changed. Head Power Supply, MPU, I/O Board, PSU Paper Table Paper table capacity is changed from 1,000 sheets (C229) to 500 sheets (C232).

  • Page 8: Specifications

    SPECIFICATIONS 1 March, 2000 1.2 SPECIFICATIONS Configuration: Floor type Master Processing: Digital Scanning (Pixel Density): 400 dpi CCD Printing Process: Pressure cylinder system Original Type: Sheets, Books Original size (Platen Mode): Maximum 304.8 x 432 mm [12.0" x 17.0"] Thickness: Less than 30 mm Weight: Do not place objects weighing more than 10 kg on the exposure glass...
  • Page 9 1 March, 2000 SPECIFICATIONS Printing Area: Metric size version models: (At 20 °C/ 65 % RH) 290 mm x 409 mm Inch size version models: 290 mm x 419 mm [11.4" x 16.5"] With optional A4 drum: 290 mm x 204 mm [11.4" x 8.0"] Edge Margins: Leading edge: 10 mm (At the "0"...
  • Page 10 SPECIFICATIONS 1 March, 2000 Paper Feed Table Capacity: 500 sheets (80 g/m / 20 lb) Paper Tray Capacity: Tray 1 (tandem): 1,000 x 2 sheets (80 g/m / 20 lb) Tray 1: 1,000 sheets (80 g/m / 20 lb) Tray 2: 500 sheets (80 g/m / 20 lb) Paper Delivery Table 1,000 sheets (80 g/m...
  • Page 11 • A3 Drum Available Options: • A4 Drum • Document Feeder • Key Counter • Memory Board (Editing Function) • PC Controller • Interface Board (Option for the China and Ricoh Asia versions, standard for the U.S.A and Europe versions)

  • Page 12: Guide To Components And Their Functions

    GUIDE TO COMPONENTS AND THEIR FUNCTIONS 1 March, 2000 1.3 GUIDE TO COMPONENTS AND THEIR FUNCTIONS 1.3.1 MACHINE EXTERIOR C232V500.WMF 1. Platen Cover or Document Lower the platen cover over a single original Feeder (Option) placed on the exposure glass for copying. If you have the optional document feeder, insert a stack of originals here.

  • Page 13: Machine Interior

    1 March, 2000 MACHINE INTERIOR 1.4 MACHINE INTERIOR C232V502.WMF C232V503.WMF...
  • Page 14 MACHINE INTERIOR 1 March, 2000 1. Main Switch Use to turn the power on or off. Use to lift or lower the paper alignment wings. 2. Paper Alignment Wing Knobs 3. Paper Alignment Wings Lift or lower the wings depending on the type of paper being used.

  • Page 15: Operation Panel

    1 March, 2000 OPERATION PANEL 1.5 OPERATION PANEL 1.5.1 KEYS C232V506.wmf 1. Quality Start key 11. Economy Mode key Press to save ink. 2. Security key 12. On Line key 3. Skip Feed key Press to select skip feed printing. 13.
  • Page 16 OPERATION PANEL 1 March, 2000 20. Program key 25. Start key Press to make a master. Press to input or recall programs. 26. Auto Cycle key 21. Number keys Use to process the master and Press to enter the desired number make prints in one operation.

  • Page 17: Indicators

    1 March, 2000 OPERATION PANEL 1.5.2 INDICATORS C232V510.wmf 1. Special Feature indicators 5. Color Drum indicator Light to indicate the special Lights when the color drum unit is features that have been selected. installed. To access the special features, lift 6.

  • Page 18: Printing Process Overview

    PRINTING PROCESS OVERVIEW 1 March, 2000 1.6 PRINTING PROCESS OVERVIEW C232V505.WMF 1. Master Ejecting: Ejects the used master wrapped around the drum into the master eject box. 2. Scanning: Scans the original image with the CCD through the mirrors and the lens. 3.

  • Page 19: Mechanical Component Layout

    1 March, 2000 MECHANICAL COMPONENT LAYOUT 1.7 MECHANICAL COMPONENT LAYOUT C232V505.WMF 1-13...
  • Page 20 MECHANICAL COMPONENT LAYOUT 1 March, 2000 1. Master Feed Control Rollers 22. Doctor Roller 2. Lens 23. Tray 2 3. CCD 24. Pressure Cylinder 4. SBU 25. Left Tandem Tray 5. Tension Rollers 26. Back Plate (Tandem Tray) 6. Platen Roller 27.

  • Page 21: Electrical Component Layout

    1 March, 2000 ELECTRICAL COMPONENT LAYOUT 1.8 ELECTRICAL COMPONENT LAYOUT 1.8.1 PRINTED CIRCUIT BOARD LAYOUT C232V511.WMF 1-15...

  • Page 22: Scanner Section

    ELECTRICAL COMPONENT LAYOUT 1 March, 2000 1.8.2 SCANNER SECTION C232V512.WMF 1.8.3 PAPER FEED SECTION C232V507.WMF 1-16...

  • Page 23: Master Eject, Pressure Cylinder, And Other Sections

    1 March, 2000 ELECTRICAL COMPONENT LAYOUT 1.8.4 MASTER EJECT, PRESSURE CYLINDER, AND OTHER SECTIONS C232V508.WMF 1-17...

  • Page 24: Paper Delivery Section

    ELECTRICAL COMPONENT LAYOUT 1 March, 2000 1.8.5 PAPER DELIVERY SECTION C232V513.WMF 1.8.6 MASTER MAKING UNIT C232V514.WMF 1-18...

  • Page 25: Drum Unit

    1 March, 2000 ELECTRICAL COMPONENT LAYOUT 1.8.7 DRUM UNIT C232V515.WMF 1-19...

  • Page 26: Relay Unit

    ELECTRICAL COMPONENT LAYOUT 1 March, 2000 1.8.8 RELAY UNIT C232V000.WMF 1.8.9 VERTICAL TRANSPORT UNIT, BACK PLATE UNIT, AND OTHER SECTIONS C232V001.wmf 1-20...

  • Page 27: Tray 1, Tray 2

    1 March, 2000 ELECTRICAL COMPONENT LAYOUT 1.8.10 TRAY 1, TRAY 2 C232V002.WMF 1.8.11 PAPER DELIVERY TABLE C232V003.wmf 1-21...

  • Page 28: Tables Of Electrical Components

    SP mode. This is an option. Interface Board Enables the connection with the PC controller. This is an option for the China and Ricoh Asia versions, and a standard component for the U.S.A and Europe versions. Thermal Head Power Provides dc power to the thermal head.
  • Page 29 1 March, 2000 ELECTRICAL COMPONENT LAYOUT Index No. Name Function Tray 1 Friction Pad Controls the up-down movement of the friction Solenoid pad unit in tray 1. Tray 2 Friction Pad Controls the up-down movement of the friction Solenoid pad unit in tray 2. Switches Index No.
  • Page 30 ELECTRICAL COMPONENT LAYOUT 1 March, 2000 Index No. Name Function Master Feed Motor Feeds the master to the drum. Provide suction to guide the master into the Master Vacuum Fans buffer duct. Ink Pump Motor Drives the ink pump to supply ink. Idling Roller Motor Presses or releases the idling roller against the drum screen.
  • Page 31 1 March, 2000 ELECTRICAL COMPONENT LAYOUT Index No. Name Function Image Position Encoder Sends the image position data to the CPU for display on the operation panel. 2nd Drum Position Checks the drum position. Sensor 1st Drum Position Checks the drum position. Sensor Clamper Close Position Detects when the clamper is in the closed...
  • Page 32 ELECTRICAL COMPONENT LAYOUT 1 March, 2000 Index No. Name Function Drum Shift Sensor Sends the image position data to the CPU for display on the operation panel. Ink Pump Sensor Monitors the operation of the ink pump to count how many cycles it has moved. Ink Cartridge Set Detects if the ink cartridge is in place.
  • Page 33 1 March, 2000 ELECTRICAL COMPONENT LAYOUT Index No. Name Function Rear Right Tray Paper Detects paper width in the right side of tray 1. Width Sensor Tandem Tray Sensor Informs whether tray 1 is a tandem tray or not. Left Tray Paper Length Detects when there is long paper in tray 1.

  • Page 34: Drive Layout

    DRIVE LAYOUT 1 March, 2000 1.9 DRIVE LAYOUT 1.9.1 OVERVIEW C232V509.WMF 1. Clamper Opening Arm Sector 9. Pressure Cylinder Drive Gear Gear (for the master eject position) (Including the Scissors Gear) 2. Master Pick-up Roller Sector Gear 10. Registration Roller Lifting Cam Drive Gear 3.

  • Page 35: Main Drive

    1 March, 2000 DRIVE LAYOUT 1.9.2 MAIN DRIVE C232V516.WMF 18. Drum 24. Idler Gear/Pulley 19. Pressure Cylinder 25. Pressure Cylinder Drive Gear (including the Scissors Gear) 20. Printing Pressure Cam 26. Primary Gear/Pulley 21. Exit Pawl Drive Cam Gear 27. Drum Drive Gear/Pulley 22.

  • Page 36: Detailed Section Descriptions

    1 March, 2000 PAPER BANK 2. DETAILED SECTION DESCRIPTIONS 2.1 PAPER BANK Front 2.1.1 OVERVIEW Rear C232D000.WMF This machine has a paper bank with two drawer-type trays. The following table shows the capacity of this paper bank. Paper Tray Paper capacity 1000 x 2 (tandem feed tray) or 1000 sheets 500 sheets (universal tray) Paper can also be fed using the paper table, which has an independent feed...

  • Page 37: Paper Feed

    PAPER BANK 1 March, 2000 2.1.2 PAPER FEED Front View C232D001.WMF The pick-up roller [A] and paper feed roller [B] are driven by the tray feed motor. The pick-up roller picks up paper from the top of the stack. Friction between the feed rollers and the friction pad [C] allows only the top sheet to pass towards the tray exit rollers.
  • Page 38 1 March, 2000 PAPER BANK Rear View C232D002.WMF The tray feed start sensor [A] controls paper feed timing from the paper trays. The tray paper feed motor turns on a pre-determined duration after actuator [B] interrupts the tray feed start sensor. Similarly, the tray registration motor turns on using actuator [C].

  • Page 39: Tandem Tray Mechanisms

    PAPER BANK 1 March, 2000 2.1.3 TANDEM TRAY MECHANISMS Tray Positioning C232D009.WMF When the tray is placed in the machine, the lock lever [A] drops behind the lock plate [B] on the slide rail support bracket to lock the tray in the proper position. NOTE: The same type of mechanism is used also for tray 2.
  • Page 40 1 March, 2000 PAPER BANK Tray Lock Mechanism C232D013.WMF During printing, the tray lock solenoid [A] turns on and lock plate [B] locks the tray. This mechanism is the same in the right and left halves of the tandem tray. NOTE: The same type of mechanism is used also for tray 2.
  • Page 41 PAPER BANK 1 March, 2000 Tandem Back Plate Drive Mechanism C232D010.WMF When the left tray paper length sensor [A] detects paper and the tray 1 paper end sensor [B] detects no paper, the back plate drive motor [C] moves the back plate [D].

  • Page 42: Paper Lift

    1 March, 2000 PAPER BANK 2.1.4 PAPER LIFT Tray 1 C232D004.WMF Tray 2 C232D005.WMF When the machine detects that the paper tray has been placed in the machine (detected by the connector at the rear of the tray), the lift motor [A] rotates and the coupling gear [B] on the tray lift motor engages the pin [C] on the lift arm shaft [D].

  • Page 43: 5Tray Upper Limit Detection And Paper Height Control

    PAPER BANK 1 March, 2000 2.1.5 TRAY UPPER LIMIT DETECTION AND PAPER HEIGHT CONTROL C232D006.WMF The tray goes up until the top of the paper stack pushes up the paper pick-up roller [A] and the actuator [B] activates the upper limit sensor [C] to stop the tray lift motor.

  • Page 44: Side Fence Positioning And Paper Size Detection

    1 March, 2000 PAPER BANK 2.1.6 SIDE FENCE POSITIONING AND PAPER SIZE DETECTION Tray 1 C232D011.WMF C232D004.WMF The front and rear tray paper width sensors [A] and [B] monitor the paper width. These sensors detect the paper size in tray 1, in combination with the reading from the left tray paper length sensor [C].
  • Page 45 PAPER BANK 1 March, 2000 Tray 2 C232D005.WMF C232D012.WMF The paper width in tray 2 is monitored in the same way as tray 1. The width sensors detect the paper size in tray 2, in combination with the reading from the tray 2 paper length sensor.

  • Page 46: Vertical Transport

    1 March, 2000 PAPER BANK 2.1.7 VERTICAL TRANSPORT Front Rear C232D500.WMF The tray registration motor [A] drives the tray registration rollers [B]. The tray feed motor [C] drives the 1st relay rollers [D], 2nd relay rollers [E], the paper feed rollers [F], and the paper pick-up rollers [G].

  • Page 47: Paper Delivery Table

    PAPER DELIVERY TABLE 1 March, 2000 2.2 PAPER DELIVERY TABLE 2.2.1 SIDE AND END PLATE DRIVE C232D015.WMF C232D016.WMF The side plate drive motor [A] moves the left and right side plates using a rack and pinion mechanism. The end plate drive motor [B] moves the end plate via a timing belt and pulleys.

  • Page 48: Main Motor Protection Mechanism

    1 March, 2000 MAIN MOTOR PROTECTION MECHANISM 2.3 MAIN MOTOR PROTECTION MECHANISM The main motor [A] drives the pressure cylinder [B] and the drum. When the pressure cylinder or drum is locked, the torque limiter [C] stops drive from the main motor gear from being transmitted to these parts.

  • Page 49: Drum Home Position Detection

    DRUM HOME POSITION DETECTION 1 March, 2000 2.4 DRUM HOME POSITION DETECTION C232D020.WMF 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 is monitored by the drum home position sensor [A], which is newly added for the actuator disk [B] on the pressure cylinder.

  • Page 50: Timing Chart

    1 March, 2000 TIMING CHART 2.5 TIMING CHART 2-15...
  • Page 51 1) When the paper bank receives the pick-up start command, it turns on the tray feed motor in the paper bank, and this starts the tray registration roller. Then, it turns on the tray exit clutch and stops the tray feed motor. At that time, the trial sheet has been sent to the tray registration roller and is held there.
  • Page 52 1 March, 2000 TIMING CHART 2-17...
  • Page 53 5) When the paper bank receives the pick-up command, it turns on the tray 2 feed clutch. 20 ms after receiving the pick- up command, the tray feed motor starts. This feeds the trial sheet until it activates the 1 relay sensor.

  • Page 54: Error Detection

    1 March, 2000 ERROR DETECTION 2.6 ERROR DETECTION 2.6.1 PAPER FEED ERROR DETECTION IN THE PAPER BANK Error during Paper Feed from the Tandem Tray Tray Registration Motor Tray Registration Sensor Paper Feed Jam The sensor is not on within 95 milliseconds.
  • Page 55 ERROR DETECTION 1 March, 2000 Error during Paper Registration from Tray 2 Tray Registration Motor Tray Registration Sensor Registration Feed Jam The sensor is not on within 165 milliseconds. 2-20...
  • Page 56 1 March, 2000 ERROR DETECTION Paper Relay Error Entry Feed Jam The sensor is not on within 75 milliseconds Tray Registration Motor 2 n d Rela y Sensor Paper Feed Motor (Main Body) 3rd Rela y Sensor Paper Registration Sensor (Main Body) Relay Jam Registration Jam The 3rd relay sensor is not...

  • Page 57: Installation

    1 March, 2000 INSTALLATION REQUIREMENTS 3. INSTALLATION 3.1 INSTALLATION REQUIREMENTS The installation location should be carefully chosen, because the environmental conditions could greatly affect the performance of the machine. 3.1.1 REQUIRED ENVIRONMENTAL CONDITIONS 1. Temperature –10 to 30°C (50 to 86°F) 2.

  • Page 58: Access To The Machine

    INSTALLATION REQUIREMENTS 1 March, 2000 3.1.4 ACCESS TO THE MACHINE Place the machine near a power source, providing clearance, as shown below. More than 10 cm (4.0") Paper Paper Feed 70 cm Delivery Table (27.6") Table More than 60 cm (23.7”) More than More than...

  • Page 59: Installation Procedure

    INSTALLATION PROCEDURE 3.2 INSTALLATION PROCEDURE 3.2.1 ACCESSORY CHECK Make sure that you have all the accessories listed below. Operating Instructions (Expect for Ricoh European Version)....1 NECR (Ricoh version only) ..............1 Brand Decals (OEM version only) ................1 set Model Name Plates (OEM version only) ................

  • Page 60: Installation Procedure

    INSTALLATION PROCEDURE 1 March, 2000 3.2.2 INSTALLATION PROCEDURE C232I001.WMF ø CAUTION Open the box from the top. If the box is lifted off the machine from the bottom, the paper delivery table may be damaged. 1. Unpack the paper bank. Take out the small box [A] which contains the paper delivery table.
  • Page 61 1 March, 2000 INSTALLATION PROCEDURE C232I501.WMF C232I004.WMF 2. Continue to unpack the paper bank. Make sure that there is a paper delivery unit inside the small box [A].
  • Page 62 INSTALLATION PROCEDURE 1 March, 2000 C232I030.WMF 3. Unpack the main body. Take out the accessory bags [A] and [B].
  • Page 63 1 March, 2000 INSTALLATION PROCEDURE C232I006.WMF C232I023.WMF ø CAUTION Only handle using the carrying handles [A] on the bottom of the machine. Your fingers could be caught during installation if you hold the bottom edge of the machine. (There is only a very narrow space between the two units.) 4.
  • Page 64 INSTALLATION PROCEDURE 1 March, 2000 C232I009.WMF C232I031.WMF 6. Remove the tape securing the covers and units. Open the front cover, and slide out the drum unit. Then, remove the master clamper protective sheet [A].
  • Page 65 1 March, 2000 INSTALLATION PROCEDURE C232I027.WMF 7. Take out the paper delivery table from the box. 8. Put up the front and rear side fences, as shown. C232I028.WMF 9. Assemble the paper delivery table, with a screw for each side.
  • Page 66 INSTALLATION PROCEDURE 1 March, 2000 C232I029.WMF 10. Attach the paper delivery table (2 screws). C232I032.WMF 11. Connect the connector [A] to the main body. 3-10...
  • Page 67 1 March, 2000 INSTALLATION PROCEDURE 12. Install a master roll. 13. Install an ink cartridge. 14. Firmly insert the plug in the wall outlet. CAUTION: Make sure that the wall outlet is near the machine and easily accessible. 15. Turn on the main switch. 16.

  • Page 68: Service Tables

    1 March, 2000 DIP SW, LED, VR, TP, AND FUSE TABLES 4. SERVICE TABLES 4.1 DIP SW, LED, VR, TP, AND FUSE TABLES 4.1.1 TEST POINTS Ink Detection Board Number Usage Ink Level Ink Level TP-12V -12V 4.1.2 DIP SWITCHES Ink Detection Board Standard A3 Optional A3...

  • Page 69: Led's

    DIP SW, LED, VR, TP, AND FUSE TABLES 1 March, 2000 4.1.4 LED'S Number Function LED101 Monitors the CPU operation. Usually, this LED is blinking. LED102 Monitors power supplied to the MPU. Usually, this LED is lit. I/O Board Number Function LED300 Not used.

  • Page 70: Service Call Codes

    1 March, 2000 SERVICE CALL CODES 4.2 SERVICE CALL CODES Code Title Conditions Possible Causes • Defective scanner HP SC02-00 Scanner motor After the scanner has left home lock (the HP position, it does not return there sensor • Scanner wire slip-off sensor remains for more than 7 seconds.
  • Page 71 SERVICE CALL CODES 1 March, 2000 Code Title Conditions Possible Causes • Defective master edge SC04-20 Master cut error The master edge sensor remains on even after the first master cut sensor • Defective cutter unit recovery operation. (Normally, the master is cut if the master •...
  • Page 72 1 March, 2000 SERVICE CALL CODES Code Title Conditions Possible Causes • Thermistor circuit open SC05-30 Drum thermistor The signal from the thermistor • Related connector open beside the ink detecting pins reaches 4.5 volts. disconnected • Thermistor short SC05-31 Drum thermistor The thermistor beside the ink short detecting pins detects an...
  • Page 73 SERVICE CALL CODES 1 March, 2000 Code Title Conditions Possible Causes • Defective sensor SC05-52 Clamper open When the master clamper is • Defective motor position sensor being opened, the sensor is not remains on when de-activated for more than 4 •...
  • Page 74 1 March, 2000 SERVICE CALL CODES Code Title Conditions Possible Causes • Defective feed SC07-01 Sensor 0 in the The sensor does not change feed pressure status. pressure detection detection board board • Defective feed remains off pressure motor • Defective feed SC07-02 Sensor 1 in the The sensor does not change feed pressure...
  • Page 75 SERVICE CALL CODES 1 March, 2000 Code Title Conditions Possible Causes • Defective separation SC07-12 Sensor 1 in the The sensor does not change separation status. pressure detection pressure board • Defective separation detection board remains on pressure motor • Defective separation SC07-13 Sensor 1 in the The sensor does not change separation...
  • Page 76 1 March, 2000 SERVICE CALL CODES Code Title Conditions Possible Causes • Defective sensor SC07-51 Wing upper When the wing guide moves • Defective motor position sensor upwards, the sensor is not remains off activated for more than 6 seconds after the wing guide motor on signal is generated.
  • Page 77 SERVICE CALL CODES 1 March, 2000 Code Title Conditions Possible Causes • Defective sensor SC30-00 Paper table lower When the table moves upwards, • Defective motor limit sensor the sensor is not de-activated for remains on more than 7.5 seconds after the paper table motor on signal is generated.
  • Page 78 1 March, 2000 SERVICE CALL CODES Code Title Conditions Possible Causes • Defective slave ROM SC31-50 Slave ROM error Checksum error in the paper tray • Defective paper tray board board • Defective paper tray SC31-51 Slave RAM error Signal transmission error in the paper tray board board •...
  • Page 79 SERVICE CALL CODES 1 March, 2000 Code Title Conditions Possible Causes • Upper low turn gate SC45-12 Upper turn gate The turn gate unit overruns its motor overrun - lower limit, and the upper low turn limit switch • Upper turn gate HP gate switch turns on.

  • Page 80: Special Tools

    1 March, 2000 SPECIAL TOOLS 4.3 SPECIAL TOOLS The following are the special tools used for service. Description Part Number Application Main Drive Securing Tool Kit C229 9000 For main drive positioning (Drum securing tool and two positioning shafts as a set) Scanner Positioning Pin Kit A006 9104 For scanner wire...

  • Page 81: Service Program Mode

    SERVICE PROGRAM MODE 1 March, 2000 4.4 SERVICE PROGRAM MODE The service program (SP) mode is used to check electrical data, change modes, or change adjustment values. 4.4.1 ACCESS PROCEDURE Service Program Mode Access Procedure (For Engineers) 1. Press the following keys on the operation panel in the following order: Clear Modes ⇒...
  • Page 82 1 March, 2000 SERVICE PROGRAM MODE 4. Using the number keys, enter the desired Sub Menu Number (listed in the service program table), then press the OK key on the bottom of the LCD (or the Enter (#) key). NOTE: The sub menu number can be shifted up or down by pressing the Prev. or Next key [A] on the bottom of the LCD.

  • Page 83: Service Program Table

    SERVICE PROGRAM MODE 1 March, 2000 4.4.2 SERVICE PROGRAM TABLE Main Menu Number List 1. Data Logging 2. Basic Settings 3. User Custom Settings 4. Input Test Mode 5. Output Test Mode 6. System Adjustment 7. Memory Data Clear 8. System Test 1.
  • Page 84 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Tools 1-001-28 Master counters M Counter Tint Mode 1-001-29 M Counter A3/DLT 1-001-29 to 35: Original 1-001-30 M Counter B4/LG sizes 1-001-31 M Counter A4-L/LT-L 1-001-43 to 47: Various 1-001-32 M Counter A4/LT copy modes...
  • Page 85 SERVICE PROGRAM MODE 1 March, 2000 User Function SP No. Display Default Tools 1-002-18 P Cnt.Tray1 Oth.Speed1-3 Print counters 1-002-19 P Cnt.Tray1 Oth.Speed4-5 ‘-L’: Lengthwise 1-002-4 to -13: Paper sizes 1-002-20 P Cnt.Tray2 A3.Speed1-3 1-002-14 to -25: Trays 1-002-21 P Cnt.Tray2 A3 Speed4-5 V: Longedge feed P Cnt.Tray2 A4B5Vspeed 1-002-22...
  • Page 86 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Tools Master and printer counters 1-030-28 UC P Counter: Code14 for each user code 1-030-29 UC M Counter: Code15 1-030-30 UC P Counter: Code15 1-030-31 UC M Counter: Code16 1-030-32 UC P Counter: Code16 1-030-33...
  • Page 87 SERVICE PROGRAM MODE 1 March, 2000 User Function SP No. Display Default Tools Number of times the user changed the ‘Misfeed’ or ‘Multifeed’ settings for 1-080 Misfeed Setting Counter paper feed or separation pressures 1-081 Multifeed Setting Count Number of times an error 1-082 Start Error Message Cnt.
  • Page 88 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Tools 1-207-5 Jam% Paper Lower Wrap 1-207-6 Jam% Paper Exit OFF Chk Feed-in jams and 1-300-1 Jam P0 Standard registration roller jams for 1-300-2 Jam P0 Thick various paper sizes and paper types 1-300-3 Jam P0 Others...
  • Page 89 SERVICE PROGRAM MODE 1 March, 2000 User Function SP No. Display Default Tools 1-311-1 Tray2 MisFeed Counter A3 paper trays in the paper bank unit 1-311-2 Tray2 MisFeed Cnt. A4B5V V: Longedge feed 1-311-3 Tray2 MisFeed Cnt. Other Tray 1 Misfeed: Jam at the 1-312-1 Trans.MisFeed Counter A3 tray registration rollers...
  • Page 90 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Tools Print counters for sorter 1-322-1 Cnt.SortPrint over A4 mode. For details, see the 1-322-2 Cnt.SortPrint under A4 sorter service manual. 1-322-3 Cnt.SortPrint Table 1-322-4 Cnt.SortPrint Tray1 1-322-5 Cnt.SortPrint Tray2 Counters for various 1-323-1...
  • Page 91 SERVICE PROGRAM MODE 1 March, 2000 2. Basic Settings User SP No. Display Function Default Setting Tools 2-002 Set Key Counter Also see 2-291. No/Yes Set Key Card 2-003 Japan only No/Yes 2-004 Sorter Select 0:None 0 to 2 1:DS (Japan only) 2:JS (C592) 2-005 Disable Paper Bank...
  • Page 92 1 March, 2000 SERVICE PROGRAM MODE User SP No. Display Function Default Setting Tools 2-040 Ink Detection Enables/disables ON/OFF various sensors for 2-041 Paper Length Detection ON/OFF test purposes 2-042-1 Paper Width Detection ON/OFF 2-042-2: OFF 2-042-2 Paper Size Indicators ON/OFF means that the 2-043...
  • Page 93 SERVICE PROGRAM MODE 1 March, 2000 User SP No. Display Function Default Setting Tools 2-301 Default Stamp Size See Note 33. 0 to 3 2-302 Default Stamp Density See Note 34. 0 to 2 2-303 Default Stamp Position See Note 35. 0 to 9 User Stamp Size 2-304...
  • Page 94 1 March, 2000 SERVICE PROGRAM MODE Notes 1: 2-011 (Display language) 0: Japanese, 1: English, 2: German, 3: French, 4: Italian, 5: Spanish, 6: Dutch 2: 2-015 (Machine Destination) Always set this mode as ‘Other.’ If ‘Japan’ is selected, User Tools 1-5 that are not used for other versions are displayed.
  • Page 95 SERVICE PROGRAM MODE 1 March, 2000 12: 2-020-16 (Default Ratio) U.S. version 0: 65%, 1: 74%, 2: 77%, 3: 93%, 4: 100%, 5: 121%, 6: 129%, 7: 155% 8: Auto Other versions 0: 71%, 1: 82%, 2: 87%, 3: 93%, 4: 100%, 5: 115%, 6: 122%, 7: 141% 8: Auto Selects a magnification ratio at power on or when the Modes Clear key is pressed.
  • Page 96 1 March, 2000 SERVICE PROGRAM MODE 20: 2-070 (Auto Combine Original mode) This SP mode determines the use of the Combine key. 0: Normal – The Combine key accesses the Combine feature, in which two originals can be combined onto one copy 1: Automatic –...
  • Page 97 SERVICE PROGRAM MODE 1 March, 2000 24: 2-125 (Drum Idling) This mode has two options: “Fast” and “Slow”. Fast is the default setting and is used with the new 16-kgf printing pressure setting. (See Pearl RTB No. 3 for more details about the new printing pressure setting.) Fast mode skips the 30-rpm drum rotation speed at the beginning of printing.
  • Page 98 1 March, 2000 SERVICE PROGRAM MODE 28: 2-270 (Print Restart in Class) This determines how the machine behaves if the Job Separator feature is not used. 1: Auto Start – After printing for one class has been finished, there is a pause of a few seconds, then printing for the next class begins automatically.
  • Page 99 SERVICE PROGRAM MODE 1 March, 2000 36: 2-304 to 2-306 (User Stamp Size, Density, and Position) These settings are the same as SP 2-301 to 2-303, except that they are for the user stamp. User stamps are stored using user tool 5-8. User tool 5-7 (SP 3-130 to 138) can be used to adjust the co-ordinates of types 0 to 8.
  • Page 100 1 March, 2000 SERVICE PROGRAM MODE 42: 2-422 (Ink Auxiliary Supply) This mode determines when ink is detected and supplied. There are three possible settings. • ‘0: After’: Ink detection and supply are done when a print job finishes. • ‘1: Before’: They are done when the Print Start key is pressed (and before starting printing).
  • Page 101 SERVICE PROGRAM MODE 1 March, 2000 3. User Custom Settings User SP No. Display Function Default Setting Tools 0 to Minimum Print 3-001 9999% Quantity 0 to Maximum Print 3-002 9999 9999% Quantity Allows the user to 50 to Magnification (A3 to 3-010-1 change the default 200%...
  • Page 102 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Setting Tools MarginErase A4 Determines the edge 3-060-8 50-216 SubScan erase margins. MarginErase B5-L For example, for A3 3-060-9 50-182 Main main scan, the width of MarginErase B5-L the original is 297 mm, 3-060-10 50-257...
  • Page 103 SERVICE PROGRAM MODE 1 March, 2000 User Function SP No. Display Default Setting Tools Use these to input the 3-070-1 Serial Number serial numbers 3-070-2 Bank Serial Number Serial number locations: PDTable Serial 3-070-3 Main body: Open front Number cover, on the left of the 3-071 Installation Date machine (master eject...
  • Page 104 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Setting Tools The number of students 3-100 Register Class 1-1 to 0-9999 in each class. (-1 to -12) 1-12 No. of grades: Up to 9 3-101 Register Class 2-1 to 0-9999 No.
  • Page 105 SERVICE PROGRAM MODE 1 March, 2000 User Function SP No. Display Default Setting Tools Stamp Rt Mdl - These specify the co- 3-126-2 -52 to 52 UpDown ordinates of the eight 3-127-1 Stamp Center - Side -72 to 72 possible positions for the preset stamp.
  • Page 106 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Setting Tools These specify the co- 3-140-1 Date Top Lft - Side 8-40 5-11 ordinates of the four Date Top Lft - 3-140-2 8-40 5-11 possible positions for the UpDown date stamp.
  • Page 107 SERVICE PROGRAM MODE 1 March, 2000 User Function SP No. Display Default Setting Tools -10 to 10 PDTablePos. A4 Default side and end 3-541-7 3-12 SidePlate plate positions on the delivery table for -10 to 10 PDTablePos. A4 3-541-8 3-12 standard paper types EndPlate -10 to 10...
  • Page 108 1 March, 2000 SERVICE PROGRAM MODE User Function SP No. Display Default Setting Tools -0.4 to PDTablePos. LT S- Default side and end 3-543-7 3-12 0.4 inch Plate plate positions on the delivery table for -0.4 to PDTablePos. LT E- 3-543-8 3-12 standard paper types...
  • Page 109 SERVICE PROGRAM MODE 1 March, 2000 4. Input Test Mode SP No. Display 4-020 Scanner HP Sensor 4-021-1 Original Length SN 0 4-021-2 Original Length SN 1 4-021-3 Original Width SN 2 4-021-4 Original Width SN 3 4-021-5 Original Length SN 4 4-021-6 Original Length SN 5 4-022...
  • Page 110 1 March, 2000 SERVICE PROGRAM MODE SP No. Display 4-101-1 Wing Upper Position SN 4-101-2 Wing Lower Position SN 4-120-1 1st Drum Position Sensor 2nd Drum Position Sensor 4-120-2 4-120-3 Drum Home Position Sensor 4-122-1 Drum Type Check 0 4-122-2 Drum Type Check 1 Ink Pump Sensor 4-123...
  • Page 111 SERVICE PROGRAM MODE 1 March, 2000 SP No. Display 4-540-7 PDTable E-Plate HP SN 4-580 Key Card Detection 4-660-1 JS Sorter Lower Unit SN 4-660-2 JS Sorter Lower Entry SN JS Sorter Upper Unit SN 4-660-3 4-660-4 JS Sorter Upper Entry SN 4-660-5 JS Sorter Midd.
  • Page 112 1 March, 2000 SERVICE PROGRAM MODE SP No. Display 4-711-6 L-Tray1 Lower Limit SN 4-712-1 Back-Plate HP SN 4-712-2 Back-Plate SN (return position sensor) Tray2 Tray Set SN 4-713-1 4-713-2 Tray2 Paper End SN 4-713-3 Tray2 Paper Volume SN 4-713-4 Tray2 Paper Width SN1 (front tray 2 paper width sensor) Tray2 Paper Width SN2 (rear tray 2 paper width sensor) 4-713-5...
  • Page 113 SERVICE PROGRAM MODE 1 March, 2000 5. Output Test Mode SP No. Display 5-001 All Indicators On 5-020 Xenon Lamp 5-021-1 Move Scanner - Scan 5-021-2 Move Scanner - Return 5-021-3 Move Scanner to HP 5-040 Master Feed Clutch 5-041 Master Vacuum Fan 5-042-1 Cutter Motor Forward...
  • Page 114 1 March, 2000 SERVICE PROGRAM MODE SP No. Display 5-084-5 Registration Motor 3rd 5-084-6 Registration Motor 4th 5-084-7 Registration Motor 5th Regist. Motor Revs. Slowest 5-084-8 5-084-9 Regist. Motor Revs. 30 rpm 5-084-10 Regist. Motor Revs. 1st 5-084-11 Regist. Motor Revs. 2nd Regist.
  • Page 115 SERVICE PROGRAM MODE 1 March, 2000 SP No. Display 5-540-4 Move E-Plate-Extension 5-580-1 Count-up Key Card 5-580-2 Key Card Motor 5-660-1 Lead Cam Motor Up For L-Unit 5-660-2 Lead Cam Motor Down For L-Unit 5-660-3 Lead Cam Motor Up For U-Unit 5-660-4 Lead Cam Motor Down For U-Unit 5-660-5...
  • Page 116 1 March, 2000 SERVICE PROGRAM MODE SP No. Display 5-713-1 Tray2 Lift Motor : Up 5-713-2 Tray2 Lift Motor : Down 5-713-3 Tray 2 UnLock Sol. (tray 2 lock solenoid) 5-713-4 Tray2 Separation Pad Sol (tray 2 friction pad solenoid) 5-714-1 Tray Paper Feed Motor For.
  • Page 117 SERVICE PROGRAM MODE 1 March, 2000 6. System Adjustment SP No. Display Function Default Settings Side-to-side registration Main Scan Pos. - 6-001-1 -5.0 to 5.0 mm adjustment; see Note 1. Platen Main Scan Position - 6-001-2 -5.0 to 5.0 mm Scanning start line Scan Start Pos.
  • Page 118 1 March, 2000 SERVICE PROGRAM MODE SP No. Display Function Default Settings FeedPressure Std See Note 8. 6-090-1 0 to 6 Special 6-090-2 Freq - Special Paper 0 to 6 V Freq - Special 6-090-3 0 to 6 Paper FeedPressure Std 6-091-1 0 to 6 Nor Ppr...
  • Page 119 SERVICE PROGRAM MODE 1 March, 2000 SP No. Display Function Default Settings See Note 9. Wing Angle - Thick 6-100-3 High/Low Paper Wing Angle - User1 6-100-4 High High/Low Paper Wing Angle - User2 6-100-5 High/Low Paper Paper Clamp - Spl See Note 10.
  • Page 120 1 March, 2000 SERVICE PROGRAM MODE SP No. Display Function Default Settings Thick Regist Delay - Do not adjust. (Changes 6-113-1 0 to 255 the registration motor on timing in thick and special 6-113-2 Regist Delay - 20 rpm 0 to 255 paper modes after the 6-113-3 Regist Delay - 30 rpm...
  • Page 121 SERVICE PROGRAM MODE 1 March, 2000 SP No. Display Function Default Settings Print Position 2 6-116-6 Do not adjust. 0 to 255 Setting Print Position 1 Do not adjust. 6-116-7 0 to 255 Setting Skip Regist Delay 16 Do not adjust. (Changes 6-117-1 0 to 255 the registration motor on...
  • Page 122 1 March, 2000 SERVICE PROGRAM MODE SP No. Display Function Default Settings BankRegistDelay – Do not adjust. (Changes the 6-140-7 0 to 255 tray registration motor on 105rpm timing after the tray BankREgistDelay – registration sensor is 6-140-8 0 to 255 120rpm activated.) Trans.Assist.Delay-...
  • Page 123 SERVICE PROGRAM MODE 1 March, 2000 SP No. Display Function Default Settings Do not adjust. (Changes the registration roller 6-143-2 0 to 255 Tray2 Feed Speed speed before the paper is clamped.) Do not adjust. (Changes the 3 relay roller speed Tray2 Mid.
  • Page 124 1 March, 2000 SERVICE PROGRAM MODE SP No. Display Function Default Settings Bank2 RegistDelay Do not adjust. (Changes 6-146-5 0 to 255 75rpm the tray registration motor Bank2 RegistDelay on timing in tray 2 after 6-146-6 0 to 255 90rpm the tray feed start sensor Bank2 RegistDelay is activated.)
  • Page 125 SERVICE PROGRAM MODE 1 March, 2000 SP No. Display Function Default Settings Bank2 SkipRgstDelay Do not adjust. (Changes 6-149-6 0 to 255 90rpm the tray registration motor Bank2 SkipRgstDelay on timing in tray 2 (when 6-149-7 0 to 255 105rpm using the skip feed mode) Bank2 SkipRgstDelay after the tray feed start...
  • Page 126 1 March, 2000 SERVICE PROGRAM MODE SP No. Display Function Default Settings For details, refer to the 6-660-1 -10 to 10 Timing Delay A3 sorter service manual. Timing Delay B4 6-660-2 -10 to 10 Sideways Timing Delay A4 6-660-3 -10 to 10 Sideways Timing Delay A4 6-660-4...
  • Page 127 SERVICE PROGRAM MODE 1 March, 2000 3: 6-010 (Master writing speed) This changes the master feed motor speed. Inputting a positive value stretches the image on the master. Inputting a negative value shrinks it. Normally, do not use this SP mode to adjust the vertical magnification. Use it only if the vertical magnification is not satisfactory by adjusting Scanning Speed (SP6- 011).
  • Page 128 1 March, 2000 SERVICE PROGRAM MODE 8: 6-90 to 99 (Paper feed and separation pressures for different paper types) These SP modes determine the paper feed and separation pressures that are automatically applied during paper feed. The user adjusts these pressures by selecting a paper type (normal, thick, special, user 1, user 2), and then by selecting how often non-feeds and double feeds are occurring.
  • Page 129 SERVICE PROGRAM MODE 1 March, 2000 7. Memory Data Clear User SP No. Display Tools 7-001 Clear Factory Settings 7-010 Clear Jam/Error Logging 7-011 Clear Resettable Counter Clear Total Counter 7-012 7-020-1 Clear U-Counter: Code 1 7-020-2 Clear U-Counter: Code 2 7-020-3 Clear U-Counter: Code 3 7-020-4...
  • Page 130 1 March, 2000 SERVICE PROGRAM MODE 8. System Test SP No. Display (Comments) 8-010-1 Scanner Free Run M 8-010-2 Magnification at FreeRun 8-011-1 ADF Free Run Mode 8-011-2 Mag. at ADF Free Run 8-020 Load Program (See "4.5.4 Load Program" section.) 8-020-1 Load Program 8-020-2...

  • Page 131: Clearing The Factory Settings (Sp7-1)

    SERVICE PROGRAM MODE 1 March, 2000 4.4.3 CLEARING THE FACTORY SETTINGS (SP7-1) ø CAUTION Performing "Clear factory settings" (SP7-1) resets a part of the settings stored in the RAM to their default settings. Normally, this SP mode should not be used. This procedure is required only after replacing the RAM on the MPU or when the machine malfunctions due to a damaged RAM.

  • Page 132: Load Program (Sp8-20)

    1 March, 2000 SERVICE PROGRAM MODE 4.4.4 LOAD PROGRAM (SP8-20) The firmware in the flash ROM on the MPU can be upgraded using a flash memory card, as follows. C232R024.WMF 1. Before downloading new software, check the current version with SP1-42. 2.

  • Page 133: User Tools

    SERVICE PROGRAM MODE 1 March, 2000 4.4.5 USER TOOLS Some items in the SP mode can be accessed with the User Tools by users. The User Tools key on the operation panel accesses these. The following table shows all the user tools. User Tools Table Display Equivalent SP No.
  • Page 134 1 March, 2000 SERVICE PROGRAM MODE Display Equivalent SP No. Long Paper Mode 2-060 Auto Combine Originals 2-070 Combine Orig. Sep. Line 2-250 4-10 Default Auto Cycle Mode 2-260 4-11 Skip Feed Mode Display 2-320 4-11 Number of Skip Feeds 3-051 4-12 Manual Idling Rotation...
  • Page 135 SERVICE PROGRAM MODE 1 March, 2000 Display Equivalent SP No. Clear User Code 3-113 Key Operator Code 2-290 Register Key Operator 3-112 Restricted Access 2-291 4-68...

  • Page 136: Preventive Maintenance

    1 March, 2000 MAINTENANCE TABLE 5. PREVENTIVE MAINTENANCE 5.1 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 137 MAINTENANCE TABLE 1 March, 2000 Interval Time Print Counter NOTE Item 300K 600K 1M 1.2M 2M Registration/Feed Dry Cloth Timing/Exit Sensors Registration Roller Dry Cloth Drum and Ink Supply Cloth Screen Drum Drive Gears Grease and Cam (Alvania Drum Flange Motor Oil Bushing (SAE #20)

  • Page 138: Replacement And Adjustment

    1 March, 2000 PAPER TRAY 6. REPLACEMENT AND ADJUSTMENT PAPER TRAY 6.1.1 PAPER TRAY REMOVAL Tandem Tray Removal C232R000.WMF C232R001.WMF 1. Draw out the left tandem tray [A]. 2. Remove the left tandem tray (4 screws). 3. Draw out the right tandem tray, then remove the friction pad unit [B] from the tandem right tray (2 screws).

  • Page 139: Paper Feed Roller And Pick-Up Roller Removal

    PAPER TRAY 1 March, 2000 6.1.2 PAPER FEED ROLLER AND PICK-UP ROLLER REMOVAL C232R002.WMF 1. Turn off the main switch. 2. Remove the tandem tray. (Refer to Paper Tray Removal, section 6.1.1) 3. Draw out tray 2. 4. Remove the pick-up roller [A] (1 snap ring). 5.
  • Page 140 1 March, 2000 PAPER TRAY C232R004.WMF 2. Remove the drive unit [C]. 3. Disconnect the connectors [D]. C232R005.WMF 4. Remove the vertical transport unit [E] (4 screws).

  • Page 141: Tandem Back Plate Drive Unit Removal

    PAPER TRAY 1 March, 2000 6.1.4 TANDEM BACK PLATE DRIVE UNIT REMOVAL Left View C232R006.WMF 1. Remove the lower left cover [A] (4 screws). 2. Disconect the connector [B]. 3. Pull out the back plate drive unit [C]. NOTE: When installing the back plate drive unit, hook the bracket [D] onto the back plate drive unit, then slide it in.

  • Page 142: Paper Width Sensor Replacement

    1 March, 2000 PAPER TRAY 6.1.5 PAPER WIDTH SENSOR REPLACEMENT C232R007.WMF 1. Remove the tray [A]. 2. Remove the bottom plate [B] (4 screws). 3. Remove the pinion [C] and rack [D]. 4. Replace the paper width sensors [E]. NOTE: To re-install the pinion, position each point [F] as shown.

  • Page 143: Tray Cover Removal

    PAPER TRAY 1 March, 2000 6.1.6 TRAY COVER REMOVAL Left tandem tray cover C232R008.WMF 1. Draw out the left tandem tray [A]. 2. Remove the left tandem tray cover, as shown (1 screw). NOTE: When re-installing the left tandem tray cover, set the hooks in the holes in the frame.
  • Page 144 1 March, 2000 PAPER TRAY Right tandem tray cover C232R009.WMF 1. Draw out the right tandem tray [A]. 2. Remove the right tandem tray cover, as shown. NOTE: When re-installing the right tandem tray cover, set the hooks in the holes in the frame.

  • Page 145: Bottom Plate Lift Wire Replacement

    PAPER TRAY 1 March, 2000 6.1.7 BOTTOM PLATE LIFT WIRE REPLACEMENT NOTE: Before replacing the rear bottom plate lift wire, remove the front bottom plate lift wire. It is necessary to remove the shaft for replacing the rear bottom plate lift wire. C232R011.WMF 1.
  • Page 146 1 March, 2000 PAPER TRAY C232R012.WMF C232R013.WMF 6. Remove the bracket [D] (4 screws). 7. Remove the wire stoppers. 8. Remove the wire covers. 9. Remove the shaft [E], then replace the rear bottom plate lift wire [F] (1 E-ring, 2 pins).

  • Page 147: Printing Section

    PRINTING SECTION 1 March, 2000 6.2 PRINTING SECTION 6.2.1 TORQUE LIMITER C232R505.WMF 1. Turn off the main switch and remove the drum. 2. Set the drum drive-securing tool. 3. Remove the rear cover and swing out the PSU (see the C229 service manual). C232R503.WMF 4.
  • Page 148 1 March, 2000 PRINTING SECTION C232R506.WMF 6. Remove the 2 springs [C]. 7. Remove the pulley bracket [D]. 8. Remove the timing belt [E]. 9. Remove the gear [F]. 10. Remove the bracket [G]. CAUTION: Screw [H] is located under the main wire harness. Take care not to damage the wire harness when removing it.
  • Page 149 PRINTING SECTION 1 March, 2000 C232R507.WMF 12. Remove the bracket [J] (4 screws). 13. Remove the bearing [K]. 14. Remove the torque limiter [L] (2 allen screws). 6-12...
  • Page 150 1 March, 2000 PRINTING SECTION C232R506.WMF C232R508.WMF 15. Install the bracket [M] CAUTION: Make sure that the positioning holes in the rear frame [N] and the drive gear [O] are in line [P] as shown. If the holes are in line, the paper exit pawl drive timing is OK.
  • Page 151 PRINTING SECTION 1 March, 2000 C232R509.WMF 17. Align the cutout in the bracket [Q] with the pawl on the torque limiter [R] as shown. 18. Install the spring. CAUTION: If the cutout and pawl are in line, the main motor drive timing is OK. If they are not, remove the spring, then make sure that the cutout and pawl are in line again.
  • Page 152 1 March, 2000 PRINTING SECTION C232R504.WMF 20. Install the gear [U]. 21. Install the wire protection cover. 22. Install the main motor control board. 23. Install the rear cover. 24. Remove the drum drive securing tool. 6-15...

  • Page 153: Feed Start Sensors And Feed Encoder

    PRINTING SECTION 1 March, 2000 6.2.2 FEED START SENSORS AND FEED ENCODER C232R500.WMF 1. First, remove the pressure cylinder (see the C229 service manual). 2. From the rear of the machine, swing out the MPU. 3. Disconnect the connectors [A] from the rear of the machine. 4.
  • Page 154 1 March, 2000 PRINTING SECTION CAUTION: Make sure that the distance between the feed encoder sensor [A] and the sensor bracket is less than 0.2 mm. 0.2 mm C232R015.WMF B: Paper table feed start sensor C: Paper tray feed start sensor 6-17...

  • Page 155: Paper Feed Section (Main Body)

    PAPER FEED SECTION (MAIN BODY) 1 March, 2000 6.3 PAPER FEED SECTION (MAIN BODY) 6.3.1 TIMING BELT TENSION ADJUSTMENT FOR THE REGISTRATION MOTOR 2 ~ 4 mm C232R014.WMF 8 ± 0.5 mm 1. Make sure that the distance between the motor and the flange is 8 ± 0.5 mm. 2.

  • Page 156: 2Timing Belt Tension Adjustment For The Paper Table Feed Motor

    1 March, 2000 PAPER FEED SECTION (MAIN BODY) 6.3.2 TIMING BELT TENSION ADJUSTMENT FOR THE PAPER TABLE FEED MOTOR 2 ~ 4 mm 5.5 ± 0.3 mm C232R014.WMF 1. Make sure that the distance between the motor and the flange is 5.5 ± 0.3 mm. 2.

  • Page 157: Paper Feed Length Adjustment

    PAPER FEED SECTION (MAIN BODY) 1 March, 2000 6.3.3 PAPER FEED LENGTH ADJUSTMENT CAUTION: The last digits of the SP numbers for this adjustment are different from the C229 model. Please refer to the chart below and note the changes in the numbers.
  • Page 158 1 March, 2000 PAPER FEED SECTION (MAIN BODY) Paper Feed Motor Stop Timing Adjustment For the Paper Feed Table To ensure that the paper reaches the registration roller (main body) properly. Changing the paper feed motor stop timing with SP 6-116-5 changes the paper feed length for the paper feed roller.
  • Page 159 PAPER FEED SECTION (MAIN BODY) 1 March, 2000 For the Paper Bank Unit - Tray 2 To ensure that the paper reaches the registration roller (main body) properly. Changing the paper feed motor stop timing with SP6-143-1 changes the paper feed length for the paper feed roller.
  • Page 160 1 March, 2000 PAPER FEED SECTION (MAIN BODY) Paper Clamping Timing Adjustment For the Paper Feed Table To ensure that the paper reaches the paper clamper on the pressure cylinder properly. Changing the paper clamping timing with SP6-116-1 (or 6-116-2) changes the paper feed length for the paper registration roller (main body).
  • Page 161 PAPER FEED SECTION (MAIN BODY) 1 March, 2000 For the Paper Bank Unit – Tray 1/Tandem Tray To ensure that the paper reaches the paper clamper on the pressure cylinder properly. Changing the paper clamping timing with SP6-151-1 changes the paper feed length for the paper registration roller (main body).

  • Page 162: Point To Point Diagram

    1 March, 2000 DETAILS 7. POINT TO POINT DIAGRAM 7.1 DETAILS Main Body • Location Map • Section A • Section B • Section C • Section D • Section E • Section F Paper Bank • Location Map • Section A •...

  • Page 163: Main Body

    MAIN BODY 1 March, 2000 7.2 MAIN BODY 7.2.1 LOCATION MAP C232S500.WMF...

  • Page 164: Section A

    1 March, 2000 MAIN BODY 7.2.2 SECTION A C232S501.WMF...

  • Page 165: Section B

    MAIN BODY 1 March, 2000 7.2.3 SECTION B C232S502.WMF...

  • Page 166: Section C

    1 March, 2000 MAIN BODY 7.2.4 SECTION C C232S503.WMF...

  • Page 167: Section D

    MAIN BODY 1 March, 2000 7.2.5 SECTION D C232S504.WMF...

  • Page 168: Section E

    1 March, 2000 MAIN BODY 7.2.6 SECTION E C232S505.WMF...

  • Page 169: Section F

    MAIN BODY 1 March, 2000 7.2.7 SECTION F C232S506.WMF...

  • Page 170: Paper Bank

    1 March, 2000 PAPER BANK 7.3 PAPER BANK 7.3.1 LOCATION MAP C232S507.WMF...

  • Page 171: Section A

    PAPER BANK 1 March, 2000 7.3.2 SECTION A C232S508.WMF 7-10...

  • Page 172: Seciton B

    1 March, 2000 PAPER BANK 7.3.3 SECITON B C232S509.WMF 7-11...

  • Page 173: Section C

    PAPER BANK 1 March, 2000 7.3.4 SECTION C C232S510.WMF 7-12...

  • Page 174: Section D

    1 March, 2000 PAPER BANK 7.3.5 SECTION D C232S511.WMF 7-13...

  • Page 175: Paper Delivery Table

    PAPER DELIVERY TABLE 1 March, 2000 7.4 PAPER DELIVERY TABLE C232S512.WMF 7-14...

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