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Stella S-C3 Service Manual

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Model S-C3
Machine Code:
B262/B280/B292/B293
SERVICE MANUAL
June 30th, 2006
Subject to change

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Summary of Contents for Stella S-C3

  • Page 1 Model S-C3 Machine Code: B262/B280/B292/B293 SERVICE MANUAL June 30th, 2006 Subject to change...

  • Page 2: Safety Notice

    Safety Notice  Important Safety Notices Prevention of Physical Injury 1. Be sure that the power cord is unplugged before disassembling or assembling parts of the copier or peripherals. 2. The wall outlet should be near the copier and easily accessible. 3.

  • Page 3: Laser Safety

    3. Dispose of replaced parts in accordance with local regulations. Laser Safety The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment.

  • Page 4: Symbols And Abbreviations

    Symbols and Abbreviations This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations is as follows: See or Refer to  Clip ring  E-ring  Screw  Connector  Clamp Short Edge Feed Long Edge Feed ...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Safety Notice..............................1  Important Safety Notices..........................1 Laser Safety..............................2 Symbols and Abbreviations..........................3 1. Installation Installation Cautions............................11 Installation Requirements..........................12 Environment..............................12 MACHINE LEVEL............................12 Minimum Operational Space Requirements.....................13 Power Requirements............................14 Copier................................15 Accessory Check............................15 Installation Procedure..........................16 Paper Tray Unit..............................21 Accessory Check............................21 Installation Procedure..........................21 Paper Tray Unit Heater............................23 Accessory Check............................23 Installation Procedure..........................24...
  • Page 6 Special Tools and Lubricants...........................48 Exterior Covers and Operation Panel......................49 Rear Cover..............................49 Copy Tray..............................49 Scale Plate..............................50 Operation Panel and Upper Covers......................51 Right Door..............................52 Bypass Tray..............................52 Platen Cover Sensor............................53 Scanner Unit..............................54 Exposure Glass............................54 Lens Block..............................55 Exposure Lamp, Lamp Stabilizer Board.....................55 Scanner Motor.............................56 Scanner HP Sensor............................58 Scanner alignment adjustment........................58 Fusing................................60...
  • Page 7 Registration Sensor............................72 Bypass Paper End Sensor...........................73 Bypass Feed Roller............................74 Bypass Feed Clutch and Friction Pad......................75 Paper Feed and Registration Clutches.......................76 Image Transfer..............................78 Transfer Roller..............................78 ID Sensor and Duplex Roller........................79 Discharge plate............................80 BICU and Controller Board ..........................81 BICU................................81 Controller Board (B280/B293 models only)...................82 Other Replacements............................85 Duplex Motor...............................85 High-Voltage Power Supply Board ......................86...
  • Page 8 BICU LED Display............................110 5. Service Tables Service Program.............................111 Using SP and SSP Modes.........................111 Copier Service Program Mode Tables....................113 ID Sensor Error Analysis (SP2-221)......................139 Memory Clear............................140 INPUT CHECK (SP5-803)........................141 OUTPUT CHECK (SP5-804)........................143 SERIAL NUMBER INPUT (SP5-811-001)....................144 NVRAM DATA UPLOAD/DOWNLOAD (SP5-824/825)..............145 Firmware Update Procedure........................147 TEST PATTERN PRINT (SP5-902-001)....................149 SMC Print (SP5-990)..........................151 Printer Service Program Mode Table.......................152...
  • Page 9 Original Modes............................167 Image Processing Steps for Each Mode....................170 Mode Adjustments.............................171 Laser Exposure...............................172 Overview..............................172 LD Safety Switches............................173 Photoconductor Unit (PCU)...........................174 Overview..............................174 DRUM Drive...............................175 Drum Charge..............................176 Overview..............................176 Charge Roller Voltage Correction......................177 Charge Roller Cleaning..........................178 Detection of New PCU..........................178 Development..............................180 Overview..............................180 Development Bias............................181 Toner Supply..............................181 Toner density control..........................182 Toner Supply If Sensor Reading is abnormal ..................183...
  • Page 10 Overview..............................194 Hot Roller Drive............................195 Pressure Roller............................196 Pressure Release............................196 Separation..............................197 Fusing Temperature Control........................197 Duplex Unit..............................201 Important Components..........................201 Duplex Printing Process..........................202 Energy Saver Modes.............................205 Overview..............................205 AOF................................206 Timers.................................206 Recovery..............................206 GDI Controller...............................207 Overview..............................207 Controller Functions...........................209 Scanner Functions.............................210 Network Interface.............................211 USB................................212 NVRAM on the GDI Controller........................214 7.
  • Page 11 GDI Model (B280/B293)........................226...

  • Page 12: Installation

    1. Installation Installation Cautions • Before installing an optional unit, do the following: • If there is a printer option on the machine, print out all data in the printer buffer. • Turn off the main switch and disconnect the power cord, the telephone line, and the network cable.

  • Page 13: Installation Requirements

    1. Installation Installation Requirements Environment –Temperature and Humidity Chart– • Temperature Range: 10°C to 32°C (50°F to 89.6°F) • Humidity Range: 15% to 80% RH • Ambient Illumination: Less than 1,500 lux (Do not expose to direct sunlight.) • Ventilation: Room air should turn over at least 3 times/hr/person •...

  • Page 14: Minimum Operational Space Requirements

    Installation Requirements Right to left: Within 5 mm (0.2") of level Minimum Operational Space Requirements Place the machine near the power source, providing clearance as shown. A: Front – 750 mm (29.6") B: Left – 100 mm (3.9") C: Rear – 105 mm (4.1") D: Right –...

  • Page 15: Power Requirements

    1. Installation • Actual minimum space requirement for left, rear, and right sides is 10mm (0.4") each, but note that this will not allow room for opening of the bypass tray, right door, platen cover, or ARDF unit. Power Requirements •...

  • Page 16: Copier

    Copier Copier Accessory Check Basic Model Description Q’ty CD-ROM (Copy Reference) (-17) CD-ROM (Printer Reference/Scanner Reference/Copy Reference) (-21) About This Machine (-17) Troubleshooting (-17) Language Kit (-26) EU Safety Sheet (-26, -67) NECR (-17) CCC Decal (-21) Paper Size Decal Warranty Sheet (Chinese) (-21) Sheet - Name - Tel (-21) GDI Model...

  • Page 17: Installation Procedure

    1. Installation CD-ROM (Driver: Printer/Scanner and Printer Reference/Scanner Reference) (-29) EU Safety Sheet (-26, -67) NECR (-17) Paper Size Decal Sheet - EULA (-26, -29, 67) Caution Decal (-26, -29, 67) Ferrite Core (B293-26, B293-67) Installation Procedure • Make sure that the copier remains unplugged during installation. 1.
  • Page 18 Copier 3. Remove the spacing wedge [C]. 4. Remove the three scanner lock pins. (A tag is hanging from each pin.) To remove: Grasp the base of the pin [D], turn the pin 90 degrees, and pull it down and out. 5.
  • Page 19 1. Installation 9. Open the front door [F]. 10. Lift lever [G], press in on latch [H] and pull the bottle holder [I] out. (You do not need to pull it completely out of the machine.) 11. Take a new bottle of toner, and shake it several times. 12.
  • Page 20 Copier 16. Remove the padding [M]. 17. Pull each tabbed strip [N] out of the PCU with one hand, supporting the PCU with the other. • Do not pull both strips at the same time, as this could damage the PCU. 18.
  • Page 21 1. Installation 22. Push the tray back into the copier. 23. Attach the appropriate Brand Decal to the center [O] of the front door if necessary. 24. Attach the appropriate tray number decal and paper-size decal to the paper tray [P]. 25.

  • Page 22: Paper Tray Unit

    Paper Tray Unit Paper Tray Unit Accessory Check Confirm that you have these accessories. Description Q’ty 1. Paper-size decals 1 sheet 2. Installation Procedure (for service person) 3. Installation Procedure (for user) Installation Procedure • Unplug the main machine's power cord before starting the following procedure. 1.
  • Page 23 1. Installation 3. Set the machine on the paper tray unit. 4. Remove the paper tray from the paper tray unit. 5. Load paper into the paper tray. Adjust the side and end fences as necessary. If loading 8 "x 14" paper, remove the end fence and set it into the special compartment.

  • Page 24: Paper Tray Unit Heater

    Paper Tray Unit Heater Paper Tray Unit Heater Accessory Check Confirm that you have the accessories listed below. Description Q’ty 1. Grounding wire 2. Relay harness 3. Clamps 4. Ferrite core 5. Heater fastening screws 6. PTU fastening screws 7. Grounding screw 8.

  • Page 25: Installation Procedure

    1. Installation Installation Procedure • Unplug the main machine's power cord before starting the following procedure. 1. Remove the paper tray unit from the copier if it is already installed. 2. Remove the paper trays from the copier and from the paper tray unit.
  • Page 26 Paper Tray Unit Heater 3. Remove the ground screw [1] at the rear of the paper tray unit. 4. Fasten the heater [2] and the supplied ground wire [3] to the paper tray unit ( x 3). Note that [1] is the ground screw you removed in the previous step and [4] and [5] are the two supplied heater fastening screws.
  • Page 27 1. Installation 7. Open the front door and remove the copy tray [7] (×1). 8. Close the front door. 9. Remove the memory card cover [8] ( x 1). 10. Remove the rear cover [9] ( x 5).
  • Page 28 Paper Tray Unit Heater 11. For B280/B293 only: Remove the upper left cover [10]. 12. For B280/B293 only: Remove the controller box [11] ( x 1,  x 5). 13. Remove the support bracket [12] ( x 3).
  • Page 29 1. Installation 14. Pass the heater harness through the hole [15] at the rear of the copier. 15. Pass relay harness [16] through the opening [17] (at the rear of the PSU) and through the other opening [15]. 16. Connect the relay harness to the heater's harness [18]. 17.
  • Page 30 Paper Tray Unit Heater 18. Attach the ferrite core [19] over the relay harness. 19. Push the ferrite core back so that it is over the heater's harness. 20. Wrap the heater's harness once around the ferrite core [20]. 21. Locate the ferrite core at the rear [24] of the copier behind the rear clamps. 22.
  • Page 31 1. Installation 33. Reassemble the copier. 34. Plug in the power cord, and check the operation.

  • Page 32: Ardf (B872)

    ARDF (B872) ARDF (B872) Accessory Check Description Q’ty 1. Stud Screw 2. Screw 3. Clamp 4. DF Exposure Glass with Mylar 5. Left Scale Guide Platen Sheet Installation Procedure Installation Procedure • Unplug the main machine's power cord before starting the following procedure.
  • Page 33 1. Installation 1. Unpack the ARDF and remove the packing tape from the bottom of the ARDF body. 2. Open the right door [A]. 3. Remove the connector cover [B] ( x 1) and rear cover [C] ( x 5).
  • Page 34 ARDF (B872) 4. Remove the left guide [D] ( x 2) and scanner left cover [E] (hook x 2). 5. Place the DF exposure glass [F] on the glass holder. • When installing the DF exposure glass, make sure that the side of the DF exposure glass with two black points faces down.
  • Page 35 1. Installation 6. Peel off the backing [G] of the double-sided tape attached to the rear side of the left scale guide [H], then install it ( x 2 removed in step 4). 7. Remove the two platen stays [I] and bracket ( x 1 each). 8.
  • Page 36 ARDF (B872) 9. Mount the DF [J] on the copier as shown. 10. Secure the screw [K]. 11. Attach the clamp [L]. 12. Connect two I/F cables [M] to the CN109 and CN110 on the BICU, and secure the ground cable [N] (...
  • Page 37 1. Installation 13. Cut the cutout [P] with nippers. 14. Reinstall the rear cover and connector cover ( x 6). 15. Close the right door. 16. Open the ARDF. 17. Place platen sheet [Q] on the exposure glass. 18. Line up the rear left corner of the platen sheet flush against corner [R] on the exposure glass. 19.
  • Page 38 ARDF (B872) 20. Check that the groove [S] of the ARDF is aligned with the groove [T] of the left scale on the scanner. • The shift value between [S] and [T] must be within ± 0.5 mm. 21. Reinstall the platen sheet if both grooves are not aligned correctly. 22.

  • Page 39: Ddst Unit (B880/893)

    1. Installation DDST Unit (B880/893) Accessory Check Description Q’ty Controller Box Screw M3 x 6 Printer Panel (B880: English + Symbol) Printer Panel (B893: Symbol) Ferrite Core (B880) CD-ROM (Printer and Scanner Driver) (-15, -17) CD-ROM (Printer/Scanner Reference) (-15, -17) CD-ROM (Printer/Scanner Driver and Printer/Scanner Reference) (-21) FCC Decal (-15) Ground Plate (B880-15, 21)

  • Page 40: Installation Procedure

    DDST Unit (B880/893) Installation Procedure • Unplug the main machine's power cord before starting the following procedure. 1. Open the right door [A]. 2. Remove the memory card cover [B] ( x 1) 3. Remove the rear cover [C] ( x 5). 4.
  • Page 41 1. Installation 7. Install the ground plate [H] ( x 2). • Insert the upper and lower hooks in the openings [I], and fasten the upper screw first. 8. Install the controller box [J] ( x 5). • Insert the bracket [K] into the frame. The connector on the controller box engages with the connector on the BICU.
  • Page 42 DDST Unit (B880/893) 11. For the North America model only: Attach the FCC decal [N] close to the LAN cable slot of the controller box. 12. Reassemble the whole copier. 13. For B880 only: Attach the ferrite core [O] to the network cable and attach the cable to the copier if a network cable is used.
  • Page 43 1. Installation 14. Plug in the power cord, and turn on the main switch. 15. Check the operations.

  • Page 44: Preventive Maintenance

    2. Preventive Maintenance PM Tables Reset the PM counter (SP7-804-001) after doing maintenance work. Key: AN: As necessary, C: Clean, R: Replace, I: Inspect Every 45k Every 90k NOTE OPTICS Reflector Optics cloth 1st mirror Optics cloth 2nd mirror Optics cloth 3rd mirror Optics cloth Platen cover...
  • Page 45 2. Preventive Maintenance Every 45k Every 90k NOTE Hot roller bearings Pressure-roller bush- ings Inlet guide Outlet guide Hot roller stripper pawls Thermistor Every 90k NOTE ARDF Separation roller Water or alcohol Pick-up roller Water or alcohol Feed roller Water or alcohol White plate Water or alcohol DF exposure glass...

  • Page 46: How To Clear The Pm Counter

    How to Clear the PM Counter How to Clear the PM Counter Reset the PM counter after your maintenance work. 1. Activate the SP mode. 2. Select SP7-804-001. 3. Press the EXECUTE key [A]. The message "Completed" is displayed when the program ends normally. An error message is displayed if the program ends abnormally.
  • Page 47 2. Preventive Maintenance...

  • Page 48: Replacement And Adjustment

    3. Replacement and Adjustment Precautions General • Turn off the main power switch and unplug the machine before starting replacement. Before turning off the main power switch, check that no mechanical component is operating. Mechanical components may stop out of their home positions if you turn off the main power switch while they are operating.

  • Page 49: Special Tools And Lubricants

    3. Replacement and Adjustment Special Tools and Lubricants Part Number Description Q’ty A1849501 Optics Adjustment Tools (2 pcs/set) 1 set A2929500 Test Chart – S5S (10 pcs/set) 1 set VSSM9000 Digital Multimeter – Fluke 87 N8036701 Flash Memory Card (4MB) N8031000 Case for Flash Memory Card A2579300...

  • Page 50: Exterior Covers And Operation Panel

    Exterior Covers and Operation Panel Exterior Covers and Operation Panel Rear Cover 1. Open the left door [A]. 2. Memory card cover [B] ( x 1) 3. Rear cover [C] ( x 5) Copy Tray • Make sure that the cables under the copy tray are in place before reassembling the copier. If these cables are caught between the copy tray and the inner cover, they may be severely damaged.

  • Page 51: Scale Plate

    3. Replacement and Adjustment 1. Open the front door [A]. 2. Copy tray [B] ( x 1) Reassembling There are several cables under the front end of the copy tray. To set these cables in place, gently pull these cables to the left-hand side (toward the PSU) and hold them there as you attach the copy tray. Scale Plate The scale plate is for the following models only: •...

  • Page 52: Operation Panel And Upper Covers

    Exterior Covers and Operation Panel 1. Scale plate [A] ( × 2) Operation Panel and Upper Covers 1. Remove the ARDF (if it has been installed). 2. Rear cover (* "Rear Cover") 3. Slide the upper left cover [A] to the rear. 4.

  • Page 53: Right Door

    3. Replacement and Adjustment Right Door 1. Open the right door [A]. 2. Release the strap [B]. 3. Right door ( × 1) Bypass Tray...

  • Page 54: Platen Cover Sensor

    Exterior Covers and Operation Panel 1. Press the stopper rails [A] inward. Platen Cover Sensor 1. Rear cover (* "Rear Cover") 2. Rear scale (* "Operation Panel and Upper Covers") 3. Platen cover sensor [A] (× 1, hook)

  • Page 55: Scanner Unit

    3. Replacement and Adjustment Scanner Unit To clean the mirrors and lenses, use a blower brush or wet cotton. Exposure Glass To clean the exposure glass, use alcohol or glass cleaner. Non-ARDF machines 1. Rear cover (* "Rear Cover") 2. Scale plate (* "Operation Panel and Upper Covers") 3.

  • Page 56: Lens Block

    Scanner Unit Lens Block • Do not disassemble the lens block. The lens block is precision adjusted before shipment. • Do not touch the screws on the CCD. The CCD is precision adjusted before shipment. 1. Exposure glass (* "Exposure Glass") 2.

  • Page 57: Scanner Motor

    3. Replacement and Adjustment 1. Exposure glass (* "Exposure Glass") 2. Front left cover, operation panel (* "Operation Panel and Upper Covers") 3. Slide the first scanner to a position where the lamp and scanner are clear of the metal lids. 4.
  • Page 58 Scanner Unit 3. Remove the right platen stay holder [A] ( x 3). 4. Scanner motor [B] ( × 3, 1 spring, 3 screw holders,  × 1) Reinstalling When reinstalling, fasten the screws loosely, set the spring in place, and tighten up the screws.

  • Page 59: Scanner Hp Sensor

    3. Replacement and Adjustment Scanner HP Sensor 1. Rear cover (* "Rear Cover") 2. Front left cover (* "Operation Panel and Upper Covers") 3. Scale plate (* "Scale Plate") 4. Scanner HP sensor [A] ( × 1, hook) • Move the first scanner from the home position if you have difficulty removing the sensor. Scanner alignment adjustment 1.
  • Page 60 Scanner Unit 5. Slide the 1st and 2nd scanners so that all four of the following are roughly aligned on both the front and back sides: • The hole on the copier's lid • The hole on the 1st scanner •...

  • Page 61: Fusing

    3. Replacement and Adjustment Fusing Fusing Unit • Before handling the fusing unit, make sure that the unit is cool enough. The fusing unit can be very hot. 1. Copy tray (* "Copy Tray") 2. Open the right door. 3. Connector cover [A] ( x 1) •...

  • Page 62: Exit Sensor

    Fusing Exit Sensor 1. Fusing unit (* "Fusing Unit") 2. Exit sensor [A] ( × 1) Hot Roller Stripper Pawls • Take care not to damage the hot roller stripper pawls and the tension springs.

  • Page 63: Hot Roller & Fusing Lamp

    3. Replacement and Adjustment 1. Fusing unit (* "Fusing Unit") 2. Separate the fusing unit into two sections: the hot roller section [A] and the pressure roller section [B] ( x 2). After removing the screws, lower the pressure roller section about halfway and then slide it toward the front side to detach it.
  • Page 64 Fusing 1. Hot roller stripper pawls and spacers (* " Hot Roller Stripper Pawls") 2. Hot roller assembly [A] ( x 2) 3. Fusing lamp [B] • When reassembling, check that the direction of the fusing lamp is correct. 4. Hot roller [C] (2 C-rings, 1 spacer, 1 gear, 2 bushings, 1 cover [D]) Reassembling Be sure that: •...

  • Page 65: Thermoswitches And Thermistor

    3. Replacement and Adjustment Thermoswitches and Thermistor 1. Hot roller assembly (* "Hot Roller & Fusing Lamp") 2. Thermoswitches ( x 2 for each) 3. Thermistor ( x 1) Reassembling Make sure of the following: • That the thermistor is in contact with the hot roller. •...

  • Page 66: Pressure Roller

    Fusing Pressure Roller 1. Separate the fusing unit into two sections (* "Hot Roller Stripper Pawls"). 2. Fusing entrance guide [A] 3. Two springs [B][C] 4. Two pressure arms [D][E] 5. Bushing [F] 6. Pressure roller [G]...

  • Page 67: Checking The Nip Band

    3. Replacement and Adjustment Checking the NIP band You can check the nip band to see if the fusing unit is in a good condition–especially, if the hot roller and pressure roller are correctly installed. 1. Activate the SP mode. 2.

  • Page 68: Pcu And Quenching Lamp

    PCU and Quenching Lamp PCU and Quenching Lamp When handling the photo conductor unit (PCU), use caution: • Do not touch the OPC drum with your bare hands. When the OPC drum is unclean, clean it with dry cloth, or clean it with wet cotton and wipe it with dry cloth. •...

  • Page 69: Quenching Lamp

    3. Replacement and Adjustment After you turn on the main power switch, the copier automatically initializes the new PCU. When the copier is executing initialization, it is important that you: • Do not turn off the main power switch. • Do not open or remove exterior covers. Quenching Lamp 1.

  • Page 70: Exhaust Fan And Main Motor

    Exhaust Fan and Main Motor Exhaust Fan and Main Motor Exhaust Fan 1. Rear cover (* "Rear Cover") 2. Exhaust fan [A] ( x 2,  x 1) Reassembling Make sure that the arrow [B] on the frame points to the rear side. The arrow indicates the direction of airflow.

  • Page 71: Main Motor

    3. Replacement and Adjustment Main Motor 1. Rear cover (* "Rear Cover") 2. High-voltage power supply board (* "High-Voltage Power Supply Board") 3. Ground plate [A] ( x 1) 4. Main motor with the gear cover [B] ( x 1,  x 7,  x 2, 2 bushings) 5.

  • Page 72: Paper Feed

    Paper Feed Paper Feed Paper Feed Roller and Friction Pad When handling the paper tray or the paper feed roller, use caution: • Do not touch the surface of paper feed rollers. • To avoid paper jams, correctly set the side and end fences in the paper tray. 1.

  • Page 73: Paper End Sensor

    3. Replacement and Adjustment Paper End Sensor 1. Paper tray 2. Open the right door. 3. PCU (* ”PCU") 4. Paper end sensor [A] ( x 1) Registration Sensor 1. Paper tray 2. Open the right door. 3. Open the paper guide [A]. •...

  • Page 74: Bypass Paper End Sensor

    Paper Feed 4. Registration sensor feeler [B] 5. Registration sensor [C] ( x 1) • Disconnect the connector (CN127 [D]) if you have difficulty removing the registration sensor. Bypass Paper End Sensor 1. Right door (* "Right Door") 2. Sensor compartment [A] 3.

  • Page 75: Bypass Feed Roller

    3. Replacement and Adjustment Bypass Feed Roller 1. Right door (* "Right Door") 2. Turn the feed roller housing upside down [A] ( x 2). 3. Feed roller shaft [B] (2 snap pawls [C], 1 spacer [D]) 4. Bypass feed roller [E]...

  • Page 76: Bypass Feed Clutch And Friction Pad

    Paper Feed Bypass Feed Clutch and Friction Pad 1. Rear cover (* "Rear Cover") 2. Right door (* "Right Door") 3. Disconnect the bypass feed clutch connector [A] (CN93). 4. Bypass feed roller housing [B] ( x 2) 5. Bypass feed clutch [C] ( x 1) 6.

  • Page 77: Paper Feed And Registration Clutches

    3. Replacement and Adjustment Paper Feed and Registration Clutches 1. Paper tray 2. High-voltage power supply board (* "High-Voltage Power Supply Board") 3. Ground plate [A] ( x 1) 4. Gear cover [B] ( x 1,  x 7,  x 2, 2 bushings) •...
  • Page 78 Paper Feed 5. Ground plate [C] ( x 1) 6. Slowly push the clutch holder [D] and remove the registration clutch [E] ( x 1,  x 1). 7. Paper feed clutch [F]...

  • Page 79: Image Transfer

    3. Replacement and Adjustment Image Transfer Transfer Roller • Do not touch the transfer roller with your bare hands. • Do not scratch the transfer roller. The transfer roller is easily damaged. 1. Right door (* "Right Door") 2. Raise the levers [A][B] at the ends of the image transfer roller. 3.

  • Page 80: Id Sensor And Duplex Roller

    Image Transfer ID Sensor and Duplex Roller 1. Right door (*"Right Door") 2. Lower guide [A] 3. Idle roller holders [B][C] 4. Idle roller [D] 5. Roller guide [E] 6. Transfer unit [F] 7. One-way gear [G] ( x 1) 8.

  • Page 81: Discharge Plate

    3. Replacement and Adjustment 9. ID sensor ( x 1) Discharge plate 1. Right door (*"Right Door") 2. Discharge plate [A].

  • Page 82: Bicu And Controller Board

    BICU and Controller Board BICU and Controller Board Note that the basic model (B262/B292) and GDI models (B280/B293) have different components. The table lists the components and necessary maintenance work. BICU Controller Controller Maintenance Work NVRAM NVRAM Save the data from the NVRAM to a memory card be- Installed None None...

  • Page 83: Controller Board (B280/B293 Models Only)

    3. Replacement and Adjustment 2. Bracket at the left-rear frame (basic models [B262/B292]:  x 2) or controller box [A] (GDI models [B280/B293]:  x 5) 3. Ground plate [B] ( x 2) 4. BICU [C] (all , 2 flat cables,  x 6) •...
  • Page 84 BICU and Controller Board 2. Controller box cover [A] ( x 12) 3. Controller board [B] ( x 5) • When replacing the controller board, remove the NVRAM [D] from the board. Install the NVRAM to the new board. When replacing the NVRAM on the controller board When you replace the NVRAM [C], make sure that the NVRAM is correctly installed.
  • Page 85 3. Replacement and Adjustment The mark [D] on the NVRAM is directed to the right side (seem from the front).

  • Page 86: Other Replacements

    Other Replacements Other Replacements Duplex Motor 1. Rear cover (* "Rear Cover") 2. Duplex motor [A] ( x 1,  x 2)

  • Page 87: High-Voltage Power Supply Board

    3. Replacement and Adjustment High-Voltage Power Supply Board 1. Rear cover (* "Rear Cover") 2. High-voltage power supply board [A] (all ,  x 4) • Remove the insulating sheet [B] if you are going to remove the contact-release solenoid (* "Contact-Release Solenoid") or the gear cover (* "Paper Feed and Registration Clutches").

  • Page 88: Psu

    Other Replacements 1. Open the front door. 2. Copy tray (* "Copy Tray") 3. PSU assembly [A] ( x 4,  x 8) 4. PSU [B] ( x 1,  x 6) • The North America models do not have the connector.

  • Page 89: Contact-Release Solenoid

    3. Replacement and Adjustment Contact-Release Solenoid 1. Rear cover (* "Rear Cover") 2. High-voltage power supply board (* "High-Voltage Power Supply Board") 3. Contact-release solenoid (1 spring,  x 1) Toner Supply Clutch 1. Toner bottle holder...
  • Page 90 Other Replacements 2. Copy tray (* "Copy Tray") 3. Rear cover (* "Rear Cover") 4. Disconnect the connector on C19 on the BICU. 5. Push the clutch coupler [A] to the rear side, and remove the clip ring [B] from the back of the copier. 6.

  • Page 91: Laser Unit

    3. Replacement and Adjustment Laser Unit • Turn off the main power switch and unplug the copier before starting replacement. The laser beam can damage your eyes severely. • Do not touch the screws on the LD board on the LD unit. Do not try to adjust any part of the LD unit. The LD unit is precision adjusted before shipment.

  • Page 92: Ld Unit And Polygon Mirror Motor

    Laser Unit 3. Laser unit [A] ( x 3,  x 2) Reassembling Make sure that the cable [B] passes under the unit. LD Unit and Polygon Mirror Motor 1. Laser unit (* "Laser Unit") 2. Laser unit cover [A] ( x 2, 1 grounding plate) 3.

  • Page 93: Adjusting Copy Image Area

    3. Replacement and Adjustment Adjusting Copy Image Area Adjust the copy image area under any of the following conditions: 1. After clearing engine data (SP5-801-002 or SP5-998-001). 2. After replacing any of the following components: • First scanner or second scanner •...
  • Page 94 Adjusting Copy Image Area Specification 0 ± 2 mm SP1-001-001 (All Trays) 0 ± 2 mm SP1-001-002 (By-pass) 0 ± 4 mm SP1-001-003 (Duplex) 5. Adjust the leading edge registration (SP1-001). 6. Measure the distance between the side edge of the image area and the side edge of the paper [B]. Specification 0 ±...

  • Page 95: Scanning

    3. Replacement and Adjustment 3. Adjust the blank margin (SP2-101). Specification 2 ± 1.5 mm SP2-101-001 (Leading Edge) [A] SP2-101-002 (Trailing Edge) [B] 2 +2.5/-1.5 mm 2 ± 1.5 mm SP2-101-003 (Left Side) [C] SP2-101-004 (Right Side) [D] 2 +2.5/-1.5 mm •...
  • Page 96 Adjusting Copy Image Area 2. Make a copy. 3. Measure the distance between the leading edge of the image area and the leading edge of the paper [A]. • The diagram shows the paper on the copy tray. Note that the paper is output with the face down. 4.
  • Page 97 3. Replacement and Adjustment Adjusting Magnification 1. Place the test chart on the exposure glass. Make sure the test chart is aligned with the rear and left scales on the exposure glass. 2. Make a copy. 3. Compare the copy with the original. 4.

  • Page 98: Df Image Adjustment

    Adjusting Copy Image Area • Replacing the lens block • Executing the memory clear (SP5-801-002 [basic model], SP5-998-001 [other models]). 1. Place 10 sheets of new A4 paper on the exposure glass. 2. Close the platen cover. 3. Activate the SP mode. 4.
  • Page 99 3. Replacement and Adjustment (The diagram shows the paper on the copy tray. Note that the paper is output with the face down.) 5. Adjust the side-to-side registration (S to S/Front Regist: SP6-006-001, S to S/Rear Regist: SP6-006-004). The image area moves to the rear side of the copier when you specify a larger value. 6.

  • Page 100: Troubleshooting

    4. Troubleshooting Service Call Conditions Summary There are four levels of service call conditions. Level Definition Reset Procedure To prevent possible damage, the machine does not Activate the SP mode, and turn the operate until the service representative resets the SC main power switch off and on.
  • Page 101 4. Troubleshooting Symptom Possible Cause Definition • Defective exposure lamp connector • Unclean scanner mirror • Scanner mirror out of position • Defective SBU board • Defective SBU connector • Lens block out of position • Incorrect position or width of white plate scanning (* SP4-015) Scanner home position error 1 •...
  • Page 102 Service Call Conditions Symptom Possible Cause Definition • The automatic SBU adjustment has failed to correct the black level ten times at the PGA adjustment. • The automatic SBU adjustment has failed to correct the black level ten times at the offset adjustment. SBU white/black level correction error •...
  • Page 103 4. Troubleshooting Symptom Possible Cause Definition • Inconsistency between the BICU firm- The BICU does not receive the memory ad- ware and the controller firmware dress report from the controller within one • Defective BICU minute. • Defective controller Charge roller current leak •...
  • Page 104 Service Call Conditions Symptom Possible Cause Definition TD sensor error The BICU detects the TD sensor outputting • Defective TD sensor extraordinary voltage (less than 0.2 V or • Loose connection of the PCU more than 4.0 V) 10 times consecutively. Development bias leak •...
  • Page 105 4. Troubleshooting Symptom Possible Cause Definition The main motor does not reach its opera- tion speed within 0.7 second. Or, the main • Overload motor remains out of its operation speed for • Defective main motor 0.7 second after reaching the operation speed.
  • Page 106 Service Call Conditions Symptom Possible Cause Definition While the fusing lamp is on, the fusing tem- • Defective thermistor perature varies 50°C or more within one • Incorrect installation of the thermistor second; and this occurs two consecutive • Defective power supply unit times.
  • Page 107 4. Troubleshooting Symptom Possible Cause Definition • BICU does not get a signal from the printer board for 1.5 seconds or more. • Defective communication between • BICU gets a break-signal after com- BICU and printer board pleting the communication with the printer board and does not get a sig- nal from the printer board for 10 sec- onds or more.
  • Page 108 Service Call Conditions Symptom Possible Cause Definition • Defective BICU • Loose connection Engine total counter error The checksum of the total counter is not • Defective NVRAM on the BICU correct. Memory error • Defective memory An error occurs during the memory check conducted when the main power switch is •...

  • Page 109: Electrical Component Troubleshooting

    4. Troubleshooting Electrical Component Troubleshooting Sensor/Switch Open Errors Sensor Connector Message Remarks CN127 Registration Sensor Paper jam CN129 Paper End Sensor Load paper CN130 Bypass Paper End The machine cannot detect paper on (None) Sensor the bypass tray. CN128 Paper Path Sensor Paper jam CN128 Exit Sensor...

  • Page 110: Blown Fuse Conditions

    Electrical Component Troubleshooting Sensor Connector Message Remarks DF CN103 Paper jam DF Original Set Sen- Sensor (None) Originals are not detected. DF CN103 DF Registration Sen- Paper jam Originals are correctly transported. DF CN103 Paper jam Inverter Sensor (None) DF CN103 Exit Sensor Paper jam CN114...

  • Page 111: Bicu Led Display

    4. Troubleshooting BICU LED Display Number Function LED2 LED2 blinks in normal operation.

  • Page 112: Service Tables

    5. Service Tables Service Program • Do not let the user access the SP mode or the SSP mode. Only service representatives are allowed to access these modes. The machine operation is NOT guaranteed after any person other than service representatives accesses the SP mode or the SSP mode.
  • Page 113 5. Service Tables Starting SSP Mode The SSP mode is not available on the basic model (the machine without the controller box). 1. Type the keys as follows: →→→ 2. Press the  key and hold it down until the SP-mode menu is displayed (about 3 seconds). 3.

  • Page 114: Copier Service Program Mode Tables

    Service Program Copier Service Program Mode Tables Conventions used in the tables: • Asterisk (*): The settings are saved in the NVRAM. Most of them return to the default values when you execute SP5-801-002. • DFU: The program is for design/factory use only. Do not change the settings. •...
  • Page 115 5. Service Tables 1103* Fusing Idling [0 = No / 1 = Yes] Enables or disables the contact-release control. The following table lists the results. Setting 0 = No 1 = Yes 1103 1 C-R control Works Does not work Idling time Shorter Longer...
  • Page 116 Service Program 1109 Nip Band Check Conducts the nip band check (* "Adjusting Nip Band" in the section "Replacement and 1109 1 Adjustment"). 1110* Fan Control Timer [30 to 60 / 30 / 1 s/step] Specifies the fan control time. The fan motor keeps its operating speed for the specified 1110 1 time before changing the speed or stopping.
  • Page 117 5. Service Tables Adjusts the voltage applied to the charge roller for the ID sensor pattern (as part of charge- roller voltage correction). The charge-roller voltage is obtained by adding SP2-001-002 to the value of SP2-001-001. Adjusts the width of the erased area (* "Adjusting Copy 2101* Erase Margin Adjustment Image Area"...
  • Page 118 Service Program [0 = 50 pages / 1 = 20 pages] Sets the number of copy/print/fax pages that can be made after toner near-end has been 2213 1 detected. Reduce the number of pages if the user normally makes copies with a high image ratio.
  • Page 119 5. Service Tables Adjusts the current applied to the transfer roller when feeding from the by-pass tray. Use a high setting (a) if the user normally feeds relatively thick paper from the by-pass tray, or (b) if waste toner is re-attracted from the drum (which can occur when using transparencies). [–2 = –4 μA / –1 = –2 μ/ 0 = 0 μA / 1 = 2 μA / 2 = Duplex +4 μA]...
  • Page 120 Service Program 2915* Polygon Mirror Motor Idling Time [0 = None / 1 = 15 s / 2 = 25 s] Specifies the polygon mirror motor idling time. The polygon mirror motor starts its operation when an original is set, a key is pressed, or the platen cover or DF is opened. The motor 2915 1 stops if no manual operation is performed for the specified time.
  • Page 121 5. Service Tables 2929* Vref Limits Adjust the upper or lower Vref limit. 2929 1 Upper [0.50 to 3.50 / 3.20 / 0.01V/step] DFU 2929 2 Lower [0.50 to 3.50 / 0.70 / 0.01V/step] DFU [30 to 90 / 30 / 1 °C/step] 2994* ID Sensor Detection Temperature Adjusts the temperature threshold.
  • Page 122 Service Program Adjusts the side-to-side registration for scanning in platen mode (* "Adjusting Copy Image 4011 1 Area" in the section "Replacement and Adjustment"). 4012* Scan Erase Margin [0 to 9.0 / 1.0 / 0.1 mm/step] 4012 1 Leading edge Adjusts the scanning margin.
  • Page 123 5. Service Tables 4606 SBU Offset-Target 4607 1 EVEN 4607 2 ODD [0 to 63 / 10 / 1 /step] 4607 3 RED Adjusts the target black level for each signal. These are used for offset adjustment in the SBU. 4607 4 GREEN 4607 5 BLUE 4607...
  • Page 124 Service Program 4640 SBU Offset-Loop 4640 1 EVEN 4640 2 ODD [0 to 10 / 0 / 1 /step] 4640 3 RED Displays the number of the offset adjustment in the SBU. 4640 4 GREEN 4640 5 BLUE 4641 SBU Gain-Loop 4641 1 EVEN 4641 2 ODD [0 to 10 / 0 / 1 /step]...
  • Page 125 5. Service Tables 4646 6 Gain-Color 4654* SBU Offset-Adjust 4654 1 EVEN 4654 2 ODD [0 to 255 / - / 1 /step] 4654 3 RED Displays the offset value of the offset adjustment in the SBU. 4654 4 GREEN 4654 5 BLUE 4658* SBU Gain-Adjust...
  • Page 126 Service Program Adjust the correction value for the white plate adjustment. Displays the current value of the white plate adjustment. 4687 2 Result If SP4-428 has not been done, this value is "0". 4690 White Peek Init 4658 1 EVEN 4658 2 ODD [0 to 255 / - / 1 /step] 4658 3 RED...
  • Page 127 5. Service Tables Checks the whole area (0 = All) or the specific areas (1 = One) to adjust the ADS level. The specific areas are as follows: 4905 1 • ARDF: ±37.5 mm from the center • Platen Cover: 15 to 90 mm from the left edge 4921* Image Adj Selection Copy...
  • Page 128 Service Program Line Width Correction 4927* Adjusts the line width correction algorithm. Positive settings produce thicker lines; negative settings produce thinner lines. This setting is only applied to the originals in SP4-921. 4927 1 Copy [–2 to 2 / 0 / 1/step] Independent Dot Erase 4928* Selects the dot erase level.
  • Page 129 5. Service Tables 4942* Black Line Erase [0 to 3 / 2 / 1/step] Selects the black line erase level. This setting is effective only when originals are scanned by the DF. 4942 1 [0 = No / 1 = Very weak / 2 = Weak / 3 = Strong] This setting is applied regardless of what mode has been selected in SP4-921.
  • Page 130 Service Program Selects the count-up timing. • 0 = Feed: At each paper feed 5121 1 • 1= Exit: At each paper exit 5501* PM Alarm Interval [0 to 9999 / 0 / 1K copies/step] 5501 1 Printout Specifies when the PM alarm occurs. 5801 Memory Clear (basic model only) 5801 2 Engine (* "Memory Clear"...
  • Page 131 5. Service Tables Telephone Specifies the telephone number of the service representative. (The number is displayed 5812 1 when a service call condition occurs.) To input a dash, press . To delete the current telephone number, press . Facsimile 5812 2 Specifies the fax number printed on user counter reports.
  • Page 132 Service Program 5912* PCU Alarm Counter (Printout) [0 to 255 / 45 / 1/step] Specifies the PCU alarm level. The PCU alarm is issued when the following condition is met: 5912 1 PAc x 1000 >= PCUc where PAc is the value specified in this SP and PCUc is the PCU counter. When you specify 0 (zero), the PCU alarm is deactivated.
  • Page 133 5. Service Tables Sub-scan Magnif [–0.9 to +0.9 / 0.0 / 0.1 %/step] 6006 5 Adjusts the sub-scan magnification for the ARDF. Origin Curl Adj [0 = No / 1 = Yes] 6006 6 Turns on or off the skew correction at 2nd side scanning. This SP is activated only when the duplex mode is selected.
  • Page 134 Service Program 7403 1 Displays the histories of the latest 10 SC codes. 7502* Counter–Paper Jam [0 to 9999 / 0 / 1/step] 7502 1 Displays the total number of copy paper jams. 7503* Counter–Orgn Jam [0 to 9999 / 0 / 1/step] 7503 1 Displays the total number of original jams, Counter-Each P Jam [0 to 9999 / 0 / 1/step]...
  • Page 135 5. Service Tables Off-Exit SN 7504 121 Paper does not reach the exit sensor. On-Exit SN 7504 122 Paper is caught at the exit sensor. Off-Dup Inverter 7504 123 Paper does not reach the duplex inverter sensor (from the registration roller). On-Dup Inverter 7504 125 Paper is caught at the duplex inverter sensor.
  • Page 136 Service Program 7507* Display-P Jam History Displays the latest 10 paper-jam history. The list below shows the possible 12 codes: 1, 10, 11, 12, 50, 60, 70, 120, 121, 122, 123, 125 7507 1 The codes correspond to the menus of SP7-504. For example, the code 1 corresponds to SP7-504-001, and the code 10 corresponds to SP7-504-10.
  • Page 137 5. Service Tables Resets all counters except for the management counters. The management counters are the counters that are not changed by NVRAM Download (SP5-825-001; * "NVRAM 7808 1 Data Upload/Download"). When the program ends normally, the message the message “Completed”...
  • Page 138 Service Program Clears the timer counter (SP7-991-001). Reset-Dev Count 7992 4 Clears the development counter (SP7-991-004). Reset-ID Er Count 7992 5 Clears the ID sensor error counter (SP7-991-005). SP8-XXX (History) 8191* T: Total Scan PGS [0 to 9999999 / 0 / 1 sheet/step] Displays the total number of scanned originals.
  • Page 139 5. Service Tables 8382 1 Displays the print count of the copier application program. 8384* P: Total Prt PGS [0 to 9999999 / 0 / 1 sheet/step] 8384 1 Displays the print count of the printer application program. 8411* Prints/Duplex [0 to 9999999 / 0 / 1 sheet/step] 8411 1 Displays the total count of the duplex printing.

  • Page 140: Id Sensor Error Analysis (Sp2-221)

    Service Program 8451* C: PrtPGS/Ppr Tray [0 to 9999999 / 0 / 1 sheet/step] 8451 1 Bypass Tray 8451 2 Tray 1 Displays the total print count classified by paper source. 8451 3 Optional Tray 8461* T: PrtPGS/Ppr Type 8462* C: PrtPGS/Ppr Type [0 to 9999999 / 0 / 1 sheet/step] 8464*...

  • Page 141: Memory Clear

    5. Service Tables • ID sensor defective Vsg < 3.5V Power source SP2-221-3 Power • ID sensor dirty when maximum power for the ID-sensor (PW in the display) (979) is applied light • Drum not get charged SP2-221-4 Vsdp No Error Conditions Vt >...

  • Page 142: Input Check (Sp5-803)

    Service Program Executing Memory Clear 1. Upload the NVRAM data to a flash memory card (* "NVRAM Data Upload/Download"). 2. Print out all SMC data lists (* "SMC Print"). • Be sure to print out all the lists. You have to manually change the SP settings if the NVRAM data upload ends abnormally.
  • Page 143 5. Service Tables Num. Sensor/Switch Registration Sensor Paper detected Not detected Exit Sensor Paper detected Not detected Duplex Inverter S Paper detected Not detected By-pass PE S Paper detected Not detected Upper PE S Paper detected Not detected Lower PE S Paper detected Not detected PCU Set Signal...

  • Page 144: Output Check (Sp5-804)

    Service Program None 1-tray paper feed unit OUTPUT CHECK (SP5-804) Conducting Output Check • To prevent mechanical or electrical damage, do not keep an electrical component on for a long time. 1. Select SP5-804. 2. Select the number (see the table below) corresponding to the component. 3.

  • Page 145: Serial Number Input (Sp5-811-001)

    5. Service Tables Num. Component Duplex Inv Motor Forward Duplex Inv Motor Hold Polygon Motor Polygon M/LD DF-Feed M DF-Transport M DF-Feed Clutch DF-Gate SOL (Junction Gate Solenoid) Fusing Solenoid Fast Dup Inv M-Rev Scan Fgate-Mono Scan Fgate-Color When checking Fan Motor High (005) or Fan Motor Low (006) note the following: •...

  • Page 146: Nvram Data Upload/Download (Sp5-824/825)

    Service Program You can specify a digit (“0” to “9”) or a capital letter (“A” to “Z”) for the first four characters of a serial number, and you can specify a digit in the other seven characters (not capital letters). Serial Number and NVRAM Serial numbers are stored in the NVRAM before shipment and are not cleared by any program.
  • Page 147 5. Service Tables NVRAM Upload (SP5-824-001) 1. Turn off the main switch. 2. Remove the memory card cover [B] ( x 1). 3. Turn the face of the flash memory card [A] (“A” is printed on it) to the rear of the copier, and insert it into the card slot [C].

  • Page 148: Firmware Update Procedure

    Service Program 1. Turn off the main power switch. 2. Remove the memory card cover [B] ( x 1). 3. Turn the face of the flash memory card [A] (“A” is printed on it) to the rear of the copier, and insert it into the card slot [C].
  • Page 149 5. Service Tables 4. Press down the power switch on the operation panel and hold it, and turn on the main power switch. 5. Press the “Execute” key [D]. The program starts running. 6. Do not touch any key while the message “Load Status...” is displayed. This message indicates that the program is running.

  • Page 150: Test Pattern Print (Sp5-902-001)

    Service Program TEST PATTERN PRINT (SP5-902-001) Executing Test Pattern Printing 1. Specify the pattern number and press the OK key. 2. Press the copy start key. The copy mode is activated (* "Using SP and SSP Modes” in this section). 3.
  • Page 151 5. Service Tables Grayscales With White Lines (Horizontal) Grayscales with White Lines (Vertical) Grayscales with White Lines (Vertical/Horizontal) Test Patterns Using IPU Pattern Vertical Lines (Single Dot) Horizontal Lines (Single Dot) Vertical Lines (Double Dot) Horizontal Lines (Double Dot) Isolated Four Dots Grid Pattern (Double Dot) Black Band (Vertical, 1024 Dots) Grayscales (Horizontal, 512 Dots)

  • Page 152: Smc Print (Sp5-990)

    Service Program Pattern Grid Pattern (double dot) Gray Scale 1 (256 grades) Gray Scale 2 (256 grades) Test Patterns Using PCI* Pattern S2M: Grid Pattern S2M: Argyle Pattern S2M: Argyle Pattern S2M: Argyle Pattern + Image* S2M: Grid Pattern S2M: Grid Pattern + Image S2M: Argyle Pattern S2M: Argyle Patten + Image Engine: Grid Pattern...

  • Page 153: Printer Service Program Mode Table

    5. Service Tables • The copy mode is activated (* "Using SP and SSP Modes” in this section”). Specify copy settings and press the  key. The machine status lists its output. 4. To return to the SP mode, press the  key. Printer Service Program Mode Table SP No.

  • Page 154: Detailed Section Descriptions

    6. Detailed Section Descriptions Overview Component Layout • The above illustration shows models B262/B280/B293. Model B292 has standard ARDF. For ARDF component layout, refer to the service manual for ARDF DF1000 (B872). 1. Exposure Lamp 20. ID (Image Density) Sensor 2.
  • Page 155 6. Detailed Section Descriptions 7. 3rd Mirror 26. Bypass Friction Pad 8. Platen Cover Sensor 27. Mixing Augers 9. Exposure Glass 28. (Main) Friction Pad 10. Exit Roller 29. Paper Feed Roller 11. Exit Sensor 30. Paper End Sensor 12. Scanner Motor 31.

  • Page 156: Electrical Components 1

    Overview Electrical Components Electrical Components 1 1. Lens Block 10. Exit Sensor 2. Exposure Lamp 11. ID (Image Density) Sensor 3. Lamp Stabilizer Board 12. Registration Sensor 4. Scanner HP Sensor 13. Paper End Sensor 5. Platen Cover Sensor 14. Toner Density Sensor 6.
  • Page 157 6. Detailed Section Descriptions • For ARDF electrical components, refer to the service manual for ARDF DF1000 (B872). Electrical Components 2 1. Duplex Motor 7. Paper Feed Clutch 2. Exhaust Fan 8. Toner Supply Clutch 3. PSU 9. Bypass Feed Clutch 4.

  • Page 158: Paper Path

    Paper Path Paper Path 1. Original Registration Sensor (Document Feed- 6. Paper Path Sensor 7. Registration Sensor 2. Exit Senor (Document Feeder) 8. By-pass Paper End Sensor 3. Inverter Sensor (Document Feeder) 9. Paper Feed Sensor (Optional Tray) 4. Original Set Sensor (Document Feeder) 10.

  • Page 159: Drive Layout

    6. Detailed Section Descriptions Drive Layout 1. Scanner Motor 7. Bypass Feed Clutch (By-pass Tray) 2. Duplex motor 8. Registration Clutch 3. Exit Roller 9. Developer Driver Gear 4. Toner Bottle Clutch 10. Drum Drive Gear 5. Main Motor 11. One-way Gear (Duplex Unit) 6.

  • Page 160: Block Diagram: Pcbs And Components

    Block Diagram: PCBs and Components Block Diagram: PCBs and Components This table lists available units and components for each model. Document Printer/ Model Fax* Controller Feeder Scanner Basic Model (B292) for Not availa- Distributed with the option- Standard Optional North America al printer/scanner Basic Model (B262) for Not availa-...

  • Page 161: Main Pcbs

    6. Detailed Section Descriptions Main PCBs SBU (SENSOR BOARD UNIT) The SBU receives analog signals from the CCD and converts these into digital signals used for image processing. Buffer Used for driving the CCD. Includes a 3V/5V converter (converts the CALDA 3V drive signal to 5V). Converts light reflected from the original into an electrical signal.
  • Page 162 Main PCBs Amplifier Inverts and amplifies the electrical signal from the CCD.

  • Page 163: Copy Process

    6. Detailed Section Descriptions Copy Process Overview The following is a brief overview. For more detailed information about each process, refer to the Core Technology manual. 1. Exposure A xenon lamp [A] exposes the original → the CCD [B] converts reflected light to analog data signal →...
  • Page 164 Copy Process In the dark, the drum charge roller [C] imparts a negative charge to the OPC drum. (The roller is kept clean by cleaning roller [D].) 3. Laser Exposure The laser unit, controlled by the BICU, fires a beam [E] at the drum, drawing the latent electrostatic image on the drum surface.

  • Page 165: Scanning

    6. Detailed Section Descriptions Scanning Overview 1. Scanner HP Sensor 7. 2nd Mirror 2. 1st Mirror 8. Scanner Motor 3. Exposure Lamp 9. 3rd Mirror 4. 1st Scanner 10. Lens Block 5. Exposure Glass 11. Lens 6. 2nd Scanner 12. CCD The HP sensor [1] senses when the scanner is at home position, ready to begin a scan.

  • Page 166: Scanner Drive

    Scanning Scanner Drive The scanner motor [A] (a stepper motor) drives a gear that turns a small drive belt [B], driving the scanner drive shaft [C]. Pulleys [D, E] on the ends of the shaft drive timing belts [F] and [G], driving the 1st scanner [H].

  • Page 167: Image Processing

    6. Detailed Section Descriptions Image Processing Overview The scanned image is processed by the following modules. In the SBU • CCD: Converts the reflected light from the image into an analog signal. Driven by the CALDA. • Amp: Amplifies the analog signal and sends it to the AFE on the BICU. In the BICU •...

  • Page 168: Image Processing Path

    Image Processing Image Processing Path The image data from the SBU goes to the IPU (Image Processing Unit) on the BICU board, which carries out the following processes on the image data: • Auto shading • White/black line correction • ADS •...
  • Page 169 6. Detailed Section Descriptions The original mode key on the operation panel has two settings, text and photo. With the default settings, the machine uses “Normal Text (Text 1)” when the Text indicator is lit, and uses “Photo Priority (Photo 1)” when the Photo indicator is lit.
  • Page 170 Image Processing surrounding (darker) background but leave the rest. Use if the customer wishes to keep this background.

  • Page 171: Image Processing Steps For Each Mode

    6. Detailed Section Descriptions Image Processing Steps for Each Mode...

  • Page 172: Mode Adjustments

    Image Processing Mode Adjustments As a service person, you can use SPs 4-922 to 4-932 to further customize each of these original modes to meet specific user requirements. If the user is experiencing a problem with copy, however, SP-based adjustment should be the last step. Always proceed as follows: 1.

  • Page 173: Laser Exposure

    6. Detailed Section Descriptions Laser Exposure Overview [A]: LD Unit [E]: Toroidal Lens [B]: Synchronization Detector Lens [F]: Polygon Mirror Motor [C]: OPC Drum [G]: Cylindrical Lens [D]: Shield Glass [H]: LD Shutter • The LD unit controls both the laser output and the laser synchronization mechanism. •...

  • Page 174: Ld Safety Switches

    Laser Exposure LD Safety Switches Safety switches are installed at the front and right doors to ensure technician and user safety and to prevent the laser beam from accidentally switching on during servicing. Opening of the front or right door opens the corresponding switch, cutting the power supply (+5VS) to the laser diode.

  • Page 175: Photoconductor Unit (Pcu)

    6. Detailed Section Descriptions Photoconductor Unit (PCU) Overview 1. Cleaning Blade 6. TD (toner density) Sensor 2. Toner Collection Coil 7. Mixing Auger 1 3. OPC Drum 8. Doctor Blade 4. Development roller 9. Charge Roller 5. Mixing Auger 2 10.

  • Page 176: Drum Drive

    Photoconductor Unit (PCU) DRUM Drive The main motor [A] drives the drum [B] through a series of gears and the drum drive shaft [C].

  • Page 177: Drum Charge

    6. Detailed Section Descriptions Drum Charge Overview The drum charge roller [A] remains in contact with the drum, producing a charge of –900 V on the drum surface. The high voltage supply board [B] supplies a negative charge to the charge roller via wire [C] and spring [D].

  • Page 178: Charge Roller Voltage Correction

    Drum Charge Charge Roller Voltage Correction Correction for Ambient Environment Efficiency of voltage transfer from the charge roller to the drum decreases as ambient temperature and humidity rise. Accordingly, the charge roller voltage must be made more negative at higher temperature and humidity.

  • Page 179: Charge Roller Cleaning

    6. Detailed Section Descriptions • Correction can be disabled with SP2-927. How Correction is Made Immediately after creating the ID sensor pattern [A] used for toner density control (* "Toner Density Control"), the machine generates another pattern [B] for charge voltage correction by intensifying the development bias (* "Development Bias") to –600 V.
  • Page 180 Drum Charge At time of copier installation The first time the machine is turned on following installation, a factory-set flag informs the machine that the PCU has not yet been initialized. The machine carries out the necessary initialization automatically. When a replacement PCU is installed Replacement PCUs have a special mechanism that trips when they first start, informing the machine that a new PCU has been installed.

  • Page 181: Development

    6. Detailed Section Descriptions Development Overview The development section consists of the following parts. 1. Development Roller 4. TD Sensor 2. ID Sensor 5. Mixing Auger 1 3. Mixing Auger 2 6. Doctor Blade The two mixing augers mix the developer (carrier/toner mix). The TD (toner density) sensor and the ID (image density) sensor are used to control the copy image density.

  • Page 182: Development Bias

    Development Development Bias Black areas of the latent image on the drum are at low negative charge (about –140 ± 50 V), with white areas at high negative charge (about –900 V). To attract negatively charged toner to black areas, the high voltage supply board [A] applies a (default) bias of –600 V to the development roller [B].

  • Page 183: Toner Density Control

    6. Detailed Section Descriptions When toner bottle [A] is pushed in, shutter [B] is pushed open by the PCU body. Pressing in lever [C] pulls off toner bottle cap [D], which is held by chuck [E]. When clutch [F] turns the bottle, the spiral grooves push toner out at [G], and the turning Mylar blades [H] push this toner through slit [I] into the developing unit.

  • Page 184: Toner Supply If Sensor Reading Is Abnormal

    Development Vref is calculated based on: • ID sensor output (Vsp/Vsg) • Existing reference voltage (Vref or Vts) – Vt Toner Supply Determination The machine supplies toner if Vt exceeds the reference voltage. • Current Vt and reference voltage values can be viewed using SP2-220. Other ID sensor values can be viewed using SP2-221.

  • Page 185: Detection Of Toner Near End And Toner End

    6. Detailed Section Descriptions • Vsg < 2.31 (at maximum power) • Vsp ≥ 1.65 • Vt ≥ 2.64 or Vt < 0.20 Current readings can be viewed using SP2-221. TD Sensor The reading is considered abnormal if TD < 0.20 V or TD > 2.64 V. Abnormal readings 10 times in succession will generate SC 390.

  • Page 186: Drum Cleaning And Toner Recycling

    Drum Cleaning and Toner Recycling Drum Cleaning and Toner Recycling • Cleaning blade [A] scrapes remaining toner from the drum after image transfer. Toner piles up on the blade. • Toner collect coil [B] transports toner from pile and drops it onto chute [C], where it slides down into the development unit through a slit located at [D].

  • Page 187: Paper Feed

    6. Detailed Section Descriptions Paper Feed Overview 1. Exit Roller 6. Bypass Friction Pad 2. Exit Sensor 7. (Main) Friction Pad 3. Registration Sensor 8. (Main) Paper End Sensor 4. Bypass Feed Roller 9. Paper Feed Roller 5. Bypass Paper End Sensor 10.

  • Page 188: Paper Feed Drive Mechanism

    Paper Feed Paper Feed Drive Mechanism From Paper Tray Main motor [A] drives gears on the registration clutch [B] and the paper feed clutch [C]. These clutches transfer drive to the registration roller [D] and paper feed roller [E]. The BICU controls clutch timing based on input from the registration sensor.
  • Page 189 6. Detailed Section Descriptions From 100-Sheet Bypass Tray Main motor [A] drives gear on registration clutch [B] and bypass feed clutch [F]. The bypass feed clutch drives the bypass feed roller [G]. Again, the BICU controls clutch timing based on input from the registration sensor.

  • Page 190: Paper Feed And Separation

    Paper Feed Paper Feed and Separation The machine uses a friction-pad feed system. Friction pad (in paper tray) Paper Lift Mechanism When tray is pushed in: Projection [B] on frame pushes rounded slider [C] in against spring [D], retracting the latch [E]. Spring [F] pushes the plate up.

  • Page 191: Paper End Detection

    6. Detailed Section Descriptions Paper End Detection Main Tray When paper runs out, feeler [A] drops into cutout, activating paper end sensor [B]. 100-Sheet Bypass Tray When paper runs out, feeler [C] drops into cutout, activating the bypass paper end sensor [D].
  • Page 192 Paper Feed Paper Registration The BICU uses input from registration sensor [A] to control clutch timing and detect misfeeds. Registration clutch timing is controlled to eliminate skew (by stopping the paper briefly as it reaches the roller, so that it buckles). The amount of buckle can be adjusted with SP1-003.

  • Page 193: Image Transfer And Paper Separation

    6. Detailed Section Descriptions Image Transfer and Paper Separation Overview The transfer roller [A] is pressed against the OPC drum [B]. The high-voltage power supply board [C] supplies a positive current to the transfer roller, attracting the toner from the drum onto the paper. The current is set in accordance with the paper's type, size, and feed tray.

  • Page 194: Transfer Roller Cleaning

    Image Transfer and Paper Separation 1. Low level: Before image transfer starts, the high voltage supply board supplies +10μA to the transfer roller. This prevents the transfer roller from attracting any positively charged toner on the drum surface. 2. High level: During image transfer, the high voltage supply board supplies a high level current (see the table) to the transfer roller.

  • Page 195: Image Fusing And Paper Exit

    6. Detailed Section Descriptions Image Fusing and Paper Exit Overview 1. Exit Roller 6. Fusing Lamp 2. Paper Path Sensor 7. Hot Roller 3. Hot Roller Strippers 8. Thermoswitch 4. Pressure Spring 9. Thermistor 5. Pressure Roller 10. Exit Sensor...

  • Page 196: Hot Roller Drive

    Image Fusing and Paper Exit Hot Roller Drive Left: Contact-release solenoid off Right: Contact-release solenoid on Mechanism The main motor [A] drives the hot roller [D] through a gear train. One of the gears in the gear train is the contact-release gear [B].

  • Page 197: Pressure Roller

    6. Detailed Section Descriptions • The copier takes a shorter time to heat the hot roller when the roller is not turning. • The temperature of the hot roller surface may become uneven when the hot roller temperature is low and the roller is not turning.

  • Page 198: Separation

    Image Fusing and Paper Exit When the right door is opened, part [A] (on each side) pulls open catch [B] (on each side), releasing pressure on the pressure roller, so that it can turn freely to allow removal of jams. When the right door is closed, part [C] pushes catch [B] closed, restoring normal pressure.
  • Page 199 6. Detailed Section Descriptions Warming up 160°C SP1-105-001 Ready 150°C SP1-105-003 Copying 160°C SP1-105-005 Low level 60°C SP1-105-007 Thick paper 165°C SP1-105-009 Temperature Transition When the fusing unit is cool, the fusing temperature should be higher to ameliorate the fusing quality. During copying, the fusing temperature is controlled in four phases as listed in the table.
  • Page 200 Image Fusing and Paper Exit Overheat Protection The BICU references the fusing temperature through the thermistor [A]. The copier prevents overheating as listed below. Normally, Feature 1 is effective in preventing overheating. Features 2 through 3 are fail-safe features. Feature 1: The BICU turns off the fusing lamp when the fusing temperature is too high.
  • Page 201 6. Detailed Section Descriptions • The thermoswitch near the center does not necessarily work earlier than the other thermoswitch. The ends of the hot roller can be much hotter than the center when, for example, paper of a small size is continuously going through the fusing unit.

  • Page 202: Duplex Unit

    Duplex Unit Duplex Unit Important Components The following components play important roles in duplex printing: • The duplex motor drives the exit roller [A] and duplex roller [D]. • One of the paper guides on the fusing unit [C] is linked to the paper path sensor [B]. The bypass tray cannot be used for duplex printing.

  • Page 203: Duplex Printing Process

    6. Detailed Section Descriptions Duplex Printing Process The main steps of the duplex printing process are as follows: 1. The controller starts to operate the main motor and duplex motor. 2. The hot roller [A] and pressure roller [B] transport the paper to the paper guide [C]. 3.
  • Page 204 Duplex Unit 9. When the leading edge of the paper reaches the registration sensor [J], the controller stops the duplex motor. The duplex roller holds the paper in the duplex unit. 10. When the OPC drum [K] gets ready for printing, the controller restarts the duplex motor. The duplex roller transports the paper.
  • Page 205 6. Detailed Section Descriptions 13. The leading edge of the paper pushes the paper guide [L]; the paper guide turns the paper path sensor [M] on. 14. The controller changes the direction of the duplex motor. The exit roller [N] changes the direction of its rotation, transporting the paper to the copy tray.

  • Page 206: Energy Saver Modes

    Energy Saver Modes Energy Saver Modes This section explains the energy saver modes. Overview The machine has two energy-saver modes: the Low Power Mode and the Night/Off Mode. The table lists the status of several components. Operation panel Engine Exhaust fan Operating Mode* Low Power Mode Night/Off Mode...

  • Page 207: Aof

    6. Detailed Section Descriptions ** The SRAM is alive and backs up the engine controller. When AOF is off, the engine controller is unable to start the Night/Off Mode. The user should keep AOF on ( → System Settings → Key Operator Tools → AOF). Timers The engine controller references the Energy Saver Timer to start the Low Power Mode, and references the Auto Off Timer to start the Night/Off Mode.

  • Page 208: Gdi Controller

    GDI Controller GDI Controller The GDI controller is standard for the B280 and B293 models. For the B262 and B292 models, the GDI controller can be installed as an optional unit. Overview B280 (Without Network Interface Card)
  • Page 209 6. Detailed Section Descriptions B293 (With Network Interface Card) This machine uses the GDI controller to enable the printer features. Main components: CPU: D8701 Flash ROM: 1MB/4MB SDRAM: 32MB/64MB 96MHz NVRAM(8KB): Stores the controller setting NVRAM(128MB):Store the MAC address USB: NET2282 Optional components: PCL Board...

  • Page 210: Controller Functions

    GDI Controller Controller Functions Paper Source Selection Tray Priority (Auto Tray Select): The Tray Priority setting determines the start of the tray search when the user selects “Auto Tray Select” with the driver. The machine searches for a paper tray with the specified paper size and type. When no tray contains paper that matches the paper size and type specified by the driver, the controller stops printing until the user loads the correct paper.

  • Page 211: Scanner Functions

    6. Detailed Section Descriptions • The interval can set with the Printer Settings in the user tools. (User Tools/ Printer Settings/ System/ Auto Continue) If Auto Continue is disabled, the machine will not print the job, but will not cancel it, so the job stays in the print queue.

  • Page 212: Network Interface

    GDI Controller The image compression method can be selected with SP mode (MR/MH/MMR for binary picture pro- cessing). Image Data Path: 1. Image Store/Image Delivery Mode The user can select the following modes from the LCD. • Delivery only After image processing and image compression, all image data for the job are stored in the printer controller RAM using TIFF file or PDF file format (binary picture processing).

  • Page 213: Usb

    6. Detailed Section Descriptions Description LED1 (Green): Link status Link success Link failure LED2 (Yellow): Data rate 100 Mbps 10 Mbps Specifications USB connectivity is provided as an option for this machine. Interface: USB 1.1, USB 2.0 Data rates: 480 Mbps (high speed), 12 Mbps (full speed) High speed mode is only supported by USB 2.0.
  • Page 214 GDI Controller • Bi-directional data communication between device and host computer via a 4-byte header and DE- VICE ID. USB 2.0 is an evolution of the USB 1.1 specification. It uses the same cables, connectors, and software interfaces so the user will see no change. It provides an easy-to-use connection to a wide range of products with a maximum data rate of 480 Mbps (high speed).

  • Page 215: Nvram On The Gdi Controller

    6. Detailed Section Descriptions Power Data – White Data + Green Power GND White Remarks about USB The machine does not print reports specifically for USB. Only one host computer is allowed for the USB connection. After starting a job using USB, do not switch the printer off until the job has been completed. When a user cancels a print job, if data transmitted to the printer has not been printed at the time of cancellation, the job will continue to print up to the page where the print job was cancelled When the controller board is replaced, the host computer will recognize the machine as a different device.

  • Page 216: Specifications

    7. Specifications General Specifications Copier Configuration: Desktop Copy Process: Laser beam scanning and electro photographic printing Originals: Sheet/Book/Object Maximum Original Size: A4 / 8 " x 14" A4 / 8 " x 14" (ARDF) Maximum A4 SEF / 8 " x 11" SEF (Copier's paper tray) A4 SEF / 8 "...
  • Page 217 7. Specifications 200% 155% Enlargement 141% 129% Full Size 100% 100% Reduction Zoom: 50% to 200%, in 1% steps Power Source: 110 – 120 V, 60 Hz or 220 – 240 V, 50/60 Hz Maximum: 900 W or less Power Consumption: Energy Saver: 25 W or less Off Mode: 1 W or less Sound Power Level...

  • Page 218: Printer

    General Specifications • From copier's paper tray • 100% size Copy Number Input: Numeric keypad, 1 to 99 (increment, decrement) Manual Image Density: 5 steps Default: 1 minute Auto Off Timer Range: 1 to 240 minutes Default: 1 minute Energy Saver Timer: Rage: 1 to 240 minutes Paper Tray: 250 sheets Copy Paper Capacity:...

  • Page 219: Scanner

    7. Specifications Windows XP Windows Server 2003 100BASE-TX/10BASE-T shielded twisted-pair (STP, Category/ Type5) Required network cable cable. Scanner Scan method Flatbed scanning Approx. 18 pages/minute [Scan size: A4SEF, Colors/Gradations: Bi- nary, Resolution: 200dpi, Scan speed * Select device data compression (Binary/Halftone): Data compression (MMR), Document feeder: ARDF, ITU-T No.1 Chart] Maximum power consump-...

  • Page 220: Paper Tray Unit

    General Specifications Custom (Simplex): Width: 139 mm to 216 mm Length: 139 mm to 1260 mm Custom (Duplex): Width: 139 mm to 216 mm Length: 160 mm to 356* : When you use 310 mm or more originals, originals weighing 55k (17 lb./ 64 g/m ) or less cannot be used in duplex scanning mode.
  • Page 221 7. Specifications 24 Vdc and 5 Vdc, from copier. If optional tray heater is installed, the copier also supplies Vac (120 Vac or Power Source: 220 – 240 Vac). Power Consumption: Maximum: 15 W (excluding optional tray heater) Average: 14 W (excluding optional tray heater) Weight: Not above 6 kg (13.2.

  • Page 222: Supported Paper Sizes

    Supported Paper Sizes Supported Paper Sizes Original Paper Sizes The copier and ARDF do not detect original paper sizes. The following table lists the paper sizes that the ARDF can transport. ARDF Paper Size (W x L) Book Simpl. Dupl. A3 SEF 297 x 420 mm –...

  • Page 223: Paper Feed

    7. Specifications ARDF Paper Size (W x L) Book Simpl. Dupl. HLT SEF 5.5" x 8.5" HLT LEF 8.5" x 5.5" F/GL (F4) SEF 8.0" x 13.0" Foolscap SEF 8.5" x 13.0" Folio SEF 8.25" x 13.0" Government 8.25" x 14" USB4 SEF 10.0"...
  • Page 224 Supported Paper Sizes Paper Size (W x L) Regular By-pass Duplex Optional PFU A4 SEF 210 x 297 mm A4 LEF 297 x 210 mm – – – – B5 SEF 182 x 257 mm – B5 LEF 257 x 182 mm –...
  • Page 225 7. Specifications Paper Size (W x L) Regular By-pass Duplex Optional PFU Eng Quarto LEF 10.0" x 8.0" – – – – Custom: Leading edge 90–216 mm – – – Side edge 139–356 mm Symbol meanings: X: Can transport –: Cannot transport...

  • Page 226: Machine Configuration

    Machine Configuration Machine Configuration Basic Model (B262/B292) Standard Component Machine Code Remarks Copier [A] B262/B292 Optional Components Machine Code Remarks 500-Sheet Paper Feed Unit [B] B421 DDST Unit [C] B880/B893 Standard/Optional Component Machine Code Remarks • Standard for B292 ARDF [D] B872 •...
  • Page 227 7. Specifications GDI Model (B280/B293) Standard Component Machine Code Remarks Copier [A] B280/B293 - DDST Unit [C] Standard for B280/B293 Optional Components Machine Code Remarks 500-Sheet Paper Feed Unit [B] B421 ARDF [D] B872 256MB/SDRAM/DIMM (PC133) [E] G332...
  • Page 228 MEMO...
  • Page 229 MEMO...

This manual is also suitable for:

B262B280B292B293

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