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Ricoh B275 Service Manual

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B125/B275

SERVICE MANUAL

001911MIU (rev. 01/10/07)

RICOH GROUP COMPANIES

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Summary of Contents for Ricoh B275

Page 1 B125/B275 SERVICE MANUAL 001911MIU (rev. 01/10/07) RICOH GROUP COMPANIES...
Page 3 RICOH GROUP COMPANIES...
Page 5 B125/B275 SERVICE MANUAL 001911MIU...
Page 7 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
Page 9 Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained uncertified users utilizing...
Page 11 PRODUCT CODE COMPANY GESTETNER LANIER RICOH SAVIN B125 A045 LW310 Aficio 240W 2400WD B275 A045 LW310 Aficio 240W 2400WD NOTE: The B275 is a ROHS compliant B125. DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 4/2004 Original Printing 1/2007 B275 ROHS Compliant Added...
Page 13 B125/B275 TABLE OF CONTENTS INSTALLATION 1. INSTALLATION PROCEDURE............ 1-1 1.1 PREPARATION..................1-1 1.1.1 ENVIRONMENT ................1-1 1.1.2 MINIMUM SPACE REQUIREMENTS..........1-2 1.1.3 MACHINE LEVEL ................1-2 1.1.4 POWER SOURCE................1-3 1.1.5 INSTALLATION OVERVIEW............1-4 Installation Flow ..................1-4 SP and User Tool Settings Required for Installation ......1-5 1.2 COPIER INSTALLATION ................1-6...
Page 14 1.4 PAPER CASSETTE INSTALLATION ............1-32 1.4.1 ACCESSORY CHECK..............1-32 1.4.2 PAPER CASSETTE INSTALLATION PROCEDURE .....1-33 1.5 HDD INSTALLATION ................1-35 1.5.1 ACCESSORY CHECK..............1-35 1.5.2 HDD INSTALLATION PROCEDURE..........1-36 1.6 INTERFACE BOARD INSTALLATION ............1-39 1.6.1 ACCESSORY CHECK..............1-39 1.6.2 INTERFACE UNIT INSTALLATION PROCEDURE......1-40 1.7 STAMP BOARD INSTALLATION ............1-44 1.7.1 ACCESSORY CHECK..............1-44 1.7.2 STAMP BOARD INSTALLATION PROCEDURE ......1-44 1.8 TABLE INSTALLATION................1-45...
Page 15 3.1.9 IDLE REGISTRATION ROLLER PANEL..........3-9 3.1.10 MANUAL FEED TABLE, ORIGINAL FEED SENSOR COVER ..3-10 3.1.11 DRAWER FRONT COVER............3-11 3.2 SCANNER ....................3-12 3.2.1 ORIGINAL WIDTH SENSORS, ORIGINAL SET SENSOR, SCANNER SWITCH ...............3-12 3.2.2 ORIGINAL FEED UNIT ROLLERS ..........3-13 3.2.3 EXPOSURE GLASS...............3-15 3.2.4 CIS....................3-16 3.2.5 SMDB, VDB..................3-17 3.2.6 SIB, CGB POWER PACK...............3-18...
Page 16 3.7.9 PRESSURE ROLLER..............3-59 3.7.10 HOT ROLLER THERMISTOR, THERMOSTATS ......3-60 3.8 MOTORS....................3-61 3.8.1 SCANNER MOTOR................3-61 3.8.2 DRUM MOTOR ................3-62 3.8.3 FUSING MOTOR, MAIN MOTOR ..........3-63 3.8.4 USED TONER BOTTLE MOTOR ...........3-66 3.9 BOARDS ....................3-67 3.9.1 MCU/IPU ..................3-67 3.9.2 PSU ....................3-69 3.9.3 NVRAM...................3-70 NVRAM Upload ..................3-70 NVRAM Removal................3-71 NVRAM Download ................3-71...
Page 17 TROUBLESHOOTING 4. TROUBLESHOOTING ..............4-1 4.1 SERVICE CALL CONDITIONS ..............4-1 4.1.1 SUMMARY ..................4-1 4.2 SC CODE DESCRIPTIONS ..............4-2 4.2.1 SC1XXX ...................4-2 4.2.2 SC2XXX ...................4-2 4.2.3 SC3XXX ...................4-2 4.2.4 SC4XXX ...................4-5 4.2.5 SC5XXX ...................4-6 4.2.6 SC6XXX ..................4-11 4.2.7 SC7XXX ..................4-13 4.2.8 SC8XXX ..................4-13 4.2.9 SC9XXX ..................4-13 4.3 JAM CODE TABLES ................4-15 4.3.1 COPIER JAM TABLES ..............4-15...
Page 18 5.3 INITIAL SETTINGS ...................5-5 5.3.1 USER TOOLS ..................5-5 System Settings ..................5-5 Copier Features ..................5-8 5.4 PRINTING TEST PATTERNS ..............5-11 5.4.1 IMAGE PROCESSING TEST PATTERNS ........5-11 5.4.2 IMAGE DATA PATH TEST PATTERNS.........5-13 5.5 INPUT CHECK ..................5-14 5.6 OUTPUT CHECK ..................5-17 5.7 SP (SERVICE PROGRAM) MODE TABLES...........5-19 SP1-XXX Feed ...................5-19 SP2-XXX Drum ...................5-28 SP3-XXX Process Control ..............5-38...
Page 19 Drawing Mode..................6-21 Background Lines Mode ..............6-22 Sharpen Text Mode ................6-23 6.3.4 INDEPENDENT DOT ERASE ............6-24 6.3.5 MTF SETTINGS ................6-25 6.4 AROUND THE DRUM ................6-26 6.4.1 OVERVIEW ..................6-26 6.4.2 DRUM DRIVE .................6-27 6.4.3 CHARGE CORONA UNIT ..............6-28 6.4.4 CORONA WIRE CLEANING ............6-29 6.4.5 DRUM CLEANING................6-30 6.4.6 COLLECTING USED TONER ............6-31 6.4.7 QUENCHING..................6-32...
Page 20 6.7.6 ROLL END DETECTION ..............6-58 6.7.7 PAPER CASSETTE MECHANISM..........6-59 6.7.8 PAPER CASSETTE FEED .............6-60 Cassette Paper Path................6-60 Paper Cassette Pre-Feeding ..............6-61 6.7.9 PAPER CASSETTE PAPER END DETECTION ......6-62 6.7.10 CONDENSATION PREVENTION..........6-63 6.7.11 REGISTRATION................6-64 6.7.12 PAPER FEED TIMING CHART ............6-65 6.8 IMAGE TRANSFER AND SEPARATION ..........6-66 6.8.1 OVERVIEW ..................6-66 Transfer Corona Unit ................6-66 Separation Corona Unit ..............6-66...
Page 21 6.11.6 RFDB, SFDB ................6-92 RFDB (Roll Feed Drive Board) ............6-92 SFDB (Sheet Feed Drive Board) ............6-92 SPECIFICATIONS SPECIFICATIONS................7-1 1. COPIER ENGINE ..................7-1 2. ROLL FEEDER B641/B642 .................7-4 3. PAPER CASSETTE B643 ................7-4 4. MACHINE CONFIGURATION ..............7-5 B125...
Page 23 Conventions Used in this Manual This manual uses several symbols. Symbol What it means Lengthwise, SEF Refer to section number (Short Edge Feed) See Core Tech Manual for  details  Screw  Connector  E-ring  Clip ring  Clamp Sideways, LEF (Long Edge Feed)
Page 25 INSTALLATION PREVENTIVE MAINTENANCE REPLACEMENT AND ADJUSTMENT TROUBLESHOOTING SERVICE TABLES DETAILED DESCRIPTIONS SPECIFICATIONS...
Page 26 INSTALLATION...
Page 28 PREPARATION 1. INSTALLATION PROCEDURE 1.1 PREPARATION 1.1.1 ENVIRONMENT 1. Temperature Range: 10°C to 30°C (50°F to 86°F) 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 Lux (do not expose the machine directly to light from the sun). 4.
Page 29 PREPARATION 1.1.2 MINIMUM SPACE REQUIREMENTS Back 600 mm Left 600 mm Right 600 mm Front 1000 mm B125I520.WMF 1. Front: 1000 mm (40") 2. Back: 600 mm (23") 3. Right: 600 mm (23") 4. Left: 600 mm (23") 1.1.3 MACHINE LEVEL 1.
Page 30 PREPARATION 1.1.4 POWER SOURCE The machine must be installed in a building that has protection against electrical malfunctions by a circuit breaker, or an equivalent device. Such devices are necessary to give the machine protection for over-current and short circuits 1.
Page 31 PREPARATION 1.1.5 INSTALLATION OVERVIEW Installation Flow This copier has these options. • Roll feeder. You can install a roll feeder with one roll (B641) or two rolls (B642). You can also install a universal paper cassette in the roll feeder. You cannot install the paper cassette without the roll feeder.
Page 32 PREPARATION SP and User Tool Settings Required for Installation This is a summary of the important SP settings that are necessary for this installation. Quick Reference for Installation SP and User Tool Settings This is a summary of the SP and User Tool settings necessary for installation. For more details, see 1.2.3.
Page 33 COPIER INSTALLATION 1.2 COPIER INSTALLATION NOTE: Always have the Service Manual with you. The installation procedures are not shipped with the machine. 1.2.1 ACCESSORY CHECK Check the accessories and their quantities against this list: Description Q’ty 1. Original Output Guides ............6 2.
Page 34 COPIER INSTALLATION 1.2.2 COPIER PRE-INSTALLATION PROCEDURE Removing the Shipping Material B125I013.WMF  CAUTION Do not connect the power cord to the power source during these installation procedures until the procedure tells you to do this. 1. Remove all the orange tape and packing materials from the copier. B125...
Page 35 COPIER INSTALLATION Set the Operation Panel Position B125I006.WMF You can adjust the position of the operation panel to decrease reflections from overhead lighting. 1. Lift or lower the operation panel [A] to one the three sets of holes to position the panel at the necessary height.
Page 36 COPIER INSTALLATION Rev. 06/2004 Setting the Copier on the Roll Feeder or Table Roll Feeder B641I007.WMF Table B662I002.WMF 1. Do not remove the shipping tape from the connectors [A] of the roll feeder [B]. This prevents damage to the connectors when the copier is put on top of the roll feeder.
Page 37 COPIER INSTALLATION B125I011.WMF B125I015.WMF 5. Remove the covers and manual feed table in this order: 1) Upper left cover [A] ( x 2) 2) Left cover [B] ( x 3) 3) Upper right cover [C] ( x 2) 4) Right cover [D] ( x 3) 5) Manual feed table [E] (...
Page 38 COPIER INSTALLATION B125I016.WMF 8. Push up the buttons [A] on the left and right sides of the upper unit to release and open it. 9. Install the studs [B] on the right side and the left side. NOTE: You must fasten each stud in the upper hole [C] on both sides. 10.
Page 39 COPIER INSTALLATION Leveling the Copier and Attaching Leg Covers B125I017.WMF B125I008.WMF 1. Open the toner hopper cover [A]. 2. Set a level [B] on the plate [C] of the development unit. 3. Put the level on the machine as shown. 4.
Page 40 COPIER INSTALLATION B125I003.WMF B125I010.WMF 6. Raise the original feed unit [A]. 7. Remove the protective sheet and tape [B]. 8. Remove the lock screws [C] ( x 2) 9. On the left and right sides, lift the hinges [D] off the support screws and lift the unit to the vertical position.
Page 41 COPIER INSTALLATION Developer B125I002.WMF 1. Push up the buttons [A] to release the upper unit. Then lift the upper unit [B]. 2. Open the toner hopper cover [C]. 3. Remove all tape and packing materials [D] in the upper unit. 4.
Page 42 COPIER INSTALLATION B125I005.WMF 5. Add one 1 kg pack of developer to the development unit. Do not add the second pack at this time. • Open the first pack of developer [A]. Notice the developer lot number on the edge of the bag •...
Page 43 COPIER INSTALLATION Toner Cartridge and ID Sensor Initialization B125I018.WMF 1. Carefully shake the toner cartridge [A] about 10 times. This makes sure that there are no clumps of toner in the cartridge. 2. Set the toner cartridge in the machine. 3.
Page 44 COPIER INSTALLATION B125I004.WMF 10. Open the upper unit. 11. Push the cleaning-blade release lever [A] to the right. NOTE: The cleaning-blade release lever keeps the cleaning blade away from the drum during transportation. To prevent damage to the drum, before you move the copier to a different location, be sure to push this lever to the left.
Page 45 COPIER INSTALLATION 1.2.3 INSTALLATION SP SETTINGS Using the SP Mode To go into and use the SP mode  1. Push 2. Push . 3. Push and hold  for 3 seconds. 4. Input the group number (“1” for “Copier”). Then input the full SP number to go directly to the SP code screen.
Page 46 COPIER INSTALLATION SP1960: Optional Paper Settings You must enable the paper supply options with this SP setting each time you add an option. NOTE: This setting is not necessary if the machine is installed without the roller feeder and paper cassette options. Do SP1960 to enable the options that you installed.
Page 47 COPIER INSTALLATION Select “Architecture” or “Engineering” (NA Only) Check the User Tool setting to determine whether “Architecture” or “Engineering” is selected for automatic width detection.  then select  “System Settings”>  “General 1. Push the “User Tools” key Features. 2.
Page 48 COPIER INSTALLATION Rev. 06/2004 ⇒ SP4960 015 Enable the HDD If you installed the optional hard disk drive, do this procedure. 1. Do SP4960 015 (HDD Connection On/Off) and set “1” (Enable) to enable the hard disk unit. 2. Switch the main power switch off, then switch it back on. NOTE: The HDD is formatted during production.
Page 49 COPIER INSTALLATION 1.2.4 COPIER FINAL INSTALLATION PROCEDURE Copy Trays, Guides, Original Exit Selection Lever B125I007.WMF B641I011.WMF 1. Attach the upper output stackers [A] on top of the machine. 2. Attach the upper output guide [B]. 3. Attach the original output guides [C]. NOTE: The original feeds out to these guides only when the upper output stackers [A] are removed.
Page 50 COPIER INSTALLATION Copy Check Scan an original to confirm that the copier operates correctly. 1. Set an original or test pattern face down on the original feed tray. 2. After about 1 second, the machine holds the original, stops again for 1 second, then feeds it.
Page 51 ROLL FEEDER INSTALLATION 1.3 ROLL FEEDER INSTALLATION 1.3.1 ACCESSORY CHECK Check the accessories and their quantities against this list: Description Q’ty 1. Lower Output Trays ............. 3 2. Leg Covers ................2 3. Movable Guides..............6 4. Shoes .................. 4 5.
Page 52 ROLL FEEDER INSTALLATION 1.3.2 ROLL FEEDER INSTALLATION PROCEDURE Setting the Copier on the Roll Feeder Set the copier on the roll feeder. Follow the instructions in “Setting the Copier on the Roll Feeder or Table” on page 1-9. Leveling the Copier and Attaching Leg Covers Make sure that the copier is level, and attach the leg covers.
Page 53 ROLL FEEDER INSTALLATION Attaching the Swinging Guide Plates B641I004.WMF B641I006.WMF  CAUTION Keep the power cord disconnected when you do these procedures. 1. Remove the protector plate [A] (no screws). 2. Install the guide plate [B] ( x 2 Blue). Hang the hooks on each end; this puts the plate in the correct position to be installed.
Page 54 ROLL FEEDER INSTALLATION Connecting the Copier and Roll Feeder B641I005.WMF " 1. Attach the right joint bracket (the spindle [B] must go through the hole [A] in the bracket). At the same time, align the plate with the holes for the three screws (blue).
Page 55 ROLL FEEDER INSTALLATION B641I009.WMF B641I014.WMF 9. Remove the rear cover of the copier ( x 2). 10. Remove the rear plate [A] of the roll feeder ( x 2). 11. Remove the shield cover [B] ( x 7). 12. Remove the ground plate [C] ( x 3). 13.
Page 56 ROLL FEEDER INSTALLATION B641I010.WMF B641I016.WMF 17. Connect the left harness [A] ( x 1,  x 1). 18. Attach the ferrite core [B] to the right harness [C] between the harness clamps. 19. Connect the right harness ( x 2,  x 2). 20.
Page 57 ROLL FEEDER INSTALLATION Attach the Mylars to the Copier 0 to –1 mm B641I020.WMF In this procedure, you will attach the narrow mylars (x2) to the rear cover of the copier. To attach the wide mylars (x2) to the backplate of the roll feeder, see the section after this one.
Page 58 ROLL FEEDER INSTALLATION Attach the Mylars to the Back of the Roll Feeder 0 to -1 mm 0 to -1 mm B641I021.WMF In this procedure, you will attach the wide mylars [A] to the rear plate [B] of the table. 1.
Page 59 PAPER CASSETTE INSTALLATION 1.4 PAPER CASSETTE INSTALLATION 1.4.1 ACCESSORY CHECK Check the accessories and their quantities against this list: Description Q’ty 1. Paper Cassette Unit............. 1 2. Screws................. 4 3. Harness Clamps ..............4 4. Paper Cassette (Universal Type)......... 1 B643I003.WMF B125 1-32...
Page 60 PAPER CASSETTE INSTALLATION 1.4.2 PAPER CASSETTE INSTALLATION PROCEDURE B643I001.WMF  CAUTION Keep the power cord disconnected when you do this procedure. 1. Open the drawer of the roll feeder. 2. Remove the front cover [A] of the roll feeder ( x 3) NOTE: If you cannot see the screw on the left or right side of the front cover, push the cutter [B] away from the top of the screw.
Page 61 PAPER CASSETTE INSTALLATION B643I002.WMF B643I004.WMF 7. Remove the rear plate of the roll feeder ( x 2). 8. Put the cassette unit [A] in the copier. The bosses must go through the holes in the flanges of the cassette unit. Then, attach the cassette unit ( x 4). 9.
Page 62 HDD INSTALLATION 1.5 HDD INSTALLATION 1.5.1 ACCESSORY CHECK Check the accessories and their quantities against this list: Description Q’ty 1. HDD Unit ................1 2. IPU Harness (1 Large, 1 Small Connector) ......1 3. PSU Harness (2 Small Connectors) ........1 4.
Page 63 HDD INSTALLATION 1.5.2 HDD INSTALLATION PROCEDURE B641I014.WMF  CAUTION Keep the power cord unplugged when doing the following procedure. 1. Remove the rear cover ( x 2). 2. Remove the ground plate [A] ( x 3). 3. Remove the PCB shield cover [B] ( x 7). B125 1-36...
Page 64 HDD INSTALLATION B663I002.WMF 4. Set the HDD [A] on the right side of the shelf. • Make sure that the leaf plate on the bottom of the HDD moves into the hole in the shelf. • Make sure that the hole [B] in the HDD support bracket is aligned with the hole in the edge of the shelf.
Page 65 HDD INSTALLATION B663I003.WMF 8. Connect the larger connector [A] of the PSU harness to the rear side of the HDD unit. 9. Open the harness clamps [B] between the HDD unit and the IPU on the left side ( x 10). 10.
Page 66 INTERFACE BOARD INSTALLATION 1.6 INTERFACE BOARD INSTALLATION 1.6.1 ACCESSORY CHECK Check the accessories and their quantities against this list: Description Q’ty 1. Interface Unit Cover............. 1 2. Interface Unit ............... 1 3. Nylon Clamps (Large)............1 4. Harness Clamp ..............1 5.
Page 67 INTERFACE BOARD INSTALLATION 1.6.2 INTERFACE UNIT INSTALLATION PROCEDURE B690I002.WMF B690I004.WMF  CAUTION Keep the power cord disconnected when you do this procedure. 1. Remove the rear cover [A] ( x 2). 2. Remove the knockout [B] from the rear cover ( x 2). 3.
Page 68 INTERFACE BOARD INSTALLATION B690I003.WMF 6. Remove the ground plate [A] ( x 3). 7. Remove the brackets [B] ( x 1 each) 8. Remove the PCB shield cover [C] ( x 7). 1-41 B125...
Page 69 INTERFACE BOARD INSTALLATION B690I005.WMF B690I009.WMF 9. Put the interface unit [A] on the shelf. 10. On the left side of the interface unit, open the harness clamp [B] on the left to release the connector. 11. Connect the bayonet connector [C] from the interface unit to the connector on the left.
Page 70 INTERFACE BOARD INSTALLATION B690I006.WMF B690I007.WMF 17. Attach the hooks [A] on the top edge of the cover bracket to the top of the interface unit. 18. Attach the cover [B] to the interface unit ( x 1). 19. Reattach the rear cover of the copier ( x 2). 20.
Page 71 STAMP BOARD INSTALLATION 1.7 STAMP BOARD INSTALLATION 1.7.1 ACCESSORY CHECK Description Q’ty 1. Stamp Board................ 1 1.7.2 STAMP BOARD INSTALLATION PROCEDURE B641I014.WMF B690I008.WMF  CAUTION Keep the power cord disconnected when you do this procedure. 1. Remove the back cover ( x 2). 2.
Page 72 TABLE INSTALLATION 1.8 TABLE INSTALLATION 1.8.1 TABLE ACCESSORY CHECK Check the accessories and their quantities against this list: Description Q’ty 1. Lower Output Trays ..............3 2. Leg Covers ................2 3. Shoes ..................4 4. Joint Brackets (Left, Right) ............2 5.
Page 73 TABLE INSTALLATION 1.8.2 TABLE INSTALLATION PROCEDURE Setting the Copier on the Table Set the copier on the table. Follow the instructions in “Setting the Copier on the Roll Feeder or Table” on pages 1-9 to 1-12 Leveling the Copier and Attaching Leg Covers Make the copier level.
Page 74 TABLE INSTALLATION Connecting the Copier and Table B662I003.WMF " B641I016.WMF 1. Put the spindle [A] through the hole [B] in the right joint bracket. Align the plate with the holes for the three screws (blue). " 2. Attach screws but do not tighten them. 3.
Page 75 TABLE INSTALLATION Attach the Mylars to the Copier 0 to –1 mm B641I020.WMF In this procedure, you will attach the narrow mylars (x2) to the rear cover of the copier. To attach the wide mylars (x2) to the backplate of the roll feeder, see the section after this one.
Page 76 TABLE INSTALLATION Attach the Mylars to the Back of the Table 0 to -1 mm 0 to -1 mm B641I021.WMF In this procedure, you will attach the wide mylars [A] to the rear plate [B] of the table. 1. On the left side of the rear plate, find the straight line [C] and “┐”,“┌” patterns [D].
Page 77 TABLE INSTALLATION Attaching the Stopper Bracket B641I015.WMF NOTE: This stopper bracket is only for machines in North America that use inch paper sizes. 1. Remove the stoppers [A] ( x 2 each). 2. Use a clean cloth soaked in alcohol to clean the surfaces [B] where the stopper brackets [C] will be attached.
Page 78 PREVENTIVE MAINTENANCE...
Page 80 PM TABLE 2. PREVENTIVE MAINTENANCE 2.1 PM TABLE Key for the PM Table Letter Action Adjust Clean Inspect Lubricate Replace NOTE: Units of measure in the PM Interval column*: Metric: 1,000 meters, Feet: 1,000 feet, Prints: 1,000 prints/A1 LEF or D 2.1.1 COPIER (B125) PM Interval Description...
Page 81 PM TABLE PM Interval Description Q’ty Comments Metric Feet Prints Around the Drum Charge Corona Wire 11.0 36.0 18.6 Replace if necessary. Corona Wire Cleaner 18.0 Charge Corona Casing Damp cloth 18.0 Grid Wires Lens paper 18.0 Transfer Corona Wire 11.0 36.0 18.6...
Page 82 PM TABLE PM Interval Description Q’ty Comments Metric Feet Prints Others Ozone Filter 18.0 Line Speed & Magnification Adjust after replacing Adjustments rollers. For details, see “SP Adjustments” in Section 3. 2.1.2 ROLL FEEDER (B641/B642) PM Interval Description Q’ty Comments Metric Feet Prints...
Page 83 CLEANING THE ENTRANCE SPURS 2.2 CLEANING THE ENTRANCE SPURS B125P901.WMF 1. Open the upper unit. 2. Retrieve the flat brush from [A] from its storage location. 3. Use the flat brush to clean the 5 entrance spurs [B]. Important: • Be sure to return the flat brush to its storage location when you are finished. B125...
Page 84 LUBRICATION POINTS 2.3 LUBRICATION POINTS 2.3.1 DEVELOPMENT SECTION (Sleeve) " B125P902.WMF (Silicone Grease G501). Development Unit Gears Apply at the points shown by the numbers in the drawing. B125...
Page 85 LUBRICATION POINTS 2.3.2 FUSING GEARS B125P903.WMF [A]: Fusing Gears (Barrieta S552R). Apply to the surface of the rim. B125...
Page 86 REPLACEMENT AND ADJUSTMENT...
Page 88 COMMON PROCEDURES 3. REPLACEMENT AND ADJUSTMENT 3.1 COMMON PROCEDURES 3.1.1 BEFORE WORKING ON THE MACHINE B125R913.WMF Always remove these items before you start work on the machine: [A]: Upper output stackers (x 2) [B]: Copy exit selection lever (x 1) [C]: Original output guides (x 6) [D]: Upper output guide (x 1) Lower output trays (x 3) (not shown)
Page 89 COMMON PROCEDURES 3.1.2 SIDE COVERS B125R502.WMF 1. Open the original feed unit [A]. 2. Open the upper unit [B]. 3. Remove the left upper cover [C] ( x 2). NOTE: If necessary, push in the release button [D] to remove the cover. 4.
Page 90 COMMON PROCEDURES 3.1.3 REAR COVER B125R914.WMF [A]: Rear cover ( x 2) B125...
Page 91 COMMON PROCEDURES 3.1.4 PAPER EXIT UNIT B125R609.WMF 1. Remove the rear cover ( x 2). (!3.1.3) 2. Open the paper exit unit and exit cover [A]. 3. Disconnect the ground wires [B] and connectors [C] ( x 3,  x 2,  x 2). 4.
Page 92 COMMON PROCEDURES 3.1.5 UNLOCKING, RAISING THE ORIGINAL UNIT B125R105.WMF 1. Open the upper unit 2. Remove the lock screws [A] ( x 2) 3. On the left and right sides, lift the hinges [B] off the support screws and lift the unit to the vertical position.
Page 93 COMMON PROCEDURES 3.1.6 REMOVING THE ORIGINAL FEED UNIT B125R106.WMF 1. Unlock the original unit and lift it. (!3.1.5) 2. Remove the plate [A] and disconnect the 2 ground wires ( x 2). 3. On the right side, disconnect the ground wires [B] (x2) ( x 2). 4.
Page 94 COMMON PROCEDURES 3.1.7 RAISING AND LOCKING THE SCANNER UNIT B125R107.WMF 1. Remove the original feed unit. (! 3.1.6) 2. Loosen the spring [A] and remove the scanner motor belt [B]. 3. Tighten the screw again to make sure that the screw and spring do not fall off. 4.
Page 95 COMMON PROCEDURES 3.1.8 TONER HOPPER COVER B125R301.WMF 1. Side covers. (!3.1.2) 2. Toner hopper cover [A]. Reinstallation • Make sure that the bent edge of the mylar [B] is attached around the edge of the plate. B125...
Page 96 COMMON PROCEDURES 3.1.9 IDLE REGISTRATION ROLLER PANEL B125R302.WMF 1. Open the upper unit. 2. Side covers. (! 3.1.2) 3. Toner hopper cover (! 3.1.8) 4. Disconnect the connector and ground wire [A] ( x 1,  x 1). 5. Idle registration roller panel [B] ( x 2) •...
Page 97 COMMON PROCEDURES Rev. 06/2004 ⇒ 3.1.10 ORIGINAL FEED TABLE, ORIGINAL FEED SENSOR COVER B125R101.WMF Unlock and lift the original feed unit. ( 3.1.5) Open the upper unit. Side covers ( 3.1.2) ⇒ [A]: Original feed table ( x 2) [B]: Original feed sensor cover ( x 2) Reinstallation •...
Page 98 COMMON PROCEDURES 3.1.11 DRAWER FRONT COVER B125R915.WMF [A]: Open the front drawer of the roll feeder. [B]: Push the cutter to the right. [C]: Front cover ( x 3) 3-11 B125...
Page 99 SCANNER 3.2 SCANNER 3.2.1 ORIGINAL WIDTH SENSORS, ORIGINAL SET SENSOR, SCANNER SWITCH B125R102.WMF Manual feed table, original feed sensor cover (! 3.1.10) [A]: Original width sensor bracket ( x 2) [B]: Original width sensors ( x 1,  x 1 each) [C]: Scanner switch (...
Page 100 SCANNER 3.2.2 ORIGINAL FEED UNIT ROLLERS [ A ] B125R108.WMF Lift and lock the scanner unit. (! 3.1.7) [A]: Original width sensor cover [B]: Original exit roller cover ( x 2) [C]: Original exit rollers ( x 2, bushings x 2) [D]: Original feed rollers (...
Page 101 SCANNER Reinstallation After you replace the original feed roller or the original exit roller, do the CIS sub scan test and adjustment, as shown below. 100 mm B125R911.WMF 1. Do SP2941 (IPU Test Pattern) and print Pattern 11. 2. Make a copy of the Pattern 11 output that you made in step 1. 3.
Page 102 SCANNER 3.2.3 EXPOSURE GLASS B125R113.WMF Unlock and lift the original feed unit. (! 3.1.6) Side covers (! 3.1.2) [A]: Left exposure glass plate ( x 1) [B]: Right exposure glass plate ( x 1) [C]: Exposure glass. Important: The exposure glass is very long and thin. It is very easy to break. Reinstallation •...
Page 103 SCANNER 3.2.4 CIS Rear View B125R110.WMF B125R109.WMF Lift and lock the scanner unit. (! 3.1.7) Original width sensor cover, original exit roller cover (! 3.1.10) [A]: At the rear, open the CIS ribbon harness clamps ( x 11) NOTE: Open only the harness clamps connected to the plate. Do not open the clamps on the bottom of the CIS unit.
Page 104 SCANNER 5. Do SP4428 002 (Image Scan Adjustment – Start) to adjust the standard white level. 1) Go into SP mode 4428 002 and push Enter (#). 2) Push “1”. The machine shows “In Progress”. 3) Put a stack of 5 sheets of A1 LEF paper on the original feed table. Use plain white paper of a type used by the customer.
Page 105 SCANNER 3.2.6 SIB, CGB POWER PACK B125R103.WMF Side covers (! 3.1.2) Manual feed table, original feed sensor cover (! 3.1.10) [A]: SIB ( x 3, ribbon connectors x 5,  x 6) [B]: CGB power pack ( x 4,  x 2, standoffs x 2) B125 3-18...
Page 106 AROUND THE DRUM 3.3 AROUND THE DRUM 3.3.1 CHARGE CORONA WIRE, GRID WIRE, WIRE CLEANER Rear B125R307.WMF Remove the OPC drum (! 3.5) NOTE: With the drum directly under the charge corona, damage to the drum will occur if the corona unit is dropped. Lift and lock the scanner unit (! 3.1.7) Scanner motor (! 3.8.1) [A]: Leaf spring (x 1)
Page 107 AROUND THE DRUM B125R308.WMF Charge corona unit (! 3.3.1) [A]: Two cover plates (pressure release) [B]: Charge corona wire (x1) [C]: Charge corona grid (pairs x 4) B125 3-20...
Page 108 AROUND THE DRUM 3.3.2 QUENCHING LAMPS B125R115.WMF B125R116.WMF OPC drum unit (!3.5.1) [A]: Quenching lamp unit ( x 3,  x 3) [B]: Quenching lamps (x3) ( x all,  x 3) NOTE: The quenching lamps are attached to the plate with double-sided tape. 3-21 B125...
Page 109 AROUND THE DRUM 3.3.3 LPH (LED PRINT HEAD) Rear B125R112.WMF Original feed unit (! 3.1.6) Lift and lock the scanner unit (! 3.1.7) [A]: Ground wire ( x 1). [B]: On each side of the machine, loosen the screws and move the plates to the rear as shown.
Page 110 AROUND THE DRUM Reinstallation 1. Adjust the position of the LPH until it is level. 2. Set the plates [B] lightly against the studs on each side. Then tighten the screws. Important: • Do not push the plates forward with force against the LPH studs. •...
Page 111 AROUND THE DRUM 3.3.4 TRANSFER CORONA, SEPARATION CORONA WIRES B125R406.WMF Open the upper unit. Side covers (! 3.1.2) [A]: Transfer unit ( x 2,  x 2) Reinstallation • At each end of the unit, make sure that the tabs [B] are fully engaged with the studs [C].
Page 112 AROUND THE DRUM B125R407.WMF Transfer unit (! 3.3.4) [A]: Left cap (tab release) [B]: Right cap (tab release) NOTE: To remove a paper guide, lift it a small distance and move it in the direction of the center. Make a note of the position of each guide. Each guide must be installed at its original position.
Page 113 DEVELOPMENT Rev. 06/2004 3.4 DEVELOPMENT 3.4.1 DEVELOPMENT UNIT B125R304.WMF Lift the upper unit. Side covers ( 3.1.2 ) ⇒ Original feed table ( 3.1.10) Toner hopper cover ( 3.1.8) Idle registration roller panel ( 3.1.9) Toner cartridge [A]: Development unit ( x 2, x 6) CAUTION...
Page 114 DEVELOPMENT Rev. 06/2004 3.4.2 DEVELOPER B125R306.WMFF B125R309.WMF 1. Remove the development unit ( 3.4) NOTE: Do not bend the bias terminal. 2. Put the development unit on a large sheet of paper. 3. Remove the casing [A] for the toner supply unit ( x 2) 4.
Page 115 DEVELOPMENT Rev. 06/2004 ⇒ B125R917.WMFMF 11. Add one (1 kg) pack of developer. Do not add the second pack at this time. • Open the first developer pack [A]. • Slowly add the first pack of developer to the development unit. Move the pack from left to right until it is empty.
Page 116 DEVELOPMENT Rev. 06/2004 ⇒ 20. Open the toner hopper cover. 21. Open the second 1 kg pack of developer and slowly add it to the development unit. Move the pack from left to right until it is empty. 22. Use a clean cloth to clean the edges around the slot of the development unit. 23.
Page 117 DEVELOPMENT 3.4.3 PAPER SET SENSOR, REGISTRATION SENSOR B125R303.WMF Idle registration roller panel (! 3.1.9) [A]: Sensor bracket ( x 1) [B]: Paper set sensor ( x 1) [C]: Registration sensor ( x 1) B125 3-30...
Page 118 DEVELOPMENT 3.4.4 TONER SUPPLY CLUTCH B125R305.WMF Development unit (! 3.4) [A]: Plate ( x 1) [B]: Cut the harness clamp. [C]: Toner supply clutch ( 1 x,  x 1, bushing x 1) NOTE: The stopper is spring-loaded and will come out suddenly after you remove the e-ring.
Page 119 DEVELOPMENT 3.4.5 DEVELOPMENT FILTER B125R306.WMF Development unit (! 3.4) [A]: Development unit casing ( x 2) [B]: Filter rack [C]: Filter B125 3-32...
Page 120 DEVELOPMENT 3.4.6 USED TONER COLLECTION BOTTLE, TONER OVERFLOW SENSOR B125R501.WMF Lift the original feed unit. Lift the upper unit. [A]: Right upper cover ( x 2) [B]: Right cover ( x 3) [C]: Loosen the leaf spring and lift it. [D]: Toner overflow sensor (...
Page 121 DRUM 3.5 DRUM 3.5.1 DRUM UNIT B125R901.WMF B125R401.WMF [A]: Open the upper unit and set the cleaning blade release lever to the left. Development unit (! 3.4) [B]: Drive belt plate, drive belt ( x 2) [C]: Drum gear, white Teflon bushing. Use the long end of a hexagonal wrench to loosen the two lock screws.
Page 122 DRUM B125R402.WMF B125R403.WMF 1. Drum unit [A]  CAUTION The drum unit is very heavy. Pull it out slowly. Important: Do not touch the surface of the drum. 2. Drum [B] ( x 2. bushings x 2, plate x 1) Reinstallation After you replace the drum: •...
Page 123 DRUM 3.5.2 CLEANING BLADE B125R404.WMF 1. Cleaning blade [A] ( x 2, springs x 2) Reinstallation After you replace the cleaning blade: • Do SP2923 (Cleaning Blade Set Mode). This applies toner to the drum and blade to decrease friction between the drum and the cleaning blade. If you do this, scratches on the drum or a bent cleaning blade are less possible to occur.
Page 124 DRUM 3.5.3 ID SENSOR, PICK-OFF PAWLS, PICK-OFF PAWL SOLENOID B125R405.WMF Drum (! 3.5.1) Cleaning blade (! 3.5.2) [A]: ID sensor ( x 3,  x 1,  x 1) [B]: Pick-off pawls (x2) (pressure release). [C]: Pick-off pawl solenoid ( x 2,  x 1) Reinstallation •...
Page 125 PAPER FEED 3.6 PAPER FEED 3.6.1 REGISTRATION CLUTCH, REGISTRATION ROLLER B125R507.WMF Side covers (! 3.1.2) [A]: Registration clutch ( x 1,  x 1) [B]: Gear cover plate ( x 5, cap x 1, drive belt x 1) [C]: Gear ( x 1, spring x 1) [D]: Gear (...
Page 126 PAPER FEED B125R506.WMF [A]: Cover plate ( x 5) [B]: Switch pressure plate Reinstallation Make sure that the vertical brace [C] is locked in the cutouts in the ceramic clutch [D]. 3-39 B125...
Page 127 PAPER FEED B125R508.WMF Used toner collection bottle (!3.4.6) [A]: Front plate ( x 4) [B]: Transport roller dust cover ( x 4) [C]: Registration roller ( x 2, bushings x 2, torque limiter x 1,  x1) B125 3-40...
Page 128 PAPER FEED 3.6.2 ROLL 1 PAPER FEED CLUTCH, FEED ROLLER B125R918.WMF Open the roll feeder drawer. Remove the paper rolls. [A]: Roll 1 feed clutch cover ( x 2) [B]: Roll 1 feed clutch ( x 1,  x 1) [C]: Roll 1 feed rollers (...
Page 129 PAPER FEED 3.6.3 ROLL 2 PAPER CLUTCH, FEED ROLLER B125R919.WMF NOTE: The procedure is for the B642 only. Open the roll feeder drawer. Remove paper roll 2 (at the rear). [A]: Roll 2 feed clutch cover ( x 2) [B]: Roll 2 feed clutch ( x 1,  x 1) [C]: Roll 2 feed rollers (...
Page 130 PAPER FEED 3.6.4 RF EXIT SENSOR B125R920.WMF Open the drawer of the roll feeder. [A]: Plate ( x 2) [B]: RF exit sensor ( x 1,  x 1) 3-43 B125...
Page 131 PAPER FEED 3.6.5 ROLL FEED MOTOR Below the front left corner of the roll feeder B125R921.WMF Open the roll feeder drawer. Drawer front cover (! 3.1.11) [A]: Loosen belt tension bracket. [B]: Gear ( x1) [C]: Roll feeder motor ( x 2,  x 1,  x 2) B125 3-44...
Page 132 PAPER FEED 3.6.6 CUTTER: MOTOR, HP SENSORS B125R922.WMF Drawer front cover (! 3.1.11) [A]: Upper bracket ( x 2) [B]: Lower bracket (spring x 1,  x 1,  x 1) 3-45 B125...
Page 133 PAPER FEED B125R923.WMF [A]: Right cutter HP switch ( x 1,  x 1) [B]: Left cutter HP switch ( x 1,  x 1) [C]: Cutter, race, and motor assembly ( x 3,  x 3,  x 2) [D]: Cutter motor (...
Page 134 PAPER FEED 3.6.7 ROLL PAPER END SENSORS B125R924.WMF Open the roll feeder drawer. [A]: Roll feeder back plate ( x 2) [B]: Roll end sensors ( x 1,  x 1 each) NOTE: The Roll Feeder B641 has one roll end sensor, and the Roll Feeder B642 has two roll end sensors.
Page 135 PAPER FEED 3.6.8 CASSETTE FEED ROLLER B125R925.WMF [A]: Paper cassette [B]: Cassette feed roller B125 3-48...
Page 136 PAPER FEED 3.6.9 CASSETTE RELAY SENSOR, CASSETTE END SENSOR B125R926.WMF B125R927.WMF Open the roll feeder drawer and remove the paper cassette. Roll feeder rear plate ( x 2 Blue) [A]: RFDB shield plate ( x 2). [B]: Paper cassette unit ( x 4,  x 2,  x 4) NOTE: Pull the unit to the rear, then remove it from the front.
Page 137 PAPER FEED 3.6.10 CASSETTE FEED MOTOR, CASSETTE OPEN SENSOR B125R928.WMF B125R929.WMF Open the roll feeder drawer and remove the paper cassette unit. [A]: Relay sensor plate, cassette end sensor plate ( x 1 each) [B]: Cassette open sensor ( x 1, pinch release x 2) [C]: Paper cassette feed assembly (...
Page 138 PAPER FEED 3.6.11 CASSETTE FEED CLUTCH B125R930.WMF Cassette feed motor (! 3.6.10) [A]: Motor mount plate ( x 2) [B]: Cassette feed clutch ( x 2,  x 1) 3-51 B125...
Page 139 FUSING SECTION 3.7 FUSING SECTION 3.7.1 PRESSURE SPRING ADJUSTMENT Rear Front B125R632.WMF 1. Open the exit cover and exit unit together. 2. To adjust the pressure, disconnect the spring [A] and connect it to a different hole. Center: Standard tension, standard pressure. Front (toward the Less tension, less pressure.
Page 140 FUSING SECTION 3.7.2 HOT ROLLER STRIPPERS B125R610.WMF [A]: Open the paper exit cover and paper exit unit together. [B]: Hot roller strippers (pressure release, spring x 1 each) 3.7.3 PRESSURE ROLLER STRIPPERS B125R612.WMF Rear cover ( x 2) (! 3.1.3) Paper exit unit and exit cover (! 3.1.4) [A]: Pressure roller strippers (spring x 1) NOTE: There are 11 pressure roller strippers.
Page 141 FUSING SECTION 3.7.4 PRESSURE ROLLER THERMISTOR, FUSING EXIT SENSOR B125R611.WMF Rear cover ( x 2) (! 3.1.3) Paper exit unit (! 3.1.4) [A]: Pressure roller thermistor ( x 1,  x 2) [B]: Fusing exit sensor ( x 1,  x 1) B125 3-54...
Page 142 FUSING SECTION 3.7.5 FUSING UNIT B125R613.WMF  CAUTION Switch the main power switch off. Then disconnect the machine from its power source. Let the fusing unit become cool for 10 minutes or more before you remove it. Open the upper unit. Paper exit unit (! 3.1.4) Pressure roller thermistor, fusing exit sensor (! 3.7.4) [A]: Braces (x3) (...
Page 143 FUSING SECTION 3.7.6 FUSING CLEANING ROLLER B125R614.WMF Fusing unit (! 3.7.5) [A]: Springs (x2) [B]: Felt plate ( x 2) [C]: Fusing cleaning roller ( x 2, bushings x 2) NOTE: The brown bushing is on the right; the white bushing is on the left. B125 3-56...
Page 144 FUSING SECTION 3.7.7 FUSING LAMP B125R615.WMF Fusing cleaning roller (! 3.7.6) [A]: Right plate ( x 1) [B]: Right support ( x 1) [C]: Left plate ( x 1) [D]: Left support ( x 1) NOTE: This is the support with the anti-static brush. [E]: Fusing lamp (...
Page 145 FUSING SECTION 3.7.8 HOT ROLLER B125R616.WMF Fusing lamp (! 3.7.7) [A]: Hot roller (springs x 2, sleeve bearings x 2, gear x 1) [B]: Lubricate with Barrierta – S552R (x2) B125 3-58...
Page 146 FUSING SECTION 3.7.9 PRESSURE ROLLER B125R617.WMF B125R618.WMF Hot roller (! 3.7.8) [A]: Pressure roller plate ( x 4) [B]: Thermistor/Thermostat plate ( x 4) [C]: Pressure roller (sleeve bearings x 2) 3-59 B125...
Page 147 FUSING SECTION 3.7.10 HOT ROLLER THERMISTOR, THERMOSTATS B125R620.WMF Fusing unit (! 3.7.5) [A]: Hot roller thermistor (x1) ( x 1) ° [B]: Thermostat 2 – 199 C ( M3x6 x 2) ° [C]: Thermostat 1 – 200 C ( M3x6 x 2) Reinstallation °...
Page 148 MOTORS 3.8 MOTORS 3.8.1 SCANNER MOTOR B125R114.WMF Original feed unit (! 3.1.6) Lift and lock the scanning unit (! 3.1.7) [A]: Scanner motor assembly ( x 2,  x 1,  x 2) [B]: Scanner motor ( x 2) 3-61 B125...
Page 149 MOTORS 3.8.2 DRUM MOTOR B125R111.WMF Original feed unit (! 3.1.6) Lift and lock the scanning unit (! 3.1.7) [A]: Belt tension plate ( x 2, spring x 1) [B]: Drum motor ( x 1,  x 3) B125 3-62...
Page 150 MOTORS 3.8.3 FUSING MOTOR, MAIN MOTOR B125R503.WMF Open the upper unit. Side covers (!3.1.2 ) [A]: Registration clutch ( x 1,  x 1) [B]: Upper unit sensor ( x 1,  x 4) [C]: Gear cover plate ( x 4,  x 5) 3-63 B125...
Page 151 MOTORS B125R504.WMF [A]: Timing belt and cap [B]: Motor mount plate ( x 8) [C]: Main power switch connector ( x 1,  x 1). [D]: Fusing motor ( x 1,  x 4) Reinstallation If it is not easy to connect the connector at the rear of the motor when you install the motor mount plate: •...
Page 152 MOTORS B125R505.WMF Remove the gear cover plate and motor mount plate. (Please refer to the two pages before this one.) [A]: Main motor ( x 2, drive belts x 2,  x 4) Reinstallation If it is not easy to connect the connector to the rear of the motor when you install the motor mount plate: •...
Page 153 MOTORS 3.8.4 USED TONER BOTTLE MOTOR B125R705.WMF PSU (! 3.9.2) Toner collection bottle (! 3.4.6) T&S power pack (! 3.9.4) [A]: Motor plate ( x 1,  x 1,  x 2) [B]: Motor ( x 2) B125 3-66...
Page 154 BOARDS 3.9 BOARDS 3.9.1 MCU/IPU B125R908.WMF B125R701.WMF Rear cover (!3.1.3) Paper exit unit (!3.1.4) [A]: Brace ( x 3) [B]: Board shield plate ( x 7) [C]: MCU/IPU board tray ( x 3,  x all,  x 15 (MCU),  x 5 (IPU)) [D]: Lift the harnesses to remove the MCU/IPU tray.
Page 155 BOARDS B125R702.WMF [A]: MCU Board ( x 9) [B]: IPU Board ( x 6) [C]: NVRAM(Data) [D]: NVRAM (Counter) (!3.9.3): Install the NVRAM from the old MCU board on the new MCU board. B125 3-68...
Page 156 BOARDS 3.9.2 PSU B125R703.WMF Rear cover (! 3.1.3) Paper exit unit (! 3.1.4) [A]: Braces (x2) ( x 2 each) [B]: PSU connectors ((x all,  x 9) [C]: PSU tray ( x 1) 3-69 B125...
Page 157 BOARDS 3.9.3 NVRAM NVRAM Upload B125R931.WMF If the electronic counter does not operate correctly, replace the NVRAM. 1. Switch the main power switch off. 2. Remove the rear cover. ( x 2) 3. Remove the MCU/IPU shield plate. (!3.9.1) 4. On the MCU, move the jumper [A] from TB4 1-2 to TB4 to 2-3. 5.
Page 158 BOARDS Rev. 06/2004 B125R702.WMF NVRAM Removal 1. Switch the main power switch off. Disconnect the machine power cord. 2. Remove the MCU/IPU tray. ( 3.9.1) 3. Pull the NVRAM chip [A, B] from the MCU board and replace it with a new chip. [A]: NVRAM (Counter) [B]: NVRAM (Data) 4.
Page 159 BOARDS 3.9.4 T&S POWER PACK B125R704.WMF PSU tray (! 3.9.2) [A]: T&S power pack mounting plate ( x 2,  x 3,  x 1) [B]: T&S power pack ( x 2) B125 3-72...
Page 160 BOARDS 3.9.5 RFDB (ROLL FEEDER DRIVE BOARD) B125R932.WMF Open the roll feeder drawer. Remove the rear plate of the roll feeder ( x 2 blue) [A]: Shield plate ( x 2) [B]: RFDB ( x 3, standoffs x 2) 3-73 B125...
Page 161 BOARDS 3.9.6 SFDB (SHEET FEED DRIVE BOARD) B125R933.WMF Paper cassette unit (! 3.6.9) [A]: SFDB ( x 2,  x 2, standoffs x 2) B125 3-74...
Page 162 OTHER 3.10 OTHER 3.10.1 HDD REPLACEMENT B125R934.WMF B125R935.WMF Rear cover ( x 2) Interface cover plate (if installed) ( x 1) Right vertical brace ( x 2) [A]: Ground plate [A] ( x 3) [B]: PCB shield cover [B] ( x 7) [C]: HDD unit (...
Page 163 OTHER B663R101.WMF [A]: HDD cover ( x 3) [B]: HDD ground plates ( x 2) [C]: HDD ( x 4) Reinstallation • If a new HDD is not available, do SP4960 015 (HDD – HDD Connection On/Off) to disable the HDD connection. This lets the customer use the machine until a replacement HDD can be installed.
Page 164 OTHER 3.10.2 COOLING FAN, OZONE FILTER [A]: Rear top cover ( x 1, x1, x2) B125R310.WMF [B]: Plates (press release) [C]: Ozone filter B125R311.WMF [D]: Cooling fan ( x 1,  x 3) B125R312.WMF 3-77 B125...
Page 165 SP ADJUSTMENTS Rev. 03/2006 3.11 SP ADJUSTMENTS 3.11.1 IMAGE ADJUSTMENT Do these adjustments if output is unsatisfactory. Before you start to measure and adjust, let the test print output become cool for three minutes. NOTE: Always do these adjustments in the sequence given in Steps 1~13 below. Step 1: Check the Registration Line Speed 1.
Page 166 SP ADJUSTMENTS Step 3: Scanning Magnification 1. Make a 1:1 copy of the A0 SEF Magnification Chart with plain roll paper. NOTE: You can use a different test chart, if it has lines 1000 mm long in the sub-scan direction and 700 mm long in the main-scan direction. 2.
Page 167 SP ADJUSTMENTS Step 6: Scanner Mask Setting Set To: Comments SP4012 001 Scanner Erase Margin – Leading Edge SP4012 002 Scanner Erase Margin – Trailing Edge SP4012 003 Scanner Erase Margin – Left SP4012 004 Scanner Erase Margin – Right Step 7: Erase Margins Set these SPs to “5”...
Page 168 SP ADJUSTMENTS 3. Adjust these SPs if a measurement is not in the standard range. Standard: Comments SP1001 001 Leading Edge Registration - Roll SP1001 003 Leading Edge Registration – Paper Cassette SP1001 005 Leading Edge Registration – Bypass Feed SP1002 001 5±0.5 mm Side-to-Side Registration –...
Page 169 SP ADJUSTMENTS Step 12: Printer: Cut Length The following SPs are necessary for this step: • SP1920 111 (Cut Length Adjustment - 1st Roll, 297 mm/11” or 12”, Plain Paper • SP1920 115 (Cut Length Adjustment -1st Roll, 1189 mm/44” or 48”, Plain Paper •...
Page 170 SP ADJUSTMENTS Step 13: Synchro Cut (Trailing Edge Registration) The following SPs are necessary for this step: • SP4961 001 (Original Adjustment – Synchro Cut Adjustment 210 mm) • SP4961 002 (Original Adjustment – Synchro Cut Adjustment 1000 mm) • SP4961 003 (Original Adjustment – Original Length Display) 1.
Page 171 SP ADJUSTMENTS Rev. 06/2004 ⇒ 3.11.2 CIS To Print the CIS Adjustment Pattern 1. Open the roll feeder drawer and cut off a sheet manually from a roll. (Turn the manual feed knob to feed the paper then push the cutter from side to side to cut.) 2.
Page 172 SP ADJUSTMENTS To Adjust the Image at the CIS Joints 1. Check the printed pattern to find if the dots are aligned at CIS 1-2. 2. If they are aligned correctly, no adjustment is necessary. -or- If they are not aligned correctly, do the next step. Here are two samples where the outputs are not aligned correctly.
Page 173 SP ADJUSTMENTS 6. Do this procedure again from Step 1 until the image at CIS 1-2 is correct. 7. Do this procedure for the other joints (CIS 2-3, CIS 3-4, CIS 4-5) The “Effect” column in this table tells you which area moves with the adjustment, and which area does not move.
Page 174 SP ADJUSTMENTS 3.11.3 LPH Doing SP Adjustment Settings for a Replacement LPH 1. Remove the replacement LPH from its box. 2. Read the label attached to the replacement LPH and note of the settings for SP2965 and SP2943. NOTE: This label is attached to the replacement LPH only. 3.
Page 175 SP ADJUSTMENTS Main Scan Adjustment: White, Black Vertical Lines 1. Check the printed pattern at LPH 1-2 for white or black lines. 2. If there are no lines, no adjustment is necessary. B125R561.WMF Normal Pattern If you see white or black lines at LPH 1-2, go to the next step. •...
Page 176 SP ADJUSTMENTS Main Scan Adjustment: LED Light Level at LPH Joints After you do the previous procedure to adjust the main scan at the LPH joints, you can do a fine adjustment on this area. To do this, you increase or decrease the intensity of the light from the four LEDs at the joints.
Page 177 SP ADJUSTMENTS To Adjust the LPH for Misalignment B125R986.WMF Broken lines [A] or [B] in the IPU Test Pattern (SP2941 11) show incorrect sub scan timing at one or both joints. 1. Go into the SP mode, and do SP2965 003 for LPH 1-2 •...
Page 178 SP ADJUSTMENTS 3.11.4 LPH DENSITY To Print the R-10 Pattern 51 1. Open the roll feeder drawer. Cut off a sheet manually from a roll. 2. Close the roll feeder drawer. 3. Go into the SP mode. Input 2941 and push . 4.
Page 179 TROUBLESHOOTING...
Page 181 SERVICE CALL CONDITIONS 4. TROUBLESHOOTING 4.1 SERVICE CALL CONDITIONS 4.1.1 SUMMARY There are 4 levels of service call conditions Level Definition Reset Procedure Fusing unit SCs shown on the operation Go into the SP mode. Set the main panel. The machine is disabled. The user power switch to “off”...
Page 182 SC CODE DESCRIPTIONS 4.2 SC CODE DESCRIPTIONS 4.2.1 SC1XXX There are no Group 1 SC codes for this machine. 4.2.2 SC2XXX There are no Group 2 SC codes for this machine 4.2.3 SC3XXX Group 3 SP codes are related to image making. Charge Corona Output Error The charge-corona feedback •...
Page 183 SC CODE DESCRIPTIONS 360-1 Hard Disk Connection Error 360-1 The machine could not • Check the connections between the detect the HDD connection. HDD and hard disk controller. • Check the HDD power connector. • Replace the HDD. • Replace the MCU. Temporary Solution: Use SP4960 015 to disable HDD access.
Page 184 SC CODE DESCRIPTIONS MSU Output Error Just after the machine was • Replace the IPU. switched on, it could not detect that the MSU (Memory Super-charger Unit) was set. Development Bias Error 392-1 The development bias • Check the MCU connectors. feedback voltage was less •...
Page 185 SC CODE DESCRIPTIONS 4.2.4 SC4XXX Group 4 SC codes are also related to image making. ID Sensor Auto Adjustment Error Vsg did not get to • Clean the ID sensor. 4 ±0.2 V when the ID • Check the ID sensor harness and sensor was adjusted connector.
Page 186 SC CODE DESCRIPTIONS 4.2.5 SC5XXX Group 5 SC codes are related to: • Paper feed • Paper transport in the paper path • Fusing Cutter Error The left and right cutter HP • Check the connections of the HP sensors stayed on or off more sensors on the left and right side.
Page 187 SC CODE DESCRIPTIONS Fusing Unit Drive Motor Error The lock signal goes LOW • Check that the motor drive path is not after the motor starts and gets overloaded. to the set speed. If the fusing • Replace the motor. motor lock signal stayed HIGH for 5 seconds during motor operation, the motor stopped...
Page 188 SC CODE DESCRIPTIONS Rev. 06/2004 Fusing Temperature Warm-up Error • Check the fusing lamp connections. The hot roller did not get to the ready temperature within 4 • Replace the fusing lamp. minutes 30 sec.: • Replace the MCU. ⇒ •...
Page 189 SC CODE DESCRIPTIONS Fusing Temperature Errors 546-1 Fusing Temperature Error 1 Fusing temperature goes up • Check the thermistor connection. and down quickly, more than • Check the fusing lamp connections. 20°C (68°C) at 1 sec. intervals. • Replace the MCU. 546 –2 Fusing Temperature Error 2 temperature goes up and...
Page 190 SC CODE DESCRIPTIONS Pressure Roller Thermistor Errors 549-1 Pressure Roller Thermistor Error 1 Fusing temperature control detected • Check the thermistor connection. that the analog voltage output by the • Replace the thermistor. pressure roller thermistor was more • Replace the MCU. than 5V.
Page 191 SC CODE DESCRIPTIONS 4.2.6 SC6XXX Group 6 SC codes are for communication errors. Communication Error Between IPU and CIS A break signal was detected • Update the software. after the communication • Replace the MCU. connection. A communication error was sent back 3 times. Communication Error Between Controller and ECU One of these problems •...
Page 192 SC CODE DESCRIPTIONS MK1 Communication Error 3: Backup RAM (Japan Only) The optional counter device • Check the serial line harnesses and sent an error because there is connectors at the counter device, the a malfunction in the backup relay board, and the controller. RAM.
Page 193 SC CODE DESCRIPTIONS 4.2.7 SC7XXX There are no Group 7 SC codes for this machine. 4.2.8 SC8XXX There are no Group 8 SC codes for this machine. 4.2.9 SC9XXX Electrical Total Counter The electrical counter is not connected. • Replace NVRAM chips. Mechanical Total Counter The mechanical counter is not •...
Page 194 SC CODE DESCRIPTIONS Software Error 1: SCU There was an unusual operation by • Set the main power switch to the software because of: “off” then to “on”. • Go into the SP mode. • An incorrect argument in the •...
Page 195 JAM CODE TABLES 4.3 JAM CODE TABLES When a copier jam occurs:  • The jam indicator lights ( • A diagram on the LCD shows you where the jam is, with instructions to help you remove the problem. • The “Code” numbers in the table are also shown.
Page 196 JAM CODE TABLES Meaning Location Comment Code Registration Sensor The leading edge fed 0.5 sec. before the time permitted for 30 mm of feed. The leading edge fed 0.5 sec. after the Registration Sensor ON time permitted for 30 mm of feed. Registration Sensor The trailing edge fed 0.5 sec.
Page 197 JAM CODE TABLES 4.3.2 SCANNER JAM TABLES Scanner Ready Check Jams These jams (DJ01~DJ08) occur if there is an original in the original feed path at these times: • Just after the machine power comes on • When the machine comes back to normal operation from an energy save mode. Code Meaning Location...
Page 198 JAM CODE TABLES Code Meaning Location Comments The original registration sensor detected the leading edge and came ON. But the DJ26 Original Exit Sensor 2 original exit sensor stayed OFF, a long time after the leading edge should get to the exit rollers.
Page 199 COVER OPEN 4.4 COVER OPEN Location Shut Off Lines Display Scanner Switch Scanner motor (24 dc line) Upper Unit Switch Toner supply clutch, paper registration clutch, drum motor, main motor, CGB power pack, cooling fan, paper junction gate solenoid, quenching lamp, pick-off pawl solenoid, fusing motor, T&S power pack (24 V dc line), fusing lamp (power relay/ac line)
Page 200 IMAGE DATA PROCESSING FLOW CHART 4.6 IMAGE DATA PROCESSING FLOW CHART 4.6.1 DATA FLOW IN 1-TO-1 COPY MODE Scanner Controller Printer Controller Data Flow OIPU (ASIC) 1 bit/pixel 8 bit/pixel E/O Parallel E/O Parallel 16.66 MHz 16.79 MHz Stamp Ri-10 IMAC Auto Shading, Magnification, Image OIPU:...
Page 201 IMAGE DATA PROCESSING FLOW CHART 4.6.3 DATA FLOW IN SCANNING MODE Scanner Controller Printer Controller Data Flow OIPU (ASIC) 1 bit/pixel 8 bit/pixel E/O Parallel E/O Parallel 16.66 MHz 16.79 MHz Stamp Ri-10 IMAC Auto Shading, Magnification, Image OIPU: Editing, Print Editing IPU Board Filtering Ri-10:...
Page 202 IMAGE DATA PROCESSING FLOW CHART 4.6.5 DATA FLOW IN PRINTING MODE (LONG) Scanner Controller Printer Controller Data Flow OIPU (ASIC) 1 bit/pixel 8 bit/pixel E/O Parallel E/O Parallel 16.66 MHz 16.79 MHz Stamp Ri-10 IMAC Auto Shading, Magnification, Image OIPU: Editing, Print Editing IPU Board Filtering...
Page 203 IMAGE DATA PROCESSING FLOW CHART 4.6.7 IMAGE PROBLEM TROUBLESHOOTING 4.6.8 FLOW CHART Image Problem VDB Test Problem image LPH Defective pattern output area 1/3 unit. VDB Defective IPU Defective or IPU Test Harness defective pattern output between the IPU and the VDB. SIB defective or SIB Test harness between...
Page 204 IMAGE DATA PROCESSING FLOW CHART 4.6.9 SCANNING 1. No image (blank copy/print, or no image with only vertical black lines on the output) Possible causes: 1) Connection problem between CIS and IPU. 2) CIS defective 2. No image (solid black copy/print, or no image with only B125T541.WMF vertical white lines on the output) Possible causes:...
Page 205 IMAGE DATA PROCESSING FLOW CHART 6. Black or white bands with no image-width 1/8 A0 (E) size Possible causes: 1) Connection problem between CIS and IPU 2) CIS output error 3) IPU board adjustment error B125T546.WMF 7. White lines every 1mm pitch in halftone areas Possible causes: CIS defective B125T547.WMF...
Page 206 IMAGE DATA PROCESSING FLOW CHART Rev. 06/2004 4.6.10 PRINTING 1. No Image (blank copy/print) Possible causes: 1) VDB board defective 2) IPU board defective 3) LPH (LED head) defective B125T549.WMF 2. Band with no image-width 1/3 of image Possible causes: 1) Connection problem between VDB and LPH 2) LPH head defective B125T550.WMF...
Page 207 IMAGE DATA PROCESSING FLOW CHART Rev. 06/2004 4.6.11 BOARD LEDS This section shows the functions of the LEDs on the most important boards. The tables show the LEDs on the IPU, MCU, VDB, SIB, and PSU. LED 1 LED 2 LED 14 LED 15 LED 16...
Page 208 IMAGE DATA PROCESSING FLOW CHART IPU LEDs Color Meaning LED 1 GREEN Not used. LED 2 GREEN Flashes while the HDC (Hard Disk Controller) operates. Flashes when an LSYNC signal (VORES) comes from the VDIP LED 3 GREEN (ASIC). Flashes when an LGATE signal (ACC01) comes from the VDIP LED 4 GREEN (ASIC).
Page 209 IMAGE DATA PROCESSING FLOW CHART MCU LEDs Color Meaning Flashes quickly while data is downloaded from the IC flash memory LED 1 GREEN card. Lights and stays on during normal operation. Lights and stays on while SCU data is downloaded from the IC flash LED 2 GREEN memory card.
Page 210 IMAGE DATA PROCESSING FLOW CHART PSU LEDs Color Meaning Normal • The machine has entered the energy save Vaa +24 V GREEN mode (Energy Star). • PSU defective, or the +24 V system has shorted or is defective. Normal • The machine has entered the energy save Vca2 –12 V GREEN mode (Energy Star).
Page 211 SERVICE TABLES...
Page 213 USING THE SP MODE 5. SERVICE TABLES 5.1 USING THE SP MODE 5.1.1 DIRECT ENTRY Normal Direct Entry 1. Go into the SP mode.  • Push • Push . • Push and hold  for 3 seconds. The initial SP mode screen is shown. SP mode Select number 1 Copy...
Page 214 USING THE SP MODE 4. Set the adjustment value. • If a minus sign (-) is necessary, push  to change the +/- sign. • If a decimal point is necessary, do not push the decimal point button. For example, to input “-1.3”, push  for the minus sign, then push . •...
Page 215 SOFTWARE UPGRADE 5.2 SOFTWARE UPGRADE The MCU (Main Control Unit) board flash-memory contains the software for this machine. To upgrade the software, one IC card is necessary. This card contains the SCU and ECU firmware. To copy the software into the flash memory on the MCU board, put the cards in the slots as shown in the procedure.
Page 216 SOFTWARE UPGRADE 5. Wait for approximately 3 minutes. When LED4 goes off and LED3 starts to flash orange slowly at two-flash intervals, the ECU upgrade is completed. 6. Switch the main power switch off. 7. Remove the IC card from the ECU slot. 8.
Page 217 INITIAL SETTINGS 5.3 INITIAL SETTINGS 5.3.1 USER TOOLS System Settings Push the “User Tools” key to go into the user tools mode. The initial user tool mode screen is shown. User Tools Specify No. 1. System Settings 2. Copier Features Exit B125S904.WMF •...
Page 218 INITIAL SETTINGS In the tables below: • The “Paper Roll 1” and “Paper Roll 2” selections are shown only after installation of the optional roll feeder. • “Cut Paper Tray” is shown only after installation of the optional paper cassette in the roll feeder.
Page 219 INITIAL SETTINGS Fusing Mode Selection Tables With this user tool, the user must set the type of paper that is used for the job. User Tools → 1. System Settings→ 1. General Features→ 02 Fusing Adjustment NOTE: Bold numbers in the tables below show the default settings (standard). Fusing Mode Selection Table: Europe/Asia Mode Paper Type...
Page 220 INITIAL SETTINGS Copier Features • Push the “User Tools” key to go into the user tools mode. The initial user tool mode screen is shown. User Tools Specify No. 1. System Settings 2. Copier Features Exit B125S906.WMF • Push  for “Copier Features” Copier Features Specify No.
Page 221 INITIAL SETTINGS 1. General Features Item Default Setting Change Initial Mode Standard Copier Auto Reset Timer 60 sec. Original Priority Text Auto Density Priority Adjust Scan Density Auto Paper Select Priority Paper Tray Priority Paper Roll 1 Copy Start Method Auto Original Size Detect Auto...
Page 222 INITIAL SETTINGS Rev. 06/2004 2. Reproduction Ratio Item Default Setting User Reduce/Enlarge Ratio: 1-3 100% Preset Reduce/Enlarge Priority Metric Version: 100% Inch Version: (Engineering): 100% Inch Version: (Architecture): 100% User Auto Reduce/Enlarge Metric Version: None (1-to-1) Inch Version (Engineering): None (1-to-1) Inch Version (Architecture): None (1-to-1) User Auto Reduce/Enlarge Original Vertical...
Page 223 PRINTING TEST PATTERNS PRINTING TEST PATTERNS 5.4.1 IMAGE PROCESSING TEST PATTERNS Print an IPU Test Pattern if you have problems with image processing (poor halftones, line widths, etc.) 1. Open the roll feeder drawer and manually cut off a sheet 914 mm (W) x 297 mm (L) (36"...
Page 224 PRINTING TEST PATTERNS Item Pattern Rope pattern 1 dot main scan even/odd reversal Rope pattern Frequency characteristic - Vertical Frequency characteristic - Horizontal Frequency characteristic - Vertical/Horizontal Gray scale 5 - Vertical/Horizontal Gray scale 6 - Vertical/Horizontal Black White Gray scale 7 - Vertical/Horizontal Independent 1 dot (16-dot interval) Independent 1 dot (32-dot interval) Independent 1 dot (64-dot interval)
Page 225 PRINTING TEST PATTERNS 5.4.2 IMAGE DATA PATH TEST PATTERNS Print an IPU test pattern to check that the CIS and IPU operate correctly. Print a VDB test pattern to check that the LPH and VDB operate correctly. 1. Open the roll feeder drawer and manually cut off a sheet 914 mm (W) x 297 mm (L) (36"...
Page 226 INPUT CHECK 5.5 INPUT CHECK You can check the sensors and switches with SP5803. • Go into one of the modes in the tables. • In each mode, the display shows an 8-digit number. The digits are given numbers 7 to 0 from left to right. •...
Page 227 INPUT CHECK Rev. 06/2004 [4] P2E Input Status bit-7 Not used bit-6 Not used bit-5 Not used bit-4 Not used bit-3 Not used bit-2 Not used bit-1 Cutter HP switch – Right 0: Home position, 1: Not home pos. bit-0 Cutter HP switch –...
Page 228 INPUT CHECK [8] Scanner 1 Input Status bit-7 Org. size sensor 30" (914 mm) 1000 0000 bit-6 Org. size A4/A sensor (Org. set sensor) 0100 0000 bit-5 Org. size A3/B sensor 0010 0000 bit-4 Org. size A2/C sensor 0001 0000 bit-3 Org.
Page 229 OUTPUT CHECK 5.6 OUTPUT CHECK You can check the operation of these parts with SP5804. Item Parts Roll feed clutch 1 Roll feed clutch 2 Cassette feed clutch Not used Not used Registration Clutch Paper Junction Gate Sol. Cooling Fan Motor Not used Roll Feed Motor - Forward Roll Feed Motor - Reverse...
Page 230 OUTPUT CHECK Item Parts Not used Not used Not used Not used Drum Potential Measuring Mode Not used Not used Scanner Feed Motor – Forward Not used CIS LED B125 5-18...
Page 231 SP (SERVICE PROGRAM) MODE TABLES 5.7 SP (SERVICE PROGRAM) MODE TABLES SP Table Key Notation What it means [range/default step] Example: [-9 ~ +9/+3.0/0.1 mm step]. Setting can be adjusted in the range ±9, value reset to +3.0 after and NVRAM reset, and the value can be changed in 0.1 mm steps with each key push.
Page 232 SP (SERVICE PROGRAM) MODE TABLES 1105 Fusing Temp. Adj. Be sure to switch the main power switch off and on after adjustment. Copy Ready Sets the copy ready fusing temperature. The setting is the Temperature difference from the target fusing temperature that is set with SP 1107.
Page 233 SP (SERVICE PROGRAM) MODE TABLES 1108 Target Temperature: Pressure Roller Sets the target fusing temperature of the pressure roller. • These temperatures are used for pressure roller feedback. Pressure roller feedback is not used if SP1104 is set to “1”. Notes •...
Page 234 SP (SERVICE PROGRAM) MODE TABLES Rev. 03/2005 1801 Feed Motor Speed Adjustment These SPs adjust the speed of roll feed for the type of paper (adjusts the speed of the roll feeder motor). Use these SPs to prevent print density that is not equal, and scratchy images, in these conditions: •...
Page 235 SP (SERVICE PROGRAM) MODE TABLES Rev. 03/2005 ⇒ 1916 Fusing Motor Speed Adjustment SP1916 001~013 adjust the basic fusing motor speed and correct the speed for different widths of paper to prevent skew in the paper feed path. The adjustment that the machine applies is the sum of the base speed (1916 001), the width adjustment (1916 010 to 013), and the paper type adjustment (1916 021 to 045).
Page 236 SP (SERVICE PROGRAM) MODE TABLES 1918 Main/Fusing Motor Setting These two SP modes adjust the rate of the speed reduction between the main motor and the fusing motor. During normal operation, the line speed in the fusing unit is slightly faster than the line speed at registration. This keeps the paper lightly stretched to prevent wrinkling and skewing.
Page 237 SP (SERVICE PROGRAM) MODE TABLES 1920 Cut Length Adjustment 1st Roll, 297 mm/11" or 12", Plain Adjusts the 297-mm cut length. Paper [-10.0 ~ +10.0/0/0.1 mm] 1st Roll, 420 mm/17" or 18", Plain Adjusts the 420-mm cut length. Paper [-10.0 ~ +10.0/0/0.1 mm] 1st Roll, 594 mm/22"...
Page 238 SP (SERVICE PROGRAM) MODE TABLES Rev. 03/2005 1920 Cut Length Adjustment 2nd Roll, 594 mm/22" or 24", Plain Adjusts the 594-mm cut length. Paper [-10.0 ~ +10.0/0/0.1 mm] 2nd Roll, 841 mm/32" or 34", Plain Adjusts the 841-mm cut length. Paper [-20.0 ~ +20.0/0/0.1 mm] 2nd Roll, 1189 mm/44"...
Page 239 SP (SERVICE PROGRAM) MODE TABLES 1960 Optional Paper Setting Enables the roll feeder or the paper cassette after they are installed. Do this SP after the installation of the roll feeder or the paper cassette, or the machine will not detect the roll feeder or the paper cassette.
Page 240 SP (SERVICE PROGRAM) MODE TABLES Rev. 06/2004 SP2-XXX Drum 2001 Charge Corona Adjustment Image Area Adjusts the charge corona output. DFU ⇒ [505~1530/1220/1 µA step] Grid for Image Area Adjusts the charge grid output. DFU [162~1080/770/1 V step] Grid for ID Sensor Adjusts the charge grid output for the ID sensor pattern.
Page 241 SP (SERVICE PROGRAM) MODE TABLES 2208 Toner Supply Setting Gain Sets the toner supply capacity for the job load. [0~3/1/1] 0: H (Low) 1: M (Medium) 2: H (High) 3: HH (Very High) Supply Pause Level Not Used Toner Supply Mode Sets the toner supply mode.
Page 242 SP (SERVICE PROGRAM) MODE TABLES 2403 Separation DC Voltage Setting Adjusts the separation dc voltage. If this setting is too high, toner will go back from the paper to the drum after transfer. The separation dc voltage can be set for plain paper, translucent paper, and film for: •...
Page 243 SP (SERVICE PROGRAM) MODE TABLES 2812 Drum Cleaning Interval DFU The drum turns in reverse after this number of jobs. This cleans the edge of the cleaning blade. [0~5/0/1Job step] 2923 Cleaning Blade Set Mode Input “1” to do this SP after you replace the OPC or cleaning blade. This SP applies toner to the drum and blade.
Page 244 SP (SERVICE PROGRAM) MODE TABLES 2926 Used Toner Tank Motor The used toner bottle motor (vibration motor) moves a cam, which hits the side of the used toner collection bottle. This makes the level of used toner in the bottle equal. After Main SW Sets the length of time that the used toner bottle motor operates.
Page 245 SP (SERVICE PROGRAM) MODE TABLES 2927 Toner Near End/End Detection Near End Level Sets the level for toner near end detection. (Vsp/Vsg = Vend). [0~15/2/1] 0: 0.150 6: 0.140 12: 0.180 1: 0.175 7: 0.145 13: 0.185 2: 0.200 8: 0.155 14: 0.190 3: 0.225 9: 0.160...
Page 246 SP (SERVICE PROGRAM) MODE TABLES 2941 IPU Test Pattern Sets the IPU Test Pattern. Print an IPU Test Pattern when you think that there is a problem with image processing. The IPU Test Pattern is also used to check if the LPH components are aligned.
Page 247 SP (SERVICE PROGRAM) MODE TABLES 2941 IPU Test Pattern Sets the IPU Test Pattern. Print an IPU Test Pattern when you think that there is a problem with image processing. The IPU Test Pattern is also used to check if the LPH components are aligned.
Page 248 SP (SERVICE PROGRAM) MODE TABLES 2943 LED Duty Adjustment Adjusts the length of time (also known as “width” or “duty”) that the LEDs of the LPH stay on. To make pixels darker, increase the exposure time. Use this SP if it is necessary to make the output of one LPH block brighter or darker. There are different adjustments for odd-numbered pixels and even-numbered pixels.
Page 249 SP (SERVICE PROGRAM) MODE TABLES Rev. 03/2005 2965 LPH Joint Adjustment Adjust these settings only after you replace the LPH. For more, refer to Section “3. Replacement and Adjustment”. LPH 1-2 Main Scan Adjusts the LPH joint for main scan between LPH1 and LPH2.
Page 250 SP (SERVICE PROGRAM) MODE TABLES Rev. 06/2004 SP3-XXX Process Control 3001 ID Sensor Settings PWM Setting Sets the level of the PWM (Pulse Width Modulation) of the ID sensor LED. DFU [0~100/35/0.1%] ID Sensor / Developer Automatically calibrates the ID sensor output to 4.0 V Initialization and also prepares the developer.
Page 251 SP (SERVICE PROGRAM) MODE TABLES SP4-XXX Scanner 4008 Scanner Sub Scan Magnification Adjusts the magnification. To do this, the machine changes the scanning speed. [-0.9 ~ +0.9/0/0.1% step] 4010 Scanner Sub Scan Registration 001 Leading Edge Adjusts the time between the sensor-on position and the leading edge of the image.
Page 252 SP (SERVICE PROGRAM) MODE TABLES 4903 Image Setting – Smoothing Filter Level Use this if density is not equal in shaded areas of the copy. The change from high to low density areas in shaded areas must be smooth. Do these SP adjustments if you see “false outlines”...
Page 253 SP (SERVICE PROGRAM) MODE TABLES 4905 Line Thickness Mode Sets the line reproduction correction for each copy mode (Text, Text/Photo, etc.) The mode groups have three SP settings: 1) Initial. Sets the main adjustment for the copy mode (Text, Text/Photo, etc.). This has an effect on line correction in the main and sub scan directions.
Page 254 SP (SERVICE PROGRAM) MODE TABLES 4905 Line Thickness Mode Sharpen Text [0~8/5/1]] 0: Low (better thin line reproduction) 5: Off 8: High (better thick line reproduction) [0~3/0/1] Main Scan – Sharpen Text 0: None 1: Weak 2: Medium 3: Strong Sub Scan –...
Page 255 SP (SERVICE PROGRAM) MODE TABLES 4906 Filter/Independent Dot Erase Settings Pale 25.0% - 55.0% [0~10/5/1] Pale 55.1% - 75.0% Pale 75.1% - 160.0% Pale 160.1% - 400.0% Generation 25.0% - 55.0% [0~10/5/1] Generation 55.1% - 75.0% Generation 75.1% - 160.0% Generation 160.1% - 400.0% Background Line 25.0% - 55.0% [0~10/5/1]...
Page 256 SP (SERVICE PROGRAM) MODE TABLES 4906 Filter/Independent Dot Erase Settings M: Background Line [0~14/7/1] [0~14/10/1] H: Background Line L: Sharpen Text [0~14/4/1] M: Sharpen Text [0~14/7/1] H: Sharpen Text [0~14/10/1] L: Drawing [0~14/4/1] M: Drawing [0~14/7/1] H: Drawing [0~14/10/1] 4907 White Level Correction 001 Threshold Raises and lowers the threshold value for white level correction.
Page 257 SP (SERVICE PROGRAM) MODE TABLES 4908 IPU Function Selection This SP checks the operations of the Ri-10 image processors on the IPU board. Pre-Filter [0~1/0/1] DFU Line Thickness 0: Start: Sets each bit to “0”. Noise Reduction 1: True: Sets each bit to “1”. Filter Mode Density Gamma Resolution 2...
Page 258 SP (SERVICE PROGRAM) MODE TABLES 4960 Media Check Input “1” to detect defective sectors on the hard disk. At the factory, the original defective sector data is stored in the non-volatile memory. This data lets the hard disk prevent access to the defective sectors. If other sectors become defective after the machine leaves the factory, this sector data must also be stored in non-volatile memory, to prevent output of defective images.
Page 259 SP (SERVICE PROGRAM) MODE TABLES 4965 Orig. Speed – Leading Edge The original feed roller tries to adjust for slippage of the feed rollers to let the machine measure the length of the original accurately. The diameter of the feed roller (32 +0/- 0.05) differs slightly from the diameter of the exit roller (32 +0.05/-00).
Page 260 SP (SERVICE PROGRAM) MODE TABLES 4973 SIB Register Setting 3 Difference in Grade Adj. Enables the function that lets you correct the alignment of the CIS elements. For more, see “SP Adjustments” in “3. Replacement and Adjustment”. [0~1/0/1] Test Pattern Selection Replaces the SIB test pattern with a scanned image.
Page 261 SP (SERVICE PROGRAM) MODE TABLES SP5-XXX Mode 5001 All Indicators On Switches on the operation panel and all LEDs on the operation panel to check that LCD and LEDs operate correctly. Push to switch on the operation panel.   Push to switch off.
Page 262 SP (SERVICE PROGRAM) MODE TABLES 5113 Optional Counter Type DFU Use this to switch on the keycard/MF accounting device. Japan Only [0 ~ 5/0/1 step] 0: None 1: Key Card – RK2, RK3, Rk4 2: Key Card – Count-down type 3: Pre-Paid Card 5: MF Keypad Disable Copying DFU...
Page 263 SP (SERVICE PROGRAM) MODE TABLES 5505 Error Alarm Interval DFU Sets the error alarm interval. Japan Only [0 ~ 255/800/1 m step] 5507 Paper Supply Call Level RDS (Concord) Only Adjusts the supply management call. The ranges, defaults, and steps are different, depending on your geographical area.
Page 264 SP (SERVICE PROGRAM) MODE TABLES 5508 CC Call Setting On/Off RDS (Concord) Only Enables and disables the CC Call features below. Jam Stay Enables/disables the automatic CC call for a paper jam that is not removed for a long time. [0~1/1/1] 0: The machine makes a CC Call automatically 1: The machine does not make a CC Call automatically...
Page 265 SP (SERVICE PROGRAM) MODE TABLES Auto Call Setting RDS (Concord) Only 5590 Door Open Enables/disables the auto call. Alarm Push On or Off to enable or disable the setting. Paper Supply Enables/disables the auto call. Alarm Push On or Off to enable or disable the setting. Toner Supply Enables/disables the auto call.
Page 266 [0~1/0/1] 0: No print 1: Print 5907 Plug & Play Sets the maker name (20 bytes) and model name (50 bytes). Maker Name Model Name 1: RICOH imagio Wide 6020 2: RICOH Aficio 240W 3: NRG A045 4: SAVIN 2400WE...
Page 267 SP (SERVICE PROGRAM) MODE TABLES Rev. 05/2006 5945 Black and White Reversal Preset Stamp Push No or Yes to switch off/on the display of the user stamps in reverse. User Stamp Page Numbering Date Stamp Background Numbering ⇒ 5958 Long Length Print Setting Set the maximum original and print lengths.
Page 268 SP (SERVICE PROGRAM) MODE TABLES Rev. 03/2005 ⇒ 5998 Developer Lot Number Use this SP to enter the developer lot number at machine installation and when the developer is replaced. Note: The lot number is embossed on the edge of the developer packet. To enter the number: 1 Enter the SP mode and select SP5998.
Page 269 SP (SERVICE PROGRAM) MODE TABLES SP7-XXX Data Log 7001 Drum Drive Motor Operation Time Shows the drum-drive-motor operation time (to check the print count and drum operation time.) 7002 Original Counter Total Sheet Count Shows the count for the features that were used. Copy Mode Sheet Count Scanner Mode Sheet Count Total Length...
Page 270 SP (SERVICE PROGRAM) MODE TABLES 7002 Original Counter Original Size: Metric: Std. B: Custom 515 mm Original Size: Metric: Std. B: Custom 364 mm Original Size: Metric: Std. B: Custom 257 mm Original Size: Metric: Std. B: Custom Bypass Inch Original Size: Inch: Eng: 8 ½...
Page 271 SP (SERVICE PROGRAM) MODE TABLES 7002 Original Counter Original Size: Inch: Arc: 4E Original Size: Inch: Arc: 5E Original Size: Inch: Arc: A Custom: 9 Original Size: Inch: Arc: B Custom: 12 Original Size: Inch: Arc: C Custom: 18 Original Size: Inch: Arc: D Custom 24 Original Size: Inch: Arc: E Custom: 30/36 Original Size: Inch: Arc: Custom: Bypass 7003...
Page 272 SP (SERVICE PROGRAM) MODE TABLES 7003 Print Counter Original Size: Metric: Std. B: 3B2 Original Size: Metric: Std. B: 2B1 Original Size: Metric: Std. B: 3B1 Original Size: Metric: Std. B: 4B1 Original Size: Metric: Std. B: Custom 728 mm Original Size: Metric: Std.
Page 273 SP (SERVICE PROGRAM) MODE TABLES 7003 Print Counter Transfer Size: Inch: Arc: 6D Transfer Size: Inch: Arc: 7D Transfer Size: Inch: Arc: 2E Transfer Size: Inch: Arc: 3E Transfer Size: Inch: Arc: 4E Transfer Size: Inch: Arc: 5E Transfer Size: Inch: Arc: Custom 9 Transfer Size: Inch: Arc: Custom 12 Transfer Size: Inch: Arc: Custom 18 Transfer Size: Inch: Arc: Custom 24...
Page 274 SP (SERVICE PROGRAM) MODE TABLES 7101 Length Count by Width Metric 914 mm Roll Shows the print length for each paper roll width. 841 mm Roll 594 mm Roll 420 mm Roll 297 mm Roll 210 mm Roll 660 mm Roll 440 mm Roll 880 mm Roll 800 mm Roll...
Page 275 SP (SERVICE PROGRAM) MODE TABLES 7204 Length Count by Tray 1st Roll Shows the total copy count for each feed station 2nd Roll Cassette By-pass feed 7207 Corona Wire Cleaning Display Cleaning Count Shows the number of times that the charge corona wire was cleaned (Range: 0~9,999,999) Clear Cleaning Count Resets the count for SP7201 001.
Page 276 SP (SERVICE PROGRAM) MODE TABLES 7304 Sheet Count by Copy Mode Text Shows the total copy count for each copy mode. Each counter counts up at the time of paper feed. Text/Photo Photo Pale Original Generation Blue Erase Photo 2 Line Drawing Erase Shift...
Page 277 SP (SERVICE PROGRAM) MODE TABLES 7403 SC History Shows the 10 most recent SC code numbers. Latest Latest 1st Latest 2nd Latest 3rd Latest 4th Latest 5th Latest 6th Latest 7th Latest 8th Latest 9th 7405 System SC History Shows the following data about the 10 most recent SC codes: •...
Page 278 SP (SERVICE PROGRAM) MODE TABLES 7504 Paper Jam Counter by Location Shows the jam count for each location. Paper Set Sensor Paper Registration Sensor Fusing Exit Sensor Original Removed Paper Set Sensor (While RF In Use) Bypass Length Over Registration Sensor OFF (Leading Edge) Registration Sensor ON (Leading Edge) Registration Sensor OFF (Trailing Edge) Registration Sensor ON (Trailing Edge)
Page 279 SP (SERVICE PROGRAM) MODE TABLES 7506 Copy Jam Counter by Paper Width Shows the jam count for each paper width. Metric 914 mm Roll 841 mm Roll 594 mm Roll 420 mm Roll 297 mm Roll 210 mm Roll 660 mm Roll 440 mm Roll 880 mm Roll 800 mm Roll...
Page 280 SP (SERVICE PROGRAM) MODE TABLES 7507 Jam History Shows the 10 most recent jams. Copy Latest Copy Latest 1st Copy Latest 2nd Copy Latest 3rd Copy Latest 4th Copy Latest 5th Copy Latest 6th Copy Latest 7th Copy Latest 8th Copy Latest 9th Original Latest Original Latest 1st...
Page 281 SP (SERVICE PROGRAM) MODE TABLES 7811 Original Counter Clear Do this SP to reset SP7002 (Original Counter). 7816 Total Sheet by Roll Counter Clear 1st Roll Resets the copy counter for each roll (SP7204) 2nd Roll Cassette By-pass feed 7819 Copy Count: Clear Width Do this SP to reset the copy counter for each roll width (SP7101) 7822...
Page 282 SP (SERVICE PROGRAM) MODE TABLES 7834 Coverage Data Clear These SPs reset the data coverage SPs shown below. Clears: SP8831 Dot Coverage Count: Accumulated Average SP8841 Dot Coverage Count: First Page Clears: SP8781 Number of Total Toner Cartridges Used Clears: SP8901 001 Toner Cartridge Count: Previous –...
Page 283 SP (SERVICE PROGRAM) MODE TABLES SP8xxx Data Log 2 These SPs are for future reference. 8781 Number of Total Toner Cartridges Used Shows and prints the sum of the total number of toner cartridges plus the total number of toner bottles installed in the machine. 8831 Dot Coverage Count: Accumulated Average Shows the average page coverage as a percent, calculated from the coverage counts...
Page 284 DETAILED DESCRIPTIONS...
Page 286 OVERVIEW 6. DETAILED DESCRIPTIONS 6.1 OVERVIEW 6.1.1 MACHINE GENERAL LAYOUT B125D969.WMF Image Writing Unit Uses an LPH (LED Print Head) Scanner Unit Uses a CIS (Contact Image Sensor) unit for scanning. The CIS is made of 5 sensor arrays connected at four joints. The CIS scans the face-down original from below.
Page 287 OVERVIEW 6.1.2 MECHANICAL COMPONENT LAYOUT B125D969.WMF B125...
Page 288 OVERVIEW 1. Original Table 16. T&S Corona Unit 2. Original Feed Rollers 17. Roll 2 Holders 3. OPC Drum 18. Roll 2 Paper Feed Rollers 4. Charge Corona Unit 19. Lower Output Guide 5. Original Exit Roller 20. Lower Output Stacker 6.
Page 289 OVERVIEW 6.1.3 DRIVE LAYOUT B125D970.WMF 1. Scanner Motor 2. Drum Motor 3. Main Motor 4. Fusing Motor B125...
Page 290 OVERVIEW Rev. 06/2004 6.1.4 ORIGINAL/COPY PAPER PATHS ⇒ B125D971.WMF 1. Manual Feed (Bypass) Path 2. Original Path (Upper) Upper output stacker installed. 3. Original Path (Straight-Through) Upper output stacker removed. 4. Paper Path (Upper) Normal (Default) 5. Paper Path (Rear) Selectable* 6.
Page 291 SCANNER 6.2 SCANNER 6.2.1 OVERVIEW B125D101.WMF Only one original can be placed face-down on the original table. Original set sensor [A]: Detects the leading edge of the paper. Then the machine stops original feed for 1 second (Delay 1). This gives the user time to put the paper straight.
Page 292 SCANNER 6.2.2 SCANNER LAYOUT 24.5 132.2 20.0 38.5 46.2 B125D951.WMF [A]: Original Width Sensors. Detect the width of the original. [B]: Original Set Sensor. Detects when the original is put on the original feed table. [C]: Original Feed Roller. Feeds the original to the original registration sensor. [D]: Original Registration Sensor.
Page 293 SCANNER Rev. 06/2004 6.2.3 ORIGINAL WIDTH DETECTION B125D103.WMF Six sensors below the original feed table detect the original width. These are the five original width sensors and the original set sensor, which is also used as an original width sensor. ⇒...
Page 294 SCANNER 6.2.4 ORIGINAL DRIVE MECHANISM B125D102.WMF The scanner motor [A] (a stepper motor) and timing belt [B] control the original feed rollers [C] and original exit rollers [C]. The signal from the original set sensor controls the on/off timing. 6.2.5 ORIGINAL FEED SPEED Original Speed 240 mm/s...
Page 295 SCANNER 6.2.6 SCANNING MECHANISM CIS Structure B125D104.WMF This machine uses a contact image sensor [A] (: Digital Processes – Image Processing – Black and White CIS Systems). The scanning unit is below the original feed path. The CIS scans black and white originals a maximum of 926.5 mm (36 inches) wide at 600 dpi.
Page 296 SCANNER 6.2.7 AUTO IMAGE DENSITY CORRECTION B125D101.WMF Auto Image Density Correction corrects the background density. First, the CIS reads the surface of the white guide plate [A]. The machine uses this reading (white point =0) as a reference point for density correction. Contact Image Sensor (Center) 70 mm 70 mm...
Page 297 IMAGE PROCESSING Rev. 06/2004 6.3 IMAGE PROCESSING 6.3.1 OVERVIEW Overall System Stamp Interface Board Board (Option) (Option) (Option) From PSU, 12V, 5V Eval. Tool (Debugging) From PSU 5V, -12V (PSU) LPH 1 LVDS LVDS LPH 1 (A4 x5) (CPLD x1) LPH 1 LEDs (Operation...
Page 298 IMAGE PROCESSING IPU Board Details The VDIP is the interface between the OIPU and the RI1001 image processors. This diagram shows a map of the IPU board, and the data flow through the machine. 16.79 MHz 8.33 MHz (Scanner Application) Appl.
Page 299 IMAGE PROCESSING 6.3.2 GENERAL IMAGE PROCESSING FLOW CHART Image processing is done in the IPU and Ri-10 image processors on the IPU board. Signal from CIS Sub Scan Magnification - Create standard data for white shading correction Shading Correction - White shading correction processing - Main scan image shift Conversion - Main scan magnification...
Page 300 IMAGE PROCESSING 6.3.3 ORIGINAL MODES Overview Here is a summary of the eight original modes that the user can set for this machine at the operation panel. Mode Function Text Best reproduction of text and sharp lines. Text mode does not detect differences between areas of the page that contain text, graphics, or photographs;...
Page 301 IMAGE PROCESSING Text Mode Image Processing Flow Related SP/UP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering SP4906-20~23 MTF Filtering Independent dot erase settings Independent Dot Erasure SP4905-01-03 Line Width Correction Line thickness mode settings SP4906 70~72 Independent dot erase settings...
Page 302 IMAGE PROCESSING Photo Mode Image Processing Flow Related SP/UP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering SP4906 24~27 Independent Dot Erase Filter/Independent Dot Erase Settings (Filter Settings) SP4906 73~75 Filter/Independent Dot Erase Settings (Independent Dot Erase) SP4905 04~06...
Page 303 IMAGE PROCESSING Text/Photo Mode Image Processing Flow Related SP/UP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering SP4906 28~31 MTF Filtering Filter/Independent Dot Erase Independent Dot Erasure Settings (Filter Settings) Line Width Correction SP4906 76~78 Filter/Independent Dot Erase...
Page 304 IMAGE PROCESSING Pale Mode Image Processing Flow Related SP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering MTF Filtering SP4905 10~12 Line Thickness Mode – Pale Independent Dot Erasure Originals. SP4906 32~35 Filter/Independent Dot Erase Settings (Filter Settings)
Page 305 IMAGE PROCESSING Generation Image Processing Flow Related SP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering MTF Filtering SP4905 13~15 Line Thickness Mode – Independent Dot Erasure Generation (Main and Sub Scan) Line Width Correction SP4906 36~39 Filter/Independent Dot Erase...
Page 306 IMAGE PROCESSING Drawing Mode Image Processing Flow Related SP/UP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering MTF Filtering SP4905 22~24 Line Thickness Mode – Line Independent Dot Erasure Drawing. Line Width Correction SP4906 48~51 Filter/Independent Dot Erase...
Page 307 IMAGE PROCESSING Background Lines Mode Image Processing Flow Related SP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering MTF Filtering SP4905 16~18 Line Thickness Mode (Blue Line Independent Dot Erasure Erase –...
Page 308 IMAGE PROCESSING Sharpen Text Mode Image Processing Flow Related SP/UP Modes Scanner Image Shading Correction Correction ↓ Conversion Main Scan Resolution SP4911-01~06 Processing Conversion Magnification corrections ↓ Filtering SP4905 19~21 MTF Filtering Line Thickness Mode (Photo 2 – Main and Sub Scan). SP4906 44~47 Filter/Independent Dot Erase Settings (Filter Settings –...
Page 309 IMAGE PROCESSING 6.3.4 INDEPENDENT DOT ERASE The purpose of independent dot erase is to remove unwanted small spots from the copy image. The user sets the strength of independent dot erase with this User Tool:  Copier Features General Features Noise Reduction →...
Page 310 IMAGE PROCESSING 6.3.5 MTF SETTINGS The MTF (Modulation Transfer Function) filter strength can be adjusted for the following requirements: • Sharper reproduction of text and lines on the same page. • Sharper lines in copies reduced in size. • Removal of rough-textured background. •...
Page 311 AROUND THE DRUM 6.4 AROUND THE DRUM 6.4.1 OVERVIEW Front B125D401.WMF Rear 1. LPH (LED Print Head) 6. T&S Unit (Separation Corona) 2. Charge Corona Unit 7. T&S Unit (Transfer Corona) 3. Quenching Lamp (LED Array) 8. Registration Rollers 4. Cleaning Blade 9.
Page 312 AROUND THE DRUM 6.4.2 DRUM DRIVE B125D404.WMF The drum motor [A] controls: • Timing gears [B] • Timing belt and wheel [C] This turns the OPC drum [D]. Gear [F] (meshed with the OPC drum) turns the cleaning unit auger [G]. When paper feed starts: •...
Page 313 AROUND THE DRUM 6.4.3 CHARGE CORONA UNIT B125D405.WMF The charge corona unit [A], above the OPC drum, uses the Scorotron (Negative) Charge Method ( Photocopying Processes – Charge – Corona Charge) There is one gold-plated charge wire behind four pair of grid wires. The grid wires make sure that the charge on the OPC drum is constant.
Page 314 AROUND THE DRUM 6.4.4 CORONA WIRE CLEANING B125D405.WMF The corona wire is cleaned immediately after the main power switch or operation power switch is turned on, if the following two conditions occur at the same time: • 600 m of paper has been fed through the machine since the last wire cleaning •...
Page 315 AROUND THE DRUM 6.4.5 DRUM CLEANING B125D401.WMF B125D972.WMF This machine uses a counter blade system to clean toner from the surface of the drum. ( Photocopying Processes – Cleaning – Counter Blade) The cleaning blade [A] is opposite to the direction that the drum turns. The counter blade has a lever [B] on the bottom side of the upper unit.
Page 316 AROUND THE DRUM 6.4.6 COLLECTING USED TONER B125D406.WMF The cleaning unit auger [A] pushes toner into the used toner collection bottle [B]. The used toner bottle motor [C] moves a cam [D] from side to side, to hit the side of the used toner collection bottle.
Page 317 AROUND THE DRUM 6.4.7 QUENCHING B125D402.WMF The quenching lamp [A], an array of LEDs, is behind the LPH [B]. After the drum [A] is cleaned by the cleaning blade, light from the quenching lamp removes unwanted charge on the drum. This prepares the drum for the subsequent copy cycle.
Page 318 AROUND THE DRUM 6.4.8 DRUM ANTI-CONDENSATION HEATERS B125D973.WMF The two heaters [A] below the drum prevent condensation around the drum and T&S unit. A cooling fan [B] moves the air. The on/off timing of these heaters is: • When the main power switch or operation switch is switched on, the heaters switch off.
Page 319 IMAGE WRITING MECHANISM 6.5 IMAGE WRITING MECHANISM B125D401.WMF B125D974.WMF LPH 1-2 LPH 2-3 LPH 2 LPH 1 LPH 3 Front B125D915.WMF This machine uses an LPH (LED Print Head) [A] that sends light directly to the OPC drum to make a latent image. The A0-size 600-dpi print head is an array of connected self-focusing lenses [B] above an LED array [C] and drive board [D], and attached to a heat sink [E].
Page 320 DEVELOPMENT 6.6 DEVELOPMENT 6.6.1 OVERVIEW B125D302.WMF 1. Auger 6. Paddle Roller 2. Doctor Blade 7. Toner Agitator 3. Development Entrance Seal 8. Toner Cartridge 4. OPC Drum 9. Separator 5. Development Roller NOTE: The development unit does not have a TD sensor. The machine uses only the ID sensor for toner supply control.
Page 321 DEVELOPMENT 6.6.2 DEVELOPMENT DRIVE MECHANISM B125D304.WMF [A]: Timing belt (from the main motor) [B]: Gear train [C]: Paddle roller [D]: Mixing auger [E]: Development roller [F]: Gear [G]: Toner supply clutch [H]: Toner agitator shaft (controlled by the toner supply clutch) The toner supply clutch engages only when the toner density control circuit turns on.
Page 322 DEVELOPMENT 6.6.3 TONER SUPPLY MECHANISM B125D302.WMF This machine uses dual-component development with toner concentration control (.Photocopying Processes – Development – Dual-component Development). The toner agitator [A] turns in the center of the toner cartridge to move toner to the paddle roller [B] in the development unit. Toner then goes to the development roller [C] and the drum [D].To control the quantity of toner that is supplied to the development unit, the machine switches the toner supply clutch on and off.
Page 323 DEVELOPMENT 6.6.4 DEVELOPER CROSS-MIXING B125D303.WMF (.Photocopying Processes – Development – Crossmixing) [A]: Doctor blade [B]: Development roller [C]: Backspill plate [D]: Paddle roller [E]: Auger inlet [F]: Mixing auger [G] Paddle roller inlet B125 6-38...
Page 324 DEVELOPMENT 6.6.5 DEVELOPMENT BIAS B125D904.WMF The CGB power pack [A] applies a negative bias (-650V) to the development roller [B], slightly higher than the remaining charge on the drum. The development bias during copying is set by SP 2201 001 (Development Bias Adjustment –...
Page 325 DEVELOPMENT 6.6.6 ID SENSOR B125D905.WMF The ID sensor [A] regularly reads two areas of the drum: • Bare surface of the drum. The ID sensor measures the reflectivity of the bare drum, converts this reading to a voltage, and stores this value (Vsg) in NVRAM. •...
Page 326 DEVELOPMENT 6.6.7 ID SENSOR OPERATION DURING MACHINE WARM-UP SW OFF Vsp/Vsg = 0.4/4.0 = 0.1 (Normal) Vsp/Vsg = 0.4/3.0 = 0.13 (Add Toner) B125D960.WMF Vsg is checked one time only, when these two conditions occur at the same time: • The machine is switched on with the main power switch or the operation switch •...
Page 327 DEVELOPMENT B125D918.WMF B125 6-42...
Page 328 DEVELOPMENT 6.6.8 TONER DENSITY CONTROL Overview This machine uses an ID sensor to control: • Toner density • Toner near end detection • Toner end detection The machine uses the ratio of Vsg/Vsp to find the quantity of toner that must be supplied to the drum.
Page 329 DEVELOPMENT Detect Supply Mode Main Table The machine uses this table from the start of the page until the length of the printed page gets to 1189 mm (46.8"). The machine uses these two parameters to control the rate of toner supply: •...
Page 330 DEVELOPMENT Fixed Supply Mode When the technician switches the machine to fixed supply mode, toner is supplied as shown in this table. Toner Supply Level (SP 2208 001) Toner supply rate Toner Supply Clutch Operation The toner supply clutch turns the toner agitator shaft to supply toner from the toner cartridge to the development unit.
Page 331 DEVELOPMENT Image Area Supply Rates 100% 0.4 sec 0.3 sec 0.4 sec 0.6 sec 0.9 sec 1.6 sec 2.7 sec 3.6sec 0.4 sec 8.8 sec 11.7sec 16.8sec 0.4sec 34.3sec B125D916.WMF The percentage values in this chart correspond to the percentages listed in the Main, Length, and Abnormal ID Sensor Tables.
Page 332 DEVELOPMENT 6.6.9 TONER END/NEAR-END DETECTION The machine compares Vsp/Vsg with two SP settings to find when the toner cartridge is almost empty (Toner Near End) or fully empty (Toner End). • SP2927 001: Toner near-end • SP2927 003: Toner end Toner Near End When Vsp/Vsg is larger than SP2927 001 three times in sequence, the machine shows a toner near-end indication.
Page 333 DEVELOPMENT Toner End Recovery Flow Chart Toner End Recovery Recovery Start Toner Cover Opened/Closed? Toner End Reset ο Recovery Times → (1) Drum Motor ON 6.5 mm (2) Drum Charge, ID Sensor Grid, QL ON 70 mm (3) D Sensor Bias ON 10 mm after (3) above: (4) Main Motor ON 70 mm...
Page 334 PAPER FEED AND REGISTRATION Rev. 06/2004 ⇒ 6.7 PAPER FEED AND REGISTRATION 6.7.1 OVERVIEW Layout Diagrams 1. Manual Feed Table (Bypass) 13. Feed Rollers (Roll 2) 2. Paper Set Sensor (Manual Feed 14. Roll 2 End Sensor (EXP) Table) 15. Lower Output Tray 3.
Page 335 PAPER FEED AND REGISTRATION Paper Exit Selection Lev er Paper Exit Selection Sensor Upper Exit Rollers Fusing Exit O PC Rollers Regis. Drum Roller Paper Set Sensor Roller Registration Paper M anual Pressure Fusing Sensor Junction Rear Feed T able Roller Exit G ate...
Page 336 PAPER FEED AND REGISTRATION Feed Station Overview The machine can feed paper from the manual feed table or the optional roll feeder. With all options installed, there are four paper feed sources: • Manual Feed Table (bypass tray) • Roll 1: Front roll in the Roll Feeder (Roll Feeder B641 has the front roll only) •...
Page 337 PAPER FEED AND REGISTRATION 6.7.2 MANUAL FEED MECHANISM B125D203.WMF The user puts a cut sheet [A] on the manual feed table (also known as the bypass tray). The paper set sensor [B] detects the leading edge of the sheet. This switches on the drum motor, main motor, and registration clutch.
Page 338 PAPER FEED AND REGISTRATION 6.7.3 ROLL FEED MECHANISM Drive B125D976.WMF One roll feed motor [A] controls the two feed rollers: The clutch [B] engages to transfer power from the motor to the feed roller [C] for Roll 1. -or- The clutch [D] engages to transfer power from the motor to the feed roller [E] for Roll 2.
Page 339 PAPER FEED AND REGISTRATION Roll Pre-feeding B125D952.WMF Check Before Pre-Feeding The machine does a pre-feed control check: • Immediately after the main power switch or operation switch is switched on. • Immediately after the roll feeder drawer is closed. • At the end of a copy job. During the pre-feed check, the cutter moves to home position: •...
Page 340 PAPER FEED AND REGISTRATION Procedure B125D977.WMF Roll paper feed starts from the pre-feed position. • The roll feed motor engages roll feed clutch 1 and turns the feed rollers [1]. • The RF exit rollers [2] feed the paper past the roll exit sensor [3] to the registration roller.
Page 341 PAPER FEED AND REGISTRATION 6.7.4 ROLL FEEDER PAPER HOLDERS B125D907.WMF B125D711.WMF The racks [A] that hold the rolls are adjustable. This lets the user install paper rolls of different widths. A roll stopper [B] is put in each end of a roll. The roll lever [C] locks the stoppers in their position after they are put in the ends of a roll.
Page 342 PAPER FEED AND REGISTRATION 6.7.5 ROLL PAPER CUTTING MECHANISM B125D978.WMF Immediately before cutting, the registration roller continues to turn at normal speed, but the roll feed motor speed increases by a small quantity. This causes the paper to buckle slightly between the registration roller and the top of the cutter, and this gives the machine time to cut the paper.
Page 343 PAPER FEED AND REGISTRATION 6.7.6 ROLL END DETECTION B125D980.WMF B125D979.WMF To detect roll end, these two reflective photo-sensors detect the black core of an empty roll: • Roll end sensor 1 [A], above Roll 1 • Roll end sensor 2 [B], above Roll 2 Also, two other sensors detect roll end if the core of the paper roll is a color other than black: •...
Page 344 PAPER FEED AND REGISTRATION 6.7.7 PAPER CASSETTE MECHANISM B125D981.WMF Support arms [A] on each side of the paper cassette go in grooves on each side when the paper cassette is set in the roll feeder. The grooves lift the supports and pull the springs attached to the bottom plate [B] of the paper cassette.
Page 345 PAPER FEED AND REGISTRATION 6.7.8 PAPER CASSETTE FEED B125D982.WMF Cassette Paper Path Paper feeds from the paper cassette when the copy job starts. The cassette feed motor switches on, and the cassette feed clutch engages to turn the cassette feed roller [A] and the grip rollers [C]. The cassette relay sensor [B]: •...
Page 346 PAPER FEED AND REGISTRATION Paper Cassette Pre-Feeding Paper does not pre-feed from the cassette before the copy job starts. The machine pre-feeds paper from the cassette only between pages of multi-page copy jobs. B125D952.WMF There are two pre-feed positions for the leading edge of cut sheets after the first sheet of a multi-page copy job.
Page 347 PAPER FEED AND REGISTRATION 6.7.9 PAPER CASSETTE PAPER END DETECTION B125D983.WMF The paper end sensor [A] is above the paper cassette. The feeler [B] falls through a hole in the cassette plate after the last sheet feeds from the cassette. The actuator [C] moves forward away from the sensor and the machine detects paper end.
Page 348 PAPER FEED AND REGISTRATION 6.7.10 REGISTRATION B125D202.WMF The main motor [A] and registration clutch [B] control the registration roller [C]. The registration clutch switches off temporarily for roll paper or cut sheets from the paper cassette. • When paper is fed from the roll feeder or paper cassette, the paper buckles paper against the roller to remove skew.
Page 349 PAPER FEED AND REGISTRATION 6.7.11 CONDENSATION PREVENTION B125D984.WMF There are four dehumidifiers, two at the front [A] and two at the rear [B], for the roll feeder. The dehumidifier switch on the right side of the roll feeder controls the operation of these dehumidifiers.
Page 350 PAPER FEED AND REGISTRATION 6.7.12 PAPER FEED TIMING CHART B125D926.WMF 6-65 B125...
Page 351 IMAGE TRANSFER AND SEPARATION 6.8 IMAGE TRANSFER AND SEPARATION 6.8.1 OVERVIEW B125D401.WMF The T&S unit contains two parts: [A] Transfer corona unit [B] Separation corona unit Transfer Corona Unit Uses a tungsten wire (diameter 80 µm) 9.6 mm above the drum. This wire applies approx.
Page 352 IMAGE TRANSFER AND SEPARATION 6.8.2 PICK-OFF PAWL OPERATION B125D205.WMF The pick-off pawls separate paper from the drum if the separation corona does not separate the paper fully. The pick-off pawl solenoid [A] moves the pick-off pawls [B] until they touch the drum.
Page 353 FUSING UNIT Rev. 06/2004 6.9 FUSING UNIT 6.9.1 OVERVIEW B125D601.WMF 1. Hot Roller 8. Pressure Release Lever 2. Fusing Cleaning Roller 9. Pressure Roller 3. Hot Roller Strippers 10. Entrance Spurs 4. Fusing Exit Rollers 11. Fusing Lamps 5. Fusing Exit Sensor 12.
Page 354 FUSING UNIT 6.9.2 PAPER FEED THROUGH THE FUSING UNIT B125D601.WMF After separation from the drum: • The paper feeds to the transport plate [1]. • The 5 sets of spurs [2] at the entrance hold the paper against the transport plate •...
Page 355 FUSING UNIT 6.9.3 FUSING PRESSURE CONTROL MECHANISM Front Rear B125D608.WMF The spring-loaded pressure levers [A] are attached to the pressure roller shaft [B]. The pressure of the springs pushes the pressure roller [C] (a silicone-rubber roller) against the hot roller [D]. To adjust the position of the pressure spring [E], change the position of the lower attachment point: Center:...
Page 356 FUSING UNIT 6.9.4 TEMPERATURE CONTROL Zero-Cross Control Test Before the machine switches on the fusing lamp, the zero-cross control test checks if the power supply is 50 Hz or 60 Hz. If the frequency does not fall in the necessary range after 10 attempts, then: •...
Page 357 FUSING UNIT Fusing Temperature Control Important: The target hot roller and pressure roller temperatures have different settings for each paper type. The correct target temperatures must be used during fusing. To make sure of this, the user must set this user tool to the paper that they will use for the job: User Tools 1.
Page 358 FUSING UNIT Fusing Temperature Control with Pressure Roller Temperature Feedback ° ° In a cool environment (15 C [59 F] or lower), the machine can be set to switch on the fusing motor and turn the hot roller and pressure roller until the pressure roller gets to its target temperature.
Page 359 FUSING UNIT Summary of Warmup Sequence with Inching On & PPC Target Tem p. PPC Ready Tem p. +1 OFF -4 ON Room T emperature " Inching (Fusing Motor On/Off Energy Save Auto Off B125D963.WMF Example: Plain Paper Step What Happens Comment °...
Page 360 FUSING UNIT Details About Pressure Roller Feedback Pressure roller thermistor outputs are used to adjust the temperature as shown in the table below where: • X is the target hot-roller temperature set with SP1107 • Y is the target pressure-roller temperature set with SP1108 Press.
Page 361 FUSING UNIT 6.9.5 HOT ROLLER CLEANING B125D601.WMF The cleaning roller [A] (parallel to the hot roller) always touches the hot roller [B] with a low pressure. The cleaning roller has a layer of material that is soaked with silicone oil. Each time the fusing motor switches on, it reverses for 2 s to clean the hot roller.
Page 362 FUSING UNIT 6.9.6 HOT ROLLER THERMISTORS AND THERMOSTATS B125D602.WMF A thermistor [A] monitors the temperature of the hot roller. One more thermistor [B] monitors the temperature of the pressure roller. ° ° Thermostat [C] (199 C) and thermostat [D] (200 C) give emergency heat protection.
Page 363 FUSING UNIT 6.9.7 FUSING UNIT DRIVE MECHANISM B125D603.WMF The fusing motor [A] (a stepper motor) controls the gears and timing belts [B] that turn the hot roller [C] The pressure of the hot roller against the pressure roller [D] and cleaning roller [E] turns these rollers in the opposite direction.
Page 364 FUSING UNIT 6.9.8 WRINKLE PREVENTION B125D610.WMF Motor Speed Control During normal operation, the fusing rollers [A] (controlled by the fusing motor) is slightly faster than the registration rollers [B] (controlled by the main motor). This stretches the paper between the registration rollers and the fusing unit to keep the paper from wrinkling inside the fusing unit.
Page 365 PAPER EXIT 6.10 PAPER EXIT 6.10.1 OVERVIEW B125D985.WMF The fusing exit rollers [5] send the paper to the paper junction gate [3]. Upper Exit When the paper junction gate [3] is closed: • The gate sends the paper to the upper exit rollers [2]. •...
Page 366 PAPER EXIT 6.10.2 SWITCHING THE PAPER EXIT B125D607.WMF B125D606.WMF Upper Exit When the “Upper Copy Output” indicator on the operation panel is ON and the paper feed exit lever [1] is UP: • The paper junction gate solenoid [2] stays off. •...
Page 367 PAPER EXIT When the paper exit selection lever is down: • The “Upper Copy Output” key indicator on the operation panel goes off and this key is disabled. Paper will feed out at the rear if this lever is down. •...
Page 368 ELECTRICAL COMPONENTS 6.11 ELECTRICAL COMPONENTS 6.11.1 OVERVIEW ! DOM: 100V 15A ! NA: 120V 15A ! EU: 230V 8A (CIS Control) (LPH Control) (3 Elements, Dehumidifiers VDIP 600 dpi, 1-bit) Scanner Controller Printer Controller (ASIC) Stamp Board Drum Anti- (Option) (Option) 5 A4-Width Condensation...
Page 369 ELECTRICAL COMPONENTS 6.11.2 DESCRIPTIONS OF ELECTRICAL COMPONENTS Number Name Description CIS1 CIS 1 (Contact Image Sensor) These transfer the image signals from the CIS LEDs to the SIB. CIS2 CIS 2 (Contact Image Sensor) CIS3 CIS 3 (Contact Image Sensor) CIS4 CIS 4 (Contact Image Sensor) CIS5...
Page 370 ELECTRICAL COMPONENTS Number Name Description PCB1 IPU (Image Processing Unit) This processes image data from the CIS (Contact Image Sensor), and sends it to the VDB (Video Drive Board) and LPH (LED Print Heads). The IPU also controls the HDD unit and the PC interfaces. PCB2 MCU (Main Control Unit) This is the machine’s main board.
Page 371 ELECTRICAL COMPONENTS Sensors Cassette End Sensor This sensor is above the paper cassette. It detects paper end after the last sheet feeds. Cassette Set Sensor This detects when the cassette is set and locked in its place. Exit Cover Sensor This detects if the exit cover on the rear of the machine is open or closed.
Page 372 ELECTRICAL COMPONENTS Roll End Sensor 3 (EXP) This detects the trailing edge of the roll after there is no more paper on Roll 1. This sensor is included because if the color of the roll core is not black, Roll End Sensor 1 cannot always detect roll end.
Page 373 ELECTRICAL COMPONENTS Number Name Description Others Recycle Counter A mechanical counter that measures the total length in meters of paper that the machine feeds. It starts from the first copy. Dehumidifier 1 (Front/Right) One of four dehumidifiers that keeps the roll feeder drawer free of moisture.
Page 374 ELECTRICAL COMPONENTS 6.11.3 MCU, IPU B125D801.WMF MCU (Main Control Unit) This is the main control board of the machine. It does the following: • System control • Base engine control • Scanner control • Image processing The MCU also sends load signals and supplies power to: •...
Page 375 ELECTRICAL COMPONENTS 6.11.4 PSU B125D802.WMF The PSU (Power Supply Unit) supplies dc for all electrical components in the machine, and controls ac input to the fusing lamps and anti-condensation lamps. B125 6-90...
Page 376 ELECTRICAL COMPONENTS 6.11.5 SMDB, VDB, SIB Cooling Fan Scanner Stop SW Operation Panel Scanner Motor CIS 1 CIS 1 CIS 1 CIS 3 CIS 5 LPH 2 Regis. Clutch LPH 1 LPH 3 SMDB CGB PP Drum Motor Main SW B125D923.WMF SMDB (Scanner Motor Drive Board) Controls the scanner motor.
Page 377 ELECTRICAL COMPONENTS 6.11.6 RFDB, SFDB RFDB B125D924.WMF The RFDB and SFDB are on the bottom plate of the drawer in the optional roll sheet feeder. RFDB (Roll Feed Drive Board) The RFDB, on the floor panel of the roll feeder, controls the motors, solenoids, and clutches for the two paper rolls in the roll sheet feeder.
Page 378 SPECIFICATIONS...
Page 380 SPECIFICATIONS SPECIFICATIONS 1. COPIER ENGINE Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet Original Image Size: Maximum: 914 x 3,600 mm (36" x 142") (W x L) Minimum: 182 x 140 mm (7" x 5") Max Original Width: 960 mm (37.7") 18 ~ 135 g/m²...
Page 381 SPECIFICATIONS Rev. 06/2004 Warm-up Time: Less than 2 minutes (Room temperature 23°C, 120 V: US, 220-240 V: EU) First Copy Time: 1st Roll Feed: 22 sec. (A1/LEF/D LEF) Manual Feed: 32 sec. (A1/LEF/D LEF) Copy Number Input: Ten-key pad, 1 to 20 (standard sizes only) Copy Paper Bypass Feed: 1 sheet Capacity:...
Page 382 SPECIFICATIONS Power Consumption 120V version: Full system *¹ Warm-up 1.4 kW Ready *² 0.03 kW During Copying 1.44 kWh Maximum 1.44 kW 220 - 240V version: Full system *¹ Warm-up 1.4 kW Ready *² 0.03 kW During Copying 1.5 kWh Maximum 1.5 kW *¹...
Page 383 SPECIFICATIONS • Roll Feeder Type 240A/B (B641/B642) Optional Equipment: • Paper Cassette Type 240 (B643) • Table Type 240 (B662) • HDD Type240 (B663) • Interface PCB Type 240 (B690) • Stamp Board (B321) • Printer Controller RW 240 (B697) •...
Page 384 SPECIFICATIONS 4. MACHINE CONFIGURATION B125V905.WMF Item Machine Code Main Frame B125 Interface PCB Type 240 B690 Stamp Board B321 Hard Disk Type 240 B663 Table Type 240 B662 Roll Feeder Type 240A/B* B641/B642 Paper Cassette Type 240* B643 Roll Holder B394 Printer/Scanner Controller in Server PC B697...
Page 385 Pulse Signal M2P3(3) PULL UP POINT TO POINT Signal Direction Ready Low CN994 CN903 CN850 CN851 Ready High CN902-1 BLOCK DIAGRAM (B125/B275) +12V INTERFACE (OPTION) Voltage STAMP BOARD (OPTION) to Printer/Scanner Controller P.GND HDD1 (OPTION) from PSU C.GND (B4) (PCB 11)
Page 386 ELECTRICAL COMPONENT LAYOUT (B125/B275) Index Index Symbol Description P to P Symbol Description P to P Sensors CIS1 CIS 1 (Contact Image Sensor) Cassette End Sensor CIS2 CIS 2 (Contact Image Sensor) Cassette Set Sensor CIS3 CIS 3 (Contact Image Sensor)

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B125