Page 1 Aficio Color 3006/4006/4106 (Iris/Lilac, A258/A259/A260) Service Manual Issued February 24, 1999, Ricoh CO., LTD.
Page 2 ø IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3.
Page 3 1. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.) 3.
Page 4: Table Of Contents
TABLE OF CONTENTS 1. OVERALL MACHINE INFORMATION ........1-1 1.1 SPECIFICATIONS ..................1-1 1.1.1 MACHINE CONFIGURATION ............1-1 1.1.2 GENERAL SPECIFICATIONS ............1-2 1.1.3 PLATEN/ARDF ORIGINAL SIZE DETECTION........ 1-6 1.1.4 COPY PAPER SIZE................. 1-7 1.1.5 APS PAPER SIZES AVAILABLE ............. 1-8 1.1.6 NOISE EMISSION ................
Page 5 Step 3: Sensor Pattern Potential Detection.......... 2-6 Step 4: Sensor Pattern Density Detection..........2-7 Step 5: Toner Amount Calculation ............2-8 Step 6: Development Potential Calculation .......... 2-9 Step 7: Selecting the Optimum VD, VB, VL ........2-10 2.1.4 PROCESS CONTROL γ CORRECTION ........2-11 What is process control γ? ..............
Page 6 Signal Processing (in the Analog ASIC)..........2-34 A/D Conversion .................. 2-34 Shading Circuit................... 2-35 D/A Conversion .................. 2-37 Scan Line Correction................2-37 2.5.4 IPU SECTION BLOCK DIAGRAM ..........2-38 2.5.5 IPU SECTION ................2-39 Picture Element Correction and Scanner Gamma Correction .... 2-39 ACS (Auto Color Selection)..............
Page 7 Transfer Belt Release Lever............... 2-78 Belt Transfer Bias................2-79 Belt Mark Detection................2-80 Transfer Belt Cleaning Mechanism ............ 2-81 2.7.3 PAPER TRANSFER MECHANISM..........2-85 Paper Transfer Unit Contact/Release Mechanism ......2-85 Paper Transfer Bias Roller Drive............2-86 Paper Transfer Bias Roller Cleaning..........2-87 Paper Transfer Bias ................
Page 8 Paper Feed-out mechanism ............. 2-114 2.11 OTHERS..................... 2-115 2.11.1 SYSTEM CONFIGURATION ............. 2-115 2.11.2 POWER STATES ..............2-116 Energy Saver Mode ................. 2-116 Power-off (Sleep) State..............2-116 Main Power Switch Off State ............2-117 Power State Transition Diagram ............2-117 2.11.3 TOUCH PANEL (A259/A260 MACHINES ONLY)......
Page 9 3.8.1 ACCESSORY CHECK ..............3-42 3.8.2 INSTALLATION ................3-43 3.9 FILM PROJECTOR TABLE (A702-19) ........... 3-45 3.10 FILM PROJECTOR UNIT (A846) ............3-47 3.10.1 ACCESSORY CHECK ..............3-47 3.10.2 INSTALLATION ................3-48 3.11 CONTROLLER INTERFACE TYPE E (A848)........3-55 3.12 OTHERS....................3-59 3.12.1 ORIGINAL TABLE INSTALLATION PROCEDURE .....
Page 10 5. PREVENTIVE MAINTENANCE ........... 5-1 5.1 PM PROCEDURES .................. 5-1 5.1.1 PM-RELATED COUNTERS............. 5-1 5.1.2 REGULAR PREVENTIVE MAINTENANCE FLOW DIAGRAM ..5-3 5.2 REGULAR PM ITEMS ................5-7 Regular PM Table ................5-7 6. REPLACEMENT AND ADJUSTMENT........6-1 6.1 COVERS, FANS, AND FILTERS.............. 6-1 6.1.1 FRONT, INNER, AND INNER TRANSFER COVERS .....
Page 11 6.5 LASER OPTICS SECTION..............6-34 6.5.1 POLYGON MIRROR MOTOR REPLACEMENT......6-35 6.5.2 LASER SYNCHRONIZING DETECTOR BOARD AND LD UNIT REPLACEMENT ..................6-37 6.5.3 SQUARENESS ADJUSTMENT ............. 6-38 6.6 DEVELOPMENT UNIT ................6-40 6.6.1 REPLACING THE DEVELOPER ........... 6-40 Developer Collection Procedure............6-40 Installing New Developer ..............
Page 12 6.9.11 PRESSURE ROLLER AND PRESSURE ROLLER FUSING LAMP ................... 6-73 6.9.12 PRESSURE ROLLER THERMOFUSE AND THERMISTOR REPLACEMENT ................6-74 6.9.13 NIP BAND WIDTH ADJUSTMENT ..........6-75 6.9.14 CAUTIONS TO BE TAKEN WHEN USING A FUSING UNIT THAT HAS BEEN IN STOCK FOR A LONG PERIOD....6-76 6.10 DUPLEX UNIT ..................
Page 13 OPTIONS ARDF (A663) 1. SPECIFICATIONS..............A663-1 2. COMPONENT LAYOUT ............A663-2 2.1 MECHANICAL COMPONENTS............A663-2 2.2 ELECTRICAL COMPONENTS ............A663-3 3. ELECTRICAL COMPONENT DESCRIPTION .......A663-4 4. DETAILED DESCRIPTIONS ..........A663-5 4.1 ORIGINAL PICK-UP MECHANISM ............ A663-5 4.2 SEPARATION AND PAPER FEED MECHANISM......A663-6 4.3 FRICTION BELT DRIVE MECHANISM ..........
Page 14 PAPER TRAY UNIT (A832/A833) 1. PRODUCT OVERVIEW ............A833- 1.1 SPECIFICATIONS ................A833-1 1.2 COMPONENT DESCRIPTION ............A833-1 1.2.1 PAPER FEED MECHANISM ............. A833-1 1.3 COMPONENT LAYOUTS..............A833-2 1.3.1 ELECTRICAL COMPONENT LAYOUT ........A833-2 1.3.2 DRIVE LAYOUT................. A833-3 1.3.3 DISASSEMBLY AND ADJUSTMENT PROCEDURES....A833-4 (1) Pick-up, paper feed, and separation rollers ......
Page 15 Staple ModeA4 sideways, two copies of a two-page original, after sorting, 150 mm/s................. A834-16 2.1.10 JAM DETECTION ..............A834-17 Paper JamA4 sideways..............A834-17 Staple Jam ................... A834-17 3. REPLACEMENT AND ADJUSTEMENT ......A834- 3.1 EXTERIOR COVER REMOVAL ............A834-18 3.1.1 FRONT COVER............... A834-18 3.1.2 REAR COVER .................
Page 16 5.4 BIN REPLACEMENT ................ A555-23 5.5 TRANSPORT MOTOR REPLACEMENT.......... A555-24 5.6 BIN JAM SENSOR ADJUSTMENT ..........A555-25 3-BIN SORTER (A849) 1. SPECIFICATIONS..............A849- 2. COMPONENT LAYOUT ............A849- 2.1 MECHANICAL COMPONENT LAYOUT..........A849-2 2.2 DRIVE LAYOUT ................. A849-3 2.3 ELECTRICAL COMPONENT DESCRIPTION ........A849-4 3.
Page 17 APPENDIX 1. TIMMING CHART A4 SIZE B/W MODE ..................1 A4 SIZE FULL COLOR MODE ..............2 A3 SIZE B/W MODE ..................3 A3 SIZE FULL COLOR MODE ..............4 2. SP MODE TABLE 3. SC CODE TABLE...
Page 18: Overall Machine Information
24 February, 1999 SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS 1.1.1 MACHINE CONFIGURATION A258 A259 A260 40-digit 4-line LCD 144 mm x 192 mm (10.4 inch) Operation Panel Hard Key Type Color Touch Panel Display Paper Tray Unit 500 sheets Duplex Edit Function Platen Cover...
Page 19: General Specifications
SPECIFICATIONS 24 February, 1999 1.1.2 GENERAL SPECIFICATIONS Configuration: Desktop Copy Process: Dry electrostatic transfer system Resolution: 400 dpi; Printer mode 600 dpi Gradations: 256 gradations Originals: Sheet/Book/Object Original Size: Maximum 11" x 17" /A3 Copy Paper Size: Maximum Minimum Paper Tray Feed 11"...
Page 20 24 February, 1999 SPECIFICATIONS Copying Speed: " x 11" (S) /A4 11" x 17"/A3 Normal Mode Full Color (4 scans) 6 cpm 3 cpm Single Color (C, M Y, K) A258: 21 cpm A258: 11 cpm A259/260: 28 cpm A259/260: 14 cpm Single Color (B, G) 9 cpm 4.5 cpm...
Page 21 SPECIFICATIONS 24 February, 1999 Duplexing: Basic Manual Duplex Manual duplexing in full color and single Model (A258): color modes Basic Auto Duplex Manual & auto duplexing in full color and Model (A259): single color modes Edit Auto Duplex Model Manual & auto duplexing in full color and (A260): single color modes Duplexing can be done on 64-105 g/m...
Page 22 24 February, 1999 SPECIFICATIONS Dimensions (without Platen Cover): Width Depth Height 620 mm 680 mm 602 mm A258 24.4" 26.8" 23.7" 620 mm 757 mm 602 mm A259 24.4" 29.8" 23.7" 620 mm 757 mm 602 mm A260 24.4" 29.8" 23.7"...
Page 23: Platen/Ardf Original Size Detection
SPECIFICATIONS 24 February, 1999 1.1.3 PLATEN/ARDF ORIGINAL SIZE DETECTION Platen ARDF Size (width x length) [mm] Inches Metric Inches Metric A3 (297 x 420) L B4 (257 x 364) L A4 (210 x 297) L A4 (297 x 210) S B5 (182 x 257) L B5 (257 x 182) S A5 (148 x 210) L...
Page 24: Copy Paper Size
24 February, 1999 SPECIFICATIONS 1.1.4 COPY PAPER SIZE Optional Trays in the main body Bypass S.Stapler Size Duplex Tray Paper Tray (A258) (width x length) (A259/A260) versions [mm] (A258/ Inches Metric Inches Metric 259/260) A3 (297 x 420) L B4 (257 x 364) L A4 (210 x 297) L A4 (297 x 210) S B5 (182 x 257) L...
Page 25: Aps Paper Sizes Available
SPECIFICATIONS 24 February, 1999 1.1.5 APS PAPER SIZES AVAILABLE — For metric machines — — — — — — — — — — — — — — — — — — — — — — — — — — — —...
Page 26: Noise Emission
24 February, 1999 SPECIFICATIONS NOTE: 1) The tables indicate the copy paper size for each original for 50 to 200 % zoom ratios. 2) After specifying a zoom ratio, APS automatically selects a paper size that guarantees the quality of the magnified copy image, if there is a paper size available for the equivalent standard reproduction ratio.
Page 27: Power Consumption
SPECIFICATIONS 24 February, 1999 1.1.7 POWER CONSUMPTION (1) Maximum power consumption 1.5 kVA (2) Average power consumption A258/A259/A260 Copiers Standby 0.4 kW Warm-up 1.3 kW 1.1 kW (B/W A4 å) Copying 0.6 kW (full color A4 å) Energy Saver Mode Value for standby minus 25 W 1.1.8 DISPLAY EDITOR SPECIFICATIONS •...
Page 28: Mechanism Overview
24 February, 1999 MECHANISM OVERVIEW 1.2 MECHANISM OVERVIEW 1.2.1 IMAGE GENERATION PROCESS A259V110.WMF 1-11...
Page 29 MECHANISM OVERVIEW 24 February, 1999 (1) Drum charge The charge corona applies a negative charge to the OPC drum and the grid ensures that this charge is even. (2) Quenching After cleaning, the OPC is fully exposed to light from an array of red LEDs, quenching the residual charge on the OPC drum in preparation for the next copy cycle.
Page 30 24 February, 1999 MECHANISM OVERVIEW (9) ID sensor The ID sensor detects the density of the sensor patches developed on the OPC drum. The signal from the ID sensor is used for process control and toner supply control. (10) Development The latent image on the drum attracts the negatively charged toner.
Page 31: Major Unit Layout And Paper Feed Path
MAJOR UNIT LAYOUT AND PAPER FEED PATH 24 February, 1999 1.3 MAJOR UNIT LAYOUT AND PAPER FEED PATH A259V109.WMF 1-14...
Page 32 24 February, 1999 MAJOR UNIT LAYOUT AND PAPER FEED PATH (1) Scanner 1. 400 dpi, 10-bit scanning in both main and sub-scan directions 2. 3-line CCD 3. Halogen exposure lamp 4. 5-phase stepper motor drive 5. Dual-side continuous scan (A4) support (in continuous copy mode) (2) Operation panel (A259, A260) 1.
Page 33 MAJOR UNIT LAYOUT AND PAPER FEED PATH 24 February, 1999 (5) Paper feed/transport system 1. Paper feed (A258) • Front loading 500 sheets, 1-layer tray + by-pass feed 2. Transport: Transport belt + fan 3. Duplexing: Duplex unit installed as a standard component (A259/A260 only) 4.
Page 34: Parts Layout
24 February, 1999 PARTS LAYOUT 1.4 PARTS LAYOUT 1.4.1 MECHANICAL COMPONENT LAYOUT 7 8 9 13 14 A259V108.WMF 1. Paper Tray (A258)/Duplex Tray 14. 1st F-theta Lens (A259/A260) 15. Polygon Mirror 2. Pressure Roller 16. Drum Cleaning Unit 3. Hot Roller 17.
Page 35: Electrical Component Layout
PARTS LAYOUT 24 February, 1999 1.4.2 ELECTRICAL COMPONENT LAYOUT A259V101.WMF Diagram 1 1. Scanner Motor Drive Board 12. Laser Synchronizing Detector Board 2 2. Scanner Motor 13. Polygon Motor Drive Board 3. Platen Cover Position Sensor 14. Polygon Motor 4. IDU Board 15.
Page 36 24 February, 1999 PARTS LAYOUT A259V102.WMF Diagram 2 1. Main Power Switch 9. Paper Transfer Unit Heater 2. Belt Cleaning H.P. Sensor 10. Counters 3. Paper Tray Detector Switch 11. Transport Fan 4. Transfer Belt Home Position Sensor 12. Front Door Switch 5.
Page 37 PARTS LAYOUT 24 February, 1999 A259V103.WMF Diagram 3 1. Paper Transfer Positioning Clutch 9. By-pass Pick-up Solenoid 2. Paper Feed Motor 10. Upper Limit Sensor 3. Registration Clutch 11. Paper End Sensor 4. Relay Clutch 12. Relay Sensor 5. By-pass Feed Clutch 13.
Page 38 24 February, 1999 PARTS LAYOUT A259V104.WMF Diagram 4 1. Operation Panel 10. Pressure Roller Thermistor 2. Paper Separation Corona Unit 11. Duplex Entrance Sensor 3. Pressure Roller Thermofuse 12. Duplex Turn Sensor 4. Pressure Roller Fusing Lamp 13. Duplex Paper End Sensor 5.
Page 39 PARTS LAYOUT 24 February, 1999 A259V105.WMF Diagram 5 1. Charge Corona Unit 6. Toner Cartridge Sensor 2. Quenching Lamp 7. Revolver H.P. Sensor 3. PCC (Pre-cleaning Corona) 8. Toner End Sensor 4. ID Sensor 9. High Voltage Supply Board: B 5.
Page 40 24 February, 1999 PARTS LAYOUT A259V106.WMF Diagram 6 1. Development Clutch 6. Fusing Clutch 2. Toner Supply Motor 7. Belt Cleaning Clutch 3. Revolver Motor 8. Tray Lift Motor 4. Belt Lubricant Clutch 9. Drum Motor 5. Fusing Motor 1-23...
Page 41 PARTS LAYOUT 24 February, 1999 A259V107.WMF Diagram 7 1. High Voltage Supply Board: C, G 7. Revolver Motor Drive Board 2. Rear Cooling Fan 8. Used Toner Sensor 3. Fusing Unit Fan 9. High Voltage Supply Board: T1, 4. PSU (Power Supply Unit) 10.
Page 42: Drive Layout
24 February, 1999 PARTS LAYOUT 1.4.3 DRIVE LAYOUT A259V111.WMF Five motors drive the mechanical components for this machine. The drive sections driven by these five motors are listed below. 1. Scanner Drive 2. Development/Drum/Transfer Belt Drive 3. Paper Feed/Registration/Paper Transfer/Transport Belt Drive 4.
Page 43: Air Flow
PARTS LAYOUT 24 February, 1999 1.4.4 AIR FLOW A259V112.WMF 1. Optics Cooling Fan 2. Fusing Unit Fan 3. Rear Cooling Fan 4. Scanner Exhaust Fan 5. Main Exhaust Fan 6. Transport Fan 7. Charge Corona Fan 8. PSU Fan 1-26...
Page 44: Electrical Component Descriptions
24 February, 1999 PARTS LAYOUT 1.4.5 ELECTRICAL COMPONENT DESCRIPTIONS Printed Circuit Boards Symbol Name Function Index-No Location Lamp regulator Supplies AC power to the exposure PCB 2 lamp. Scanner motor drive Supplies DC power to the scanner PCB 5 board motor.
Page 45: Motors
PARTS LAYOUT 24 February, 1999 Motors Symbol Name Function Index-No Remarks Scanner motor Drives the scanner. Polygon mirror motor Drives the polygon mirror (laser unit). 1-14 Fusing motor Drives the transport and fusing units. Paper feed motor Drives the paper feed unit. Tray lift motor Lifts the tray bottom plate.
Page 46: Sensors
24 February, 1999 PARTS LAYOUT Sensors Symbol Name Function Index-No Remarks Platen cover position Detects if the platen cover is opened or sensor closed. Scanner H.P. sensor Detects the scanner home position. 1-21 Original length sensor Detects the length of the original. Original width sensor Detects the width of the original.
Page 47: Switches
PARTS LAYOUT 24 February, 1999 Symbol Name Function Index-No Remarks Duplex entrance Detects when copy paper comes into 4-11 (A259/A260 sensor the duplex unit. models only) Duplex turn sensor Detects when copy paper is being 4-12 (A259/A260 reversed in the duplex unit. models only) Oil end sensor Detects if there is silicone oil in that...
Page 48: Solenoids
24 February, 1999 PARTS LAYOUT Solenoids Symbols Name Function Index-No Remarks By-pass pickup Lowers the by-pass pick-up roller. SOL1 solenoid Junction gate solenoid Raises the junction gate for the duplex SOL2 2-14 tray. (A259/A260 copiers only) Lamps Symbol Name Function Index-No Remarks Hot roller fusing lamp Provides heat to the hot roller.
Page 49: Counter
PARTS LAYOUT 24 February, 1999 Counter Symbol Name Function Index-No Remarks Upper mechanical Indicates the total number of counter development cycles made using the C, 2-10 M, and Y development units; Lower mechanical Shows the total number of black 2-10 counter developments.
Page 50: Detailed Descriptions
24 February, 1999 PROCESS CONTROL 2. DETAILED DESCRIPTIONS 2.1 PROCESS CONTROL 2.1.1 OVERVIEW This copier provides the following forms of process control: • Potential control (done every process control self check) • Process control gamma calibration (done every process control self check, after potential control) •...
Page 51: Potential Control
PROCESS CONTROL 24 February, 1999 2.1.2 POTENTIAL CONTROL Overview Potential control is the process of controlling the development potential to maintain the density of the toner image on the drum. It does this by compensating for variations in drum chargeability and toner chargeability. The machine uses the image density (ID) sensor to measure drum reflectivity and the density of a standard sensor pattern.
Page 52 24 February, 1999 PROCESS CONTROL (2) Initial process control self check The initial process control starts automatically when the power is turned on (or when the machine returns to standby mode from sleep mode), but only if the hot roller in the fusing unit is less than 100 degrees centigrade. This process control is done only when SP3-125 (Set Potential Control Method) is set to "0 (Auto)."...
Page 53: Process Control Self Check
PROCESS CONTROL 24 February, 1999 2.1.3 PROCESS CONTROL SELF CHECK Flow Chart Start Step (1) Adjustment (ID sensor) Step (2) ID sensor pattern generation Sensor pattern potential Step (3) detection Sensor pattern density Step (4) detection Step (5) Toner amount calculation Development potential Step (6) calculation...
Page 54: Step 1: Vsg Adjustment
24 February, 1999 PROCESS CONTROL Step 1: V Adjustment The type of ID sensor used in this machine responds differently for black and color, so there are two V values, one for black toner and one for CMY toner. The type of ID sensor used in this machine is very sensitive, and outputs some voltage even if there is no light being reflected off the drum.
Page 55: Step 3: Sensor Pattern Potential Detection
PROCESS CONTROL 24 February, 1999 Step 3: Sensor Pattern Potential Detection Process The potential sensor detects the potential on each grade of the 16-grade sensor pattern latent image, for each colour, and the output is stored in memory. Feedback Type Potential Sensor Feedback circuit A259A003.WMF This copier uses a feedback potential sensor.
Page 56: Step 4: Sensor Pattern Density Detection
24 February, 1999 PROCESS CONTROL Step 4: Sensor Pattern Density Detection Process The development rollers of the respective colors develop the sensor pattern latent images for K, Y, C, and M generated in Step (2). In Step (4), the ID sensor detects the densities of the 16 patch patterns for each color.
Page 57: Step 5: Toner Amount Calculation
PROCESS CONTROL 24 February, 1999 A259A010.WMF A259A009.WMF Figure C Relationship between the Figure B Relationship between the output of the diffused reflection ID sensor output of the diffused reflection ID and the amount of toner on the drum for sensor and the amount of toner on the K toner drum for C, M, and Y toners Figure A shows the relationship between the output of the normal reflection ID...
Page 58: Step 6: Development Potential Calculation
24 February, 1999 PROCESS CONTROL Step 6: Development Potential Calculation Amount of toner on the drum When the development When the development A259A011.WMF potential is smaller potential is larger The development potential (V ) is the capability to attract toner to the drum and can be shown as: V •...
Page 59 PROCESS CONTROL 24 February, 1999 NOTE: For Y, C, and M toners, the new type of ID sensor allows higher densities of toner to be measured accurately (refer to the descriptions in Step 4, Sensor Pattern Density Detection). This permits the calculation of γ M/A at a higher accuracy than a normal reflection ID sensor, because the measurements at higher densities (M/A values) are more reliable.
Page 60: Process Control Γ Correction
24 February, 1999 PROCESS CONTROL 2.1.4 PROCESS CONTROL γ γ γ γ CORRECTION What is process control γ γ γ γ ? After process control, the proper values for V have been defined for the maximum laser power. However, the medium (greyscale) range is ignored. To improve this situation, a new process called ‘process control gamma correction’...
Page 61: Process Control Gamma Correction Timing
PROCESS CONTROL 24 February, 1999 Process control gamma correction timing The machine automatically does process control gamma correction at the end of every process control self check. 2-12...
Page 62: Toner Supply Control
24 February, 1999 TONER SUPPLY CONTROL 2.2 TONER SUPPLY CONTROL 2.2.1 TONER SUPPLY CONTROL METHOD This machine has two toner supply control methods: fuzzy control mode, and fixed supply mode. Normally this machine uses fuzzy control. The fixed supply method is used only when abnormal conditions occur during the process control self check.
Page 63: Calculating The Amount Of Toner On The Drum
TONER SUPPLY CONTROL 24 February, 1999 2.2.3 V DETECTION FOR TONER SUPPLY CONTROL The copier generates an ID sensor pattern using a 2 0 m m standard laser diode power. The copier generates this pattern between the K, C, M, and Y images, and then detects the density using the ID sensor.
Page 64: Image Area Ratio
24 February, 1999 TONER SUPPLY CONTROL Image Area Ratio This is a measure of how much toner will be needed for each color on a page. From the image data from the image processing unit (IPU), the machine determines the total amount of the color on the page. It takes into account the grayscale values for each pixel for that color.
Page 65: Detecting Toner Near End/End
TONER SUPPLY CONTROL 24 February, 1999 2.2.7 DETECTING TONER NEAR END/END 0.25 A259D555.WMF A259D554.WMF YMC Toner K Toner Toner Near-end For the Y, C, and M toners, the copier first detects toner near-end using the toner end sensor (see ’Development – Toner End Detection’). The toner end sensor detects the toner end condition during development.
Page 66: Toner Near End Detection
24 February, 1999 TONER SUPPLY CONTROL Toner near end detection Toner end sensor The toner end sensor detects light reflected from a mirror inside the toner hopper (see ‘Development – Toner End Detection’). There are two levels of output, namely High (5V: no reflection/toner present) and Low (0V: reflection detected/no toner).
Page 67: Toner End Recovery
TONER SUPPLY CONTROL 24 February, 1999 Toner end recovery The copier enters the recovery process in the following cases: 1. The front door is opened and a toner cartridge is removed or inserted. This is regarded as an ordinary replacement procedure for the toner cartridge. •...
Page 68: Drum Unit
24 February, 1999 DRUM UNIT 2.3 DRUM UNIT 2.3.1 OVERVIEW A259D201.WMF The drum unit is to the right of the drawer unit. It can easily be removed by pulling out the drawer unit. The drum unit consists of the OPC drum [A], the charge corona unit [B], a quenching lamp [C], the drum potential sensor [D], the ID sensor [E], the carrier catcher [F], and a cleaning unit [G].
Page 69: Drive Mechanism
DRUM UNIT 24 February, 1999 2.3.2 DRIVE MECHANISM A259D202.WMF The drum motor [A] (a brushless motor) drives the drum via gears and a timing belt. This motor also drives the cleaning unit using a timing belt [C]. This motor contains a drive controller circuit, which controls the drum rotation. Since the drum shaft does not pass all the way through the drum from front to rear, a flywheel [D] is mounted on the shaft at the rear of the drum to eliminate uneven drum rotation.
Page 70: Drum Charge
24 February, 1999 DRUM UNIT 2.3.3 DRUM CHARGE A259D203.WMF This copier uses a single wire scorotron corona unit to charge the drum. The single corona wire applies a negative charge to the drum surface (–670 V is the standard voltage). The stainless steel grid plate [A] makes the corona charge uniform.
Page 71: Drum Cleaning
DRUM UNIT 24 February, 1999 2.3.4 DRUM CLEANING A259D204.WMF Pressure is continuously applied to the lubricant bar above the cleaning brush by a spring [A]. The cleaning brush [B] spreads out the toner remaining on the drum, which makes it easier for the cleaning blade to remove. The brush collects toner from the drum surface and the cleaning blade [C] scrapes off the remaining toner on the drum.
Page 72: Quenching
24 February, 1999 DRUM UNIT 2.3.6 QUENCHING A259D205.WMF The quenching lamp [A] is a row of LEDs. It turns on immediately after the Start key is pressed and the drum motor starts. The light is red, to protect the drum from optical fatigue.
Page 73: Scanner Unit
SCANNER UNIT 24 February, 1999 2.4 SCANNER UNIT 2.4.1 OVERVIEW A259D001.WMF An image of the original illuminated by the exposure lamp [A] (a halogen lamp) is reflected onto a color CCD [B] (Charge Coupled Device) via the 1st [C], 2nd [D], and 3rd [E] mirrors, filter, and lens.
Page 74: Scanner
24 February, 1999 SCANNER UNIT 2.4.2 SCANNER A259D001.WMF The 1st scanner consists of the exposure lamp [A], main and sub reflectors [B], and 1st mirror [C]. This model uses a halogen lamp with nine elements. The frosted surface of the exposure lamp ensures even exposure in the main scan direction. The exposure lamp is energized by a dc supply to avoid uneven light intensity caused by power fluctuations while the 1st scanner moves in the sub-scan direction.
Page 75: Scanner Drive
SCANNER UNIT 24 February, 1999 2.4.3 SCANNER DRIVE A259D002.WMF A five-phase stepper motor [A] drives the scanner. This motor drives the 1st [B] and 2nd [C] scanners via two scanner wires. The wires at the front side and the rear side are the same, for easy assembly. In full size mode, the 1st scanner speed is 156 mm/s during scanning, and 1638 mm/s when the scanner returns.
Page 76: Color Ccd
24 February, 1999 SCANNER UNIT 2.4.4 COLOR CCD 5000 A259X001.WMF The color CCD converts light reflected from the original into three analog signals, one for each of the three basic colors Red, Green, and Blue. The signals are called the R, G, and B signals. Each of the four scans (for toner colors YMCK) generates a separate set of three signals (RGB).
Page 77: White Plate Scanning
SCANNER UNIT 24 February, 1999 2.4.5 WHITE PLATE SCANNING A259D801.WMF There is a white plate [A] for auto shading, stuck on the exposure glass [B] underneath the left scale. When this white plate is scanned, the output from all the CCD elements in a line should in theory be equal, but actually it is not, for the following reasons: •...
Page 78: Original Size Detection
24 February, 1999 SCANNER UNIT 2.4.7 ORIGINAL SIZE DETECTION A259D003.WMF There are three APS sensors (reflective photosensors) in the optics cavity for original size detection. The original width sensor [A] detects the original width, while the original length sensors [B] and [C] detect the original length. The original width sensor [A] and the original length sensor [B] have two internal beams.
Page 79 SCANNER UNIT 24 February, 1999 The machine cannot recognize the size of the original on the exposure glass if it is A5 lengthwise/HLT or smaller. Therefore, when all sensor outputs are off, the machine either will detect A5 lengthwise/HLT or will display an error message stating that it cannot detect the size of the original (this depends on SP 4-303).
Page 80: Others
24 February, 1999 SCANNER UNIT 2.4.8 OTHERS A259D004.WMF Anti-condensation Heater There is an anti-condensation heater [A] on the left side of the optical base plate. It turns on when the main switch is off (if the machine is plugged into the wall outlet), to prevent moisture from forming on the optics.
Page 81: Image Processing
IMAGE PROCESSING 24 February, 1999 2.5 IMAGE PROCESSING 2.5.1 OVERVIEW Scanner IPU Board S c a n n e r I P U C C D Section Section Scanner M a i n M a i n Drive Control Control I m a g e B o a r d B o a r d...
Page 82: Scanner Section Block Diagram
24 February, 1999 IMAGE PROCESSING 2.5.2 SCANNER SECTION BLOCK DIAGRAM 10bit 10bit 10bit Analog Field A S I C Converter M e m o r y A G C 4 Mbit 10bit 10bit 10bit Analog Shading Field C C D A S I C Converter Circuit...
Page 83: Scanner Section
IMAGE PROCESSING 24 February, 1999 2.5.3 SCANNER SECTION Photoelectric Conversion (by the CCD) The color CCD converts the light reflected from the original into RGB analog signals (6.615 MHz for each signal: even-pixel and odd-pixel). Each CCD line has 5,000 pixels and a resolution of 400 dpi (15.7 pixels/mm). Signal Processing (in the Analog ASIC) (1) Signal Amplification Operational amplifiers boost odd-pixel and even-pixel RGB analog signals from the...
Page 84: Shading Circuit
24 February, 1999 IMAGE PROCESSING Shading Circuit A259D509.WMF (1) Shading Compensation Before scanning each original, the machine generates a reference white waveform (also known as "white shading data") by scanning 5 mm of the white reference plate [A] in the sub-scan direction (this equals 79 lines at 100% magnification). The white shading data is calculated for each pixel across the main scan.
Page 85 IMAGE PROCESSING 24 February, 1999 W h i t e 1 0 2 3 Correction Black Correction 1 line 1 line A259X005.WMF The shading circuit corrects the video signal for each pixel obtained during image scanning as follows: (Video data for each pixel) – (Black shading data for each line) X 1023 (White shading data for each pixel) –...
Page 86: D/A Conversion
24 February, 1999 IMAGE PROCESSING D/A Conversion The CPU monitors the digital feedback signals from the shading circuits and calculates correction factors. Then the D/A circuit converts the signals from the CPU into analog signals and feeds them back to the operational amplifiers and the clamps inside the Analog ASICs.
Page 87: Ipu Section Block Diagram
IMAGE PROCESSING 24 February, 1999 2.5.4 IPU SECTION BLOCK DIAGRAM A259X007.WMF 2-38...
Page 88: Ipu Section
24 February, 1999 IMAGE PROCESSING 2.5.5 IPU SECTION Picture Element Correction and Scanner Gamma Correction (1) Picture Element Correction A259D803.WMF Picture Element Correction The Picture Element Correction circuit does two things. 1. Completion of the Scan Line Correction process The discrepancy in the spacing of the RGB signals from the CCD in the sub-scan direction is corrected by the line correction circuit in the scanner section (refer to Scanner Section –...
Page 89 IMAGE PROCESSING 24 February, 1999 (2) Scanner Gamma Correction (RGB Gamma) RGB Signal After Image Data Scanner γ Correction 1023 2 5 5 Image Scanner Data Input 1 0 2 3 Dark Light Dark Light Fig. 1 A259X008.WMF Fig. 2 A259X009.WMF The RGB video signals from the CCD are converted to 10-bit digital signals in the scanner section and sent to the IPU section.
Page 90: Acs (Auto Color Selection)
24 February, 1999 IMAGE PROCESSING ACS (Auto Color Selection) A259D511.WMF Auto color selection mode determines if an original is black/white or color. Then black copy mode or full color mode is automatically selected to match the original. To recognize if the original has a color area or not, the RGB video signals are compared.
Page 91: Auto Letter/Photo Separation
IMAGE PROCESSING 24 February, 1999 Auto Letter/Photo Separation Text Area A259D512.WMF In auto text/photo mode, the original image is separated into text and photo areas (dot screen areas). "Text" refers to an original or area of an original that contains text and/or line drawings.
Page 92 24 February, 1999 IMAGE PROCESSING (2) Dot screen separation Dot screen areas are separated from non-dot screen areas (mainly text). The machine determines that if white pixels are not detected around the non-white pixels, it is a dot screen area. The machine can do this by only referring to the green signal.
Page 93: Filtering And Color Conversion
IMAGE PROCESSING 24 February, 1999 Filtering and Color Conversion (1) RGB Smoothing Filter Photo Text Before After A259D521.WMF A259D515.WMF A259D514.WMF Depending on the results of auto text/photo separation (or depending on the selected original mode), the appropriate software filters are applied to the RGB video signals.
Page 94 24 February, 1999 IMAGE PROCESSING b. ADS (Auto Image Density Selection) A259D523.WMF In ADS mode, the user does not set the threshold; the machine calculates it, guided by input from the user for F/C and 2C mode (there are 5 settings in the “User Tools”...
Page 95 IMAGE PROCESSING 24 February, 1999 (4) Color Conversion A259D516.WMF A matrix converts the RGB video signals from each scanning cycle into YMCK video signals. The content of the matrix depends on the selected mode. The transparency for each color toner is not ideal, as shown above. Color conversion compensates for the difference between ideal and actual characteristics.
Page 96 24 February, 1999 IMAGE PROCESSING A. Color conversion mode Color conversion mode is a user feature, not to be confused with color conversion (RGB to CMYK) described above. In color conversion mode, a selected color (C/M/Y/R/G/B/K/W) on an original that falls within the recognized thresholds for that color is converted into a different color on the copy.
Page 97 IMAGE PROCESSING 24 February, 1999 (5) UCR (Under Color Removal) Principle A259D525.WMF Obtaining the right colors using YMC toner addition does not always work perfectly. For example, if the same quantity of toner for each color (YMC) is put on the paper, ideally the image should become black, but in reality it becomes a dark color, such as dark blue.
Page 98 24 February, 1999 IMAGE PROCESSING Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 A259D526.WMF In this example, the UCR ratio is 70%. For a Black Image When copying a black image, the ID values for all colors are equal (figure 1). For each color, the ID value is reduced by the amount of the UCR ratio (70% in the example).
Page 99: Changes In Ucr Ratio With Image Density And Copy Mode
IMAGE PROCESSING 24 February, 1999 Changes in UCR Ratio with Image Density and Copy Mode Text Mode M I N A259D511.WMF A259D508.WMF - Text Areas - The UCR ratio in text areas is always 100%. - Photo Areas, with ACS Priority set to Bk - In photo areas, when the user sets the ACS priority to Bk, UCR begins to replace color toner with Bk toner at low image densities (when the RGB common value [MIN] is about 13).
Page 100: Main Scan Magnification
24 February, 1999 IMAGE PROCESSING Main Scan Magnification A259D527.WMF The machine changes the scanner speed to reduce or enlarge the original in the sub-scan direction. However, an LSI on the IPU Board handles reduction and enlargement in the main scan direction. Scanning and laser writing are done at a fixed pitch (the CCD elements cannot be squeezed or expanded).
Page 101: Gamma (Γ) Correction (Printer Gamma)
IMAGE PROCESSING 24 February, 1999 Gamma (γ γ γ γ ) Correction (Printer Gamma) Fig. 1 A259D528.WMF Fig. 2 A259D529.WMF (1) KCMY Gamma Ideally, the gamma curves for Yellow, Magenta, Cyan, and Black are identical, as shown in figure 1. However, they are not because electrical components always vary slightly, resulting in varying gamma curves, as shown in figure 2.
Page 102 24 February, 1999 IMAGE PROCESSING – ID max. – This mode adjusts the total image density level as shown in figure 3. A259D530.WMF Fig. 3 – High ID – The High ID mode adjusts the image density between Level 6 and Level 9 of the color gradation scale on the C-4 test chart (figure 4).
Page 103 IMAGE PROCESSING 24 February, 1999 (2) ACC Test Pattern Dark Light A259X010.WMF The IPU board firmware has a test pattern that has eight 17-step gradation scales for each color (KCMY), including background white, for Text and Photo modes. (3) ACC (Auto Color Calibration) This machine automatically calibrates the printer gamma curve when the user selects ACC.
Page 104: Area Editing
24 February, 1999 IMAGE PROCESSING (4) Gradation Treatment (Dither Processing) A259X012.WMF A259X011.WMF This machine has two kinds of dither patterns in copier mode. In Text mode, the dither patterns are made with 1 x 1 dot units, to obtain fine resolution.
Page 105: Laser Exposure
LASER EXPOSURE 24 February, 1999 2.6 LASER EXPOSURE 2.6.1 OVERVIEW A259D102.WMF A: Laser Diode Unit (LDU) F: Laser Synchronization Detector Board-2 (LSDB-2) B: F-theta Lenses G: Polygon Mirror C: Barrel Toroidal Lens (BTL) H: Cylindrical Lens D: Drum Mirror I: OPC Drum E: Laser Synchronization Detector Board-1 J: Toner Shield Glass (LSDB-1)
Page 106: Optical Path
24 February, 1999 LASER EXPOSURE 2.6.2 OPTICAL PATH Overview A259D102.WMF The output path from the laser diode to the drum is shown above. The LD unit [A] sends a laser beam to the polygon mirror [G] through the cylindrical lens [H]. Each side of the polygon mirror reflects a full main scan line.
Page 107 LASER EXPOSURE 24 February, 1999 A259D102.WMF Cylindrical Lens The cylindrical lens [A] focuses the laser beam and sends it to the polygon mirror. Polygon Mirror The polygon mirror assembly consists of the polygon mirror motor [B] and the polygon mirror itself [C]. As the mirror rotates, it reflects the laser beam across the drum, via the f-theta lens, BTL, and drum mirror.
Page 108: F-Theta Lenses And The Btl
24 February, 1999 LASER EXPOSURE F-theta Lenses and the BTL Wide spacing Narrow spacing Evenly spaced pixels A259D504.PCX The angles between pixels are equal. However, if the beam were to go directly to the drum as shown in the upper illustration, the spacing between pixels would depend on the angle of the beam.
Page 109: Laser Synchronizing Detector Boards
LASER EXPOSURE 24 February, 1999 Laser Synchronizing Detector Boards A259D102.WMF Some of the optical components are made of plastic, and may expand and contract with changes in temperature. If this happens, the number of pulses in the laser main scan across the drum will vary. To counteract the effects of this, the machine adjusts the gap between laser pixels to keep the number of laser pulses in each main scan constant.
Page 110: Gradation Control (Laser Pulse Width And Laser Power Modulation)
24 February, 1999 LASER EXPOSURE Gradation Control (Laser Pulse Width and Laser Power Modulation) PM (32 levels) Data: 32 Data: 48 Data: 64 Data: 136 Data: 255 Data: 0 Data: 16 (8 levels) 1 dot A259D505.WMF Black White Data A259D506.WMF To make the latent image, the laser beam illuminates the image area on the drum surface.
Page 111: Dpi Writing
LASER EXPOSURE 24 February, 1999 600 DPI Writing In printer mode, the resolution is 600 dpi (in copier mode: 400 dpi). The LD writing frequency in printer mode shifts from 16.06 MHz (copier mode) to 24.08 MHz (printer mode), which is about 1.5 times. For the sub-scan, the drum motor speed shifts from 156 mm/s to 104 mm/s (2/3 speed).
Page 112: Auto Power Control (Apc)
24 February, 1999 LASER EXPOSURE Auto Power Control (APC) LD5V VIDEO Current LEVEL Control LD OFF LD Drive Board A259D501.WMF Even if a constant electric current is applied to the laser diode, the intensity of the output light changes with the temperature. The intensity of the output decreases as the temperature increases.
Page 113: Ld Safety Switches
LASER EXPOSURE 24 February, 1999 LD Safety Switches C N 2 0 9 CN1-23, 25, 27, 29 C N 6 0 3 - 5 C N 2 1 3 - 2 -5, 11 C N 5 C N 6 0 5 -5, 11 -2, 4, 6, 8 C N 2 1 0...
Page 114: Development Unit
24 February, 1999 DEVELOPMENT UNIT 2.6 DEVELOPMENT UNIT 2.6.1 OVERVIEW Photoconductive drum A259D301.WMF The development unit is a revolver type. The revolver rotates counter-clockwise to develop colors in the order of K, Y, C, and M. The development and drum units are in the drawer unit.
Page 115: Overview
DEVELOPMENT UNIT 24 February, 1999 2.6.2 REVOLVER MECHANISM Overview A259D302.WMF The revolver unit is composed of four development units, one for each color (KYCM). It develops colors by rotating the revolver counter-clockwise (as viewed from the front of the copier), 90 degrees at a time, in the order of K, Y, C, and M. In printer mode, development is carried out in the order of Y, C, M, and K.
Page 116: Revolver Drive
24 February, 1999 DEVELOPMENT UNIT Revolver Drive A259D303.WMF A259D317.WMF The revolver drive motor [A] turns the revolver unit around the revolver shaft [B]. The revolver rotates counter-clockwise as viewed from the front of the copier in 90- degree steps. The revolver unit home position lies 22.5 degrees before the K development position, so the revolver is turned 22.5 degrees before starting development.
Page 117: Revolver Home Position Detection
DEVELOPMENT UNIT 24 February, 1999 Revolver Home Position Detection 22.50 A259D304.WMF A259D317.WMF The revolver H.P. sensor [A] is at the front of the drawer unit. The actuator [B] is attached to the revolver shaft. The revolver is at home position when the edge of the actuator just enters the sensor.
Page 118: Development Mechanisms
24 February, 1999 DEVELOPMENT UNIT 2.6.3 DEVELOPMENT MECHANISMS Overview A259D318.WMF The developer (380 g) in each development unit is supplied to the development roller [A] by the two mixing augers [B] and attracted onto the roller surface by the magnets inside the development roller. The attracted developer is trimmed to the desired thickness by the magnetic doctor [C], and then carried out to the drum [D] where the latent image is developed.
Page 119: Development Drive
DEVELOPMENT UNIT 24 February, 1999 Development Drive A259D306.WMF The revolver unit contains four development mechanisms. At any one time, only one development mechanism is driven (the one for the color that is being developed). The drum motor drives the development roller and screws via the timing belt [A] and development clutch [B], and rotates the toner bottle through gears (see Toner Agitation).
Page 120: Toner Agitation
24 February, 1999 DEVELOPMENT UNIT Toner Agitation A259D314.WMF When the drum motor drives the development mechanism that is at the development position, it also turns the toner bottle through gears, and this agitates the toner. 2-71...
Page 121: Development Bias
DEVELOPMENT UNIT 24 February, 1999 Development Bias A259D315.WMF This is a revolver development mechanism, so there is only one bias terminal. When a development unit is at the development position, the development input shaft [D] is in contact with the bias terminal [E] at the front of the drawer unit. At this time, voltage passes from the high voltage supply board –...
Page 122: Toner Supply Mechanism
24 February, 1999 DEVELOPMENT UNIT Toner Supply Mechanism A259D307.WMF A259D309.WMF The toner supply motor [A] supplies toner in the development unit that is at the development position via gears that are behind the supply auger [B]. Toner is fed forward as the toner bottle rotates, and it falls into the toner supply section [C].
Page 123: Toner Cartridge Detection
DEVELOPMENT UNIT 24 February, 1999 Toner Cartridge Detection A259D310.WMF The toner cartridge sensor [A] detects the metallic mark on the toner bottle. This sensor is on the upper front side of the drawer unit. Incorrect Toner Installation Prevention A259D311.WMF Each toner cartridge has pins [A] to prevent it from being installed in the wrong place.
Page 124: Toner End Detection
24 February, 1999 DEVELOPMENT UNIT Toner End Detection A259D313.WMF Overview There are two toner end detection mechanisms in this machine. • Toner end sensor (C, M, and Y toners) • ID sensor (K, C, M, and Y toners) Black toner near-end is detected by the ID sensor only. For C, M, and Y, the machine detects near-end only if both the ID sensor and the toner end sensor detect it.
Page 125: Transfer Belt Unit
TRANSFER BELT UNIT 24 February, 1999 2.7 TRANSFER BELT UNIT 2.7.1 OVERVIEW Each color toner is individually placed on the transfer belt, which in turn transfers the combined toner image to the paper. A259D401.WMF 1. Bias roller (transfer belt) 9. Paper separation corona unit 2.
Page 126: Belt Transfer Mechanisms
24 February, 1999 TRANSFER BELT UNIT 2.7.2 BELT TRANSFER MECHANISMS Transfer Belt Drive A259D402.WMF The drum motor [A] drives the transfer belt [B] via gears. The coupling gear [C] transfers drive from the motor to the belt drive roller [D] and secures the rear of the unit.
Page 127: Transfer Belt Release Lever
TRANSFER BELT UNIT 24 February, 1999 Transfer Belt Release Lever 2 mm A259D415.WMF 18 mm A259D403.WMF The transfer belt unit has a release lever [A] at the front. This is because the transfer belt always contacts the drum during copying (the nip band width is about 18 mm), but must be moved away from the drum to remove the transfer belt unit.
Page 128: Belt Transfer Bias
24 February, 1999 TRANSFER BELT UNIT Belt Transfer Bias A259D404.WMF The belt transfer bias mechanism uses a bias roller [A] to minimize the toner scattering around the transfer belt (scattering is reduced because lower voltages are used in this type of system than with a corona wire transfer system). The high voltage supply board –...
Page 129: Belt Mark Detection
TRANSFER BELT UNIT 24 February, 1999 Belt Mark Detection A259D405.WMF The machine uses the transfer belt home position sensor [A] to align the position of the image on the belt for each color by detecting the belt mark [B]. The FGATE signal is generated when the belt mark is detected, and this signal allows image data to be written to the drum.
Page 130: Transfer Belt Cleaning Mechanism
24 February, 1999 TRANSFER BELT UNIT Transfer Belt Cleaning Mechanism A259D421.WMF (1) Contact/release mechanism At the end of a copy job, the belt cleaning clutch [A] (a half-turn clutch) transfers drive from the fusing motor to the belt cleaning cams [B] in the cleaning unit. These cams move the cleaning blade [C], the entrance seal [D], and the lubricant brush into contact with the transfer belt.
Page 131 TRANSFER BELT UNIT 24 February, 1999 A259D420.WMF (3) Contact/release timing The entrance seal [A] contacts the belt before the cleaning blade [B]. This prevents toner from falling onto the paper. The inlet seal contact/release ever [C] controls the contact and release timing of these components. The lubricant brush [D] makes contact and releases at the same time as the blade.
Page 132 24 February, 1999 TRANSFER BELT UNIT (5) Belt lubricant mechanism A259D419.WMF A259D422.WMF Normal machine use generates a film of toner on the belt. Toner filming reduces the ability of toner to separate from the belt. To solve this problem, the lubricant brush [A] applies a small amount of lubricant to the transfer belt.
Page 133 TRANSFER BELT UNIT 24 February, 1999 (6) Toner collection mechanism A259D408.WMF In the transfer belt unit, the toner collection coil [A] at the front of the transfer belt unit transports the toner removed from the transfer belt cleaning unit to the used toner tank [B].
Page 134: Paper Transfer Mechanism
24 February, 1999 TRANSFER BELT UNIT 2.7.3 PAPER TRANSFER MECHANISM Paper Transfer Unit Contact/Release Mechanism A259D416.WMF General Mechanism When the paper is about 10 mm before the paper transfer nip, the paper transfer positioning clutch [A] (a half-turn clutch) turns on, rotating the paper transfer cam [B] by half a turn.
Page 135: Paper Transfer Bias Roller Drive
TRANSFER BELT UNIT 24 February, 1999 Double-page transfer mode For certain smaller paper sizes (A4/LT or smaller), two pages are transferred to the transfer belt at the same time. The machine generates an ID sensor pattern between every page. Therefore, there is one between the two images in double page transfer mode.
Page 136: Paper Transfer Bias Roller Cleaning
24 February, 1999 TRANSFER BELT UNIT Paper Transfer Bias Roller Cleaning A259D417.WMF The cleaning blade [A] scrapes off the toner on the paper transfer bias roller [B]. To improve cleaning efficiency, spring plates press the lubricant bar [C] against the bias roller and the bar applies lubricant to the bias roller.
Page 137: Paper Transfer Bias
TRANSFER BELT UNIT 24 February, 1999 Paper Transfer Bias In this machine, paper transfer voltage is applied using a bias roller and constant current. The high voltage supply board – T2, D [A] applies bias voltage to the paper transfer bias roller [B] and the paper separation corona unit [C]. The bias terminal [D] moves up and down while the transfer unit repeats the contact/release operations, so it always remains connected.
Page 138 24 February, 1999 TRANSFER BELT UNIT A259D413.WMF 4. Paper feed speed There are SP modes to adjust the current used for different paper types, such as OHP or thick paper. 5. Duplex mode: For the front and back sides of the paper There are SP modes to adjust the current used for the front and back sides of the paper.
Page 139: Paper Separation Mechanism
24 February, 1999 2.7.4 PAPER SEPARATION MECHANISM A259D412.WMF The separation corona unit pulls the paper off the transfer belt. In addition, the paper separates from the belt as a result of the curvature of the belt. The corona unit also improves copy quality at low humidity. 2-90...
Page 140: Paper Feed And Registration
24 February, 1999 PAPER FEED AND REGISTRATION 2.8 PAPER FEED AND REGISTRATION 2.8.1 OVERVIEW A259D701.WMF 1. Paper tray detector switch 10. By-pass paper width detection board 2. Tray bottom plate 11. By-pass paper end sensor 3. Tray bottom plate lift arm 12.
Page 141: Paper Tray
PAPER FEED AND REGISTRATION 24 February, 1999 2.8.2 PAPER TRAY Paper Feed/Separation The paper tray feed station uses a feed and reverse roller system. The paper feed unit is made up of a pick-up roller, a paper feed roller, a separation roller, and a relay roller.
Page 142: Paper Lift
24 February, 1999 PAPER FEED AND REGISTRATION Paper Lift A259D704.WMF The paper tray detector switch [A] detects when the paper tray [B] is placed in the machine. When the machine detects that the paper tray is in the machine, the tray lift motor [C] turns on and the coupling gear [D] on the tray lift motor engages the pin [E] on the lift arm shaft [F].
Page 143: Paper End Detection
PAPER FEED AND REGISTRATION 24 February, 1999 Paper End Detection A259D714.WMF A259D716.WMF If there is some paper in the paper tray, the paper stack raises the paper end feeler [A] and the paper end sensor [B] is deactivated. When the paper tray runs out of paper, the paper end feeler drops into the cutout [C] in the tray bottom plate and the paper end sensor is activated.
Page 144: Tray Paper Height Sensor
24 February, 1999 PAPER FEED AND REGISTRATION Tray Paper Height Sensor Full This copier can detect the remaining volume of paper in the paper tray. However, there is no indication of this on the operation panel, and the sensors are only used by the printer controller so that the PC user can check how much paper is 35 11 33 34 35...
Page 145: By-Pass Tray
PAPER FEED AND REGISTRATION 24 February, 1999 2.8.3 BY-PASS TRAY By-pass Table Mechanism A259D604.WMF The by-pass feed table switch [A] detects when the by-pass feed table is open. Then the CPU turns on the by-pass feed indicator on the operation panel. The by-pass table can hold up to 50 sheets of paper.
Page 146: Paper End Detection
24 February, 1999 PAPER FEED AND REGISTRATION Paper End Detection A259D708.WMF The paper end sensor actuator [A] is next to the pick-up roller. When there is paper in the tray, the paper lifts the actuator out of the by-pass paper end sensor [B]. When paper is all used up, the actuator falls on its own weight, entering the by- pass paper end sensor, and the machine detects that the tray is empty.
Page 147: Paper Size Detection
PAPER FEED AND REGISTRATION 24 February, 1999 Paper Size Detection A259D605.WMF B4,B5 B5,B6 EU/Asia DLT,LT A4,A5 12x18 A259D606.WMF 12x18 10x14 LG,LT,F4,HLT The by-pass paper width detection board [A] monitors the paper width. The rear side fence is connected to the terminal plate [B]. When the side fences are being moved to match the paper width, the terminal plate slides along the wiring patterns on the detection board.
Page 148: Pick-Up Roller
24 February, 1999 PAPER FEED AND REGISTRATION Pick-up Roller A259D709.WMF The pick-up roller [A] is normally held up by the springs [B] on the pick-up solenoid arm. When it is time to feed the paper, the pick-up solenoid [C] turns on, causing the pick-up roller to contact the paper.
Page 149: Paper Transport, Fusing, And Paper Exit
PAPER TRANSPORT, FUSING, AND PAPER EXIT 24 February, 1999 2.9 PAPER TRANSPORT, FUSING, AND PAPER EXIT 2.9.1 MAJOR COMPONENTS A259D611.WMF 1. Hot roller 14. Pressure roller thermistor 2. Hot roller thermofuse 15. Pressure roller thermofuse 3. Oil supply roller 16. Paper exit sensor 4.
Page 150: Drive Mechanism
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT 2.9.2 DRIVE MECHANISM A259D612.WMF The fusing motor [A] drives the fusing and paper exit units. The fusing clutch [B] transmits drive to the fusing drive gear [C]. When the cpu detects that the front door is opened (by the signal from the front door switch), it turns off the clutch, which releases the drive gear [B].
Page 151: Fusing Unit
PAPER TRANSPORT, FUSING, AND PAPER EXIT 24 February, 1999 2.9.3 FUSING UNIT Fusing Mechanism A259D613.WMF The hot and pressure rollers each have a fusing lamp: 800 W [A] for the hot roller [B] and 400 W [C] for the pressure roller [D]. The hot roller thermistor [E] and pressure roller thermistor [F] control the temperature of these lamps.
Page 152: Fusing/Pressurization Mechanism
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT Fusing/Pressurization Mechanism A259D504.WMF The hot and pressure rollers are silicone rollers. The oil supply mechanism makes it easier for paper to separate from the rollers after fusing. Springs [C] and a bracket press the pressure roller [A] against the hot roller [B]. When disassembling the fusing unit, pressure between the rollers is released by unscrewing the pressure release screw [D] and lowering the pressure lever [E].
Page 153: Oil Supply Mechanism
PAPER TRANSPORT, FUSING, AND PAPER EXIT 24 February, 1999 Oil Supply Mechanism A259D615.WMF A259D616.WMF The gear [A] and cam gear [B] on the fusing knob shaft at the front of the fusing unit are always engaged. The actuator [C] for the oil pump roller is in contact with this cam gear.
Page 154: Cleaning Mechanism
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT Cleaning Mechanism A259D617.WMF The cleaning roller [A] cleans the hot roller [B]. Toner and dust on the hot roller adheres to the cleaning roller. Then the scraper [C] scrapes off the toner and dust on the cleaning roller.
Page 155: Inverter And Paper Exit Mechanisms
PAPER TRANSPORT, FUSING, AND PAPER EXIT 24 February, 1999 2.9.4 INVERTER AND PAPER EXIT MECHANISMS Paper Exit A259D601.WMF The paper exit roller [A] suppots the paper fed from the fusing unit to improve the ability of the paper to stack. Junction Gate Mechanism (A259/A260 Only) A259D602.WMF After fusing, the junction gate [B] feeds paper either to the paper exit tray or the...
Page 156: Paper Exit Door Mechanism (A259/A260 Only)
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT Paper Exit Door Mechanism (A259/A260 Only) A259D603.WMF The paper exit door [A] opens to help remove paper jams in the inverter. The relay rollers [B] are released when the paper exit door opens. The paper exit door switch [C] detects whether the paper exit door is open or closed.
Page 157: Duplex Tray (A259/A260 Copiers Only)
DUPLEX TRAY (A259/A260 COPIERS ONLY) 24 February, 1999 2.10 DUPLEX TRAY (A259/A260 COPIERS ONLY) 2.10.1 OVERVIEW A259D643.WMF 1. End fence 8. Vertical transport roller 2. End fence jogger H.P. sensor 9. Paper feed roller 3. Side fence jogger 10. Duplex turn sensor 4.
Page 158: Drive Mechanism
24 February, 1999 DUPLEX TRAY (A259/A260 COPIERS ONLY) 2.10.2 DRIVE MECHANISM A259D667.WMF The duplex feed motor [A] drives all the rollers in the duplex tray using a series of gears and a timing belt [B]. Helical gears are used to reduce noise. The duplex feed motor also drives the duplex bottom plate up and down.
Page 159: Paper Feed Into The Duplex Tray
DUPLEX TRAY (A259/A260 COPIERS ONLY) 24 February, 1999 2.10.3 PAPER FEED INTO THE DUPLEX TRAY The duplex feed motor is a stepper motor. The direction that the motor turns depends on whether the duplex unit is stacking or feeding. 1. Duplex Stacking A259D644.WMF Paper enters the duplex unit passing the entrance sensor [A], the duplex turn sensor [B], the paper feed roller [C], and the separation roller [D].
Page 160: Duplex Entrance To Duplex Tray
24 February, 1999 DUPLEX TRAY (A259/A260 COPIERS ONLY) 3. Duplex Entrance To Duplex Tray A259D646.WMF The duplex feed motor [A] starts after the leading edge of the paper activates the paper exit sensor. This motor drives the duplex feed rollers [B] and the duplex entrance rollers [C].
Page 161: Jogger Mechanism
DUPLEX TRAY (A259/A260 COPIERS ONLY) 24 February, 1999 2.10.4 JOGGER MECHANISM A259D648.WMF A259D649.WMF A259D650.WMF There are two motors for driving the fences. The side fence jogger motor [A] drives the side jogger fences. The end fence jogger motor [B] drives the end jogger fence. Using two separate motors for the side and end fences allows the duplex tray to handle all paper sizes from A3/11"...
Page 162: Paper Feed From The Duplex Tray
24 February, 1999 DUPLEX TRAY (A259/A260 COPIERS ONLY) 2.10.5 PAPER FEED FROM THE DUPLEX TRAY Bottom Plate Lift Mechanism A259D653.WMF A259D655.PCX While the first side is being copied, the duplex feed motor [A] turns clockwise and the cam clutch gear [B] turns counter-clockwise (see the above drawing). Then all copies are stacked in the duplex tray unit.
Page 163: Paper Feed-Out Mechanism
DUPLEX TRAY (A259/A260 COPIERS ONLY) 24 February, 1999 Paper Feed-out mechanism A259D651.WMF A259D647.WMF While paper is stacking in the duplex tray, the paper flatteners [A] correct curl at the leading edge of the paper. After all the paper is stacked in the duplex tray, the jogger fences square the paper and the duplex feed motor turns counter-clockwise briefly to prepare to feed the paper from the duplex tray.
Page 164: Others
Both the main control board and the scanner IPU board have flash memory so that their programs can be replaced using a flash ROM card. The main control board controls the printer controller through the CIVIC interface (this is Ricoh’s proprietary parallel colour video interface). 2-115...
Page 165: Power States
OTHERS 24 February, 1999 2.11.2 POWER STATES Energy Saver Mode In energy saver mode, all indicators on the operation panel except the Main Power indicator and the LED on the Energy Saver key are turned off and the fusing lamps are held in the standby state.
Page 166: Main Power Switch Off State
24 February, 1999 OTHERS Main Power Switch Off State When the main power switch is off, all power is shut off except the following heaters, which are always on whenever the power cord is connected to the outlet. • Optics anti-condensation heater •...
Page 167: Touch Panel (A259/A260 Machines Only)
OTHERS 24 February, 1999 2.11.3 TOUCH PANEL (A259/A260 MACHINES ONLY) This copier contains a large full-color LCD (640 x 480 dots) operation panel. The CPU (LCD controller) on the main control board controls this operation panel. Using DMA, the scanner IPU stores the display image data generated during area manipulation in the VRAM on the main control board before it is transferred to the operation panel.
Page 168: Bus Switch Board (Optional)
24 February, 1999 OTHERS 2.11.4 BUS SWITCH BOARD (OPTIONAL) Main Printer Controller Control Board From the printer CIVIC From the copier controller interface Bus Switch Board Video bus switching control LD Main Control Board A259D811.WMF The printer controller is an option for this copier. The bus switch board interfaces the copier with the controller.
Page 169: Installation Procedure
24 February, 1999 INSTALLATION REQUIREMENTS 3. INSTALLATION PROCEDURE 3.1 INSTALLATION REQUIREMENTS ø CAUTION Rating Voltages for Peripherals ARDF “Rating voltage of Output connector; Max. DC 24 V” CONTROLLER INTERFACE “Rating voltage of Output connector; Max. AC 120 V (N. America) Max.
Page 170: Dimensions
INSTALLATION REQUIREMENTS 24 February, 1999 3.1.1 DIMENSIONS 1,330 1,322 1,070 A258: 757 857 A259: 20 Bins 1,040 1,110 10 Bins 3 Bins Unit: mm A259I122.WMF 52.4" 52.0" 42.1" 37.0" 16.8" 24.4" 5/5" 24.4" 6.7" 15.0" 12.6" 4.7" A258: 26.7" 29.8" 33.7" A259: 29.8"...
Page 171: Environmental Requirements
24 February, 1999 INSTALLATION REQUIREMENTS 3.1.2 ENVIRONMENTAL REQUIREMENTS To ensure the optimum copy quality, the following environmental requirements need to be observed. When installing this copier at the customer site, make sure that the location meets the following requirements. 1. Avoid an area which is exposed to direct sunlight or is excessively illuminated (the illumination should not exceed 2000 lux.).
Page 172 INSTALLATION REQUIREMENTS 24 February, 1999 ø CAUTION 1. Do not install the machine in a very humid or dusty area. 2. Do not install the machine on a shaky or inclined floor. 3. Completely pull out and hold all four handles when moving the machine.
Page 173: Minimum Space Requirements
24 February, 1999 INSTALLATION REQUIREMENTS 3.1.3 MINIMUM SPACE REQUIREMENTS Provide clearance for the copier, as shown below. If one or more options (such as the ADF or sorter stapler) are added to the copier, this clearance should be provided around the entire system. 10 cm (3.9") or more 42 cm 10 cm...
Page 174: Power Requirements
INSTALLATION REQUIREMENTS 24 February, 1999 3.1.4 POWER REQUIREMENTS ø WARNING 1. Install the machine as close to the outlet as possible. Firmly plug in the machine after installation. 2. Avoid multi-wiring. 3. The power cord should be placed where it cannot be stepped on or flattened by the machine.
Page 175: Copier Installation
24 February, 1999 COPIER INSTALLATION 3.2 COPIER INSTALLATION 3.2.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: Description Q'ty 1. Paper Size Decal ..............1 2. Operating Instructions (not -26/-27 machines) ....1 3.
Page 176: Copier Installation Procedure
COPIER INSTALLATION 24 February, 1999 3.2.2 COPIER INSTALLATION PROCEDURE Tape Removal Filament A259I101.WMF Tape 1. Remove the strips of filament tape indicated in the above diagram.
Page 177 24 February, 1999 COPIER INSTALLATION – A258 only – A259I115.WMF 1. Remove the clamping materials [A] from the paper tray. – A259/A260 only – A259I114.WMF A259I502.WMF 1. Remove the protectors [B] from the metal rollers. 2. Peel off the two pieces of filament tape [C] from the duplex unit and remove the protective sheet [D].
Page 178: Removing The Inner Transfer Cover And Paper Transfer Locking Screw
COPIER INSTALLATION 24 February, 1999 Removing the Inner Transfer Cover and Paper Transfer Locking Screw A259R201.WMF A259I506.WMF A259I507.WMF NOTE: Place a mat on the floor to keep the floor clean before doing this procedure. 1. Open the front cover and remove the revolver locking screw [A] and the inner cover [B] (2 screws).
Page 179 24 February, 1999 COPIER INSTALLATION NOTE: After pulling out the drawer unit, take one of the following actions to prevent the drum unit from being exposed to external light: • Complete the procedure promptly and replace the drawer unit as soon as possible.
Page 180: Developer Installation
COPIER INSTALLATION 24 February, 1999 Developer Installation A259R204.WMF NOTE: 1) If the drawer unit [A] is left out, the drum is exposed to light. This may cause optical fatigue, resulting in image anomalies (see the Troubleshooting section 7.4). Therefore, after pulling out the drawer unit, remove the drum unit (2 connectors [B]) and cover it with a black sheet or 5 (or more) white sheets of paper.
Page 181 24 February, 1999 COPIER INSTALLATION A259R302.WMF A259R301.WMF 1. Remove the left revolver stopper [A] from its storage place in the drawer unit (1 screw) and put it in the rear hole [B] in the revolver side panel and in the notch [C] on the drawer unit stay.
Page 182 COPIER INSTALLATION 24 February, 1999 A259R303.WMF A259R306.WMF A259R309.WMF 3. Remove the developer cover [A] (2 screws). 4. Place the development unit [B] in the developer installation position [C] and pour in 1 bag (380 g) of developer [D]. NOTE: Pour developer into the auger from the development roller side. This speeds the agitation of the developer and prepares it for use more quickly.
Page 183 24 February, 1999 COPIER INSTALLATION A259R302.WMF A259I310.WMF 6. Replace the developer cover (2 screws) and put the development unit [A] in the drawer unit (2 lock screws [B]). ø CAUTION 1. When replacing the developer cover, do not apply excessive force to the center of the development unit.
Page 184 COPIER INSTALLATION 24 February, 1999 A259I110.WMF A259I119.WMF 8. After all the color developers have been installed, return the revolver stopper to the front stay of the drawer unit. 9. Reinstall the drum unit (2 connectors). 10. Close the drawer unit (2 screws). 11.
Page 185: Pressure Release Lever Set-Up
24 February, 1999 COPIER INSTALLATION Pressure Release Lever Set-up A259I104.WMF A259I509.WMF 1. Install the charge corona unit [A] with the corona cleaner [B] (2 screws). 2. Reinstall the transfer belt stay (5 screws). 3. Set up the pressure release lever [C] as follows: 1) Remove the snap ring [E] from the transfer unit.
Page 186: Installing Fusing Silicone Oil
COPIER INSTALLATION 24 February, 1999 Installing Fusing Silicone Oil A259I106.WMF 1. Draw the fusing unit [A] half-way out of the main unit and remove the oil cap [B]. 2. Pour in silicone oil [C]. 3. Close the oil cap and push the fusing unit back in. 4.
Page 187: Initialization And Function Checks
24 February, 1999 COPIER INSTALLATION Initialization and Function Checks 1. Open the front cover and turn on the main switch. 2. When “Close the Front Cover” is displayed, close the front cover, then enter SP [T → ò → ó → ì → E] mode.
Page 188: Setting The Tray Paper Size
COPIER INSTALLATION 24 February, 1999 Setting the Tray Paper Size First, change the position of the side fences and the end fence in each tray to match the paper size you will be using. Then set the paper size for each tray at the operation panel using the following procedure.
Page 189: Setting The Language And Unit Of Measurement
24 February, 1999 COPIER INSTALLATION Setting the Language and Unit of Measurement When the required language is other than English, French, German, Italian and Spanish, the main program for that language must be downloaded to the main control board. Then, the desired language can be selected. (Replacement and Adjustment –...
Page 190: Relocation Procedure
COPIER INSTALLATION 24 February, 1999 3.2.3 RELOCATION PROCEDURE A259I117.WMF A259I116.WMF 1. Remove the inner transfer cover [A] and release the belt pressure as shown: • • 1) Take off the snap ring and pull the lever off the pin ‘ ’...
Page 191: Paper Tray Unit (A832/A833)
24 February, 1999 PAPER TRAY UNIT (A832/A833) 3.3 PAPER TRAY UNIT (A832/A833) 3.3.1 ACCESORY CHECK Check the quantity and condition of the accessories in the box with the following list: Description Q'ty 1. Right Support Bracket............1 2. Left Support Bracket ............1 3.
Page 192: Installation
PAPER TRAY UNIT (A832/A833) 24 February, 1999 3.3.2 INSTALLATION A832I505.WMF A832I501.WMF A832I503.WMF ø CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape as shown. 2. Set the copier [A] on the paper tray unit [B]. 3-24...
Page 193 24 February, 1999 PAPER TRAY UNIT (A832/A833) A832I507.WMF A832I504.WMF 3. Open the right door [A] of the paper tray unit. 4. Secure the copier to the paper tray unit with the joint screw [B]. 5. Remove the connector cover [C] from the rear cover of the copier (1 screw). 6.
Page 194 PAPER TRAY UNIT (A832/A833) 24 February, 1999 A832I508.WMF A832I509.WMF 9. Attach the support brackets [A] to the bottom of the paper tray unit as shown (4 screws). ø CAUTION If you do not attach the support brackets, the machine may fall forwards when the paper trays are pulled open.
Page 195: Tray Heater (Option)
24 February, 1999 PAPER TRAY UNIT (A832/A833) TRAY HEATER (OPTION) A833I501.WMF A833I502.WMF A833I503.WMF 1. Remove all the trays (A832: 2 trays, A833: 3 trays). 2. A832 only: Remove the lower front cover (2 screws). 3. Remove the rear cover (4 screws). 4.
Page 196: Platen Cover (A749-01)
PLATEN COVER (A749-01) 24 February, 1999 3.4 PLATEN COVER (A749-01) A749I501.WMF A749I500.WMF A749I503.WMF 1. Cut the platen holder cover [A] out of the upper rear cover [B] with wire cutters. 2. Insert the platen holders [C] as shown (1 screw for each). 3.
Page 197: Ardf (A663)
24 February, 1999 ARDF (A663) 3.5 ARDF (A663) 3.5.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: Description Q'ty 1. New Equipment Condition Report........1 2. Installation Procedure ............1 3. Stud Screw................1 4.
Page 198: Installation
ARDF (A663) 24 February, 1999 3.5.2 INSTALLATION A663I500.WMF A663I501.WMF A663I503.WMF A663I502.WMF ø CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape [A]. 2. Stick the sponge retainer [B] on the top cover of the copier as shown. 3.
Page 199: 20-Bin Sorter Stapler (A834)
24 February, 1999 20-BIN SORTER STAPLER (A834) 3.6 20-BIN SORTER STAPLER (A834) 3.6.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: Description Q'ty 1. Staple Position Decal............1 2. Chain .................. 1 3.
Page 200: Installation
20-BIN SORTER STAPLER (A834) 24 February, 1999 3.6.2 INSTALLATION A834I500.WMF A834I501.WMF A834I50I8.WMF ø CAUTION Unplug the copier power cord before starting the following procedure. When handling the sorter stapler, make sure to hold the parts shown [A]. Otherwise, the resulting damage may cause paper jams at the entrance. NOTE: 1) Keep the shipping retainers after installing the machine.
Page 201 24 February, 1999 20-BIN SORTER STAPLER (A834) A834I504.WMF A834I503.WMF 3. Remove the two plastic caps [A] from the copier left cover with nippers or a small screw driver. 4. Release lever [B] on the sorter stapler and remove the sorter stapler mounting frame [C], as shown.
Page 202 20-BIN SORTER STAPLER (A834) 24 February, 1999 A834I502.WMF 5. Mount the sorter stapler mounting frame [A] on the copier, as shown (5 screws M4 x 20). When hooking the sorter stapler mounting frame on the left side of the copier, make sure that the positioning hooks [B] on the frame are properly inserted in the positioning holes [C] in the copier.
Page 203 24 February, 1999 20-BIN SORTER STAPLER (A834) A834I505.WMF A834I507.WMF A834I506.WMF 6. Install the sorter stapler [A] on the frame (2 hinge pins at the rear), as shown. 7. Tighten the M4 x 20 screw [B]. NOTE: This screw prevents the sorter stapler from falling down. 8.
Page 204: 10-Bin Sorter Stapler (A555)
10-BIN SORTER STAPLER (A555) 24 February, 1999 3.7 10-BIN SORTER STAPLER (A555) 3.7.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: Description Q'ty 1. Misfeed Removal Decal ............1 2. Staple Position Decal............1 3.
Page 205: Installation
24 February, 1999 10-BIN SORTER STAPLER (A555) 3.7.2 INSTALLATION Do not lift this way. A555I500.WMF A555I501.WMF A555I502.WMF ø CAUTION Unplug the copier power cord before starting the following procedure. Do not lift the sorter stapler by holding the entrance guide [A]. Otherwise, the resulting damage may cause paper jams to occur at the entrance.
Page 206 10-BIN SORTER STAPLER (A555) 24 February, 1999 A555I513.WMF A555I522.WMF A555I504.WMF 3. Remove the caps [A] with nippers, and remove the mounting frame [B] from the sorter stapler by releasing the lever [C]. 4. Remove the exit paper guide [D] from the mounting frame [B]. 3-38...
Page 207 24 February, 1999 10-BIN SORTER STAPLER (A555) A555I523.WMF 5. Fit the hooks [A] on the sorter stapler mounting frame into the holes [B]. Then tighten four M4 x 14 screws. 3-39...
Page 208 10-BIN SORTER STAPLER (A555) 24 February, 1999 Do not lift this way. A555I500.WMF A555I508.WMF 6. Install the sorter stapler [A] on the frame (1 screw M4 x 8). NOTE: Do not lift the sorter stapler by holding the entrance guide [B] when installing it.
Page 209 24 February, 1999 10-BIN SORTER STAPLER (A555) A555I510.WMF A555I509.WMF A555I512.WMF A555I511.WMF 11. Open the front door [A] of the sorter stapler and swing the stapler unit [B] down. 12. Remove the green plastic clip [C] from the staple cartridge and correct the position of the staple sheet [D] if necessary.
Page 210: 3-Bin Sorter (A849)
3-BIN SORTER (A849) 24 February, 1999 3.8 3-BIN SORTER (A849) 3.8.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list. Description Q'ty 1. Installation Procedure ............1 2. Connecting Bracket............. 1 3. Arm Bracket ................ 1 4.
Page 211: Installation
24 February, 1999 3-BIN SORTER (A849) 3.8.2 INSTALLATION A849I500.WMF A566I503.WMF ø CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape. 2. Remove the connecting bracket from the side of the sorter. 3. Remove the two caps from the copier left cover with nippers or a small screwdriver.
Page 212 3-BIN SORTER (A849) 24 February, 1999 A849I504.WMF A849I501.WMF 7. Install the sorter unit [A] on the frame. 8. Install the shoulder screw [B] to lock the sorter unit in place. 9. Mount the arm bracket [C] with 1 clip [D]. 10.
Page 213: Film Projector Table (A702-19)
24 February, 1999 FILM PROJECTOR TABLE (A702-19) 3.9 FILM PROJECTOR TABLE (A702-19) A702I101L.WMF A702I102L.WMF 1. Remove the upper right cover [A] (1 screw). 2. Install the table [B] (7 screws). 3-45...
Page 214 FILM PROJECTOR TABLE (A702-19) 24 February, 1999 A702I103L.WMF A702I104L.WMF A702I105L.WMF 3. Install the lower cover [A] (2 screws). 4. Install the table cover [B]. 5. Install the joint cover [C]. 3-46...
Page 215: Accessory Check
24 February, 1999 FILM PROJECTOR UNIT (A846) 3.10 FILM PROJECTOR UNIT (A846) 3.10.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box with the following list: Description Q'ty 1. Mirror Unit ................1 2. Power Cord ................. 1 3.
Page 216 FILM PROJECTOR UNIT (A846) 24 February, 1999 3.10.2 INSTALLAITON A846I509.WMF ø CAUTION Unplug the copier power cord before starting the following procedure. NOTE: The film projector table (A702-19) must be installed before starting the following procedure. 1. Place the projector unit [A] on the table by aligning the holes in the projector base plate with the positioning pins [B].
Page 217 24 February, 1999 FILM PROJECTOR UNIT (A846) A846I500.WMF A846I510.WMF A846I511.WMF 2. Remove the lamp cover [A] (1 screw) and open the reflector cover [B]. Then, plug the projector lamp [C] into the socket. Then close the reflector cover. NOTE: The projector lamp should be inserted horizontally until it stops. 3.
Page 218 FILM PROJECTOR UNIT (A846) 24 February, 1999 A846I513.WMF õ A846I501.WMF 5. Connect the optical fiber cable [A] to the copier. 6. Connect the power cord [B] to the power inlet and plug it into the wall outlet. ø WARNING After plugging the power cord into the wall outlet, do not touch the electrical components inside the projector unit.
Page 219 24 February, 1999 FILM PROJECTOR UNIT (A846) A846I502.WMF 7. Place the film position sheet [A] on the exposure glass, aligning it at the rear left corner. NOTE: “D” is written at the corner mark [D] on the film position sheet for the A258/A259/A260 copiers.
Page 220 FILM PROJECTOR UNIT (A846) 24 February, 1999 A846I503.WMF 9. Set the film strip holder [A] into the film projector unit at the base film setting position. NOTE: Push the film strip holder lightly to confirm that the film strip holder is set correctly.
Page 221 24 February, 1999 FILM PROJECTOR UNIT (A846) A846I504.WMF A846I505.PCX A846I507.WMF A846I506.WMF 16. Adjust the angle [A] of the mirror unit as follows: 1) Turn on the copier main switch and wait for the ready condition. 2) Open the lens cover and position the mirror unit on the exposure glass. 3) Set the correction filter [B] for positive films in the filter slot.
Page 222 FILM PROJECTOR UNIT (A846) 24 February, 1999 A846I508.WMF A846I506.WMF 8-2) When the trailing part is dark [A]. a) Move the front and rear arm guides [B] to the right so that the mirror angle is increased (2 screws each). NOTE: Position the arm guides at the same location at front and rear, using the ruler decals.
Page 223: Controller Interface Type E (A848)
24 February, 1999 CONTROLLER INTERFACE TYPE E (A848) 3.11 CONTROLLER INTERFACE TYPE E (A848) A848I501.WMF A848I502.WMF A848I503.WMF ø CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the lower rear cover [A] (3 screws). 2. Remove the upper rear cover [B] (4 screws). 3.
Page 224 CONTROLLER INTERFACE TYPE E (A848) 24 February, 1999 A848I504.WMF A848I505.WMF A848I506.WMF 8. Attach 2 clamps [A] to the rear bracket of the copier. 9. Connect the power supply cord [B]. 10. Remove the main board [C] (A258: 11 connectors and 7 screws, A259/A260:14 connectors and 7 screws).
Page 225 24 February, 1999 CONTROLLER INTERFACE TYPE E (A848) – A258 only – – A259/A260 only – A848I511.WMF A848I512.WMF A848I508.WMF 16. Remove the operation panel [A] (A258: 2 screws, 1 connector and 1 grounding wire (European model), A259/260: 2 screws, 2 connectors, 2 grounding wires, and 1 flat cable).
Page 226 CONTROLLER INTERFACE TYPE E (A848) 24 February, 1999 A848I510.WMF A848I509.WMF 20. Secure the I/F unit [A] to the copier (3 screws, 1 screw with washer [B]). 21. Install the printer controller [C] in the I/F unit [A]. (4 screws) 22. Reinstall the operation panel (2 screws), the right cover (1 screw), and rear right cover (1 screw).
Page 227: Others
24 February, 1999 OTHERS 3.12 OTHERS 3.12.1 ORIGINAL TABLE INSTALLATION PROCEDURE A259I505.WMF 1. Remove two caps [A] from the main unit cover. 2. Insert the shoulder screws [B]. Do not tighten them yet. 3. Mount the original table [C] so that it hangs on the shoulder screws. 4.
Page 228: Key Counter Holder Installation Procedure
OTHERS 24 February, 1999 3.12.2 KEY COUNTER HOLDER INSTALLATION PROCEDURE A259R418.WMF 1. Remove the right front cover from the main unit (1 screw). 2. Cut away a section [A]. 3. Plug in the connector [B] for the key counter holder. 4.
Page 229: Service Tables
24 February, 1999 SERVICE PROGRAM (SP) MODES 4. SERVICE TABLES 4.1 SERVICE PROGRAM (SP) MODES 4.1.1 HOW TO ENTER SP MODE Follow the procedure shown below to enter SP mode. TýòýóýìýE 1) Press the clear modes key and enter 107. 2) Then hold down the clear/stop key for more than 3 seconds.
Page 230: Sp Mode Table
SP MODE TABLE 24 February, 1999 4.3 SP MODE TABLE See Appendix 2.
Page 231: Sp Mode Additional Notes
24 February, 1999 SP MODE ADDITIONAL NOTES 4.4 SP MODE ADDITIONAL NOTES 4.4.1 SP5-804 OUTPUT CHECK No. for Load Name Actual Display A258 A259/A260 Class 3 Drum motor, standard speed, DRUM MT 1ST CW ON=1, OFF=0 ON, OFF forward Drum motor, half speed, DRUM MT 2ND CW ON=1, OFF=0 ON, OFF...
Page 232 SP MODE ADDITIONAL NOTES 24 February, 1999 No. for Load Name Actual Display A258 A259/A260 Class 3 Main exhaust fan motor EXH FAN ON=1, OFF=0 ON, OFF Fusing fan motor, high speed FUSER FAN H SPD ON=1, OFF=0 ON, OFF Fusing fan motor, half speed FUSER FAN L SPD ON=1, OFF=0 ON, OFF...
Page 233: Sp5-803 Input Check
24 February, 1999 SP MODE ADDITIONAL NOTES No. for Load Name Actual Display A258 A259/A260 Class 3 Bin lift motor SS BIN LIFT MT ON=1, OFF=0 ON, OFF SRC Grip motor SS CHACK MT ON=1, OFF=0 ON, OFF SR Stapler motor SS STAPLER MT ON=1, OFF=0 ON, OFF SR...
Page 234 SP MODE ADDITIONAL NOTES 24 February, 1999 No. for Sensor/Switch Name Actual Display Condition Class 3 3rd vertical transport SEN PAPER TX3 0 (PE) 4th vertical transport SEN PAPER TX4 0 (PE) Relay SEN PAPER TX1 1 (PE) 1st tray paper end SEN TRAY1 PE 0 (PE) 2nd tray paper end...
Page 235: Sorter
24 February, 1999 SP MODE ADDITIONAL NOTES Scanner No.for Sensor/Switch Name Actual Display Condition Class 3 Scanner home position HOME SENCER 1 (Set) Platen cover position ATSUBAN SENSER 1 (Set) Sorter No. for Name Actual Display Sorter type Condition Class 3 Entry SEN SS ENTER SEN 1 (Paper...
Page 236: Ardf
SP MODE ADDITIONAL NOTES 24 February, 1999 ARDF No. for Name Actual Display Condition Class 3 Width small ADF_SIZE_SMALL 1 (ON) Width medium ADF_SIZE_MIDDLE 1 (ON) Size large ADF_SIZE_LARGE 1 (ON) Registration ADF_REGIST_SEN 1 (Paper present) Paper exit ADF_OUT_SEN 1 (Paper present) Lift-up ADF_LIFT_SEN 1 (Set)
Page 237: To 5-955-016 Ld_Pwm (16-Gradation)
24 February, 1999 SP MODE ADDITIONAL NOTES 4.4.5 5-955-002 TO 5-955-016 LD_PWM (16-GRADATION) Defines the LD values for the 16 –gradations printed on test patterns SP5-955-018: 5, 16. 002: 1/15 (for the second grade) 003: 2/15 (for the third grade) 004: 3/15 (for the fourth grade) 005: 4/15 (for the fifth grade) 006: 5/15 (for the sixth grade)
Page 238: User Tool
USER TOOL 24 February, 1999 4.5 USER TOOL 4.5.1 USER TOOL MENU System settings Menu Panel Tone Ready/Tone Copy Count Display System Reset Function Reset Control Panel Off Auto Timer Tray Paper Size –––– Tray Priority Auto Tray Switch Interleave Print Output Tray Prio.
Page 239 24 February, 1999 USER TOOL COPY FEATURES Menu General Features APS Priority ADS Priority (FC) ADS Prio. (B&K/SC) Orig. Mode Priority Orig. Type Priority Col. Mode Priority Photo Type (Auto) –––– Copy Reset Max. Copy Q’ty Original Tone Margin Adjustment Set User Ratio Initial Mode Set Key Operator Tools...
Page 240: System Settings
USER TOOL 24 February, 1999 4.5.2 SYSTEM SETTINGS Menu Description Panel Tone The beeper (key tone) sounds when a key is pressed. This beeper can be turned on or off. Note Default: On Ready/Tone Choose whether the machine beeps when it becomes ready for a copy run after power up.
Page 241 24 February, 1999 USER TOOL Menu Description Tray Paper Select the size of the copy paper set in the paper tray. Size Note If the specified paper size differs from the size of paper actually set in the paper tray, a paper misfeed might occur because the paper size is not detected correctly.
Page 242 USER TOOL 24 February, 1999 Menu Description 3 Side Full When this mode is off, narrow margins on all 4 sides of the original Bleed are not copied. 1: 2±2mm, 0.08"±0.08" 2: 2±2/–1.5mm, 0.08"+0.08"/–0.06" 3: 2±2mm, 0.08"±0.08" 4: 5±2mm, 0.2"±0.08" A259M500.WMF When you turn it on, margins 1, 2 and 3 are copied.
Page 243 24 February, 1999 USER TOOL Menu Description Program Use to register or change the key operator code (up to 8 digits). KeyOpCode Auto Rower DH mode Disable 4-15...
Page 244: Copy Features
USER TOOL 24 February, 1999 4.5.3 COPY FEATURES General Features Menu Description APS Priority As a default setting, the Auto Paper Select is selected just after the machine is turned on or when modes are cleared. You can cancel this setting. Note Default: On ADS Priority (FC)
Page 245 24 February, 1999 USER TOOL Menu Description Copy Reset The machine returns to its initial condition automatically after your job is finished. The time can be set from 10 to 300 seconds, or off. 1. Select [On] or [Off] with the ü û keys. 2.
Page 246 USER TOOL 24 February, 1999 Menu Description Accessible You can assign user codes to each color mode. Operators must Modes input their user codes before using each color mode (Full Color, Black, Single Color, and Twin Color). The machine keeps count of the number of copies made under each user code.
Page 247: Image Adjustment
24 February, 1999 USER TOOL Image Adjustment Menu Description A.D.S. (FC) You can register your user code (8 digits). 1. Input your desired user code with the [Number] keys. 2. Press the [OK] key. 3. Select the color mode you want to use with the new code with the keys.
Page 248 USER TOOL 24 February, 1999 Menu Description A.C.S. Priority You can select color images or black & white images that are priority detected in Auto Color Selection mode. Note Default: Full Color Color Sensitivity When in Color Erase or Color Conversion mode, the function can be made more or less sensitive to the color to be erased or converted.
Page 249: Set Favorite Keys
24 February, 1999 USER TOOL Menu Description ADF Mixed Sizes By default, you cannot set originals of different sizes at one time in the document feeder. You can cancel this setting. Note Default: Off If you select [On] , the copying speed will be reduced. When setting different length originals, all originals must be flush with the back fence of the document feeder.
Page 250: Tp/Sw/Led/Fuse
TP/SW/LED/FUSE 24 February, 1999 4.6 TP/SW/LED/FUSE 4.6.1 MAIN CONTROL BOARD TEST POINTS Stand-by TP No. Signal Description Remarks Implementation TP101 Ground 0 to 5.0 TP102 Ground 0 to 5.0 TP103 TP X-axis ground terminal 0 to 5.0 TP X-axis power terminal 0 to 5.0 In the press sense mode, held at the...
Page 251: Scanner Ipu Board Test Points
24 February, 1999 TP/SW/LED/FUSE Stand-by TP No. Signal Description Remarks Implementation TP154 UPHT_TH Analog input from the fusing 0 to 5.0 thermistor (upper) TP155 /IACK Used to get an interrupt 0 to 5.0 Active L vector. LWHT_TH Analog input from the fusing 0 to 5.0 TP156 thermistor (lower)
Page 252: Ld Main Control Board Test Points
TP/SW/LED/FUSE 24 February, 1999 4.6.3 LD MAIN CONTROL BOARD TEST POINTS Stand- TP No. Signal Description Remarks by(V) Implementation TP601 Ground LDON Shortening this terminal to 0 to 5.0 Active L ground causes the LD to stay TP602 on in full mode during the polygon ON period.
Page 253: I/O Control Board Test Points
24 February, 1999 TP/SW/LED/FUSE 4.6.4 I/O CONTROL BOARD TEST POINTS Stand- TP No. Signal Description Remarks by(V) Implementation RP_SEN2 Paper height sensor signal 1 0 to 5.0 Shade "H" TP201 (right) TP202 RP_SEN1 Paper height sensor signal 2 (left) 0 to 5.0 Shade "H"...
Page 254 TP/SW/LED/FUSE 24 February, 1999 Stand- TP No. Signal Description Remarks by(V) Implementation PWM_C Charge corona current control 0 to 5.0 TP236 signal TP237 PWM_G Grid voltage control signal 0 to 5.0 TP239 VCC2A Analog +5V power source TP240 VCC2 Digital +5V power source TP241 AGND Power ground...
Page 255 24 February, 1999 TP/SW/LED/FUSE Stand- TP No. Signal Description Remarks by(V) Implementation TP283 XFUS_CL Fusing clutch ON/OFF signal 0 to 24.0 ON = "L" Belt cleaning clutch ON/OFF XBC_CL 0 to 24.0 ON = "L" TP284 signal TP285 XFEED_CL Paper feed clutch ON/OFF signal 0 to 24.0 ON = "L"...
Page 256: Switch Specifications
TP/SW/LED/FUSE 24 February, 1999 4.6.5 SWITCH SPECIFICATIONS Scanner IPU Board Description Remarks SW2-1 1 scan SW2-2 Motor excitation off SW2-3 Lamp on SW2-4 Free-running SW2--5 IPU input select ON: External image input OFF: Scanner image input SW2--6 Not used. 4.6.6 LED SPECIFICATIONS Function Outline Remarks Main control board...
Page 257: Fuse Specifications
24 February, 1999 TP/SW/LED/FUSE 4.6.7 FUSE SPECIFICATIONS PSU (US model) FUSE R Parts Rating Vendor Name Model No. Replaceable AC input main fuse SOC CORP or CES6-15AN1 or 11070629 FU101 125/250Vac LITTELFUSE 314015 SOC CORP or ULTSC-8AN1 or PSU AC input fuse 11070393 FU102 125/250Vac...
Page 258: Psu (European/Asian Model)
TP/SW/LED/FUSE 24 February, 1999 PSU (European/Asian Model) FUSE R Parts Rating Vendor Name Model No. Replaceable PSU AC input fuse LITTELFUSE 215005 or 11070879 FU102 INC or 125/250Vac A505-5A BUSSMANN 2A 125Vac/ AC output WICKMANN- K19372/2A (11070621) FU103 250V dehumidification WERKE GMBH heater fuse SOC CORP or...
Page 259: Preventive Maintenance
24 February, 1999 PM PROCEDURES 5. PREVENTIVE MAINTENANCE 5.1 PM PROCEDURES 5.1.1 PM-RELATED COUNTERS The major PM related counters available in the SP modes are summarized below. After performing a PM procedure, clear the PM counters. SP7-803 (Show PM Counter) SP7-803-001: Counter for preventive maintenance SP7-804 (Clear PM Counter) SP7-804-001: Counters for 60 kD preventive maintenance parts...
Page 260 PM PROCEDURES 24 February, 1999 SP7-203 (Show Image Production Counters) Shows the usage of major components by number of images produced. SP7-207 (Show Cleaning Counters) Shows the number of uses of the cleaning-related parts. SP7-210 (Show Fusing Counters) Shows the number of uses of the fusing related parts SP 7-910 (paper separation corona counters) Shows the number of uses of the separation corona SP 7-911 (duplex tray counters)
Page 261: Regular Preventive Maintenance Flow Diagram
24 February, 1999 PM PROCEDURES 5.1.2 REGULAR PREVENTIVE MAINTENANCE FLOW DIAGRAM NOTE: To replace the developer and the drum, the procedure to use depends on the combination of developers and drum to be replaced (See 6-6 Development Unit) 6 0 K D Check counters.
Page 262 PM PROCEDURES 24 February, 1999 1. Wipe the development unit toner catch pan with a dry cloth or Development unit clean with vacuum. 2. Replace developers (K, C, M, and Y) if necessary. 3. Clean the entire development unit (including covers and gears). 4.
Page 263 24 February, 1999 PM PROCEDURES Perform the following cleaning procedures every Paper feed unit visit: 1. Clean the paper feed pickup roller, feed roller, and separation roller with alcohol or water. 2. Clean the by-pass pickup roller, feed roller, and separation roller with alcohol or water.
Page 264 PM PROCEDURES 24 February, 1999 Developer setup 1. Install all unit covers with only the paper transfer unit removed. and forced self- 2. Turn on the main power switch. check process 3. Set SP1-108 (Select presence/absence of fusing unit) to control "None"...
Page 265: Regular Pm Items
24 February, 1999 REGULAR PM ITEMS 5.2 REGULAR PM ITEMS Regular PM items: To be performed every 60,000 developments in accordance with the following table. Regular PM Table NOTE: To wipe off toner, use a dry cloth. If toner is mixed with alcohol, it solidifies.
Page 266 REGULAR PM ITEMS 24 February, 1999 Schedule PM item Remarks Development Wipe with a dry cloth or unit toner catch clean with a vacuum cleaner. Developer (K) Developer life is 60 kD. Developer Developer life is 45 kD for (C, M, Y) each color.
Page 267 24 February, 1999 REGULAR PM ITEMS Schedule PM item Remarks Belt cleaning Wipe with a dry cloth or unit (toner catch clean with a vacuum pan and cleaner. entrance seal) Belt cleaning blade Belt lubricant Replace when worn or cracked. Lubricant brush Clean with a vacuum cleaner if it is too dirty.
Page 268 REGULAR PM ITEMS 24 February, 1999 Schedule PM item Remarks Pressure Wipe with a dry cotton cleaning roller cloth. (US model only) Pressure roller Europe/Asia model only blade Pressure roller Europe/Asia model only Fusing unit Wipe with a dry cloth bottom frame Europe/Asia model only Upper...
Page 269 24 February, 1999 REGULAR PM ITEMS Schedule PM item Remarks Paper feed separation roller Paper feed roller Duplex tray Wipe with a dry cloth. bottom plate Duplex trays Wipe with a dry cloth. (mylar and feeler) 5-11...
Page 270 REGULAR PM ITEMS 24 February, 1999 ∆ P: Inspect T: Replace O: Clean : Lubricate Action Post-maintenance PM Item action Paper feed Clean each paper tray with a roller: Feed dry or damp cloth (cotton cloth). Guideline: Every 200,000 normal sheets Roller: Clean each paper tray with a Follower...
Page 271 24 February, 1999 REGULAR PM ITEMS Action Post-maintenance PM Item action Transport Clean with alcohol or cotton roller cloth if stained. Follower roller Clean with alcohol or cotton cloth if stained. Clean with alcohol or cotton cloth if stained. Bin/stapler Clean with a blower brush sensor Bearing...
Page 272: Replacement And Adjustment
24 February, 1999 COVERS, FANS, AND FILTERS 6. REPLACEMENT AND ADJUSTMENT 6.1 COVERS, FANS, AND FILTERS 6.1.1 FRONT, INNER, AND INNER TRANSFER COVERS A259R901.WMF 1. Remove the chain [A] from the hook. 2. Remove the pins [B] (two) from the hinges. 3.
Page 273: Rear Covers
COVERS, FANS, AND FILTERS 24 February, 1999 6.1.2 REAR COVERS A259R902.WMF NOTE: When removing the covers, follow the step order. When installing the covers, follow the removal procedure in reverse. 1. Remove the used toner cover [A] (3 screws). 2. Remove the rear cover [B]. 3.
Page 274: Right Covers
24 February, 1999 COVERS, FANS, AND FILTERS 6.1.3 RIGHT COVERS A259R903.WMF 1. Open the front cover. 2. Remove the right front cover [A] (1 screw). 3. Remove the right cover [B] (1 screw). 4. Remove the used toner and rear covers (see “Rear Covers”). 5.
Page 275: Exposure Glass
COVERS, FANS, AND FILTERS 24 February, 1999 6.1.5 EXPOSURE GLASS A259R905.WMF 1. Remove the vertical scale [A] (2 screws). 2. Remove the horizontal scale [B] (3 screws). 3. Remove the exposure glass [C]. NOTE: When reinstalling the exposure glass, ensure that the white plate faces down and to the left.
Page 276: Used Toner Tank
24 February, 1999 COVERS, FANS, AND FILTERS 6.1.8 USED TONER TANK A259R906.WMF NOTE: Place a mat on the floor to keep the floor clean before doing this procedure. 1. Remove the used toner cover [A] (3 screws). 2. Pull out the used toner tank [B]. 3.
Page 277: Main Exhaust Fan Filter
COVERS, FANS, AND FILTERS 24 February, 1999 6.1.10 MAIN EXHAUST FAN FILTER A259R908.WMF 1. Remove the used toner cover [A] (3 screws). 2. Pull out the main exhaust fan filter [B]. 6.1.11 SCANNER EXHAUST FAN FILTER A259R909.WMF 1. Remove the left center cover [A] (1 screw). 2.
Page 278: Main Exhaust Fan
24 February, 1999 COVERS, FANS, AND FILTERS 6.1.12 MAIN EXHAUST FAN A259R710.WMF A259R711.WMF NOTE: Place a mat on the floor to keep the floor clean before doing this procedure. 1. Remove the used toner rear cover and rear cover (see "Rear Covers"). 2.
Page 279: Drum Unit
DRUM UNIT 24 February, 1999 6.2 DRUM UNIT ø WARNING Turn off the power and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. CAUTION DECAL LOCATIONS Two caution decals are located as shown below. CLASS-1.WMF A259I120.WMF LASER-4.WMF...
Page 280 24 February, 1999 DRUM UNIT ø CAUTION A259R310.WMF DO NOT TOUCH the revolver unit, the toner cartridge, the toner end sensor, or the toner cartridge sensor, while the front door switch is actuated. This is because the revolver might rotate automatically due to a timed process control self check, or if the start key is pressed.
Page 281: Pulling Out The Revolver/Drum Drawer
DRUM UNIT 24 February, 1999 6.2.1 PULLING OUT THE REVOLVER/DRUM DRAWER A259R201.WMF A259R204.WMF A259R201.WMF NOTE: Place a mat on the floor to keep the floor clean before performing these procedures. 1. Remove the following covers in the indicated order (see "Covers, Fans, and Filters"): 1) Front cover 2) Inner transfer cover [A]...
Page 282 24 February, 1999 DRUM UNIT NOTE: 1) After pulling out the drawer unit, pull out the drum unit (2 connectors) and shield the drum unit from light with a black sheet or 5 (or more) white sheets of paper. 2) If the drawer unit is left out, the drum is exposed to light. This may cause optical fatigue, resulting in image anomalies (see "Troubleshooting –...
Page 283: Drum Replacement
DRUM UNIT 24 February, 1999 6.2.2 DRUM REPLACEMENT A259R204.WMF A259R205.WMF A259R211.WMF 1. Remove the connectors [B] (2) and lift out the drum unit [A]. 2. Turn the drum unit upside down, so that it rests as shown in the bottom left diagram, and remove the 2 screws.
Page 284 24 February, 1999 DRUM UNIT NOTE: 1) After replacing the drum or the cleaning blade, rotate the drum forward two or three times to settle the setting powder between the drum surface and the cleaning blade. 2) When installing the cleaning blade [A], make sure that the front and rear ends of the blade do not rest over the cleaning unit side seal [B].
Page 285: Cleaning Blade And Pcc Wire Replacement
DRUM UNIT 24 February, 1999 6.2.3 CLEANING BLADE AND PCC WIRE REPLACEMENT A259R213.WMF A259R216.WMF A259R210.WMF 2. Remove the drum unit [A] and place it in the work area (see “Drum Replacement”). 3. Remove the cleaning unit [B] from the drum unit (2 screws). 4.
Page 286: Cleaning Brush Replacement
24 February, 1999 DRUM UNIT 6.2.4 CLEANING BRUSH REPLACEMENT A259R212.WMF 1. Remove the drum unit and place it in the work area (see “Drum Replacement”). 2. Remove the cleaning unit from the drum unit (2 screws) (see “Cleaning Blade and PCC Wire Replacement”). 3.
Page 287: Lubricant Bar Replacement
DRUM UNIT 24 February, 1999 6.2.5 LUBRICANT BAR REPLACEMENT A259R208.WMF 1. Remove the drum unit and place it in the work area (see “Drum Replacement”). 2. Remove the cleaning unit from the drum unit (2 screws) (see “Cleaning Blade and PCC Wire Replacement). 3.
Page 288: Charge Corona Grid And Wire Replacement
24 February, 1999 DRUM UNIT 6.2.6 CHARGE CORONA GRID AND WIRE REPLACEMENT A259R201.WMF A259R202.WMF 1. Remove the charge corona duct cover [A]. 2. Remove the charge corona unit [B] with the corona cleaner (2 screws). 3. Replace the grid. 1) Unscrew the screw [C] (1 screw). 2) Remove the grid [D] and replace it.
Page 289: Potential Sensor Replacement
DRUM UNIT 24 February, 1999 6.2.7 POTENTIAL SENSOR REPLACEMENT A259R206.WMF NOTE: The potential sensor consists of a sensor element and a control board. You must replace both the sensor and the control board at the same time. 1. Remove the drum (see “Drum Replacement”). 2.
Page 290: Scanner Unit
24 February, 1999 SCANNER UNIT 6.3 SCANNER UNIT 6.3.1 EXPOSURE LAMP REPLACEMENT A259R005.WMF 1. Remove the exposure glass (see “Covers, Fans, and Filters”). 2. Move the first scanner next to the opening in the frame. 3. Push the exposure lamp terminal [A] in the direction shown, and remove the lamp [B].
Page 291: Sbu Replacement
SCANNER UNIT 24 February, 1999 6.3.2 SBU REPLACEMENT A259R003.WMF A259R004.WMF 1. Remove the exposure glass (see Covers, Fans, and Filters). 2. Remove the upper right cover [A] (see Covers, Fans, and Filters). 3. Remove the scanner inner cover [B] (9 screws). 4.
Page 292: Scanner Ipu Board Replacement
24 February, 1999 SCANNER UNIT 6.3.3 SCANNER IPU BOARD REPLACEMENT A259R020.WMF A259R014.WMF A259R007.WMF 1. Remove the right cover (see section 6.1). 2. A259/A260 only: Remove the shield plate [A] (3 screws). 3. Remove the Flash ROM card cover [B] (3 screws). 4.
Page 293: Scanner Wire/Scanner Motor Replacement
SCANNER UNIT 24 February, 1999 6.3.4 SCANNER WIRE/SCANNER MOTOR REPLACEMENT A259R011.WMF A259R008.WMF A259R009.WMF 1. Remove the exposure glass and the exterior covers. 2. Remove the upper right stay [A] (4 screws) and the upper left stay [B] (4 screws). 3. To change the front scanner wire: Remove the wire cover [C] (2 screws). To change the rear scanner wire: Do the following.
Page 294 24 February, 1999 SCANNER UNIT A259R010.WMF 4. Remove the scanner motor [A] (1 connectors, 1 ground wire, 4 screws, 1 tension spring [B], 1 timing belt [C]. NOTE: When reinstalling the scanner motor, pull the timing belt taut with the tension spring.
Page 295 SCANNER UNIT 24 February, 1999 A259R013.WMF A259R012.WMF 5. Loosen the wire clamp screw [A] and remove the scanner wire. Then loosen the clamp screw on the side where the wire will not be replaced. 6. Route the new scanner wire as shown. Take care to thread the wire on the pulley the correct way round.
Page 296 24 February, 1999 SCANNER UNIT A259R013.WMF 7. Hook the spring [A] onto the wire tension bracket [B], then loosen and retighten the screw permanently. 8. Secure the wire with the scanner wire clamp [C]. 9. Remove the scanner locking pins [D]. 10.
Page 297: Aps Sensors
SCANNER UNIT 24 February, 1999 6.3.5 APS SENSORS A259R002.WMF 1. Remove the exposure glass. 2. Replace the APS sensors [A] (1 screw and 1 connector). 3. Remove the upper right cover [B] (1 screw) and the scanner inner cover [C] (9 screws).
Page 298: Scanner Hp Sensor
24 February, 1999 SCANNER UNIT 6.3.6 SCANNER HP SENSOR A259R015.WMF 1. Remove the exposure glass (see section 6.1.). 2. Remove the upper left cover (see section 6.1.). 3. Remove the scanner HP sensor [E] (1 screw, 1 connector). 6-27...
Page 299: Copy Image Adjustment
COPY IMAGE ADJUSTMENT 24 February, 1999 6.4 COPY IMAGE ADJUSTMENT 6.4.1 PRINTER GAMMA ADJUSTMENT Setting the KCMY standard values Use the auto color calibration function (see the Operating Instructions). Gamma Data Print Out Use SP 7-904 to print the current printer gamma settings for copier and printer mode.
Page 300: Adjustment Procedure
24 February, 1999 COPY IMAGE ADJUSTMENT Copy mode Low ID 4-910-001 4-911-001 4-912-001 4-913-001 Middle ID 4-910-002 4-911-002 4-912-002 4-913-002 Text mode High ID 4-910-003 4-911-003 4-912-003 4-913-003 IDmax 4-910-004 4-911-004 4-912-004 4-913-004 Low ID 4-915-001 4-916-001 4-917-001 4-918-001 Photo Middle ID 4-915-002 4-916-002...
Page 301: Standard Copy Quality
COPY IMAGE ADJUSTMENT 24 February, 1999 Standard Copy Quality IDmax: (K, C, M, and Y) Adjust the offset value so that the density of level 10 matches the C-4 chart. A259R561.WMF Middle ID: (K, C, M, and Y) Adjust the offset value so that the density of level 6 matches the C-4 chart.
Page 302: Acc Target Adjustment
24 February, 1999 COPY IMAGE ADJUSTMENT 6.4.2 ACC TARGET ADJUSTMENT The ACC targets can be adjusted with SP 4-501 and 4-502. This should be done after the SBU is replaced. The SP modes to adjust are as follows. Copier: 4-501 Printer: 4-502 4-501-001: Text K 4-502-001: Text/Photo K...
Page 303: Main Scan Dot Position Correction
COPY IMAGE ADJUSTMENT 24 February, 1999 6.4.3 MAIN SCAN DOT POSITION CORRECTION NOTE: Before adjusting the scanner, adjust the printer registration. 1. Enter the SP mode and open SP4-010 and SP4-011. 2. Check that each value corresponds to the factory-set value. 3.
Page 304 24 February, 1999 COPY IMAGE ADJUSTMENT 6. Referring to the diagram lower down the page, change the values in accordance with the following rules: Case 1. When the yellow line is to the left of the black line, and the cyan line is to the right of the black line.
Page 305: Laser Optics Section
LASER OPTICS SECTION 24 February, 1999 6.5 LASER OPTICS SECTION ø WARNING Turn off the power and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. CAUTION DECAL LOCATIONS Two caution decals are located in the laser section as shown below. LASER-3.WMF A259R503.WMF ø...
Page 306: Polygon Mirror Motor Replacement
24 February, 1999 LASER OPTICS SECTION 6.5.1 POLYGON MIRROR MOTOR REPLACEMENT A259R107.WMF A259R102.WMF 1. Remove the following covers (see "Covers, Fans, and Filters"). • Right cover (1 screw) • Operation panel (A259/A260: 2 screws, 3 connectors, and 2 grounding wires A258: 2 screws, 1 connector, and 1 grounding wire [Europe only]) •...
Page 307 LASER OPTICS SECTION 24 February, 1999 A259R103.WMF A259R104.WMF 9. Disconnect 3 connectors [A]. 10. Remove the optical housing unit [B] (4 screws). 11. Remove the optical housing cover [C] (10 hooks). 12. Remove the polygon mirror motor [D] (4 screws and 1 connector). ø...
Page 308: Laser Synchronizing Detector Board And Ld Unit Replacement
24 February, 1999 LASER OPTICS SECTION 6.5.2 LASER SYNCHRONIZING DETECTOR BOARD AND LD UNIT REPLACEMENT A259R105.WMF 1. Remove the optical housing unit (see "Polygon Mirror Motor Replacement"). 2. Replace the laser synchronizing detector boards [A] (2 screws and 1 connector each).
Page 309: Squareness Adjustment
LASER OPTICS SECTION 24 February, 1999 6.5.3 SQUARENESS ADJUSTMENT A259R111.WMF This procedure finely adjusts the image obliqueness caused by the laser unit. NOTE: This procedure is used to finely adjust the inclination of horizontal lines in the image (across the page) by turning the laser unit, which tilts the scanning line of the laser beam.
Page 310 24 February, 1999 LASER OPTICS SECTION Direction of paper feed A259R567.WMF Turning in the direction of arrow A: This tilts horizontal lines in the image clockwise. Turning in the direction of arrow B: This tilts horizontal lines in the image counterclockwise.
Page 311: Development Unit
DEVELOPMENT UNIT 24 February, 1999 6.6 DEVELOPMENT UNIT 6.6.1 REPLACING THE DEVELOPER Developer Collection Procedure A259R204.WMF A259R215.WMF NOTE: Place a protective sheet on the floor. Take care not to spill developer on the customer's floor. 1. Remove the left and right inner covers, transfer belt stay, and charge corona unit, then pull out the drawer unit (2 screws).
Page 312 24 February, 1999 DEVELOPMENT UNIT A259R301.WMF A259R302.WMF 3. Remove the left revolver stopper [A] from its storage location on the drawer unit (1 screw) and fit it into the slot [B] at the rear of the revolver side panel and in the notch [C] on the drawer unit stay.
Page 313 DEVELOPMENT UNIT 24 February, 1999 A259R303.WMF A259R307.WMF 5. Remove the developer cover [A] (2 screws). 6. Hold the development unit upside down in the developer collection bag, then rotate the sleeve in the forward direction [B] to collect the developer. NOTE: When rotating the sleeve in the forward direction, keep the sleeve side facing up so that the developer will not be scooped up onto the sleeve.
Page 314: Installing New Developer
24 February, 1999 DEVELOPMENT UNIT Installing New Developer A259R306.WMF A259R309.WMF 1. Place the development unit [A] in the developer installation position [B] and pour in 1 bag (380 g) of developer [C]. NOTE: 1) When installing new developer, place the development unit on a flat space.
Page 315 DEVELOPMENT UNIT 24 February, 1999 A259R302.WMF 3. Replace the developer cover (2 screws) and put the development unit [A] in the drawer unit (2 lock screws [B]). ø CAUTION 1. When replacing the developer cover and development unit, do not apply excessive force to the center of the development unit.
Page 316 24 February, 1999 DEVELOPMENT UNIT A259R301.WMF 4. Remove the revolver stopper [A], rotate the revolver to the next color, then follow the developer installation procedure from step 1. NOTE: The revolver unit rotates counterclockwise. Do NOT try to turn it in the other direction.
Page 317: Post Developer Collection Procedure
DEVELOPMENT UNIT 24 February, 1999 6.6.2 POST DEVELOPER COLLECTION PROCEDURE Follow the procedure in the flow chart shown below during the post developer collection procedure. Also use this flowchart after replacing the drum. Start Open front cover and turn on power Close front cover Replace only developers?
Page 318: Development Unit Replacement
24 February, 1999 DEVELOPMENT UNIT 6.6.3 DEVELOPMENT UNIT REPLACEMENT A259R308.WMF The development unit [A] service part is the same for each of the KYCM colors. Each unit has four pins. When replacing a development unit, cut off one of the pins [B]. For example, when installing a new development unit for black, cut off the pin marked Bk.
Page 319: Toner Collection Tray Cleaning
DEVELOPMENT UNIT 24 February, 1999 6.6.4 TONER COLLECTION TRAY CLEANING A259R204.WMF A259R215.WMF A259R305.WMF NOTE: Place a protective sheet on the floor. Take care not to spill developer on the customer's floor. 1. Remove the left and right inner covers, transfer belt stay, and charge corona unit, then pull out the drawer unit [A] (2 screws).
Page 320: Transfer Belt Unit
24 February, 1999 TRANSFER BELT UNIT 6.7 TRANSFER BELT UNIT 6.7.1 TRANSFER BELT SECTION Transfer Belt and Cleaning Unit A259R401.WMF A259R405.WMF NOTE: Take care not to get the customer site dirty. Put down a floor mat before removing the cleaning unit. 1.
Page 321 TRANSFER BELT UNIT 24 February, 1999 A259R406.WMF A259R407.WMF 6. Remove the cleaning unit retainers [A] from the cleaning unit (2 snap rings) and remove the cleaning unit [B]. 7. Lift up the belt unit and detach the upper part of the transfer belt bracket (2 screws).
Page 322 24 February, 1999 TRANSFER BELT UNIT A259R416.WMF A259R417.WMF A259R405.WMF 10. Replace the transfer belt and reset the transfer belt bracket. NOTE: When installing a new transfer belt, make sure that the belt rims at both ends are past the ends of the roller. 11.
Page 323: Cleaning Blade Replacement
TRANSFER BELT UNIT 24 February, 1999 Cleaning Blade Replacement NOTE: Take care not to get the customer site dirty. Put down a floor mat before removing the cleaning unit. A259R416.WMF A259R412.WMF A259R417.WMF 1. Turn the lubricant bracket [A] as shown (unhook 2 springs [B] at both ends). 2.
Page 324: Lubricant Bar And Lubricant Brush Replacement
24 February, 1999 TRANSFER BELT UNIT Lubricant Bar and Lubricant Brush Replacement A259R413.WMF A259R414.WMF 1. Remove the lubricant bracket [A] (2 screws and 2 springs [B]). 2. Remove the lubricant bar [C]. 3. Remove the lubricant brush [D] (2 snap-rings [E], 2 bearings, and 1 gear). NOTE: When reinstalling the lubricant bar, make sure that the springs [F] are set properly.
Page 325: Paper Transfer Unit
TRANSFER BELT UNIT 24 February, 1999 6.7.2 PAPER TRANSFER UNIT Lubricant Bar And Blade Replacement A259R403.WMF 1. Remove the paper transfer guide plate (2 screws). 2. Remove the lubricant bar [A]. 3. Remove the blade [B] (3 screws). Paper Separation Corona Wire Replacement A259R404.WMF 1.
Page 326: Transfer Roller Replacement
24 February, 1999 TRANSFER BELT UNIT Transfer Roller Replacement A259R402.WMF 1. Remove the paper transfer guide plate [A] (2 screws). 2. Remove the drive gear [B]. 3. Remove the front and rear bearings [C] (1 E-ring). 6-55...
Page 327: Paper Feed And Registration Section
PAPER FEED AND REGISTRATION SECTION 24 February, 1999 6.8 PAPER FEED AND REGISTRATION SECTION 6.8.1 BY-PASS FEED TABLE REMOVAL A259R701.WMF 1. Remove the right cover (see "Covers, Fans, and Filters"). 2. Disconnect the connector [A]. 3. Remove the front snap ring [B]. 4.
Page 328: By-Pass Feed, Pick-Up And Separation Rollers, And Torque Limiter Replacement
24 February, 1999 PAPER FEED AND REGISTRATION SECTION 6.8.3 BY-PASS FEED, PICK-UP AND SEPARATION ROLLERS, AND TORQUE LIMITER REPLACEMENT A259R708.WMF 1. Remove the by-pass feed table. 2. Open the vertical transport door [A]. 3. Remove the snap rings and replace the rollers. NOTE: Clean the pick-up [B], feed [C], and separation rollers [D] with a moistened cloth.
Page 329: By-Pass Feed Unit Replacement
PAPER FEED AND REGISTRATION SECTION 24 February, 1999 6.8.4 BY-PASS FEED UNIT REPLACEMENT A259R703.WMF 1. Remove the following covers (see "Covers, Fans, and Filters"): • Right front cover • Right cover • Right rear cover 2. Open the vertical transport door [A]. 3.
Page 330: Vertical Transport Door Replacement
24 February, 1999 PAPER FEED AND REGISTRATION SECTION 6.8.6 VERTICAL TRANSPORT DOOR REPLACEMENT A259R706.WMF 1. Open the vertical transport door [A]. 2. Remove the bracket [B] (1 screw). 3. Push in hinge [C], and remove the vertical transport door. 6.8.7 PAPER TRAY PICK-UP, PAPER FEED, AND SEPARATION ROLLER REPLACEMENT A259R709.WMF 1.
Page 331: Paper Feed Unit And Clutch Replacement
PAPER FEED AND REGISTRATION SECTION 24 February, 1999 6.8.8 PAPER FEED UNIT AND CLUTCH REPLACEMENT A259R712.WMF A259R707.WMF 1. Remove the following covers (see "Covers, Fans, and Filters"): 1) Used toner cover 2) Rear cover 3) Right rear cover 2. Remove the vertical transport door. 3.
Page 332: Copy Image Area Adjustment
24 February, 1999 PAPER FEED AND REGISTRATION SECTION 6.8.9 COPY IMAGE AREA ADJUSTMENT Adjust the leading edge registration for each paper type and line speed (normal paper, OHP, thick paper, 2/3 speeds) to determine the leading edge margin. Also adjust the side to side registration for each paper feed station, to determine the left and right edge margins.
Page 333: Leading Edge Registration
PAPER FEED AND REGISTRATION SECTION 24 February, 1999 Leading Edge Registration Standard value: 5 ± 2 mm 1. Enter SP mode 1-1 (leading edge registration adjustment). 2. Select the level 3 SP mode for the condition you wish to adjust. •...
Page 334: Side-To-Side Registration
24 February, 1999 PAPER FEED AND REGISTRATION SECTION Side-to-side Registration Standard value: 2 ± 2 mm 1. Enter SP mode 1-2 (side-to-side registration adjustment). 2. Select the paper feed unit to test. • Manual feed (by-pass feed table) • Tray 1 (Copier paper feed tray): A258 only •...
Page 335: Paper Transport, Fusing, And Paper Exit Sections
PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 24 February, 1999 6.9 PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 6.9.1 FUSING UNIT REMOVAL A259R514.WMF ø CAUTION 1. Be careful when handling the fusing unit. It is very hot. 2. Take care not to spill silicone oil on the floor. If silicone oil spills on the floor, immediately clean it up with a suitable solvent.
Page 336: Transport Unit Removal
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 6.9.2 TRANSPORT UNIT REMOVAL A259R516.WMF A259R517.WMF 1. Remove the fusing unit. 2. Remove the transport unit lever [A] (1 screw). 3. Remove the inner cover [B] (1 screw). 4. Remove the mounting bracket [C] (1 screw). 5.
Page 337: Fusing Unit Top Cover Removal
PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 24 February, 1999 6.9.3 FUSING UNIT TOP COVER REMOVAL A259R606.WMF 1. Remove the fusing unit knob [A] (1 screw). 2. Remove the fusing unit top cover [B] (2 screws). 6-66...
Page 338: Oil Supply Pad And Oil Blade Replacement
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 6.9.4 OIL SUPPLY PAD AND OIL BLADE REPLACEMENT A259R502.WMF A259R607.WMF A259R569.WMF A259R519.WMF 1. Remove the fusing unit top cover. 2. Remove the oil supply pad [A] (5 screws). 3. Remove the oil supply unit mounting screws (2 screws) and release the oil supply unit [B] from the top of the fusing unit.
Page 339: Hot Roller Thermofuse Replacement
PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 24 February, 1999 6.9.5 HOT ROLLER THERMOFUSE REPLACEMENT A259R601.WMF 1. Remove the top cover. 2. Remove the hot roller thermofuse [A] (1 screw and 2 connectors). 6.9.6 FUSING UNIT DISASSEMBLY A259R602.WMF 1. Remove the top cover. 2.
Page 340: Cleaning Roller Scraper Cleaning
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 6.9.7 CLEANING ROLLER SCRAPER CLEANING A259R518.WMF 1. Remove the top cover. 2. Remove the lock lever [A] (1 step screw). 3. Remove the cleaning roller scraper [B] (2 screws). 4. Clean the cleaning roller scraper with a dry cloth. 6-69...
Page 341: Hot Roller Thermistor Replacement
PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 24 February, 1999 6.9.8 HOT ROLLER THERMISTOR REPLACEMENT A259R603.WMF 1. Disassemble the fusing unit (see Fusing Unit Disassembly). 2. Remove the oil sump [A] (1 screw). 3. Replace the hot roller thermistor [B] (1 screw and 1 connector). 6-70...
Page 342: Hot Roller Fusing Lamp Replacement
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 6.9.9 HOT ROLLER FUSING LAMP REPLACEMENT A259R507.WMF 1. Disassemble the fusing unit (see Fusing Unit Disassembly). 2. Remove the front and rear lamp holders [A] (1 screw each). 3. Replace the fusing lamp (2 connectors). NOTE: The hot roller fusing lamp is an 800 W lamp.
Page 343: Hot Roller And Cleaning Roller Replacement And Cleaning
PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 24 February, 1999 6.9.10 HOT ROLLER AND CLEANING ROLLER REPLACEMENT AND CLEANING A259R605.WMF 1. Disassemble the fusing unit (see Fusing Unit Disassembly). 2. Remove the hot roller fusing lamp. 3. Remove the front [A] and rear [B] roller stoppers (1 screw each). 4.
Page 344: Pressure Roller And Pressure Roller Fusing Lamp
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 6.9.11 PRESSURE ROLLER AND PRESSURE ROLLER FUSING LAMP A259R553.WMF A259R510.WMF 1. Disassemble the fusing unit into two parts (See Fusing Unit Disassembly, Section 6.9.6). 2. Remove the oil tank [A]. 3.
Page 345: Pressure Roller Thermofuse And Thermistor Replacement
PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 24 February, 1999 6.9.12 PRESSURE ROLLER THERMOFUSE AND THERMISTOR REPLACEMENT A259R511.WMF A259R512.WMF A259R513.WMF 1. Remove the paper exit door [A] (1 snap ring). 2. Replace the pressure roller thermofuse [B] (1 screw and 2 connectors). 3.
Page 346: Nip Band Width Adjustment
24 February, 1999 PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 6.9.13 NIP BAND WIDTH ADJUSTMENT A259R515.WMF NOTE: 1) Check and adjust the nip band width AFTER the copier has warmed up. 2) Place an OHP sheet on the by-pass feed table before starting this procedure.
Page 347: Cautions To Be Taken When Using A Fusing Unit That Has Been In Stock For A Long Period
PAPER TRANSPORT, FUSING, AND PAPER EXIT SECTIONS 24 February, 1999 6.9.14 CAUTIONS TO BE TAKEN WHEN USING A FUSING UNIT THAT HAS BEEN IN STOCK FOR A LONG PERIOD NOTE: When using a fusing unit that has been in stock for an extended period, press the pump with your fingers to check whether an adequate amount of oil is pumped up.
Page 348: Duplex Unit
24 February, 1999 DUPLEX UNIT 6.10 DUPLEX UNIT 6.10.1 DUPLEX UNIT REMOVAL A259R570.WMF 1. Open the duplex unit [A]. 2. Remove the duplex unit (4 screws). 6.10.2 SEPARATION ROLLER REPLACEMENT A259R571.WMF 1. Remove the duplex unit (see procedure 10.1). 2. Remove the separation roller assembly [A] (2 screws). 3.
Page 349: Feed Roller Replacement
DUPLEX UNIT 24 February, 1999 6.10.3 FEED ROLLER REPLACEMENT A259R572.WMF A259R573.WMF 1. Open the duplex unit. 2. Remove the guide rail [A] (1 screw and 1 snap-ring). 3. Remove the upper guide plate [B] and lower guide plate [C] (1 snap-ring). 4.
Page 350: Duplex Feed Motor Replacement
24 February, 1999 DUPLEX UNIT 6.10.4 DUPLEX FEED MOTOR REPLACEMENT A259R574.WMF 1. Perform steps 1 through 4 of Feed Roller Replacement. 2. Remove the bracket [A] (1 screw). 3. Remove the feed roller shaft assembly [B] (2 snap-rings). 4. Remove the pulley [C] and the timing belt [D]. 5.
Page 351 DUPLEX UNIT 24 February, 1999 A259R575.WMF A259R577.WMF 6. Disconnect the connector [A] of the duplex feed motor [B]. 7. Close the side fences [C] and remove the duplex feed assembly [D] (5 screws). 8. Remove the duplex feed motor assembly (3 screws). 9.
Page 352: System And Electronics
24 February, 1999 SYSTEM AND ELECTRONICS 6.11 SYSTEM AND ELECTRONICS Flash ROM card handling precautions: • Never insert or remove a Flash ROM card with the main power switch on. • Do not turn the main power switch off during the software installation process. •...
Page 353: Main Program Downloading
SYSTEM AND ELECTRONICS 24 February, 1999 6.11.2 MAIN PROGRAM DOWNLOADING A259R523.WMF 1. Turn off the main power switch on the copier. 2. Open the front cover and remove the transfer inner cover (see "Covers, Fans, and Filters"). 3. Insert the Flash ROM card [A] that contains the new main program. NOTE: Insert the Flash ROM card with side “B”...
Page 354: Nv-Ram Uploading And Downloading
24 February, 1999 SYSTEM AND ELECTRONICS 6.11.3 NV-RAM UPLOADING AND DOWNLOADING With SP mode, copier settings can be uploaded to a Flash ROM card from the NV- RAM inside the machine, or downloaded from a Flash ROM card to the NV-RAM. The Flash ROM card must contain the main program.
Page 355: Ram Clear
SYSTEM AND ELECTRONICS 24 February, 1999 6.11.4 RAM CLEAR RAM Clear Procedure NOTE: Clearing the RAM resets all SP and UP values to the defaults, except the serial number and main counter value. Therefore, it is important to clear the RAM using the procedure shown below. 1.
Page 356: Precautions When Replacing The Nv-Ram
24 February, 1999 SYSTEM AND ELECTRONICS Precautions when replacing the NV-RAM A259I110.WMF A259R112.WMF The NV-RAM stores the counter value and the copier settings. The procedure for replacing the NV-RAM on the main control board is given below. Make sure you have the factory settings that come with the copier before beginning the following procedure: 1.
Page 357: Touch Panel Calibration (A259/A260 Only)
SYSTEM AND ELECTRONICS 24 February, 1999 6.11.5 TOUCH PANEL CALIBRATION (A259/A260 ONLY) A259R600.WMF It is necessary to calibrate the touch panel in the following cases: • After the operation panel is replaced. • The touch panel coordinates are illegible or misaligned. •...
Page 358: Troubleshooting
24 February, 1999 SERVICE CALL (SC) ERRORS 7. TROUBLESHOOTING 7.1 SERVICE CALL (SC) ERRORS 7.1.1 SC TYPES AND RESETTING PROCEDURES Type Display Method How to Reset Fusing unit SCs displayed on the operation Turn the main switch off then on before entering panel.
Page 359 SC TABLE 24 February, 1999 7.2 SC TABLE See APPENDIX-3.
Page 360: Process Control Error Conditions
24 February, 1999 PROCESS CONTROL ERROR CONDITIONS 7.3 PROCESS CONTROL ERROR CONDITIONS 7.3.1 PROCESS CONTROL SELF-CHECK RESULTS (SP3-975-00) Self-check results 03-975-00 Displayed Related Item Major Cause Remarks Value SP No. Successful None Forced termination (door None Power is turned off during self- opened, etc.) check.
Page 361: Developer Setup Results (Sp3-964-00)
PROCESS CONTROL ERROR CONDITIONS 24 February, 1999 7.3.2 DEVELOPER SETUP RESULTS (SP3-964-00) Displayed Related Item Major Cause Remarks Value SP No. Successful Unable to perform Development unit error, mixed calculation, invalid γ colors (gamma) or Vk value Vd adjustment error Drum deterioration, optical fatigue Vpl adjustment error...
Page 362: Self-Check Process Control Related Scs
24 February, 1999 PROCESS CONTROL ERROR CONDITIONS 7.3.3 SELF-CHECK PROCESS CONTROL RELATED SC (1) SC385: Vsg adjustment error The LCD displays SC385 when the output from the ID sensor is outside 1.8 ± 0.05V during Vsg adjustment. Turning the power off then on resets this condition. However, SC385 is lit again after the end of each copy job even when this SC condition is reset by turning the power off then on.
Page 363: Drum Light Fatigue
DRUM LIGHT FATIGUE 24 February, 1999 7.4 DRUM LIGHT FATIGUE Leaving the drum exposed to direct sunlight will cause it damage. This damage creates light fatigue on the drum, an effect that will be visible on the print out. When the drawer unit is slid out, even if the drum remains in the drawer unit, it will be exposed to direct and reflected light.
Page 364 APPENDIX-1 TIMING CHARTS...
Page 365: A4 Size B/W Mode
24 February, 1999 A4 SIZE B/W MODE A4 SIZE B/W MODE TIMMING-A4BW.WMF...
Page 366: A4 Size Full Color Mode
A4 SIZE FULL COLOR MODE 24 February, 1999 A4 SIZE FULL COLOR MODE TIMMING-A4FC.WMF...
Page 367: A3 Size B/W Mode
24 February, 1999 A3 SIZE B/W MODE A3 SIZE B/W MODE TIMMING-A3BW.WMF...
Page 368: A3 Size Full Color Mode
A3 SIZE FULL COLOR MODE 24 February, 1999 A3 SIZE FULL COLOR MODE TIMMING-A3FC.WMF...
Page 369: Sp Mode Table
APPENDIX-2 SP MODE TABLE...
Page 370 24 February, 1999 SP TABLE SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 1. Paper feed/transport/fusing units [Feed] 01-001: Leading edge registration adjustment [Lead Edge Regist] 01-001-01 [Normal Paper] 0 mm -5.0 to 5.0 mm Adjusts the registration at the leading edge position by changing the registration clutch operation timing 01-001-02...
Page 371 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 1-101: Oil End Sensor [Oil End Sensor] 1-101-000 [Fuser Oil End Check] 0 = Not used Specifies whether the oil end sensor is used. 1 = Used 01-104: 01-104-00...
Page 372 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 01-105-02 Hot roller, 1st side, Standby mode 165 °C 100 to 200 °C Sets the target operating temperatures of the hot and [Hot Rllr/ Standby] pressure rollers in various modes.
Page 373 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 01-105-14 Hot roller, 2nd side, Copy mode, 160 °C 100 to 200 °C Sets the number of forced toner supply operations. Normal paper, 1C [Hot Rllr/ Nrml: SC: Dplx] 01-105-15 Hot roller, 2nd side, Copy mode,...
Page 374 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 01-106: Fusing temperature display [Roller Tmp. Display] 01-106-01 Lower roller °C to °C Displays the surface temperature at the center of the [Pressure Roller Temp] pressure roller (lower roller) in °C.
Page 375 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 01-801-04 Fusing motor speed adjustment: Half 0.0% -0.1 to 1.0% Do not adjust the factory settings. speed [Fusing Mt: Half Spd] 01-801-05 Paper feed motor speed adjustment: 0.1% -0.1 to 1.0% Half speed...
Page 376 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 2. Drum unit [Drum] 02-101: Feed and scanning margin adjustments [Blnk Mrgn] 02-101-01 Feed margin adjustment: Leading 0 mm -4.0 to 4.0 mm Adjusts the margins in the feed (sub-scan) direction.
Page 377 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-112: Main-scan magnification adjustment (adjusts the laser diode clock frequency) [Main Scn Mag] 02-112-01 Copy mode (400 DPI) -1.00 to 1.00% 0.01 Adjusts the magnification in the main-scan direction [Lsync Mag Adj COPY] for copier mode.
Page 378 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-207: Forced toner supply [Forced Toner Splly] 02-207-01 0: OFF, 1: ON Moves the toner cartridge of the selected color to the development position and forces toner to be supplied 02-207-02 0: OFF, 1: ON in accordance with the settings of SP2-208.
Page 379 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 2-212: Toner near-end threshold [Toner Near End Thd] 2-212-001 Black toner 0.05mg/cm 0.000 to 1.00 0.001 Do not change the factory settings unless directed by [bBkMATnNEnd] technical support staff..
Page 380 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 2-301: Belt transfer bias [Belt transfer bias] 2-301-01 1st colour, 4C mode [1st 4C-mode] 1700 300 to 3000 Half speed: OHP/thick paper modes 2/3 speed: Printer mode 2-301-02 2nd colour, 4C mode [2nd 4C-mode]...
Page 381 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-310: Paper transfer bias setup [Belt transfer bias] 02-310-01 Paper transfer forced environment 0 to 3 Specifies whether the transfer bias is to be switched switchover according to the detected value from the humidity [Paper transfer bias]...
Page 382 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-310-12 Image area: OHP:3C 10 µA 1 to 50 µA Adjusts the paper transfer belt bias for various paper [OHP 3C] types and modes. 02-310-13 Image area: OHP:4C 10 µA...
Page 383 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-310-25 Image area: Thick paper: back side: 7 µA 1 to 50 µA Adjusts the paper transfer belt bias for various paper types and modes. [THICK Back 4C] 02-310-26 Image area: 2/3 speed: back side: 1C...
Page 384 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-313-08 Thick paper: Less than A4 Lengthwise 100% 10 to 400% Paper transfer bias correction factors for various [THICK under A5 Lengthwise] paper types and sizes. Adjust only if there are problems with insufficient 02-313-09 OHP:LT Sideways or larger...
Page 385 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-314-11 OHP: 3C 0 µA -20 to 40 µA For the paper leading edge, this correction value is [OHP: 3C] added to the paper transfer image area setting. Adjust only if there are problems with insufficient 02-314-12 OHP: 4C...
Page 386 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-314-27 2/3 speed: back side: 3C 0 µA -20 to 40 µA For the paper leading edge, this correction value is [NRML_2/3 Back 3C] added to the paper transfer image area setting.
Page 387 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-315-12 OHP: 4C 0 µA -20 to 40 µA For the paper trailing edge, this correction value is [OHP 4C] added to the paper transfer image area setting. Adjust only if there are problems with insufficient 02-315-13 2/3 speed: 1C...
Page 388 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-315-28 2/3 speed: back side: 4C 0 µA -20 to 40 µA For the paper trailing edge, this correction value is [NRML_2/3 Back 4C] added to the paper transfer image area setting.
Page 389 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-316-28 [High-Hum NRML_2/3 4C] 10 to 400 Corrects the paper transfer belt bias for the type of paper and copy mode depending on the humidity. 02-316-29 [High-Hum NRML Back 1C] 10 to 400...
Page 390 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 02-955: Method of detecting the transition from toner near-end to toner end [Toner End Detection Count] 02-955-00 0: Pixel count and number of pages 0 or 1 Selects the method for determining the number of 1: Number of pages only...
Page 391 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 3. Process control system [Process] 03-103: [Vsp Display] 03-103-01 to V 0.01 Displays V for the ID sensor pattern just developed 03-103-02 to V 0.01 03-103-03 to V...
Page 392 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 03-125: Process control method [Potential Control] 03-125-00 Process control method 0 to 2 Specifies whether process control is to be executed. [0:Auto. 1:FIX, 2:Auto+2/3 Spd] 0: Automatic - process control enabled (keep the machine at this setting in normal cases) 1: Fixed...
Page 393 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 03-902: Current pointer table row number [Pointer Table No] 03-902-01 mg/cm to mg/cm 0.001 Displays the pointer table row number (to determine , and V ) selected during the latest process 03-902-02 mg/cm...
Page 394 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 03-974: Maximum target toner amount [Potential Control Target] 03-974-01 [Max M/A: K] 0.7mg/cm 0.5 to 0.001 Sets the target toner M/A maximum to be used during 1.5mg/cm process control when calculating the development potential (corresponding to the amount of toner in a...
Page 395 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 4. Scanner 04-008: Sub-scan Magnification [Subscan Magnification] 04-008-00 Scanner sub-scan magnification -1.0 to 1.0% Adjusts the magnification of the scanned image in the adjustment feed direction.
Page 396 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-303: APS minimum size setting [APS Minimum size setting] 04-303-00 [0: Out of detection, 1: A5 L] 0 to 1 Specifies whether the original width is to be recognized as A5/HLT portrait when the original width sensor outputs are all set to OFF (A5R or smaller, or no original) in platen mode.
Page 397 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-427: RGB reference setup [RGB REF] 04-427-01 R: 0 [R_REF0] Sets or displays the reference voltage for the A/D converters on the scanner IPU for each RGB color. 04-427-02 G: 0 [G_REF0] Do not adjust the factory settings.
Page 398 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-502: ACC target [ACC Target Adjustment: Printer] 04-502-01 Printer mode, text/photo, K 0 to 50 Adjusts the ACC targets for text and photo mode in [Printer: Text: K] printer mode 04-502-02...
Page 399 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-505: ACC machine difference correction value, light areas [ACC Device Correction: HL] 04-505-01 -128 to 127 Adjusts the machine difference correction value for low ID areas during ACC.
Page 400 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-521-05 [Low ID (Option)] 0 to 30 Printer 2 is not used in this machine. Do not adjust these SP modes. 04-521-06 [Middle ID (Option)] 0 to 30 04-521-07 [High ID (Option)]...
Page 401 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-904 Scanner IPU board tests Selects the CCD output and internal test pattern [IPU Board Test] outputs. 04-904-01 Scanner IPU board test 1 0 to 0x17 Tests the scanner IPU board.
Page 402 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-911: Manual gamma adjustment: Copy: Letter C [Manual gamma Adj: Copier: C] 04-911-01 Offset (low ID) 0 to 30 Use these SPs to adjust the colour balance if the [Low ID (Offset): Text] results of ACC are not satisfactory.
Page 403 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-912-08 Option (ID max) 0 to 30 Use these SPs to adjust the colour balance if the [ID max (Option) Text] results of ACC are not satisfactory. This is for magenta toner in letter mode, using copy mode.
Page 404 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-914: Manual gamma adjustment: Copy: Letter, single color K [Manual gamma Adj: Copier: SC K] 04-914-01 Offset (low ID) 0 to 30 Use these SPs to adjust the colour balance if the [Low ID (Offset): Text] results of ACC are not satisfactory.
Page 405 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-915-08 Option (ID max) 0 to 30 Use these SPs to adjust the colour balance if the [ID max (Option) Photo] results of ACC are not satisfactory. This is for black toner (full colour mode) in photo mode, using copy mode.
Page 406 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-917: Manual gamma adjustment: Copy: Photo M [Manual gamma Adj: Copier: M] 04-917-01 Offset (low ID) 0 to 30 Use these SPs to adjust the colour balance if the [Low ID (Offset): Photo] results of ACC are not satisfactory.
Page 407 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-918-08 Option (ID max) 0 to 30 Use these SPs to adjust the colour balance if the [ID max (Option) Photo] results of ACC are not satisfactory. This is for yellow toner in photo mode, using copy mode.
Page 408 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-920: Manual gamma adjustment: Printer: C [Manual gamma Adj: Printer: C] 04-920-01 Offset (low ID) 0 to 30 Use these SPs to adjust the colour balance if the [Low ID (Offset)] results of ACC are not satisfactory.
Page 409 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-921-08 Option (ID max) 0 to 30 Use these SPs to adjust the colour balance if the [ID max (Option)] results of ACC are not satisfactory. This is for magenta toner using printer mode (for both text and photo data).
Page 410 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 04-932: Main scan dot position correction [Picture Element Correction] 04-932-01 [Red: Left] 0 to 9 Adjusts the left and right ends of the red and blue scan lines to align them with the green scan line.
Page 411 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 05. Operation mode/system [Mode] 05-001-00 Operation panel all on 0 to 1 Turns on all the indicators to test the operation panel [0: OFF, 1: ON] display functions.
Page 412 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 05-120: Clear mode when key counter removed [Clear Md On/Off: Key Counter] 05-120-00 [Clear Md On/Off: Key Counter] 0 to 1 Specifies whether the current mode is cleared or not when the key counter is removed.
Page 413 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 05-128: User Code + Coin Lock [User Code + Coiun Lock] 05-128-00 [User Code + Conie Lock] 0 to 1 Selects whether both User Code and Coin Lock can be used.
Page 414 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 05-507: SC Supply alarm setup: Copy count by size [Alarm Level] 05-507-01 [Toner End] 0 to 1 Specifies whether supply alarm calls are to be made. This mode specifies whether supply calls are to be 05-507-02 Count of Copy...
Page 415 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 5-611: Toner Ratios in 2C mode [Toner Amount Ration in 2C] 5-611-01 [Cyan in Blue] Determines the amounts of toner used to produce R, G, and B in 2C mode 5-611-02 [Magenta in Blue]...
Page 416 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 05-810: [SC Reset] 05-810-00 [SC Reset] 0 to 1 Resets a type A service call condition, which is caused by the fusing section. 1 = Reset After resetting the SC code, the main switch has to be turned off and on.
Page 417 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 05-827: Main program download [Program Down Load] 05-827-00 [Program Down Load] 0 to 1 Downloads the main program from an IC card. See ‘Replacement &...
Page 418 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 05-955-14 16 grayscales-13: LD_PWM setup 0 to 255 See ’Service Tables – SP Mode Additional Notes’ . [LD PWM value: 13/16 Gradation] 05-955-15 16 grayscales-14: LD_PWM setup 0 to 255 [LD PWM value: 14/16 Gradation]...
Page 419 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 6. Peripherals [Pheriphs] 06-006: ADF registration adjustment [ADF Regist] 06-006-01 Main scan 0 mm -3.0 to 3.0 mm Original scanning position adjustment when using the [Horizontal] ADF.
Page 420 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 7. Logging 07-008: Set Counter Display [Set Counter Display] 07-008-00 1 to 4 This controls the way that the counters are displayed on the LCD. 1: Full color counter and K counter (no.
Page 421 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 07-203-05 Rear cooling fan filter 0 to 9999999 Shows the number of uses of components related to [Rear Filter Counter] image production. 07-203-06 PCC wire 0 to 9999999 [Pcc Wire Counter]...
Page 422 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 07-210: Component usage counters (components related to fusing) [Roller Counter] 07-210-01 Hot roller (pages) Pages 0-9999999 Shows the number of uses of components related to [Hot Roller [Print]] pages fusing...
Page 423 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 07-402-07 [latest-6] 0 to 65535 Shows the 10 most recently detected SCs. 07-402-08 [latest-7] 0 to 65535 07-402-09 [latest-8] 0 to 65535 07-402-010 [latest-9] 0 to 65535 07-502 Total Number of Paper Jams [Total Paper Jam] 07-502-01...
Page 424 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 07-504-14 0 to 65535 Shows the number of paper jams at each location. [Sorter [Staple] 07-504-15 0 to 65535 [Proof Tray] 07-504-16 0 to 65535 07-505: Original Jam Counter [Original Jam Counter] [Feed] 07-505-01...
Page 425 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 07-804 [PM Counter Clear] 07-804-01 PM counter all clear: 1 PM 1: Clear Resets all counters for 1 PM components to zero. [1PM Parts All Clear] 07-804-02 PM counter all clear: 2 PM 1: Clear...
Page 426 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 07-818: Clear development counters [Dev.Counter Clear] 07-818-01 1: Clear Resets the development operation counters to zero. 07-818-02 1: Clear 07-818-03 1: Clear 07-818-04 1: Clear 07-819: Clear Paper Size Counters [Paper Size Counter Clear] 07-819-00...
Page 427 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 07-910: Transfer unit counter display [Transfer Belt Counter] 07-910-01 Paper separation corona wire (prints) 0 to 9999999 Shows the number of uses of a transfer related [Paper Separation Wire [Print]] component.
Page 428 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 8. Special operating modes [Special Mode] 08-111: Special mode 1: Leading edge registration adjustment [Sp.Mode1:LeadEdge Registration] 08-111-01 [Normal Paper] 0 mm -5.0 to 5.0 mm Adjusts the leading edge registration for the paper type selected when using special operating mode 1.
Page 429 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 08-130: Special mode 1: Paper transfer bias, image area [Sp.Mode1: Image] 08-130-02 [1C] 10 µA 1 to 50 µA See SP 2-310. 08-130-05 [4C] 18µA 1 to 50 µA...
Page 430 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 08-136-34 Low temperature, low humidity, 4C 100% 10 to 400% See SP 2-316. Back side [Low Tmp/Hum: 4C Back] 08-136-37 High temperature, high humidity, 1C 100% 10 to 400% Back side...
Page 431 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 08-215-07 Pressure roller, 1 sided: Standby mode 150 °C 100 to 200 °C See SP 1-105. [Pressure Rllr/ Standby] 08-215-08 Pressure roller, 1 sided: Copy mode 150 °C 100 to 200 °C [Pressure Rllr/ Nrml: FC]...
Page 432 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 08-236: Special mode 2: Paper transfer bias, environment correction coefficient [Sp.Mode2:Tmp/Hum Corection] 08-236-01 Low temperature, low humidity: 1C 100% 10 to 400% See SP 2-316. [Low Tmp/Hum: 1C] 08-236-02 Low temperature, low humidity: 4C...
Page 433 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 08-313: Special mode 3: Paper feed timing adjustment [Sp.Mode3:P.Feed Tmg] 08-313-01 By-pass 0 mm -5.0 to 5.0 mm See SP 1-003. [By-ps Feed: Normal] 08-313-02 Copier paper feed 0 mm...
Page 434 24 February, 1999 SP TABLE Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 08-334: Special mode 3: Paper transfer bias, leading edge area correction [SP.Mode3:Lead Edge Current] 08-334-01 [1C] µA -20 to 40 µA See SP 2-314. 08-334-04 [4C] µA...
Page 435 SP TABLE 24 February, 1999 Item Default SP7- SP No. Value Range Step Description [Display] Value 902/3 08-336-38 High temperature, high humidity: 4C 100% 10 to 400% See SP 2-316. Back side [High Tmp/Hum: 4C Back]...
Page 436 APPENDIX-3 SC CODE TABLE...
Page 437 24 February, 1999 SC CODES SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Blown lamp SC101 Exposure - Timing & Condition - 1. Visually check the lamp element or check the continuity • The lamp output check •...
Page 438 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Scanner motor out SC120 Scanner HP - Timing & Condition - SC121 1. In SP 5-804-104, stop supplying the current to the sensor does scanner motor. Check the output signal from the The scanner H.P.
Page 439 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type SC130 Scanner start - Timing - Same as SC120 Same as SC120 • Scanning start error • While the scanner motor is Sequence error Replace the sub and/or main scanner IPU board(s). running - Condition - The scanning start signal is...
Page 440 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC170 Video - Timing - 1. Check if the flat cable is firmly connected at CN421 and processing CN404 on the SBU and scanner IPU board. Just after the main switch is CCD flat cable •...
Page 441 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Non-standard bar SC191 Bar code scan - Timing - 1. Check if the bar code is damaged or scratched. error Just after the main switch is code label 2.
Page 442 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Incorrect serial SC195 Serial number - Timing - 1. Check and re-enter the serial number properly. error Just after the main switch is number NOTE: Contact your product specialist for the detailed •...
Page 443 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC320 Polygon motor - Condition - 1. Check that the connector (CN602-4) on the LD control • The PMLOCK signal is not error board is properly connected.
Page 444 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC323 LD error - Timing - 1. Check if the connectors (CN1 & CN605) on the LD drive board and LD main control board are properly During LD writing connector •...
Page 445 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Belt mark detection SC326 FGATE1 error - Timing & Condition - 1. Clean the belt mark located on the back side of the transfer belt or replace the belt if the belt mark is dirty or error The main control board does •...
Page 446 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type SC327 FGATE2 error - Timing & Condition - Same as SC326 Same as SC326. When two pages are to be written on the transfer belt at the same time, the main control board does not receive the 2nd FGATE signal from...
Page 447 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC361 Revolver HP - Timing & Condition - 1. Check if the sensor connector is properly connected. sensor error The home position is not connector 2.
Page 448 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type SC386 Amount of The amount of toner obtained Defective toner end This SC is only logged in the memory (not displayed), so toner on during YCM ID pattern sensor, dirt in toner no particular action is required (no adverse influence is sensor pattern...
Page 449 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC400 Image transfer 1. Check if the connectors of high voltage cables and - Timing - belt bias error trigger lines are properly connected on the high voltage connectors When the image transfer belt •...
Page 450 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC440 Drum motor - Timing & Condition - 1. Check if the drum is locked by the cleaning blade. If it • The feedback signal from error is, replace the cleaning blade.
Page 451 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Dirty or damaged SC452 Transfer belt - Timing & Condition- 1. Check if the transfer belt release lever is properly set. mark detection The main control board does belt mark 2.
Page 452 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC495 Temperature - Timing & Condition - 1. Check that the connectors (CN236, 214 & CN302) are sensor error properly connected on the I/O control board and main The temperature sensor connector •...
Page 453 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Defective upper SC501 1st paper tray - Timing & Condition - SC502 1. Check if the spring of pick-up solenoid comes off. • The upper limit sensor error limit sensor SC503...
Page 454 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Duplex unit not set SC522 Duplex - Side - Timing & Condition - SC524 1. Pull out and re-insert the duplex unit. • The home position is still fence jogger properly 2.
Page 455 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC542 Hot roller - Timing & Condition - 1. Check if the following connectors are properly warm-up error connected: The hot roller thermistor does connectors •...
Page 456 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Fusing unit not set SC543 Hot roller - Timing - 1. Check if the fusing unit is properly instaled. fusing lamp Every 1 second when the properly 2.
Page 457 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type SC545 Hot roller - Timing - Same as SC543 Same as SC543 ready Every 1 second after the temperature temperature reaches the abnormal ready condition - Condition - The hot roller thermistor output does not reach the ready temperature within 7...
Page 458 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Fusing unit not SC551 Pressure roller - Timing - 1. Check if the fusing unit is properly installed. thermistor Every 1 second after the installed properly 2.
Page 459 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Fusing unit not SC553 Pressure roller - Timing - 1. Check if the fusing unit is properly installed. overheat Every 1 second when the installed properly 2.
Page 460 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type SC555 Pressure roller - Timing - Same as SC553 Same as SC553 ready Every 1 second after the temperature temperature reaches the abnormal ready condition - Condition - The pressure roller thermistor output does not reach the ready temperature within 7...
Page 461 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection of SC558 Zero cross - Timing & Condition - 1. Check if the following connectors are properly signal connected; Zero cross signals generated connectors •...
Page 462 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection or SC620 ADF - Timing & Condition - 1. Check that the cable is properly connected on the ADF communica- main board and main control board or check if it is After the main control board damaged cable •...
Page 463 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type • Poor connection or SC630 RDS - Timing & Condition - 1. Check that the cables are properly connected on the communica- CSS/bank interface board and main control board or The main control board damaged cable •...
Page 464 SC CODES 24 February 1999 Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type SC722 Sorter jogger The jogger does not return to Defective jogger HP Defective jogger HP sensor: Check the connections. Test motor error its home position within the sensor (including with SP5-803-128.
Page 465 24 February 1999 SC CODES Related Item Detection Conditions Possible Causes Troubleshooting Procedure Type SC741 Optional paper The paper tray unit self- Defective paper tray Defective paper tray unit control board: Replace. tray unit error diagnostics detect an error unit control board and notify the main control board.
Page 466 SC CODES 24 February 1999 Temperature/Resistance Conversion Reference Table Re lation ship betw een the fusing therm is tor res istan ces and tem perature s Lower-lim it Standard Upper-lim it Tem perature V alue V alue V alue 21 1.7 32 9.3 39 8.9 16 6.8...
Page 467 APPENDIX-4 RSS (Remote service system)
Page 468 31 March, 1999 RSS SET UP 1. RSS (REMOTE SERVICE SYSTEM) 1.1 RSS SET UP A259I302.WMF A259I303.WMF Line Adapter A259I304.WMF Machine No. Jumper set PI device code ø CAUTION Unplug the machine power cord before starting the following procedure. NOTE: When connecting only one machine to the line adapter, start from step 6. 1.
Page 469 SP MODE SETTING 31 March, 1999 1.2 SP MODE SETTING After installing the machine and line adapter, set SP5-816-000 [RDS On/Off] to 1. Check and set the value of the following SP modes. Ensure they are set correctly. • SP5-501-000 [Set PM Counter]: 60000 developments (Default) •...
Page 470 31 March, 1999 CHECKING ITEMS USING RSS 1.3 CHECKING ITEMS USING RSS 1.3.1 READ ONLY ITEMS Item Paper End for each Tray (By-pass, 1st, 2nd, 3rd, 4th) Staple End Toner Near End for each color (K,Y,M,C) Door Open: Front cover, Vertical transport door, Paper exit door, Transport guide plate (for Paper Tray Unit), Sorter (door switch) Jammed Paper Position Machine Condition (1: Warming up, 2: Ready, 3: Copying, 4: Abnormal, 5: Adjustment...
Page 471 CHECKING ITEMS USING RSS 31 March, 1999 1.3.2 CALL AND READ ITEMS Item PM Alarm SC Alarm Jam Alarm Used Toner Tank Alarm Fusing Oil End Alarm Continuously Jams Auto Call Long Time Jam Condition Auto Call (more than 15 minuets) Continuously Cover Open Auto Call (more than 15 minuets) SC Auto Call Manual Call: PM Start...
Page 472 31 March, 1999 OTHERS 1.3.4 EXECUTE ITEMS Item SP2-207 [Forced toner supply] (K, C, M, Y) SP5-810-000 [SC Reset] SP7-804-001 [1PM Parts Counter Clear] SP7-804-002 [2PM Parts Counter Clear] SP7-804-003 [PM Counter Clear] SP7-807-000 [SC/Jam Counter Clear] SP7-808-000 [All Counter Clear] SP7-810-000 [All Copy Counter Clear] 1.4 OTHERS...
Page 473 Printed Circuit Boards Fig. No.- Symbol Name Function Location Index No. PCB1 Supplies AC and DC power. Lamp regulator Supplies AC power to the exposure PCB 2 lamp. Converts the light reflected from the PCB3 original into video signals. Scanner IPU board Converts the RGB image signal from the PCB4 CCD to a KCMY signal and sends it to...
Page 474 Motors Fig. No.- Symbol Name Function Location Index No. Scanner motor Drives the scanner. Polygon mirror motor Drives the polygon mirror (laser unit). 1-14 Revolver drive motor Rotates the revolver unit. Duplex feed motor Drives the paper feed roller in the 4-14 duplex unit.
Page 475 Sensors Fig. No.- Symbol Name Function Location Index No. Toner end sensor Detects the presence or absence of toner in a cartridge. Toner cartridge sensor Detects the presence or absence of toner cartridges. Detects if the revolver is at the home Revolver H.P.
Page 476 Fig. No.- Symbol Name Function Location Index No. Side fence jogger HP Detects the home position of the 4-15 sensor duplex unit side fence. (A259/A260 models only) End fence jogger HP Detects the home position of the 4-19 sensor duplex unit end fence. (A259/A260 models only) Duplex paper end...
Page 477 Fig. No.- Symbols Name Function Location Index No. Fusing clutch Transmits drive to the fusing unit. Belt lubricant clutch Transmits drive to the belt lubricant mechanism. Solenoids Fig. No.- Symbols Name Function Location Index No. By-pass pickup Lowers the by-pass pick-up roller. SOL1 solenoid Junction gate solenoid Raises the junction gate for the duplex...
Page 478 Thermofuses Symbol Name Function Fig. No.- Location Index No. Hot roller thermofuse Protects the hot roller from overheating. Pressure roller Protects the pressure roller from thermofuse overheating. Thermostat Symbol Name Function Fig. No.- Location Index No. Prevents the exposure lamp from Thermostat 1-22 overheating when it is on for a long time.
Page 479 A259S101.WMF Fig. 1...
Page 480 A259S102.WMF Fig. 2...
Page 481 A259S103.WMF Fig. 3...
Page 482 A259S151.WMF Fig. 4...
Page 483 A259S105.WMF Fig. 5...
Page 484 A259S106.WMF Fig. 6...
Page 485 A259S107.WMF Fig. 7...
Page 486 A258/A259/A260 POINT TO POINT DIAGRAM (110V, 120V) <−−−> <−−−> <−−−>...
Page 487 <−−−> <−−−> <−−−> <−−−> <−−−>...

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Ricoh Aficio Color 3006 Service Manual

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