Page 1: Service Manual
A163/A251/A252 B047/B048 SERVICE MANUAL 001317MIU RICOH GROUP COMPANIES...
Page 3 ® ® RICOH GROUP COMPANIES...
Page 5 A163 SERVICE MANUAL 001317MIU...
Page 7 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
Page 9 Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained uncertified users utilizing...
Page 11 LEGEND COMPANY PRODUCT CODE GESTETNER RICOH SAVIN A163 FW740 A251 FW750 A252 FW760 B047 A040 FW770 7700W B048 A041 FW780 7800W DOCUMENTATION HISTORY REV. NO. DATE COMMENTS Original Printing 5/95 Revised Pages 5/96 Reprint 6/98 A251/A252 Addition 8/2001 B047/B048 Addition...
Page 13: Important Safety Notices
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. Note that some components of the copier and the peripherals are supplied with electrical voltage even if the main switch is turned off.
Page 14 OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. 2. Caution: The RAM pack on the main control board has a lithium battery which can explode if replaced incorrectly.
Page 15: Table Of Contents
Rev. 06/2004 Table of Contents OVERALL MACHINE INFORMATION 1. SPECIFICATIONS ........1-1 2.
Page 16 Rev. 06/2004 4.4.2 Recovery From Toner (Near) End condition ..... . 2-17 4.4.3 Toner Density Sensor ........2-18 4.5 DEVELOPMENT BIAS .
Page 17 Rev. 06/2004 1.4 INSTALLATION PROCEDURE ........3-4 1.5 INSTALLATION PROCEDURE .
Page 18 Rev. 06/2004 6.8 ORIGINAL FEED ..........4-39 6.9 PAPER FEED .
Page 19 Rev. 06/2004 4.6 PICK-OFF PAWL UNIT REMOVAL ....... . 5-18 4.7 GRID VOLTAGE ADJUSTMENT .
Page 20 Rev. 06/2004 1.2 UNEVEN COPY IMAGE ......... 6-2 1.3 DIRTY BACKGROUND .
Page 21 Rev. 06/2004 7.1 EXTERIOR COVER REMOVAL ........7-16 7.1.1 Front Cover Removal .
Page 23: Overall Machine Information
OVERALL MACHINE INFORMATION...
Page 25: Specifications
Rev. 11/2000 1. SPECIFICATIONS Configuration: Table top Copy Process: Electrostatic transfer system Original Feed: Sheet feed Original Skew 2 mm/400mm Tolerance: Original Size: Maximum: 914 x 2,000 (36" x 80")mm Minimum: A4 (8 " x 11") lengthwise Copy Size: Same as "Original Size" Copying Speed: 3 cpm (A1/D sideways) First Copy:...
Page 26 Paper Feeding: Manual feed (roll feeder optional) Image Fusing: Heat and pressure type, teflon (upper) and silicone rubber (lower) rollers Fusing Lamp: Nichrome wire lamp (115 V: 1,100 W, 230 V: 1,100 W) Self-diagnostic Codes: 11 codes, displayed in copy counter Power Source: 115 V/60 Hz..15 A 220 V/50 Hz..7 A...
Page 27: Paper Path
2. PAPER PATH A: Original Path B: Paper from the manual feed C: Paper from the roller feed D: Paper exit E: Original Path from Rear Feeder A163...
Page 28: Drum Processes
3. DRUM PROCESSES 1. Charge In the dark the charge corona unit applies a negative charge to the drum. The grid plate ensures the charge is applied uniformly. The charge remains on the surface of the drum because the photoconductive drum has a high electrical resistance in the dark.
Page 29 3. Development The magnetic developer brush on the development roller comes in contact with the latent image on the drum surface. Toner particles are electrostatically attracted to the negatively charged latent image areas. 4. Pre-Transfer Lamp The pre-transfer lamp (PTL) illuminates the drum prior to image transfer. This reduces the attraction between the toner and the drum, thus making image transfer easier.
Page 30: Mechanical Component Layout
4. MECHANICAL COMPONENT LAYOUT 22 23 24 1. 1st Original Feed Roller 14. Roll Feeder 2. 1st Press Rollers 15. Paper Registration Rollers 3. Copy Tray 16. Development Unit 4. Exit Rollers 17. Toner Cartridge 5. Fusing Exit Rollers 18. Manual Feed Table 6.
Page 31: Drive Layout
Rev. 5/95 5. DRIVE LAYOUT 1. Original Feed Roller Pulley 9. Fusing Drive Chain 2. Original Feed Roller One Way Pulley 10. Exit Unit Drive Belt 3. Development Unit 11. Hot Roller Drive Gear 4. Development Unit Relay Gear 12. Fusing Drive Sprocket/Gear 5.
Page 32: Electrical Component Layout
6. ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper) index numbers. Name Function Index. No. Motors Main Drives all mechanical components except the fans. (DC Motor) Exhaust Fan Removes the ozone built up around the drum section to the ozone filter.
Page 33 Name Function Index. No. Main Controls all copier functions both directly and through other PCBs. Converts the ac voltage to dc voltage. AC Drive Provides ac power to the fusing lamp and PSU. FL Regulator Stabilizes power to the exposure lamp. Operation Panel Control the operation panel display.
Page 34 1-10 A163...
Page 35: Detailed Section Descriptions
DETAILED SECTION DESCRIPTIONS...
Page 37: Drum
DRUM 1.1 DRUM CHARACTERISTICS The organic photoconductor (OPC) drum has the following characteristics: It is able to accept a high negative electrical charge in the dark. (The electrical resistance of the OPC drum is high in the absence of light.) The electric charge on the drum surface dissipates when the drum is exposed to light.
Page 38: Drum Drive
1.2 DRUM DRIVE The OPC drum [A] is 80 millimeters in diameter and 970 millimeters long. It turns constantly when the main motor [B] is on. When the main motor turns on, the drive is transmitted to the drum in the following way: main motor drive gear [C] idle gears [D]...
Page 39: Charge
CHARGE 2.1 OVERVIEW Charge Charge/ Grid Power Pack Grid This model uses a single wire corona unit [A] to charge the OPC (organic photoconductor) drum [B]. The corona unit generates a corona of negative ions when a high negative voltage is applied to it by the charge/grid power pack. To make the negative corona uniform, a grid consisting of 8 wires is installed on the charge corona unit between the corona wire and the drum.
Page 40: Charge Corona Circuit
Rev. 5/95 2.2 CHARGE CORONA CIRCUIT Charge/Bias/Grid PP CN243 CN340-1 24V Va CN340-2 CN243-8 CN106 Main Board DC/DC CN340-3 Converter Charge CN106 Grid Drive CN340-4 DC/DC Grid Detect CN340-6 -A10 Converter The PSU supplies +24 volts (V ) to the charge/bias/grid power pack as the power supply source.
Page 41: Corona Unit Ventilation
2.3 CORONA UNIT VENTILATION If ozone produced by the corona charge stays in the charge corona area, it may cause uneven corona charging to the drum. To prevent this, ozone is vacuumed out through the exhaust fan [A], and changed to oxygen by the ozone filter before being blown out of the copier.
Page 42: Exposure
EXPOSURE 3.1 OVERVIEW Light from the exposure lamp [A] reflects off the original and through the fiber optics [B] to the OPC drum [C]. During exposure, the original moves across the exposure glass at the same speed as the drum’s peripheral velocity. The platen plate [D] presses the original [E] flat against the exposure glass [F] just above the fiber optic array.
Page 43: Paper And Original Feed
Rev. 5/95 3.2 PAPER AND ORIGINAL FEED 3.2.1 Basic Operation (Manual Feed) When the entrance sensor [A] of the manual feed table detects the leading edge of the copy paper, the main motor starts rotating and the drum process (exposure lamp, change corona,...
Page 44 The original feed rollers rotate with the rotation of the main motor. The original is pulled by the 1st original feed roller [A] just after the original is placed on the original feed table. The original registration sensor [C] detects the leading edge of the original, and the "Set Original"...
Page 45: Original Jam Check Timing
3.2.2 Original Jam Check Timing There is only one sensor (original registration sensor) in the original path. Therefore, original jam cannot be detected during the time that a maximum original length (2m) passes this sensor. The original jam check is done after the leading edge of the original has moved 2.5 m (around 50 seconds).
Page 46: Drive Mechanism
3.2.3 Drive Mechanism The original feed rollers are driven through the original feed drive pulley and belt by the main motor as mentioned in the drum drive section. The paper registration rollers [A] are rotated by the main motor [B] through the gears [C] and the paper registration clutch [D].
Page 47: Fl Regulator Control
Rev. 5/95 3.3 FL REGULATOR CONTROL [D] Main Board [C] Light Sensor The FL regulator [A] receives 24 volts dc at CN401-1 from the PSU [B]. The control signal, which is a pulse width modulated (PWM) signal, is received at CN1-3.
Page 48: Manual Id Control
Rev. 5/95 3.4 MANUAL ID CONTROL Light Sensor Light Sensor Manual ID Level Manual ID Level Output [V] Output [V] 0.78 1.53 0.892 1.73 0.899 1.93 0.938 2.13 1.02 2.33 1.24 2.52 1.45 2.72 3.4.1 Manual ID Control The user can select one of 14 manual ID levels. For each level, the intensity of the light output by the exposure lamp (as measured by the light sensor) varies.
Page 49: Development
Rev. 5/95 DEVELOPMENT 4.1 OVERVIEW [C] [B] When the main motor turns on, the paddle roller [A] and development roller [B] start turning. The paddle roller picks up developer in its paddles and transports it to the development roller. Internal magnets in the development roller attract the developer to the development roller sleeve.
Page 50: Drive Mechanism
4.2 DRIVE MECHANISM When the main motor [A] is on, the paddle roller [B], development roller [C], and mixing auger [D] in the development unit are driven through the development drive chain [E] and gears [F]. The toner agitator shaft [G] is rotated through the gears [H] by the toner supply clutch [I] engaged in the toner supply condition.
Page 51: Cross-Mixing
4.3 CROSS-MIXING "Cross-mixing" keeps the developer’s toner and carrier evenly mixed and evenly distributes the developer within the development unit. Cross-mixing also agitates the developer to generate the necessary triboelectric charge on the toner and carrier particles. The arrows in the above illustration show the developer movement directions within the machine.
Page 52: Toner Density Control
4.4 TONER DENSITY CONTROL The toner supply amount ratio is determined by the following conditions. 51 ~ 100 101 ~ 150 151 ~ 200 201 ~ 250 0 ~ 50 sheets 251 sheets ~ sheets sheets sheets sheets Level (~ 30 m) (150 m ~) (30 ~ 60 m) (60 ~ 90 m)
Page 53: Toner Near End Condition
4.4.1 Toner Near End Condition When TS level 5 is detected 3 times in a row, the toner near end condition is detected and the add toner indicator starts flashing. When in the toner near end condition, 16 more meters (A1/D size: 27 copies) can be copied. Then the add toner indicator will light and the machine will not operate.
Page 54: Toner Density Sensor
Rev. 5/95 4.4.3 Toner Density Sensor Toner Density Sensor Main Board CN104-A11 [12V] CN104-B20 Control TS Control CN104-A10 TS. FB Circuit CN104-B21 Coils The toner density sensor circuit controls the amount of toner in the developer mixture. The toner density sensor is powered by 12 volts from CN104-A11 of the main board.
Page 55: Development Bias
4.5 DEVELOPMENT BIAS 4.5.1 Basic Concept When the drum is exposed, most of the negative charge is eliminated from the areas where light strikes the drum. This leaves a negative charge pattern corresponding to the dark areas of the original. After exposure, however, a small residual charge of about --100 volts (for white paper) remains in the exposed areas.
Page 56: Toner Supply
4.6 TONER SUPPLY To allow a compact design, the toner supply mechanism is built into the toner cartridge. An agitator [A] in the toner cartridge turns when the toner supply clutch is engaged. As the agitator rotates, mylar strips [B] on the ends of the agitator force toner through small holes (0.5 mm in diameter) in a plastic strip [C] along one side of the toner cartridge.
Page 57: Image Transfer And Paper Separation
Rev. 5/95 IMAGE TRANSFER AND PAPER SEPARATION [A] [C] [D] 5.1 PRE-TRANSFER LAMP (PTL) After the latent image is developed but before the image is transferred to the copy paper, the drum surface is illuminated by the pre-transfer lamp [A]. This illumination reduces the negative potential on the drum surface.
Page 58: Pick-Off Mechanism
5.4 PICK-OFF MECHANISM The pick-off pawl solenoid [A] is energized after the registration clutch turns on to feed the copy paper to the drum. The pick-off shaft [B] then rotates clockwise and the pick-off pawls [C] touch the drum surface. Just after the leading edge of the copy paper passes the pick-off pawls, the pick-off solenoid turns off again.
Page 59: T/S Corona Circuit
5.5 T/S CORONA CIRCUIT Rev. 5/95 The T/S power pack is powered by +24 volts (Va) from the PSU. The dc/dc converters and dc/ac inverter change the +24 volts supply into the high voltages used by the transfer and separation coronas. The main board turns on the transfer corona using PWM signal (T.Drive).
Page 60: Cleaning
CLEANING 6.1 OVERVIEW This copier uses the counter blade system for drum cleaning. The blade [A] is angled against the drum rotation. This counter blade system has the advantage of high cleaning efficiency. The cleaning blade removes any toner remaining on the drum after the image is transferred to the copy paper.
Page 61: Collection Of Used Toner
6.2 COLLECTION OF USED TONER The toner collection coil [A], which is rotated by the main motor [B] through the gears [C], moves used toner from the cleaning unit to the toner collection bottle [D]. The toner collection bottle capacity is enough to hold used toner from making 1220 m copies.
Page 62: Quenching
Rev. 5/95 QUENCHING After the drum [A] is cleaned by the cleaning blade, light from the quenching lamp [B] neutralizes any charge remaining on the drum. The quenching lamp turns on and off at the same time as the main motor. The main board turns on the quenching lamp LEDs by dropping CN104-B26 to 0 volt.
Page 63: Fusing And Paper Exit
FUSING AND PAPER EXIT 8.1 OVERVIEW After separation from the drum, copy paper rides on the transport plate [A]. The small separation rollers [B] hold the paper against the transport plate so that the back curled paper is straightened before it enters the fusing section. Two rollers fuse the image to the copy paper by applying heat and pressure.
Page 64: Drive Mechanism
8.2 DRIVE MECHANISM 8.2.1 Fusing Unit Drive The hot roller [A] is turned by the hot roller drive gear [B] as shown. The pressure roller [C] is friction driven by the hot roller. The fusing rollers turn constantly when the main motor [D] is on, driven via the gear [E], through the fusing drive chain [F], sprocket [G], and gear [H], to the hot roller drive gear.
Page 65: Fusing Temperature Control
Rev. 5/95 8.3 FUSING TEMPERATURE CONTROL 8.3.1 Fusing Circuit Operation The fusing lamp is powered by the ac drive board and controlled by the main board. The ac drive board receives direct wall voltage ac power (not stepped down) at T201 and T202.
Page 66: Overheat Protection
8.3.2 Overheat Protection The overheat protection circuit on the main board turns off the fusing lamp if the temperature goes too high. The input from TH1 (Hot Roller Thermistor) goes to pin 3 of IC17 as well as to the CPU.
Page 67: Temperature Control
8.4 TEMPERATURE CONTROL Roller Temp. ( C) Pressure Roller Temp. ( C) Operating Temperature Lower Limit Lower Limit The main board monitors the temperature of the hot roller through TH1 and the temperature of the pressure roller through TH2. The CPU determines whether or not to turn on the fusing lamp based on the combination of the input from these two thermistors.
Page 68 The operating temperature of the hot roller and pressure roller can be adjusted using SP #--7 and SP #--8. These programs are used to compensate for variations in the response of different thermistors. SP #--7 adjusts the hot roller temperature and SP #--8 adjusts the pressure roller temperature. SP #--7 shift the temperature in 1 degree increments (--9°C to +9°C).
Page 69 The position of the unlit lamp corresponds to the fusing temperature mode as shown below. (Normal) Mode1 Mode 5 Mode 7 Mode 2 Mode 4 Mode 6 Mode 3 (High) Mode 5 Mode 6 Mode 8 Mode 7 (Low) Mode 2 Mode 3 Mode 5 Mode 4...
Page 70: Energy Saver Function
8.5 ENERGY SAVER FUNCTION When the copier is not in use, the energy saver function reduces the power consumption by decreasing the fusing temperature. When the Clear Modes/Stand-by key is hold down for over 2 seconds, the copier goes into the energy saver mode. A message is displayed on copy counter and all the other indicators turn off.
Page 71: Fusing Entrance Guide Height
8.6 FUSING ENTRANCE GUIDE HEIGHT Paper creasing may occur depending on the type of paper used. The fusing entrance guide [A] height is changed by adjusting a lever (there are three settings). A163 2-35...
Page 72: Roll Cutting Rail
ROLL CUTTING RAIL 9.1 ROLL CUTTING RAIL The roll cutting rail cuts sheets of paper from the paper roll. For inserting paper between the slide shafts [A] and cutter guide stay [B], the holders [C] hold the slide shafts at the upper position by keeping the gap constant.
Page 73: Installation
INSTALLATION...
Page 75: Environment
1. ENVIRONMENT 1. Temperature Range: C to 30 C (59 F to 86 2. Humidity Range: 20% to 80% RH 3. Ambient Illumination: Less than 1,500 Lux (do not expose to direct sunlight). 4. Ventilation: Minimum space 20 m Room air should turn over at least 30 /hr/person.
Page 76: Minimum Space Requirements
1.1 MINIMUM SPACE REQUIREMENTS Back 600 mm Right Left 600 mm 600 mm Front 1000 mm 1. Front: 1,000 mm (39 in) 2. Back: 600 mm (24 in) 3. Right: 600 mm (24 in) 4. Left: 600 mm (24 in) 1.2 MACHINE LEVEL 1.
Page 77: Power Source
1.3 POWER SOURCE 1. Input Voltage Level: 115 V/60 Hz More than 15 A (for U.S.A. version) 220 V/230 V/240 V/50 Hz More than 7 A (for European version) 2. Permissible Voltage Fluctuation: 3. Do not set anything on the power cord. NOTE: a) Make sure the plug is firmly inserted in the outlet.
Page 78: Installation Procedure
1.4 INSTALLATION PROCEDURE Copier Check the accessories and their quantities according to the following list: Guide Wire ............. 2 pcs Copy Tray ............... 1 pc Copy Guide ............1 pc A163...
Page 79 1. Lower the feet [A] so that the table does not move while the copier is being installed on the table. 2. Place the copier [B] on the table [C] (Place the copier feet [D] into the table holes [E]). Warning: The copier is not attached to the table.
Page 80 Rev. 5/95 3. Open the paper path section [A] and remove two strips of shipping tape [B]. 4. Remove the right upper cover [C] (2 screws). 5. Remove the drum protection sheet [D], and remove the screw [E] to apply cleaning blade pressure to the drum.
Page 81 Rev. 5/95 6. Open the original feed unit [A], manual feed table [B], and toner supply cover [C]. Remove a sheet [D] covering the developer entrance. Pour 1 kg of the developer [E] into the development unit evenly across its width as shown, then close all doors.
Page 82 Rev. 5/95 NOTE: If the fusing temperature is lower than 60 C when the main switch is turned on, the main motor will rotate. In this case, it is not necessary to access the SP mode when loading the second Kg of developer (in step 11).
Page 83 Rev. 5/95 12. Press the following keys on the operation panel: Clear key [A] + key [B] --key [C] Clear/Stop key [D] 13. Press the Clear/Stop key again for longer than 3 seconds. The roll paper end and call service indicators will blink (SP mode). 14.
Page 84 15. Install the toner cartridge [A] as shown. 16. Remove the sealing tape [B] from the cartridge and turn the knob [C] until it stops. A163 3-10...
Page 85 17. Attach the guide wires [A] to the copy tray [B]. 18. Install the copy tray [B] and copy guide [C]. 19. Reinstall all the covers. 20. Check the copy quality and copier operation. 3-11 A163...
Page 86: Installation Procedure
1.5 INSTALLATION PROCEDURE Table Check the accessories and their quantities according to the following list: Top Plate ..............1 Left Side Plate ............1 Right Side Plate ............. 1 Middle Plate ............1 Rear Cover ............. 1 Screws with Spring Washer - M4x8 .......14 A163 3-12...
Page 87 Rev. 5/95 A, B NOTE: To ensure grounding, paint has been removed from the surfaces around the screw holes [A] (only from the surfaces where the two components meet) and from the surface around the screw hole [B] at the inside of the left plate.
Page 88 1.6 INSTALLATION PROCEDURE Roll Cutting Rail Check the accessories and their quantities according to the following list: Cutter Guide ............1 pc Cutter Knife ............1 pc Roll Paper Arm ............2 pcs Roll Paper Shaft ............. 1 pc Roll Shaft Holder ............ 2 pcs Roll Flange .............
Page 89 [J] [G] [C] [F] 3. Attach the roll paper arms [A] to the cutter guide [B]. (Install each arm pin [C] into each cutter guide hole [D]. Position the cutter guide pin [E] in the lower slot of the roll paper arm [F].) 4.
Page 91: Service Tables
SERVICE TABLES...
Page 93: Preventive Maintenance Schedule
PREVENTIVE MAINTENANCE SCHEDULE PM TABLE Symbol key: I=Inspect L=Lubricate R=Replace A=Adjust C=Clean 2.1KM 4.3KM 6.4KM 8.6KM 10.8KM (3.6K) (7.2K) (10.8K) (14.4K) (18K) Notes ) A1 sideways/D size A. Original Feed 1 First original Alcohol feed roller 2 Second Alcohol original feed roller 3 1st and 2nd Alcohol...
Page 94 2.1KM 4.3KM 6.4KM 8.6KM 10.8KM (3.6K) (7.2K) (10.8K) (14.4K) (18K) Notes ) A1 sideways/D size 5 T/S corona Dry cloth wires 6 T/S corona Dry cloth end blocks and casing 7 Pick-off pawls Dry cloth 8 Quenching Clean using Lamp blower brush if necessary E.
Page 95 2.1KM 4.3KM 6.4KM 8.6KM 10.8KM (3.6K) (7.2K) (10.8K) (14.4K) (18K) Notes ) A1 sideways/D size 8 Exit guide plate Clean using suitable solvent if necessary Others 1 Chain Lubricate with G501 if necessary 2 Gears Lubricate with G501 if necessary 3 Ozone filter F.
Page 96: Regular Pm Procedure
REGULAR PM PROCEDURE 1. Make a copy Make a copy of OS-A1 chart. 2. Original Feed Clean the original table using alcohol. (every 3.6K) Inspect the 1st and 2nd press rollers. If they are dirty, clean them using alcohol. Original Feed 1.
Page 97 Around Drum Clean the charge corona end blocks and casing. (every 7.2K) Around Drum Replace the charge corona wires and T/S corona (every 18K) wires. 5. Cleaning Unit 1. Inspect the cleaning blade. Replace it, if it is (every 3.6K) damaged.
Page 98 7. Paper Feed 1. Clean the registration roller using water. (every 3.6K) 2. Clean the paper feed guide plates using water. 3. Clean the manual table using water. 8. Fusing Unit Clean the small separation rollers using suitable (every 3.6K) solvent.
Page 99: Service Tables
SERVICE TABLES TEST POINTS Main Board Number Function TP101 (+24V) TP102 Vcc (+5V) TP103 TP104 Toner density sensor (CN104-A10) TP105 Light sensor output (CN104-B1) Charge/Bias/Grid Power Pack Number Function Development Bias Voltage Grid Voltage VARIABLE RESISTORS Charge/Bias/Grid Power Pack Number Function Charge Corona Voltage Caution: VR1 should not be changed in the field.
Page 100: Service Tools
SERVICE TOOLS SERVICE PROGRAM MODE The service program (SP) mode is used to check electrical data, change mode or adjustment values. 3.1.1 Service Program Mode Access Procedure How to access the SP mode for service representatives (All service program modes can be accessed with this procedure.) Press the following keys in sequence.
Page 101 How to change settings 1. Access the SP mode and select the program number. 2. Press the key to select the paper length indicator (the four digit indicator beside the mark). 3. The present setting is displayed in the paper length indicator. 4.
Page 102: Service Program Mode Table
3.1.2 Service Program Mode Table 1: A "*" before the mode number means that the mode can be accessed by custormers or sales representative. 2: In the data colum, the default value is printed in bold letters. The default settings for several items depend on the machine destination (refer to page 4-26.).
Page 103 Rev. 1/26/96 Mode No. Function Data Leading Edge To change the leading edge margin (print Count up/down at Increase/Decrease number) increase/decrease speed, the every: Speed Setting customer holds down the + or -- key. Then, 0: 0.1 second after a few 0.25 second intervals (See SP 1: 0.50 second mode 12), the speed begins to change.
Page 104 Rev. 12/22/95 Mode No. Function Data Optional Paper Up to 10 different paper size can be stored UdEF: Undefined Size Setting from 23 to 32. If "19" is selected in SP No. 22, this data is used as fixed paper size when the "Preset Cut"...
Page 105 Mode No. Function Data Roll Feeder To adjust the cutting length of 1100 mm in 0: Standard Cutting Length the plain paper mode. --50.0 0 50.0 mm Adjustment (1100 Longer Shorter mm, Plain Paper) Roll Feeder To adjust the cutting length of 1100 mm in Cutting Length the translucent paper mode.
Page 106 Mode No. Function Data Used Toner Clear used toner counter. 0: Full toner Counter Clear condition is not detected 1: Full toner condition is detected. To clear the counter, input "0" even if "0" is already indicated. Developer Determines the warm-up time to increase the 0: 1 minute Warm-up Setting Q/M of the developer.
Page 107 Mode No. Function Data Fixed Paper Selects the interval of each step for SP60. (In mm mode) Length Special 0: 100 mm Mode 1: 50 mm 2: 60 mm 3: 120 mm 4: 200 mm 5: 240 mm 6: 250 mm 7: 500 mm 8: 600 mm (In inch mode)
Page 108 Mode No. Function Data Total Copy Displays the total copy length/number SP70: t = XXX,XXX Length/Number according to the following units. SP71: t =XXX,XXX Display SP70 = Yard SP72: t =XXX,XXX SP71 = meter SP73: t =XXX,XXX SP72 = 100 inches SP74: t4=XXX,XXX SP73 = 50 inches SP75: t...
Page 109 Mode No. Function Data Misfeed Record Displays the locations of the last five J1 = XX (Last jam) Display misfeeds one after the other. J2 = XX (1 before the last jam) J3 = XX (2 before the last jam) J4 = XX (3 before the last jam) J5 = XX (4 before...
Page 110 Mode No. Function Data RAM Clear Clears selected data items form the RAM. To 0: Not Used clear the memory, input the number of the 1: Copy Number item you want to delete, then press the Counter (The memory for key.
Page 111 Mode No. Function Data 11: Change the setting to the U.S.A. version 12: Not Used 13: Not Used 14: Not Used 15: Not Used 16: Not Used 17: Factory use 18: Not Used 19: Not Used 20: Not Used 21: Clear all the memories and change the setting to the U.S.A...
Page 112 Mode No. Function Data Light Sensor Change the light sensor setting. 50: Standard Adjustment Turn on and off the exposure lamp using the Copy Media key. Darker Lighter Tracing paper: ON Film: OFF Hot Roller Change the hot roller temperature setting. 0: Standard Temperature Adjustment...
Page 113 Mode No. Function Data Separation AC Determines the AC separation corona 170: Standard Voltage Setting voltage. In this mode, the separation corona can be High --14 turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Separation AC Determines the AC separation corona 190: Standard...
Page 114 Mode No. Function Data Toner Density Selects the toner density setting. The toner 0: Standard Setting density changes according to the copy length 1: Low after the developer is replaced. 2: High Copy length Std. High (A1 size) ~ 30 m 4.25V 4.35V 4.00V (~50 sheets) ~ 60 m...
Page 115 Mode No. Function Data Toner Sensor Displays the real time toner sensor output A = X,XX Voltage Display voltage. (Real Time) In this mode, the PTL, main motor, QL and A = Toner Sensor the bias voltage for non-image areas can be Voltage turned on and off using the Copy Media key.
Page 116 Mode No. Function Data Fluorescent Lamp Counts the time when the fluorescent lamp is 0~250: The total time Abnormal Time in full power during the copy cycle. (seconds) that the --61 Check 2 fluorescent lamp is at full power. --62 Not Used --63 Factory Use Only Manual Feed Beeper sounds if a sheet is set on the...
Page 117 Fixed Paper Size Pattern Data (SP No.22) In mm Mode 1189, 841, 594, 420, 297 2000, 1189, 841, 594, 420, 297, 245 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 245 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1189, 841, 594, 420, 297, 245 2000, 1800, 1456, 1189, 1030, 841, 728, 594, 515, 420, 364, 297, 245 2000, 1500, 1230, 880, 625, 450, 330, 245...
Page 118 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 44.0, 34.0, 22.0, 17.0, 11.0, 9.6 80.0, 78.0, 76.0, 74.0, 72.0, 70.0, 68.0, 66.0, 64.0, 62.0, 60.0, 58.0, 56.0, 54.0, 52.0, 50.0, 48.0, 46.0, 44.0, 42.0, 40.0, 38.0, 36.0, 34.0, 32.0, 30.0, 28.0, 26.0, 24.0, 22.0, 20.0, 18.0, 16.0, 14.0, 12.0, 10.0, 9,6 80.0, 72.0, 60.0, 48.0, 36.0, 24.0, 12.0, 9.6 80.0, 78.0, 72.0, 66.0, 60.0, 50.0, 54.0, 48.0, 42.0, 36.0, 30.0, 24.0, 18.0, 12.0, 9.6...
Page 119: Input/Output Check Mode
INPUT/OUTPUT CHECK MODE The input check mode allows you to check the current status of electrical components (such as sensors, switches, etc.) from the operation panel. The output check mode allows you to turn the individual electrical components (such as motors, solenoids, etc.) ON/OFF from the operation panel. 3.2.1 INPUT/OUTPUT CHECK MODE ACCESS PROCEDURE How to access the output check mode Press the following keys in sequence.
Page 120: Input Check Mode Table
Rev. 5/95 3.2.2 INPUT CHECK MODE TABLE The on/off status of the selected electrical component is displayed on the paper length indicator ("ON" or "OFF" is displayed.). If a program number not used is selected, "NOT" is displayed. Program Sensor/Switch /Signal Registration Sensor Exit Sensor Original Registration Sensor...
Page 121: Output Check Mode Table
3.2.3 OUTPUT CHECK MODE TABLE Press the key to turn on the selected electrical component. The status of the component is displayed on the paper length indicator. To turn off the component, press the key again. Program Electrical Component Main Motor Toner Supply Clutch Pick off solenoid Registration Clutch...
Page 122: Power On Initial Setting Mode
POWER ON INITIAL SETTING MODE The initial setting, when the main switch is turned on, can be changed in this mode. The procedure is as follows: 1. Turn on the main switch while holding the Emergencey stop key down indicators blink). 2.
Page 123: Jam Code List
JAM CODE LIST When a document (original) jam or paper jam occurs, the cause of the jam is displayed by using the following jam code. ACCESS PROCEDURE 1. When a document jam or paper jam occurs, press and hold the Clear/Stop key.
Page 124 Code Cause of Jam SP Mode No. Roll feeder. SP80 PJ90 motor does not turn off after paper is fed 500 mm more (Others) than the maximum paper length. Registration sensor does not turn off after paper is fed PJ98 2500 mm.
Page 125: Special Tools And Lubricants
SPECIAL TOOLS AND LUBRICANTS DESCRIPTION PART NO. REMARKS Digital Multimeter 54209507 BECKMAN RMS3030 Deluxe Test Lead BECKMAN DL241 54209508 Accessory Kit Grease -- Mobil Temp.78 54479078 400 g/can Grease-G501 52039501 Current Measuring Drum A0239520 Test Chart OS-A1 A0239504 (2 sheets/set) Spring Hook 54199653 Setting Powder...
Page 126: Service Remarks
SERVICE REMARKS DRUM UNIT 6.1.1 Drum The organic photoconductor drum is comparatively more sensitive to light and ammonia gas than a selenium drum. 1. Never expose the drum to direct sunlight. 2. Never expose the drum to direct light of more than 1,000 Lux for more than a minute.
Page 127: Charge Corona
15. When the drum unit is removed from the copier, do not close the paper path section if possible. Otherwise, the gas springs at both sides open the paper path section forcibly if the paper path section is released. If you close the paper path section, take care not to injure yourself by opening the paper path section.
Page 128: Optics
OPTICS 1. Clean the exposure glass with water or alcohol. 2. Clean the fiber optics array with lens paper or silicone cloth. 3. Make sure that the exposure glass is under the rear original guide plate when reassembling. 4. Make sure that the direction of the aperture of the exposure lamp is towards the fiber optics array side (rear side) when reassembling.
Page 129: Transfer And Separation
TRANSFER AND SEPARATION 1. Clean the corona wires with a blower brush. If the wires are cleaned with a dry cloth, make sure that the wire does not become stretched. 2. When adjusting the corona current, always use the drum current measuring drum.
Page 130: Fusing Unit
Rev. 9/27/96 6.7 FUSING UNIT 1. Be careful not to damage the edges of the hot roller strippers and tension springs. 2. Do not touch the fusing lamp with bare hands. 3. Make sure that the fusing lamp does not touch the hot roller. 4.
Page 131: Original Feed
Rev. 9/27/96 5. Scrape some black areas on the copy using a cotton cloth approximately 5 times. 6. Check whether the toner is peeled off on the areas that correspond with the scraped parts of the pressure roller. If white lines and/or bands appear, the pressure roller should be replaced with a new one.
Page 133 REPLACEMENT AND ADJUSTMENT...
Page 135: Exterior Covers
EXTERIOR COVERS LEFT SIDE COVER REMOVAL 1.1.1 Left Upper Cover 1. Remove the left upper cover [A] (2 screws). 1.1.2 Left Lower Cover 1. Open the paper path section [B]. 2. Remove the left lower cover [C] (2 screws). RIGHT SIDE COVER REMOVAL 1.2.1 Right Upper Cover 1.
Page 136: Original Feed Unit Removal
OPTICS ORIGINAL FEED UNIT REMOVAL 1. Remove the left and right upper covers. 2. Remove the copy tray [A]. 3. Push the projections [B] into the holes [C] of the rear side of the original feed unit as shown and remove the operation panel [D] (2 connectors). 4.
Page 137: Exposure Glass Removal
EXPOSURE GLASS REMOVAL 1. Remove the original feed unit. 2. Remove the exposure glass bracket [A] (2 screws). 3. Remove the rear original guide plate [B] (2 screws). 4. Remove the exposure glass [C] by sliding it out to the right side and lifting up the left side as shown.
Page 138: Fiber Optics Array Removal
FIBER OPTICS ARRAY REMOVAL 1. Follow the steps from 1 to 3 of the exposure lamp removal. 2. Remove the original registration sensor bracket [A] (1 screw). 3. Lift up the fiber optics array [B] and remove it from the left side by sliding it out to the right side as shown.
Page 139: Light Sensor Replacement
Rev. 5/95 LIGHT SENSOR REPLACEMENT 1. Remove the exposure lamp. 2. Replace the light sensor [A] (1 screw, 1 connector). 3. Perform light sensor adjustment. See page 5-39 A163...
Page 140: Development Unit Removal
DEVELOPMENT DEVELOPMENT UNIT REMOVAL 1. Remove the left and right upper cover. 2. Open the paper path section and original feed unit. 3. Remove the toner supply cover [A]. 4. Remove the manual entrance feed cover [B] (2 pins). 5. Remove the paper feed driven unit [C] (2 screws and 1 connector). A163...
Page 141 6. Remove the 4 shoulder screws [A] and 2 screws [B] fixing the development unit. 7. Disconnect the 14p connector [C] and remove it out of the cutout [D]. 8. Remove the development unit [E]. CAUTION: Do not loosen the painted screws [F] which determine the development doctor blade height and do not push the doctor blade [G] too strongly, otherwise the doctor gap may change.
Page 142: Developer Removal
DEVELOPER REMOVAL NOTE: Be careful not to bend the bias terminal. 1. Remove the development unit and place it on a large sheet of paper [A] as shown. 2. Remove the toner supply unit casing [B] (2 pins) and development filter [C] and bracket [C] and clean them.
Page 143: Toner Density Sensor Replacement
TONER DENSITY SENSOR REPLACEMENT 1. Remove the development unit. 2. Disconnect the harness connector [A] and take the harness from the 2 clamps [B]. 3. Remove the 2 screws [C] of the toner density sensor holder. 4. Pull out the harness from the toner density sensor side until the relay connector [D] appears.
Page 144: Ptl Replacement
PTL REPLACEMENT 1. Remove the paper feed driven unit (follow the steps from 1 to 5 of the development unit removal). 2. Remove the PTL assembly [A] (4 screws, 3 connectors, and 4 clamps [B]). A163 5-10...
Page 145: Development Bias Voltage Adjustment
DEVELOPMENT BIAS VOLTAGE ADJUSTMENT NOTE: This adjustment is required when the charge/bias/grid power pack is replaced. Preparation: 1. Turn off the main switch, and remove the rear cover. 2. Connect the ground terminal of the multimeter to the machine ground, and connect the voltage terminal to TP1 on the charge/bias/grid power pack.
Page 146: Bias Voltage For Non-Image Area
3.5.2 Bias Voltage for Non-image Area ADJUSTMENT STANDARD: dc --200 1. Access SP mode and select No. --21. 2. Press the key to turn on the bias voltage. 3. Check the multimeter. If the voltage is not that of the standard voltage, press key and then change the voltage using keys.
Page 147: Drum Unit
DRUM UNIT DRUM UNIT REMOVAL 1. Remove the development unit. 2. Remove the 2 screws [A] at both ends. 3. Remove the timing belt [B] and disconnect the harness connector [C]. 4. Remove the drum unit [D]. 5. Place the drum unit on the flat floor. NOTE: (1) When reinstalling the drum unit, hook the drum unit guides [E] on the pins [F] of the copier side plates.
Page 148: Drum Replacement
Rev. 5/95 DRUM REPLACEMENT 1. Remove the drum unit. 2. Remove the pulley [A] (1 C-ring). 3. Remove the 2 bearing holders [B] (2 screws each). NOTE: Be careful not to scratch the drum with the pick-off pawls when removing or reinstalling the drum. 4.
Page 149: Cleaning Blade Replacement
Rev. 5/95 CLEANING BLADE REPLACEMENT 1. Remove the drum unit. 2. Remove the charge corona unit (Pg 5-16) 3 Remove the quenching lamp unit [A]. 4. Remove the pressure spring [B] and bushing [C]. 5. Slide the cleaning blade [D] to the left side and remove it from the right side. NOTE: 1.
Page 150: Charge Corona Unit Removal
CHARGE CORONA UNIT REMOVAL 1. Remove the drum unit. 2. Remove the ground springs [A]. 3. Remove the charge corona unit [B] (2 connectors). NOTE: When reinstalling the charge corona unit, make sure that the 2 connectors (C for the charge corona, G for the grid bias) are set properly.
Page 151: Charge Corona Wire Replacement
CHARGE CORONA WIRE REPLACEMENT 1. Remove the charge corona unit. 2. Remove the 4 grid wires [A] (4 springs). 3. Remove the endblock covers [B]. 4. Replace the corona wire [C] (1 spring). NOTE: (1) Make sure that the grid wires are correctly placed on the eight slots [D], are all straight, and not crossed.
Page 152: Pick-Off Pawl Unit Removal
PICK-OFF PAWL UNIT REMOVAL 1. Remove the drum unit and place it as shown. 2. Remove the pressure spring [A] and pick-off pawl unit [B] (2 screws and 1 connector). NOTE: When installing and/or removing the pick-off pawl unit, do not press too strongly.
Page 153: Grid Voltage Adjustment
Rev. 2/7/96 GRID VOLTAGE ADJUSTMENT ADJUSTMENT STANDARD: dc --940 10V. NOTE: This adjustment is required when the charge/bias/grid power pack is replaced. 1. Turn off the main switch and remove the rear cover. 2. Connect the ground terminal of the multimeter to the machine ground, and connect the voltage terminal to TP2 on the charge/bias/grid power pack.
Page 154: Drum Current Adjustment
DRUM CURRENT ADJUSTMENT NOTE: a) The drum currents vary with environmental conditions such as humidity and atmospheric pressure. Generally it is not necessary to adjust the drum currents because they have already been adjusted for a wide range of environments at the factory. b) Drum current adjustment is necessary whenever the power packs are replaced: adjustment may also be necessary to correct problems with paper separation, incomplete toner transfer, or image density.
Page 155 4. Install the drum unit [B] on the machine. CAUTION: Be careful not to turn on the main motor. If the main motor accidentally turns on, some parts around the drum may be damaged. 5-21 A163...
Page 156: Charge Current Adjustment
4.8.1 Charge Current Adjustment ADJUSTMENT STANDARD: dc--1000 20 A WARNING: Make sure that the machine is unplugged before connecting the multimeter on the charge/bias/grid power pack. Pay extreme attention when connecting the multimeter. The potential of the charge corona terminal becomes --5kV. 1.
Page 157: Transfer Current Adjustment
4.8.2 Transfer Current Adjustment ADJUSTMENT STANDARD: dc --100 5 A (Leading edge to 20 mm from the trailing edge) dc --150 5 A (20 mm trailing edge) 1 Connect the multimeter as shown above. 2. Set the multimeter range at dc 200 A. 3.
Page 158: Separation Current Adjustment
4.8.3 Separation Current Adjustment ADJUSTMENT STANDARD: ac 250 10 A (Normal Paper) ac 350 10 A (Film and leading edge of translucent paper) dc --20 2.5 A 1. Connect the multimeter as shown above. 2. Set the multimeter range at ac 2 mA. 3.
Page 159 Rev. 5/95 12. Set the multimeter range at dc 200 A. 13. Select SP mode No. --16. 14. Press the key to turn on the separation corona. 15. Check the multimeter. Press the key and then change the current using keys so that the dc separation current is dc --20 2.5 A.
Page 160: Fusing
FUSING FUSING UNIT REMOVAL 1. Remove the copier rear cover. 2. Open the exit cover [A] and remove the shoulder screws [B] at both ends. 3. Disconnect the connector [C] and flex the hinge arms [D] of the exit cover slightly to the outside of the exit unit shafts and remove.
Page 161 5. Disconnect the connectors [A]. 6. Remove the screw [B] fixing the safety switch bracket. 7. Remove the 2 screws [C]. 8. While pressing down the fusing pressure release bar [D], pull out the fusing unit. NOTE: While pressing down the fusing pressure release bar [D], set the fusing unit on the guides [E] and align the cuts [F] to the side plates [G] at both ends when reinstalling the fusing unit.
Page 162: Hot Roller Replacement
Rev. 5/95 HOT ROLLER REPLACEMENT NOTE: Be careful not to damage the hot roller thermistor when removing and reinstalling the hot roller. 1. Remove the fusing unit. 2. Remove the pressure springs [A]. 3. Remove the fusing lamp brackets [B] and cushions [C] (1 screw each). 4.
Page 163: Pressure Roller Replacement
Rev. 5/95 PRESSURE ROLLER REPLACEMENT CAUTION: 1) Do not touch the hot roller or pressure roller while they are hot. 2) Be careful not to damage the hot roller thermistor [A] and pressure roller thermistor [B] when removing and reinstalling the pressure roller. 1.
Page 164: Pressure Roller Thermistor Replacement
PRESSURE ROLLER THERMISTOR REPLACEMENT 1. Follow step 1 to 5 of the fusing unit removal. 2. Remove the pressure roller thermistor [A] (1 screw). PRESSURE ROLLER STRIPPER UNIT REPLACEMENT 1. Follow step 1 to 5 of the fusing unit removal. 2.
Page 165: Hot Roller Thermistor Replacement
[E] [D] HOT ROLLER THERMISTOR REPLACEMENT 1. Remove the fusing unit. 2. Remove the 4 screws [A] of the fusing stay. 3. Disconnect the thermofuse connector [B] from the fusing lamp harness [C]. 4. Remove the hot roller thermistor [D] (1 screw and 1 spring, 7 clamps [E]). FUSING THERMOFUSE REPLACEMENT 1.
Page 166: Fusing Temperature Adjustment
FUSING TEMPERATURE ADJUSTMENT Caution: When the main switch is turned on, the machine will suddenly start to drive the fusing section. Keep your hands away from any mechanical and electrical components during this period. This procedure is required only when the hot roller thermistor is replaced. Adjustment standard: Mode 1 (155 C), Mode 2 (160 C), Mode 3 (165 C), Mode 4 (170 C), Mode 5 (180 C), Mode 6 (190 C), Mode 7 (196 C) 1.
Page 167: T & S Corona Unit
T & S CORONA UNIT T & S CORONA UNIT REMOVAL 1. Open the paper path section [A] and take out the T & S corona unit [B] (2 connectors [C]). NOTE: 1) Make sure that the T & S corona unit is set correctly by pressing it down when reinstalling.
Page 168: Transfer And Separation Corona Wire Replacement
TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT NOTE: (1) Handle the new wire by the ends only. Oil from your hands may cause uneven charging of the drum. (2) Do not stretch or bend the corona wires. (3) Do not rub the corona wires with rough material (sand paper, etc.) as this will damage the corona wire.
Page 169: Separation Corona Wire Replacement
6.2.2 Separation Corona Wire Replacement 1. Remove the separation corona wire [C]. 2. Hook the new separation corona wire on the terminal [D] of the right endblock. NOTE: Make sure that the wire junction [E] is positioned inside the right endblock.
Page 170: Others
OTHERS OZONE FILTER REPLACEMENT NOTE: Take care not to damage the mylars [A] on the rear feed table. 1. Open the fusing exit cover [B] and exit unit [C]. 2. Remove the copy tray [D]. 3. Remove the rear feed table assembly [E] (2 screws and 1 connector). 4.
Page 171: Anticondensation Heater Installation
ANTICONDENSATION HEATER INSTALLATION 1. Remove the rear cover of the machine (2 screws). 2. Remove the T&S corona unit. 3. Install the anticondensation heater [A] (3 screws). 4. Put the harness of the heater into the cutout [B] of the frame. 5.
Page 172: Copy Quality Adjustment
Rev. 5/95 COPY QUALITY ADJUSTMENT -- General Information -- Image density is affected by the following factors: (1) Light Intensity (2) Bias Voltage (3) Toner Density (4) Grid Voltage (5) Charge Corona Current The items listed above must be kept in balance to maintain correct image density. In the field, image density should be adjusted first by changing the light intensity.
Page 173: Light Sensor Adjustment
LIGHT SENSOR ADJUSTMENT 1. Every Call 2. When replacing the following part When: Exposure lamp Light sensor Drum RAM on the main board Purpose: To maintain the correct light intensity. Level 2 (10%) of the 9 step gray scale on the OS-A1 chart Adjustment should be slightly visible when the 4th manual image density Standard:...
Page 174: Image Bias Adjustment
IMAGE BIAS ADJUSTMENT 1. The image is blurred even though the image density in black solid areas is acceptable. When: 2. Dirty background, where the problem is not caused by excess toner and cannot be solved by adjusting the light sensor voltage.
Page 175: Toner Density Adjustment
TONER DENSITY ADJUSTMENT Customer wants to change the overall image density of the When: copies. Purpose: To change toner concentration inside development unit. Perform: SP #-22 How: Change the toner density setting by SP #-22 NOTE: The toner density can also be adjusted using SP #-30 (toner density sensor voltage setting).
Page 177: Troubleshooting
TROUBLESHOOTING...
Page 179: Copy Quality Troubleshooting
1. COPY QUALITY TROUBLESHOOTING 1.1 LOW IMAGE DENSITY Is the used paper moist or extremely dry? Replace the paper. Is the toner sensor voltage within the no toner supply level (level 0) ? (Refer to Page 2-16.) Is there sufficient toner in the cartridge? Replace the toner cartridge.
Page 180: Uneven Copy Image
1.2 UNEVEN COPY IMAGE Make a solid black copy using SP# --51. Is the image density even? Is the developer level in the development unit? Check and correct the machine level. Clean the charge corona wire, grid wire, and transfer corona wire. Check if they are correctly set on the slots of the end blocks.
Page 181: Dirty Background
1.3 DIRTY BACKGROUND Clean the optics and check the copy image. No good Change the light sensor setting to a lighter position using SP# - -6. No good Is the bias voltage correct? Adjust the bias voltage. Is the toner sensor voltage much lower than the threshold between level 0 and 1? (Check using SP#--32 referring to Page 2-16.) Check the main board and toner supply clutch.
Page 182: Black Line Or Band
1.4 BLACK LINE OR BAND Vertical line or band? Does the black line appear at 251 mm intervals? Clean or replace the drum. If a black band appears 250 mm from the leading edge, turn the main switch off and on . If the problem is not fixed, check the T&...
Page 183: Entirely Blank Copy
1.5 ENTIRELY BLANK COPY Is the used paper moist? Replace the paper. Are the terminals of the charge corona unit and the T& S corona unit connected properly? Set the terminals properly. Is the charge corona wire or the T & S corona wire broken? Replace the broken part.
Page 184: Paper Creasing
1.6 PAPER CREASING Is the used paper moist? Change the paper. Is the paper feed direction the same as the paper fiber direction? Change the paper transport direction, if possible. (NOTE 1.) Decrease the fusing temperature using SP mode #1 to #3. (NOTE 2.) NOTE: 1.
Page 185: Service Call Condition
2. SERVICE CALL CONDITION When a service call condition occurs, the Call Service indicator and service call codes are displayed. When the service call conditions E2, E3, E4, E5, E6, E7, and E8 conditions occur, for safety reason they cannot be cleared by turning the main switch off and on. Accessing SP38 and changing the date from "1"...
Page 186: Sc Code E-3: Hot Roller Thermistor Open
2.3 SC Code E-3: Hot Roller Thermistor Open -Definition- The temperature detected by the hot roller thermistor does not reach 50 C within 3 minutes after the main switch is turned on. <Point to check> Hot roller thermistor AC drive board ( T202-2, RA201-T4) Fusing thermofuse Main board (CN106-A2, -A5, -B11, -B14, -B15) 2.4 SC Code E-4: Hot Roller Thermistor Short...
Page 187: Sc Code E-6: Pressure Roller Thermistor Short
2.6 SC Code E-6: Pressure Roller Thermistor Short -Definition- The resistance of the pressure roller thermistor is less than 0.55 K . <Point to check> Pressure roller thermistor Main board (CN106-A2, -A5, -B11, -B14, -B15) 2.7 SC Code E-7: Fusing Overheat -Definition- The temperature detected by the hot roller thermistor becomes higher than 250 C <Point to check>...
Page 188: Sc Code E-8: Fusing Warm-Up Error
2.8 SC Code E-8: Fusing Warm-up Error -Definition- The temperature detected by the hot roller thermistor does not reach the target ready temperature within 12 minutes after main switch is turned on. <Point to check> Hot roller thermistor Fusing lamp Fusing thermofuse AC drive board (T202-2, RA201-T4) Main board (CN106-A2, -A5, -B11, -B14, -B15)
Page 189: Sc Code E-10: Main Motor Abnormal
2.10 SC Code E-10: Main Motor Abnormal -Definition- The main board does not receive a signal from the main motor for 2 seconds while the main motor is on. <Point to check> Main motor Mechanical interference of the main motor drive Main board (CN106-A12, -A13) 2.11 SC Code E-11: Toner Density Sensor adjustment Error -Definition-...
Page 190: Blown Fuse Table
Rev. 5/95 3. BLOWN FUSE TABLE 3.1 POWER SUPPLY UNIT Europe version Fuse Specification Symptom 250V 4A No power. No indication. 250V 6.3A Beeper sounds. 250V 6.3A E=10 is indicated. 250V 6.3A Not used. USA version Fuse Specification Symptom 125V 8A No power.
Page 191: Roll Feeder
ROLL FEEDER...
Page 193: Specifications
1. SPECIFICATIONS Roll Paper Size: Width: 210 mm to 914 mm, 8 " to 36" Length: 150 meters Diameter: Less than 170 mm Cut Size: --Preset Cut: 1189 mm, 841 mm, 594 mm, 420 mm, 297 mm 48", 36", 24", 18", 12" 46", 34", 22", 17", 11"...
Page 194: Mechanical Component And Drive Layout
2. MECHANICAL COMPONENT AND DRIVE LAYOUT 1. Paper Feed Motor 5. Paper Feed Rollers 2. Idle Pulley 6. Paper Roll Spool 3. Timing Belt 7. Paper Roll 4. Cutter Motor 8. Cutter Unit A163...
Page 195: Electrical Component Descriptions
Rev. 5/95 3. ELECTRICAL COMPONENT DESCRIPTIONS The index numbers refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper). Name Function Index No. Motors Paper Feed Drives all mechanical components except the cutter unit (DC Stepper Motor).
Page 196 A163...
Page 197: Mechanical Operation
4. MECHANICAL OPERATION 4.1 BASIC OPERATION The paper feed rollers [A], which are turned by the paper feed motor, feed paper from the paper roll [B] through the cutter unit [C] to the paper leading edge sensor [D] according to the signal from the copier. When the paper feed motor starts, the copier CPU starts measuring the length of the paper.
Page 198 Rev. 5/95 After the leading edge of the paper reaches the exit rollers [A], the paper is directed to the copier registration roller [B]. The registration roller stops rotating after the registration sensor [C] detects the leading edge of the copy paper. The copy paper is fed to the registration roller and stops to wait for the original.
Page 199: Cutter Unit Opening And Closing Mechanism
4.2 CUTTER UNIT OPENING AND CLOSING MECHANISM The gear [A] from the paper feed motor disengages from the cutter unit gears [B] when the roll cutter unit is unlocked from the lower position and lifted up. At this time, the cutter unit is locked at the upper position by the lock lever [C], and the wheel [D] on the right side can be rotated manually to position the leading edge of the roll paper.
Page 200: Cutter Operation
4.3 CUTTER OPERATION The cutter unit uses a sliding rotary cutting blade [A] which is pulled past a fixed blade by a drive wire. The rotary cutting blade allows the cutter unit to cut paper in both directions. There are home position switches [B] at both ends of the cutter unit.
Page 201: Service Tables
5. SERVICE TABLES 5.1 TEST POINTS Function TP No. TP903 (24 V) TP901 (5 V) TP902 5.2 BLOWN FUSE CONDITION Component Unit Symptom F901 (250V/1.0A) RF Main board The AC line for the R/F antihumidity heaters is cut. The heaters are not turned on.
Page 202 6. INSTALLATION PROCEDURE Roll Feeder (A571) CAUTION: Unplug the copier power cord before starting the following procedure. Check the accessories and their quantities according to the following list: Harness Cover ................2 pcs Angle Bracket ................1 pc Spacer ..................1 pc Small Cap..................
Page 203 1. Lower the feet [A] so that the table does not move while the roll feeder is being installed on the table and the copier. NOTE: Do not place the roll feeder unit [B] onto the floor roughly, to prevent the left and right covers from being damaged.
Page 204 5. Open the copier paper path section and remove the copier left lower cover [A] (2 screws), lower right front cover [B] (2 screws), lower right middle cover [C], toner collection bottle [D], and rear cover [E] (2 screws). 6. Remove the small caps [F] from the copier rear cover using cutting pliers. 7.
Page 205 NOTE: Take care not to drop the manual feed table when removing the bracket [A]. 8. Remove the lower front cover [B] (2 screws), reinforcement plate [C] (1 screw), bracket [A] (4 screws) (which is changed by the harness), and the manual feed table [D].
Page 206 9. Mount the roll feeder unit on the copier (hook the mounting arms [A] on both sides into the mounting rail [B]). NOTE: Lift the unit by holding the plate [C] just under the size marks. 10. Install the angle bracket [D] and spacer [E] (4 screws). 11.
Page 207 NOTE: To ensure grounding, tighten the screws for the ground wire until the spring washers [A] are flattened. 12. Secure the grounding wire [B] (1 screw with spring washer) to the inside of the table. 13. Run the roll feeder harness [C] and roll feeder heater harness [D] through the holes in the table rear cover (right [E] and left [F]) 14.
Page 208 Length PRG. 1100 PRG. Temperature NORMAL HIGH (VELLUM) LOW (FILM) 18. Plug in the power supply cord and turn on the main switch. 19. Press the following keys on the operation panel: Clear Modes key [A] + key [B] - key [C] Clear/Stop key [D] 20.
Page 209: Replacement And Adjustment
7. REPLACEMENT AND ADJUSTMENT 7.1 EXTERIOR COVER REMOVAL 7.1.1 Front Cover Removal 1. Remove the front cover [A] (2 screws). NOTE: If the screw holes for the front cover become worn by the screws, extra holes are provided next to the original screw holes. 7.1.2 Left and Right Cover NOTE: Be careful not to drop and damage the lower front cover [B].
Page 210: Cutter Unit Removal
7.2 CUTTER UNIT REMOVAL 1. Remove the roll feeder left and right covers. 2. Remove the 4 screws [A] of the cutter unit. 3. Take out the cutter unit [B] (1 connector [C]). NOTE: When reinstalling the cutter unit, attach the cutter unit cover [D] with the cutter unit.
Page 211: Paper Feed Roller Replacement
7.3 PAPER FEED ROLLER REPLACEMENT [H] [G] 1. Remove the cutter unit. 2. Unlock and lift the paper feed roller unit [A] using the release lever [B]. 3. Remove the release lock lever [B] (2 screws). 4. Remove the feed roller guide plate [C] (6 screws). 5.
Page 212: Paper Feed Motor Timing Belt Tension Adjustment
7.4 PAPER FEED MOTOR TIMING BELT TENSION ADJUSTMENT If the timing belt tension for the paper feed motor is not correct, the paper cut length varies for each copy paper. Readjust the timing belt tension for the paper feed if this occurs. 1.
Page 213: Cut Length Adjustment
Rev. 5/95 7.5 CUT LENGTH ADJUSTMENT The cut length adjustment should be done when the roll feeder is installed to correct cutting errors. The cut error correction data is determined in the factory without the copier installed. The cut length varies depending on the copier on which it is installed and/or paper type used.
Page 214: Roll Feed Paper Skew Adjustment
7.6 ROLL FEED PAPER SKEW ADJUSTMENT 1. Mark a line [A] on the exposure glass [B]. 2. Make 594 x 1189 mm copies from the roll feeder unit. NOTE: 594 mm wide paper is easier to adjust than 841 mm wide paper. 3.
Page 215 A251/A252 Service Manual The A251/A252 machines are based on the A163 copier. Only the differences from the base copier are described in the following pages. Therefore, this documentation should be treated as an insert version of the base copier’s service manual. It should always be utilized together with the base copier’s service manual.
Page 217 TABLE OF CONTENTS 1. OVERALL MACHINE INFORMATION ......... 1-1 1.1 SPECIFICATIONS..................1-1 1.2 PAPER PATH .................... 1-3 1.4 MECHANICAL COMPONENT ..............1-4 1.5 DRIVE LAYOUT ..................1-6 1.6 ELECTRICAL COMPONENT DESCRIPTIONS ........1-7 2. DETAILED SECTION DESCRIPTIONS........2-1 2.1 DRUM ......................2-1 2.1.2 DRUM DRIVE......................
Page 218 5.5 FUSING ..................... 5-7 5.5.1 FUSING UNIT REMOVAL................... 5-7 5.6 T & S CORONA UNIT................5-9 6.5.1 TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT......5-9 5.8 COPY QUALITY ADJUSTMENT ............. 5-11 5.8.4 REGISTRATION ADJUSTMENT ................5-11 6. TROUBLESHOOTING..............6-1 6.2 SERVICE CALL CONDITIION..............6-1 6.2.12 SC CODE E-14: ZERO CROSS SIGNAL DETECTION ABNORMAL ......
Page 219 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. Note that some components of the copier and the peripherals are supplied with electrical voltage even if the main switch is turned off.
Page 220 SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner cartridge or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductors according to local regulations. (These are non-toxic supplies.) 3.
Page 221 A251/A252 OVERALL MACHINE INFORMATION A251/A252 DETAILED SECTION DESCRIPTIONS A251/A252 INSTALLATION A251/A252 SERVICE TABLES A251/A252 REPLACEMENTS AND ADJUSTMENT A251/A252 TROUBLESHOOTING...
Page 225 OVERALL INFORMATION...
Page 227: Overall Machine Information
SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS Configuration: Table top Copy Process: Electrostatic transfer system Original Feed: Sheet feed Original Size: Maximum: 914 x 2,000 (36" x 80")mm Minimum: A4 (8 " x 11") lengthwise Copy Size: Same as “Original Size” Copying Speed: 3 cpm (A1/D sideways) First Copy:...
Page 228 SPECIFICATIONS Power Source: 115 V/60 Hz ..15 A 220 V/50 Hz ..7 A 230 V/50 Hz ..7 A 240 V/50 Hz ..7 A Power Consumption: Maximum: 1.4 kW Warm-up: 1.2 kW Ready: 0.04 to 1.2 kW Copy cycle: 1.4 kW Dimensions (W x D x H): A251: 1,080 x 570 x 490 mm...
Page 229: Paper Path
PAPER PATH 1.2 PAPER PATH - A252 copier - - A251 copier - A252V500.PCX A252V504.WMF A: Original Path (A251 copier) B: Paper from the manual feed C: Paper from the roller feed D: Paper exit E: Original Path from Rear Feeder F: Original Path (A252 copier): Switching back A251/A252...
Page 230: Mechanical Component
MECHANICAL COMPONENT 1.4 MECHANICAL COMPONENT 25 1 A252V502.PCX 1st Original Feed Roller 14. Roll Feeder 1st Press Rollers 15. Paper Registration Rollers Copy Tray 16. Development Unit Exit Rollers 17. Toner Cartridge Fusing Exit Rollers 18. Manual Feed Table Hot Roller 19.
Page 231 MECHANICAL COMPONENT A252V505.WMF 26. Original Guide 30. Original Rear Roller 27. Rear Copy Tray (Option Copy Tray) 31. Original Entrance Press Roller 28. Original Feed Motor 32. Original Rear Press Roller 29. Original Entrance Roller A251/A252...
Page 232: Drive Layout
DRIVE LAYOUT 1.5 DRIVE LAYOUT A252V503.WMF - A252 copier only - A252V501.WMF Original Feed Roller Pulley 11. Hot Roller Drive Gear Original Feed Roller One Way Pulley 12. Fusing Drive Sprocket/Gear Development Unit 13. Toner Collection Coil Drive Gear Development Unit Relay Gear 14.
Page 233: Electrical Component Descriptions
ELECTRICAL COMPONENT DESCRIPTIONS 1.6 ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout on the reverse side of the Point to Point (Water proof paper) index numbers. Name Function Index. No. Motors Main Drives all mechanical components except the original feed section (A252only) and the fans. (DC Motor) Exhaust Fan Removes the ozone built up around the drum...
Page 234 ELECTRICAL COMPONENT DESCRIPTIONS Name Function Index. No. Printed Circuit Boards Main Controls all copier functions both directly and through other PCBs. Converts the AC voltage to DC voltage. AC Drive Provides AC power to the fusing lamp and PSU. FL Regulator Stabilizes power to the exposure lamp.
Page 235 DETAILED DESCRIPTIONS...
Page 237: Detailed Section Descriptions
DRUM 2. DETAILED SECTION DESCRIPTIONS 2.1 DRUM 2.1.2 DRUM DRIVE - A252 copier only - A252D502.WMF A252D503.WMF The OPC drum [A] is 80 millimeters in diameter and 970 millimeters long. It turns constantly when the main motor [B] is on. When the main motor turns on, the drive is transmitted to the drum as follows: main motor drive gear [C] idle gears [D]...
Page 238: Exposure
EXPOSURE 2.3 EXPOSURE 2.3.2 PAPER AND ORIGINAL FEED (A252 ONLY) 26 mm 15 mm J: Original Rear Roller K: Original Rear Sensor A252D500.WMF A252D501.WMF In this machine (A252 copier), first, the leading edge [A] of the original is inserted into the original table and the original is delivered to the appropriate start position. Then the original is switched back while it is being scanned.
Page 239 EXPOSURE When the original entrance sensor is turned off by the trailing edge [E] of the original, the roll paper feed motor turns on and paper feeding starts. When the trailing edge of the original reaches the original feed start position (26 mm ahead of the original registration sensor [F]), the original feed motor stops to wait for the copy paper.
Page 240: Development
DEVELOPMENT 2.4 DEVELOPMENT 2.4.2 TONER DENSITY CONTROL Recovery from Toner End Condition After replacing the toner cartridge (opening and closing the original feed unit), the main motor rotates the development unit for 60 seconds. During this period, toner is supplied at 100% of the supply amount until TS level reaches 3. Then, the main motor rotates the development unit for another 30 seconds.
Page 241: Fusing And Paper Exit
FUSING AND PAPER EXIT 2.8 FUSING AND PAPER EXIT 2.8.1 OVERVIEW (A252 COPIER) The copy paper is delivered to the lower paper exit. The location of the fusing exit sensor is different from the A163 and A251 copier. Except for this difference, the A252 copier is identical to the with A251 and A163 copiers.
Page 243: Installation
INSTALLATION...
Page 245: Installation Requirements
INSTALLATION REQUIREMENTS 3. INSTALLATION 3.1 INSTALLATION REQUIREMENTS 3.1.1 ENVIRONMENT 1. Temperature Range: 15 C to 30 C (59 F to 86 F) 2. Humidity Range: 20% to 80% RH 3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight).
Page 246: Minimum Space Requirements
INSTALLATION REQUIREMENTS 3.1.2 MINIMUM SPACE REQUIREMENTS Back 600 mm Left Right 600 mm 600 mm Back 1,000 mm A252I505.WMF 1. Front: 1,000 mm (39 in) 2. Back: 600 mm (24 in) 3. Right: 600 mm (24 in) 4. Left: 600 mm (24 in) 3.1.3 MACHINE LEVEL 1.
Page 247: Power Source
INSTALLATION REQUIREMENTS 3.1.4 POWER SOURCE 1. Input Voltage Level: 120 V, 60 Hz More than 15 A (for U.S.A. version) 220 ~ 240 V, 50/60 Hz More than 7 A (for European version) 2. Permissible Voltage Fluctuation: 3. Do not set anything on the power cord. NOTE: 1) Make sure the plug is firmly inserted in the outlet.
Page 248: Copier
INSTALLATION PROCEDURE 3.2 INSTALLATION PROCEDURE 3.2.1 COPIER Accessory Check Check the accessories and their quantities according to the following list: - A252 copier - Original Guide ................. 6 pcs Operating Instruction Holder ........... 1 pc - A251 copier - Guide Wire ................2 pcs Copy Tray ................
Page 249: Installation Procedure
INSTALLATION PROCEDURE A252I500.WMF 1. Lower the feet [A] so that the table does not move while the copier is being installed on the table. 2. Place the copier [B] on the table [C] (Place the copier feet [D] into the table holes [E]).
Page 250 INSTALLATION PROCEDURE A252I501.WMF A252I510.WMF A252I502.WMF 3. Open the paper path section [A]. 4. Remove the right upper cover [B] (2 screws). 5. Remove the drum protection sheet [C] and remove the screw [D] to apply cleaning blade pressure to the drum. 6.
Page 251 INSTALLATION PROCEDURE A252I511.WMF A252I503.WMF A252I504.WMF 8. Remove two shipping cushions [A]. 9. Open the original feed unit [B], manual feed table [C], and toner supply cover [D]. Remove a sheet [E] covering the developer entrance. Pour 1 kg of the developer [F] into the development unit evenly across its width as shown.
Page 252 INSTALLATION PROCEDURE A252I508.WMF NOTE: If the fusing temperature is lower than 60 C when the main switch is turned on, the main motor will rotate. In this case, it is not necessary to access the SP mode to load the total 2kg of developer (Steps 11 to 14). Turn off the main switch to stop the main motor after the developer is loaded from the development entrance.
Page 253 INSTALLATION PROCEDURE A252I508.WMF 15. Press the following keys on the operation panel: Clear key [A] + key [B] – key [C] Clear/Stop key [D] 16. Press the Clear/Stop key again for longer than 3 seconds. The roll paper end and call service indicators will blink (SP mode). 17.
Page 254 INSTALLATION PROCEDURE A252I507.WMF 18. Install the toner cartridge [A] as shown. 19. Remove the sealing tape [B] from the cartridge and turn the knob [C] until it stops. A251/A252 3-10...
Page 255 INSTALLATION PROCEDURE A252I506.WMF A252I509.WMF A252 copier only (step 20) 20. Install the original guides [A]. A251 copier only (step 21 and 22) 21. Attach the guide wires [B] to the copy tray [C]. 22. Install the copy tray [C] and copy guide [D]. 23.
Page 256: Table (A)
INSTALLATION PROCEDURE 3.2.2 TABLE (A836) Accessory Check Check the accessories and their quantities according to the following list: Top Plate ................1 Left Side Plate ................ 1 Right Side Plate ..............1 Middle Plate ................1 Rear Cover ................1 Screws with Spring Washer - M4 x 8 ........
Page 257 INSTALLATION PROCEDURE A, B A836I501.WMF A836I500.WMF NOTE: To ensure grounding, paint has been removed from the surfaces around the screw holes [A] (only from the surfaces where the two components meet) and from the surface around the screw hole [B] at the inside of the left plate.
Page 258: Copy Tray (A836-10)
INSTALLATION PROCEDURE 3.2.3 COPY TRAY (A836-10) Accessory Check Check the accessories and their quantities against the following list: Front Copy Tray Stay.............. 1 Rear Copy Tray Stay .............. 1 Copy Tray Support..............1 Copy Tray Guide..............2 Copy Tray Sheet ..............3 Nylon Clamp ................
Page 259 INSTALLATION PROCEDURE A836I501.WMF A836I502.WMF 1. Install the front copy tray stay [A] and rear copy tray stay [B] (4 screws each). NOTE: This step should be done during the table installation when the table and the copy tray are installed at the same time. Refer to the table installation procedure.
Page 260 INSTALLATION PROCEDURE A836I503.WMF A836I504.WMF 4. Adhere the copy tray sheets with rubber [A] to the middle plate [B] of the table so that the copy tray sheets are positioned between the screw holes [C] on the rear copy tray stay [D] as shown in the illustration. 5.
Page 261 INSTALLATION PROCEDURE A836I505.WMF 5 mm 5 mm A836I506.WMF A836I508.WMF 7. Adhere the rear copy tray sheet - center (long) [A] and the two rear copy tray sheets - short [B] onto the exit cover as shown. 8. Adhere the copy tray stoppers [C] to the front side of the table middle plate [D]. 3-17 A251/A252...
Page 262 INSTALLATION PROCEDURE 3.2.4 ROLL FEEDER (A571) CAUTION Unplug the copier power cord before starting the following procedure. Accessory Check Check the accessories and their quantities according to the following list: Harness Cover ............... 2 pcs Angle Bracket ................. 1 pc Spacer ...................
Page 263 INSTALLATION PROCEDURE A571I500.WMF A571I501.WMF A571I502.WMF 1. Lower the feet [A] so that the table does not move while the roll feeder is being installed on the table and the copier. NOTE: Do not place the roll feeder unit [B] onto the floor roughly, to prevent the left and right covers from being damaged.
Page 264 INSTALLATION PROCEDURE A571I503.WMF A571I504.WMF A571I505.WMF 5. Open the copier paper path section and remove the copier left lower cover [A] (2 screws), lower right front cover [B] (2 screws), lower right middle cover [C], toner collection bottle [D], and rear cover [E] (2 screws). 6.
Page 265 INSTALLATION PROCEDURE A571I506.WMF NOTE: Take care not to drop the manual feed table when removing the bracket [A]. 8. Remove the lower front cover [B] (2 screws), reinforcement plate [C] (1 screw), bracket [A] (4 screws) (which is changed by the harness), and the manual feed table [D].
Page 266 INSTALLATION PROCEDURE A571I507.WMF A571I508.WMF 9. Mount the roll feeder unit on the copier (hook the mounting arms [A] on both sides into the mounting rail [B]). NOTE: Lift the unit by holding the plate [C] just under the size marks. 10.
Page 267 INSTALLATION PROCEDURE - A251 copier - A571I512.WMF A571I513.WMF A571I510.WMF NOTE: To ensure grounding, tighten the screws for the ground wire until the spring washers [A] are flattened. 12. Secure the grounding wire [B] (1 screw with spring washer) to the inside of the table.
Page 268 INSTALLATION PROCEDURE A571I514.WMF Length PRG. PRG. 1100 Temperature NORMAL HIGH (VELLUM) LOW (FILM) 19. Plug in the power supply cord and turn on the main switch. 20. Press the following keys on the operation panel: Clear Modes key [A] + key [B] –...
Page 269: Service Tables
SERVICE TABLES...
Page 271: Service Tools
SERVICE TOOLS 4. SERVICE TABLES 4.3 SERVICE TOOLS 4.3.1 SERVICE PROGRAM MODE All items except for the following are common with the A163 copier. Please refer to the A163 copier service manual. Service Program Mode Table Mode No. Function Data 0: 2 minutes Paper Feed Out Refer to the A163 service manual for details.
Page 272 SERVICE TOOLS Mode No. Function Data Synchro-cut Adjusts the cut length in the semi-synchro 25 (Shorter) Length Adjustment cut mode (A251 copier). (Longer) Adjusts the cut length in the synchro cut, 1 mm/step preset cut, and variable cut modes (A252 copier).
Page 273 SERVICE TOOLS Mode No. Function Data Toner Near End Displays the total number of toner near end dtn = XX Counter conditions (dtn). Also, displays the toner Hdt = XX,XXX counter (SP78) at the last toner end condition (Hdt). Not Used Not Used Number of Displays the total number of originals in the...
Page 274 SERVICE TOOLS Mode No. Function Data 0: Not Used RAM Clear Clears selected data items from the RAM. To clear the memory, input the number of 1: Machine Operation the item you want to delete, then press the (The memory for SP67) key.
Page 275 SERVICE TOOLS Mode No. Function Data 11: Change the settings to the U.S.A. version 12: Change the settings to the Europe version 13: Change the settings to the Asia version 14: Charge the settings to the Hoechst version 15: Change the settings to the Regma version 16: Change the settings...
Page 276 SERVICE TOOLS Mode No. Function Data Total Counter Unit Selects the unit in which the total counter 0: 1 yard Setting counts up by. 1: 1 m 2: 100 inches 3: 50 inches 4: A1 length (594 mm) 5: Sheet (Any size) 6: 1 foot Registration Adjusts the paper registration.
Page 277 SERVICE TOOLS Mode No. Function Data Synchro-cut Adjusts the original cut length in Synchro Length Auto Cut mode at 1189 mm. 1 step = 0.1 mm Adjustment Insert the 1189 mm length original five times (this number displayed on the copy number (1,189 mm) indicator can be changed : 1 to 10).
Page 278 SERVICE TOOLS Mode No. Function Data 0: Non-Length Display Cut Length In semi-synchro cut mode, the machine Display Mode stores the 1st original cut length and 1: Length Display displays it in the paper length counter. In this case, the paper cut mode will be automatically changed to the Preset/Variable cut mode.
Page 279: Input/Output Check Mode
SERVICE TOOLS 4.3.2 INPUT/OUTPUT CHECK MODE Input Check Mode Table The on/off status of the selected electrical component is displayed in the paper length indicator (“ON” or “OFF” is displayed). If a program number not used is selected, “NOT” is displayed. Program No.
Page 280 SERVICE TOOLS Output Check Mode Table Press the Bypass Select key to turn on the selected electrical component. The status of the component is displayed in the paper length indicator. To turn off the component, press the Bypass Select key again. Program No.
Page 281: Jam Code List
JAM CODE LIST 4.4 JAM CODE LIST 4.4.2 JAM CODE TABLE Code Cause of Jam Remarks dJ01 Initial misfeed at the original entrance sensor. A252 only dJ02 Initial misfeed at the original registration sensor. dJ03 Initial misfeed at the original rear sensor. A252 only dJ05 Initial misfeed at the entrance sensor.
Page 282 JAM CODE LIST Code Cause of Jam Remarks Original registration sensor does not turn off after paper is dJ45 fed 2,500 mm. Registration sensor OFF condition is detected just after pJ51 starting the copy process. Registration sensor OFF condition is detected before pJ52 A251 only starting the roll feeder again.
Page 283 JAM CODE LIST Fixed Paper Size Pattern Data (SP No. 22) In mm Mode 0: 1189, 841, 594, 420, 297 1: 2000, 1189, 841, 594, 420, 297, 245 2: 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 245 3: 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1189, 841, 594, 420, 297, 4: 2000, 1800, 1456, 1189, 1030, 841, 728, 594, 515, 420, 364, 297, 245...
Page 284 JAM CODE LIST 12: 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 48.0, 42.0, 36.0, 24.0, 18.0, 12.0, 9.6 13: 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 44.0, 42.0, 34.0, 22.0, 17.0, 11.0, 9.6 14: 80.0, 78.0, 76.0, 74.0, 72.0, 70.0, 68.0, 66.0, 64.0, 62.0, 60.0, 58.0, 56.0, 54.0, 52.0, 50.0, 48.0, 46.0, 44.0, 42.0, 40.0, 38.0, 36.0, 34.0, 32.0, 30.0, 28.0, 26.0, 24.0, 22.0,...
Page 285: Service Remarks
SERVICE REMARKS 4.6 SERVICE REMARKS 4.6.12 AC DRIVE BOARD Noise Filter AC Drive Board TB202 TB201 A252M500.WMF Service Remark for 220 240 V Version Make sure that the harnesses are connected to the noise filter and ac drive board as shown correctly 1.
Page 286 SERVICE REMARKS AC Drive Board TB201 TB202 A252M500.WMF Service Remarks for 120 V Version Make sure that the harness is connected to the ac drive board as shown correctly 1. Set the power supply cord harness hot line (black wire) yellow connector to TB201 on ac drive board.
Page 287: Replacement And Adjustment
REPLACEMENT AND ADJUSTMENT...
Page 289: Optics
OPTICS 5. REPLACEMENT AND ADJUSTMENT 5.2 OPTICS [A] [D] A252R500.WMF A252R501.WMF 5.2.1 ORIGINAL FEED UNIT REMOVAL (A252 ONLY) 1. Remove the left and right upper covers. 2. Remove the upper original guide [A]. 3. Push the projections [B] into the holes [C] of the rear side of the original feed unit as shown and remove the operation panel [D] (1 screw and 2 connectors).
Page 290: Exposure Glass Removal (A252 Only)
OPTICS A252R510.WMF A252R502.WMF 5.2.2 EXPOSURE GLASS REMOVAL (A252 ONLY) 1. Remove the original feed unit. 2. Remove the exposure glass bracket [A] (1 screw). 3. Remove the exposure glass stoppers [B] (2 screws). 4. Remove the exposure glass [C] by sliding it out to the right side and lifting up the left side as shown.
Page 291: Exposure Lamp Removal
OPTICS 5.2.4 EXPOSURE LAMP REMOVAL A252R511.WMF 1. Remove the fiber optics array. NOTE: If the exposure lamp is too tight to be turned, remove one side of the exposure lamp socket (1 screw) and remove the exposure lamp. 2. Turn the exposure lamp [A] 1/4 of a turn and remove. NOTE: Make sure that the direction of the aperture [B] of the exposure lamp is towards the fiber optics array side (rear side).
Page 292: Light Sensor Replacement (A252 Only)
OPTICS 5.2.5 LIGHT SENSOR REPLACEMENT (A252 ONLY) A252R503.WMF 1. Follow the steps from 1 to 2 of the fiber optics array removal. 2. Replace the light sensor [A] (1 screw, 1 connector). A251/A252...
Page 293: Synchro-Cut Length Adjustment (A252 Only)
OPTICS 5.2.6 SYNCHRO-CUT LENGTH ADJUSTMENT (A252 ONLY) This adjustment should be carried out when the original registration and/or original entrance sensor is replaced. 1. Measure the actual length of A3 (297) and A0 (1189) originals. 2. Access SP#-35 (synchro-cut length auto adjustment, 297 mm) and input the difference between the measured length and 297 mm.
Page 294: Drum Unit
DRUM UNIT 5.4 DRUM UNIT 5.4.1 DRUM UNIT REMOVAL A252R504.WMF A252R505.WMF 1. Remove the development unit. 2. Remove the 2 screws [A] at both ends. 3. Remove the timing belt [B] (A251 copier)/grounding plate spring [B] (A252 copier) and disconnect the harness connector [C]. 4.
Page 295: Fusing
FUSING 5.5 FUSING 5.5.1 FUSING UNIT REMOVAL A252R509.WMF NOTE: Close the paper path section to remove and reinstall the fusing unit. 1. Remove the copier rear cover. 2. Open the exit cover [A] and remove the shoulder screws [B] at both ends. Remove the screws [C] for the grounding wires.
Page 296 FUSING A252R507.WMF A252R508.WMF A252R506.WMF 5. Disconnect the connectors [A]. 6. Remove the screw [B] fixing the safety switch bracket. 7. 220 ~ 240 V version only: Remove the 2 screws [C] and bronze plate [D] (2 screws). 8. While pressing down the fusing pressure release bar [E], pull out the fusing unit.
Page 297: T & S Corona Unit
T & S CORONA UNIT 5.6 T & S CORONA UNIT 5.6.1 TRANSFER AND SEPARATION CORONA WIRE REPLACEMENT A252R512.WMF NOTE: 1) Handle the new wire by the ends only. Oil from your hands may cause uneven charging of the drum. 2) Do not stretch or bend the corona wires.
Page 298 T & S CORONA UNIT Separation Corona Wire Replacement 1. Remove the separation corona wire [C]. 2. Hook one end of the new separation corona wire on the terminal [D] of the right endblock. 3. Hook the center part of the separation corona wire on the spring [E] of the left endblock.
Page 299: Copy Quality Adjustment
COPY QUALITY ADJUSTMENT 5.8 COPY QUALITY ADJUSTMENT 5.8.4 REGISTRATION ADJUSTMENT When: Registration is not within the adjustment standard. Purpose: To maintain proper registration. Adjustment ") 3 mm (0 0.12 Standard: Perform: SP#-5, SP#-27 (A252 rear original feed) How: Change the registration roller start timing by SP#-5 and/or SP#-27 1.
Page 301: Troubleshooting
TROUBLESHOOTING...
Page 303: Service Call Conditiion
SERVICE CALL CONDITION 6. TROUBLESHOOTING 6.2 SERVICE CALL CONDITION The following service conditions are newly added as the A251 and A252 copiers. For other SC conditions, refer to the A163 copier for details. To clear SC E-15, access SP38 and change the data from “1” to “0”. 6.2.12 SC CODE E-14: ZERO CROSS SIGNAL DETECTION ABNORMAL - Definition -...
Page 304: Blown Fuse Table
BLOWN FUSE TABLE 6.3 BLOWN FUSE TABLE 6.3.1 POWER SUPPLY UNIT Europe Version Fuse No. Specification Symptom FU301 250 V 5A No power. FU302 250 V 6.3 A Flourescent lamp does not light. Black copy. FU303 250 V 6.3 A No indication.
Page 305 B047/B048 SERVICE MANUAL – Insert Version – The B047/B048 machines are based on the A163/A251/A252 copiers. Only the differences from the base copier are described in the following pages. Therefore, this documentation should be treated as an insert version of the base copier’s service manual.
Page 307 INSERTION PROCEDURE OF SERVICE MANUAL 1. Replace the book spine tag with the new one. 2. Insert the B047/B048 service manual after the A163/A251/A252 manual.
Page 309 B047/B048 TABLE OF CONTENTS This manual describes new items for the J2SS-C3 (B047/B048). Please refer to the J2SS Mark II (A251/A252) manual for the descriptions marked with “*” in page column. OVERALL INFORMATION 1. OVERALL MACHINE INFORMATION ........1-1 1.1 SPECIFICATIONS..................1-1 1.2 PAPER PATH....................1-3 1.3 DRUM PROCESSES ................
Page 310 Recovery from Toner End Condition.............2-5 Toner Density Sensor ................* 2.4.5 DEVELOPMENT BIAS ..............* Basic Concept..................* Manual Image Density Bias ..............* 2.4.6 TONER SUPPLY ................* 2.5 IMAGE TRANSFER AND PAPER SEPARATION ........* 2.5.1 PRE-TRANSFER LAMP (PTL) ............* 2.5.2 IMAGE TRANSFER.................
Page 311 Both copiers (step 24 and 25).............3-12 3.2.2 TABLE (B439) ................3-13 Accessory Check ................3-13 3.2.3 COPY tray (B440)................3-15 Accessory Check ................3-15 3.2.4 ROLL FEEDER1 and 2 (B435/b436) ..........3-19 Accessory Check ................3-19 3.2.5 Roll Cutting Rail (B437) ..............3-28 SERVICE TABLES 4. SERVICE TABLES..............4-1 4.1 PREVENTIVE MAINTENANCE SCHEDULE ...........
Page 312 4.6.9 PAPER FEED.................. * 4.6.10 ROLL FEEDER................* 4.6.11 OTHERS..................* 4.6.12 AC DRIVE BOARD ...............4-29 Service Remark for 220 ~ 240 V Version..........4-29 Service Remarks for 120 V Version ............4-30 REPLACEMENT AND ADJUSTMENT 5. REPLACEMENT AND ADJUSTMENT........5-1 5.1 EXTERIOR COVERS ................* 5.1.1 LEFT SIDE COVER REMOVAL ............
Page 313 5.5 FUSING .....................5-2 5.5.1 FUSING UNIT REMOVAL ............... * 5.5.2 HOT ROLLER REPLACEMENT ............* 5.5.3 PRESSURE ROLLER REPLACEMENT.......... * 5.5.4 PRESSURE ROLLER THERMISTOR REPLACEMENT ....* 5.5.5 PRESSURE ROLLER STRIPPER UNIT REPLACEMENT....* 5.5.6 HOT ROLLER STRIPPER UNIT REPLACEMENT......* 5.5.7 HOT ROLLER THERMISTOR REPLACEMENT ......5-2 5.5.8 FUSING THERMOFUSE REPLACEMENT ........5-2 5.5.9 FUSING TEMPERATURE ADJUSTMENT ........5-3...
Page 314 SC Code E-10: Main Motor Abnormal...........6-3 SC Code E-11: Toner Density Sensor Adjustment Error ......6-3 SC Code E-13: Total Counter Abnormal..........6-4 SC Code E-14: Zero Cross Signal Detection Abnormal......6-4 SC Code E-15: Main Switch Abnormal ..........6-4 SC Code E-17: Unstable Fusing Temperature ........6-4 SC Code E-18: Fusing Lamp Continuous Light ........6-4 6.3 BLOWN FUSE TABLE ................6-5 6.3.1 POWER SUPPLY UNIT..............6-5...
Page 315 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. Note that some components of the copier and the peripherals are supplied with electrical voltage even if the main switch is turned off.
Page 316 SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner cartridge or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductors according to local regulations. (These are non-toxic supplies.) 3.
Page 317 B047/B048 OVERALL INFORMATION B047/B048 DETAILED DESCRIPTIONS B047/B048 INSTALLATION B047/B048 SERVICE TABLES B047/B048 REPLACEMENT AND ADJUSTMENT B047/B048 TROUBLESHOOTING ROLL FEED UNIT B435/B436...
Page 321 OVERALL INFORMATION...
Page 323 SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS Configuration: Table top Copy Process: Electrostatic transfer system Original Feed: Sheet feed Original Size: Maximum: 914 x 3,000 (36" x 118")mm Minimum: A4 (8 " x 11") lengthwise Copy Size: Same as “Original Size” Copying Speed: 4 cpm (A1/D sideways) First Copy:...
Page 324: Specifications
SPECIFICATIONS Self-diagnostic Codes: 16 codes, displayed on the copy counter Power Source: 115 V/60 Hz, 12 A 220 ~ 240V/50, 60 Hz, 7A Power Consumption: Maximum: 1.4 kW Warm-up: 1.3 kW Ready: 0.04 to 1.3 kW Copy cycle: 1.4 kW Dimensions (W x D x H): B047: 1,080 x 570 x 490 mm 42.5"...
Page 325: Paper Path
PAPER PATH 1.2 PAPER PATH - B047 copier - - B048 copier - B047V102.WMF B048V102.WMF A: Original Path B: Manual Feed Path C: Roll Feeder Path D: Paper Exit E: Original Path: Rear Feeder There are two versions of this machine. The B047 is the basic version. It can only make one copy at a time.
Page 326: Mechanical Components
MECHANICAL COMPONENTS 1.4 MECHANICAL COMPONENTS 20 21 22 B047V101.WMF 1. 1st Original Feed Roller 12. Roll Feed Unit (1 roll or 2 rolls) 2. 1st Press Rollers 13. Roll Paper 3. Copy Tray 14. Paper Registration Rollers 4. Exit Rollers 15.
Page 327 MECHANICAL COMPONENTS B048V101.WMF 23. Original Guide 27. Original Roller Feed Motor 24. Optional Copy Tray 28. Original Rear Press Roller 25. Original Entrance Roller 29. Original Rear Roller 26. Original Entrance Press Roller B047/B048...
Page 328: Electrical Components
ELECTRICAL COMPONENTS 1.6 ELECTRICAL COMPONENTS Refer to the electrical component layout on the reverse side of the Point to Point index (Water proof paper). Name Function Index. No. Motors Main Drives all mechanical components except the fans (DC Motor). Exhaust Fan Removes the ozone built up around the drum section to the ozone filter (DC Motor).
Page 329 ELECTRICAL COMPONENTS Name Function Index. No. Printed Circuit Boards Main Controls all copier functions both directly and through other PCBs. Converts the voltage from AC to DC voltage. AC Drive Provides AC power to the fusing lamp and PSU. FL Regulator Stabilizes power to the exposure lamp.
Page 331: Detailed Section Descriptions
DETAILED DESCRIPTIONS...
Page 333: Detailed Section Descriptions
EXPOSURE 2. DETAILED SECTION DESCRIPTIONS 2.3 EXPOSURE 2.3.2 PAPER AND ORIGINAL FEED (B048 ONLY) 26 mm 10 mm J: Original Rear Roller K: Original Rear Sensor L: Fiber Optics Array B047D500.WMF B047D501.WMF NOTE: For clarity’s sake, the following description will refer to the paper’s edges as edge [A] (furthest edge from the operator) and edge [B] (closest to the operator).
Page 334: Scanning
EXPOSURE 4 seconds after the sensor is activated, the original feed motor starts rotating. This delay gives the user time to align edge [A] against the original entrance rollers [D]. This helps prevent skew. The original is fed through the machine to the scanning start position [E].
Page 335: Start Key Enable
EXPOSURE Start Key Enable When the start key enabled (SP34) is set, the start key acts as a starting trigger. In this mode, when the original activates the original registration sensor, edge [B] is delivered to the original registration sensor position. Everything pauses until the user presses the start key.
Page 336: Toner Density Control
DEVELOPMENT 2.4 DEVELOPMENT 2.4.4 TONER DENSITY CONTROL The toner supply amount ratio is determined by the following conditions. 51 ~ 100 101 ~ 150 151 ~ 200 201 ~ 250 0 ~ 50 sheets 251 sheets ~ sheets sheets sheets sheets Level (~ 30 m)
Page 337: Recovery From Toner End Condition
DEVELOPMENT Recovery from Toner End Condition After replacing the toner cartridge (opening and closing the original feed unit), the main motor rotates the development unit for 60 seconds. During the first 30 seconds, toner is supplied at 100% of the supply amount until TS level reaches 3. The main motor continues to rotate the development unit for another 30 seconds.
Page 338: Used Toner Collection
CLEANING 2.6 CLEANING 2.6.2 USED TONER COLLECTION B047D101.WMF B047/B048 copiers have a used toner overflow sensor [A] and a used toner cover switch [B]. When the used toner overflow sensor detects that the used toner tank is full, the overflow indicator begins blinking on the operation panel. 30 more meters (A1/D size: 50 copies, SP51) can be copied.
Page 339: Fusing And Paper Exit
FUSING AND PAPER EXIT 2.8 FUSING AND PAPER EXIT 2.8.1 OVERVIEW B047D102.WMF Two thermofuses [A] (184 C, 192 C) keep the fusing unit from overheating. Two thin-film thermistors measure the hot roller and pressure roller’s temperature. The hot roller is a thin-shell, Teflon coated roller. The thinner roller allows a much- shorter warm-up time.
Page 340: Temperature Control
FUSING AND PAPER EXIT 2.8.3 TEMPERATURE CONTROL Hot Roller Temperature Control Hot Roller Temp. (°C) Mode 8 1 9 8 Mode 7 Mode 6 1 9 0 Mode 5 1 8 0 Mode 4 Mode 3 1 7 0 Mode 2 Mode 1 1 6 0 1 5 0...
Page 341: Energy Star Compliant Machines (All The Destination)
ENERGY STAR COMPLIANT MACHINES (ALL THE DESTINATION) 2.10 ENERGY STAR COMPLIANT MACHINES (ALL THE DESTINATION) In conjunction with the modification for the Energy Star compliance, field technicians need to understand the new operation modes, and must be able to configure the machine for the customer’s specific environment/requirements. This section lists all the differences between the Energy Star compliant machines and the previous models.
Page 343: Installation
INSTALLATION...
Page 345: Installation Requirements
INSTALLATION REQUIREMENTS 3. INSTALLATION 3.1 INSTALLATION REQUIREMENTS 3.1.1 ENVIRONMENT 1. Temperature Range: 15 C to 30 C (50 F to 86 F) 2. Humidity Range: 20% to 80% RH 3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight).
Page 346: Minimum Space Requirements
INSTALLATION REQUIREMENTS 3.1.2 MINIMUM SPACE REQUIREMENTS Back 600 mm Left Right 600 mm 600 mm Front 1,000 mm B047I505.WMF 1. Front: 1,000 mm (39 in) 2. Back: 600 mm (24 in) 3. Right: 600 mm (24 in) 4. Left: 600 mm (24 in) 3.1.3 MACHINE LEVEL 1.
Page 347: Power Source
INSTALLATION REQUIREMENTS 3.1.4 POWER SOURCE Important: The machine must be installed in a building/facility equipped with a protective device such as a circuit breaker, as the machine relies on such devices for protection against over-current and short circuits. 1. Input Voltage Level: 120 V, 60 Hz More than 12 A (for U.S.A.
Page 348 INSTALLATION PROCEDURE 3.2 INSTALLATION PROCEDURE 3.2.1 COPIER Accessory Check Check the accessories and their quantities according to the following list: - B048 copier - Original Guides................ 6 pcs Operating Instruction Holder............ 1 pc Operating Sheet ..............1 pc Caution Decal (-27 only) ............1 pc Operating Instructions (-17 only)..........
Page 349: Installation Procedure
INSTALLATION PROCEDURE B047I024.WMF Preparation for the B047 copier on the roll feeder. When B047 copier is placed on the roll feeder, first remove the lower front cover [A] and the manual feed table [B] for installation. 1. Remove the lower front cover [A] (2 screws), reinforcement plate [C] (1 screw), bracket [D] (4 screws) (which is hung by the harness), and the manual feed table [B].
Page 350 INSTALLATION PROCEDURE - B047 model - - B048 model - B047I500.WMF B048I502.WMF NOTE: The installation procedures are not shipped with the copier, always bring this manual with you. CAUTION 1. Unplug the power cord before performing the following procedures. 2. Before starting the installation, make sure the machine is level. 3.
Page 351 INSTALLATION PROCEDURE B047I103.WMF B047I001.WMF B047I104.WMF B047I105.WMF 3. Remove all the tape strips [A] as shown. 4. Open the original feed unit [B]. 5. Remove the cushion [C] and close the original feed unit. 6. Release the lock levers [D] and open the paper path section [E]. 7.
Page 352 INSTALLATION PROCEDURE B047I503.WMF B047I504.WMF 11. Open the original feed unit [A], manual feed table [B], and toner supply cover [C]. Remove the sheet [D] covering the developer entrance. Pour 1 kg of the developer [E] into the development unit evenly across its width as shown. NOTE: Close the paper path section before opening the toner supply cover.
Page 353 INSTALLATION PROCEDURE B435I508.WMF NOTE: If the fusing temperature is lower than 60 C when the main switch is turned on, the main motor must rotate to generate a triboelectric charge on the developer and toner. However, to prevent damage to the hot roller, the main motor will wait until the hot roller’s temperature reaches 80 C before rotating.
Page 354 INSTALLATION PROCEDURE B435I508.WMF 17. To enter the SP mode, press the following keys on the operation panel: Clear key [A] + key [B] – key [C] Clear/Stop key [D] Clear/Stop key [D] again and hold for at least 3 seconds. 18.
Page 355 INSTALLATION PROCEDURE B047I507.WMF 20. Install the toner cartridge [A] as shown. 1) Shake the cartridge 5 to 10 times and insert it into the toner hopper. 2) Peel off the green tape [B] from right to left to expose the clear tape and toner supply holes.
Page 356: B048 Copier Only (Step 21)
INSTALLATION PROCEDURE B047I506.WMF B047I509.WMF B048 copier only (step 21) 21. Install the original guides [A] and original guide wire [B]. B047 copier only (step 22 and 23) 22. Attach the guide wires [C] to the copy tray [D]. 23. Install the copy tray [D] and copy guide [E]. Both copiers (step 24 and 25) 24.
Page 357: Table (B)
INSTALLATION PROCEDURE 3.2.2 TABLE (B439) Accessory Check Check the accessories and their quantities according to the following list: Top Plate ................1 Left Side Plate ................ 1 Right Side Plate ..............1 Middle Plate ................1 Rear Cover ................1 Screws with Spring Washers –...
Page 358 INSTALLATION PROCEDURE B439I500.WMF B439I551.WMF 1. Loosely install the top plate [A], left [B], and right side plate [C] (6 screws). 2. Turn the table up-side down. Be sure to rotate it as shown in the illustration. 3. Install the middle plate [D] and rear cover [E] (4 screws each). 4.
Page 359: Copy Tray (B)
INSTALLATION PROCEDURE 3.2.3 COPY TRAY (B440) Accessory Check Check the accessories and their quantities against the following list: Copy Tray Stay................ 1 Copy Tray Support..............1 Copy Tray Guides..............2 Copy Tray Sheets (with rubber pads) ........3 Rear Copy Trays..............3 Copy Tray Stoppers..............
Page 360 INSTALLATION PROCEDURE B440I117.WMF B440I118.WMF B440I121.WMF B440I119.WMF 1. Place the copy tray stay [A] under the copy tray as shown. 2. Adhere the copy tray sheets (the Mylar strips with rubber pads) [B] to the table’s middle plate [C]. Make sure the center copy tray sheets is positioned between the screw holes [D] on the copy tray as shown.
Page 361 INSTALLATION PROCEDURE 10 5mm 0 5mm 10 5mm 0 2mm B440I114.WMF B440I113.WMF B440I116.WMF 0 2mm B440I115.WMF 5. Remove the rear cover [A] (2 screws). 6. Attach the rear copy tray sheets [B] and the tray sheet guides [C] to the rear cover as shown.
Page 362 INSTALLATION PROCEDURE B440I120.WMF 60 10mm 60 10mm 80 10mm B440I123.WMF 8. Hook the rear copy trays [A] onto the copy tray stay [B]. 9. Attach the copy tray stoppers [C] onto the bottom of the middle plate [D]. B047/B048 3-18...
Page 363: Roll Feeder1 And 2 (B435/B)
INSTALLATION PROCEDURE 3.2.4 ROLL FEEDER1 AND 2 (B435/B436) Accessory Check Check the accessories and their quantities according to the following list: Harness Covers ............... 2 pcs Ground Plates................2 pcs Roll Feeder Drive Board ............1 pc Left Joint Bracket ..............1 pc Right Joint Bracket..............
Page 364 INSTALLATION PROCEDURE B047I024.WMF Preparation for the B047 copier on the roll feeder. When B047 copier is placed on the roll feeder, first remove the lower front cover [A] and the manual feed table [B] for installation. 1. Remove the lower front cover [A] (2 screws), reinforcement plate [C] (1 screw), bracket [D] (4 screws) (which is hung by the harness), and the manual feed table [B].
Page 365 INSTALLATION PROCEDURE B436I102.WMF CAUTION 1. Unplug the main machine’s power cord before starting the following procedure. 2. Before starting the installation, make sure the machine is level. 3. The copier is very heavy (85 kg, 187 lbs). To avoid serious injury, make sure that you have a sufficient number of people to assist you.
Page 366 INSTALLATION PROCEDURE B435I507.WMF B435I506.WMF 3. Release the lock lever [A] and open the copier paper path section [B]. 4. Remove the copier’s left lower cover [C] (2 screws), lower right front cover [D] (2 screws), lower right middle cover [E], and toner collection bottle [F] (1 connector).
Page 367 INSTALLATION PROCEDURE B435I105.WMF B435I101.WMF B435I104.WMF B435I127.WMF 5. Pull out the paper tray [A] and install the left [B] and right [C] joint brackets (2 screws each: blue). 6. Remove the paper tray stopper [D] (1 screw). NOTE: After the copier has been placed on the roll feeder, the paper tray can be pulled out and the paper tray stopper can be removed.
Page 368 INSTALLATION PROCEDURE B435I106.WMF B435I122.WMF B435I124.WMF B435I108.WMF B435I110.WMF 8. Remove the roll feeder’s rear cover [A] (6 screws). 9. Remove the copier’s rear cover [B] (2 screws). 10. Remove the small caps [C] from the copier’s rear cover using cutting pliers. 11.
Page 369 INSTALLATION PROCEDURE Joint harness [G] — Copier Main Control board (3 clamps) AC harness [H] — AC Drive board [I] B435I107.WMF B435I109.WMF B435I125.WMF 13. Install the grounding plates [A] (1 screw for each: M4x8). 14. Secure the grounding wire [B] (1 screw: M4x8 with a spring washer) to the copier.
Page 370 INSTALLATION PROCEDURE [C, D] 19. Hook the guide plate [A] on the copier and then secure it (2screws: M4x8). 20. Install the front joint cover [B] (2 screws: M3x6 with flat washers). 21. Reassemble the copier. 22. Install the left and right joint covers [C, D] (2 screws for each: M4x8 each). B047/B048 3-26...
Page 371 INSTALLATION PROCEDURE B435I508.WMF Length PRG. PRG. 1100 Temperature NORMAL 23. Plug in the power supply cord and turn on the main switch. 24. To enter the SP mode, press the following keys on the operation panel: Clear Modes key [A] + key [B] –...
Page 372: Roll Cutting Rail (B)
INSTALLATION PROCEDURE 3.2.5 ROLL CUTTING RAIL (B437) The installation is identical to that of the A163 copier’s roll cutting rail (A570). Please refer to the A163 service manual for details. The roll cutting rail and the roll feeder cannot both be installed on the same machine at the same time. B047/B048 3-28...
Page 373 SERVICE TABLES...
Page 375 SERVICE TOOLS 4. SERVICE TABLES 4.3 SERVICE TOOLS 4.3.1 SERVICE PROGRAM MODE Service Program Mode Table 1. A “*” before the mode number means that the mode can be accessed by customers or sales representative. 2. In the data column, the default value is printed in bold letters. The default settings for several items depend on the machine destination (refer to page 4-28.).
Page 376 SERVICE TOOLS Mode No. Function Data Leading Edge This sets the speed at which the Changes every: Increase/Decrease leading edge setting increases or 0: 0.1 second Speed Setting decreases. 1: 0.50 second 2: 0.25 second When the customer holds down the + 3: 0.05 second or –...
Page 377 SERVICE TOOLS Mode No. Function Data Length Size Adjusts the speed of the original feed –1.0 Magnification motor (B048 copier only). Shorter Longer The setting can be changed by the key operation. Semi-synchro Cut Sets the cutting method for semi- 0: Pressing the roll Original Scanning synchro cut mode (B047 copiers only).
Page 378 SERVICE TOOLS Mode No. Function Data New Developer Carries out the new developer If the initialization is Initialization initialization for 5 minutes. The canceled before returning machine counts down the remaining to the normal operating time on the display. After the mode, do it again from the initialization, the machine automatically beginning.
Page 379 SERVICE TOOLS Mode No. Function Data Roll Feeder Cutting Adjusts the cutting length of 300 mm in 0: Standard Length Adjustment the plain paper mode. –9.9 9.9 mm (300 mm, Plain Longer Shorter Paper) When this value is changed, the values for SP43 and SP44 are automatically changed according to the following table:...
Page 380 SERVICE TOOLS Mode No. Function Data Roll Feeder Cutting Adjusts the cutting length of 1,100 mm 0: Standard Length Adjustment in the plain paper mode. –50 50 mm (1,100 mm, Plain Longer Shorter Paper) When this value is changed, the values for SP46 and SP47 are automatically changed according to the following table:...
Page 381 SERVICE TOOLS Mode No. Function Data Toner End Determines the maximum number of 0: 27 sheets Detection Setting copies (when A1 paper is used) that 1: 9 sheets can be made after the toner near end 2: 18 sheets condition has been detected. 3: 36 sheets Toner Overflow Determines the maximum copy length...
Page 382 SERVICE TOOLS Mode No. Function Data Copy Number Limit Determines the maximum number of 0: 99 sheets (B047) Setting copies. The default settings for the 1: 10 sheets (B048) B047 and B048 copiers are different. 2: 20 sheets 3: 30 sheets 4: 40 sheets 5: 50 sheets 6: 60 sheets...
Page 383 SERVICE TOOLS Mode No. Function Data Fixed Paper Length Selects the interval of each step for (In mm mode) Special Mode SP60. 0: 100 mm 1: 50 mm 2: 60 mm 3: 120 mm 4: 200 mm 5: 240 mm 6: 250 mm 7: 500 mm 8: 600 mm...
Page 384 SERVICE TOOLS Mode No. Function Data Total Copy Length/ Displays the total copy length in feet. SP69: t6 =XXX,XXX Number Display (Feet) Total Copy Displays the total copy length/number SP70: t = XXX,XXX Length/Number according to the following units. SP71: t = XXX,XXX Display SP70 = Yard...
Page 385 SERVICE TOOLS Mode No. Function Data Roll Feed Speed Adjust the roll feed speed for –50.0 50.0 Adjustment translucent paper. 10 steps = 0.09% (translucent paper) Roll Feed Speed Adjust the roll feed speed for film. –50.0 50.0 Adjustment (film) 10 steps = 0.09% Number of Displays the total number of jams by...
Page 386 SERVICE TOOLS Mode No. Function Data RAM Clear Clears selected data items from the 0: Not Used RAM. 1: Machine Operation To clear the memory, input the number (The memory for of the item you want to delete, then SP67) press the "...
Page 387 SERVICE TOOLS Mode No. Function Data RAM Clear Clears selected data items from the 21: Clear all the memory RAM. and change the To clear the memory, input the number settings to the U.S.A. of the item you want to delete, then version press the "...
Page 388 SERVICE TOOLS Mode No. Function Data Hot Roller Change the hot roller temperature 0: Standard Temperature setting. –9 Adjustment Decrease Increase Pressure Roller Change the pressure roller 0: Standard Temperature temperature setting. –9 Adjustment Decrease Increase Hot Roller/ Displays the hot roller temperature and Fu = XXX Pressure Roller pressure roller temperature.
Page 389 SERVICE TOOLS Mode No. Function Data Separation AC Determines the AC separation corona 170: Standard Voltage setting voltage. In this mode, the separation corona High can be turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF To facilitate setting SP modes, when SP#-14 is entered, SP#-15 will be...
Page 390 SERVICE TOOLS Mode No. Function Data Bias Voltage for Determines the development bias 4: Standard Non-image Area voltage for the non-image area. Setting In this mode, the bias voltage can be High turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF Toner Density...
Page 391 SERVICE TOOLS Mode No. Function Data Length Size The fusing roller’s speed is slightly –100 Magnification higher than the drum speed. Shorter Longer Compensation on The speed of the copy paper transport –2.5% +2.5% Leading Edge will increase slightly after the leading edge of the copy paper enters the fusing unit.
Page 392 SERVICE TOOLS Mode No. Function Data Synchro-cut Length Adjusts the original cut length in –9.9 Auto Adjustment Synchro Cut mode based on a 297 1 step = 0.1 mm (297 mm) mm sheet (standard length). Insert the 297 mm length original five times (this number displayed on the copy number indicator can be changed : 1 to 10).
Page 393 SERVICE TOOLS Mode No. Function Data No Misfeed Ignores jam error signals, except for 0: Normal Detection Mode initial jams. The setting automatically 1: No Misfeed Detection resets to “0” when the main switch is turned off. Free Run Mode The machine caries out copy operation 0: Normal without an original.
Page 394 SERVICE TOOLS Mode No. Function Data Fluorescent Lamp Tracks the amount of time that the 0 ~ 250: Abnormal Time fluorescent lamp is at full power during The total time Check 2 the copy cycle. (seconds) that the fluorescent lamp is at full power.
Page 395 SERVICE TOOLS Mode No. Function Data Cut Length Display In semi-synchro cut mode, the 0: Non-Length Display Mode machine stores the 1st original cut 1: Length Display length and displays it in the paper length counter. The paper cut mode will automatically be changed to the Preset/Variable cut mode.
Page 396 SERVICE TOOLS Mode No. Function Data Fusing Determines how the machine recovers 0: No recovery Temperature when the fusing temperature drops (The machine simply Recovery Setting below the target value. This is only continues copying, triggered when making multiple copies ignoring the fusing using fusing mode 8 (highest temperature.)
Page 397 SERVICE TOOLS 4.3.2 INPUT/OUTPUT CHECK MODE Input Check Mode Table The on/off status of the selected electrical component is displayed in the paper length indicator (“ON” or “OFF” is displayed). If the selected program number is not used, “NOT” is displayed. Program No.
Page 398 SERVICE TOOLS Program No. Electrical Component Note Exposure Lamp (100% duty ratio) Exposure Lamp (selected ID level) Main Charge Corona Grid Voltage Transfer Charge Corona Not Used Separation Charge Corona Exhaust Fan 16 to 19 Not Used Bias Voltage for the Image Area Bias Voltage for the Non-image Area Main Charge Corona + Grid Voltage Main Motor + PTL + Bias Voltage for the...
Page 400 JAM CODE LIST Code Cause of Jam Remarks Original registration sensor does not turn off after paper is dJ45 fed 3,500 mm. Registration sensor OFF is detected just after starting the pJ51 copy process. Registration sensor OFF is detected before starting the roll pJ52 B047 only feeder again.
Page 401 JAM CODE LIST Fixed Paper Size Pattern Data (SP No. 22) In mm Mode 0: 1189, 841, 594, 420, 297 1: 3000, 2000, 1189, 841, 594, 420, 297, 280 2: 3000, 2400, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 280 3: 3000, 2400, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1189, 841, 594, 420, 297, 280...
Page 402 JAM CODE LIST 10: 118.0, 96.0, 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 47.5, 45.0, 42.5, 40.0, 37.5, 35.0, 32.5, 30.0, 27.5, 25.0, 22.5, 20.0, 17.5, 15.0, 12.5, 11.0, 10.0 11: 118.0, 96.0, 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 48.0, 42.0, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0 12: 118.0, 96.0, 80.0, 77.5, 75.0, 72.5, 70.0, 67.5, 65.0, 62.5, 60.0, 57.5, 55.0, 52.5, 50.0, 48.0, 42.0, 36.0, 24.0, 18.0, 12.0, 11.0...
Page 403 SERVICE REMARKS 4.6 SERVICE REMARKS 4.6.12 AC DRIVE BOARD Noise Filter AC Drive Board TB201 TB202 B047S500 WMF Service Remark for 220 240 V Version Make sure that the harnesses are connected to the noise filter and ac drive board as shown.
Page 404 SERVICE REMARKS AC Drive Board TB202 TB201 B047S501.WMF Service Remarks for 120 V Version Make sure that the harness is connected to the ac drive board as shown correctly 1. Set the power supply cord harness hot line (black wire) white connector to TB201 on ac drive board.
Page 405 REPLACEMENT AND ADJUSTMENT...
Page 407 DRUM UNIT 5. REPLACEMENT AND ADJUSTMENT 5.4 DRUM UNIT 5.4.2 DRUM REPLACEMENT B047R539.WMF 1. Remove the drum unit. 2. Remove the pulley [A] (1 C-ring). 3. Remove the 2 bearing holders [B] (2 screws each). NOTE: Be careful not to scratch the drum with the pick-off pawls when removing or reinstalling the drum.
Page 408 FUSING 5.5 FUSING B047R101.WMF 5.5.7 HOT ROLLER THERMISTOR REPLACEMENT 1. Remove the fusing unit. 2. Remove the hot roller thermistor [A] (1 screw, clamps). 5.1.8 FUSING THERMOFUSE REPLACEMENT 1. Remove the fusing unit. 2. Remove the fusing thermofuse [B] (2 screws, 6 clamps, and 2 connectors). B047/B048...
Page 409 FUSING 5.1.9 FUSING TEMPERATURE ADJUSTMENT B047R538.WMF CAUTION When the main switch is turned on, the machine will suddenly start to drive the fusing section. However, this does not occur immediately. The machine waits until the hot roller is heated to above 80 C. Keep your hands away from any mechanical and electrical components during this period.
Page 410 COPY QUALITY ADJUSTMENT 5.8 COPY QUALITY ADJUSTMENT 5.8.4 REGISTRATION ADJUSTMENT Registration is not within the registration tolerance. When: To maintain proper registration. Purpose: ") 0 3 mm (0 0.12 Registration Tolerance: SP#-5 (by-pass feed), SP#-29 (B048 rear original feed), SP#-45 (roll Perform: feed) Change the start timing of the registration roller using SP#-5, SP#-27,...
Page 411 TROUBLESHOOTING...
Page 413: Service Call Conditions
SERVICE CALL CONDITIONS 6. TROUBLESHOOTING 6.2 SERVICE CALL CONDITIONS When a service call condition occurs, the Call Service indicator ! and SC codes are displayed. SC Codes E2, E3, E4, E5, E6, E7, E8, E15, E17 and E18 cannot be cleared by simply turning the main switch off and on.
Page 414: Sc Code E-4: Hot Roller Thermistor Short
SERVICE CALL CONDITIONS 11 May, 2001 SC Code E-4: Hot Roller Thermistor Short Definition The resistance of the hot roller thermistor is less than 0.11 K . Points to Check Hot roller thermistor Main board (CN102-A5, -B11, -B13, -B14) SC Code E-5: Pressure Roller Thermistor Open Definition The resistance of the pressure roller thermistor is more than 0.53 M .
Page 415: Sc Code E-8: Fusing Warm-Up Error
SERVICE CALL CONDITIONS SC Code E-8: Fusing Warm-up Error Definition After turning on the machine, the temperature detected by the hot roller thermistor does not reach the target ready temperature within 12 minutes. Points to Check Hot roller thermistor Fusing lamp Fusing thermofuse AC drive board Main board (CN102-A3, -A5, -B11, -B13, -B14)
Page 416: Sc Code E-13: Total Counter Abnormal
SERVICE CALL CONDITIONS 11 May, 2001 SC Code E-13: Total Counter Abnormal Definition Total counter does not operate. Points to Check Main board AC Drive board SC Code E-14: Zero Cross Signal Detection Abnormal Definition The zero cross signal is not detected within 0.5 second of turning on the main switch.
Page 417: Blown Fuse Table
BLOWN FUSE TABLE 6.3 BLOWN FUSE TABLE 6.3.1 POWER SUPPLY UNIT Europe Version Fuse No. Specification Symptom FU301 250 V 3.15 A No power. FU302 250 V 6.3 A No indication. Beeper sounds. FU303 250 V 6.3 A This symptom will occur when all of three fuses are open.
Page 419: Roll Feeder Unit
ROLL FEED UNIT B435/B436...
Page 421: Overall Machine Information
SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS Roll Paper Size: Width: 210 mm to 914 mm, 8 " to 36" Length: 150 meters Diameter: Less than 170 mm Cut Size: –Preset Cut: 1189 mm, 841 mm, 594 mm, 420 mm, 297 mm 48", 36", 24", 18", 12"...
Page 422 ELECTRICAL COMPONENT DESCRIPTIONS 1.2 ELECTRICAL COMPONENT DESCRIPTIONS The index numbers refer to the electrical component layout on the reverse side of the Point to Point index (Water proof paper). Name Function Index No. Motors Cutter Drives the cutter (DC Reversible Motor). Roll Feed Drives all mechanical components except the cutter unit (Dc Stepper Motor).
Page 423: Detailed Section Descriptions
MECHANICAL OPERATION 2. DETAILED SECTION DESCRIPTIONS 2.1 MECHANICAL OPERATION 2.1.1 BASIC OPERATION B436D501.WMF B436D103.WMF There are two types of the roll feed unit. B435 Roll feed unit has one roll feed unit (1st [A]). B436 Roll feed unit has two roll feed units (1st [A] and 2nd [B]). The cutter unit [C] uses a sliding rotary cutting blade.
Page 424 MECHANICAL OPERATION B436D502.WMF After the leading edge of the paper reaches the exit rollers [A], the paper is directed to the copier registration roller [B]. The registration roller stops rotating once the registration sensor detects the leading edge of the copy paper. The copy paper stops and waits for the original.
Page 425: Roll Edition Detection
MECHANICAL OPERATION 2.1.2 ROLL EDITION DETECTION B436D503.WMF The roll paper end sensor [A] is located above each roll. When the roll paper runs out and the roll paper end sensor detects the black core of the roll, roll end is indicated on the operation panel.
Page 426: Cutter Operation
MECHANICAL OPERATION 2.1.4 CUTTER OPERATION B436D104.WMF The cutter unit uses a sliding rotary cutting blade [A] which is pulled past a fixed blade by a drive wire. The rotary cutting blade allows the cutter unit to cut paper in both directions. There are home position switches [B] at both ends of the cutter. The cutter motor turns off, stopping the cutting action, when the rotary cutting blade knob plate [C] turns off one of these switches.
Page 427: Replacement And Adjustment
CUTTER UNIT REPLACEMENT 3. REPLACEMENT AND ADJUSTMENT 3.1 CUTTER UNIT REPLACEMENT B436R102.WMF B436R103.WMF 1. Remove the roll feed unit’s front cover [A] (2 screws and 4 hooks) and left inner cover [B] (2 screws). 2. Remove the left tray lock lever [C] (1 screw and 1 spring) and tray stopper [D] (2 shoulder screws and 1 spring).
Page 428: Roll Feed Leading Edge Sensor Replacement
ROLL FEED LEADING EDGE SENSOR REPLACEMENT 3.2 ROLL FEED LEADING EDGE SENSOR REPLACEMENT B436R107.WMF 1. Pull out the roll feed unit. 2. Remove the sensor casing [A] (2 screws). 3. Replace the leading edge sensor [B] (1 screw and 1 connector). NOTE: When reinstalling the sensor casing, be sure to align the sensor casing’s pins [C] with the holes [D] in the sensor bracket.
Page 429: Roll Feed Unit Removal
ROLL FEED UNIT REMOVAL 3.3 ROLL FEED UNIT REMOVAL B436R101.WMF 1. Pull out the roll feed unit [A]. 2. Remove the 4 screws [B] (right side 2 screws and left side 2 screws). 3. Lift the roll feed unit and place it gently onto the floor or other flat surface. B435/B436...
Page 430: Roll Feed Clutch Replacement
ROLL FEED CLUTCH REPLACEMENT 3.4 ROLL FEED CLUTCH REPLACEMENT B436R104.WMF B436R105.WMF 1. Remove the roll feed unit. 2. Remove the left inner cover. 3. Remove the roll feed paper guide plate [A] (4 screws). 4. Remove the roller knob bracket [B] (1 screw). 5.
Page 431: Roll Feed Motor Replacement
ROLL FEED MOTOR REPLACEMENT 3.5 ROLL FEED MOTOR REPLACEMENT 1. Pull out the roll feed unit. 2. Remove the left inner cover. 3. Remove the four screws [A] securing the roll feed motor, then remove the roll feed motor [B] (1 connector). 7-11 B435/B436...
Page 432: Roll End Sensor Replacement
ROLL END SENSOR REPLACEMENT 3.6 ROLL END SENSOR REPLACEMENT 1. Remove the 2 screws [A] holding the clamps for the power supply cord. 2. Remove the roll feed rear cover [B] (6 screws). 3. Remove the roll end sensor bracket [C] (1 screw and 1 hook). 4.
Page 433: Cut Length Adjustment
CUT LENGTH ADJUSTMENT 3.7 CUT LENGTH ADJUSTMENT The cut length adjustment should be done when the roll feeder is installed to correct cutting errors. The cut error correction data is determined in the factory without the copier installed. The cut length varies depending on the copier on which it is installed and/or paper type used.
Page 434: Side Registration Adjustment
SIDE REGISTRATION ADJUSTMENT 3.8 SIDE REGISTRATION ADJUSTMENT 1. Raise the lever [A] in the left roll holder [B]. 2. Adjust the roll paper side position. Lower the lever to fix the position. B435/B436 7-14...
Page 435 TECHNICAL SERVICE BULLETINS...
Page 437 BULLETIN NUMBER: 740-001 05/12/95 APPLICABLE MODEL: FW740 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FW740 Parts Catalogs. This information should b e incorporated into all existing FW740 Parts Catalog documentation. UPDATE NO. 1 - SPRING HOOK - The old style Spring Hook (54199653) is no longer produced.
Page 438 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 002 10/11/95 APPLICABLE MODEL: FW740 SUBJECT: GROUNDING PLATE SPRING AND BUSHINGS GENERAL: To ensure grounding of the Lower Entrance Guide, the Grounding Plate Spring has been replaced by the Grounding Wire as shown below. Also, the material of the Exit Unit Bushing has been changed. This information should be incorporated into all existing FW740 Parts Catalog documentation.
Page 439 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 003 12/22/95 APPLICABLE MODEL: FW740 SUBJECT: FIELD SERVICE MANUAL - INSERT GENERAL: The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bull etin package contains 2 sets of replacement pages. PAGES: The revised areas have been highlighted by an arrow Additional Information...
Page 440 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 004 1/26/96 APPLICABLE MODEL: FW740 SUBJECT: ENERGY STAR MODIFICATION (DETAILS) GENERAL: To conserve energy, the copier automatically turns "OFF" 30 minutes after the last copy job has been completed. The details of the machine operation are as follows: AUTO OFF MODE To automatically turn "OFF"...
Page 441 Tech Service Bulletin No. FW740-004 Page 2 of 4 The Auto Off mode is prohibited during the following conditions: * The roll feeder is operating * A sheet of paper is set on the feed table * A Jam or SC indicator is "ON" * The Toner End indicator is "ON"...
Page 442 Tech Service Bulletin No. FW740-004 Page 3 of 4 Continued...
Page 443 Tech Service Bulletin No. FW740-004 Page 4 of 4...
Page 444 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 005 1/26/96 APPLICABLE MODEL: FW740 SUBJECT: PARTS CATALOG UPDATES GENERAL: To meet Energy Star requirements, the following parts have been changed. Main Switch Relay (new part) Relay AC Harness Lower DC Harness Upper DC Harness NOTE: For more information regarding Energy Star Office Equipment, refer to Publications Bulletin...
Page 445 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP 03/20/96 BULLETIN NUMBER: FW740 - 005 REISSUE APPLICABLE MODEL: FW740 SUBJECT: PARTS CATALOG UPDATES GENERAL: To meet Energy Star requirements, the following parts have been changed. Main Switch Relay (new part) Relay AC Harness Lower DC Harness Upper DC Harness...
Page 446 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 006 2/7/96 APPLICABLE MODEL: FW740 SUBJECT: FIELD SERVICE MANUAL - INSERT GENERAL: The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bull etin package contains 2 sets of replacement pages. PAGES: The revised areas have been highlighted by an arrow 5-19...
Page 447 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 007 02/21/96 APPLICABLE MODEL: FW740 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FW740 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. UPDATE NO.
Page 448 Tech Service Bulletin No. FW740 - 007 Page 2 of 2 UPDATE NO. 2 - PARTS CATALOG CORRECTION - Add Spacer (A1634355) to your Parts Catalog as indicated below. Fusing Entrance Guide Plate 20 mm Spacer - Fusing Entrance REFERENCE PART NUMBER DESCRIPTION PAGE...
Page 449 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 008 03/20/96 APPLICABLE MODEL: FW740 SUBJECT: ORIGINAL STOPPERS GENERAL: Rubber tubes have been added on the both right and left original stoppers to ensure that the origina l stoppers are being held in position. This information should be incorporated into all existing FW74 0 Parts Catalog documentation.
Page 450 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 009 09/27/96 APPLICABLE MODEL: FW740 SUBJECT: PARTS CATALOG ADDITIONS GENERAL: The following Parts Catalog additions are being issued for all FW740 Parts Catalogs. This informatio n should be incorporated into all existing Parts Catalog documentation. Page 14 Philips Pan Head Screw Photointeruptor...
Page 451 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 010 09/27/96 APPLICABLE MODEL: FW740 SUBJECT: FUSING TEMPERATURE ADJUSTMENT PROCEDURE GENERAL: To achieve optimal copy quality, it may be necessary to adjust the fusing temperature based on the t ype of copy paper used and the specific environmental conditions in which the machine is located.
Page 452 Tech Service Bulletin No. FW740 - 010 Page 2 of 2 2. Vellum Paper TA-70 Azon Vellum Erazable Vellum Regma 91gr Environ L/L M/M H/H L/L M/M H/H L/L M/M H/H L/L M/M H/H Mode 8 Mode 7 Mode 6 O Mode 5 Mode 4 Mode 3...
Page 453 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 011 09/27/96 APPLICABLE MODEL: FW740 SUBJECT: PRESSURE ROLLER EVALUATION PROCEDURE GENERAL: The following procedure is a method to determine whether the pressure roller should be replaced. 1. Access SP mode with the steps below. In order, press Clear Modes (C) key, Plus (+) key, Minus (-) key, Clear/Stop key, press and hold the Clear/Stop key again for longer than 3 seconds.
Page 454 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 012 10/15/96 APPLICABLE MODEL: FW740 SUBJECT: PHOTOINTERUPTOR GENERAL: The Photointeruptor shown below is missing from the Parts Catalog. This information should be added to all existing FW740 Parts Catalog documentation. REFERENCE PART NUMBER DESCRIPTION...
Page 455 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: FW740 - 013 01/16/97 APPLICABLE MODEL: FW740 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FW740 Parts Catalogs. The following informatio n should be incorporated into all existing Parts Catalog documentation. UPDATE NO.
Page 456 Tech Service Bulletin No. FW740 - 013 Page 2 of 2 REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM A1634171 Pressure Roller Stripper A1634175 Pressure Roller Stripper Ass’y A1744155 Stopper Guide - Paper Exit AE044020 Pressure Roller Stripper AA066285 Stripper Spring A1634176...
Page 457 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U####*;KHN#g#NEH NLfFMfMK %440-'%&0)#13()0U# *;KHN SUBJECT: T/S CORONA UNIT GENERAL: A part number has been assigned to the T/S Corona Unit. This information should be incorporated into all existing FW740 Parts Catalog documentation. REFERENCE NEW PART NO. DESCRIPTION PAGE ITEM A1633849 T/S Corona Unit (EU)
Page 458 SUBJECT: BLANK COPIES SYMPTOM: Intermittent blank copies, partially blank copies or blank copies. POSSIBLE CAUSES: 1. Arcing from Charge Corona. 2. Arcing from the High Voltage Leads / Receptacles. 3. No voltage output from the C, G, B Power Pack. 4.
Page 459 %EJG#g#gNNE NHfFMfML The chart listed below shows the Last Bulletin %440-'%&0)#13()0U Number issued for the A163 series. ####+)78)82)6#h#2f% Bulletin Cross Reference ####6-'3,#g#*;KHN Ricoh Group Companies Last Bulletin No. ####7%:-2#h#2f% Gestetner Ricoh Savin SUBJECT: SPRING REPLACEMENT – CHARGE CORONA UNIT SYMPTOM: Difficulty when replacing Charge Corona Wires.
Page 460 All copiers manufactured after the Serial Number listed below will have new style parts installed during production. MODEL NAME SERIAL NUMBER Gestetner N/A Ricoh FW740 A3847050073 Savin N/A INTERCHANGEABILITY CHART: OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
Page 461 No Suffix A1635230 Main Board The Main Board ROM revision A (file name 740A1A.EXE) can be downloaded through the Ricoh Technical Services BBS. NOTE: For more information about the Ricoh Technical Services BBS, order the Guide to Operation (P/N BBS00001) through normal NSPC channels.
Page 462 The part number for the Small Cap (A163 RIC/NRG)/(A251/A252) was incorrect. The following part correction is being issued for all A571 Parts Catalog Sections. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM A5717479 A5717497 Small Cap (A163 RIC/NRG)/(A251/A252) CONTROL NO. 296 RICOH GROUP COMPANIES...
Page 463 [A] are flattened NOTE-2: Ensure that both wires Attach the Long Wire [C] to are connected before the copier. powering up the copier. Attach the Short Wire [B] to the stand. RICOH GROUP COMPANIES CONTROL NO. 316...
Page 464 A2515228C to A2515228D (FW750), & A2525238C to A2525238D (FW760). The Main PCB ROM revision “D” file name A251MA1D.EXE (FW750), file name A252MA1D.EXE (FW760) and ROM Revision “B” file name A163ma1B.exe (FW740) can be downloaded through the Ricoh Technical Services FTP Site http://tsc.ricohcorp.com.
Page 465 3. The bushing on the right side only, for both original drive roller (AF020451) are lubricated with Mobil Temp 78 to decrease the friction load. The PCB ROM revision “D” (file name A252MA1D.EXE) can be downloaded through the Ricoh Technical Services FTP Site http://tsc.ricohcorp.com.
Page 466 1 set of replacement pages. PAGES: ⇒ The revised areas have been highlighted by an arrow • Updated Information (Specifications Page – STM) • Updated Information (Specifications Page – FSM)     CONTROL NO. 006WID 2000 RICOH Corporation. All rights reserved.
Page 467 Rev. 11/2000 1. SPECIFICATIONS Configuration: Table top Copy Process: Electrostatic transfer system Original Feed: Sheet feed Original Skew 2 mm/400mm Tolerance: Original Size: Maximum: 914 x 2,000 (36" x 80")mm Minimum: A4 (8 " x 11") lengthwise Copy Size: Same as "Original Size" Copying Speed: 3 cpm (A1/D sideways) First Copy:...
Page 468 Rev. 11/2000 1. SPECIFICATIONS Configuration: Table top Copy Process: Electrostatic transfer system Original Feed: Sheet feed Original Skew 2 mm/400mm Tolerance: Original Size: Maximum: 914 x 2,000 (36" x 80")mm Minimum: A4 (8 " x 11") lengthwise Copy Size: Same as "Original Size" Copying Speed: 3 cpm (A1/D sideways) First Copy:...
Page 469 Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually. Copyright 2002 RICOH Corporation. All rights reserved. CONTROL NO 011WID...
Page 470 The following part addition is being issued for all A163/A251/A252 Parts Catalogs. Item 44 Spacer AA132097 REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM AA132097 Spacer DENOTES NEW ITEM NUMBER Copyright 2002 RICOH Corporation. All rights reserved. CONTROL NO 011WID...
Page 471 NOTE: When replacing with the modified parts for the first time, they must be installed together as a set. The following part update is being issued for all A163/A251/A252 Parts Catalogs. Copyright 2003 RICOH Corporation. All rights reserved. Page 1 of 2...
Page 472 UNITS AFFECTED: All A163/A251/A252 copiers manufactured after the serial numbers listed below will have the new style Guides installed during production. MODEL NAME SERIAL NUMBER Ricoh FW740 Service Parts Only Ricoh FW750 Service Parts Only Ricoh FW760 Service Parts Only...
Page 473 8)',2-'%0#7)6:-')#&900)8-2 &900)8-2#291&)6U %IKE#g#NNE NMfEEfML %440-'%&0)#13()0U The chart listed below shows the Last Bulletin Number issued for the A571 series. ####+)78)82)6#h#2f% Bulletin Cross Reference ####6-'3,#h#6300#*))()6#(14#*;KHN Ricoh Group Companies Last Bulletin No. ####7%:-2#h#2f% Gestetner Ricoh 5000 Savin SUBJECT: SMALL CAP GENERAL: The following part correction is being issued for the A571 Parts Section.
Page 474 The following parts updates are being issued for all A836 Parts Catalog Section. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM A8364465 A86364469 Rear Copy Tray – Small (760S) A8364468 Rear Copy Tray Sheet – Center A1744493 Copy Tray Sheet RICOH GROUP COMPANIES CONTROL NO. 314...
Page 475 Part number Description Index Part number Description A2521611 Fiber Optics (B048) B0471640 Fiber Optics (B047) B0471630 Fiber Optics (B047) B0481640 Fiber Optics (B048) B0481630 Fiber Optics (B048)     Copyright 2002 RICOH Corporation. All rights reserved. CONTROL NO 010WID...
Page 476 The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages. An arrow has highlighted the revised areas PAGES: 4-25 Jam Code Table (Updated Information). Copyright 2002 RICOH Corporation. All rights reserved.
Page 478 Toner Supply Unit Plate E - Ring Seal – 22x52x0.5 Shaft Holder Spring – 10N Toner Supply Clutch Left Side Plate Joint Shaft Unit – Toner Hopper Joint Shaft – Toner Hopper Copyright 2003 RICOH Corporation. All rights reserved. Page 1 of 2...
Page 479 MODEL NAME SERIAL NUMBER RICOH FW770 Gestetner A040 H8630400001 SAVIN 7700W Lanier LW110 RICOH FW780 Gestetner A040 H8730400001 SAVIN 7800W Lanier LW111 INTERCHANGEABILITY CHART: OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
Page 480: Receiving Tray Cover Assembly
Deleted: Item 14 & Item 104 Deleted: Items 104 REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM B0471331 Receiving Tray Cover 04340082B Tapping Screw – M4x8 n - 3 Copyright 2003 RICOH Corporation. All rights reserved. Page 1 of 1...
Page 481 SUBJECT: FAN MOTOR HARNESS GENERAL: The following part update is being issued for all B047/B048 Parts Catalogs. REFERENCE PART NO. CORRECT DESCRIPTION INCORRECT DESCRIPTION PAGE ITEM A1744203 SEAL:FAN:HARNESS FAN MOTOR HARNESS Copyright 2004 RICOH Corporation. All rights reserved. Page 1 of 1...

This manual is also suitable for:

A163 A251 A252 B047 B048

Ricoh FW780 Service Manual

Table of Contents

Overall Machine Information

Detailed Section Descriptions

Installation

Service Tables

Troubleshooting

Roll Feeder

Table of Contents

1 Overall Machine Information

2 Detailed Section Descriptions

3 Installation

4 Service Tables

5 Replacement and Adjustment

6 Troubleshooting

Detailed Section Descriptions/Detailed Section Descriptions

Detailed Section Descriptions

Detailed Section Descriptions

Installation

Roll Feeder Unit

Overall Machine Information

Detailed Section Descriptions

Replacement and Adjustment

Quick Links

SERVICE MANUAL

Chapters

Troubleshooting

Related Manuals for Ricoh FW780

Summary of Contents for Ricoh FW780