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Ricoh A163 Service Manual

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Table of Contents

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A163/A251/A252
B047/B048
SERVICE MANUAL
001317MIU
RICOH GROUP COMPANIES

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Summary of Contents for Ricoh A163

  • Page 1 A163/A251/A252 B047/B048 SERVICE MANUAL 001317MIU RICOH GROUP COMPANIES...
  • Page 3 ® ® RICOH GROUP COMPANIES...
  • Page 5 A163 FIELD 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 FW770 B048 FW780 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 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

    3.2 INPUT/OUTPUT CHECK MODE ........4-27 A163...
  • Page 16 2.1 ORIGINAL FEED UNIT REMOVAL ....... . . 5-2 A163...
  • Page 17 6. T & S CORONA UNIT ........5-33 A163...
  • Page 18 2.10 SC Code E-10: Main Motor Abnormal ......6-11 2.11 SC Code E-11: Toner Density Sensor adjustment Error ....6-11 A163...
  • Page 19 ............. 7-20 7.6 ROLL FEED PAPER SKEW ADJUSTMENT ..... . . 7-21 A163...

  • Page 21: Overall Machine Information

    OVERALL MACHINE INFORMATION...

  • Page 23: Specifications

    1,860 A1 or D copies per cartridge (6% original) Development Bias: Negative Toner Density Control: Direct toner density detection by induction sensor Image Density Adjustment: Development bias control + exposure control Paper Separation: Dual wire ac corona and pick-off pawls Cleaning: Cleaning blade A163...
  • Page 24 Optional Equipment and Machine Configuration Configuration Additional equipment Optional equipment Main frame Roll feeder (A571) Table (A714) A163 copier Roll cutting rail (A570) Side guides (A569) Other Optional Equipment • Paper Spool • Drum anti-condensation heater Specifications are subject to change without notice.

  • Page 25: Component Layout And Descriptions

    COMPONENT LAYOUT AND DESCRIPTION...

  • Page 27: Paper Path

    1. 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

    High intensity light from a fluorescent lamp is reflected from the moving original through the fiber optic array. The charge on the drum surface is dissipated in direct proportion to the intensity of the reflected light, thus producing an electric latent image on the drum surface. A163...
  • Page 29 7. Cleaning The cleaning blade, which is angled against drum rotation (counter blade system), removes any toner remaining on the drum surface. 8. Quenching The light from the quenching lamp electrically neutralizes the surface of the drum. A163...

  • Page 30: Mechanical Component Layout

    3. MECHANICAL COMPONENT LAYOUT 22 23 24 A163...
  • Page 31 20. 2nd Original Feed Roller 8. Gas Spring 21. Original Table 22. 2nd Press Rollers 9. OPC Drum 10. T/S Corona Unit 23. Exposure Lamp 11. Main Drive Unit 24. Fiber Optic Array 12. Table 25. Cleaning Blade 13. Paper Spool A163...

  • Page 32: Drive Layout

    12. Fusing Drive Sprocket/Gear 5. Development Drive Chain 13. Toner Collection Coil Drive Gear 6. Paper Registration Roller Clutch 14. Drum Drive Gear 7. Drum Drive Relay Gear 15. Original Feed Drive Pulley 8. Main Motor 16. Original Feed Drive Belt A163...

  • Page 33: Electrical Component Descriptions

    Detects the density of toner in the developer. Original Detects when the original lead edge passes at Registration the front of the exposure glass. Light Detects the intensity of the exposure lamp output. Entrance Feed Detects when copy paper is inserted (jam detector). A163...
  • Page 34 Transfer/ Provides high voltage power for the transfer Separation corona and separation. Thermistors Hot Roller Monitors the hot roller’s surface temperature. Pressure Roller Monitors the pressure roller’s surface temperature. Thermofuses Fusing Protects against fusing overheat. Heaters A163...
  • Page 35 Anticondensation Keeps moisture from forming inside the copier (option). Others Total Counter Keeps track of the total length of copies made (Europe) or the total copies made (U.S.A.). Circuit Breaker Guards against voltage surges in the input (Europe, Asia)/ power. Fuse (U.S.A.) A163...
  • Page 36 2-10 A163...

  • Page 37: Installation

    INSTALLATION...

  • Page 39: Environment

    7. Avoid placing the machine in an area filled with corrosive gases. 8. Avoid any area higher than 2,000 m (6,500 ft) above sea level. 9. Place the machine on a strong and level base. 10. Avoid any area where the machine may be subjected to frequent strong vibration. A163...

  • Page 40: Minimum Space Requirements

    4. Left: 600 mm (24 in) 1.2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level Make sure that the machine is level using a carpenter’s level. A163...

  • Page 41: Power Source

    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. b) Avoid multi-wiring. A163...

  • Page 42: 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 43 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. Pushing the copier too hard may cause it to drop onto the floor. While moving the copier, push the table. A163...
  • Page 44 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. Remove paper from transport section. Close the paper path section. A163...
  • Page 45 [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. 7. Plug in the power supply cord and turn on the main switch. A163...
  • Page 46 11. Press the RF Select key to stop the main motor after the developer is loaded from the development entrance. Pour in another kg of developer into the development unit evenly across its width (Total: 2 Kg). Press the Clear Modes/Stand by key 3 times to leave the SP mode. A163...
  • Page 47 14. Select 36 using the + and - keys. Enter "1" by pressing the following keys. Function Select key [E] + key RF Select key [F] Five minutes later, the copier will automatically return to the normal operating mode from SP mode. (New developer initialization) A163...
  • Page 48 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 49 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 50: Installation Procedure

    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 51 2. Turn the table up-side down in the direction of A. 3. Install the middle plate [F] and rear cover [G] (4 screws each). 4. Tighten all the screws until the spring washers [H] of screws are flattened. 5. Flip the table the correct way. 3-13 A163...
  • Page 52 Roll Paper Arm ............2 pcs Roll Paper Shaft ............. 1 pc Roll Shaft Holder ............ 2 pcs Roll Flange ............. 2 pcs 1. Remove the small caps [A] from the lower front cover. 2. Attach the roll shaft holders [B] as shown. A163 3-14...
  • Page 53 7. Push the roll flanges [I] inside to fix the roll paper position. 8. Set the roll paper shaft on the roll shaft holder. 9. Set the paper between the cutter guide stay [J] and slide shafts [K]. 10. Check the roll cutting rail operation. 3-15 A163...

  • Page 55: Service Tables

    SERVICE TABLES...

  • Page 57: Preventive Maintenance Schedule

    Clean at 60K filter (A1 sideways/ D size) D. Around drum 1 Corona wires Dry cloth 2 Grid wires Dry cloth 3 Charge corona Dry cloth end blocks and casing 4 Pre-transfer Clean using lamp blower brush if necessary A163...
  • Page 58 3 Thermistors Clean using suitable solvent 4 Hot roller Clean using strippers suitable solvent 5 Pressure roller Clean using stripper suitable solvent 6 Entrance guide Clean using plate suitable solvent if necessary 7 Exit turn guide Clean using alcohol A163...
  • Page 59 ) 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. Roll Feeder 1 Feed Roller Alcohol A163...

  • Page 60: Regular Pm Procedure

    2. Clean the T/S corona end blocks, casing using a dry cloth. 3. Clean the pick-off pawls using a dry cloth. 4. Clean the pre-transfer lamp if it is dirty. 5. Clean the quenching lamp if it is dirty. A163...
  • Page 61 1. Clean the cartridge holder using a dry cloth if it is (every 3.6K) dirty. 2. Clean the entrance seal using a dry cloth if it is dirty. Development Unit Replace the developer. (every 30K) Development Unit Clean the development filter. (every 60K) A163...
  • Page 62 2. Inspect the drive gears. Lubricate using G501 if necessary. 3. Replace the ozone filter. 10. Roll Feeder 1. Clean the feed roller using alcohol. (every 3.6K) 11. Copy Quality. 1. Check the copy quality. 2. Perform the light sensor adjustment. A163...

  • Page 63: Service Tables

    Function Transfer Corona Voltage VRD (DC) Separation Corona Voltage (DC) VRD (AC) Separation Corona Voltage (AC) Caution: VRT, VRD (DC), and VRD (AC) should not be changed in the field. They can be adjusted using SP #--12 to --17. A163...

  • Page 64: Service Tools

    How to select the program number The program number can be selected by the keys. The selected program number is displayed in the lead edge erase indicator (the two digit indicator beside the mark). To select the program number quickly, hold down key. A163...
  • Page 65 1. Access the SP mode and select the program number. 2. Press the key and select the paper length indicator (the four digit indicator beside the mark). 3. Press the key, then the paper length indicator shows the data. 4. Press key again to stop displaying the data. A163...

  • Page 66: Service Program Mode Table

    Selects the time to when the registration 0: 2 seconds Time Setting roller starts rotating after the entrance sensor 1: 0.7 second detects the paper leading edge. 2: 1 second 3: 3 seconds 4: 4 seconds 5: 5 seconds A163 4-10...
  • Page 67 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" key is pressed. 4-11 A163...
  • Page 68 To adjust the cutting length of 300 mm in the Cutting Length translucent paper mode. Adjustment (300 mm, Translucent Paper) Roll Feeder To adjust the cutting length of 300 mm in the Cutting Length translucent film mode. Adjustment (300 mm, translucent Film) A163 4-12...
  • Page 69 Indicates the copy length after clearing the tF=XX,XXX Counter used toner counter. This counter is (Beeper) automatically cleared if the clear mode key is pressed after turning off and on the main switch in the full toner condition. 4-13 A163...
  • Page 70 Each time +/-- key is pressed while holding 0: Normal Length Special the Preset Cut key down, the length selected 1: Fixed Paper Mode in SP mode 61 is increased/reduced from the Length Special preset paper size. Mode A163 4-14...
  • Page 71 Month Internal Use Only RAM Abnormal Displays the total number of abnormal A number is added if Condition Check conditions of the back-up RAM. an abnormal RAM condition is detected when the machine is powered on. Not Used 4-15 A163...
  • Page 72 Jt = Total Jam Location in each SP number are as follows: SP80: Jt, J90, J98, J99 SP81: J01, J02, J03, J04 SP82: J20, J21, J22, J23 SP83: J30, J31, J32 SP84: J40, J41, J42, J43 SP85: J56, J57, J58, J59 A163 4-16...
  • Page 73 ↓ = XX (2 before the last error code) ↓ = XX (3 before the last error code) ↓ = XX (4 before the last error code) ↓ Beeper (XX= Error Code) Not Used 4-17 A163...
  • Page 74 For the toner density step control, this counter counts down from 150 (m) to 0 (m) after the developer initialization. When the developer initialization is done, this counter to 150 and after 150m of copies, the counter stays at 0. If this counter is cleared, the counter is set to 0. A163 4-18...
  • Page 75 Inch/mm Selects the unit in which the edge margin and 0: mm Exchange paper length is indicated by. 1: Inch Not Used Registration Adjusts the paper registration. 0: Standard --9.9 ← 0 → 9.9 mm Adjustment Advance Delay 4-19 A163...
  • Page 76 40 ← 120 → 249 at Paper Trailing paper trailing edge. Edge Setting In this mode, the transfer corona can be High --13 turned on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF A163 4-20...
  • Page 77 0 ← 4 → 8 Non-image Area the non-image area. Setting In this mode, the bias voltage can be turned High --21 on and off using the Copy Media key. Translucent paper = ON Translucent Film = OFF 4-21 A163...
  • Page 78 Copy Media key. Translucent paper = ON Translucent Film = OFF Toner Sensor Displays the toner sensor output voltage for A = X,XX --31 Voltage Display the last copy. (Beeper) (Last Copy) A163 4-22...
  • Page 79 Counts the time when the exposure sensor is 0~250: The total time Abnormal Time more than 1 V higher than the target value. (seconds) that the --60 Check 1 lamp voltage is more than 1 volt higher than the target value. 4-23 A163...
  • Page 80 1: Combine comes first. If this mode is selected, copy Originals Mode --68 process continues to the paper trailing edge even if the original trailing edge comes first. Using this mode, several originals can be combined on copy sheet. A163 4-24...
  • Page 81 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, 36.0, 34.0, 24.0, 22.0, 18.0, 17.0, 12.0, 11.0, 9.6 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, 36.0, 24.0, 18.0, 12.0, 9.6 4-25 A163...
  • Page 82 80.0, 72.0, 64.0, 57.3, 48.0, 46.8, 40.6, 36.0, 34.0, 33.1, 28.7, 24.0, 23.4, 22.0, 20.3, 18.0, 17.0, 16.6, 14.4, 12.0, 11.7, 11.0, 10.1, 9.6 The data stored in SP23 to 32 Default Settings (SP # --1) SP. No. U.S.A. #--2 #--3 A163 4-26...

  • Page 83: Input/Output Check Mode

    To select an output check mode, press the key. The selected number is displayed on the lead edge erase indicator (the two digit indicator beside the mark). To select the program number quickly, hold down the key. 4-27 A163...

  • Page 84: Input Check Mode Table

    Door Switch (Status is "ON" when the door is open.) --7 to --9 Not Used --10 R/F Leading Edge Sensor --11 Roll Feeder Door Switch --12 Right Cutter Switch --13 Left Cutter Switch --14 Paper End Sensor A163 4-28...

  • Page 85: Output Check Mode Table

    Roll Feeder Dehumidity Heaters *Note Roll Feeder Cutter Motor Roller Feeder Paper Feed Motor NOTE: The cutter unit continuously moves between the left and right cutter switches. The number of the movement (0~9999) is displayed on the paper length indicator. 4-29 A163...

  • Page 86: Power On Initial Setting Mode

    2. Input the operation panel setting that the customer requires (paper size, image density, etc.). 3. Turn off the main switch. The setting, just before the main switch is turned off, is memorized as the power on initial setting. It appears again when the main switch is turned on. A163 4-30...

  • Page 87: Jam Code List

    SP85 PJ56 edge. (Roll Feeder Jams) Leading edge sensor OFF check at the paper trailing PJ57 edge. PJ58 Entrance sensor ON during the roll feeding. Registration sensor ON check at the paper leading edge PJ59 (in roll feeding). 4-31 A163...
  • Page 88 Registration sensor does not turn off after paper is fed PJ98 2500 mm. Original registration sensor does not turn off after paper PJ99 is fed 2500 mm. NOTE: To display total jam number, access SP mode No. 80. A163 4-32...

  • Page 89: Special Tools And Lubricants

    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 54429101 4-33 A163...

  • Page 90: Service Remarks

    13. Be careful not to scratch the drum with the pick-off pawls when removing or reinstalling the drum. 14. When installing and/or removing the pick-off pawl unit, do not press too strongly. Otherwise, the drum unit may deform. A163 4-34...

  • Page 91: Charge Corona

    6. Make sure that the grid wires are correctly placed on the eight slots, are all straight, and not crossed. 7. Do not expand and bend the corona wires and grid wires. 8. Make sure that the wire junction is positioned inside the right endblock. 4-35 A163...

  • Page 92: Optics

    9. During the developer initialization, do not turn off the main switch, or do not open the original feed unit or the paper path section, or do not unplug the copier power cord. If these conditions happen, do the developer initialization again, the toner density sensor cannot be adjusted. A163 4-36...

  • Page 93: Transfer And Separation

    If "FULL" is indicated in the copy counter, SP#52 can also be reset to 0 by pressing the Clear Modes/Standby key after opening and closing the paper path section. Instruct customers to deal with the toner collection bottle if the "FULL" condition is indicated. 4-37 A163...

  • Page 94: Fusing Unit

    For example, if the proper setting is Mode 3, select Mode 2 for this test. Refer to TSB No. FW740-010 for more information regarding the proper settings for particular types of paper and the adjustment procedure for non-listed papers. A163 4-38...

  • Page 95: Original Feed

    (Do not clear RAM memory if you have placed the old RAM on the new main board.) 3. Take care not to damage the mylars on the rear feed table during servicing. 4. When replacing a sensor, do not overtighten the screws. This may damage the sensor. 4-39 A163...

  • Page 97: Replacement And Adjustment

    REPLACEMENT AND ADJUSTMENT...

  • Page 99: Exterior Covers

    3. Remove the right lower rear cover [H] (1 screw). REAR COVER REMOVAL 1.3.1 Rear Cover 1. Remove the rear cover [I] (2 screws). NOTE: When re-installing the rear cover, push in the rear cover hooking portion [J] over the copier bottom plate as shown. A163...

  • Page 100: Optics

    [D] (2 connectors). 4. Open the original feed unit [E] and unhook the stoppers [F] at both ends. 5. Turn the original feed unit and two bushings [G] at both ends 1/4 of a turn and remove. A163...

  • Page 101: Exposure Glass Removal

    (1 screw) and remove the exposure lamp. 3. Turn the exposure lamp [E] 1/4 of a turn and remove. NOTE: Make sure that the direction of the aperture [F] of the exposure lamp is towards the fiber optics array side (rear side). A163...

  • Page 102: Fiber Optics Array Removal

    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. NOTE: When reassembling, be careful not to damage the right side [C] of the fiber optics array by touching the optics side plate [D]. A163...

  • Page 103: 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 104: Development Unit Removal

    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 105 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. A163...

  • Page 106: Developer Removal

    4. Turn the paddle roller knob [D] clockwise. The developer will fall out onto the paper. 5. Repeat step 4 until all of the developer has been dumped out. 6. Clean the development unit prior to reassembling. Especially, clean the right end of the unit. A163...

  • Page 107: Toner Density Sensor Replacement

    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. 5. Replace the toner density sensor [E] (2 screws and 1 connector). A163...

  • Page 108: 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 109: Development Bias Voltage Adjustment

    3. Check the multimeter. If the voltage is not that of the standard voltage, press key and then change the voltage using keys. 4. If the voltage is within that of the standard voltage, press the key. 5-11 A163...
  • Page 110 3. Check the multimeter. If the voltage is not that of the standard voltage, press key and then change the voltage using keys. 4. If the voltage is within the standard, press the key. A163 5-12...

  • Page 111: Drum Unit

    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. (2) Hold both ends of the drum unit to carry it. 5-13 A163...

  • Page 112: Drum Replacement

    5. Loosen the drum knob [D] by turning it counter clockwise as shown. 6. Remove the drum flange [E]. 7. Replace the drum with new one. NOTE: when reinstalling the gear [F], make sure that the direction of the projection of the gear is on the drum side. A163 5-14...

  • Page 113: Cleaning Blade Replacement

    [F] can be taken through the rear side from where the rear feed table assembly is removed (follow steps 1 to 3 of the ozone filter replacement). 3. When replacing the cleaning blade, apply setting powder on the edge of the cleaning blade. 5-15 A163...

  • Page 114: Charge Corona Unit Removal

    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. A163 5-16...

  • Page 115: Charge Corona Wire Replacement

    (5) Do not use any solvent to clean the wire as this will cause uneven charge on the drum. (6) Make sure that the wire junction [E] is positioned inside the right endblock. 5-17 A163...

  • Page 116: 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. Otherwise, the drum unit may deform. A163 5-18...
  • Page 117 7. Check the multimeter. If the voltage is not that of the standard voltage, press key and then change the voltage using keys. 8. If the voltage is within that of the standard voltage, press the key. 5-19 A163...

  • Page 118: Drum Current Adjustment

    The drum currents should be adjusted by changing SP mode setting. Preporation 1. Remove the developer unit. 2. Remove the drum unit. 3. Remove the OPC drum from the drum unit, and install the current measurement drum [A] instead of the OPC drum. A163 5-20...
  • Page 119 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 120 8. Check the multimeter. If the voltage is not that of the standard voltage, press key and then change the voltage using keys so that the charge current is dc --1000 ± 20 µA. 9. If the voltage is within that of the standard voltage, press the key. A163 5-22...
  • Page 121 10. Check the multimeter. Press the key and then change the voltage using keys so that the transfer current is dc --150 ± 5 µA. 11. If the voltage is within that of the standard voltage, press the key. 5-23 A163...
  • Page 122 10. Check the multimeter. Press the key and then change the current using keys so that the ac separation current is ac 350 ± 10 µA. 11. If the voltage is within that of the standard voltage, press the key. A163 5-24...
  • Page 123 19. Check the multimeter. Press the key and then change the current using keys so that the dc separation current is dc --20 ± 2.5 µA. 20. If the voltage is within that of the standard voltage, press the key. 5-25 A163...
  • Page 124 4. Turn the exit unit 1/4 of a turn to the front side (rear view) and remove it by pulling out. NOTE: When reinstalling the exit unit, set the right hinge [F] between the two pulleys [G] and raise the left hinge [H] using tape [I]. A163 5-26...
  • Page 125 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. 5-27 A163...

  • Page 126: Hot Roller Replacement

    4. Remove the fusing lamp [D] from the left side as shown (1 connector [E], rear view). 5. Remove the 2 C-rings [G], 1 gear [H], 2 bushings [I], and 2 bearings [J]). 6. Slide the hot roller [K] to the right side and remove it from the left side. A163 5-28...

  • Page 127: Pressure Roller Replacement

    5. Replace the pressure roller (2 stoppers [I] and 1 shaft [J]). NOTE: When reinstalling pressure roller, set the right pressure roller stopper and push the pressure roller shaft to the right from the left, and set the left pressure roller stopper [ ]. 5-29 A163...

  • Page 128: Pressure Roller Thermistor Replacement

    1. Follow step 1 to 5 of the fusing unit removal. 2. Remove the pressure roller stripper unit [B] (4 screws). HOT ROLLER STRIPPER UNIT REPLACEMENT 1. Follow step 1 to 4 of the fusing unit removal. 2. Remove the hot roller stripper unit [C] (2 screws). A163 5-30...
  • Page 129 4. Remove the hot roller thermistor [D] (1 screw and 1 spring, 7 clamps [E]). FUSING THERMOFUSE REPLACEMENT 1. Follow step 1 to 3 of the hot roller thermistor replacement. 2. Remove the fusing thermofuse [F] (1 screw and 4 clamps [G]). 5-31 A163...
  • Page 130 7. If the actual temperature is different from the value for the mode being used (use SP#1 to find out the current mode), adjust the temperature using SP#-7. 8. Repeat steps 5 to 7 and confirm the temperature. 9. Reassemble the machine. A163 5-32...

  • Page 131: 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. 2) Remove the connector cover [D] (1screw) for connecting the 2 connectors. 5-33 A163...

  • Page 132: Transfer And Separation Corona Wire Replacement

    (4) Do not use any solvent to clean the wire as this will cause uneven charging of the drum. 6.2.1 Preparation 1. Remove the T & S corona unit. 2. Remove the paper guides [A] and endblock covers [B]. A163 5-34...

  • Page 133: Separation Corona Wire Replacement

    (special tool: 54199653). While pushing the spring [G] in the direction of the arrow, hook the separation corona wire on the spring. 4. Set the wire on the slots [H]. 6.2.3 Transfer Corona Wire Replacement 1. Remove the transfer corona wire [I]. 2. Install the new transfer corona wire. 5-35 A163...

  • Page 134: Others

    4. Unhook the blower duct [F] and remove. 5. Unhook the fan support plate [G] and remove. 6. Replace the ozone filter [H]. NOTE: When reinstalling the rear feed table assembly, fix the 2 screws [I] while pushing the assembly. A163 5-36...

  • Page 135: Anticondensation Heater Installation

    3. Install the anticondensation heater [A] (3 screws). 4. Put the harness of the heater into the cutout [B] of the frame. 5. Connect the connector of the heater [C] with the one beside the ac drive board. 5-37 A163...

  • Page 136: Copy Quality Adjustment

    NOTE: Adjusting grid voltage will not affect toner supply amount, but will affect the amount of charge reaching the drum. Exposing the the drum to light will not disipate all residual voltage resulting in overtoning and background. A163 5-38...

  • Page 137: Light Sensor Adjustment

    6. Change SP #-6 setting in the SP mode. If the image density is too dark: Increase SP #-6 setting. If the image density is too light: Decrease SP #-6 setting. 7. Confirm that image density is within the adjustment standard. 5-39 A163...

  • Page 138: Image Bias Adjustment

    1. Make a copy after adjusting the light intensity. 2. If the image is blurred: Decrease bias voltage by one step and readjust light intensity. If the background is dirty: Increase bias voltage by one step and readjust light intensity. A163 5-40...

  • Page 139: Toner Density Adjustment

    Change the registration roller start timing by SP #-5. 1. Make several copies by using the manual feed or roll feeder and check the registration. 2. Adjust the registration using SP #-5 if the registration is not within the adjustment standard. 5-41 A163...

  • Page 141: Troubleshooting

    TROUBLESHOOTING...

  • Page 143: Copy Quality Troubleshooting

    Does the image density recover (without dirty background) after forcing supply of toner using SP#62? Check the charge corona, transfer corona and development bias. Check the toner sensor and main board. Check the light sensor, FL regulator and main board. A163...

  • Page 144: Uneven Copy Image

    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. Clean the optics. If the problem is not fixed, replace the exposure lamp. A163...

  • Page 145: Dirty Background

    Check the toner sensor. Make several blank copies. Is the background still dirty? Check the cleaning blade. Are the grid voltage and the charge corona current correct? Adjust the grid voltage and/or the charge corona current. Replace the drum. A163...

  • Page 146: Black Line Or Band

    If the separation corona leakage is detected, the separation corona will be turned off. This condition will not be reset until the main switch is turned off and on. If the separation corona does not turn on, a black band appears 250 mm from the paper leading edge. A163...

  • Page 147: Entirely Blank Copy

    Check the main board, charge/bias/grid power pack, and T & S power pack. Does leakage occur in the T & S endblocks? Replace the defective parts. Are the development drive gears broken? Replace the broken gears. Check the drum drive mechanism. A163...

  • Page 148: Paper Creasing

    Decrease the fusing temperature using SP mode #1 to #3. (NOTE 2.) NOTE: 1. If there is rib shape creasing, the paper feed direction should be the same as the paper fiber direction. 2. After decreasing the fusing temperature, check if the image is completely fused on the paper. A163...

  • Page 149: Service Call Condition

    The temperature detected by the hot roller thermistor does not reach 100 C within 4 minutes and 30 seconds after the main switch is turned on. <Point to check> Fusing thermofuse Hot roller thermistor AC drive board (T202-2, RA201-T4) Main board (CN106-A2, A4, B12, B14, B15) A163...

  • Page 150: Sc Code E-3: Hot Roller Thermistor Open

    Main board (CN106-A2, -A5, -B11, -B14, -B15) 2.5 SC Code E-5: Pressure Roller Thermistor Open -Definition- The resistance of the pressure roller thermistor is more than 0.53 MΩ. <Point to check> Pressure roller thermistor Main board (CN106-A2, -A4, -B12, -B14, -B15) A163...

  • Page 151: Sc Code E-6: Pressure Roller Thermistor Short

    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> Hot roller thermistor Fusing thermofuse AC drive board (T202-2, RA201-T4) Main board (CN106-A2, -B14, -B15) A163...

  • Page 152: Sc Code E-8: Fusing Warm-Up Error

    The toner density sensor voltage is less than 0.5 volts or more than 4.5 volts. NOTE: This condition is not detected until 251 copies since initializing developer. <Point to check> Toner density sensor Flow of the developer at the toner density sensor area Main board (CN104-A10, -A11, -B20, -B21) A163 6-10...

  • Page 153: Sc Code E-10: Main Motor Abnormal

    If clearing the SC condition, the previous data of SP#-30 is still used until its next initialization. <Point to check> Toner density sensor Developer Flow of the developer at the toner density sensor area Main board (CN104-A10, -A11, -B20, -B21) 6-11 A163...

  • Page 154: Blown Fuse Table

    250V 6.3A E=10 is indicated. 250V 6.3A Not used. USA version Fuse Specification Symptom 125V 8A No power. No indication. 250V 5A Beeper sounds. 250V 5A E=10 is indicated. 250V 5A Not used. FU5 125V 1A Counter No symptoms A163 6-12...

  • Page 155: Roll Feeder

    ROLL FEEDER...

  • Page 157: Specifications

    Power Source: +24 volts and +5 volts from the copier Power Consumption: Maximum 110 W Dimensions (W x D x H): 1,080 mm x 475 mm x 295 mm 42.71" x 18.70" x 11.61" Weight: 29 kg, 63.8 lb A163...

  • Page 158: 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 159: Electrical Component Descriptions

    45%). Printed Circuit Board RF Control Controls all roll cutter unit functions in accordance with copier CPU. Others Upper RF Removes humidity from the roll paper Antihumidity Heater Lower RF Removes humidity from the roll paper Antihumidity Heater A163...
  • Page 160 A163...

  • Page 161: Mechanical Operation

    [D] according to the signal from the copier. When the paper feed motor starts, the copier CPU starts measuring the length of the paper. (The paper length is measured by counting the number of steps as the paper feed motor [stepper motor] turns.) A163...
  • Page 162 The registration roller brake ensures that the very stiff types of paper will not rotate the registration rollers when the paper buckles while it is stopped at these rollers. A163...

  • Page 163: Cutter Unit Opening And Closing Mechanism

    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. A163...

  • Page 164: Cutter Operation

    There are home position switches [B] at both ends of the cutter unit. The cutter motor turns off, stopping the cutting action, when the rotary cutting blade knob plate [C] turns off one of these switches. A163...

  • Page 165: 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. A163...

  • Page 166: Installation Procedure

    Spacer ..................1 pc Small Cap..................1 pc Screws - M4x8 ................8 pcs Screws with Spring Washer - M4x8 ..........2 pcs NOTE: When the Roll Feeder is installed on the copier, the table (A714) is required. A163 7-10...
  • Page 167 2. Remove the shipping tapes [C] and shipping cushions [D]. 3. Remove the left and right covers [E and F] (3 screws each). 4. Remove the front cover [G] (2 screws) and lower the front cover arms [H] to the down position. 7-11 A163...
  • Page 168 (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. Remove the table rear cover [G] (4 screws). A163 7-12...
  • Page 169 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]. 7-13 A163...
  • Page 170 [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. Install the small cap [F] (2 screws). A163 7-14...
  • Page 171 15. Connect the roll feeder heater harness connector [I] to the copier ac drive board connector. 16. Install the harness covers [J] (1 screw each). 17. Reinstall Manual Feed Table 18. Reattach all the covers and manual feed table excluding the roll feeder right cover. 7-15 A163...
  • Page 172 22. Input values into SP modes 42 to 47 in accordance with the decal that is attached to the right side plate. 23. Press the Clear Modes key 3 times to leave the SP mode. 24. Reattach the roll feeder right cover. 25. Check the roll feeder operation. A163 7-16...

  • Page 173: Replacement And Adjustment

    NOTE: Be careful not to drop and damage the lower front cover [B]. 1. Remove the left and right covers [C and D] (3 screws each). NOTE: When reattaching the left and/or right covers, unlock and lift the cutter unit for easier assembly. 7-17 A163...

  • Page 174: 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. A163 7-18...

  • Page 175: Paper Feed Roller Replacement

    3. Remove the release lock lever [B] (2 screws). 4. Remove the feed roller guide plate [C] (6 screws). 5. Replace the paper feed roller [D] (2 allen screws [E], 1 gear [F], 1 snap ring [G], 2 bushings [H], and 1 retaining ring [I]). 7-19 A163...

  • Page 176: 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. Remove the small cap [A] (2 screws). 2. Loosen the screw [B] and re-tighten it. A163 7-20...

  • Page 177: Cut Length Adjustment

    2. Current SP data #42..0 Copy sample length = 297 -- 4 Set SP mode #42...+ 4.0 4. Make A0 lengthwise and A3 sideways copies using preset cut mode and check their length. 5. Repeat steps 2 to 4 if necessary. 7-21 A163...

  • Page 178: Roll Feed Paper Skew Adjustment

    NOTE: If the 10 or more copies are made continuously, the nip band width of the fusing unit may change. For correct adjustment, do this procedure at least 10 minutes after a continuous copy run of 10 or more. A163 7-22...
  • Page 179 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...
  • Page 181 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 182 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 183 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 184 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 185 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 189 OVERALL INFORMATION...

  • Page 191: 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 192 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 193: 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 194: 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 195 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 196: 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 197: 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 198 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 199 DETAILED DESCRIPTIONS...

  • Page 201: 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] ⇒...

  • Page 202: 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 203 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 204: 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 205: Fusing And Paper Exit

    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 207: Installation

    INSTALLATION...

  • Page 209: 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). 4. Ventilation: Minimum space 20 m Room air should turn over at least 30 m /hr/person.

  • Page 210: 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 211: 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) ±10% 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 212: 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 213 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 214 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 215 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 216 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 217 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 218 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 219 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 220: 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 221 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 222: 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 223 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 224 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 225 INSTALLATION PROCEDURE A836I505.WMF 265 ± 5 mm 265 ± 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.
  • Page 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233: Service Tables

    SERVICE TABLES...

  • Page 235: 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...
  • Page 236 Fixed Paper Size “42.0” size is added to the following modes Pattern Setting in the inch mode: Refer to the A163 copier manual and page 4-13 of this manual for details. 0, 1, 2, 3, 4, 7, 8, 9, 11, 12, 13, and 18 *33 Not Used -10 (Shorter) ←...
  • Page 237 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 238 10: Change the settings to the Japan version *Note1: This counter is not used for the toner density step control (described on page 2-16 in the A163 manual). *Note2: For the toner density step control, this counter counts down from 150 (m) to 0 (m) after the developer initialization.
  • Page 239 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 240 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 241 SERVICE TOOLS Mode No. Function Data -50 ← 0 → 50 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 242 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 243: 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 244: Output Check Mode Table

    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 245: 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 246 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 247 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 248 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 249: 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 250 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 251: Replacement And Adjustment

    REPLACEMENT AND ADJUSTMENT...

  • Page 253: 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 254: 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 255: 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 256: 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 257: 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 258: 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 259: 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 260 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 261: 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 262 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 263: 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. 0 ± 3 mm (0 ± 0.12 Adjustment ") 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 265: Troubleshooting

    TROUBLESHOOTING...

  • Page 267: Service Call Conditiion

    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”.

  • Page 268: 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 269 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 271 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 273 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 274 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 275 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 276 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 277 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 278 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 279 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 280 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 281 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 285 OVERALL INFORMATION...
  • Page 287 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 288: 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 289: 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 290: 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 291 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 292: 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 293 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 295: Detailed Section Descriptions

    DETAILED DESCRIPTIONS...

  • Page 297: 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 298: 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 299: 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 300: 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 301: 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 302: 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 303: Fusing And Paper Exit

    However, extra care should be taken while working around the hot roller. It is very easy to damage. Like the A163/A251/A252 copiers, if the fusing temperature is lower than 60°C when the main switch is turned on, the machine assumes that it has not been used recently, and the main motor must rotate to generate the necessary triboelectric charge on the toner and developer.

  • Page 304: 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 305: 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 307: Installation

    INSTALLATION...

  • Page 309: 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). 4. Ventilation: Room air should turn over at least 3 times per hour.

  • Page 310: 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 311: 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 312 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 313: 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 314 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 315 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 316 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 317 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°...
  • Page 318 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 319 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 320: 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 321 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 322 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 323 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 324 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 325 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. 7. Install the rear cover (2 screws). 3-17 B047/B048...
  • Page 326 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 327 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 328 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 329 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 330 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 331 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 332 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 333 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 334 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 335 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 336 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.
  • Page 337 SERVICE TABLES...

  • Page 339: Service Program Mode

    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 340 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 341 SERVICE TOOLS Mode No. Function Data –1.0 ← 0.0 → 1.0 Length Size Adjusts the speed of the original feed 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 342 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 343 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 ← 0 → 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 344 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 ← 0 → 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 345 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 346 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 347 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 348 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 349 SERVICE TOOLS Mode No. Function Data –50.0 ← 0 → 50.0 Roll Feed Speed Adjust the roll feed speed for Adjustment translucent paper. 10 steps = 0.09% (translucent paper) –50.0 ← 0 → 50.0 Roll Feed Speed Adjust the roll feed speed for film. Adjustment (film) 10 steps = 0.09% Number of...
  • Page 350 Japanese version *Note1: This counter is not used for the toner density step control (described on page 2-16 in the A163 manual). *Note2: For the toner density step control, this counter counts down from 150 (m) to 0 (m) after the developer initialization.
  • Page 351 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 352 SERVICE TOOLS Mode No. Function Data Hot Roller Change the hot roller temperature 0: Standard Temperature setting. –9 ← 0 → 9°C Adjustment Decrease Increase Pressure Roller Change the pressure roller 0: Standard Temperature –9 ← 0 → 9°C temperature setting. Adjustment Decrease Increase Hot Roller/...
  • Page 353 SERVICE TOOLS Mode No. Function Data Separation AC Determines the AC separation corona 170: Standard Voltage setting voltage. 130 ← 170 → 220 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...
  • Page 354 SERVICE TOOLS Mode No. Function Data Bias Voltage for Determines the development bias 4: Standard Non-image Area voltage for the non-image area. 0 ← 4 → 8 Setting In this mode, the bias voltage can be High turned on and off using the Copy Media key.
  • Page 355 SERVICE TOOLS Mode No. Function Data –100 ← 10 → 100 Length Size The fusing roller’s speed is slightly 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 356 SERVICE TOOLS Mode No. Function Data Synchro-cut Length Adjusts the original cut length in –9.9 ← 0 → 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 357 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 358 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 359 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 360 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 361 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 362 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 364 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 365 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 366 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 367 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 368 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 369 REPLACEMENT AND ADJUSTMENT...
  • Page 371 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 372 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 373 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 374 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, How:...
  • Page 375 TROUBLESHOOTING...

  • Page 377: 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 378 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 KΩ. 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 MΩ.
  • Page 379 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 •...
  • Page 380 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 381 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 383 ROLL FEED UNIT B435/B436...
  • Page 385 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 φ170 mm Cut Size: –Preset Cut: 1189 mm, 841 mm, 594 mm, 420 mm, 297 mm 48", 36", 24", 18", 12"...
  • Page 386 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 387 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 388 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 389: 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 390 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 391: Cutter Unit Replacement

    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 392 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 393: 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 394: 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 395: 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 396: 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 397: 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 398: 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 399 TECHNICAL SERVICE BULLETINS...
  • Page 401 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 402 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. 12. PAPER EXIT SECTION 1 13. PAPER EXIT SECTION 2 (A163) The material of this bushing has been changed.
  • Page 403 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: ⇒...
  • Page 404 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: •...
  • Page 405 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 406 Tech Service Bulletin No. FW740-004 Page 3 of 4 Continued...
  • Page 407 Tech Service Bulletin No. FW740-004 Page 4 of 4...
  • Page 408 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 409 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 410 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: ⇒...
  • Page 411 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. •...
  • Page 412 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 ITEM 0 → 1 A163 4355 Spacer - Fusing Entrance...
  • Page 413 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 414 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 415 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 416 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 417 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 418 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 419 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. •...
  • Page 420 Tech Service Bulletin No. FW740 - 013 Page 2 of 2 REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM 1 → 0 A1634171 Pressure Roller Stripper 0 → 1 A1634175 Pressure Roller Stripper Ass’y 0 → 1 A1744155 Stopper Guide - Paper Exit 0 →...
  • Page 421 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 422       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 423 ° B e fo r e A fte r 4 .0 m m 2 .9 m m GENERAL: The following parts corrections are being issued for all A163 Parts Catalogs. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM...
  • Page 424 Tech Service Bulletin No. A163 – 001 Page 2 of 2 UNITS AFFECTED: 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...
  • Page 425 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 426 ####+)78)82)6#h#2f% ####6-'3,#h#*;KHN ####7%:-2#h#2f% SUBJECT: SMALL CAP GENERAL: 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...
  • Page 427 [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 428 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 429 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 430 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 431 1,860 A1 or D copies per cartridge (6% original) Development Bias: Negative Toner Density Control: Direct toner density detection by induction sensor Image Density Adjustment: Development bias control + exposure control Paper Separation: Dual wire ac corona and pick-off pawls Cleaning: Cleaning blade A163...
  • Page 432 1,860 A1 or D copies per cartridge (6% original) Development Bias: Negative Toner Density Control: Direct toner density detection by induction sensor Image Density Adjustment: Development bias control + exposure control Paper Separation: Dual wire ac corona and pick-off pawls Cleaning: Cleaning blade A163...
  • Page 433 PAGE ITEM AZ320079 AZ320099 Power Pack – C.G.B UNITS AFFECTED: All A163/A251/A252 copiers manufactured after the Serial Numbers listed below will have the new style Power Pack – C.G.B installed during production. MODEL NAME SERIAL NUMBER Gestetner Ricoh FW740 Service parts only...
  • Page 434 SAVIN - NA SUBJECT: SPACER GENERAL: Please add the following component, which was omitted from the Parts Catalog: 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.
  • Page 435 5000 Savin SUBJECT: SMALL CAP GENERAL: The following part correction is being issued for the A571 Parts Section. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM A5717479 A5717497 Small Cap (A163 RIC/NRG)(A251/A252) RICOH GROUP COMPANIES CONTROL NO. 304...
  • Page 436 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 1→0 A1744493 Copy Tray Sheet 2→0 RICOH GROUP COMPANIES CONTROL NO. 314...
  • Page 437 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 438 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.

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