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A292/A293/A292P/A293P B098 SERVICE MANUAL
(To be used in conjunction with A229 Service Manual) 000930MIU
RICOH GROUP COMPANIES
®
®
A292/A293/A292P/A293P/B098 SERVICE MANUAL
RICOH GROUP COMPANIES
A292/A293/A292P/A293P B098 SERVICE MANUAL
000930MIU
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. All product names, domain names or product illustrations, including desktop images, used in this document are trademarks, registered trademarks or the property of their respective companies. They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies. No such use, or the use of any trade name, or web site is intended to convey endorsement or other affiliation with Ricoh products.
2002 RICOH Corporation. All rights reserved.
WARNING
The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection. Ricoh Corporation
LEGEND
PRODUCT CODE A292 A293 A292 w/G594 Controller A293 w/G594 Controller B098 GESTETNER 3355 3370 --5502 LD055 LANIER 5455 5470 RICOH Aficio 551 Aficio 700 Aficio 551P Aficio 700P Aficio 1055 SAVIN 2055DP 2070DP --2555
DOCUMENTATION HISTORY
REV. NO. * 1 DATE 5/2000 10/2002 COMMENTS Original Printing B098 Addition
Rev. 10/2002
TABLE OF CONTENTS
COMPARISON BETWEEN A292/A293 AND A229 OVERALL INFORMATION
1. OVERALL MACHINE INFORMATION ........................................ 1-1
1.1 SPECIFICATIONS.....................................................................................1-1 1.1.1 COPIER ENGINE .............................................................................1-1 1.1.2 ADF ..................................................................................................1-5 1.2 MACHINE CONFIGURATION ...................................................................1-6 1.3 MECHANICAL COMPONENT LAYOUT ...................................................1-7 1.3.1 COPIER ENGINE .............................................................................1-7 1.3.2 ADF ..................................................................................................1-9 1.4 PAPER PATH..........................................................................................1-10 1.5 COPY PROCESS....................................................................................1-11 1.6 DRIVE LAYOUT ......................................................................................1-13 1.6.1 COPIER ENGINE ...........................................................................1-13 1.6.2 ADF ................................................................................................1-14 1.7 ELECTRICAL COMPONENT DESCRIPTION.........................................1-15 1.7.1 COPIER ENGINE ...........................................................................1-15 1.7.2 ADF ................................................................................................1-21
DETAILED DESCRITPIONS
2. DETAILED DESCRIPTIONS ....................................................... 2-1
2.1 DOCUMENT FEEDER ..............................................................................2-1 2.1.1 PICK-UP ROLLER RELEASE ..........................................................2-1 2.1.2 BOTTOM PLATE LIFT......................................................................2-2 2.1.3 PICK-UP AND SEPARATION ..........................................................2-3 2.1.4 ORIGINAL FEED ..............................................................................2-4 2.1.5 ORIGINAL SIZE DETECTION..........................................................2-5 Original Length .....................................................................................2-5 Original Width .......................................................................................2-5 2.1.6 ORIGINAL TRANSPORT .................................................................2-6 2.1.7 ORIGINAL SKEW CORRECTION ....................................................2-7 2.1.13 ORIGINAL INVERSION AND FEED-OUT ......................................2-8 General Operation ................................................................................2-8 Original Inversion ..................................................................................2-9 Original Exit (Single-Sided Original Mode)..........................................2-10 Original Exit (Double-Sided Original Mode) ........................................2-11 2.1.9 JAM CONDITIONS .........................................................................2-12 Feed-in................................................................................................2-12 Feed-out .............................................................................................2-12 Inversion .............................................................................................2-12
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2.2 SCANNING..............................................................................................2-13 2.2.1 OVERVIEW ....................................................................................2-13 2.2.2 SCANNER DRIVE ..........................................................................2-14 2.2.3 ORIGINAL SIZE DETECTION IN BOOK MODE ............................2-15 2.3 IMAGE PROCESSING ............................................................................2-16 2.3.1 OVERVIEW ....................................................................................2-16 2.3.2 SBU ................................................................................................2-17 2.3.3 AUTO IMAGE DENSITY (ADS) ......................................................2-18 2.3.4 IPU (IMAGE PROCESSING UNIT).................................................2-19 Overview.............................................................................................2-19 2.3.5 IMAGE PROCESSING STEPS AND RELATED SP MODES.........2-20 2.3.6 AUTO SHADING ............................................................................2-25 Black Level Correction ........................................................................2-25 White Level Correction........................................................................2-25 2.3.7 BACKGROUND ERASE.................................................................2-26 Background Erase ..............................................................................2-26 2.3.13 INDEPENDENT DOT ERASE ......................................................2-27 2.3.9 FILTERING, MAIN SCAN MAGNIFICATION/REDUCTION ...........2-28 Overview.............................................................................................2-28 Filtering ...............................................................................................2-28 Main Scan Magnification/Reduction....................................................2-29 Sub Scan Magnification ......................................................................2-29 2.3.10 GAMMA (G) CORRECTION.........................................................2-30 2.3.11 GRADATION PROCESSING .......................................................2-30 Three-graduation Processing..............................................................2-30 Four-graduation Processing................................................................2-31 Error Diffusion and Dithering...............................................................2-31 2.3.12 LINE WIDTH CORRECTION........................................................2-31 2.4 LASER EXPOSURE................................................................................2-32 2.4.1 AUTO POWER CONTROL.............................................................2-32 2.4.2 DUAL BEAM WRITING ..................................................................2-33 2.4.3 LASER BEAM PITCH CHANGE MECHANISM (FOR A292/A293 ONLY) .................................................................2-34 2.4.4 LD SAFETY SWITCHES ................................................................2-35 2.5 DRUM UNIT ............................................................................................2-36 2.5.1 PROCESS CONTROL....................................................................2-36 Overview.............................................................................................2-36 Drum potential sensor calibration .......................................................2-37 VSG adjustment..................................................................................2-37 VG Adjustment....................................................................................2-38 LD power adjustment ..........................................................................2-39 Toner Density Adjustment...................................................................2-39 VREF Update......................................................................................2-40 2.5.2 DRUM UNIT COMPONENTS.........................................................2-41 2.5.3 DRUM CHARGE.............................................................................2-42 Overview.............................................................................................2-42 Charge Corona Wire Cleaning Mechanism.........................................2-43 2.5.4 DRUM CLEANING AND TONER RECYCLING..............................2-44 Overview.............................................................................................2-44
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Drive Mechanism ................................................................................2-45 Cleaning Blade Pressure Mechanism and Side-to-Side Movement....2-46 2.5.5 OTHERS.........................................................................................2-47 Air Flow Around the Drum...................................................................2-47 Pick-off Mechanism ............................................................................2-48 2.6 DEVELOPMENT AND TONER SUPPLY ................................................2-49 2.6.1 OVERVIEW ....................................................................................2-49 2.6.2 DEVELOPMENT MECHANISM......................................................2-50 2.6.3 DEVELOPMENT BIAS ...................................................................2-51 2.6.4 TONER DENSITY CONTROL ........................................................2-52 Overview.............................................................................................2-52 Sensor control mode...........................................................................2-52 Image pixel count control ....................................................................2-53 2.6.5 TONER END DETECTION.............................................................2-54 Toner Near End ..................................................................................2-54 Toner End ...........................................................................................2-54 2.6.6 TONER END RECOVERY .............................................................2-54 2.6.7 ABNORMAL TD AND ID SENSOR CONDITIONS .........................2-55 2.7 IMAGE TRANSFER AND PAPER SEPARATION ...................................2-56 2.7.1 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM ...2-56 2.7.2 TRANSFER BELT UNIT LIFT MECHANISM..................................2-57 2.7.3 TRANSFER BELT CLEANING MECHANISM ................................2-58 2.13 PAPER FEED........................................................................................2-59 2.13.1 OVERVIEW ..................................................................................2-59 2.13.2 DRIVE MECHANISM....................................................................2-60 2.13.3 TANDEM LCT TRAY 1 ..............................................................2-61 Overview.............................................................................................2-61 Connecting the Left and Right Sides of the Tray ................................2-62 Paper Lift/Remaining Paper Detection................................................2-63 Fence Drive ........................................................................................2-65 Rear Fence Drive................................................................................2-66 Tray Positioning ..................................................................................2-67 2.13.4 TRAY POSITIONING MECHANISM TRAYS 1 TO 3 .................2-68 2.13.5 PAPER LIFT MECHANISM - TRAYS 2 AND 3.............................2-69 2.13.6 VERTICAL TRANSPORT MECHANISM ......................................2-70 2.13.7 PAPER REGISTRATION..............................................................2-71 Overview.............................................................................................2-71 2.13.13 PAPER SIZE DETECTION TRAY 2 ........................................2-72 2.9 IMAGE FUSING ......................................................................................2-73 2.9.1 OVERVIEW ....................................................................................2-73 2.9.2 FUSING ENTRANCE GUIDE .........................................................2-74 2.9.3 FUSING DRIVE MECHANISM .......................................................2-75 2.10 PAPER EXIT/DUPLEX ..........................................................................2-76 2.10.1 OVERVIEW ..................................................................................2-76 2.10.2 INVERTER ...................................................................................2-77 Feed-in and Jogging ...........................................................................2-77 Feed-out .............................................................................................2-78 2.10.3 DUPLEX TRAY FEED MECHANISM ...........................................2-79 2.10.4 BASIC DUPLEX FEED OPERATION ...........................................2-80
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Longer than A4 / Letter lengthwise .....................................................2-80 2.11 ENERGY SAVER MODES ....................................................................2-83 2.11.1 LOW POWER MODE ...................................................................2-83 Entering low power mode ...................................................................2-83 What happens in low power mode......................................................2-83 Return to stand-by mode ....................................................................2-83
INSTALLATION
3. INSTALLATION PROCEDURE................................................... 3-1
3.1 INSTALLATION REQUIREMENTS ...........................................................3-1 3.1.1 ENVIRONMENT ...............................................................................3-1 3.1.2 MACHINE LEVEL .............................................................................3-1 3.1.3 MINIMUM SPACE REQUIREMENTS...............................................3-2 3.1.4 POWER REQUIREMENTS ..............................................................3-2 3.2 COPIER (A292/A293/B0913) ....................................................................3-3 3.2.1 ACCESSORY CHECK......................................................................3-3 3.2.2 INSTALLATION PROCEDURE ........................................................3-4 3.3 LCT (11/B5137) .......................................................................................3-14 3.3.1 ACCESSORY CHECK....................................................................3-14 3.3.2 INSTALLATION PROCEDURE ......................................................3-15 3.4 3,000-SHEET FINISHER (9/B5136) ........................................................3-20 3.4.1 ACCESSORY CHECK....................................................................3-20 3.4.2 INSTALLATION PROCEDURE ......................................................3-21 3.5 PUNCH UNIT INSTALLATION (A1312) FOR 9/B5136 FINISHER..........3-24 3.5.1 ACCESSORY CHECK....................................................................3-24 3.5.2 PUNCH UNIT INSTALLATION .......................................................3-25 3.6 FINISHER (B302) ....................................................................................3-28 3.6.1 INSTALLATION PROCEDURE ......................................................3-28 3.7 PUNCH UNIT INSTALLATION (A1312) FOR B302 FINISHER...............3-31 3.7.1 ACCESSORY CHECK....................................................................3-31 3.7.2 PUNCH UNIT INSTALLATION .......................................................3-32 3.13 KEY COUNTER INSTALLATION ..........................................................3-35 3.9 COPY CONNECTOR KIT INSTALLATION (10) ......................................3-36 3.10 LG KIT (B375/B51313) ..........................................................................3-39 3.10.1 ACCESSORY CHECK..................................................................3-39 3.10.2 INSTALLATION PROCEDURE ....................................................3-40
SERVICE TABLES
4. SERVICE TABLES...................................................................... 4-1
4.1 GENERAL CAUTIONS..............................................................................4-1 4.1.1 DRUM...............................................................................................4-1 4.1.2 DRUM UNIT .....................................................................................4-1 4.1.3 TRANSFER BELT UNIT ...................................................................4-2 4.1.4 SCANNER UNIT...............................................................................4-2 4.1.5 LASER UNIT ....................................................................................4-2 4.1.6 CHARGE CORONA..........................................................................4-3
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4.1.7 DEVELOPMENT ..............................................................................4-3 4.1.13 CLEANING .....................................................................................4-4 4.1.9 FUSING UNIT...................................................................................4-4 4.1.10 PAPER FEED.................................................................................4-4 4.1.11 USED TONER ................................................................................4-4 4.2 SERVICE PROGRAM MODE....................................................................4-5 4.2.1 SERVICE PROGRAM MODE OPERATION.....................................4-5 Service Program Access Procedure .....................................................4-5 Accessing Copy Mode from within an SP Mode ...................................4-7 Selecting the Program Number.............................................................4-8 Inputting a Value or Setting for an SP Mode.........................................4-9 4.2.2 SERVICE PROGRAM MODE TABLES ..........................................4-10 4.2.3 TEST PATTERN PRINTING (SP2-902) .........................................4-66 Test Pattern Table (SP2-902-2: Test Pattern Printing IPU) .............4-66 Test Pattern Table (SP2-902-3: Test Pattern Printing Printing) .......4-66 4.2.4 INPUT CHECK ...............................................................................4-67 Main Machine Input Check (SP5-1303) ..............................................4-67 ADF Input Check (SP6-007) ...............................................................4-71 4.2.5 OUTPUT CHECK ...........................................................................4-72 Main Machine Output Check (SP5-1304) ...........................................4-72 ADF Output Check (SP6-0013) ..........................................................4-73 4.2.6 SYSTEM PARAMETER AND DATA LISTS (SMC LISTS) .............4-73 4.2.7 MEMORY ALL CLEAR (SP5-1301) ................................................4-74 4.2.13 SOFTWARE RESET ....................................................................4-75 4.2.9 SYSTEM SETTING AND COPY SETTING (UP MODE) RESET ...4-75 System Setting Reset .........................................................................4-75 Copy Features Reset ..........................................................................4-75 4.3 PROGRAM AND DATA DOWNLOAD.....................................................4-76 4.3.1 OVERVIEW ....................................................................................4-76 4.3.2 DOWNLOAD THE BICU SOFTWARE FROM BICU TO FLASH MEMORY CARD .............................................................................4-77 4.3.3 DOWNLOAD NVRAM DATA TO THE BICU ..................................4-78 4.3.4 DOWNLOAD NVRAM DATA FROM BICU TO FLASH MEMORY CARD .............................................................................................4-79 4.3.5 DOWNLOAD STAMP DATA TO THE BICU ...................................4-80 4.4 USER PROGRAM MODE .......................................................................4-81 4.4.1 HOW TO ENTER AND EXIT UP MODE.........................................4-81 4.4.2 UP MODE TABLE ..........................................................................4-81 System Setting Table..........................................................................4-81 Copy Features Table ..........................................................................4-82 4.4.3 IMAGE QUALITY SETTING BY UP MODE....................................4-86 Text Mode...........................................................................................4-86 Text/Photo Mode ................................................................................4-90 Photo Mode ........................................................................................4-91 Pale Mode...........................................................................................4-92 Generation Mode ................................................................................4-92 4.5 TEST POINTS/DIP SWITCHES/LEDS....................................................4-93 4.5.1 DIP SWITCHES..............................................................................4-93 4.5.2 TEST POINTS ................................................................................4-93
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4.5.3 FUSES............................................................................................4-94 4.5.4 VARIABLE RESISTORS ................................................................4-95 4.5.5 LEDS ..............................................................................................4-95 4.6 SPECIAL TOOLS AND LUBRICANTS ....................................................4-95 4.6.1 SPECIAL TOOLS ...........................................................................4-95 4.6.2 LUBRICANTS .................................................................................4-95 4.7 FIRMWARE HISTORY .............................................................................4-96
PREVENTIVE MAINTENANCE
5. PREVENTIVE MAINTENANCE SCHEDULE .............................. 5-1
5.1 PM TABLE.................................................................................................5-1
REPLACEMENT AND ADJUSTMENT
6. REPLACEMENT AND ADJUSTMENT........................................ 6-1
6.1 EXTERIOR ................................................................................................6-1 6.1.1 FILTERS...........................................................................................6-1 Ozone Filter: Duct .................................................................................6-1 Filter Vacuum........................................................................................6-1 6.2 DOCUMENT FEEDER ..............................................................................6-2 6.2.1 COVER REMOVAL ..........................................................................6-2 6.2.2 FEED UNIT REMOVAL AND SEPARATION ROLLER REPLACEMENT...............................................................................6-4 6.2.3 FEED BELT REPLACEMENT ..........................................................6-5 6.2.4 PICK-UP ROLLER REPLACEMENT ................................................6-6 6.2.5 SENSOR REPLACEMENT...............................................................6-7 Entrance and Registration Sensors ......................................................6-7 Width Sensor ........................................................................................6-8 Exit Sensor and Inverter Sensor ...........................................................6-9 6.2.6 TRANSPORT BELT REPLACEMENT............................................6-10 6.3 SCANNER UNIT......................................................................................6-11 6.3.1 EXPOSURE GLASS.......................................................................6-11 6.3.2 LENS BLOCK .................................................................................6-12 6.3.3 ORIGINAL SIZE SENSORS ...........................................................6-13 6.3.4 EXPOSURE LAMP .........................................................................6-14 6.3.5 SCANNER MOTOR / MCU.............................................................6-15 Scanner Motor ....................................................................................6-15 MCU....................................................................................................6-15 6.3.6 SCANNER WIRES .........................................................................6-16 Rear Scanner Drive Wire ....................................................................6-19 Front Scanner Drive Wire ...................................................................6-20 Reinstallation ......................................................................................6-21 6.4 LASER UNIT ...........................................................................................6-23 6.4.1 CAUTION DECAL LOCATIONS .....................................................6-23 6.4.2 LD UNIT REPLACEMENT..............................................................6-24 6.4.3 LASER BEAM PITCH ADJUSTMENT ............................................6-25 6.4.4 POLYGON MIRROR MOTOR REPLACEMENT ............................6-29
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6.5 DRUM UNIT ............................................................................................6-30 6.5.1 DRUM POTENTIAL SENSOR REPLACEMENT ............................6-30 6.5.2 DRUM MOTOR REPLACEMENT...................................................6-31 6.5.3 TONER OUTPUT AND RECYCLING PUMP UNIT REPLACEMENT.............................................................................6-32 6.6 DEVELOPMENT AND TONER SUPPLY ................................................6-34 6.6.1 DEVELOPMENT AND AIR DUST FILTER REPLACEMENT .........6-34 6.6.2 DEVELOPER REPLACEMENT ......................................................6-35 6.6.3 TONER END SENSOR REPLACEMENT.......................................6-37 6.6.4 DEVELOPMENT MOTOR REPLACEMENT ..................................6-37 6.7 TRANSFER BELT UNIT..........................................................................6-38 6.7.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION ....................6-38 - Removal - .........................................................................................6-38 - Installation - ......................................................................................6-38 6.13 PAPER FEED........................................................................................6-40 6.13.1 PAPER TRAY REMOVAL ............................................................6-40 Tandem Tray Removal .......................................................................6-40 Universal trays (Customer adjust/Technician adjust) Removal...........6-42 6.13.2 REAR FENCE RETURN SENSOR REPLACEMENT...................6-43 6.13.3 REAR FENCE HP SENSOR REPLACEMENT.............................6-44 6.13.4 BOTTOM PAPER SENSOR REPLACEMENT .............................6-45 6.13.5 BOTTOM PLATE LIFT WIRE REPLACEMENT ...........................6-46 6.13.6 TANDEM LCT PAPER SIZE CHANGE ........................................6-48 6.13.7 BY-PASS PAPER SIZE BOARD REPLACEMENT.......................6-51 6.13.13 PAPER FEED CLUTCH/RELAY CLUTCH REMOVAL...............6-53 6.13.9 BY-PASS FEED MOTOR/CLUTCH REMOVAL ...........................6-56 6.13.10 REGISTRATION MOTOR REMOVAL ........................................6-57 6.13.11 PAPER TRAY UNIT REMOVAL .................................................6-58 6.9 FUSING UNIT..........................................................................................6-59 6.9.1 FUSING UNIT REMOVAL ..............................................................6-59 6.9.2 FUSING THERMISTOR/THERMOFUSE/THERMOSTAT REPLACEMENT.............................................................................6-60 Fusing Thermistor Replacement.........................................................6-60 Fusing Thermofuse Replacement (for A292/A293 only) .....................6-60 Fusing Thermostat Replacement (for B0913 only) .............................6-61 Fusing Thermostat Replacement (for B0913 only) .............................6-61 6.9.3 FUSING LAMP REPLACEMENT ...................................................6-62 6.9.4 HOT ROLLER REPLACEMENT .....................................................6-63 6.9.5 OIL SUPPLY/CLEANING ROLLER REPLACEMENT ....................6-65 6.9.6 PRESSURE ROLLER CLEANING ROLLER REPLACEMENT ......6-66 6.9.7 MAGNET POSITION ADJUSTMENT .............................................6-67 6.9.13 HOT ROLLER STRIPPER PAWL REPLACEMENT .....................6-68 6.10 PAPER EXIT/DUPLEX UNIT.................................................................6-70 6.10.1 1ST AND 2ND EXIT SENSOR .....................................................6-70 6.10.2 JOGGER MOTOR ........................................................................6-71 6.10.3 DUPLEX ENTRANCE SENSOR ..................................................6-71 6.10.4 DUPLEX TRANSPORT/DUPLEX FEED CLUTCHES ..................6-72 6.10.5 DUPLEX TRANSPORT SENSOR 1 .............................................6-72 6.10.6 DUPLEX TRANSPORT SENSORS 2 & 3 ....................................6-73
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6.10.7 INVERTER EXIT CLUTCH ...........................................................6-74 6.10.13 DUPLEX INVERTER SENSOR ..................................................6-74 6.11 BOARDS AND OTHER ITEMS .............................................................6-75 6.11.1 BICU BOARD ...............................................................................6-75 6.11.2 I/O BOARD ...................................................................................6-76 6.11.3 PSU ..............................................................................................6-77 6.11.4 PAPER FEED CONTROL BOARD (PFC) ....................................6-77 6.12 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING .....................6-78 6.12.1 PRINTING ....................................................................................6-78 Registration - Leading Edge ...............................................................6-78 Registration Side-to-Side .................................................................6-78 Tray 1..................................................................................................6-79 Tray 2..................................................................................................6-79 Tray 3..................................................................................................6-80 By-pass Tray.......................................................................................6-80
TROUBLESHOOTING
7. TROUBLESHOOTING ................................................................ 7-1
7.1 SERVICE CALL CONDITIONS .................................................................7-1 7.1.1 SUMMARY .......................................................................................7-1 7.1.2 SC CODE DESCRIPTIONS .............................................................7-2 7.2 ELECTRICAL COMPONENT DEFECTS ................................................7-46 7.2.1 SENSORS ......................................................................................7-46 7.2.2 SWITCHES.....................................................................................7-50 7.3 BLOWN FUSE CONDITIONS .................................................................7-51
FIRMWARE HISTORY
8. A292/A293 FIRMWARE MODIFICATION HISTORY .................. 8-1
3,000-SHEET FINISHER (B312/B586)
1. OVERALL MACHINE INFORMATION ........................................ 9-1
1.1 1.2 1.3 1.4 1.5 SPECIFICATIONS.....................................................................................9-1 ELECTRICAL COMPONENT LAYOUT.....................................................9-4 ELECTRICAL COMPONENT DESCRIPTION...........................................9-6 MECHANICAL COMPONENT LAYOUT ...................................................9-8 DRIVE LAYOUT ........................................................................................9-9
2. DETAILED DESCRIPTIONS ..................................................... 9-10
2.1 TRAY AND STAPLER JUNCTION GATE MECHANISM ........................9-10 Upper tray mode .................................................................................9-10 Sort/stack mode..................................................................................9-10 Staple mode........................................................................................9-10 2.2 PRE-STACK MECHANISM .....................................................................9-11 2.3 JOGGER UNIT PAPER POSITIONING MECHANISM............................9-12
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Vertical Paper Alignment ....................................................................9-12 Horizontal Paper Alignment ................................................................9-12 2.4 STAPLER UNIT MOVEMENT MECHANISM ..........................................9-13 Side-to-side:........................................................................................9-13 Rotation: .............................................................................................9-13 2.5 STAPLER ................................................................................................9-14 2.6 FEED-OUT MECHANISM .......................................................................9-15 2.7 SHIFT TRAY UP/DOWN MECHANISM ..................................................9-16 2.13 SHIFT TRAY SIDE-TO-SIDE MECHANISM..........................................9-17 2.9 PUNCH UNIT DRIVE MECHANISM........................................................9-18 2.10 PUNCH WASTE COLLECTION MECHNISM........................................9-19 2.11 JAM CONDITIONS................................................................................9-20
3. SERVICE TABLES.................................................................... 9-21
3.1 DIP SWITCHES.......................................................................................9-21 3.2 TEST POINTS .........................................................................................9-21 3.3 FUSES ....................................................................................................9-21
4. REPLACEMENT AND ADJUSTMENT...................................... 9-22
4.1 COVER REPLACEMENT ........................................................................9-22 Rear Cover .........................................................................................9-22 Upper Left Cover ................................................................................9-22 Upper Cover .......................................................................................9-22 Front Door...........................................................................................9-22 Left Front Cover..................................................................................9-22 Shift Tray ............................................................................................9-23 Lower Left Cover ................................................................................9-23 Right Cover.........................................................................................9-23 Front Shift Tray Cover.........................................................................9-23 Rear Shift Tray Cover .........................................................................9-23 4.2 POSITIONING ROLLER REPLACEMENT..............................................9-24 4.3 ALIGNMENT BRUSH ROLLER REPLACEMENT ...................................9-25 4.4 SENSOR REPLACEMNT ........................................................................9-26 4.4.1 STACK HEIGHT SENSOR 1 AND 2...............................................9-26 4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR ........................9-27 Upper Tray Paper Limit Sensor ..........................................................9-27 Upper Tray Exit Sensor.......................................................................9-27 4.4.3 SHIFT TRAY EXIT SENSOR..........................................................9-28 4.4.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSOR...........9-29 Entrance Sensor .................................................................................9-29 Stapler Tray Entrance Sensor.............................................................9-29 4.4.5 STAPLER ROTATION HP SENSOR..............................................9-30 4.5 STAPLER REMOVAL..............................................................................9-31 4.6 PUNCH POSITION ADJUSTMENT.........................................................9-32 Right to left..........................................................................................9-32 Front to rear ........................................................................................9-32
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BOOKLET FINISHER A763
1. OVERALL MACHINE INFORMATION ...................................... 10-1
1.1 SPECIFICATIONS...................................................................................10-1 1.2 ELECTRICAL COMPONENT DESCRIPTION.........................................10-3 1.3 MECHANICAL COMPONENT LAYOUT .................................................10-7
2. DETAILED DESCRIPTIONS ..................................................... 10-8
2.1 JUNCTION GATE MECHANISM.............................................................10-8 2.1.1 SHIFT TRAY MODE .......................................................................10-8 A4/LT sideways or shorter ..................................................................10-8 Longer than A4 sideways....................................................................10-8 2.1.2 PROOF TRAY MODE.....................................................................10-9 2.1.3 BOOKLET STITCH MODE .............................................................10-9 2.2 PRE-STACK MECHANISM ...................................................................10-10 2.3 PAPER SHIFT MECHANISM ................................................................10-11 2.4 PAPER POSITIONING MECHANISM ...................................................10-12 2.5 STAPLER UNIT MOVEMENT MECHANISM ........................................10-13 2.5.1 DRIVE...........................................................................................10-13 2.5.2 MOVEMENT.................................................................................10-13 Front and Rear Stapling....................................................................10-13 Tow-position Stapling........................................................................10-13 2.6 STAPLER ..............................................................................................10-14 2.7 SHIFT TRAY MECHANISM...................................................................10-15 2.13 BOOKLET UNIT GATE MECHANISM.................................................10-16 2.9 RELAY ROLLER AND POSITIONING PLATE MECHANISM ...............10-18 2.10 POSITIONING ROLLER MECHANISM...............................................10-19 2.11 BOOKLET UNIT JOGGER MOVEMENT MECHANISM......................10-20 2.12 BOOKLET STAPLER UNIT .................................................................10-21 2.13 PAPER FOLDER MECHANISM ..........................................................10-22
3. INSTALLATION ...................................................................... 10-24
3.1 ACCESSORY CHECK ..........................................................................10-24 3.2 INSTALLATION PROCEDURE .............................................................10-25
4. REPLACEMENT AND ADJUSTMENT.................................... 10-30
4.1 REMOVAL .............................................................................................10-30 4.1.1 UPPER DOOR .............................................................................10-30 4.1.2 UPPER REAR COVER.................................................................10-31 4.1.3 LOWER REAR COVER................................................................10-31 4.1.4 TOP COVER ................................................................................10-32 4.1.5 UPPER INNER COVER ...............................................................10-32 4.1.6 SHIFT TRAY UNIT .......................................................................10-33 4.1.7 UPPER SHIFT GUIDE..................................................................10-34 4.1.13 LOWER SHIFT GUIDE...............................................................10-34 4.1.9 EXIT UNIT ....................................................................................10-35 4.1.10 BUFFER ROLLER UNIT.............................................................10-36 4.1.11 STAPLER ...................................................................................10-37
A292/A293/B098 x SM
Rev. 10/2002
4.1.12 FINISHER BOARD ....................................................................10-38 4.1.13 BOOKLET UNIT .........................................................................10-39 4.1.14 FOLDER ROLLERS ...................................................................10-41 4.1.15 FOLDER PLATE.........................................................................10-44 Removal............................................................................................10-44 Reinstalling .......................................................................................10-45 4.1.16 BOOKLET STAPLER UNIT ........................................................10-46 Removal............................................................................................10-46 Adjustment........................................................................................10-47 4.1.17 BOOKLET BOARD .....................................................................10-49 4.1.113 POSITIONING PLATE UNIT ....................................................10-49 4.1.19 1ST AND 2ND BOOKLET UNIT GATES ....................................10-50 4.2 ADJUSTMENT ......................................................................................10-51 4.2.1 SHIFT TRAY HEIGHT ..................................................................10-51 4.2.2 JOGGER FENCE POSITION .......................................................10-52 4.2.3 STAPLING POSITOIN..................................................................10-53 4.2.4 BOOKLET STAPLING POSITION.................................................10-54
COPIER CONNECTION KIT B322
1. SPECIFICATIONS..................................................................... 11-1 2. DETAILED DESCRIPTIONS ..................................................... 11-2
2.1 OVERVIEW .............................................................................................11-2 2.2 BASIC OPERATION................................................................................11-3 2.2.1 NO SORT AND NO STAPLE MODE ..............................................11-3 2.2.2 SORT, STAPLE MODE ..................................................................11-4 2.2.3 OPERATION IN IRREGULAR CONDITIONS.................................11-5 Paper end during copying ...................................................................11-5 Copy tray full.......................................................................................11-5 Paper jam ...........................................................................................11-5
LCT A698/B587
1. OVERALL MACHINE INFORMATION ...................................... 12-1
1.1 1.2 1.3 1.4 1.5 SPECIFICATIONS...................................................................................12-1 MECHANICAL COMPONENT LAYOUT .................................................12-2 ELECTRICAL COMPONENT LAYOUT...................................................12-3 ELECTRICAL COMPONENT DESCRIPTIONS ......................................12-4 DRIVE LAYOUT ......................................................................................12-5
2. DETAILED DESCRIPTIONS ..................................................... 12-6
2.1 PAPER FEED MECHANISM ...................................................................12-6 2.2 TRAY LIFT MECHANISM........................................................................12-7 Tray lifting conditions ..........................................................................12-7 Tray lowering conditions .....................................................................12-7 2.3 PAPER STACK HEIGHT DETECTION ...................................................12-9
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Rev. 10/2002
3. SERVICE TABLES.................................................................. 12-10
3.1 TEST POINTS .......................................................................................12-10
4. REPLACEMENT AND ADJUSTMENT.................................... 12-11
4.1 COVER REMOVAL ...............................................................................12-11 Tray Cover ........................................................................................12-11 Right Cover......................................................................................12-11 Front Cover.......................................................................................12-11 Upper Rear Cover.............................................................................12-11 Lower Rear Cover.............................................................................12-12 Feed Unit Cover................................................................................12-12 4.2 ROLLER REPLACEMENT ....................................................................12-13 4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ...........12-13 Pick-up Roller ...................................................................................12-13 Paper Feed Roller.............................................................................12-13 Separation Roller ..............................................................................12-13 4.3 PAPER END SENSOR REPLACEMENT..............................................12-14 4.4 PAPER FEED SENSOR REPLACEMENT............................................12-15 4.5 PAPER POSITION SENSOR REPLACEMENT ....................................12-16 4.6 PICK-UP SOLENOID REPLACEMENT.................................................12-17 4.7 LIFT MOTOR REPLACEMENT .............................................................12-18 4.13 SIDE FENCE POSITION CHANGE.....................................................12-19
3,000-SHEET FINISHER B302
1. OVERALL MACHINE INFORMATION ...................................... 13-1
1.1 1.2 1.3 1.4 SPECIFICATIONS...................................................................................13-1 MECHANICAL COMPONENT LAYOUT .................................................13-3 ELECTRICAL COMPONENT DESCRIPTION.........................................13-4 DRIVE LAYOUT ......................................................................................13-6
2. DETAILED DESCRIPTIONS ..................................................... 13-7
2.1 TRAY AND STAPLER JUNCTION GATE ...............................................13-7 Upper Tray Mode ................................................................................13-7 Sort/Stack Mode .................................................................................13-7 Staple Mode........................................................................................13-7 2.2 PAPER PRE-STACKING ........................................................................13-8 2.3 JOGGER UNIT PAPER POSITIONING ..................................................13-9 Vertical Paper Alignment ....................................................................13-9 Horizontal Paper Alignment ................................................................13-9 Paper Stack Correction.......................................................................13-9 2.4 STAPLER UNIT MOVEMENT ...............................................................13-10 Side-to-Side ......................................................................................13-10 Rotation (1) .......................................................................................13-11 Rotation (2) .......................................................................................13-11 2.5 STAPLER ..............................................................................................13-12 2.6 FEED-OUT ............................................................................................13-14 2.7 SHIFT TRAY UP/DOWN MOVEMENT..................................................13-15
A292/A293/B098 xii SM
Rev. 10/2002
2.13 SHIFT TRAY SIDE-TO-SIDE MOVEMENT .........................................13-16 2.9 PUNCH UNIT DRIVE ............................................................................13-17 2.10 PUNCH WASTE COLLECTION ..........................................................13-18 2.11 JAM CONDITIONS..............................................................................13-19
3. SERVICE TABLES.................................................................. 13-20
3.1 DIP SWITCHES.....................................................................................13-20 3.2 TEST POINTS .......................................................................................13-20 3.3 FUSES ..................................................................................................13-20
4. REPLACEMENT AND ADJUSTMENT.................................... 13-21
4.1 COVER REPLACEMENT ......................................................................13-21 Front Door.........................................................................................13-21 Left Inner Cover ................................................................................13-21 Inner Cover .......................................................................................13-21 Table.................................................................................................13-22 Upper Tray........................................................................................13-22 Left Upper Cover ..............................................................................13-22 Left Lower Cover...............................................................................13-22 Upper Cover .....................................................................................13-22 Rear Cover .......................................................................................13-22 Shift Tray ..........................................................................................13-23 Front Shift Tray Cover.......................................................................13-23 Rear Shift Tray Cover .......................................................................13-23 4.2 POSITIONING ROLLER REPLACEMENT............................................13-24 4.3 ALIGNMENT BRUSH ROLLER REPLACEMENT .................................13-25 4.4 SENSOR REPLACEMENT ...................................................................13-26 4.4.1 STACK HEIGHT 1, 2 AND EXIT GUIDE OPEN SENSOR ...........13-26 Stack Height Sensors 1 and 2 ..........................................................13-26 Exit Guide Open Sensor ...................................................................13-26 4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR ......................13-27 Upper Tray Paper Limit Sensor ........................................................13-27 Upper Tray Exit Sensor.....................................................................13-27 4.4.3 SHIFT TRAY EXIT SENSOR........................................................13-28 4.4.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSORS ......13-29 Entrance Sensor ...............................................................................13-29 Stapler Tray Entrance Sensor...........................................................13-29 4.4.5 PRE-STACK STOPPER SENSOR ...............................................13-30 4.4.6 STAPLE WASTE HOPPER SENSOR ..........................................13-31 4.4.7 STAPLER ROTATION HP AND STAPLER RETURN SENSORS 13-32 Stapler Rotation HP Sensor..............................................................13-32 Stapler Return Sensor ......................................................................13-32 4.5 STAPLER REMOVAL............................................................................13-33 4.6 PUNCH POSITION ADJUSTMENT.......................................................13-34 Right to Left ......................................................................................13-34 Front to Rear.....................................................................................13-34
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!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 paper tray unit are supplied with electrical voltage even if the main power switch is turned off. 4. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 5. If the Start key is pressed before the copier completes the warm-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed. 6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands. HEALTH SAFETY CONDITIONS 1. Never operate the copier without the ozone filters installed. 2. Always replace the ozone filters with the specified ones at the specified intervals. 3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention. 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. The NVRAM on the system control board has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations.
1
1. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations. 4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.
!WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
!WARNING
WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:
2
Rev. 10/2002
3,000 SHEET FINISHER B312/B586
BOOKLET FINISHER A763
COPIER CONNECTION KIT B322
LCT A698/B587
3,000 SHEET FINISHER B302
TAB POSITION 8
FIRMWARE HISTORY A292/A293/B098
TAB POSITION 7
TROUBLESHOOTING A292/A293/B098
TAB POSITION 6
REPLACEMENT AND ADJUSTMENT A292/A293/B098
TAB POSITION 5
PREVENTIVE MAINTENANCE A292/A293/B098
TAB POSITION 4
SERVICE TABLES A292/A293/B098
TAB POSITION 3
INSTALLATION A292/A293/B098
TAB POSITION 2
DETAILED DESCRIPTIONS A292/A293/B098
TAB POSITION 1
OVERALL INFORMATION A292/A293/B098
COMPARISON BETWEEN A292/A293 AND A229
DIFFERENT POINTS
SECTION 1: OVERALL INFORMATION
Section
Specifications
Item
Copy Size Zoom Copying Speed 1 to 1 Copying Speed with ADF Resolution First Copy Time
Description
Minimum: A5/51/2" x 81/2" Lengthwise in 2nd Tray Minimum: 25% (A229: 32%) 70/55 cpm (A229: 65/55 cpm) 70 cpm (A229: 50 cpm) ARDF: New A294 Scanning: 600 dpi (A229: 400 dpi) Printing: 600 dpi (A229: 400 dpi) Face Up: 3.5 seconds, Face Down: 5.3 seconds (A229: Face Up: 3.7 seconds, Face Down: 5.5 seconds) Tray 1: 3,100 sheets (A229: 1,000 sheets) Tray 3: 550 sheets (A229: 1,500 sheets) RAM: 48 MB (A229: 12 MB) HDD: 4.3 GB (A229: 1.7 GB) (Refer to service manual) Document Server function is available as a standard function. User Stamp, etc. Finisher (B312): Pre-stack function Finisher (A763): Folds paper in half with 2 staples Finisher (B302): Pre-stack function, 100 sheets for staple Punch Unit (for B312 B302, A812): 2 holes (80 mm / 6.5 mm) (Same as A229) 3 holes (108-108 mm / 8 mm) (Same as A229) 4 holes (21-70-21 mm / 6.5 mm) (New) 4 holes (80-80-80 mm / 6.5 mm) (New) 2 holes (70 mm / 8 mm) (New) LCT (A698): Upgraded version Copy Connector Unit (B322) Output Tray (B333) Tab Sheet Holder (B373) 81/2" x 14" Size Kit (B375) New Toner (NA: Type 5105D, EU/Asia: Type 5205D) New Developer (Type 15) Toner Particle: 9.5 µm (A229: 7.5 µm)
Page
1-1 1-2 1-2 N/A 1-2 1-2
Copy Paper Capacity Memory Capacity Power Consumption Additional Feature Additional Feature Peripherals
1-2 N/A 1-3 N/A N/A 1-4
Consumable
2-49
SM
1
A292/A293
DIFFERENT POINTS
SECTION 2: DETAILED DESCRIPTIONS
Section
Scanning
Item
Overview
Description
· The number of exposure lamp is one. (A229: 2 lamps) · The CCD is changed to 4-channel type because of a higher processing speed. (A229: 2 channels) · A reflector is added to 1st scanner. · The Scanner Motor has been changed to a DC Servo type because of a higher processing speed. · The location of Lamp Regulator moves onto the 1st scanner. · The LD unit and Polygon Motor have been changed because of a higher processing speed. · The method controlling the LD has been changed because the standard resolution has been changed from 400 dpi to 600 dpi. The toner amount in the development unit is updated using Vsp/Vsg data in addition to the Vref update. The holes for airflow have been added to Drum Flange to make cooling power up because of higher processing speed. 362 mm/s (A229: 330 mm/s) This is because a higher copying speed. One of the conditions making the cleaner start moving "only if the fusing temperature is lower than 100°C" has not been used any more because the other condition "only when 5000 or more copies have been made since the last movement" is effective enough to function. · The turning direction of the brush has been changed to the counter direction to increase the cleaning ability. · The brush has been changed from a rope type to a straight type. A rope type scrapes off the drum surface too much because of the change of the turning direction. The location of the cam gear is changed onto the main frame to increase reliability. TBA The pattern has become darker to increase reliability of toner supply control. The shaft of the roller does not turn. It is not necessary to lubricate conductive grease on the shaft.
Page
2-13
Laser Exposure
Overview
N/A
Process Control
Image Density Control
2-36
Drum Unit
Drum Flange
2-47
Drum Unit
Rotation Speed Corona Wire Cleaner
N/A 2-43
Cleaning
Cleaning Brush
2-44
Development
Cleaning Blade Side-to-Side Movement Toner Supply Control ID Sensor Pattern
2-46
N/A N/A
Lower Development Roller
N/A
A292/A293
2
SM
Rev. 08/2000 Section
Transfer
DIFFERENT POINTS Item Description
The surface treatment has been changed to increase cleaning ability. The nylon tube has been added as the surface of the cleaning bias roller to increase the cleaning ability. This allows to increasing the maximum charging voltage up to 1000 V (A229: 330 V). A bearing has been added to the bushing to make the movement smoother. The gear has been changed to a diagonal type with the color of black to decrease a jitter level. 1st Copy (Front): 65µA (A229: 60µA) 2nd Copy (Front): 65µA (A229: 60µA) By-pass Tray (Front): 75µA (A229: 70µA) Post Card (Front): 165µA (A229: 150µA) This is because of a higher drum rotation speed. The type of the Torque Limitter has been changed from a non-contact magnet type to a metal powder type to increase reliability. The paper size setting can be done at the front side of the tray for easier operation. The By-pass Tray Switch has been deleted. The bypass tray indicator is always on the operation panel and turns on when paper is placed in the tray. The thick paper mode is used for any paper type in all paper feed stations to increase paper transportation ability. The number of copies, which can be made after the toner overflow switch is activated and the "full toner collection bottle" indication lights, becomes only "up to 100 copies". The other one "the copy job is allowed to end" is not effective any more. The grip and the jam removal decal have been changed. The procedure of jammed paper removal has also been changed. The Fusing Sensor has been added to detect a jammed paper with an accordion shape. The Inverter Exit Clutch has been added to stop a paper coming into the duplex unit for a while. This is to keep the maximum productivity of printing even when it takes a longer time for image processing for a paper coming out of the duplex unit. When the clutch is ON, paper stops. The Inverter Exit Sensor has been added to control the ON/OFF timing of the Inverter Exit Clutch. The Jogger Fences start moving 83 ms after the trailing edge of paper passes the Duplex Entrance Sensor. (A229: 100 ms) An inlet is added to change the airflow direction of the exhaust fan to downward. This is to i