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Ricoh Gestetner 5450, Service Manual

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SERVICE MANUAL

(Machine code: C229)

Summary of Contents for Gestetner 5450

Page 1: ...SERVICE MANUAL Machine code C229...

Page 2: ...ent induce vomiting by sticking a finger down your throat or by giving soapy or strong salty water to drink OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1 The printer and its peripherals must be installe...

Page 3: ...an environmentally safe manner and in accordance with local regulations 3 When keeping used lithium batteries from the main processing units in order to dispose of them later do not store more than 10...

Page 4: ...ent induce vomiting by sticking a finger down your throat or by giving soapy or strong salty water to drink OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1 The printer and its peripherals must be installe...

Page 5: ...an environmentally safe manner and in accordance with local regulations 3 When keeping used lithium batteries from the main processing units in order to dispose of them later do not store more than 10...

Page 6: ...ze Maximum 304 8 x 432 mm 12 0 x 17 0 Thickness Less than 30 mm Weight Less than 10 kg In ADF Mode Document size Maximum 297 x 864 mm 11 6 x 33 8 Minimum 105 x 128 mm 4 2 x 5 1 Document weight 52 3 10...

Page 7: ...60 75 90 105 120 sheets minute 5 steps Master Process Time Platen mode Less than 15 5 seconds A3 paper Less than 12 seconds A4 paper ADF mode Less than 19 5 seconds A3 paper Less than 16 seconds A4 pa...

Page 8: ...hermal master roll type 420 mm width 110 m roll Yield 200 masters roll at A3 size Max run length per master 2 000 prints Master Storage Conditions Temperature 10 C to 40 C Humidity 10 to 95 RH Recomme...

Page 9: ...SPECIFICATIONS 1 July 1998 1 4 Available Options A3 Drum A4 Drum Document Feeder Key Counter Memory Board Editing Function PC Controller Interface Board Standard for the U S A and European versions...

Page 10: ...cess the Image Density key and so on 3 Operation Panel Operator controls and indicators are located here 4 Master Feed Unit Open the master feed unit when installing the master 5 Paper Feed Tray Down...

Page 11: ...MACHINE INTERIOR 1 July 1998 1 6 1 3 MACHINE INTERIOR C229V501 WMF...

Page 12: ...7 Paper Delivery Side Plates These plates align the prints on the paper delivery tray 8 Paper Delivery Side Plate Knobs Use to move the side plates 9 Master Eject Unit Front Handle E1 Use to pull out...

Page 13: ...key 6 Make up key 7 Overlay key 8 Edge Erase key 9 Image Density key Press to make prints darker or lighter 10 Tint key 11 Economy Mode key 12 On Line key 13 Job Separator key 14 Combine key Press to...

Page 14: ...ting press to stop the machine 21 Enter key Use to enter data in selected modes 22 Clear Modes key Press to clear the previously entered job settings 23 Start key Press to make a master 24 Auto Cycle...

Page 15: ...nstalled 2 Monitors The monitors light up when a non standard condition occurs within the machine 6 Counter Displays the number of prints entered While printing it shows the number of prints remaining...

Page 16: ...e image on the master The master then wraps around the drum 4 Paper Feeding Sends paper to the drum section 5 Printing Presses the paper fed from the paper feed section against the drum This transfers...

Page 17: ...tion Rollers 15 Doctor Roller 16 Pressure Cylinder 17 Ink Roller 18 Idling Roller 19 Transport Belts 20 Job Separator Unit 21 Paper Delivery Table 22 Master Eject Rollers 23 Master Eject Box 24 Master...

Page 18: ...1 July 1998 ELECTRICAL COMPONENT LAYOUT 1 13 Overall Information 1 6 ELECTRICAL COMPONENT LAYOUT 1 6 1 PRINTED CIRCUIT BOARD LAYOUT C229V007 WMF 1 2 3 4 5 6 7 10 11 9 8...

Page 19: ...ELECTRICAL COMPONENT LAYOUT 1 July 1998 1 14 1 6 2 SCANNER SECTION 1 6 3 PAPER FEED SECTION C229V001 WMF C229V002 WMF 20 21 22 23 24 25 26 27 19 18 34 33 32 31 30 29 28 11 12 13 14 15 16 17...

Page 20: ...ly 1998 ELECTRICAL COMPONENT LAYOUT 1 15 Overall Information 1 6 4 MASTER EJECT PRESSURE CYLINDER AND OTHER SECTIONS C229V003 WMF 38 37 39 40 41 42 43 44 46 48 45 49 50 51 52 53 54 55 56 57 58 59 35 3...

Page 21: ...CTRICAL COMPONENT LAYOUT 1 July 1998 1 16 1 6 5 PAPER DELIVERY SECTION 1 6 6 MASTER MAKING UNIT C229V010 WMF C229V005 WMF 60 61 62 63 64 65 66 67 68 69 72 73 74 71 70 75 77 78 80 81 79 82 83 84 85 86...

Page 22: ...1 July 1998 ELECTRICAL COMPONENT LAYOUT 1 17 Overall Information 1 6 7 DRUM UNIT C229V006 WMF 88 87 89 90 91 92 93 94 95 97 96...

Page 23: ...Supply Board Provides dc power to the thermal head 11 Sensor Board Unit SBU Contains the CCD and outputs a video signal to the MPU 19 Feed Pressure Detection Board Sends data about the paper feed pre...

Page 24: ...unit components 60 Transport Vacuum Fan Provides suction so that paper is held firmly on the transport belts 61 Air Knife Fan Provides air to separate the paper leading edge from the drum 63 Wing Gui...

Page 25: ...8 Pressure Plate HP Sensor Detects when the pressure plate is at the home position 39 Pressure Plate Limit Position Sensor Detects when the pressure plate is at the lowest position 41 Image Shift HP S...

Page 26: ...e position 80 Master Set Sensor Detects whether a master roll is present 81 Platen Release Sensor Detects when the platen pressure is applied against the thermal head 85 Master End Sensor Detects when...

Page 27: ...r 5 Pressure Plate Motor 6 Exit Pawl Drive Cam Gear 7 Paper Delivery Unit Drive Gear Pulley 8 Main Motor 9 Pressure Cylinder Drive Gear Including the Scissors Gear 10 Registration Roller Lifting Cam D...

Page 28: ...0 Printing Pressure Cam 21 Exit Pawl Drive Cam Gear 22 Main Motor 23 Printing Pressure Cam Drive Gear 24 Idler Gear Pulley 25 Pressure Cylinder Drive Gear including the Scissors Gear 26 Primary Gear P...

Page 29: ...Charge Coupled Device C The 1st scanner D consists of the exposure lamp a reflector E and the 1st mirror F A DC power supply energizes the exposure lamp to avoid uneven light intensity when the 1st s...

Page 30: ...Changing the scanner drive motor speed changes the image length in the sub scan direction Image processing on the MPU board accomplishes reduction and enlargement in the main scan direction SP6 011 1...

Page 31: ...e is used the magnification ratio affects the image reading area However for Auto Magnification Image Rotation or Image Repeat modes combined with Platen mode the original width A and length B sensors...

Page 32: ...e original size from the number of activated sensors Original Size Length Sensors Width Sensors A4 A3 version LT DLT version L1 L2 L3 L4 S1 S2 A3 11 x 17 O O O O O O B4 10 x 14 O O O O O X F4 81 2 x 1...

Page 33: ...converter built into the SBU transforms the analog signals into 8 bit signals This assigns a value to each pixel from a scale of 256 grades Then the digitized image data goes to the MPU board The ima...

Page 34: ...t the start of the main scan line as shown As the scanner scans down the page the IPU on the MPU detects the peak white level for each scan line within this narrow strip only From this peak white leve...

Page 35: ...of the CCD signal 64 pixels are blackened at the end and takes an average of the black dummy data Then the CPU deletes the black level value of each image pixel White Level Correction The machine rea...

Page 36: ...ring Main Scan Magnification Filtering The MTF and smoothing filters are software filters that enhance the desired image qualities of the selected original mode The MTF filter used in all modes except...

Page 37: ...d of the scan line in ADF mode as compared with platen mode In platen mode the original is placed face down on the exposure glass and the corner at A is at the start of the main scan The scanner moves...

Page 38: ...shold value The threshold value changes based on a compensation curve Gamma curve which corresponds to selected image settings For example if a darker image is selected a compensation curve which conv...

Page 39: ...processed The user must be sure to scan the command sheets before the original The image processing chip in the MPU modulates the image data for the command sheet and then stores the modulated command...

Page 40: ...t the applied voltage to the specific value for the thermal head Thermal Head Protection The thermistor on the thermal head provides thermal head protection preventing the thermal head from overheatin...

Page 41: ...Do not touch the master film surface with bare hands Connect and disconnect the connectors carefully Keep them horizontal and firmly reconnect them Do not touch the connector terminals with bare hands...

Page 42: ...lock mechanism locks the drum at this position to prevent the drum from moving during master ejection At the same time the master pick up roller A touches the drum picking up the leading edge of the m...

Page 43: ...o open the drum master clamper F The master pick up roller D moves against the drum at the same time because it is connected through an idle gear A link plate connects the drum guide E to the clamper...

Page 44: ...sensor A determines this position NOTE The same drum guide also moves when the drum is at the master making position There is another stud on the rear drum flange which is used to secure the drum at t...

Page 45: ...moves the master pick up roller against the drum through the idle gear D while driving the clamper opening arm C At the same time as the drum master clamper B closes after the master is picked up the...

Page 46: ...d up from the drum The master eject sensor detects this Then when the drum starts turning they turn on again to feed the ejected master to the eject box while the drum turns towards the master making...

Page 47: ...r eject rollers C When the unit is slid out explained below the joint D disengages Master Eject Roller Unit Slide out Mechanism The master eject roller unit E can be slid out of the machine as shown f...

Page 48: ...to the box An independent dc motor the pressure plate motor drives the pressure plate The motor is in the pressure plate drive unit on the rear frame of the machine separate from the master eject box...

Page 49: ...the rear of the box Masters are ejected from an open door at the rear of the box The side opposite the eject lever side A of the inner bottom case is connected to a belt B This helps the inner bottom...

Page 50: ...into a position where it can act as a feed guide for the used master on its way to the eject box Compression The pressure plate compresses the master into the box Drive The pressure plate motor A driv...

Page 51: ...n side until both the pressure plate HP sensor A and the limit position sensor B are actuated 2 As shown in the upper right diagram the pressure plate turns counterclockwise until the home position se...

Page 52: ...master During this operation the machine can recognize how full the eject box is by monitoring the lower limit and home position sensors When there are no or very few masters in the box If there are n...

Page 53: ...ure plate movement the torque limiter allows this gear to slip Master Box Full Detection Mechanism As explained above the pressure plate motion range narrows as the ejected masters build up in the box...

Page 54: ...mit position inside the box which is only possible if the box is fairly empty At 6 s after the motor turns on Drum Master Box Direction Drum Direction HP Eject Position Compressing Position Stays for...

Page 55: ...e master is fed while the thermal head develops the image on it The master vacuum fans I temporarily suck the fed master into the master buffer duct J This is done because the used master is still bei...

Page 56: ...e machine the master edge sensor B checks the leading edge of the master The master is fed 18 mm more after the master edge sensor B is activated It has now been caught by the master feed control roll...

Page 57: ...r A catches the master leading edge the entrance plate is opened The normal position of the entrance plate is open Master End Detection There is a solid fill black area at the end of the master roll W...

Page 58: ...and thermal head is always under tension There is a torque limiter E built into the tension roller drive gear This allows the tension roller to become free from the master feed motor drive when the m...

Page 59: ...tion Just before master making the platen release motor starts turning until the sensor is inactive this indicates that the platen pressure is now applied to prepare for master making When master maki...

Page 60: ...turning creating suction to guide the master into the duct A At this time the master feed control roller has already caught the leading edge of the master This roller does not start turning until the...

Page 61: ...drum guide The arm is different from the one used for opening the master clamper at the master eject position The clamper motor E drives the arm and opens the master clamper F in synchronization with...

Page 62: ...following cases When a master roll is put in the machine the master is fed until the master feed control roller catches the leading edge of the master During master clamping the master feed control ro...

Page 63: ...ynchronizing it with the drum rotation When master making is complete and the master is stored in the master buffer duct the drum turns continuously to wrap the master The cutter cuts the master when...

Page 64: ...ped NOTE As explained in Master Feed and Stop Control in 2 5 2 Master Set Mechanism the master edge sensor only controls the master stop position at the master feed control roller after a roll is put...

Page 65: ...ront the operation side of the machine the blades cut the master The cutter motor keeps turning in one direction However the cutter holder returns to the home position when it reaches the front end of...

Page 66: ...set sensor A a push switch detects when the unit is out The operation panel displays a message in this case 2 4 6 OPENING DOOR FOR MISFED MASTER REMOVAL There is a jam removal dial to manually rotate...

Page 67: ...he drum are the ink roller D and doctor roller E which create a precisely maintained gap known as the doctor gap to supply a thin layer of ink on the screens and master F This machine uses the drum id...

Page 68: ...chanism is inside the drum The ink pump motor C drives the ink pump D supplying ink from the ink cartridge to the ink roller E via the ink distributor F Ink Pump Operation Monitoring The ink pump sens...

Page 69: ...tecting the capacitance between the pins the ink supply motor maintains the ink level If the pins detect an insufficient amount of ink after activating the ink pump motor for 40 seconds a no ink condi...

Page 70: ...k detection board The settings depend on the drum type in the following manner DPS901 1 2 Standard Drum ON ON Optional Color Drum OFF ON Optional A4 Drum ON OFF Not Used OFF OFF Note If the CPU detect...

Page 71: ...turned in the reverse direction The ink roller only touches the screen during the printing process During the printing process ink passes to the paper through holes in the screens and the master This...

Page 72: ...the Quality Start mode is active and there is no master on the drum drum idling is skipped although the LED on the operation panel turns on When printing for the next original starts the machine enter...

Page 73: ...e thermistor A reports approximately 15 C or lower If the detected temperature is 28 C or higher it is a high temperature condition The number of drum idling rotations depends on temperature and perio...

Page 74: ...he table below In all cases the drum idling roller returns to home position when drum rotation speed reaches 75 rpm Change of drum rotation speed rpm with temperature Temperature Trial Print 1st Print...

Page 75: ...on panel The motor moves the rear drum flange B via the rack and pinion as shown At the same time it rotates the pulse disk This allows the drum shift sensor C to generate pulse signals for sending to...

Page 76: ...et correctly and the front lever C is raised the drum is locked into position The connector D allows electrical contact for the drum components Drum Rotation Lock Mechanism The rotation stopper E prev...

Page 77: ...The actuator on the rear drum flange activates these sensors as the drum turns There are three drum stop positions home master eject and master making The CPU starts counting the main motor encoder pu...

Page 78: ...drum starts turning soon after the drum master clamper clamps the leading edge of the master The 2nd drum master sensor checks for the presence of the master master clamping error check If a master is...

Page 79: ...ressure against the paper depend on the paper type selected at the operation panel Each component has a separate dc motor to adjust the pressure The operator is free from complicated adjustments for p...

Page 80: ...to the registration roller The friction pad D is mounted on a block E and spring pressure is applied to this block As explained later the spring pressure is changed by a dc motor to adjust the paper...

Page 81: ...motor on timing is maintained by the feed start sensor C A short time after the pressure cylinder D starts rotating the actuator A on the rear of the pressure cylinder activates the sensor After a pr...

Page 82: ...ettings Paper Separation Pressure The paper separation pressure is applied from the bottom of the friction pad block A by a spring on the friction pad base E The direction of the paper separation pres...

Page 83: ...or releasing the spring C through the rack D The lever F moves up or down depending on the tension of the spring If the spring is pulled the lever moves upwards reducing the paper feed pressure The po...

Page 84: ...ype with intermediate chances of double and non feed Pressure Settings for Each Paper Type For each of these paper types standard thick special user 1 user 2 the user has two settings Misfeed and Doub...

Page 85: ...ng table shows the default settings for each paper type For the pressure the higher the SP mode value the higher the pressure For details about the paper clamper see Pressure Cylinder For details abou...

Page 86: ...APER FEED 1 July 1998 2 58 2 6 4 PAPER REGISTRATION MECHANSM Registration Roller Drive The lower registration roller A is driven by a stepper motor B the registration motor C229D058 WMF A B Rear Front...

Page 87: ...ing edge to be caught by the paper clamper on the pressure cylinder Therefore the registration motor start timing after the paper feed start sensor is activated depends on the printing speed selected...

Page 88: ...n roller This is to prevent interference from the registration rollers while the paper is being fed by the drum and the pressure cylinder When the high point of the cam A on the drum drive gear reache...

Page 89: ...h the rollers the motor remains stopped to create a buckle in the paper to obtain precise paper registration and to prevent paper skew The motor starts turning a pre determined period after the sensor...

Page 90: ...ifficult to feed at the level position In the slanted position the tray capacity is reduced As the paper table A is lowered from the closed position the pin on the lever C engages the cutout in the lo...

Page 91: ...s 2 6 7 PAPER TABLE OPEN DETECTION When the paper table is open the lever A activates the paper table set sensor B If the paper table remains closed and the sensor is not activated guidance will be di...

Page 92: ...down To reduce noise there is a shutter cover below the table which is a combination of 5 plates The shutter closes the opening beneath the paper table when the table is lifted up NOTE Although each...

Page 93: ...s During a printing run sheets are fed from the stack and the pick up roller lowers When the paper height sensor is de actuated the paper table motor starts turning and lifts the paper table until the...

Page 94: ...e side plate friction pads on the front and rear paper side fences prevent multiple feed These are especially useful when thin paper is used There are two spring plates B applying pressure against the...

Page 95: ...s activated If B4 sized or 8 1 2 x 14 paper or larger is set on the paper table the paper length sensor B is activated The actuator plate C is attached to the rack for the paper side fences The paper...

Page 96: ...le master sizes Printing on a large master A3 sized cut or small master A4 sideways sized cut is selected automatically only if the optional ADF is used The printing pressure cams include two shapes o...

Page 97: ...s it After the high point of the cam passes the bearing the clamper closes and holds the paper using magnets When Thick Paper mode is selected on the operation panel the paper is not clamped The clamp...

Page 98: ...s fed towards the paper delivery unit As the pressure cylinder rotates the other high point of the cam B reaches the bearing at the front end of the clamper The clamper is again opened and the paper i...

Page 99: ...he arms This occurs when the paper reaches the image transfer area When the arms are released the two printing pressure springs pull the pressure cylinder up against the drum through the front and rea...

Page 100: ...t original s image is always made on a large master This is to prevent the drum screen from drying if the next printing job is not done for a long time Therefore a small master is not made when there...

Page 101: ...ection and Feedback of Pressure Cylinder Rotation Fluctuation Since the pressure cylinder does not have a perfectly circular cross section the rotation speed tends to fluctuate The feed encoder B whic...

Page 102: ...Overview The main motor D rotates the pressure cylinder through the main drive timing belt B image up down shift mechanism A timing belt F and gears as shown above The gear E is also driven by the ma...

Page 103: ...reinstall the drum because the position of the drum drive gear will have changed The knob A is used to rotate the main motor drive manually A small plate covers the knob normally because it is only f...

Page 104: ...ure cylinder in order to prevent the paper from being wrapped around the pressure cylinder The paper guide wings B help to feed out the paper to the delivery table A dc motor the wing guide motor chan...

Page 105: ...s clockwise when the cam follower rides on the high point of the cam and the exit pawl moves away from the drum This happens when the master clamper on the drum is approaching the exit pawl When the m...

Page 106: ...d the motor automatically changes the angle of the wing guides NOTE The paper types that can be selected are standard thick and special Two additional settings for paper types can be customized as use...

Page 107: ...e paper more evenly on the table Both edges of the paper are guided by the guides as the copy is fed out Then the paper is rapidly fed out against the end plate for stacking The front side fence C can...

Page 108: ...R DELIVERY JAM SENSORS Paper Delivery Jam The exit sensor A detects paper jams Paper Lower Wrapping The lower wrapping jam sensor B detects when paper is wrapped around the pressure cylinder C229D034...

Page 109: ...tation is transmitted to the main drive timing belt C via the route opposite to the normal main motor drive At the same time as the knob is turned the drive position indicator disk F turns through the...

Page 110: ...motor C lowers the sliding arm A high friction material a type of sandpaper is attached to the edge of the sliding arm and it touches the top sheet of the paper stack Then the job separator motor turn...

Page 111: ...returns the job separation motor turns until the slider HP sensor C a micro switch turns on While the sliding arm is being lowered onto the top sheet of the paper stack the paper sensor D a micro swi...

Page 112: ...ion must also be changed so that the paper will be caught properly by the paper clamper on the pressure cylinder This is also necessary to make sure that the printing pressure application area is corr...

Page 113: ...shaft as it moves around the surface of the primary gear A The image shift gear turns the primary gear as it moves around its surface The primary gear is connected to the idler pulley G via a timing...

Page 114: ...otor B As the motor turns this encoder generates a pulse signal The CPU uses this to detect the amount of motor rotation The detected amount is displayed on the operation panel as the image shift amou...

Page 115: ...IGINAL FEED ERROR DETECTION IN THE ADF Registration Sensor DF Feed Motor DF Feed Clutch Image Scanning Start L 80 mm Feed in Original Feed in Jam The sensor is still off 5 seconds after the motor turn...

Page 116: ...Stays OFF Master Eject Sensor stays on Jam Still off after 8 seconds Jam Drum Master Box Direction Drum Direction HP Eject Position Compressing Position Stays for 2 seconds Returned to HP Does not re...

Page 117: ...n Release Motor Master Feed Motor Duct Entrance Solenoid Master Feed Clutch 1st Check The master edge sensor stays off when 5 seconds has passed Master Feed Jam 1 s Master Set Error Detection The mast...

Page 118: ...aster Clamping Error The 2nd drum master sensor stays off At this time the status of the master edge sensor is checked If the sensor remains activated it means that a master cut error has occurred and...

Page 119: ...FEED ERROR DETECTION Paper Feed Start Sensor Paper Feed Motor Registration Sensor Registration Motor Paper Feed Timing Sensor Delay Paper Feed Jam The sensor is not on within 400 pulses 125 6 mm Delay...

Page 120: ...nsor Paper Exit Sensor Lower Wrapping Jam Sensor The sensor status check when the feed start sensor turns on The paper exit sensor is off and the lower wrapping jam sensor remains off Paper jam wrappe...

Page 121: ...right 3 1 2 ENVIRONMENTS TO AVOID 1 Locations exposed to direct sunlight or strong light more than 1 500 lux 2 Areas with corrosive gases 3 Dusty areas 4 Locations directly exposed to cool air from an...

Page 122: ...ACCESS TO MACHINE Place the machine near a power source providing clearance as shown below C231I510 WMF More than 10 cm 4 0 65 cm 25 6 More than 60 cm 23 7 More than 60 cm 23 7 141 cm 55 6 More than 6...

Page 123: ...3 2 1 MAIN BODY Accessory Check Make sure that you have all the accessories listed below Operating Instructions Expect for Ricoh European Version 1 NECR Ricoh version only 1 Brand Stickers OEM version...

Page 124: ...e box from the top If opened from the bottom the paper delivery table may be damaged 1 Unpack the box Take out the small box A inside that contains the paper delivery table CAUTION First open the uppe...

Page 125: ...uly 1998 INSTALLATION PROCEDURE 3 5 Installation 2 Continue to unpack the box Make sure that there are the accessory bag A and the paper delivery unit inside the small box B C229I010 WMF C229I002 WMF...

Page 126: ...shown 2 screws packed with the table CAUTION Only handle using the carrying handles A on the bottom of the machine Otherwise your fingers may be pinched between the main body and the table during ins...

Page 127: ...1 July 1998 INSTALLATION PROCEDURE 3 7 Installation 4 Remove the tape securing the covers and units and the master clamper protective sheet A as shown C229I004 WMF C229I011 WMF A...

Page 128: ...TION PROCEDURE 1 July 1998 3 8 5 Take out the paper delivery table from the box 6 Set the front and rear side fences as shown 7 Assemble the paper delivery table as shown two screws C229I008 WMF C229I...

Page 129: ...aster roll 10 Install the ink cartridge 11 Firmly insert the plug in the wall outlet CAUTION Make sure that the wall outlet is near the machine and easily accessible 12 Turn on the main switch 13 Pres...

Page 130: ...2 2 AUTO DOCUMENT FEEDER OPTION Accessory Check Make sure that you have all the accessories listed below Document feeder unit 1 DF harness 1 Screws 2 Thumb screws 4 Stabilizer brackets 2 DF scale cov...

Page 131: ...rst remove the rear exterior cover of the main body A Remove the memory board A If installed as this is an option B Disconnect the flat cable B NOTE Gently pull out the lever C to release the flat cab...

Page 132: ...crews 2 Swing out the MPU bracket A 6 screws 3 Run the DF harness accessory as shown and fasten it with the clamps B 5 clamps which were originally used in the main body 4 Connect the cable connector...

Page 133: ...the two stabilizer brackets A to the back of the table using the thumbscrews B 4 screws All components are in the accessories 2 Attach the caution label C as shown CAUTION This procedure must be done...

Page 134: ...ape 2 Remove the left scale B 2 screws 3 Place the DF exposure glass C on the glass holder 4 Peel off the backing D of the double side tape attached to the rear side of the scale guide E then install...

Page 135: ...he DF to the left then secure the DF unit with the 2 screws M4 10 9 Connect the I F harness B to the main body 10 Attach the original direction decals C to the DF table as shown 11 Turn the main switc...

Page 136: ...s as a standard part not an option 1 Remove the rear cover and the right rear cover 2 Install the I F board A in CN102 on the MPU 2 screws 3 Connect the cable B accessory to the I F board 4 Attach the...

Page 137: ...m z Color Drum A4 Drum 1 Take the color drum out of the drum case Remove the holder A 2 Remove the protective paper in the master clamper 3 Attach the appropriate color decal accessory B to the drum c...

Page 138: ...iginal scale is replaced the SBU must be calibrated with SP6 32 1 4 1 2 MASTER EJECT SECTION 1 Master Pick up Roller Drive Gear and Master Clamper Drive Arm Positions These parts must be positioned co...

Page 139: ...d Roller and Paper Separation Roller 2 Do not touch the surfaces of the rollers with bare hands 4 1 5 DRUM AND DRUM DRIVE SECTION 1 Doctor Roller Normally the doctor roller gap is not adjusted or chan...

Page 140: ...rear of the machine the MPU and I O board have to be moved out of the way See 6 4 MPU and PSU Opening Procedures 3 Power Supply Unit When replacing the power supply unit be sure to adjust the voltage...

Page 141: ...al A4 Drum Not used DPS901 1 ON OFF ON OFF DPS901 2 ON ON OFF OFF 4 2 3 POTENTIOMETERS I O Board Number Usage VR303 Master Eject Sensor Adjustment VR304 Master End Sensor Adjustment Do not adjust VR30...

Page 142: ...e Master Edge Sensor LED304 Monitors the feed control CPU operation Usually this LED is blinking LED305 Monitors power supplied to the I O board Usually this LED is lit 4 2 5 FUSES Power Supply Unit F...

Page 143: ...rgy pulse error The CPU detects an abnormal thermal head energy control pulse Defective MPU Defective PSU SC03 02 Thermal head thermistor short The signal from the thermal head thermistor reaches 4 88...

Page 144: ...SC05 11 Image shift HP sensor remains off At power on the sensor is not activated for more than 25 seconds after the image shift motor on signal is generated Defective sensor Defective motor SC05 12...

Page 145: ...6 seconds after the pressure cam shift motor on signal is generated Defective sensor Defective motor SC05 43 A4 cam sensor remains off The sensor does not activate for more than 6 seconds after the p...

Page 146: ...activate after the idling roller motor on signal is generated Defective sensor Defective motor SC05 61 Idling HP sensor remains off The sensor does not activate after the idling roller motor on signa...

Page 147: ...ard Defective feed pressure motor SC07 05 Sensor 2 in the feed pressure detection board remains off The sensor does not change status Defective feed pressure detection board Defective feed pressure mo...

Page 148: ...ins on The sensor does not change status Defective separation pressure detection board Defective separation pressure motor SC07 17 Sensor 3 in the separation pressure detection board remains off The s...

Page 149: ...ivated for more than 9 seconds after the slider lift motor on signal is generated Defective sensor Defective motor Defective job separator board SC07 70 Slider HP sensor remains on At the slider movin...

Page 150: ...r the paper table motor on signal is generated Defective sensor Defective motor SC30 03 Paper table lower limit sensor remains off At the table moving downwards timing the sensor is not activated for...

Page 151: ...rive Securing Tool Kit Drum securing tool and two positioning shafts as a set C229 9000 For main drive positioning See 6 11 2 Main Drive Mechanism section ROM Board 2 A193 9351 For program download Se...

Page 152: ...key for more than 3 seconds 2 The following is displayed on the LCD when the SP mode is accessed 3 Using the number keys enter the desired Main Menu Number listed below and in the service program tab...

Page 153: ...ring the number with the number keys 6 Follow the Change Adjustment Values or Modes procedure below klqbW klqbW klqbW klqbW To cancel the SP mode press the Clear Modes key or the Return or End key on...

Page 154: ...Mode 0 1 001 9 M Counter Zoom Mode 0 1 001 10 M Counter Dir Mag 0 1 001 11 M Counter Make up Mode 0 1 001 12 M Counter Make up Photo 0 1 001 13 M Counter Margin Erase 0 1 001 14 M Counter Online Mode...

Page 155: ...8 M Counter Autocycle Master counters 1 001 28 to 34 Original sizes 1 001 35 36 44 to 48 Various copy modes 1 001 39 to 43 Various types 0 1 002 1 Total Print Counter 0 1 002 2 Resettable Print Counte...

Page 156: ...21 UC M Counter Code11 0 1 030 22 UC P Counter Code11 0 1 030 23 UC M Counter Code12 0 1 030 24 UC P Counter Code12 0 1 030 25 UC M Counter Code13 0 1 030 26 UC P Counter Code13 0 1 030 27 UC M Counte...

Page 157: ...es 0 1 082 Start Error Message Cnt Number of times an error message appeared when the Start key was pressed 0 1 102 1 Jam DF Feed in Error 0 1 102 2 Jam DF Feedout Error 0 1 104 1 Jam Master Set Error...

Page 158: ...pes L Lengthwise 0 1 301 1 Jam P1 A3 B4 Standard 0 1 301 2 Jam P1 A3 B4 Thick 0 1 301 3 Jam P1 A3 B4 Others 0 1 301 4 Jam P1 A4 B5 L Standard 0 1 301 5 Jam P1 A4 B5 L Thick 0 1 301 6 Jam P1 A4 B5 L Ot...

Page 159: ...ers 0 1 304 1 M Set Error Low Temp 0 1 304 2 M Set Error Normal Temp 0 1 304 3 M Set Error High Temp 0 1 305 1 M Clamp Error Low Temp 0 1 305 2 M Clamp Error Nor Temp 0 1 305 3 M Clamp Error High Temp...

Page 160: ...43 2 020 13 Default Make up Pattern2 0 0 to 43 2 020 14 Default Make up Pattern3 0 0 to 43 2 020 15 Default Make up Pattern4 Defaults for various user settings See Notes 2 to 9 0 0 to 43 2 030 Panel...

Page 161: ...s Mode Yes Yes No 4 17 2 290 Key Operator Code OFF ON OFF 6 6 2 291 Restricted Access See Note 23 OFF ON OFF 6 8 2 300 Stamp Type See Note 24 0 0 to 6 5 1 2 301 Default Stamp Size See Note 25 0 0 to 3...

Page 162: ...h 2 German 3 French 4 Italian 5 Spanish 6 Dutch 7 Chinese 2 2 020 1 Default original mode 0 Letter 1 Letter Photo 2 Photo 3 Pencil 3 2 020 3 Default paper type 0 Special 1 Standard 2 Thick 3 User 1 4...

Page 163: ...ssed 2 Enabled fully 11 2 031 Background correction This can be used in letter photo photo and tint modes to prevent the background of an original from appearing on copies See Detailed Section Descrip...

Page 164: ...for A3 masters 0 The counters go up by 1 only 1 The master counter goes up by 2 2 The master and print counters both go up by 2 17 2 090 APS A5 Size Detection This determines how the machine behaves...

Page 165: ...e default 1 Solid 2 Broken line type A 3 Broken line type B 4 Crop marks 22 2 270 Print Restart in Class This determines how the machine behaves if the Job Separator feature is not used 1 Auto Start A...

Page 166: ...user stamp User stamps are stored using user tool 5 8 User tool 5 7 SP 3 130 to 138 can be used to adjust the co ordinates of types 0 to 8 29 2 308 Date Stamp Position 0 Upper left horizontal 1 Lower...

Page 167: ...e a rough idea of what type of paper the user is using as types User 1 and User 2 0 This paper type is not being used at present 1 Standard no feed Standard paper type non feed likely 2 Standard doubl...

Page 168: ...ad Energy Standard 7 0 to 99 3 020 2 T Head Energy Economy Thermal head energy in standard and economy modes as percentage of full power Also see SP 2 032 25 0 to 99 3 030 Auto Reset Time Determines h...

Page 169: ...ain 96 50 105 3 9 3 060 18 MarginErase Card L Sub 144 50 148 3 9 3 060 19 MarginErase Card Main 144 50 148 3 9 3 060 20 MarginErase Card Sub 96 50 105 3 9 3 060 21 MarginErase Custom Main 66 50 300 3...

Page 170: ...99 3 5 3 101 1 to 12 Register Class 2 1 to 2 12 0 0 9999 3 5 3 102 1 to 12 Register Class 3 1 to 3 12 0 0 9999 3 5 3 103 1 to 12 Register Class 4 1 to 4 12 0 0 9999 3 5 3 104 1 to 12 Register Class 5...

Page 171: ...l UpDown 0 52 to 52 5 4 3 127 1 Stamp Center Side 0 72 to 72 5 4 3 127 2 Stamp Center UpDown 0 52 to 52 5 4 3 128 1 Stamp Lft Mdl Side 24 8 to 144 5 4 3 128 2 Stamp Lft Mdl UpDown 0 52 to 52 5 4 3 130...

Page 172: ...1 2 Date Btm Rt UpDown 8 8 40 5 11 3 142 1 Date Btm Lft Side 12 8 40 5 11 3 142 2 Date Btm Lft UpDown 20 8 40 5 11 3 143 1 Date Top Rt Side 8 8 40 5 11 3 143 2 Date Top Rt UpDown These specify the co...

Page 173: ...it SN 4 080 Paper Table Lowering SW 4 081 Paper End Sensor 4 082 Table Lower Limit Sensor 4 083 Paper Table Height SN 4 084 Paper Registration SN 4 085 Paper Feed Timing Sensor 4 086 1 Paper Feed Pres...

Page 174: ...etect 4 140 Image Shift HP Sensor 4 141 Drum Shift HP Sensor 4 142 1 Clamp Close Position SN 4 142 2 Clamper Open Position SN 4 143 P Cylinder Feed Encoder 4 400 Front Door Open Detect 4 500 DF Instal...

Page 175: ...late to HP 5 061 1 M Eject Motor Forward 5 061 2 M Eject Motor Reverse 5 080 1 Paper Table Motor Up 5 080 2 Paper Table Motor Down 5 081 1 Paper Pressure Motor Up 5 081 2 Paper Press Motor Down 5 082...

Page 176: ...hift Pressure Cam to A4 5 124 1 Drum Idling Roller ON 5 124 2 Idling Roller Return 5 140 1 Clamper Motor Open 5 140 2 Clamper Motor Close 5 141 1 Image Shift Motor 5 141 2 Image Shift Motor 5 142 1 Dr...

Page 177: ...DrumMaster 1 SN 2 5 0 0 to 5 0V 6 020 3 V Thresh DrumMaster 2 SN 2 5 0 0 to 5 0V 6 020 4 V Thresh Master End SN 0 9 0 0 to 5 0V 6 020 5 V Thresh Paper Exit SN 2 5 0 0 to 5 0V 6 020 6 V Thresh Master E...

Page 178: ...eq User 2 Paper 5 0 to 6 6 094 3 V Freq User 2 Paper 6 0 to 6 6 095 1 SepPressure Std Special 1 0 to 6 6 095 2 Freq Special Paper 3 0 to 6 6 095 3 V Freq Special Paper 4 0 to 6 6 096 1 SepPressure Std...

Page 179: ...3 Feed Delay 30 rpm 200 0 to 255 6 111 4 Feed Delay 60 rpm 199 0 to 255 6 111 5 Feed Delay 75 rpm 130 0 to 255 6 111 6 Feed Delay 90 rpm 78 0 to 255 6 111 7 Feed Delay 105 rpm 40 0 to 255 6 111 8 Fee...

Page 180: ...5 6 115 3 Regist Delay 30 rpm 43 0 to 255 6 115 4 Regist Delay 60 rpm 40 0 to 255 6 115 5 Regist Delay 75 rpm 35 0 to 255 6 115 6 Regist Delay 90 rpm 30 0 to 255 6 115 7 Regist Delay 105 rpm 25 0 to 2...

Page 181: ...2 0 to 255 6 130 Drum Master Clamp Regist See Note 11 0 10 0 to 10 0mm Notes 1 6 001 Main scan position Inputting a positive number moves the image away from the operation side of the machine Use the...

Page 182: ...res by selecting a paper type normal thick special user 1 user 2 and then by selecting how often non feeds and double feeds are occurring The user customizes the user 1 and user 2 types by selecting f...

Page 183: ...the machine clamps the paper or not depends on the paper type selected by the user standard special thick user 1 user 2 The settings for user 1 and user 2 depends on the type of paper that the user ha...

Page 184: ...r U Counter Code 11 6 2 7 020 12 Clear U Counter Code 12 6 2 7 020 13 Clear U Counter Code 13 6 2 7 020 14 Clear U Counter Code 14 6 2 7 020 15 Clear U Counter Code 15 6 2 7 020 16 Clear U Counter Cod...

Page 185: ...the optional memory board 8 070 4 Jams Errors Details Needs the optional memory board 8 071 Basic Settings Printout Needs the optional memory board 8 072 1 UserCustomSettings Print excludes class mode...

Page 186: ...leared even after performing Clear factory settings SP7 1 SP2 10 Sizes in Metric or Inch SP2 11 Select Language Type SP2 380 Japanese Display Type Do not use SP2 390 A3 DLT Drum Selection SP2 421 Type...

Page 187: ...e U1 to U4 ROMs in the correct sockets on the ROM board A as shown above 4 Remove the cover B 5 Plug the ROM board into the connector on the MPU 6 Loosen the screw C to adjust the ROM board stand posi...

Page 188: ...y 2 230 2 5 Panel Beeper 2 030 2 6 LCD Contrast Adjustment 6 050 3 1 Default Paper Type 2 020 3 3 2 Default Master Density 2 020 4 3 3 Default Original Mode 2 020 1 3 4 Magnification Ratio Settings 3...

Page 189: ...Stamp Size 2 304 5 6 User Stamp Density 2 305 5 7 Default User Stamp Position 2 306 5 7 User Stamp Position Adjustments 3 130 to 3 138 5 8 Register User Custom Stamps 8 100 1 to 4 5 9 Date Stamp Type...

Page 190: ...tor C C C C Soft Cloth Scanner Guide Rail C C C C Dry Cloth Platen Cover White Plate C C C C Damp Cloth Exposure Glass C C C C Dry Cloth Master Feed Thermal Head C Alcohol Platen Roller C C C R Expect...

Page 191: ...ler C C C C Dry Cloth Drum and Ink Supply Cloth Screen R R Drum Drive Gears and Cam L L L Grease Alvania 2 Drum Flange Bushing L L L Motor Oil SAE 20 In Outside of Drum C C C C Alcohol Ink Nozzle C C...

Page 192: ...NT 6 1 EXTERIOR 6 1 1 EXPOSURE GLASS OPERATION PANEL AND UPPER COVERS A Exposure glass First remove the left scale B and upper scale C D Operation panel E Lower operation panel cover F Rear upper cove...

Page 193: ...EXTERIOR 1 July 1998 6 2 6 1 2 REAR AND LEFT COVERS A Rear cover B Left cover C229R512 WMF A B...

Page 194: ...1 July 1998 EXTERIOR 6 3 Replacement Adjustment 6 1 3 FRONT DOOR AND RIGHT FRONT AND RIGHT REAR COVERS A Front door B Right front cover C Right rear cover C229R510 WMF A B C...

Page 195: ...EXTERIOR 1 July 1998 6 4 6 1 4 INNER COVER AND KNOB COVER A Inner cover B Knob cover C229R511 WMF A B...

Page 196: ...e copy image 2 Measure the difference between the leading edge registration of the original and the print If the registration does not meet specifications go to the next step 3 Access SP6 2 1 Scan Sta...

Page 197: ...automatically made after making a master tends to be inconstant Do not use the trial print to check the copy image 2 Measure the difference between the side to side edge registration of the original...

Page 198: ...e copy image 2 Measure the difference between the magnification of the original and the print If the vertical magnification does not meet specifications go to the next step 3 Access SP6 11 1 Scanning...

Page 199: ...to use the data printout function Carry out all copy image adjustments See 6 2 Copy Image Adjustment Sensor board unit calibration See 6 5 8 Sensor Board Unit Calibration Master end sensor adjustment...

Page 200: ...as this is an option B Flat cable NOTE Gently pull out the lever C to release the flat cable as shown It can easily be damaged Also when reconnecting it carefully push it back as shown D Then remove 7...

Page 201: ...NIT 6 5 1 LENS COVER 1 Remove the scales and exposure glass See 6 1 1 Exposure Glass Operation Panel and Upper Covers 2 Remove the flat cable A 1 screw 3 Remove the right lens cover B 6 screws and lef...

Page 202: ...el and Upper Covers section 3 Remove the exposure glass bracket A 1 screw 4 Disconnect the platen cover sensor B and remove the lower rear scanner frame C 5 screws 5 Disconnect the scanner H P sensor...

Page 203: ...Lens Cover 3 Change the original size sensors A two for 110 120 V machines and three for 220 240 V machines 2 screws each Lens Block SBU Assembly 1 Remove the exposure glass and operation panel See 6...

Page 204: ...6 5 2 Scanner Frame 3 Remove the connector cover A 1 screw 4 Press the lamp holder B down with a screwdriver as shown 5 Slide the xenon lamp C forward and remove it 1 connector klqbW klqbW klqbW klqb...

Page 205: ...COVER SENSOR 1 Remove the exposure glass and upper rear cover See 6 1 1 Exposure Glass Operation Panel and Upper Covers 2 Replace the platen cover sensor A 1 connector 3 Remove the scale bracket B 1...

Page 206: ...panel See 6 1 1 Exposure Glass Operation Panel and Upper Covers 2 Remove the lens covers See Lens Cover 3 Remove the scanner frames See Scanner Frame 4 Disconnect the cable A 5 Remove the tension spr...

Page 207: ...1 Lens Cover 3 Remove the scanner frames See 6 5 2 Scanner Frame 4 Remove the pin A securing the 1st scanner and remove the 1st scanner 5 Remove the spring B 6 Loosen the screw C securing the wire ten...

Page 208: ...the wire tension spring pulled as shown by step 7 in the illustration on the previous page 12 Install the 1st scanner and adjust its position with the scanner positioning pins P N A0069104 A Then clam...

Page 209: ...aced When the standard white plate located behind the original scale is replaced PROCEDURE 1 Place about 10 sheets of paper on the exposure glass 2 Turn on the main switch and access the SP mode Clear...

Page 210: ...ION 6 6 1 MASTER EJECT ROLLER UNIT Unit Removal First open the front door A Supporter B Master eject roller unit Master Eject Sensor First remove the master eject roller unit See the procedure above A...

Page 211: ...e the left exterior cover 3 To remove the master eject drive unit A slide it out in the paper delivery direction and pull down the top of the unit towards the operation panel See the arrows in the ill...

Page 212: ...tment Sensors and Motors in the Master Eject Drive Unit First remove the master eject drive unit See the previous procedure A Master Eject Motor B Pressure Plate HP Sensor C Pressure Plate Limit Posit...

Page 213: ...wly until the LED turns off 4 If the sensor is dirty clean or replace it 5 For how to access SP mode refer to the Service Program Mode section PROCEDURE 1 Turn on the main switch then access SP6 20 1...

Page 214: ...alled in the correct position PROCEDURE 1 The master eject clamper drive arm B must be flush with the cutout in the frame as shown 2 Holding the arm in the above position install the sector gear A so...

Page 215: ...MASTER FEED SECTION 1 July 1998 6 24 6 7 MASTER FEED SECTION 6 7 1 MASTER MAKING UNIT REMOVAL First slide out the master making unit A Then remove it 2 screws B C229R034 WMF A B B...

Page 216: ...ED SECTION 6 25 Replacement Adjustment 6 7 2 MASTER SET ROLLER AND PLATEN ROLLER First remove the master making unit from the machine A Front bracket B Rear bracket C Master set roller unit C229R087 W...

Page 217: ...26 Disassemble the master set roller unit D Master set roller NOTE When re installing the springs at the non operation side refer to the above diagram E Platen roller E slide it towards the operation...

Page 218: ...position Refer to 6 7 10 Master Feed Mylar Positioning 3 Make sure that there is no foreign material on the thermal head surface especially on the heating elements Don t touch the surface with bare ha...

Page 219: ...4 SENSORS MOTORS AND CUTTER IN THE MASTER MAKING UNIT Duct Entrance Solenoid First remove the master making unit from the machine A Front platen roller bracket B Front cover C Master making unit righ...

Page 220: ...1 July 1998 MASTER FEED SECTION 6 29 Replacement Adjustment D Duct entrance solenoid C229R064 WMF D...

Page 221: ...sor and Master Feed Clutch First remove the master making unit from the machine A Rear platen roller bracket B Rear cover C Cable cover Disconnect the connector D between the cutter unit and the cable...

Page 222: ...reinstalling the cutter unit There are 6 of these mylars across the length of the cutter unit Refer to 6 7 10 Master Feed Mylar Positioning I Platen release motor J Platen release sensor NOTE Make su...

Page 223: ...SECTION 1 July 1998 6 32 K Master feed clutch NOTE 1 Push the pawl L out from the centerto slide the clutch off the shaft 2 At installation make sure that the stopper M is positioned as shown C229R04...

Page 224: ...ION 6 33 Replacement Adjustment Master Feed Motor First remove the master making unit from the machine A Rear platen roller bracket B Master making unit rear cover C Master making unit right cover C22...

Page 225: ...1 July 1998 6 34 D Thermal head cover E Stay NOTE Take care when removing the thermal head and the stay because these are connected to a cable from a sensor F Rail G Master feed motor C229R060 WMF C2...

Page 226: ...TION 6 35 Replacement Adjustment Master Set Sensor A Thermal head cover NOTE Take care when removing the thermal head cover because it is connected to the cable from the sensor B Master set sensor C22...

Page 227: ...MASTER FEED SECTION 1 July 1998 6 36 Master End Sensor A Rear platen roller bracket B Master making unit rear cover C Master making unit right cover C229R041 WMF C229R057 WMF A B C...

Page 228: ...ON 6 37 Replacement Adjustment D Thermal head cover E Stay NOTE Be careful when removing the thermal head cover and the stay because these are connected to cables from sensors F Master end sensor C229...

Page 229: ...that the master vacuum fans are installed the correct way around If they are installed the wrong way around there will be no suction in the master buffer duct resulting in master jams PROCEDURE When...

Page 230: ...and access the SP mode Clear Modes 1 0 7 Clear Stop Then select SP 5 402 the thermal head voltage adjustment of the output mode 4 Press the Start key to apply the voltage to the thermal head The volta...

Page 231: ...ing cases When the sensor is replaced When the MPU is replaced 2 If the sensor is dirty clean or replace it 3 For how to access the SP mode refer to the Service Program Mode section PROCEDURE 1 Turn o...

Page 232: ...While adjusting make sure to attach all exterior covers to avoid external light 8 Do not turn the VRs excessively Turn slowly until the LED turns off 9 If the sensor is dirty clean or replace it 10 F...

Page 233: ...hat the drum is installed 6 Turn on the main switch then access SP6 20 6 Sensor Voltage and Threshold Adjustment for Master Edge Sensor 7 Remove the rear cover and access the I O board Turn VR307 C cl...

Page 234: ...Once the platen pressure release mechanism is disassembled the platen release cam A must be reinstalled in the correct position PROCEDURE When tightening the screws to secure the mechanism make sure t...

Page 235: ...tter unit the master duct or the guide plate of the lower master feed control roller install the lower tension roller or lower master feed control roller as shown in the illustration C229R114 WMF C229...

Page 236: ...if you do settle it upside down wipe off the ink around the ink roller beforehand using SP 2 40 select OFF in ink detection mode and feed paper until ink ends 2 Loosen the stopper B the drum lock sole...

Page 237: ...black sensor patches B must be to the left of the master clamper Position the clamper on the top of the drum and view from the operation side refer to the upper illustration 4 Make sure that the corre...

Page 238: ...B To rotate the drum release the stopper C on the rear of the drum CAUTION 1 When replacing the drum clamper install the spring on the opposite side as shown in the illustration 2 Do not settle the d...

Page 239: ...The side with the sandpaper B must be facing the black patch A 5 Do not allow the inside of the master clamper to become dirty with ink If it is dirty with ink the master may slip off and the image po...

Page 240: ...NOTE Remove the cloth screen and metal screen first 1 First pull out the ink cartridge holder A Drum shift motor B Ink pump motor C Drum shift HP sensor NOTE When reinstalling the drum shift motor un...

Page 241: ...DRUM 1 July 1998 6 50 2 E Ink detection pin 3 First remove the ink pump unit F Ink pump G Ink pump sensor 4 H Idling roller motor C229R051 WMF C229R053 WMF E F G H...

Page 242: ...1 July 1998 DRUM 6 51 Replacement Adjustment 5 First remove the sensor bracket 1 screw I Idling roller HP sensor C229R054 WMF I...

Page 243: ...VRs excessively 4 If the sensor is dirty clean or replace it 5 For how to access the SP mode refer to the Service Program Mode section PROCEDURE 1 Remove the master that is wrapped around the drum an...

Page 244: ...adjusting make sure to attach all exterior covers to avoid external light 3 Do not turn the VRs excessively 4 If the sensor is dirty clean or replace it 5 For how to access the SP mode refer to the Se...

Page 245: ...Voltage and Threshold Adjustment for 2nd Drum Master Sensor 6 The sensor input voltage is displayed on the operation panel Check if it is 0 3 volts or more 7 If the sensor input voltage is 0 3 volts...

Page 246: ...d metal screens from the drum unit 3 Wipe off the ink around the ink roller and the doctor roller 4 Insert a 0 08 mm gap gauge between the doctor roller and the ink roller Then make sure that a 0 1 mm...

Page 247: ...ect the probes and the grounding lead of an oscilloscope as follows Probe CH1 to TP1 Probe CH2 to TP2 Grounding lead to TP 12V Select the 5 s range 3 Turn on the main switch 4 Make sure that the wavef...

Page 248: ...nd the rear cove See 6 1 Exterior section 2 From the rear of the machine swing out the MPU See 6 4 MPU and PSU Opening Procedures 3 Remove the following parts A Two springs B Front bracket 2 screws C...

Page 249: ...PAPER FEED SECTION 1 July 1998 6 58 6 9 2 PAPER FEED ROLLER PICK UP ROLLER AND FRICTION PAD A Pick up roller 1 clip B Paper feed roller 1 clip C Friction pad C229R513 WMF A B C...

Page 250: ...wdriver C Sensor cover 2 screws D Paper width detection board 1 screw 1 connector 6 9 4 PAPER HEIGHT SENSOR First remove the master making unit see 6 7 1 Master Making Unit Removal A Feed cover 2 scre...

Page 251: ...DETECTION BOARD 1 Remove the master making unit See 6 7 1 Master Making Unit Removal A Feed cover 2 screws 2 Swing out the MPU See 6 4 MPU and PSU Opening Procedures B Rear rail guide C Feed pressure...

Page 252: ...REGISTRATION ROLLER 1 Remove the master making unit See 6 7 1 Master Making Unit Removal A Feed cover 2 screws 2 Swing out the MPU See 6 4 MPU and PSU Opening Procedures B Pulley cover 1 screw C Paper...

Page 253: ...uly 1998 6 62 3 E Right paper guide plate 1 screw F Paper feed roller 1 clip G Pick up roller 1 clip 4 Remove the clips H and slide the bushing I towards the operation side J Paper feed roller unit C2...

Page 254: ...Replacement Adjustment 5 K Rear rail guide 2 screws L Connectors from the feed pressure detection board 6 Remove the front exterior cover and inner cover M Front rail guide 2 screws N Feed pressure u...

Page 255: ...PAPER FEED SECTION 1 July 1998 6 64 7 O Sensor bracket 1 screw 8 Remove the paper registration and feed timing sensors from the bracket 9 P Upper registration roller C229R036 WMF C229R527 WMF O P...

Page 256: ...ws 7 connectors 3 Remove the registration motor F 2 screws 1 connector 4 Remove the pulley E 2 Allen screws 5 Remove the bearing holder B and the bearing A 2 screws From the front 6 Remove the front e...

Page 257: ...PU and PSU Opening Procedures 2 Remove the pulley cover A and the bracket B 3 screws 7 connectors 3 Remove the registration roller lifting cam C CAUTION There is the set position for the cam When rein...

Page 258: ...g the registration roller lifting cam A on the shaft align the cam follower a bushing at the center or within two divisions to the right of the center 2 If the cam follower cannot be put in the correc...

Page 259: ...ps 4 After the paper table stops check if the distance A between the lower edge of the stay and the upper face of the table until it is 76 5 mm 5 If the distance is not correct adjust the upper limit...

Page 260: ...OR PURPOSE To ensure smooth paper feed 1 Make sure that the distance between the motor and the flange is 8 5 0 5 mm 2 Apply a 500g load to the center of the belt using a tension gauge Make sure that t...

Page 261: ...eed 1 Make sure that the distance between the end of the lower registration roller shaft and the edge of the pulley is 0 0 5 mm 2 Apply a 500g load to the center of the belt using a tension gauge Make...

Page 262: ...4 3 Change the settings as necessary Defaults for SP91 Standard 3 Frequent 5 Very Frequent 6 The available pressure levels are from 0 to 6 0 is the weakest 6 is the strongest Paper separation pressure...

Page 263: ...110 and 6 111 these change the paper feed start timing PROCEDURE 1 Turn on the main switch then access the SP mode 2 Enter SP6 116 3 3 Increase or decrease the value on the display NOTE 1 Before chang...

Page 264: ...access the SP mode 2 Enter SP6 116 1 NOTE The paper clamping timing depends on the paper type selected at the operation panel SP6 116 1 is the adjustment for normal paper only For thick paper use SP6...

Page 265: ...inder is easily damaged Removal Procedure 1 Remove the drum 2 Remove the bracket A 1 screw 1 connector 3 Remove the left exterior cover 5 screws 4 Remove the paper delivery unit See 6 12 1 Paper Deliv...

Page 266: ...8 Turn the cylinder clockwise 80 degrees so that the positioning hole A in the side of the cylinder is at the top The flat part of the cylinder faces the upper right side as shown 9 Remove the screw a...

Page 267: ...the drum position CAUTION There is the encoder plate at the rear of the cylinder Be careful not to damage it when removing the cylinder 12 Pull the cylinder toward you and rest put it on the flat area...

Page 268: ...ure cylinder so that the round hole C is uppermost Rest the pressure cylinder on the flat area of the inner cover D CAUTION There is an encoder plate B at the rear of the cylinder Be careful not to da...

Page 269: ...the black cam as shown to the right Position the bearing A on the bearing holder 6 While the round hole B is uppermost push the pressure cylinder towards the non operation side to engage the joint be...

Page 270: ...m the rear of the machine swing out the MPU See 6 4 MPU and PSU Opening Procedures 3 Disconnect the connectors D from the rear of the machine 4 Remove the feed encoder B and feed start sensor C CAUTIO...

Page 271: ...3 PRINTING PRESSURE ADJUSTMENT PURPOSE To improve the print results 1 Move the printing pressure bracket to its highest position then tighten the screw A 2 Adjust the clearance C to be 6 6 0 3 mm by...

Page 272: ...te the printing pressure cams so that the arm moves to the lower most position NOTE Use the main drive rotation knob When the top of the cam meets the bearing A during turning the knob the arm is at t...

Page 273: ...6 11 1 MAIN MOTOR From the rear 1 Turn off the main switch and remove the rear cover 6 screws 1 ground wire 2 Swing out the PSU See 6 4 MPU and PSU Opening Procedures 3 Remove the main motor control...

Page 274: ...2 screws 8 Remove the timing belt F 9 Remove the bracket G 5 screws 2 cord clamps CAUTION Screw H is located under the main wire harness Take care not to damage the wire harness when removing it From...

Page 275: ...998 6 84 Again from the rear 12 Remove the power cord bracket J 4 screws 13 Remove the main motor K 5 screws CAUTION After you replace the main motor you must adjust the exit pawl drive timing See 6 1...

Page 276: ...BELT Disassembly Procedure 1 Turn off the main switch and disconnect the power plug 2 Remove the drum 3 Remove the rear exterior cover 6 screws 1 ground wire 4 Swing out the MPU and PSU See 6 4 MPU a...

Page 277: ...UP DOWN SHIFTING DRIVE SECTION 1 July 1998 6 86 From the rear 7 Remove the main motor control board A 3 screws 4 connectors 8 Remove the wire protection cover B 2 screws 9 Remove the bracket C 1 scre...

Page 278: ...Remove the pulley bracket E 2 screws 12 Remove the timing belt F 13 Remove the bracket G 5 screws 2 cord clamps CAUTION Screw H is located under the main wire harness Take care not to damage the wire...

Page 279: ...r for PSU and MPU 4 screws 17 Remove the drive unit B 6 screws 1 cord clamp 18 Disassemble the drive unit to remove the upper cover 2 E rings 2 bearings 1 spring 7 screws 19 Remove the image shifting...

Page 280: ...g position Printing pressure cam drive gear reinstalling position Registration roller lifting cam reinstalling position Paper exit pawl drive cam reinstalling position Pressure cylinder rotation knob...

Page 281: ...n the bearing sleeve properly also before installing the main drive unit on the machine rear frame in step 13 4 Strongly push the shaft of the image shift gear against the other gears and firmly tight...

Page 282: ...8 Set the image shift arm A in the home position Align the hole in the upper plate B with the elongated hole in the image shift arm 9 Align the hole in the pressure cylinder drive disk E with the hole...

Page 283: ...awl Removal 13 While aligning and holding the pressure cylinder horizontally as shown set the main drive unit so that the convex points of the pressure cylinder s drive disk C meet the concave points...

Page 284: ...the image up down shift drive unit C against the image shift arm sector gear and secure the unit 3 screws 3 connectors NOTE 1 Ensure that the unit is set without any play 2 Do not push on the unit to...

Page 285: ...unit in the machine 20 Close the front cover connect the power plug then turn on the main switch The up down image shifting mechanism will initialize NOTE This procedure is needed to return the image...

Page 286: ...erior and inner covers 4 screws each 26 From the operation side of the machine insert the two positioning shafts B special tools to secure the pressure cylinder and printing pressure cams in their hom...

Page 287: ...normal 28 Turn the main motor A counterclockwise and set the drum drive disk B in the home position If the disk is turned too much at this point reset from step 26 CAUTION These steps are needed to pu...

Page 288: ...e the pressure cylinder drive gear A 2 screws CAUTION Don t turn the gear by force while securing it 31 Install the printing pressure cam drive gear and firmly tighten the 2 screws B NOTE 1 To remove...

Page 289: ...l drive timing See 6 12 7 Paper Exit Pawl Drive Timing Adjustment 35 Adjust the pressure cylinder rotation knob See 6 11 3 Pressure Cylinder Rotation Knob Adjustment 36 Remove all special tools the dr...

Page 290: ...ng edge margin of copies 10 mm is not constant Check the position of the printing pressure cams Use the positioning shaft a special tool to check if the cam position is correct See steps 26 through 31...

Page 291: ...e align the long hole of the drum drive disk A exactly with the shaft below it 2 Loosen two screws C so that the pulley D freely turns 3 Turn the timing belt E by hand until the triangle mark on the i...

Page 292: ...URPOSE If the position of the scissors gear is not correct the paper feed registration will vary 1 Loosen the lock nut B 2 Tighten the screw so that the gear meshes on both gears are aligned as shown...

Page 293: ...TING DRIVE SECTION 1 July 1998 6 102 6 11 5 IMAGE UP DOWN SHIFT WORM GEAR POTISION ADJUSTMENT Fully push up the worm gear A and push down the worm gear shaft B While holding them together secure with...

Page 294: ...home position Align the hole in the upper plate with the elongated hole in the image shift arm A 2 Push the image up down shift drive unit C against the image shift arm sector gear and secure the unit...

Page 295: ...IVERY UNIT AND AIR KNIFE FAN UNIT 1 Turn off the main switch 2 Remove the paper delivery cover A 4 screws 3 Remove the paper delivery unit B 2 screws 3 connectors ground wire knob belt 4 Remove the ai...

Page 296: ...e from the unit 4 screws A Driven roller shaft B Upper unit C Paper guide wings D Drive roller shaft E Transport belts CAUTION 1 When reassembling the actuator F for the wing upper and lower position...

Page 297: ...July 1998 6 106 6 12 3 PAPER EXIT SENSOR REMOVAL First remove the paper delivery unit See 6 12 1 Paper Delivery Unit and Air Knife Fan Unit A Vacuum fan unit 4 screws B Paper exit sensor 1 screw 1 co...

Page 298: ...PAPER DELIVERY SECTION 6 107 Replacement Adjustment 6 12 4 VACUUM MOTOR REMOVAL First remove the paper delivery unit See 6 12 1 Paper Delivery Unit and Air Knife Fan Unit A Vacuum motor 2 screws C229...

Page 299: ...PAPER DELIVERY SECTION 1 July 1998 6 108 6 12 5 PAPER EXIT PAWL REMOVAL 1 Remove the drum unit 2 Remove the paper exit pawl A 1 screw C229R519 WMF A...

Page 300: ...the solenoid is on turn the cylinder half way round by hand 3 Leave SP mode 3 Adjust the clearance between the paper pick off plate A and the surface of the pressure cylinder until it is 1 0 3 mm loo...

Page 301: ...sk is in the home position NOTE Normally the disk is in the home position after the drum is removed If necessary set the drum securing tool A to make sure that the drum drive disk is in the home posit...

Page 302: ...vered without paper wrap or damage 1 Turn the main drive manually so that the bearing A of the exit pawl arm C rides on the low point of the cam NOTE Use the main drive rotation knob to turn the main...

Page 303: ...1 July 1998 7 1 P to P 7 POINT TO POINT DIAGRAM Location Map Section A Section B Section C Section D Section E Section F NOTE The symbols used in the diagrams are as follows PP2 WMF...

Page 304: ...1 July 1998 7 2 Location Map C229S500 WMF...

Page 305: ...1 July 1998 7 3 P to P Section A C229S501 WMF...

Page 306: ...1 July 1998 7 4 Section B C229S502 WMF...

Page 307: ...1 July 1998 7 5 P to P Section C C229S503 WMF...

Page 308: ...1 July 1998 7 6 Section D C229S504 WMF...

Page 309: ...1 July 1998 7 7 P to P Section E C229S505 WMF...

Page 310: ...1 July 1998 7 8 Section F C229S506 WMF...

Page 311: ...22 1 7 2 MAIN DRIVE 1 23 2 DETAILED SECTION DESCRIPTIONS 2 1 2 1 SCANNER AND OPTICS 2 1 2 1 1 OVERVIEW 2 1 2 1 2 SCANNER DRIVE 2 2 2 1 3 ORIGINAL SIZE DETECTION IN PLATEN MODE 2 3 2 2 IMAGE PROCESSIN...

Page 312: ...RESSURE MECHANISM 2 71 2 7 4 PRINTING PRESSURE CAM SHIFTING FOR 2 72 2 7 5 PAPER FEED CONTROL MECHANISM 2 73 2 7 6 PRESSURE CYLINDER DRIVE MECHANISM 2 74 2 8 PAPER DELIVERY 2 76 2 8 1 OVERVIEW 2 76 2...

Page 313: ...OLS 4 51 5 PREVENTIVE MAINTENANCE 5 1 5 1 MAINTENANCE TABLE 5 1 6 REPLACEMENT AND ADJUSTMENT 6 1 6 1 EXTERIOR 6 1 6 1 1 EXPOSURE GLASS OPERATION PANEL AND 6 1 6 1 2 REAR AND LEFT COVERS 6 2 6 1 3 FRON...

Page 314: ...ADJUSTMENT 6 56 6 9 PAPER FEED SECTION 6 57 6 9 1 PAPER TABLE UNIT 6 57 6 9 2 PAPER FEED ROLLER PICK UP ROLLER AND 6 58 6 9 3 PAPER WIDTH DETECTION BOARD 6 59 6 9 4 PAPER HEIGHT SENSOR 6 59 6 9 5 FEED...

Page 315: ...6 12 3 PAPER EXIT SENSOR REMOVAL 6 106 6 12 4 VACUUM MOTOR REMOVAL 6 107 6 12 5 PAPER EXIT PAWL REMOVAL 6 108 6 12 6 GAP ADJUSTMENT BETWEEN PAPER 6 109 6 12 7 PAPER EXIT PAWL DRIVE TIMING 6 110 6 12...

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