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Ricoh LDD250, Service Manual

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Ricoh LDD250 Service Manual Download Page 368

MASTER FEED

C262/C265 6-46

SM

6.6.3 MASTER MAKING AND FEED MECHANISM

Master Feed Mechanism

The master feed motor [F], a stepper motor, drives the master set [A], platen [B]
and tension [C] rollers.
The master feed control motor [G] drives the master feed control roller [D].
The tension roller feeds the master slightly faster than the platen roller, to prevent
the master from creasing. Therefore, the master between the platen roller 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 master is
under excessive tension, to prevent damage to the master.
In the diagram, the black arrows show the roller directions when the master is fed
forwards. The white arrows show the mechanism when it feeds the master in
reverse.

C262D036.WMF

[C]

[B]

[A]

[E]

[F]

[G]

[D]

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Summary of Contents for LDD250

Page 1: ...LDD280 C262 LDD250 C265 SERVICE MANUAL 002648MIU rev 05 31 06...

Page 2: ......

Page 3: ...C262 C265 SERVICE MANUAL...

Page 4: ......

Page 5: ...C262 C265 SERVICE MANUAL 002648MIU...

Page 6: ......

Page 7: ...RMISSION 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 respe...

Page 8: ......

Page 9: ...tion 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...

Page 10: ......

Page 11: ...LEGEND PRODUCT CODE COMPANY GESTETNER LANIER RICOH SAVIN C262 CP6364 LDD280 HQ9000 3590DNP C265 CP6334 LDD250 HQ7000 3580DNP DOCUMENTATION HISTORY REV NO DATE COMMENTS 04 2006 Original Printing...

Page 12: ......

Page 13: ...1 18 Installation Procedure 1 18 1 2 3 ADF OPTION 1 19 Accessory Check 1 19 Installation Procedure 1 20 ADF stabilizer installation 1 23 1 2 4 ADDITIONAL DRUMS OPTION 1 24 1 2 5 EXTENSION HDD TYPE 1...

Page 14: ...Installation 3 10 3 3 6 SBU SENSOR BOARD UNIT CALIBRATION 3 12 3 4 COPY IMAGE ADJUSTMENT 3 13 3 4 1 LEADING EDGE REGISTRATION ADJUSTMENT 3 13 3 4 2 SIDE TO SIDE REGISTRATION ADJUSTMENT 3 14 3 4 3 VER...

Page 15: ...E 3 55 3 7 22 MASTER FEED MYLAR POSITIONING 3 57 3 8 DRUM SECTION 3 58 3 8 1 DRUM UNIT 3 58 3 8 2 DRUM CLOTH SCREEN 3 58 3 8 3 DRUM MASTER CLAMPER METAL SCREEN 3 61 3 8 4 MOTORS AND SENSORS IN THE DRU...

Page 16: ...MENT 3 111 3 10 5 PRINTINGPRESSUREHPSENSOR PRINTINGPRESSURE POSITIONSENSOR PRESSURECAMSHIFTMOTOR 3 112 3 10 6 PRINTING PRESSURE ADJUSTMENT 3 113 3 10 7 PRINTING PRESSURE RELEASE ARM GAP ADJUSTMENT 3 1...

Page 17: ...4 4 3 MASTER MAKING UNIT 4 13 4 4 4 DRUM 4 13 4 4 5 MASTER EJECT 4 16 4 4 6 PAPER FEED 4 17 4 4 7 PRINTING AND PRESSURE CYLINDER 4 18 4 4 8 PAPER EJECT 4 19 4 4 9 PAPER SEPARATION 4 20 4 4 10 FUSES O...

Page 18: ...mper 5 2 3 Ink Roller Unit 5 2 5 1 6 MAIN DRIVE SECTION 5 3 1 Main Drive Adjustment 5 3 5 1 7 ELECTRICAL COMPONENTS 5 3 1 ECU and I O Boards 5 3 2 ACU ECU and Power Supply Unit 5 3 3 Power Supply Unit...

Page 19: ...er Sections 6 4 Paper Delivery Section 6 4 Master Making Unit 6 5 6 1 3 TABLE OF ELECTRICAL COMPONENTS 6 6 Boards 6 6 Motors 6 6 Switches 6 7 Sensors 6 8 Solenoids 6 10 Others 6 10 6 1 4 DRIVE LAYOUT...

Page 20: ...late Operation Timing Charts 6 39 6 6 MASTER FEED 6 41 6 6 1 OVERVIEW 6 41 6 6 2 MASTER SET MECHANISM 6 42 Master Roll Set 6 42 Master Feed and Stop Control Edge Detection 6 42 Master End Detection 6...

Page 21: ...6 76 6 8 1 OVERVIEW 6 76 Feed and Separation 6 76 Feed Separation Pressure 6 76 Registration 6 76 6 8 2 PAPER FEED MECHANISM 6 77 6 8 3 PAPER FEED SEPARATION PRESSURE ADJUSTMENT MECHANISM 6 78 Paper...

Page 22: ...PRESSURE CYLINDER DRIVE MECHANISM 6 107 Overview 6 107 Pressure Cylinder HP Return Mechanism Manual Pressure Cylinder Rotation 6 108 6 9 9 PRINT PRESSURE ADJUSTMENT MECHANISM 6 109 Mechanism 6 109 Au...

Page 23: ...14 4 JAM INDICATION WHEN YOU TURN ON THE POWER 6 131 6 14 5 JAM INDICATION DURING PRINTING 6 131 6 14 6 JAM DISPLAY WHEN THE DRUM STOPS AT HOME POSITION BECAUSE OF PAPER UPPER WRAPPING 6 131 6 14 7 MA...

Page 24: ......

Page 25: ...you ingest ink by accident 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 peri...

Page 26: ...ng used lithium batteries from the main processing units and ACU in order to dispose of them later do not store more than 100 batteries from the main processing units and ACU per sealed box Storing la...

Page 27: ...ANCE REPLACEMENT AND ADJUSTMENT LARGE CAPACITY TRAY SYSTEM C641 TROUBLESHOOTING SERVICE TABLES DETAILED DESCRIPTIONS SPECIFICATIONS TAB POSITION 2 TAB POSITION 1 TAB POSITION 3 TAB POSITION 4 TAB POSI...

Page 28: ...SPECIFICATIONS...

Page 29: ......

Page 30: ...34 0 Minimum 148 x 210mm 5 8 x 8 3 Print Paper Size Maximum 325 x 447 mm 12 8 x 17 6 Minimum 70 x 148 mm 2 8 x 5 8 Print Paper Weight 47 1 to 209 3 g m2 12 5 to 55 6 lb Printing Area A3 290 x 412 mm D...

Page 31: ...above 340 W Standby Not above 52 W Not above 52 W Standby Energy saver mode Not above 7 W Not above 8 W Mainframe ADF LCS HDD 802 11b PS3 module RAM C265 US EU AA Copying 60 rpm Not above 210 W Not ab...

Page 32: ...copying C265 ADF Not more than 17 seconds A4 copying Not more than 20 seconds A3 copying Platen Not more than 12 2 seconds A4 copying Not more than 16 seconds A3 copying Paper Table Capacity 1 000 sh...

Page 33: ...oon Navy Orange Teal Violet Gold Hunter Green Burgundy Reflex blue Ink Storage Conditions Temperature 5 C to 40 C Optimum conditions 15 C to 25 C Humidity 10 to 95 RH Optimum conditions 20 to 70 RH Re...

Page 34: ...INSTALLATION...

Page 35: ......

Page 36: ...and left to right 1 1 2 ENVIRONMENTS TO AVOID 1 Locations exposed to direct sunlight or strong light more than 1 500 lux 2 Dusty areas 3 Areas containing corrosive gases 4 Locations directly exposed t...

Page 37: ...CCESS TO THE MACHINE Put the machine near a power source and give clearance as shown below C262I001 WMFF 23 7 More than 60 cm 142 cm 55 9 More than 60 cm 23 7 70 5 cm 27 7 More than 10 cm 4 0 Paper De...

Page 38: ...WER SOCKETS FOR PERIPHERALS CAUTION Rating Voltage for Peripherals Make sure to plug the cables into the correct sockets C262I049 WMF ADF Rating Voltage of Output Connector for Accessory Max DC 24 V L...

Page 39: ...5 22 only 1 3 Carrying handle stopper 4 4 Ferrite Core 1 5 NECR C262 27 C262 52 C265 27 C265 52 only 1 6 Manuals for this machine Printed Manuals 1 7 Easy Operation Guide Printed Manuals 1 8 Safety In...

Page 40: ...s lifted off the machine from the bottom the paper delivery table may be damaged 1 Unpack the box Take out the small box A which contains the paper delivery table NOTE First open the top of the box an...

Page 41: ...INSTALLATION PROCEDURE C262 C265 1 6 SM 2 Continue to unpack the box Make sure that the accessory bag A is included C262I003 WMFF A...

Page 42: ...the table CAUTION Only handle with the carrying handles A on the bottom of the machine Otherwise your fingers may be pinched between the main body and the table during installation The gap between th...

Page 43: ...INSTALLATION PROCEDURE C262 C265 1 8 SM C262I044 WMFF C262I046 WMFF...

Page 44: ...INSTALLATION PROCEDURE SM 1 9 C262 C265 Installation 4 Remove the tape that secures the covers and units C262I006 WMFF C262I007 WMFF C262I008 WMFF...

Page 45: ...INSTALLATION PROCEDURE C262 C265 1 10 SM 5 Open the front cover and slide out the drum unit Then remove the master clamper protective sheet A C262I045 WMFF C262I009 WMFF A A...

Page 46: ...PROCEDURE SM 1 11 C262 C265 Installation 6 Insert the carrying handle A in the machine and attach the carrying handle stopper B 7 Take out the paper delivery table C from the box C262I021 WMFF C262I00...

Page 47: ...ALLATION PROCEDURE C262 C265 1 12 SM 8 Remove the tape that secures the paper delivery table 9 Attach the paper delivery table A x 2 10 Open the paper table B C262I010 WMFF C262I011 WMFF C262I042 WMFF...

Page 48: ...n the master guide C 13 Open the master tray cover D 14 The master roll E must be positioned as shown in the illustration 15 Close the master tray cover D 16 Insert the master roll F NOTE Make sure th...

Page 49: ...14 SM 17 Close the master guide A 18 Push in the master making unit B until it stops 19 Open the front cover and pull out the ink holder C 20 Remove the cap of the new ink cartridge D C262I035 WMFF C...

Page 50: ...tion 21 Insert the new ink cartridge A into the ink holder B 22 Return the ink holder C to its original position until it clicks and close the front cover 23 Put a stack of paper on the paper table D...

Page 51: ...utlet NOTE Make sure that the wall outlet is near the machine and easily accessible 28 Open the main switch cover B and turn on the main switch C 29 Place the original on the exposure glass or ADF 30...

Page 52: ...the time SP Codes Setting SP No Menu Function SP3 001 6 Tel Number for Service Do this SP and input the contact numbers of the customer engineer These numbers are shown when a service call is issued S...

Page 53: ...SM 1 2 2 PLATEN COVER OPTION Accessory Check Check the quantity and condition of the accessories in the box against this list Description Quantity 1 Stepped Screw 2 Installation Procedure 1 Install t...

Page 54: ...quantity and condition of the accessories in the box against this list Description Quantity 1 Stepped Screw 2 2 Screws 3 3 Screwdriver 1 4 DF Exposure Glass 1 5 Decal Exposure Glass 1 6 Decal Scale mm...

Page 55: ...INSTALLATION PROCEDURE C262 C265 1 20 SM Installation Procedure 1 Remove the strips of tape 2 Remove the left scale A x 2 C262I012 WMFF C262I047 WMFF A...

Page 56: ...n 4 Peel off the backing C of the double sided tape attached to the rear side of the scale guide D then install the scale guide 2 screws removed in step 2 5 Install the two stud screws E 6 Mount the D...

Page 57: ...n 10 Connect the power cord then turn the main switch on 11 Make a full size copy with the ADF Then check to make sure the side to side and leading edge registrations are correct If they are not adjus...

Page 58: ...zer installation 1 Attach the two stabilizer brackets A to the back of the table using the thumbscrews x 4 2 Attach the caution label B as shown CAUTION This procedure must be done to prevent the mach...

Page 59: ...DRUMS OPTION There are three types of drum units A3 Size Color or black DLT Size Color or black A4 Size Black only 1 Remove the master clamper protective sheet A from the drum unit 2 Remove the tape...

Page 60: ...nd from drying NOTE If the user is concerned about security make a new blank master to wrap around the drum At this time the user s master now on the drum will go into the eject box which is locked 6...

Page 61: ...the dip switch 901 for drum type detection on the ink detection board B to color drum To do this DIPSW 901 1 must be off and 901 2 must be on 2 Then set the DPS902 dip switches A on the drum to specif...

Page 62: ...Base Yellow Base Default 0 other For example you install a drum with DPS 902 1 and 2 both set to OFF this means ID0 If this drum contains blue ink then set SP 2 10 1 to 2 blue Then blue will be shown...

Page 63: ...User Tools Online Printer Features List Test Print Configuration Page After you turn the power on the machine displays Please wait Stamp data is being transferred to the hard disk This takes about 1 m...

Page 64: ...mage the controller board or cause a bad connection between the DIMM and controller contacts If the upper contact is pushed in and bent the resulting poor connection could cause the entire system to n...

Page 65: ...troller cover A x 8 4 Insert the PS3 module B into Slot 2 5 Turn the machine on and print a configuration page to make sure that the machine can see the Adobe PostScript 3 Adobe PDF 1 2 10 User Tools...

Page 66: ...ptions IEEE 802 11b I F Unit Type 1 IEEE 1284 Parallel Board Type 1 If a different card is installed in slot A you must remove it before you install the IEEE 802 11b I F Unit Type 1 1 Turn the machine...

Page 67: ...for these options IEEE 802 11b I F Unit Type 1 IEEE 1284 Parallel Board Type 1 If a different card is installed in slot A you must remove it before you install the IEEE 1284 Parallel Board Type 1 1 Tu...

Page 68: ...machine off 2 Remove the rear cover x 6 3 Remove the controller cover A x 8 CAUTION Make sure that the DIMM is inserted correctly 1 2 6 4 Remove the SDRAM DIMM standard onboard memory 64MB B from Slo...

Page 69: ...INSTALLATION PROCEDURE C262 C265 1 34 SM 1 2 10 CONFIGURATION PAGE EXAMPLE PRINTOUT This is an example of a configuration page C262I050 WMFF...

Page 70: ...PREVENTIVE MAINTENANCE...

Page 71: ......

Page 72: ...h Alcohol Expected Life 30K masters Cutter Unit R Damp Cloth Alcohol Expected Life 30K masters Master Feed Control Roller R Expected Life 30K masters Platen Roller R Expected Life 30K masters Paper Fe...

Page 73: ...s Pressure Cylinder C Damp Cloth Alcohol Paper Clamper on Pressure Cylinder R C Damp Cloth Alcohol Feed Encoder C Feed Start Sensor C Damp Cloth Alcohol Feed Encoder Brush Bracket R Expected Life 6000...

Page 74: ...REPLACEMENT AND ADJUSTMENT...

Page 75: ......

Page 76: ...switch and unplug the machine before you attempt any of the procedures in this section NOTE This manual uses several symbols The meaning of those symbols are as follows See or Refer to screw connector...

Page 77: ...ERS C262 C265 3 2 SM 3 2 2 LEFT COVER RIGHT FRONT AND RIGHT REAR COVERS REAR COVER A Left cover x 5 B Cover cap x 1 C Rear cover x 6 D Right rear cover x 2 E Right front cover x 2 C262R001 WMF A B C D...

Page 78: ...2 3 OPERATION PANEL LEFT SCANNER COVER REAR UPPER COVER RIGHT SCANNER COVER LOWER PANEL COVER A Operation panel x 3 x 1 B Left scanner cover x 2 C Rear upper cover D Right scanner cover x 2 E Lower o...

Page 79: ...65 3 4 SM 3 2 4 EXPOSURE GLASS SCALES A Left scale x 2 B Upper scale x 3 C Exposure glass NOTE When you install the glass make sure that the dot is at the rear left corner as shown in the diagram C262...

Page 80: ...peration panel Left scanner cover Rear upper cover Right scanner cover Lower operation panel cover 3 2 3 Left scale Upper scale Exposure glass 3 2 4 A Exposure glass bracket x 1 B Lower rear scanner f...

Page 81: ...After you install the lamp push the lamp holder H up to the original position so that it can hold the lamp properly 3 3 2 LENS COVER Left scale Upper scale Exposure glass 3 2 4 A Right scanner cover...

Page 82: ...ustment 3 3 3 ORIGINAL SIZE SENSORS Right scanner cover 3 2 3 Left scale Upper scale Exposure glass 3 2 4 Lens cover 3 3 2 A Original width sensor x 1 x 1 B Original length sensor x 1 x 1 C Original s...

Page 83: ...SBU SCANNER DRIVE MOTOR Right scanner cover 3 2 3 Left scale Upper scale Exposure glass 3 2 4 Lens cover 3 3 2 A Lamp stabilizer x 2 B SBU Lens block assembly x 1 x 5 Do the SBU calibration if you in...

Page 84: ...SCANNER UNIT SM 3 9 C262 C265 Replacement Adjustment C Scanner drive motor x 1 x 2 1 spring C262R008 WMF C...

Page 85: ...n screws C Scanner wires Installation 1 Wrap the new scanner wire around the pulley as shown then temporarily secure the pulley with tape 2 Re install the 1ST scanner Then secure the first and second...

Page 86: ...cket 10 Tighten the tension bracket G 11 Secure the scanner drive pulley H 1 Allen screw 12 Remove the scanner positioning pins I P N A0069104 13 Slide the scanner to the left and right several times...

Page 87: ...ut the old RAM on the new MBU When the SBU is replaced When the standard white plate located behind the original scale is replaced 1 Put about 10 sheets of paper on the exposure glass 2 Turn on the ma...

Page 88: ...k the 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 001 3 Sc...

Page 89: ...is 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 origina...

Page 90: ...direction as shown in the diagram 3 The distance should be 122 mm If it is not 122 mm calculate the necessary adjustment with the following formula 122 measured value 122 x 100 x x 4 Access SP6 001 7...

Page 91: ...BOARDS C262 C265 3 16 SM 3 5 BOARDS 3 5 1 ACU AND ECU PSU OPENING PROCEDURE Rear Cover 3 2 2 A Open out the ACU ECU assembly x 6 B Open out the PSU x 6 C262R029 WMF C262R030 WMF A B...

Page 92: ...62 C265 Replacement Adjustment 3 5 2 ACU ECU I O Rear cover 3 2 2 A ACU assembly x 6 x 1 B Controller cover x 8 C Upper ground plates x 2 D Lower ground plates x 2 E Guide rail x 1 C262R016 WMF C262R0...

Page 93: ...3 18 SM F ACU x 7 G ECU x 9 x 11 CAUTION After you install the new ECU do these adjustments SBU Calibration 3 3 6 Copy Image Adjustments 3 4 Also see ECU and I O Board Replacement 3 5 5 C262R018 WMF...

Page 94: ...3 19 C262 C265 Replacement Adjustment H I O x 6 x 16 3 5 3 PSU Rear Cover 3 2 2 A PSU x 6 x 11 CAUTION Do the thermal head voltage adjustment 3 7 15 after you install the new PSU C262R020 WMF C262R02...

Page 95: ...BOARDS C262 C265 3 20 SM 3 5 4 DOUBLE FEED DETECTOR BOARD Rear cover 3 2 2 ECU 3 5 1 A Double feed detector board x 3 x 3 C262R158 WMF A...

Page 96: ...4 Sensor board unit calibration 3 3 6 Master end sensor adjustment 3 7 15 NOTE If you use the backup RAM A IC38 from the old ECU on the new one all data including data in the SP modes will be restore...

Page 97: ...MASTER EJECT SECTION C262 C265 3 22 SM 3 6 MASTER EJECT SECTION 3 6 1 MASTER EJECT BOX First open the front cover A Master eject box C262R179 WMF A...

Page 98: ...the front cover A Supporter x 1 B Master eject roller unit C Lower master eject roller unit x 6 D Master eject sensor cover x 1 E Master eject sensor bracket x 1 F Master eject sensor x 1 x 1 NOTE Do...

Page 99: ...2 A Bracket x 1 B Master eject drive unit x 2 x 4 NOTE 1 To remove the master eject drive unit B slide it out towards the paper delivery direction and pull down the top of the unit towards the operati...

Page 100: ...ensor x 1 F Master eject motor x 2 x 1 G Pressure plate motor bracket x 2 H Pressure plate motor x 2 x 1 3 6 4 MASTER EJECT BOX LOCK SOLENOID Left cover 3 2 2 Master eject box 3 6 1 A Master eject box...

Page 101: ...ke 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 SP mode refer to the Service Program Mo...

Page 102: ...installed in the correct position 1 The master eject clamper drive arm B must be flush with the cutout in the frame as shown 2 While you hold the arm in the above position install the sector gear A T...

Page 103: ...e distance between the main frame and the edge of the master making unit is 110 mm or less If you pull the unit out more than 110 mm you cannot do step 4 2 Remove the connector cover C 3 Remove the tw...

Page 104: ...ASTER FEED SECTION SM 3 29 C262 C265 Replacement Adjustment 5 Remove the master making unit F x 2 CAUTION When you install the master making unit make sure to attach the two connectors A C262R032 WMF...

Page 105: ...one way clutch and marking C as shown in the diagram D Platen roller bracket x 1 E Platen roller Hexagon bolt x 2 x 4 NOTE 1 When you install the one way clutch F position the one way clutch and mark...

Page 106: ...lacement Adjustment I Front bracket x 2 J Tension roller guide x 3 K Upper tension roller x 4 NOTE When you install the one way clutch L position the one way clutch and marking M as shown in the diagr...

Page 107: ...5 3 32 SM 3 7 3 THERMAL HEAD Master making unit 3 7 1 A Master making unit right cover x 5 B Thermal head cover x 2 C Thermal head base x 2 x 2 D Thermal head x 10 C262R036 WMF C262R035 WMF C D A B 0...

Page 108: ...d the eccentric bushing H 2 After the replacement adjust the thermal head voltage 3 7 15 3 Make sure that there is no foreign material on the thermal head surface especially on the heating elements 4...

Page 109: ...M 3 7 5 CUTTER UNIT MASTER FEED CONTROL MOTOR CLAMP TENSION ROLLER UPPER MASTER FEED CONTROL ROLLER Master making unit 3 7 1 A Master making unit rear cover x 3 B Harness covers x 2 C Cutter unit x 1...

Page 110: ...tor bracket x 3 x 1 F Master feed control motor x 2 NOTE When you tighten the screws to secure the tension bracket D make sure that the small holes in the rear frame are in line with the small hole in...

Page 111: ...MASTER FEED SECTION C262 C265 3 36 SM J Master edge sensor cover x 1 K Master making unit frame x 2 L Upper master feed control roller x 4 C262R042 WMF J K L...

Page 112: ...tment 3 7 6 PLATEN RELEASE SENSOR PLATEN RELEASE MOTOR Master making unit 3 7 1 Master making unit right cover 3 7 3 A Master making unit rear cover x 3 B Harness covers x 2 C Cover bracket x 1 D Plat...

Page 113: ...3 38 SM E Platen release motor bracket x 2 x 1 F Platen release motor x 2 NOTE When you install the platen release motor bracket make sure that the gear is positioned correctly Platen Release Cam Adju...

Page 114: ...65 Replacement Adjustment 3 7 7 MASTER AMOUNT SENSOR Master making unit 3 7 1 Master making unit right cover 3 7 3 A Master making unit rear cover x 3 B Rear master flange x 1 C Master amount sensor x...

Page 115: ...MASTER DUCT SENSOR MASTER SUCTION FANS MASTER FEED MOTOR Master making unit 3 7 1 1 Open the master tray cover A B Master making unit right cover x 5 C Thermal head cover x 2 D Master making unit rear...

Page 116: ...nt E Lower master cover x 2 F Master duct sensor bracket x 1 x 1 G Master duct sensor x 1 H Master suction fans x 2 x 1 NOTE When you install the master suction fans position the cable and marking I a...

Page 117: ...NSOR MASTER EDGE SENSOR Master making unit 3 7 1 A Master set cover x 6 B Master edge sensor cover x 1 C Master set sensor x 1 x 1 NOTE Do the master set sensor adjustment 3 7 18 after you install the...

Page 118: ...43 C262 C265 Replacement Adjustment 3 7 10 FLAT CABLE Master making unit 3 7 1 A Cable cover x 2 B Flat cable x 2 3 7 11 MASTER END SENSOR Right scanner cover 3 2 3 A Master end sensor x 1 x 1 C262R17...

Page 119: ...ASTER BUFFER FANS Master making unit 3 7 1 A Master buffer fans x 2 x 1 each NOTE When you install the fans position the cable and marking B as shown in the diagram 3 7 13 UNIT LOCK SOLENOID 2ND DRUM...

Page 120: ...2 B Sensor bracket x 5 C Master making unit lock solenoid x 2 x 1 D Master making unit lock detector x 1 x 1 E 2nd drum master sensor bracket x 1 x 1 F 2nd drum master sensor x 1 NOTE Do the 2nd drum...

Page 121: ...he platen release mechanism is disassembled the platen release cam A must be reinstalled in the correct position Procedure When you tighten the screws to secure the mechanism make sure that the small...

Page 122: ...of the thermal head 1 Turn off the main switch Then remove the rear cover to access the PSU A 2 Check the voltage on the thermal head decal NOTE The value is different for each thermal head 3 Turn on...

Page 123: ...SENSOR ADJUSTMENT Purpose To ensure that the sensor detects the end mark a solid black area on the master roll Standard 0 8 volts CAUTION 1 The sensor adjustment is required in the following cases Whe...

Page 124: ...oll NOTE The master roll must not be installed for this adjustment 2 Turn on the main switch then access SP6 004 3 Sensor Voltage and Threshold Adjustment for Master Edge Sensor 3 Press the Start key...

Page 125: ...Rear Cover 3 2 2 1 Turn on the main switch then access SP6 004 4 Sensor Voltage and Threshold Adjustment for Master Set Sensor 2 Pull out the master making unit from the machine and open the master s...

Page 126: ...heck if the value of SP6 004 4 is 3 0 volts or more 8 If the sensor input voltage is 3 0 volts or more adjustment is completed 9 If the sensor input voltage is less than 3 0 volts adjust VR1 until the...

Page 127: ...operation side or the non operation side If the eccentric bushings D are turned one graduation the image skew amount E is corrected by 0 2 mm 5 Tighten the Allen screws C 6 Tighten the four screws B...

Page 128: ...ake a new master The machine will wrap this master around the drum 2 Take out the drum unit from the machine 3 Measure the clearance at the leading edge A and the trailing edge B between the edge of t...

Page 129: ...B 32 0 31 8 0 2 remove the spacer E at the operation side on the master making unit NOTE 1 A B Positive value Decrease the thickness of spacers at the operation side 2 A B Negative value Decrease the...

Page 130: ...aster roll if the edge was not cut evenly This happens for example after a master misfeed jam D Jam NOTE The following procedure cannot be done if a misfeed or SC error condition was not corrected 1 L...

Page 131: ...key down push in the master making unit C NOTE The machine will then trim the leading edge After this is completed a beep will be heard and the operation panel will show Master Misfeed and remove the...

Page 132: ...hermal head the cutter 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...

Page 133: ...nector cover x 1 C Drum handle x 5 x 1 NOTE Do not put the drum unit upside down However if you must put it upside down wipe off the ink around the ink roller first use SP2 2 1 select OFF and feed pap...

Page 134: ...59 C262 C265 Replacement Adjustment D Front bracket x 1 E Front inner bracket x 1 F Loosen the stopper F Then turn the drum until the clamper unit is positioned on the top of the drum C262R055 WMF C2...

Page 135: ...ew screen the black sensor patch I 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 above illustration 4 Make sure th...

Page 136: ...DRUM SECTION SM 3 61 C262 C265 Replacement Adjustment 3 8 3 DRUM MASTER CLAMPER METAL SCREEN Drum cloth screen 3 8 2 A Drum clamper x 2 C262R059 WMF C262R057 WMF A B C...

Page 137: ...f the drum 2 When replacing the drum clamper install the spring on the opposite side as shown in the illustration 3 Do not put the drum unit upside down However if you must put it upside down wipe off...

Page 138: ...correct way around The side with the sandpaper F must be facing the black patch G 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...

Page 139: ...RS AND SENSORS IN THE DRUM Drum cloth screen 3 8 2 Drum clamper 3 8 3 Metal screen 3 8 3 1 First pull out the ink cartridge holder A Ink cartridge cover x 4 B Ink pump unit x 3 x 1 C Ink detection pin...

Page 140: ...t motor cover x 2 E Drum shift motor unit x 4 x 4 F Drum shift motor G Drum shift HP sensor NOTE When reinstalling the drum shift motor unit insert the bearings H into the drum flange edge as shown I...

Page 141: ...DRUM SECTION C262 C265 3 66 SM J Sensor bracket x 1 K Idling roller HP sensor x 1 L Ink supply roller cover x 2 M Sensor bracket x 1 N Ink flow sensor x 1 C262R066 WMF C262R067 WMF J K L M N...

Page 142: ...67 C262 C265 Replacement Adjustment O Ink supply roller unit x 4 3 8 5 INK ID DETECTION INK FLOW SENSOR CONNECTOR A Drum release grip x 2 B Connector cover x 1 C Drum handle x 5 x 1 C262R165 WMF C262...

Page 143: ...Purpose To ensure that ink on the ink roller spreads evenly on the drum screen 1 Take out the drum unit from the machine 2 Remove the drum front cover A x 2 3 Remove the drum cloth and metal screens f...

Page 144: ...e doctor roller and the ink roller Then make sure that a 0 1 mm gauge cannot pass through the gap NOTE Check the gap at the left center and right 6 If the gap is not correct loosen the screws B on bot...

Page 145: ...next page A B IMPORTANT If you cannot correctly calibrate the sensor with this procedure try the Ink Detection Adjustment procedure 1 Remove the ink around the ink roller Set SP2 2 1 Ink Detection to...

Page 146: ...P2 2 1 to its default ink detection ON 1 Remove the drum front cover A 2 Connect the probes and grounding lead of an oscilloscope to the following points on the ink detection board B Probe CH1 to TP1...

Page 147: ...0 mm closer on the non operation side during printing which causes the image to turn obliquely on the paper C262R069 WMF C262R070 WMF Paper feeding direction Operation side Non operation side 1 5 to 2...

Page 148: ...he non operation side by 1 0 mm turn the eccentric bushing C counterclockwise one graduation 2 Please check the machine after adjusting because the effect of moving the bushing by one graduation diffe...

Page 149: ...tion 5 3 1 Rear Cover 3 2 2 1 Remove the master that is wrapped around the drum and install the drum in the main body 2 Turn on the main switch then access SP6 004 5 Sensor Voltage and Threshold Adjus...

Page 150: ...eplacement Adjustment 7 If the sensor input voltage is 3 0 volts or more adjustment is completed 8 If the sensor input voltage is less than 3 0 volts adjust VR3 until the sensor input voltage is 3 0 v...

Page 151: ...light 3 Do not turn the VRs excessively 4 If the sensor is dirty clean or replace it 5 For how to access SP mode refer to the Service Program Mode section 5 3 1 Rear Cover 3 2 2 1 Remove the master t...

Page 152: ...rn the knob until the indicator moves to the point shown B NOTE This step moves the black patch on the drum screen to the sensor 7 Access SP6 004 6 Sensor Voltage and Threshold Adjustment for 2nd drum...

Page 153: ...PAPER TABLE UNIT PAPER FEED ASSEMBLY Front cover Knob cover Inner cover 3 2 1 Rear cover Right rear cover Right front cover 3 2 2 Open out the ACU ECU assembly 3 5 1 A Springs B Front bracket x 2 C R...

Page 154: ...PAPER FEED SECTION SM 3 79 C262 C265 Replacement Adjustment E Paper feed assembly x 4 x 3 C262R087 WMF E...

Page 155: ...e pick up roller and the paper feed roller position the one way clutch correctly The clutch must point towards the front of the machine as shown in the diagram 2 After you install a new feed roller re...

Page 156: ...CTION BOARD A Paper table rear cover x 3 NOTE Carefully push out the two hooks B with a screwdriver C Paper width detection board bracket x 3 D Paper width detection board x 1 x 1 E Paper length senso...

Page 157: ...unit 3 7 1 A Feed cover x 2 B Paper height sensor bracket x 1 x 1 C Paper height sensor NOTE When you install the paper height sensor bracket make sure that the small hole in the stay D is in the lin...

Page 158: ...ED PRESSURE DETECTION BOARD Master making unit 3 7 1 Feed cover 3 9 4 Open out the ACU ECU assembly 3 5 1 Double feed detector board 3 5 4 A Rear rail bracket x 3 B Feed pressure detection board x 2 x...

Page 159: ...OLLER RELEASE SENSOR Master making unit 3 7 1 Feed cover 3 9 4 A Front rail bracket x 2 B Registration roller sensor bracket x 2 x 1 C Registration roller press sensor x 1 D Registration roller releas...

Page 160: ...Rear cover Right rear cover 3 2 2 Master making unit 3 7 1 Feed cover 3 9 4 Paper table unit 3 9 1 Paper feed assembly 3 9 1 Open out the ACU ECU assembly 3 5 1 A Double feed detector board x 3 x 3 B...

Page 161: ...TE There is a correct position for the cam Because of this when you reinstall the cam do the registration roller lifting cam position adjustment 3 9 13 H Right paper guide plate x 1 I Paper feed rolle...

Page 162: ...Front cover Inner cover Knob cover 3 2 1 K Rear rail bracket x 3 L Front rail bracket x 2 M Feed pressure unit x 4 x 5 NOTE When tightening the feed pressure unit pass the pin through the small hole...

Page 163: ...PAPER FEED SECTION C262 C265 3 88 SM O Sensor bracket x 1 x 2 P Paper registration sensor Q Paper feed timing sensor C262R085 WMF O P Q...

Page 164: ...OLLER Paper registration sensor Paper feed timing sensor 3 9 7 A Upper stay x 5 x 1 NOTE Push up the upper stay B Upper registration rear bracket NOTE Slide the upper registration rear bracket C towar...

Page 165: ...he correct friction pad at A as shown above use SP 5 42 to move the necessary pad to A To move friction pad A to the replacement position turn on the main switch then access SP 5 42 1 and push the Sta...

Page 166: ...SEPARATION PRESSURE DETECTION BOARD FRICTION PAD SHIFT MOTOR Paper feed assembly 3 9 1 A Friction pad unit cover x 2 B Separation pressure detection board x 2 C Friction pad shift motor bracket x 2 x...

Page 167: ...N PAD POSITION SENSORS 1 2 Paper feed assembly 3 9 1 A Friction pad unit cover x 2 B Friction pad position sensor bracket x 4 x 3 C Friction pad position sensors 1 2 D Separation pressure motor bracke...

Page 168: ...2 1 Rear cover Right rear cover Right front cover 3 2 2 Open out the ACU ECU assembly 3 5 1 Pressure cylinder 3 10 1 A Double feed detector board x 3 x 3 B Pulley cover x 1 C Lifting cam bracket x 2 D...

Page 169: ...t home position before the adjustment 1 When installing the registration roller lifting cam A on the shaft align the cam follower a bushing at the center or within one division to the right of the cen...

Page 170: ...n on the main switch 2 Feed a sheet of the customer s typical print paper from the paper feed table into the machine until the leading edge runs against the feed roller A 3 Turn VR101 B clockwise unti...

Page 171: ...o ensure smooth paper feed 1 Make sure that the distance between the motor and the flange is 8 0 0 5mm 2 Apply a 500g load to the center of the belt using a tension gauge Make sure that the belt defle...

Page 172: ...mooth paper feed 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 tensi...

Page 173: ...Defaults for SP6 009 1 Standard 3 SP6 009 2 Frequent 5 SP6 009 3 Very Frequent 6 The available pressure levels are from 0 to 6 0 is the weakest 6 is the strongest Paper separation pressure adjustment...

Page 174: ...31 2 21 2 Changing the value by 1 increases the paper feed motor s on time and feeds the paper an extra 0 3 mm 4 Leave the SP mode then check the paper feed performance If the problem still occurs rep...

Page 175: ...switch then access the SP mode 2 Enter SP6 027 1 to 8 Paper Clamp Timing Pulse NOTE The paper clamping timing depends on the paper type selected at the operation panel and the print speed SP6 027 1 to...

Page 176: ...acing the pressure cylinder because the pressure cylinder is made of soft rubber Also the encoder in the rear of the pressure cylinder is easily damaged Removal procedure Drum unit 3 8 1 Left cover 3...

Page 177: ...the side of the pressure cylinder is at the top The flat part of the pressure cylinder faces towards the upper right as shown 2 Remove the screw and flip over the stopper F from left to right 3 Put th...

Page 178: ...at the rear of the pressure cylinder Be careful not to damage it when removing the pressure cylinder 5 Pull the pressure cylinder toward you and put it on the flat area of the inner cover G 6 With the...

Page 179: ...ioned horizontally but leans to the upper right just slightly 1 Hold the pressure cylinder so that the round hole C is uppermost Rest the pressure cylinder on the flat area of the inner cover D NOTE T...

Page 180: ...ing lower wrapping jams and support the bottom of the pressure cylinder 4 Then put the pressure cylinder into the hole where the drum was Use both hands 5 Install the pressure cylinder while positioni...

Page 181: ...NOTE 1 If it cannot enter push while turning the pressure cylinder a little Check if the joint is engaged properly by turning the pressure cylinder slightly 2 Set the bearing stopper G as shown 7 Ins...

Page 182: ...ER HARNESS FEED ENCODER CLEANING BRUSH Drum unit 3 8 1 Rear cover 3 2 2 Open out the ACU ECU assembly 3 5 1 1 Disconnect the connector A from the rear of the machine 1 clamp B C Knob cover x 1 2 Turn...

Page 183: ...ed encoder bracket x 1 NOTE When re installing the feed encoder bracket E make sure to put the hook F on the feed encoder bracket in the correct place on the main body G attach the hook exactly at the...

Page 184: ...stment H Feed encoder x 1 I Feed start sensor x 1 J Feed encoder harness the white connector goes to the feed encoder H and the black connector goes to the feed start sensor I K Feed encoder cleaning...

Page 185: ...a mark on the screw and the bracket This will show you how much to tighten the screw before you do the 1st drum master sensor guide adjustment After you re install the 1st drum sensor guide do the 1s...

Page 186: ...up to the printing position 1 Access SP5 64 2 for the printing pressure release solenoid and select Start 2 Turn the knob A until the flat part of the cylinder B is in the position shown 3 Leave SP mo...

Page 187: ...CAM SHIFT MOTOR Rear cover 3 2 2 ECU 3 5 1 A Printing pressure sensor bracket x 1 x 1 B Printing pressure position sensor x 1 C Printing pressure HP sensor x 1 D Encoder x 1 E Bracket x 1 F Print pre...

Page 188: ...the printing pressure lever is disengaged when the printing pressure release solenoid is energized 1 Rotate the printing pressure cams so that the arm moves to the lowest position NOTE Use the main d...

Page 189: ...Procedure 1 Turn off the main switch and disconnect the power plug Then remove the following parts Drum unit 3 8 1 Rear cover 3 2 2 Left cover 3 2 2 Paper delivery unit 3 12 2 Air knife fan unit 3 12...

Page 190: ...springs C 6 Remove the pulley bracket D x 2 7 Remove the timing belt E 8 Remove the gear F x 2 9 Loosen the screw G 10 Remove the bracket H x 5 Cord clamp x 2 Bearing x 2 NOTE One of the screws is und...

Page 191: ...AND IMAGE UP DOWN SHIFTING DRIVE SECTION C262 C265 3 116 SM 11 Remove the bracket I x 4 12 Remove the bearing J 13 Remove the torque limiter K Hexagon bolt x 2 14 Remove the main motor L x 4 C262R180...

Page 192: ...drive timing adjustment The following procedure shows the correct time to do this 1 Make sure that the drum drive disk is in the home position by setting the drum drive securing tool A NOTE 1 The too...

Page 193: ...AND IMAGE UP DOWN SHIFTING DRIVE SECTION C262 C265 3 118 SM 2 Install the main motor D x 4 3 Install the torque limiter E Hexagon bolt x 2 4 Install the bearing F 5 Install the bracket G x 4 C262R181...

Page 194: ...pawl on the torque limiter J as shown 8 Attach the spring K and secure the screw L NOTE If the cutout and pawl are in line the main motor drive is OK If they are not remove the spring K then make sure...

Page 195: ...he indicator disk bracket Q and the timing belt R x 2 14 Install the indicator disk bracket Q and the timing belt R when the line and arrow on the indicator disk S are in line x 2 and the actuator is...

Page 196: ...securing tool V 18 Install the PSU 3 5 3 19 Install the job separator unit 3 12 3 20 Install the paper delivery unit 3 12 2 21 Install the air knife fan unit 3 12 2 22 Install the paper delivery cove...

Page 197: ...Disassembly Procedure 1 Turn off the main switch and disconnect the power plug Then remove this part Rear cover 3 2 2 2 Swing out the ACU ECU assembly and PSU 3 5 1 3 Remove the double feed detector b...

Page 198: ...IVE AND IMAGE UP DOWN SHIFTING DRIVE SECTION SM 3 123 C262 C265 Replacement Adjustment From the rear 5 Remove the main motor control board E x 3 x 4 6 Remove the wire protection cover F x 2 C262R143 W...

Page 199: ...gear J x 2 11 Loosen the screw K 12 Remove the bracket L x 5 Cord clamp x 2 Bearing x 2 NOTE 1 One of the screws is under the main wire harness Take care not to damage the wire harness when you remove...

Page 200: ...IMAGE UP DOWN SHIFTING DRIVE SECTION SM 3 125 C262 C265 Replacement Adjustment 13 Remove the image shift unit O x 3 x 2 14 Remove the supporter for the ACU ECU assembly and PSU P x 4 C262R145 WMF C26...

Page 201: ...WN SHIFTING DRIVE SECTION C262 C265 3 126 SM 15 Printing pressure sensor bracket Q x 1 x 1 16 Remove the printing pressure cam drive gear R x 2 17 Remove the main drive unit S x 6 Cord clamp x 1 C262R...

Page 202: ...ng the main drive section z Drum home position z Image shifting arm home position z Pressure cylinder drive reinstalling position z Scissors gear reinstalling position z Printing pressure cam drive ge...

Page 203: ...ft arm B in the home position To do this align the hole in the upper plate C with the elongated hole in the image shift arm 3 Align the hole in the pressure cylinder drive disk D with the hole in the...

Page 204: ...the machine rear frame From the operation side 4 Remove the front cover the knob cover and the inner cover 3 2 1 5 From the operation side of the machine insert the positioning shaft A special tools...

Page 205: ...ide 6 Secure the main drive unit B on the machine rear frame x 2 NOTE 1 Install the two screws temporarily because you must tighten them in step 8 2 When installing the main drive unit align the elong...

Page 206: ...the convex points of the pressure cylinder s drive disk E meet the concave points of the pressure cylinder drive transmission disk F made of white plastic NOTE Hold the drum drive disk image shifting...

Page 207: ...ector gear and secure the unit x 3 x 3 NOTE 1 Ensure that the unit is set without any play 2 Do not push on the unit too strongly Ensure that the image shift arm moves smoothly after securing the unit...

Page 208: ...the image shift arm to its home position If the image shift arm is not returned to home position exactly in this step correct positioning for each main drive part will not be obtained 16 Turn off the...

Page 209: ...ely NOTE Do not remove the screws 19 From the operation side of the machine insert the two positioning shafts E special tools to secure the pressure cylinder and printing pressure cams in their home p...

Page 210: ...motor will not turn smoothly since the drive is secured with the special tools this is normal 21 Turn the main motor H counterclockwise and set the drum drive disk I in the home position If the disk i...

Page 211: ...force while setting the tool If you turned the disk return to step 20 then do step 21 23 Secure the pressure cylinder drive gear J x 2 24 Install the printing pressure cam drive gear and firmly tight...

Page 212: ...11 4 Pressure cylinder rotation knob adjustment 5 Remove all special tools the drum drive securing tool and two positioning shafts 6 Adjust the gap between the exit pawl and the drum Also adjust the...

Page 213: ...t When the leading edge margin of copies 6 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 step...

Page 214: ...cover 3 2 1 Rear cover 3 2 2 Paper delivery unit 3 12 2 Printing pressure cam shift unit 3 12 3 2 Make sure that the drum drive disk is in the home position by installing the drum drive securing tool...

Page 215: ...ls to secure the pressure cylinder and printing pressure cams in the their home positions z Pass one shaft through the pressure cylinder as shown z Pass the other shaft through the two printing pressu...

Page 216: ...lacement Adjustment 6 Remove the printing pressure sensor bracket F x 1 x 1 7 Remove the upper cover G x 7 x 1 Bearing x 1 Spring x 1 NOTE Do not remove the bearing and E ring H 8 Loosen the screw I 9...

Page 217: ...C265 3 142 SM 10 Remove the scissors gear J Hexagon bolt x 2 NOTE When replacing the scissors gear check the registration roller lifting cam position K as shown The short central line must be aligned...

Page 218: ...ot available 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 ma...

Page 219: ...t A 2 Tighten the screw so that the gear meshes on both gears are aligned as shown B 3 Turn the screw fully counterclockwise circle to loosen it as shown C 4 Holding the screw tighten the lock nut A 3...

Page 220: ...in the home position Align the hole in the upper plate with the elongated hole in the image shift arm B 2 Push the image up down shift drive unit C against the image shift arm sector gear and secure...

Page 221: ...make sure that the image shift gear moves smoothly along the drum drive gear 1 Turn off the main switch and disconnect the power plug Then remove these parts Drum unit 3 8 1 Rear cover 3 2 2 2 Swing o...

Page 222: ...ft arm 6 Loosen the three screws E The play between the image shift gear and the drum drive gear is automatically removed NOTE Do not touch the two hexagon bolts F If you do it can damage the image sh...

Page 223: ...PAPER DELIVERY SECTION C262 C265 3 148 SM 3 12 PAPER DELIVERY SECTION 3 12 1 PAPER EXIT PAWL Drum unit 3 8 1 A Paper exit pawl x 1 C262R112 WMF A...

Page 224: ...262 C265 Replacement Adjustment 3 12 2 PAPER DELIVERY UNIT AIR KNIFE FAN UNIT PAPER PICK OFF PLATE Left cover 3 2 2 Knob cover 3 2 1 A Paper delivery cover x 4 B Knob x 1 C Paper delivery unit x 3 x 3...

Page 225: ...PAPER DELIVERY SECTION C262 C265 3 150 SM D Air knife fan unit x 2 x 1 E Paper pick off plate x 2 Spring x 1 C262R115 WMF D E...

Page 226: ...3 151 C262 C265 Replacement Adjustment 3 12 3 JOB SEPARATOR UNIT PRINTING PRESSURE CAM SHIFT UNIT Paper delivery unit 3 12 2 A Job separator unit x 2 x 2 B Printing pressure cam shift unit x 2 x 3 C26...

Page 227: ...ORT VACUUM FAN PAPER EXIT SENSOR Paper delivery unit 3 12 2 A Transport vacuum fan x 2 x 1 B Upper cover x 4 x 1 C Paper guide wings D Paper exit sensor x 1 E Wing guide motor unit x 2 x 1 F Drive rol...

Page 228: ...8 1 Master eject box 3 6 1 Left cover 3 2 2 Knob cover 3 2 1 1 Apply the printing pressure as follows to push the pressure cylinder up to the printing position 1 Access SP5 64 2 and select Start for t...

Page 229: ...ws CAUTION Be sure to do this adjustment after pushing the pressure cylinder up to the printing section If the gap is adjusted with the pressure cylinder in the non printing section the paper pick off...

Page 230: ...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 position If the sp...

Page 231: ...thout paper wrap or damage 1 Turn the main drive manually so that the bearing A of the exit pawl arm rides on the low point of the cam NOTE Use the main drive rotation knob to turn the main drive 2 By...

Page 232: ...S A Chocks x 2 B Buffer fin bracket x 2 C Normally do not disassemble parts B to E in the field D Buffer fin E Buffer fin link C262R183 WMF C262R184 WMF A A B B D E D E D D E D E Operation side Non op...

Page 233: ...TROUBLESHOOTING...

Page 234: ......

Page 235: ...the power LED to go off and then switch the main power switch off NOTE 1 If the problem concerns electrical circuit boards first disconnect then reconnect the connectors before replacing the PCBs 2 If...

Page 236: ...efective ECU SC202 Thermal head thermistor short The signal from the thermal head thermistor reaches more than 4 27 volts Thermistor open circuit Related connector disconnected SC203 Thermal head temp...

Page 237: ...cts an abnormal signal from the main motor encoder Defective main motor Defective main motor drive board SC302 Main Motor lock Drum Home position sensor error When the drum is at the home position dru...

Page 238: ...ctivated more than 8 5 seconds Defective sensor Defective motor SC313 Clamper motor lock Clamper close position sensor error When the master clamper is being opened the sensor is not activated after t...

Page 239: ...ck solenoid error The eject box lock sensor does not Off after lifting lock twice Defective box lock solenoid Defective sensor Paper Delivery and Exit SC500 Feed pressure motor lock The sensor does no...

Page 240: ...When the slider moves upwards the sensor is not de activated for more than 9 seconds after the slider lift motor on signal is generated Defective sensor Defective motor Defective ECU baord Motor belt...

Page 241: ...istory in the program of NVRAM Miss the Firmware version up SC601 Flash ROM ECU error Upload error to Flash ROM Defective ECU SC602 Ri10 error Ri10 cannot be started read write Defective ECU board SC6...

Page 242: ...ol returned an error during the self diagnostic test Defective ACU board SC824 Self diagnostic Error NVRAM The resident non volatile RAM returned an error during the self diagnostic test NVRAM of ACU...

Page 243: ...onnection SC860 Startup without HDD connection at main power on The hard disk connection is not detected Initialize HDD Defective HDD Damaged data SC861 Startup without HDD detection at power switch o...

Page 244: ...r The software attempted to perform and unexpected operation However unlike SC990 the object of the error is continuity of the software Software bug Internal parameter incorrect Insufficient working m...

Page 245: ...cted but an original is present The printed image shifts when Auto Reduce Enlarge image rotation or image repeat is used Original length width sensors Original detected but no original is present The...

Page 246: ...is the widest possible size and the image on the output shifts up or down Original width sensor Does not detect an original but there is an original The machine reads only one part of the image and th...

Page 247: ...t button is pushed SC211 occurs platen release motor lock Platen release sensor Stays off detects that platen pressure is released but it is applied If the sensor does not turn on 5 seconds after the...

Page 248: ...it is Drum rotation low speed will not stop when the Start button is pushed 1st drum position sensor symptom during master making The sensor detects the drum is at the 1st position but it is not SC31...

Page 249: ...t the ink leakage Replace or clean the ink detection pin Detects a cartridge but no cartridge is present The printed image will be pale because the drum tries to supply ink without an ink cartridge In...

Page 250: ...onds The movement between the master eject position and HP takes more than 3 seconds Pressure plate HP sensor Does not detect the pressure plate at home position SC400 occurs if one of these things oc...

Page 251: ...not detect the paper size Detects a long paper size but it is not long paper Pressure is applied between the drum and pressure cylinder after the trailing edge of the paper on the drum and ink will tr...

Page 252: ...is pressure The separation pressure detection board does not detect the pressure continually when the print button is pushed SC501 Separation pressure motor Stays on detects a friction pad but one is...

Page 253: ...r lock occurs Stays on detects that the wing is at the lower position but it is not If the sensor does not turn off when the wing guide motor moves up SC506 wing guide motor lock occurs Wing lower pos...

Page 254: ...home position If the sensor does not turn off SC510 slider lift motor lock occurs Slider HP sensor Stays off does not detect the slider but it is at home position If the sensor does not turn on SC510...

Page 255: ...F OFF OFF OFF NOTE 1 Do not turn the all the dip switches off or the machine will detect that there is no drum 2 Do not change DIPSW 3 because it is used for TC IIR If the setting is changed an error...

Page 256: ...Usage VR1 Master set sensor adjustment VR2 Master Eject Sensor Adjustment VR3 1st Drum Master Sensor Adjustment VR4 Master End Sensor Adjustment Do not adjust VR5 Master Edge Sensor Adjustment VR6 2n...

Page 257: ...During firmware download quick blink After firmware download slow blink LED102 During firmware download quick blink After firmware download slow blink NOTE The Green LED of the start button on the op...

Page 258: ...TP AND FUSE TABLES C262 C265 4 24 SM Main Motor Drive Board Fuse Rated Current Protect F1 12A Main Motor I O Board Fuse Protect FU1 Not used FU2 Transport Suction Fan Air Knife Fan FU3 Air Knife Fan F...

Page 259: ...SERVICE TABLES...

Page 260: ......

Page 261: ...alibrated with SP6 005 1 5 1 2 MASTER EJECT SECTION 1 Master Pick up Roller Drive Gear and Master Clamper Drive Arm Positions These parts must be positioned correctly See 3 6 6 Reassembling the Master...

Page 262: ...surfaces of the rollers with bare hands 5 1 5 DRUM AND DRUM DRIVE SECTION 1 Doctor Roller Normally the doctor roller gap is not adjusted or changed It tends to be difficult to adjust in the field If t...

Page 263: ...d I O board have to be moved out of the way See 3 5 1 ACU ECU and PSU Opening Procedures 3 Power Supply Unit When replacing the power supply unit be sure to adjust the voltage supplied to the thermal...

Page 264: ...ng Tool Kit Drum securing tool and two positioning shafts as a set C229 9000 For main drive positioning Scanner Positioning Pin Kit 4 pins as a set A006 9104 For scanner wire installation SD Card B645...

Page 265: ...Press J press press D 5 times to open the Self Diagnostics menu 2 On the touch screen press Touch Screen Adjust or press 3 Use a pointed not sharp tool to press the upper left mark 4 Press the lower...

Page 266: ...data 5 4 1 ENABLING AND DISABLING SERVICE PROGRAM MODE NOTE The Service Program Mode is for use by service representatives only If this mode is used by anyone other than service representatives for a...

Page 267: ...MODES Copy System SP SP modes related to the engine functions Printer SP SP modes related to the printer functions Select one of the Service Program modes Copy System or Printer from the touch panel a...

Page 268: ...ted when pressing If not just press the required SP Mode number Press two times to leave the SP mode and return to the copy window to resume normal operation Press to move the highlight on the left to...

Page 269: ...number and title of the item that you want to set and press it The small entry box on the right activates and shows the below default or the current settings NOTE Refer to the Service Tables for the r...

Page 270: ...tus check 5 Output Test Mode Motors and other components on off check 6 System Adjustment Various adjustments 7 Memory Data Clear Resets or clears the SP mode data 8 System Test Various data printouts...

Page 271: ...inal type used 1 4 1 Standard Paper 2 Thick Paper 3 Thin Paper 4 Special 5 User Setting 1 Master Counter Paper Type 6 User Setting 2 Master counters for each paper type used 1 Economy Mode 1 2 Economy...

Page 272: ...m Red 4 Color Drum Blue 5 Color Drum Green 6 Color Drum Brown 7 Color Drum Gray 8 Color Drum Yellow 9 Color Drum Purple 10 Color Drum Maroon 11 Color Drum Navy 12 Color Drum Orange 13 Color Drum Hunte...

Page 273: ...lamp Error 3 Master Cut Error 4 Master Eject ON Check 5 Master Pressure Plate Error 6 Master Eject OFF Check 7 Paper Registration ON Check 8 Paper Feed Timing ON Check 9 Paper Feed Timing OFF Check 10...

Page 274: ...rpm 29 Jam P1 Standard 120rpm 30 Jam P1 Standard 135rpm 31 Jam P1 Thick 60rpm 32 Jam P1 Thick 75rpm 33 Jam P1 Thick 90rpm 34 Jam P1 Thick 105rpm 35 Jam P1 Thick 120rpm 36 Jam P1 Thick 135rpm 37 Jam P1...

Page 275: ...Jam P2 Others 120rpm 72 Jam P2 Others 135rpm 1 18 Paper Jam LCS 1 Paper Feed LCIT 1 19 Other Counter 1 Set Master 2 Ejected Master 3 Ink Pump Rotation 4 Master End 5 Ink End 6 Master Eject Box Full Nu...

Page 276: ...if required 1 20 Service Information 2 Service Call Counter Displays the latest 40 Service Call codes 1 From Paper Table 60rpm 2 From Paper Table 75rpm 3 From Paper Table 90rpm 4 From Paper Table 105r...

Page 277: ...23 HDD Format Picture Files 24 HDD Format Fonts Data 25 HDD Format Job Log Data 27 Vender Selection 28 Ghost Image Removal 29 Drum Ink Exhaust 1 Drum Screen 2 Paper Clamper 3 Feed Pressure 4 Separati...

Page 278: ...ON OFF 2 4 Destination Setting 1 Machine Code Setting See Note 2 3 Drum Selection See Note 3 DLT A3 4 Machine Destination 0 Japan 1 North America 2 Europe 3 China 5 Vendor Selection Different depends...

Page 279: ...Note 10 On OFF 14 TH Writing Mode See Note 11 OFF On OFF 15 TH Swinging Quantity See Note 11 2 1 to 5mm 16 Print Pressure Constance Mode See Note 12 OFF On OFF 17 Print Pressure in Adjust See Note 12...

Page 280: ...m Detection Time Length 15 3 30 2 Door Open Time Length 15 3 30 3 Continuous Master Jam Cnt 2 2 10 2 08 CC Call 4 Continuous Paper Jam Cnt 3 2 10 1 Supply Alarm OFF On OFF 2 Master End Alarm OFF On OF...

Page 281: ...tch settings on the drum But A3 and DLT have the same dip switch configuration Then the machine uses this SP to tell the difference between A3 and DLT The drum size detected by the machine changes the...

Page 282: ...Standard Black SP2 5 3 7 Color SP2 5 13 7 Z Economy Mode 1 Black SP2 5 4 17 Color SP2 5 14 17 Z Economy Mode 2 Black SP2 5 5 27 Color SP2 5 15 27 T The temperature of the ink Drum Ink Temp Control SP2...

Page 283: ...ed and supplied There are three possible settings 0 After Ink detection and supply are done when a print job finishes 1 Before They are done when the Print Start key is pressed and before starting pri...

Page 284: ...be changed by the print speed and the temperature Default OFF pressure is changed by print speed and temperature 2 6 17 Print Pressure In Fixing Mode Settings 0 to 6 Default 3 13 2 6 18 Print Pressure...

Page 285: ...aster is wrapped to prevent the ink in the drum from becoming dry During this procedure the excess ink in the drum transfers to the master If there is a lot of excess ink you must make more than one m...

Page 286: ...Type Set to Yes if installed 0 0 None 1 Add card 2 Sub crd 3 Prepaid Card 4 Coin Rack 4 Set Paper Delivery Table Japan only No No Yes 5 Set Paper Feed Station No No Yes 6 Set Sorter Japan only No No...

Page 287: ...counters at the time of replacement will be stored in the machine The parts for which this information can be recorded are Cloth screen Paper clamper Pick up roller Paper feed roller Friction pad A B...

Page 288: ...aster Eject Sensor 3 Pressure Plate HP Sensor 4 Pressure Plate Limit Pos SN 4 20 Master Eject Unit 5 Eject Box Lock Sensor 1 Paper Table Lowering Switch 2 Paper Table Lower Limit Sensor 3 Paper Table...

Page 289: ...ition Sensor 4 Drum Type Check 0 5 Drum Type Check 1 6 Color Drum ID SN 1 7 Color Drum ID SN 2 8 1st Drum Master Sensor 9 2nd Drum Master Sensor 10 Clamper Close Position Sensor 11 Clamper Open Positi...

Page 290: ...nsor 7 Paper Width Detection 1 8 Paper Width Detection 2 9 Paper Width Detection 3 10 Paper Width Detection 4 11 Paper Width Detection 5 12 Paper Width Detection 6 13 Paper Length Sensor 14 Paper End...

Page 291: ...it Lock Solenoid Lock 5 010 Master Making Unit 19 Unit Lock Solenoid Unlock 1 Master Eject Motor Forward 2 Master Eject Motor Reverse 3 Pressure Plate Motor to Limit 4 Pressure Plate Motor to Eject Po...

Page 292: ...2 30 rpm 3 1st Speed 4 2nd Speed 5 3rd Speed 6 4th Speed 7 5th Speed 5 051 Registration Motor 8 6th Speed 1 Wing Guide Motor Up 2 Wing Guide Motor Down 3 Air Knife Fan Side 4 Air Knife Fan Center 5 05...

Page 293: ...r 2 Master Counter Up 1 All Indicators On 2 PSU Fan Motor 5 080 Other Sections Main Body 3 Auto Shut Off 1 Slider Lift Motor Up 2 Slider Lift Motor Down 3 Job Separator Motor Forward 5 090 Job Separat...

Page 294: ...0 0 to 2mm 1 Letter 1 0 to 2 2 Letter Photo 1 0 to 2 3 Photo 1 0 to 2 4 Pencil 1 0 to 2 6 2 Master Making Density 5 Tint See Note 5 1 0 to 2 6 3 Drum Master Clamp 1 Drum Master Clamp Registration See...

Page 295: ...8 1 A3 Drum 0 5 to 5mm 2 DLT Drum 0 5 to 5mm 6 7 Drum Master Length 3 A4 Drum Adjust if the cut length of the master is not correct 0 5 to 5mm 5 A4 Cut Adjust A4 Master cut 0 5 to 5mm 6 8 Ink Detectio...

Page 296: ...6 4 Sep Pressure Std Thick Paper 1 0 to 6 5 Thick Paper Frequently 2 0 to 6 6 Thick Paper Very Frequently 4 0 to 6 7 Sep Pressure Std Thin Paper 2 0 to 6 8 Thin Paper Frequently 4 0 to 6 9 Thin Paper...

Page 297: ...er 6 13 Delivery Wing Angle 6 User 2 Paper See Note 14 Upper Lower Upper 1 16 rpm 290 0 to 32767 2 30 rpm 500 0 to 32767 3 60 rpm 193 0 to 32767 4 75 rpm 106 0 to 255 5 90 rpm 48 0 to 255 6 105 rpm 54...

Page 298: ...to 32767 5 105 rpm 160 0 to 255 6 120 rpm 126 0 to 255 6 19 2nd Time Feed Delay Thick 7 135 rpm Do not adjust Changes the registration motor on timing in special paper mode after the feed start timing...

Page 299: ...Note 17 31 0 to 255 5 90 rpm 27 0 to 255 6 105 rpm 22 0 to 255 7 120 rpm 18 0 to 255 8 135 rpm 10 0 to 255 1 16 rpm 37 0 to 255 2 30 rpm 37 0 to 255 3 60 rpm 33 0 to 255 4 75 rpm 30 0 to 255 5 90 rpm...

Page 300: ...0 to 255 2 Feed Stop Timing Pulse See Replacements and Adjustments Paper Feed Length Adjustment for how to use See Note 20 21 0 to 255 3 Feed Stop Timing Pulse LCIT 13 0 to 255 4 Print Position 2 Sett...

Page 301: ...0 to 6 2 16 rpm 0 0 to 6 3 30 rpm 0 0 to 6 4 1st Speed 1 0 to 6 5 2nd Speed 3 0 to 6 6 3rd Speed 4 0 to 6 7 4th Speed 5 0 to 6 8 5th Speed 5 0 to 6 9 6th Speed 6 0 to 6 1 Trial Print 1 0 to 6 2 16 rpm...

Page 302: ...position Inputting a positive number moves the image away from the leading edge of the printer paper Use the point key to switch between and 3 6 1 5 and 6 Scanning speed Inputting a positive value st...

Page 303: ...and CAUTION Adjust this SP mode before adjusting the Scanning Speed SP6 1 5 6 Procedure Enter SP8 5 1 TH Test Patterns and print pattern number 6 On the printout measure the distance of 10 intervals...

Page 304: ...for that 7 6 4 7 List of Sensor Adjustments A list of the following sensor adjustments is displayed Master End Sensor ROLL Master Eject Sensor EJCT Master Edge Sensor TOP Master Set Sensor SET 1st Dru...

Page 305: ...applied during paper feed The feed pressure used by the machine is controlled by the following items The paper type selected by the user normal thick thin special user 1 user 2 The frequency at which...

Page 306: ...le wing angle The machine lifts or lowers the wings depending on the paper type selected by the user standard thick thin special user 1 user 2 The settings for user 1 and user 2 depend on the type of...

Page 307: ...ease the amount of paper bending decrease the value of the SP 19 6 30 Paper Feed Jam Check Pulse This SP mode adjusts the amount of time from starting the paper feed roller until jam detection If the...

Page 308: ...n However when thick paper is used it should be lowered because thick paper strongly pushes the paper clamper This causes friction to the smooth rotation of the pressure cylinder due to play in the cy...

Page 309: ...rror Logging 1 User Code 2 Key Operator Code 7 3 Code Clear 3 Security Code Clear 1 Feed Pressure 2 Separation Pressure 3 Friction Pad Settings 4 Wing Guide Angle 5 Feed Control Data 7 4 Reset Paper F...

Page 310: ...13 All System Adjustment 14 Paper Feed Adjustment 8 1 Data Printout 15 Option Adjustment Print 1 Controller 2 Engine SD Card 3 Engine SD Card 4 Panel 5 Language 8 2 Download Program 6 PostScript 8 5...

Page 311: ...ION 1 This mode continues until main power is shut off 2 In some cases there will be a large quantity of data and many masters will be consumed to print out the hex dump Be careful when you use this m...

Page 312: ...e machine through other boards ECU Controls the engine functions both directly and through other boards PS3 For PostScript 3 NOTE There are 2 files in this firmware module Operation Panel Controls the...

Page 313: ..._1 01_sd bin Can store different versions ECU C2621111A_1 00_sd bin ECU 1 file C2621111B_1 01_sd bin Can store different versions PS3 C6402222_A 1 sd bin PS3 2 files C6402222_A 2sd bin Cannot store di...

Page 314: ...C262 firmware in the C262 folder 4 Wait until the data is transferred completely CAUTION Do not remove the SD card from the PC until after all data is transferred at this time the PC says that it is s...

Page 315: ...e Chg button C to select the version that you want to download After selecting push the Download D button to start downloading ECU SP8 2 2 Engine On the left indicated by ROM A you can see the firmwar...

Page 316: ...panel Push the Download button C to start downloading Panel SP8 2 3 On the left indicated by ROM A you can see the firmware version that is now in the machine On the right indicated by NEW B you can...

Page 317: ...buttons D to scroll through the possible languages If you do not wish to change one of the two language firmware modules in the machine select NON with the arrow keys After selecting push the Download...

Page 318: ...o Lighting 2 If an error occurred during the download do the download again when the display panel shows the SP mode screen If this is not possible the related board and possibly the ACU must be repla...

Page 319: ...the module then repeat the installation procedure 33 Incorrect SD card version The firmware on the SD card is not correct or data is damaged 34 Module mismatch Correct module is not on the SD card The...

Page 320: ...reset and start to count The electrical counter will not count unless you do this procedure 2 2 4 1 Machine Code Setting When the machine code is set the destination language and so on will be set au...

Page 321: ...DETAILED SECTION DESCRIPTIONS...

Page 322: ......

Page 323: ...er Feed Roller 14 Registration 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...

Page 324: ...MECHANISM OVERVIEW C262 C265 6 2 SM 6 1 2 ELECTRICAL COMPONENT LAYOUT Printed circuit board layout Scanner Section C262D902 WMF C262D903 WMF 1 2 3 4 5 7 10 11 12 14 15 16 8 9 6 13...

Page 325: ...6 3 C262 C265 Detailed Descriptions Paper Feed Section Drum Unit C262D904 WMF C262D905 WMF 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 49 50 51 52 55 54...

Page 326: ...SM Master Eject Pressure Cylinder and Other Sections Paper Delivery Section C262D906 WMF C262D907 WMF 84 85 86 87 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 82 83 102 88 91 92 90 8...

Page 327: ...MECHANISM OVERVIEW SM 6 5 C262 C265 Detailed Descriptions Master Making Unit C262D908 WMF 116 118 117 119 103 104 105 106 107 108 109 110 111 112 113 114 115...

Page 328: ...per separation pressure to the CPU 59 Ink Detection Board Checks if there is ink in the drum Motors Index No Name Function 15 Scanner Drive Motor Drives the scanner 17 Registration Pressure Motor Rele...

Page 329: ...ator unit 99 Transport Vacuum Fan Provides suction so that paper is held firmly on the transport belts 102 Air Knife Fans Three fans provide air to separate the paper leading edge from the drum 103 Ma...

Page 330: ...er table is at its lower limit position 32 Paper Table Set Sensor Detects if the paper table is closed 33 Paper Length Sensor Detects when long paper is on the paper table 36 Paper End Sensor Detects...

Page 331: ...ting pressure level when the printing pressure mechanism is at a different position from the home position level 2 76 Feed Start Sensor Checks the pressure cylinder position for the paper feed start t...

Page 332: ...ey pull the release arms to apply the printing pressure against the drum 86 Master Eject Box Lock Solenoid Locks the master eject box so that old masters cannot be removed This security feature can be...

Page 333: ...ler Sector Gear 11 Registration Motor 3 Master Eject Motor 12 Paper Feed Motor 4 Image Shift Motor 13 Paper Table Motor 5 Pressure Plate Motor 14 Clamper Motor 6 Exit Pawl Drive Cam Gear 15 Drum Guide...

Page 334: ...Cylinder 25 Pressure Cylinder Drive Gear Including the Scissors Gear 20 Printing Pressure Cam 26 Primary Gear Pulley 21 Exit Pawl Drive Cam Gear 27 Drum Drive Gear Pulley 22 Main Motor 28 Image Shift...

Page 335: ...canner D consists of the exposure lamp and the 1st mirror E A lamp stabilizer energizes the exposure lamp The light reflected by the reflector is of almost equal intensity to reduce shadows on pasted...

Page 336: ...scanning the scanners are always in their home positions when the scanner H P sensor H detects the 1st scanner The ADF motor feeds the original through the ADF In reduction enlargement mode changing t...

Page 337: ...remain off The main CPU can recognize the original size from the number of activated sensors Original Size Length Sensors Width Sensors A4 A3 version LT DLT version L1 L2 L3 L4 W1 W2 A3 11 x 17 O O O...

Page 338: ...ea A is a narrow strip at the start of the main scan line as shown As the scanner scans down the page the ECU board detects the peak white level for each scan line within this narrow strip only From t...

Page 339: ...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 ECU board The image data then goes to t...

Page 340: ...on Before scanning the original the machine reads a reference waveform from the white plate The average of the white video level for each pixel is stored as the white shading data in the FIFO memory i...

Page 341: ...scan direction lines parallel to the feed direction are emphasized When the filter is stronger in the sub scan direction lines at right angles to the feed direction are emphasized When the MTF filter...

Page 342: ...he 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 converts each pix...

Page 343: ...to specify how various areas of the original will be processed The user must be sure to scan the command sheets before the original The ECU board modulates the image data for the command sheet and the...

Page 344: ...unit it is necessary to readjust 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 t...

Page 345: ...are hands If this occurs clean the surface with alcohol Do not damage the heating elements Remove any foreign materials from the platen roller Remove foreign materials Do not touch the master film sur...

Page 346: ...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 347: ...to 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 348: ...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 349: ...r 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 th...

Page 350: ...in to feed the ejected master to the eject box while the drum turns towards the master making position The master eject sensor not shown is located just under the lower master eject roller and it moni...

Page 351: ...Eject Roller Unit Slide out Mechanism The master eject roller unit A can be slid out of the machine as shown for easy master jam removal The unit contains the master pick up roller upper and lower mas...

Page 352: ...r into 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...

Page 353: ...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 354: ...wer is necessary to return the solenoid to the initial position As a result the box remains locked when power is switched off A sensor not shown in this diagram detects the status of the lock mechanis...

Page 355: ...te rotates 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 m...

Page 356: ...e homing operation starts by turning the pressure plate toward the drum and then it returns to the home position The homing operation is as follows 1 The pressure plate turns clockwise as seen from th...

Page 357: ...the pressure plate again turns clockwise to return to the exact home position The home position sensor status changes now from off on off Shift to the Master Eject Position When the Start key is pres...

Page 358: ...o or very few masters in the box If there are no or only a few masters in the box the pressure plate can move to its lowest position The pressure plate limit position sensor detects this position The...

Page 359: ...n 7 seconds after the pressure plate starts traveling from the master eject ready position the pressure plate motor stops The pressure plate stays in the same position for 2 seconds to compress the ma...

Page 360: ...on When the pressure plate cannot travel past the master box full position from the master eject ready position this means that the master box is full In this case the home position sensor A remains a...

Page 361: ...ject start position A master eject jam occurs when the master eject sensor doesn t turn on at this time Master Eject The master eject sensor under the master eject roller detects master eject jams Whe...

Page 362: ...t Position Sensor turns on 2 After the motor turns on 4 5 seconds A3 master 3 5 seconds A4 master Number of HP Sensor On or Off Edges The first on edge is just after the motor starts 5 times Normal 4...

Page 363: ...e scanned image The 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 This is done because the used mas...

Page 364: ...ter Feed and Stop Control Edge Detection After the master making unit is inserted the master set sensor A detects the leading edge of the master The master is fed in reverse B until the master set sen...

Page 365: ...er feed control roller E and it stops This is the stand by position for master making NOTE 1 The master set mechanism does not start until the master set sensor A turns on If the sensor does not turn...

Page 366: ...62 C265 6 44 SM Master End Detection There is a solid fill black area at the end of the master roll When the master end sensor A detects this area the operation panel displays the master end message C...

Page 367: ...speed of rotation increases when the diameter of the master roll decreases From the measured speed of rotation the CPU calculates the remaining amount of master on the roll The display panel shows the...

Page 368: ...prevent the master from creasing Therefore the master between the platen roller and thermal head is always under tension There is a torque limiter E built into the tension roller drive gear This allo...

Page 369: ...ase cam position For details refer to the Replacement and Adjustment section Just before master making the platen release motor starts turning until the sensor is inactive this indicates that the plat...

Page 370: ...tion 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 drum reaches the mas...

Page 371: ...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 the drum guide movement The drum guide moves...

Page 372: ...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 roller turns and sends...

Page 373: ...feed the master synchronizing 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 cut...

Page 374: ...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 the...

Page 375: ...t is stopped At this time the master edge sensor is not used to detect when to stop the master The master edge sensor only controls the master stop position at the master feed control roller after a r...

Page 376: ...here the machine detects that there is a broken piece of master in the duct and a caution is shown on the display Opening the Door for Misfed Master Removal If pieces of the master remain in the maste...

Page 377: ...h switch detects when the unit is out The operation panel displays a message in this case Master Making Unit Lock Mechanism During master making or master feeding the master making unit lock solenoid...

Page 378: ...after 5 seconds Master set error The master end sensor is on and master set sensor is off after platen pressure is released Master will feed for 10mm when master set sensor is off Second master misfee...

Page 379: ...cut error is detected by master edge sensor OFF Cut error jam ON Service Call Cut after error This is for when the master could not be cut at first trial SC 300 Main motor lock occurs if the master is...

Page 380: ...p known as the doctor gap to supply a thin layer of ink on the screens and master F This machine uses the drum idling roller G to supply ink onto the screens and master before printing The length of t...

Page 381: ...upply mechanism is completely 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 Monitorin...

Page 382: ...remaining ink amount when the main switch is turned on if the remaining amount of ink is less than half The remaining ink is estimated from the number of revolutions of the ink pump Because of this w...

Page 383: ...e Detection There are also dip switches on the ink detection board see the diagram at the top of the next page To use these switches you must remove a cover 2 screws The settings depend on the drum ty...

Page 384: ...etection dip switch on the ink detection board A is set to color drum DIPSW 901 1 is off and 901 2 is on then you can set the DPS902 dip switches B to specify the ID of the color The connecter C is fo...

Page 385: ...ocation of color codes 0 1 2 3 4 5 6 7 8 Other Red Blue Green Brown Gray Yellow Purple Maroon 9 10 11 12 13 14 Navy Orange Teal Red Base Blue Base Yellow Base Default 0 other For example you install a...

Page 386: ...machine detects the ink before 26 seconds go to step 8 If the machine does not detect the ink before 26 seconds go to step 7 7 A blank master is wrapped around the drum and the drum and pressure cylin...

Page 387: ...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 is because the pressure cylinder below the dru...

Page 388: ...However if there is no master on the drum drum idling is not done Even if the Quality Start mode is active and there is no master on the drum drum idling is skipped although the LED on the operation...

Page 389: ...on if the thermistor A reports approximately 19 C or lower If the detected temperature is 29 C or higher it is a high temperature condition The number of drum idling rotations depends on temperature a...

Page 390: ...ation speed rpm with temperature Temperature Trial Print 1st Print 2nd Print 3rd Print 4th Print 5th Print 6th Print 7th Print High 29 C or higher 16 90 105 120 135 135 135 135 Normal 19 to 29 C 16 75...

Page 391: ...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 392: ...hold the drum When the upper grip A is pulled up it releases the drum locking mechanism Front Lock Lever When the drum is set correctly and the front lever C is raised the drum is locked into position...

Page 393: ...ions Drum Rotation Lock Mechanism The rotation stopper E prevents the drum from turning when it is removed from the machine When the drum is replaced contact with the rear frame disengages the stopper...

Page 394: ...DRUM C262 C265 6 72 SM 6 7 5 DRUM DRIVE MECHANISM C262D063 WMF C262D065 WMF C262D066 WMF A B C D E...

Page 395: ...tion of the drum 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...

Page 396: ...mines if the master making process correctly wrapped the master around the drum The drum starts turning soon after the drum master clamper clamps the leading edge of the master The 2nd drum master sen...

Page 397: ...home position is monitored by the drum home position sensor A Green LED B turns on when the drum is at the home position Red LED C warns that the drum is not at the home position NOTE 1 If the red LED...

Page 398: ...the operation panel Each component has a separate dc motor to adjust the pressure The operator is free from complicated adjustments for paper feed and separation pressures There are two friction pads...

Page 399: ...ller does not resist the paper feed To prevent a paper misfeed the feed speeds are changed to match the printing speed Since paper feed timing must be synchronized with pressure cylinder rotation so t...

Page 400: ...motor A rotates pulling or releasing the spring B through the rack C The lever D moves up or down depending on the tension of the spring If the spring is pulled the lever moves upwards reducing the pa...

Page 401: ...rated from the paper stack by the friction between the paper feed roller A and the friction pad B and fed to the registration roller The friction pad B is mounted on a block C and spring pressure is a...

Page 402: ...To use the normal pad A the friction pad shift motor C drives the rack D When friction pad position sensors 1 E and 2 F are both actuated the friction pad shift motor stops To use the custom pad B th...

Page 403: ...Standard double feed Standard paper type double feed likely Thick no feed Thick paper type non feed likely Thick double feed Thick paper type double feed likely Thick medium Thick paper type with inte...

Page 404: ...gher the pressure Feed pressure Jam Occurrence Separation pressure Jam Occurrence Paper Type Very few Some times Frequ ently Very few Some times Frequ ently Wing Guides Paper Clamp Standard 3 5 6 3 5...

Page 405: ...paper skew Paper feed timing must be synchronized with the pressure cylinder rotation so the registration motor on timing is maintained by the feed start sensor C A short time after the pressure cylin...

Page 406: ...ed to maintain the paper feed motor start timing This was mentioned earlier in Paper Feed Mechanism Image Up Down Shift Mode In addition the registration motor start timing is changed by pressing the...

Page 407: ...ased from the lower registration 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...

Page 408: ...turning a pre determined period after the sensor is activated by the paper The sensor is also used to detect jams Paper Slip Correction The paper feed timing sensor B is also used to detect paper jam...

Page 409: ...operates during printing and not for the trial print The retry is done only one time If paper is not fed then a misfeed occurs Paper feed retry m echani sm 1st drum position sensor Feed start sensor R...

Page 410: ...d paper can be removed easily The registration press motor B turns and pushes down the pin C This releases the pressure of the registration roller The registration roller press sensor D detects when t...

Page 411: ...e paper The sensor measures this at about 13 mm from the leading edge of the paper If the quantity of light becomes less the machine detects a double feed NOTE 1 Do not use paper that is printed on th...

Page 412: ...the registration sensor detects the paper quicker than normally If this occurs the paper feed motor stops until the correct time to feed the paper into the machine to prevent the paper from being fed...

Page 413: ...which are difficult 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 cutou...

Page 414: ...up or 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...

Page 415: ...Detection The 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...

Page 416: ...PAPER FEED C262 C265 6 94 SM 6 8 12 SIDE FENCE LOCK LEVER To prevent the side fences from moving during printing the user can push down the levers A C262D087 WMF A...

Page 417: ...otosensor is 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...

Page 418: ...paper table motor starts turning and lifts the paper table until the sensor is actuated again In this way the top of the paper stack remains at the same position during printing When the tray lowers...

Page 419: ...2 B Amount 3 C Lower limit D 25 ON ON OFF ON 1 OFF ON 1 OFF 50 ON OFF ON OFF ON 1 OFF 75 ON OFF OFF ON OFF 100 ON OFF OFF OFF OFF ON 1 1 Either OFF or ON NOTE The paper end sensor detects when the lev...

Page 420: ...imum length paper 447mm 1st drum position sensor Feed start sensor Paper registration sensor Paper feed motor 184 degrees 307 degrees 200 degrees 254 7 The maximum lenghtpaper 447mm is entered in the...

Page 421: ...imum length paper 447mm passes the registration roller at 254 7 degrees after drum home position At 200 degrees the previous sheet is still passing the paper feed roller Paper feed jam A jam Feed Star...

Page 422: ...ter 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 one for...

Page 423: ...e outer surface of the pressure cylinder and the encoder plate C for monitoring the speed of rotation is on the rear of the pressure cylinder The actuators for the feed start timing sensor are also on...

Page 424: ...f the cam B reaches the bearing C on the lever at the front end of the paper clamper and the clamper closes Shortly afterwards the bearing C reaches the low point D and the clamper opens to release th...

Page 425: ...essure release lever A Then the printing pressure release solenoid E can release the arms This occurs when the paper reaches the image transfer area When the arms are released the two printing pressur...

Page 426: ...st 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 427: ...o the paper and it is 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 op...

Page 428: ...and Feedback of Fluctuations in Pressure Cylinder Rotation Since the pressure cylinder does not have a perfectly circular cross section the rotation speed tends to fluctuate The feed encoder B which i...

Page 429: ...R DRIVE MECHANISM 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...

Page 430: ...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 for emergen...

Page 431: ...djust the support springs C to change the print pressure There are 6 pressure settings as shown below The print pressure HP sensor D detects the print pressure home position this is pressure level 2 T...

Page 432: ...sure adjustment mechanism is adjusted for the current temperature conditions The adjustment is done when the machine detects that the drum is at home position Then at the start of master making the pr...

Page 433: ...the machine counts for a few pulses from the feed encoder sensor number of pulses adjustable with SP 6 020 Then the registration motor turns on 5 The machine counts the pulses from starting the regist...

Page 434: ...ped around the pressure cylinder or entering under the delivery unit But if the paper is firmly stuck to the pressure cylinder the plate moves away to prevent damage The paper guide wings B help to fe...

Page 435: ...am follower on the exit pawl lever A rides on the cam The exit pawl is connected to the exit pawl lever The lever turns clockwise when the cam follower rides on the high point of the cam and the exit...

Page 436: ...ir knife fans A above the paper delivery unit These fans blow air against the leading edge of the paper that is just fed from the drum This helps to separate the paper from the drum The air knife fans...

Page 437: ...nder the pick off plate cannot remove it In this case the paper moves back the pick off plate and lifts it away from the pressure cylinder This prevents jams that are caused by the paper being stuck a...

Page 438: ...e is changed the motor automatically changes the angle of the wing guides The paper types that can be selected are standard thin thick and special Two additional settings for paper types can be custom...

Page 439: ...ngle of the small paper guide A on each side fence can be changed by pulling the small paper guide The small guides help to stack the paper more evenly on the table Both edges of the paper are guided...

Page 440: ...dges also make the paper fall more slowly and the ink dries before the paper reaches the stack The following table shows the recommended positions for these plates and for the paper guide wings for ea...

Page 441: ...ouches the top sheet of the paper stack Then the job separator motor turns on again to return the sliding arm Only the top sheet is moved and it is moved by about 25 mm The sliding arm stays in the sa...

Page 442: ...he 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 switch turns...

Page 443: ...escriptions 6 10 7 PAPER 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 pres...

Page 444: ...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 shaft E...

Page 445: ...rs when the paper exit sensor detects the paper twice Upper and lower wrapping jam B jam Feed start sensor Paper exit sensor Lower wrapping jam sensor 35 37 A B C The machine checks for jams at three...

Page 446: ...ition 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 co...

Page 447: ...e 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 448: ...the security mode unless you have permission from the administrator 6 12 3 SPECIFICATIONS OF SECURITY MODE The additional print feature cannot be used When security mode is disabled temporarily securi...

Page 449: ...be removed Not applicable Security button always enabled if Higher is selected Security Button Pressed Additional prints are not possible the administrator also cannot do this The drum cannot be remov...

Page 450: ...d This time is set with a user tool System Settings Timer Settings Energy Saver Timer There is also a timed auto off mode In this mode the machine will automatically go to auto off mode at a set time...

Page 451: ...per feed timing sensor are both on immediately after the main switch is turned on During printing paper upper wrapping is detected see section 6 14 3 but after the drum stops the paper feed timing sen...

Page 452: ...ensor 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 wrapp...

Page 453: ...d Timing Paper Exit Lower Wrapping Jam Display Not ON Paper misfeed A Not ON Paper registration misfeed A OFF Not ON OFF Paper upper wrapping misfeed B OFF Not ON ON Paper lower wrapping misfeed B Not...

Page 454: ...ys 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 reach...

Page 455: ...aten 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 Master Set Error Detection The maste...

Page 456: ...s Master 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...

Page 457: ...D ERROR DETECTION IN THE ADF Registration Sensor DF Feed Motor DF Feed Clutch Image Scanning Start L 150 mm Feed in Original Feed in Jam The sensor is still off 5 seconds after the motor turns on Orig...

Page 458: ...or 2 1 CN204 B8 B11 Sensor E Sensor A Sensor K Sensor C B9 B10 4 3 1 CN327 3 4 2 CN372 6 7 3 2 6 7 2 3 CN256 2 1 4 3 1 3 4 2 1 2 3 4 CN220 B5 B6 Master Eject Motor CN413 2 1 1 2 FAN 2 Air Knife Fan 1...

Page 459: ...86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 Terminal 12V 12V INK_SN 5V 5V 5V 5V 5V 5V 5V 5V 5V CGND CGND CGND CGND CGND CGND ENCO_CAT FEEDENCD FEEDMIDD PENTSN FEEDSTBK FEEDST PFEEDSN PSENTAN BANK_ON...

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