RICOH GROUP COMPANIES
A294/A295
SERVICE MANUAL
000902MIU
®
®
SERVICE MANUAL
A294/A295
RICOH GROUP COMPANIES
A294/A295
SERVICE MANUAL
000902MIU
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2000 RICOH Corporation. All rights reserved.
WARNING
The Service Manual contains information regarding
service techniques, procedures, processes and
spare parts of office equipment distributed by
Ricoh Corporation. Users of this manual should be
either service trained or certified by successfully
completing a Ricoh T echnical Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Corporation
LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
A294-I
A295-I
A294-II
A295-II
3285 Aficio 850 2085DP
32105 Aficio1050 2105DP
8502 Aficio 1085 2585
10502 Aficio 1105 25105
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 1/2000 Original Printing
1 7/2000 A295 Addition
29 / 2 0 0 1
A294-II/A295-II Addition
Rev. 10/2000
TABLE OF CONTENTS
OVERALL INFORMATION
1. OVERALL MACHINE INFORMATION........................................ 1-1
1.1 SPECIFICATIONS.....................................................................................1-1
1.1.1 COPIER ENGINE.............................................................................1-1
1.1.2 ADF ..................................................................................................1-4
1.2 MACHINE CONFIGURATION...................................................................1-5
1.3 COMPONENT LAYOUT............................................................................1-6
1.3.1 COPIER ENGINE.............................................................................1-6
1.3.2 ADF ..................................................................................................1-7
1.4 PAPER PATH............................................................................................1-8
1.5 COPY PROCESS......................................................................................1-9
1.6 DRIVE LAYOUT......................................................................................1-11
1.6.1 COPIER ENGINE...........................................................................1-11
1.6.2 ADF ................................................................................................1-12
1.7 ELECTRICAL COMPONENT DESCRIPTIONS......................................1-13
1.7.1 COPIER ENGINE...........................................................................1-13
1.7.2 ADF ................................................................................................1-19
DETAILED DESCRIPTIONS
2. DETAILED SECTION DESCRIPTIONS ...................................... 2-1
2.1 DOCUMENT FEEDER..............................................................................2-1
2.1.1 PICK-UP ROLLER RELEASE..........................................................2-1
2.1.2 BOTTOM PLATE LIFT......................................................................2-2
2.1.3 PICK-UP AND SEPARATION...........................................................2-3
2.1.4 ORIGINAL FEED..............................................................................2-4
2.1.5 ORIGINAL SIZE DETECTION.......................................................... 2-5
2.1.6 ORIGINAL TRANSPORT .................................................................2-6
2.1.7 ORIGINAL SKEW CORRECTION....................................................2-7
2.1.8 ORIGINAL INVERSION AND FEED-OUT........................................2-8
2.1.9 JAM CONDITIONS.........................................................................2-12
2.2 SCANNING..............................................................................................2-13
2.2.1 OVERVIEW....................................................................................2-13
2.2.2 SCANNER DRIVE..........................................................................2-14
2.2.3 ORIGINAL SIZE DETECTION IN BOOK MODE............................2-15
2.3 IMAGE PROCESSING............................................................................2-17
2.3.1 OVERVIEW....................................................................................2-17
2.3.2 SBU................................................................................................2-18
2.3.3 AUTO IMAGE DENSITY (ADS)......................................................2-19
2.3.4 IMAGE PROCESSING STEPS AND RELATED SP MODE...........2-20
2.3.5 AUTO SHADING ............................................................................2-26
2.3.6 BACKGROUND ERASE.................................................................2-27
2.3.7 INDEPENDENT DOT ERASE........................................................2-28
SM i A294A295
Rev. 10/2000
2.3.8 FILTERING, MAIN SCAN MAGNIFICATION/REDUCTION ...........2-29
2.3.9 GAMMA (γ ) CORRECTION............................................................2-31
2.3.10 GRADATION PROCESSING........................................................2-31
2.3.11 LINE WIDTH CORRECTION........................................................2-32
2.4 LASER EXPOSURE................................................................................2-33
2.4.1 OVERVIEW....................................................................................2-33
2.4.2 OPTICAL PATH..............................................................................2-34
2.4.3 AUTO POWER CONTROL (APC)..................................................2-35
2.4.4 FOUR BEAM LASER WRITING.....................................................2-36
2.4.5 LD SAFETY SWITCHES................................................................2-37
2.5 DRUM UNIT ............................................................................................2-38
2.5.1 PROCESS CONTROL....................................................................2-38
2.5.2 TONER DENSITY CONTROL........................................................2-43
2.5.3 DRUM UNIT COMPONENTS.........................................................2-46
2.5.4 DRIVE.............................................................................................2-47
2.5.5 DRUM CHARGE.............................................................................2-48
2.5.6 DRUM CLEANING..........................................................................2-50
2.5.7 OTHERS.........................................................................................2-53
2.6 DEVELOPMENT .....................................................................................2-56
2.6.1 OVERVIEW....................................................................................2-56
2.6.2 DEVELOPMENT MECHANISM......................................................2-57
2.6.3 DRIVE.............................................................................................2-58
2.6.4 CROSSMIXING..............................................................................2-59
2.6.5 DEVELOPMENT BIAS ...................................................................2-60
2.7 TONER SUPPLY AND RECYCLING.......................................................2-61
2.7.1 TONER BANK................................................................................2-61
2.7.2 SUPPLYING TONER TO THE DEVELOPMENT UNIT..................2-65
2.7.3 TONER HOPPER...........................................................................2-66
2.7.4 TONER RECYCLING AND WASTE TONER COLLECTION..........2-68
2.8 PAPER FEED ..........................................................................................2-71
2.8.1 OVERVIEW....................................................................................2-71
2.8.2 DRIVE.............................................................................................2-72
2.8.3 PAPER LIFT – TRAYS 2 & 3..........................................................2-73
2.8.4 PICK-UP AND FEED – TRAYS 1 TO 3..........................................2-75
2.8.5 REMAINING PAPER/
PAPER END DETECTION – TRAYS 2 & 3 ....................................2-79
2.8.6 PAPER SIZE DETECTION – TRAYS 2 & 3....................................2-80
2.8.7 TRAY LOCK – TRAYS 2 & 3..........................................................2-81
2.8.8 TANDEM FEED – TRAY 1 .............................................................2-82
2.8.9 VERTICAL TRANSPORT...............................................................2-89
2.8.10 PAPER REGISTRATION..............................................................2-90
2.9 IMAGE TRANSFER AND PAPER SEPARATION...................................2-93
2.9.1 OVERVIEW....................................................................................2-93
2.9.2 IMAGE TRANSFER AND PAPER SEPARATION..........................2-94
2.9.3 TRANSFER BELT UNIT LIFT.........................................................2-96
2.9.4 PAPER TRANSPORTATION AND BELT DRIVE...........................2-97
2.9.5 TRANSFER BELT CLEANING.......................................................2-98
2.9.6 TONER COLLECTION...................................................................2-99
2.9.7 TRANSFER ANTI-CONDENSATION HEATER............................2-100
A294/A295 ii SM
Rev. 10/2000
2.10 FUSING...............................................................................................2-101
2.10.1 OVERVIEW................................................................................2-101
2.10.2 FUSING ENTRANCE GUIDE.....................................................2-102
2.10.3 FUSING UNIT DRIVE................................................................. 2-103
2.10.4 FUSING LAMP CONTROL.........................................................2-104
2.10.5 OIL SUPPLY AND CLEANING................................................... 2-105
2.10.6 PAPER COOLING......................................................................2-106
2.10.7 FUSING PRESSURE .................................................................2-107
2.10.8 HOT ROLLER STRIPPER RELEASE........................................2-108
2.11 PAPER EXIT/DUPLEX........................................................................2-109
2.11.1 OVERVIEW................................................................................2-109
2.11.2 PAPER EXIT MECHANISM........................................................ 2-110
2.11.3 DUPLEX DRIVE MECHANISM...................................................2-111
2.11.4 INVERTER..................................................................................2-112
2.11.5 DUPLEX TRAY FEED MECHANISM .........................................2-114
2.11.6 BASIC DUPLEX FEED OPERATION.........................................2-115
2.12 ENERGY SAVER MODES..................................................................2-119
2.12.1 OVERVIEW................................................................................2-119
2.12.2 ENERGY SAVER (PANEL OFF) MODE ....................................2-120
2.12.3 LOW POWER MODE .................................................................2-121
2.12.4 OFF MODE.................................................................................2-122
2.12.5 SUMMARY .................................................................................2-124
2.13 OTHERS..............................................................................................2-125
2.13.1 OPERATION UNIT.....................................................................2-125
2.13.2 DOOR SAFETY SWITCH LOCK TOOLS...................................2-126
2.13.3 HDD CONTROL .........................................................................2-127
2.13.4 DATA PATH THROUGH THE INTERFACE BOARD.................2-129
INSTALLATION
3. INSTALLATION PROCEDURE................................................... 3-1
3.1 INSTALLATION REQUIREMENTS...........................................................3-1
3.1.1 ENVIRONMENT...............................................................................3-1
3.1.2 MACHINE LEVEL.............................................................................3-1
3.1.3 MINIMUM SPACE REQUIREMENTS...............................................3-2
3.1.4 POWER REQUIREMENTS..............................................................3-2
3.2 COPIER (A294).........................................................................................3-3
3.2.1 ACCESSORY CHECK......................................................................3-3
3.2.2 INSTALLATION PROCEDURE........................................................3-5
3.3 FINISHER INSTALLATION (B302)..........................................................3-13
3.3.1 ACCESSORY CHECK....................................................................3-13
3.3.2 INSTALLATION PROCEDURE......................................................3-14
3.4 LCT INSTALLATION (B303)....................................................................3-17
3.4.1 ACCESSORY CHECK....................................................................3-17
3.4.2 INSTALLATION PROCEDURE......................................................3-18
3.4.3 INSTALLATION PROCEDURE FOR THE TRAY HEATER KIT..3-19B
3.5 PUNCH UNIT INSTALLATION (A812)....................................................3-20
3.5.1 ACCESSORY CHECK....................................................................3-20
3.5.2 PUNCH UNIT INSTALLATION.......................................................3-21
SM iii A294A295
Rev. 9/2001
3.6 A3/DLT TRAY (B331)..............................................................................3-24
3.6.1 ACCESSORY CHECK....................................................................3-24
3.6.2 INSTALLATION PROCEDURE......................................................3-25
3.7 KEY COUNTER INSTALLATION............................................................3-28
3.8 INTERFACE BOARD
(CD-RW/TANDEM COPY KIT/PRINTER CONTROLLER)......................3-31
3.8.1 INSTALLATION PROCEDURE......................................................3-31
3.8.2 INSTALLATION NOTES FOR CD-R/RW .......................................3-32
3.9 TRANSPORTATION REMARKS.............................................................3-32
3.9.1 TONER TRANSPORT TUBE CLEANING ......................................3-32
SERVICE TABLES
4. SERVICE TABLES...................................................................... 4-1
4.1 GENERAL CAUTIONS..............................................................................4-1
4.1.1 DRUM...............................................................................................4-1
4.1.2 DRUM UNIT......................................................................................4-1
4.1.3 TRANSFER BELT UNIT...................................................................4-2
4.1.4 SCANNER UNIT ...............................................................................4-2
4.1.5 LASER UNIT.....................................................................................4-2
4.1.6 CHARGE CORONA..........................................................................4-3
4.1.7 DEVELOPMENT...............................................................................4-3
4.1.8 CLEANING.......................................................................................4-4
4.1.9 FUSING UNIT...................................................................................4-4
4.1.10 PAPER FEED.................................................................................4-4
4.1.11 USED TONER................................................................................4-4
4.2 SERVICE PROGRAM MODE....................................................................4-5
4.2.1 SERVICE PROGRAM MODE OPERATION.....................................4-5
4.2.2 SERVICE PROGRAM MODE TABLES..........................................4-10
4.2.3 TEST PATTERN PRINTING (SP2-902).........................................4-59
4.2.4 INPUT CHECK ...............................................................................4-60
4.2.5 OUTPUT CHECK ...........................................................................4-68
4.2.6 SYSTEM PARAMETER AND DATA LISTS (SMC LISTS).............4-70
4.2.7 MEMORY ALL CLEAR (SP5-801)..................................................4-70
4.2.8 SOFTWARE RESET ......................................................................4-71
4.2.9 SYSTEM SETTING AND
COPY SETTING (UP MODE) RESET............................................4-71
4.3 PM COUNTER ........................................................................................4-72
4.3.1 PM COUNTER ACCESS PROCEDURE........................................4-72
4.4 PROGRAM DOWNLOAD........................................................................4-78
4.5 NVRAM DATA DOWNLOAD...................................................................4-80
4.6 LANGUAGE DATA DOWNLOAD............................................................4-81
4.7 STAMP DATA DOWNLOAD....................................................................4-81
4.8 USER PROGRAM MODE .......................................................................4-82
4.8.1 HOW TO ENTER AND EXIT UP MODE.........................................4-82
4.8.2 UP MODE TABLE...........................................................................4-82
4.8.3 IMAGE QUALITY SETTING BY UP MODE....................................4-85
4.8.4 LEDS..............................................................................................4-91
A294/A295 iv SM
Rev. 9/2001
4.9 TEST POINTS/DIP SWITCHES/LEDS....................................................4-92
4.9.1 DIP SWITCHES..............................................................................4-92
4.9.2 TEST POINTS................................................................................4-93
4.9.3 FUSES............................................................................................4-93
4.9.4 VARIABLE RESISTORS ................................................................4-93
4.10 SPECIAL TOOLS AND LUBRICANTS..................................................4-94
4.10.1 SPECIAL TOOLS .........................................................................4-94
4.10.2 LUBRICANTS...............................................................................4-94
PREVENTIVE MAINTENANCE
5. PREVENTIVE MAINTENANCE SCHEDULE .............................. 5-1
5.1 PM PARTS................................................................................................5-1
REPLACEMENT AND ADJUSTMENT
6. REPLACEMENT AND ADJUSTMENT........................................ 6-1
6.1 EXTERIOR................................................................................................6-1
6.1.1 FRONT.............................................................................................6-1
6.1.2 RIGHT ..............................................................................................6-2
6.1.3 LEFT.................................................................................................6-3
6.1.4 REAR................................................................................................ 6-4
6.2 DOCUMENT FEEDER..............................................................................6-5
6.2.1 COVER REMOVAL ..........................................................................6-5
6.2.2 FEED UNIT REMOVAL AND
SEPARATION ROLLER REPLACEMENT .......................................6-7
6.2.3 FEED BELT REPLACEMENT..........................................................6-8
6.2.4 PICK-UP ROLLER REPLACEMENT................................................6-9
6.2.5 SENSOR REPLACEMENT.............................................................6-10
6.2.6 TRANSPORT BELT REPLACEMENT............................................6-14
6.2.7 MOTOR REPLACEMENT ..............................................................6-15
6.2.8 FEED-IN CLUTCH REPLACEMENT..............................................6-17
6.3 SCANNER UNIT......................................................................................6-18
6.3.1 EXPOSURE GLASS.......................................................................6-18
6.3.2 LENS BLOCK.................................................................................6-19
6.3.3 ORIGINAL SIZE SENSORS...........................................................6-20
6.3.4 EXPOSURE LAMP.........................................................................6-21
6.3.5 LAMP REGULATOR.......................................................................6-22
6.3.6 OPTICS DUST FILTER..................................................................6-23
6.3.7 SCANNER H.P. SENSOR..............................................................6-24
6.3.8 SCANNER MOTOR........................................................................6-25
6.3.9 SCANNER DRIVE WIRES .............................................................6-26
6.4 LASER UNIT ...........................................................................................6-29
6.4.1 CAUTION DECAL LOCATIONS.....................................................6-29
6.4.2 LDB AND LD FILTER REPLACEMENT .........................................6-30
6.4.3 POLYGON MIRROR MOTOR REPLACEMENT............................6-31
6.4.4 LASER SYNCHRONIZATION DETECTOR REPLACEMENT........6-32
SM v A294A295
Rev. 05/2004
6.5 DRUM UNIT ............................................................................................6-33
6.5.1 DRUM UNIT REMOVAL AND DRUM REPLACEMENT .................6-33
6.5.2 QUENCHING LAMP REPLACEMENT ...........................................6-34
6.5.3 GRID PLATE/CHARGE CORONA WIRE/
WIRE CLEANER REPLACEMENT.................................................6-35
6.5.4 DRUM POTENTIAL SENSOR REPLACEMENT ............................6-37
6.5.5 CLEANING BLADE/ID SENSOR REPLACEMENT ........................6-38
6.5.6 CLEANING BRUSH REPLACEMENT............................................6-39
6.5.7 PICK-OFF PAWL REPLACEMENT ................................................6-40
6.5.8 DRUM FILTER REPLACEMENT....................................................6-41
6.5.9 OPC DRUM CHANGE....................................................................6-41
6.6 DEVELOPMENT AND TONER SUPPLY ................................................6-42
6.6.1 DEVELOPMENT UNIT REMOVAL.................................................6-42
6.6.2 DEVELOPER REPLACEMENT ......................................................6-43
6.6.3 DEVELOPMENT AND AIR DUST FILTER REPLACEMENT .........6-45
6.6.4 DEVELOPMENT ENTRANCE, FRONT, & REAR SIDE SEALS ...6-46
6.6.5 TONER DENSITY SENSOR REPLACEMENT...............................6-47
6.6.6 TONER HOPPER SENSOR REPLACEMENT ...............................6-48
6.6.7 DEVELOPMENT MOTOR REPLACEMENT...................................6-49
6.6.8 DEVELOPMENT ROLLER SHAFT CLEANING .............................6-50
6.7 TRANSFER BELT UNIT..........................................................................6-51
6.7.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION ....................6-51
6.7.2 TRANSFER BELT REPLACEMENT...............................................6-53
6.7.3 TRANSFER BELT CLEANING BLADE REPLACEMTNT...............6-55
6.7.4 TRANSFER BELT BIAS BRUSH REPLACEMENT ........................6-56
6.8 PAPER FEED..........................................................................................6-57
6.8.1 PAPER TRAY REMOVAL ..............................................................6-57
6.8.2 PAPER FEED ROLLER REPLACEMENT......................................6-60
6.8.3 PAPER FEED AND VERTICAL TRANSPORT CLUTCH, AND
TRAY LIFT, PAPER FEED, AND
PAPER END SENSOR REMOVAL ...............................................6-61
6.8.4 REAR FENCE RETURN SENSOR REPLACEMENT.....................6-64
6.8.5 REAR FENCE HP SENSOR REPLACEMENT...............................6-65
6.8.6 RIGHT 1ST TRAY PAPER SENSOR REPLACMENT....................6-66
6.8.7 BOTTOM PLATE LIFT WIRE REPLACEMENT..............................6-67
6.8.8 PAPER DUST REMOVER CLEANING ..........................................6-69
6.8.9 REGISTRATION SENSOR CLEANING .........................................6-70
6.8.10 UNIVERSAL TRAY SIZE SWITCH REPLACEMENT ...................6-71
6.8.11 1ST TRAY LIFT MOTOR REMOVAL ...........................................6-72
6.8.12 LIFT MOTOR REMOVAL (2ND & 3RD TRAYS)...........................6-73
6.8.13 PAPER FEED MOTOR REMOVAL ..............................................6-74
6.8.14 RELAY MOTOR, UPPER RELAY CLUTCH,
LCT RELAY CLUTCH REMOVAL................................................6-75
6.8.15 REGISTRATION MOTOR REMOVAL..........................................6-76
6.8.16 COPIER FEED UNIT/DEVELOPMENT FAN MOTOR
REMOVAL....................................................................................6-77
6.8.17 LCT RELAY AND RELAY SENSOR REMOVAL ..........................6-78
6.8.18 TANDEM FEED TRAY PAPER SIZE CHANGE ...........................6-79
6.8.19 MECHANICAL SIDE REGISTRATION ADJUSTMENT ................6-82
A294/A295 vi SM
Rev. 2/2000
6.9 FUSING UNIT..........................................................................................6-83
6.9.1 OIL SUPPLY & CLEANING WEB UNIT REMOVAL.......................6-83
6.9.2 HOT ROLLER UNIT REMOVAL AND
PRESSURE ROLLER REPLACEMENT.........................................6-84
6.9.3 HOT ROLLER REPLACEMENT.....................................................6-86
6.9.4 OIL SUPPLY & CLEANING WEB REPLACEMENT.......................6-88
6.9.5 WEB CLEANING ROLLER REPLACEMENT.................................6-90
6.9.6 HOT ROLLER STRIPPER REPLACEMENT..................................6-91
6.9.7 PRESSURE ROLLER STRIPPER REPLACEMENT......................6-92
6.9.8 PRESSURE ROLLER CLEANING ROLLER REPLACEMENT ......6-93
6.9.9 FUSING AND EXIT UNIT REMOVAL.............................................6-94
6.9.10 FUSING PRESSURE ADJUSTMENT ..........................................6-95
6.10 PAPER EXIT/DUPLEX UNIT.................................................................6-96
6.10.1 EXIT SENSOR REPLACEMENT..................................................6-96
6.10.2 DUPLEX UNIT REMOVAL ...........................................................6-97
6.10.3 DUPLEX UNIT INNER COVER REMOVAL..................................6-98
6.10.4 JOGGER MOTOR REPLACEMENT ............................................6-99
6.10.5 DUPLEX UNIT CLUTCH REPLACEMENT.................................6-100
6.10.6 DUPLEX ENTRANCE SENSOR REPLACEMENT.....................6-101
6.10.7 DUPLEX TRANSPORT SENSORS 2 & 3 ..................................6-102
6.10.8 DUPLEX TRANSPORT SENSOR 1/
DUPLEX INVERTER SENSOR..................................................6-103
6.11 TONER BANK.....................................................................................6-104
6.11.1 WASTE TONER BOTTLE REMOVAL........................................6-104
6.11.2 TONER BANK UNIT REMOVAL.................................................6-105
6.11.3 TONER SUPPLY MOTOR AND
TONER SUPPLY MOTOR SENSOR REMOVAL.......................6-108
6.11.4 ACCESS TO INSIDE THE TONER BANK..................................6-109
6.12 BOARDS AND OTHER ITEMS ...........................................................6-110
6.12.1 SICU BOARD.............................................................................6-110
6.12.2 HARD DISK DRIVE....................................................................6-111
6.12.3 BCU BOARD..............................................................................6-112
6.12.4 I/O BOARD.................................................................................6-113
6.12.5 PSU............................................................................................6-114
6.12.6 CHARGE/GRID/BIAS POWER PACK........................................6-115
6.12.7 FUSING/DUPLEX MOTOR REPLACEMENT.............................6-116
6.12.8 DRUM MOTOR REPLACEMENT...............................................6-117
6.13 COPY IMAGE ADJUSTMENT: PRINTING/SCANNING......................6-118
6.13.1 PRINTING...................................................................................6-118
6.13.2 PARALLELOGRAM IMAGE ADJUSTMENT ..............................6-121
6.13.3 SCANNING.................................................................................6-123
6.13.4 ADF IMAGE ADJUSTMENT.......................................................6-124
6.14 TOUCH SCREEN CALIBRATION.......................................................6-125
SM vii A294A295
Rev. 9/2001
TROUBLESHOOTING
7. TROUBLESHOOTING ................................................................ 7-1
7.1 SERVICE CALL CONDITIONS .................................................................7-1
7.1.1 SUMMARY.......................................................................................7-1
7.1.2 SC CODE DESCRIPTIONS .............................................................7-2
7.2 ELECTRICAL COMPONENT DEFECTS.................................................7-37
7.2.1 SENSORS......................................................................................7-37
7.2.2 SWITCHES.....................................................................................7-41
7.3 BLOWN FUSE CONDITIONS .................................................................7-42
7.4 FIRMWARE HISTORY............................................................................7-43
7.4.1 A294 / A295 FIRMWARE MODIFICATION HISTORY....................7-43
3,000-SHEET FINISHER B302
1. OVERALL MACHINE INFORMATION........................................ 8-1
1.1 SPECIFICATIONS.....................................................................................8-1
1.2 MECHANICAL COMPONENT LAYOUT....................................................8-3
1.3 ELECTRICAL COMPONENT DESCRIPTION...........................................8-4
1.4 DRIVE LAYOUT........................................................................................8-6
2. DETAILED DESCRIPTIONS ....................................................... 8-7
2.1 TRAY AND STAPLER JUNCTION GATE.................................................8-7
2.2 PAPER PRE-STACKING...........................................................................8-8
2.3 JOGGER UNIT PAPER POSITIONING.....................................................8-9
2.4 STAPLER UNIT MOVEMENT.................................................................8-10
2.5 STAPLER................................................................................................ 8-12
2.6 FEED-OUT..............................................................................................8-14
2.7 SHIFT TRAY UP/DOWN MOVEMENT....................................................8-15
2.8 SHIFT TRAY SIDE-TO-SIDE MOVEMENT.............................................8-16
2.9 PUNCH UNIT DRIVE ..............................................................................8-17
2.10 PUNCH WASTE COLLECTION............................................................8-18
2.11 JAM CONDITIONS................................................................................8-19
3. SERVICE TABLES.................................................................... 8-20
3.1 DIP SWITCHES.......................................................................................8-20
3.2 TEST POINTS.........................................................................................8-20
3.3 FUSES.....................................................................................................8-20
4. REPLACEMENT AND ADJUSTMENT...................................... 8-21
4.1 COVER REPLACEMENT........................................................................8-21
4.2 POSITIONING ROLLER REPLACEMENT..............................................8-24
4.3 ALIGNMENT BRUSH ROLLER REPLACEMENT...................................8-25
4.4 SENSOR REPLACEMENT......................................................................8-26
4.4.1 STACK HEIGHT 1, 2 AND EXIT GUIDE OPEN SENSOR.............8-26
4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR........................8-27
4.4.3 SHIFT TRAY EXIT SENSOR..........................................................8-28
A294/A295 viii SM
Rev. 8/2000
4.4.4 ENTRANCE AND
STAPLER TRAY ENTRANCE SENSORS .....................................8-29
4.4.5 PRE-STACK STOPPER SENSOR.................................................8-30
4.4.6 STAPLE WASTE HOPPER SENSOR............................................8-31
4.4.7 STAPLER ROTATION HP AND
STAPLER RETURN SENSORS.....................................................8-32
4.5 STAPLER REMOVAL..............................................................................8-33
4.6 PUNCH POSITION ADJUSTMENT.........................................................8-34
4.7 ROM HISTORY.......................................................................................8-35
4.7.1 FIRMWARE MODIFICATION HISTORY........................................8-35
LARGE CAPACITY TRAY B303
1. OVERALL MACHINE INFORMATION........................................ 9-1
1.1 SPECIFICATIONS.....................................................................................9-1
1.2 MECHANICAL COMPONENT LAYOUT....................................................9-2
1.3 ELECTRICAL COMPONENT DESCRIPTIONS........................................9-3
1.4 DRIVE LAYOUT........................................................................................9-5
2. DETAILED DESCRIPTIONS ....................................................... 9-6
2.1 PAPER FEED ............................................................................................9-6
2.2 PICK-UP AND FEED.................................................................................9-7
2.2.1 OVERVIEW......................................................................................9-7
2.2.2 PICK-UP AND FEED........................................................................9-8
2.2.3 SEPARATION ROLLER RELEASE..................................................9-9
2.3 PAPER LIFT............................................................................................9-10
2.3.1 TRAY DETECTION ........................................................................9-10
2.3.2 LIFT MECHANISM .........................................................................9-10
2.3.3 LIFT SENSOR................................................................................9-11
2.4 PAPER SIZE DETECTION......................................................................9-12
2.5 PAPER END DETECTION......................................................................9-13
3. REPLACEMENT AND ADJUSTMENT...................................... 9-14
3.1 EXTERIOR COVER REMOVAL..............................................................9-14
3.2 INNER COVER REMOVAL.....................................................................9-15
3.3 PAPER FEED ROLLER REPLACEMENT...............................................9-16
3.4 LCT MOTOR REPLACEMENT................................................................9-17
3.5 RELAY SENSOR REPLACEMENT.........................................................9-18
3.6 PAPER HEIGHT SENSOR AND
PAPER SIZE SWITCH REPLACEMENT.................................................9-19
3.7 MAIN DRIVE BELT REPLACEMENT......................................................9-20
3.8 SIDE REGISTRATION ADJUSTMENT...................................................9-21
SM ix A294A295
Rev. 9/2001
A3/DLT TRAY KIT B331
1. OVERALL MACHINE INFORMATION...................................... 10-1
1.1 SPECIFICATIONS...................................................................................10-1
2. DETAILED DESCRIPTIONS ..................................................... 10-2
2.1 SECTIONAL DESCRIPTION...................................................................10-2
3. REPLACEMENT AND ADJUSTMENT...................................... 10-3
3.1 BOTTOM PLATE LIFT WIRE REPLACEMENT ......................................10-3
DIFFERENCES FROM THE A294 I / A295 I MODELS
1 DETAILED SECTION DESCRIPTIONS ..................................... 11-1
1.1 TONER AND DEVELOPER.....................................................................11-1
1.2 NEWLY ADDED: DEVELOPMENT SUCTION MOTOR AND
SUCKED TONER COLLECTION BOTTLE.............................................11-1
1.3 DEVELOPMENT UNIT............................................................................11-2
1.4 TONER BANK UNIT................................................................................11-3
1.5 CLEANING UNIT..................................................................................... 11-3
1.6 FUSING UNIT..........................................................................................11-4
1.7 NEW ADDITIONS TO TRANSFER CURRENT CONTROL.....................11-5
1.8 CHARGE CORONA UNIT.......................................................................11-6
1.9 ELECTRICAL COMPONENTS................................................................11-6
1.10 SOFTWARE..........................................................................................11-8
2 SERVICE TABLES..................................................................... 11-9
2.1 SERVICE PROGRAM MODE..................................................................11-9
3 PREVENTIVE MAINTENANCE SCHEDULE ........................... 11-13
3.1 PM PARTS............................................................................................11-13
4 TROUBLESHOOTING ............................................................. 11-14
4.1 SERVICE CALL CONDITIONS .............................................................11-14
A294/A295 x SM
!
IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the copier power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that some components of the copier and the paper tray unit are
supplied with electrical voltage even if the main power switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers off
or open while the main switch is turned on, keep hands away from electrified
or mechanically driven components.
5. If the Start key is pressed before the copier completes the warm-up period
(the Start key starts blinking red and green alternatively), keep hands away
from the mechanical and the electrical components as the copier starts
making copies as soon as the warm-up period is completed.
6. The inside and the metal parts of the fusing unit become extremely hot while
the copier is operating. Be careful to avoid touching those components with
your bare hands.
HEALTH SAFETY CONDITIONS
1. Never operate the copier without the ozone filters installed.
2. Toner and developer are non-toxic, but if you get either of them in your eyes
by accident, it may cause temporary eye discomfort. Try to remove with eye
drops or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on
those models.
2. The NVRAM on the SICU has a lithium battery which can explode if replaced
incorrectly. Replace the NVRAM only with an identical one. The
manufacturer recommends replacing the entire NVRAM. Do not recharge or
burn this battery. Used NVRAM must be handled in accordance with local
regulations.
SM 1 A294/A295
SAFETY AND ECOLOGICAL
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly
when exposed to an open flame.
2. Dispose of used toner, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, do not
put more than 100 batteries per sealed box. Storing larger numbers or not
sealing them apart may lead to chemical reactions and heat build-up.
NOTES
FOR DISPOSAL
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of
laser-based optical units in the field. The optical housing unit can only be repaired
in a factory or at a location with the requisite equipment. The laser subsystem is
replaceable in the field by a qualified Customer Engineer. The laser chassis is not
repairable in the field. Customer engineers are therefore directed to return all
chassis and laser subsystems to the factory or service depot when replacement of
the optical subsystem is required.
!
WARNING
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
!
WARNING
WARNING: Turn off the main switch before attempting any of the
procedures in the Laser Unit section. Laser beams can
seriously damage your eyes.
CAUTION MARKING:
A294/A295 2 SM
OVERALL INFORMATION A294/A295
Rev. 9 /2001
LARGE CAPACITY TRAY B303
DETAILED DESCRIPTIONS A294/A295
A3/DLT TRAY KIT B331
INSTALLATION A294/A295
DIFFERENCES FROM A294 I/A295 I
SERVICE TABLES A294/A295
TAB
POSITION 1
TAB
POSITION 2
TAB
POSITION 3
TAB
POSITION 4
PREVENTIVE MAINTENANCE A294/A295
REPLACEMENT AND ADJUSTMENT A294/A295
TROUBLESHOOTING A294/A295
3,000-SHEET FINISHER B302
TAB
POSITION 5
TAB
POSITION 6
TAB
POSITION 7
TAB
POSITION 8
OVERALL INFORMATION
1. OVERALL MACHINE INFORMATION
SPECIFICATIONS
1.1 SPECIFICATIONS
1.1.1 COPIER ENGINE
Configuration: Console
Copy Process: Dry electrostatic transfer system
Originals: Sheet/Book
Original Size: Maximum: A3/11" x 17"
Minimum: A5, 5
Original Alignment: Rear left corner
Paper Size/Weight:
Size: Mainframe, Tray 1 (Tandem Tray):
A4 sideways and LT sideways
Mainframe, Trays 2 and 3 (Universal Trays):
Europe/Asia:
A5 sideways - A3 lengthwise,
8-kai sideways, 16-kai
N. America:
5
" x 8
1/2
LCT, Trays 4 ~ 6:
A4 sideways, B5 sideways, LT sideways, A5, HLT
Duplex Tray: A5/HLT (lengthwise or sideways)
"x 8
1/2
" sideways - 11" x 17" lengthwise
1/2
" (using ADF)
1/2
to A3/DLT, except that tab paper cannot
be used
Overall
Information
Weight: Mainframe, Trays 1 to 3:
52 to 163 g/m
2
16 to 40 lbs Bond
50 to 60 lbs Cover
90 lbs Index (no Tab)
LCT, Trays 4 and 5:
52 to 216 g/m
2
16 to 40 lbs Bond
50 to 80 lbs Cover
90 to 110 lbs Index
LCT, Tray 6:
Same as Mainframe, Trays 1 to 3
Duplex Tray:
64 to 163 g/m
2
20 to 40 lbs Bond
50 to 60 lbs Cover
90 lbs Index (no Tab)
SM 1-1 A294/A295
SPECIFICATIONS
Reproduction Ratios: 7 reduction and 5 enlargement
Metric Version Inch Version
400%
200%
Enlargement
Full Size 100% 100%
Reduction
141%
122%
115%
93%
82%
75%
71%
65%
50%
25%
Zoom: 25 ~ 400%
Rev. 6/2000
400%
200%
155%
129%
121%
93%
85%
78%
73%
65%
50%
25%
Copy Speed: A294: Max. 85 CPM (A4/8
A295: Max. 105 CPM (A4/8
" x 11" sideways)
1/2
" x 11" sideways)
1/2
Resolution: Scanning: 600 dpi
Printing: 600 dpi
Gradation: 256 levels
Warm-up Time: Less than 360 s (from Off mode)
First Copy Time:
(1st Tray, A4 sideways)
Finisher upper tray: face down
A294: Less than 5.4 s
A295: Less than 4.9 s
Finisher upper tray: face up
A294: Less than 4.1 s
A295: Less than 3.8 s
Copier: face down
A294: Less than 4.5 s
A295: Less than 4.2 s
Copier: face up
A294: Less than 3.2 s
A295: Less than 2.9 s
Copy Number Input: Ten-key pad, 1 to 9999
Copy Paper Capacity: 1st Tray: 1,000 sheets (2,000 when used as a tandem
tray)
2nd/3rd Tray: 500 sheets each
4th/5th Tray (LCT): 1,000 sheets each
6th Tray (LCT): 2,500 sheets
Memory Capacity: A294: RAM: 48 MB x 2, HDD: 4.3 GB x 2
A295: RAM: 48 MB x 2, HDD: 6.8 GB x 2
Toner Replenishment: Cartridge exchange (1,450 g/cartridge)
A294/A295 1-2 SM