Aficio B064, B065, B140, B141, B163 Service Manual

...

MODEL MT-C1

Machine Code: B064/B065

MODEL MT-C2

Machine Code:

B140/B141/B163/B142/B143/B228

MODEL MT-C3/C3.5

Machine Code:

B246/B248/B249/B250/B252/B253/

D052/D053/D054

SERVICE MANUAL

February 2008

Subject to Change

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged.

2. The wall outlet should be near the copier and easily accessible.

3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off.

4. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components.

5. If the Start key is pressed before the copier completes the warm-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed.

6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands.

HEALTH SAFETY CONDITIONS

1. Never operate the copier without the ozone filters installed.

2. Always replace the ozone filters with the specified ones at the specified intervals.

3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models.

2. The NVRAM on the system control board has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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.

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:

What This Manual Contains

This preliminary manual describes the installation procedures for the B064/B140/B246 Series Copiers and their peripheral devices:

Conventions in this Manual

This manual describes more than one machine.

The following short notations are used in text to refer to the following machines.

Short Notations What They Mean

B064 Series

B140 Series

B246 Series

B064/B065

B140/B141/B142/B143/B163/B228

B246/B248/B249/B250/B252/B253

This manual uses several symbols.

Symbol What it means









  =

Refer to section number See Core Tech Manual for

details Screw Connector E-ring Clip ring Clamp

Long Edge Feed (LEF)Short Edge Feed (SEF)

1. INSTALLATION .......................................................................................................................... 1-1

1.1 INSTALLATION REQUIREMENTS ..................................................................................... 1-1

1.1.1 OPERATING ENVIRONMENT .................................................................................. 1-1

1.1.2 MACHINE LEVEL ...................................................................................................... 1-2

1.1.3 MINIMUM SPACE REQUIREMENTS ....................................................................... 1-3

1.1.4 DIMENSIONS ............................................................................................................ 1-4

B064 Series................................................................................................................... 1-4

B140 Series................................................................................................................... 1-5

B246 Series................................................................................................................... 1-6

1.1.5 PERIPHERAL/OPTION SUMMARY TABLE ............................................................. 1-7

1.1.6 POWER REQUIREMENTS ....................................................................................... 1-9

1.2 MAIN MACHINE (B064 SERIES/B140 SERIES/B246 SERIES)....................................... 1-10

1.2.1 ACCESSORY CHECK............................................................................................. 1-10

1.2.2 INSTALLATION PROCEDURE ............................................................................... 1-11

Removing Tapes and Retainers ................................................................................. 1-11

Connecting the ADF.................................................................................................... 1-14

Removing and Filling the Development Unit............................................................... 1-14

Re-installing the Development Unit ............................................................................ 1-17

Initializing the Drum Settings (B064 Series) ............................................................... 1-18

Initializing the Drum Settings (B140/B246 Series)...................................................... 1-19

Tandem Tray............................................................................................................... 1-20

Machine Level............................................................................................................. 1-22

Date/Time Setting ....................................................................................................... 1-22

SP Codes .................................................................................................................... 1-22

1.3 A3/DLT FEEDER KIT (B475)............................................................................................. 1-23

1.3.1 ACCESSORY CHECK............................................................................................. 1-23

1.3.2 INSTALLATION PROCEDURE ............................................................................... 1-24

1.4 LCT (B473)......................................................................................................................... 1-26

1.4.1 ACCESSORY CHECK............................................................................................. 1-26

1.4.2 INSTALLATION PROCEDURE ............................................................................... 1-27

Removing Tape........................................................................................................... 1-27

Preparing the Main Machine ....................................................................................... 1-28

Installing the LCT ........................................................................................................ 1-28

1.5 LG/B4 FEEDER KIT (B474)............................................................................................... 1-31

1.5.1 ACCESSORY CHECK............................................................................................. 1-31

1.5.2 INSTALLATION PROCEDURE ............................................................................... 1-32

1.6 3000-SHEET FINISHERS (B468/B469/B674)................................................................... 1-35

1.6.1 ACCESSORY CHECK............................................................................................. 1-35

1.6.2 INSTALLATION PROCEDURE ............................................................................... 1-36

Removing Tapes and Retainers ................................................................................. 1-36

Installation................................................................................................................... 1-38

Selecting the Staple Supply Name ............................................................................. 1-41

Enabling Booklet Binding ............................................................................................ 1-41

1.7 PUNCH UNIT (B377) ......................................................................................................... 1-42

1.7.1 ACCESSORY CHECK............................................................................................. 1-42

1.7.2 INSTALLATION PROCEDURE ............................................................................... 1-43

1.8 COVER INTERPOSER TRAY (B470) ............................................................................... 1-45

1.8.1 ACCESSORY CHECK............................................................................................. 1-45

1.8.2 INSTALLATION PROCEDURE ............................................................................... 1-46

Removing Tapes and Retainers ................................................................................. 1-46

Attaching the Extensions ............................................................................................ 1-48

Attaching the Interposer Tray...................................................................................... 1-49

Attaching the Corner Plates for the B478/B706.......................................................... 1-50

Right Rear Corner Plate (B478/B706 only)................................................................. 1-50

Right Front Corner Plate (B478/B706 only) ................................................................ 1-51

Attaching the Finisher to the Machine ........................................................................ 1-52

1.9 9-BIN MAILBOX (B471) ..................................................................................................... 1-54

1.9.1 ACCESSORY CHECK............................................................................................. 1-54

1.9.2 INSTALLATION PROCEDURE ............................................................................... 1-55

Removing Tapes and Retainers ................................................................................. 1-55

Installation................................................................................................................... 1-56

1.10 3000 SHEET FINISHER (B478/B706)............................................................................. 1-58

1.10.1 ACCESSORY CHECK........................................................................................... 1-58

1.10.2 INSTALLATION ..................................................................................................... 1-59

1.11 PUNCH UNIT (B531/B812).............................................................................................. 1-63

1.11.1 ACCESSORY CHECK........................................................................................... 1-63

1.11.2 INSTALLATION ..................................................................................................... 1-64

1.12 JOGGER UNIT (B513)..................................................................................................... 1-68

1.12.1 ACCESSORY CHECK........................................................................................... 1-68

1.12.2 INSTALLATION PROCEDURE ............................................................................. 1-69

1.13 Z-FOLDING UNIT (B660)................................................................................................. 1-70

1.13.1 ACCESSORY CHECK........................................................................................... 1-70

1.13.2 INSTALLATION PROCEDURE ............................................................................. 1-71

Before You Begin........................................................................................................ 1-71

Unpacking ................................................................................................................... 1-72

Docking to the Finisher ............................................................................................... 1-73

Docking to the Main Frame......................................................................................... 1-76

1.14 2000/3000 SHEET FINISHERS (B700/B701) ................................................................. 1-78

1.14.1 ACCESSORIES ..................................................................................................... 1-78

1.14.2 INSTALLATION PROCEDURE ............................................................................. 1-79

Removing Tapes and Retainers ................................................................................. 1-79

Docking the Finisher ................................................................................................... 1-82

Attaching the Trays ..................................................................................................... 1-85

Leveling the Finisher................................................................................................... 1-86

Selecting the Staple Supply Name ............................................................................. 1-87

Enabling Booklet Binding (B700 Only)........................................................................ 1-87

Auxiliary Trays............................................................................................................. 1-88

1.15 PUNCH UNIT (B702) ....................................................................................................... 1-90

1.15.1 ACCESSORIES ..................................................................................................... 1-90

1.15.2 INSTALLATION PROCEDURE ............................................................................. 1-91

1.16 COVER INTERPOSER TRAY (B704) ............................................................................. 1-94

1.16.1 ACCESSORIES ..................................................................................................... 1-94

1.16.2 INSTALLATION PROCEDURE ............................................................................. 1-95

Removing Tapes and Retainers ................................................................................. 1-95

Preparing the Finisher (B700/B701/B706).................................................................. 1-96

Attaching the Extensions for the B706........................................................................ 1-97

Prepare the Cover Interposer for the B706................................................................. 1-98

Attach the Extensions to the B706.............................................................................. 1-99

Attaching the Extensions for the B700/B701 ............................................................ 1-100

Attaching the Interposer Tray (B700/B701/ B706).................................................... 1-101

Attaching the Corner Plates for the B706 ................................................................. 1-102

Docking the Finisher and Interposer to the Machine (B700/B701/B706) ................. 1-104

1.17 OUTPUT JOGGER UNIT (B703)................................................................................... 1-106

1.17.1 ACCESSORIES ................................................................................................... 1-106

1.17.2 INSTALLATION PROCEDURE ........................................................................... 1-107

1.18 MAIL BOX (B762) .......................................................................................................... 1-109

1.18.1 ACCESSORY CHECK......................................................................................... 1-109

1.18.2 INSTALLATION PROCEDURE ........................................................................... 1-110

1.19 COPY TRAY (B756)....................................................................................................... 1-113

1.19.1 ACCESSORIES ................................................................................................... 1-113

1.19.2 INSTALLATION ................................................................................................... 1-114

1.20 KEY CARD BRACKET (B498), KEY COUNTER BRACKET (B452)............................. 1-117

1.20.1 KEY CARD BRACKET B498 ACCESSORIES.................................................... 1-117

1.20.2 KEY COUNTER BRACKET B452 ACCESSORIES ............................................ 1-118

1.20.3 INSTALLATION ................................................................................................... 1-119

Assemble the Key Counter Bracket.......................................................................... 1-119

Install the Key Card Bracket and Assembled Key Counter ...................................... 1-120

1.21 COPY CONNECTOR KITS............................................................................................ 1-122

1.21.1 COPY CONNECTOR KIT (B525-10, -12) FOR B064 SERIES ........................... 1-122

ACCESSORY CHECK.............................................................................................. 1-123

Installation................................................................................................................. 1-124

Installing the Hardware ............................................................................................. 1-125

1.21.2 COPY CONNECTOR KIT (B328-03) FOR B140 SERIES .................................. 1-129

ACCESSORY CHECK.............................................................................................. 1-129

Preparation................................................................................................................ 1-130

Installation................................................................................................................. 1-131

1.21.3 COPY CONNECTOR (B842) FOR B246 SERIES .............................................. 1-134

Accessories............................................................................................................... 1-134

Preparation................................................................................................................ 1-135

Installation................................................................................................................. 1-136

1.22 MFP OPTIONS: B064 SERIES...................................................................................... 1-139

1.22.1 PRINTER/SCANNER KIT (G338), PRINTER KIT (G339)................................... 1-139

ACCESSORY CHECK.............................................................................................. 1-139

1.22.2 INSTALLATION PROCEDURE ........................................................................... 1-140

Inserting DIMMs........................................................................................................ 1-140

Installation Procedure ............................................................................................... 1-141

1.22.3 PS3 (B525-08) ..................................................................................................... 1-143

1.22.4 USB 2.0 (B525-01)............................................................................................... 1-144

ACCESSORY CHECK.............................................................................................. 1-144

Installation Procedure ............................................................................................... 1-144

USB SP Settings....................................................................................................... 1-145

1.22.5 IEEE1394 (G561) FIREWIRE INTERFACE ........................................................ 1-146

ACCESSORY CHECK.............................................................................................. 1-146

Installation Procedure ............................................................................................... 1-147

UP Mode Settings for IEEE 1394 ............................................................................. 1-148

SP Mode Settings for IEEE 1394.............................................................................. 1-149

1.22.6 IEEE802.11B WIRELESS LAN (G628) ............................................................... 1-150

ACCESSORY CHECK.............................................................................................. 1-150

Installation Procedure ............................................................................................... 1-151

UP Mode Settings for Wireless LAN......................................................................... 1-152

SP MODE SETTINGS FOR 802.11B WIRELESS LAN.......................................................... 1-154

1.22.7 FILE FORMAT CONVERTER (MLB) (B519)....................................................... 1-155

Accessory Check ......................................................................................................1-156

Installation Procedure ............................................................................................... 1-156

Installing the Firmware.............................................................................................. 1-156

Installing the Hardware ............................................................................................. 1-157

iii

1.23 MFP OPTIONS: B140 SERIES...................................................................................... 1-158

1.23.1 MERGING APPLICATIONS ON ONE SD CARD................................................ 1-158

Overview ................................................................................................................... 1-158

Merging Applications................................................................................................. 1-159

Undo Exec................................................................................................................. 1-160

1.23.2 OVERVIEW.......................................................................................................... 1-161

1.23.3 PRINTER/SCANNER KIT (B659) ........................................................................ 1-162

ACCESSORY CHECK.............................................................................................. 1-162

Installation................................................................................................................. 1-163

1.23.4 PS3 (B525-15) ..................................................................................................... 1-166

ACCESSORY CHECK.............................................................................................. 1-166

Installation................................................................................................................. 1-166

1.23.5 USB 2.0 INTERFACE BOARD (B596-01) ........................................................... 1-167

ACCESSORY CHECK.............................................................................................. 1-167

Installation................................................................................................................. 1-167

1.23.6 IEEE 1394 INTERFACE BOARD (B581-01) ....................................................... 1-168

ACCESSORY CHECK.............................................................................................. 1-168

Installation................................................................................................................. 1-168

1.23.7 IEEE 802.11B INTERFACE BOARD (B582-01, -02)........................................... 1-169

ACCESSORY CHECK.............................................................................................. 1-169

Installation................................................................................................................. 1-169

1.23.8 BLUETOOTH INTERFACE UNIT (G377)............................................................ 1-171

ACCESSORY CHECK.............................................................................................. 1-171

Installation................................................................................................................. 1-171

1.23.9 FILE FORMAT CONVERTER (B609).................................................................. 1-172

ACCESSORY CHECK.............................................................................................. 1-172

Installation................................................................................................................. 1-172

1.23.10 DATA OVERWRITE SECURITY UNIT (B735).................................................. 1-173

ACCESSORY CHECK.............................................................................................. 1-173

Before You Begin… .................................................................................................. 1-173

Seal Check And Removal ......................................................................................... 1-174

Installation Procedure ............................................................................................... 1-175

1.24 MFP OPTIONS: B246 SERIES...................................................................................... 1-178

1.24.1 OVERVIEW.......................................................................................................... 1-178

1.24.2 COMMON PROCEDURES.................................................................................. 1-179

Inserting SD Cards.................................................................................................... 1-179

Storing Copied SD Cards.......................................................................................... 1-179

1.24.3 PRINTER SCANNER KIT (B841) ........................................................................ 1-180

ACCESSORY CHECK.............................................................................................. 1-180

Installation................................................................................................................. 1-181

1.24.4 POSTSCRIPT3 (B525) ........................................................................................ 1-184

Accessories............................................................................................................... 1-184

Installation................................................................................................................. 1-184

1.24.5 IEEE1394 INTERFACE BOARD (B581).............................................................. 1-185

Accessories............................................................................................................... 1-185

Installation................................................................................................................. 1-185

1.24.6 WIRELESS LAN G813 (802.11B)........................................................................ 1-186

Accessories............................................................................................................... 1-186

Installation................................................................................................................. 1-186

1.24.7 BLUETOOTH INTERFACE UNIT TYPE C B826 ................................................ 1-187

Accessories............................................................................................................... 1-187

Installation................................................................................................................. 1-187

1.24.8 FILE FORMAT CONVERTER TYPE C B609...................................................... 1-188

ACCESSORY CHECK.............................................................................................. 1-188

Installation................................................................................................................. 1-188

1.24.9 DATA OVERWRITE SECURITY UNIT TYPE C B735 ........................................ 1-189

ACCESSORY CHECK.............................................................................................. 1-189

Before You Begin… .................................................................................................. 1-189

Seal Check And Removal ......................................................................................... 1-190

Installation Procedure ............................................................................................... 1-191

1.24.10 REMOTE COMMUNICATION GATE TYPE CM1 (B818) ................................. 1-194

Accessories............................................................................................................... 1-194

Installation................................................................................................................. 1-194

1.24.11 USB HOST INTERFACE UNIT TYPE A (B825)................................................ 1-197

Accessory Check ......................................................................................................1-197

Installation................................................................................................................. 1-197

1.24.12 BROWSER UNIT TYPE B (B828) ..................................................................... 1-198

Accessories............................................................................................................... 1-198

Installation................................................................................................................. 1-198

1.24.13 COPY DATA SECURITY UNIT TYPE C (B829) ............................................... 1-199

Accessories............................................................................................................... 1-199

Installation................................................................................................................. 1-199

B246 Series: IPU ...................................................................................................... 1-199

1.24.14 VM CARD (B861)............................................................................................... 1-201

Accessories............................................................................................................... 1-201

Installation................................................................................................................. 1-201

1.24.15 IEEE1284 B679 ................................................................................................. 1-202

Accessories............................................................................................................... 1-202

Installation................................................................................................................. 1-202

1.24.16 GIGABIT ETHERNET G381 .............................................................................. 1-203

Accessories............................................................................................................... 1-203

Installation................................................................................................................. 1-203

2. PREVENTIVE MAINTENANCE .................................................................................................. 2-1

2.1 PM TABLES ......................................................................................................................... 2-1

2.1.1 MAIN MACHINE ........................................................................................................ 2-1

2.1.2 ADF............................................................................................................................ 2-5

2.1.3 OPTIONAL PERIPHERAL DEVICES ........................................................................ 2-5

LCT (Large Capacity Tray) B473.................................................................................. 2-5

Cover Interposer Tray B470.......................................................................................... 2-5

3000-Sheet Finisher with 50-sheet stapler and Saddle-Stitching B468/B469/B674 .... 2-6

3000-Sheet Finisher B478/B706................................................................................... 2-6

Z-Folding Unit Type 2105 (B660) ................................................................................. 2-6

2000/3000-Sheet Booklet Finisher B700/B701............................................................. 2-7

Punch B702................................................................................................................... 2-7

2.2 RELATED SP CODES......................................................................................................... 2-7

3. REPLACEMENT AND ADJUSTMENT....................................................................................... 3-1

3.1 GENERAL CAUTIONS ........................................................................................................ 3-1

3.1.1 DRUM ........................................................................................................................ 3-1

3.1.2 DRUM UNIT............................................................................................................... 3-1

3.1.3 TRANSFER BELT UNIT ............................................................................................ 3-2

3.1.4 SCANNER UNIT ........................................................................................................ 3-2

3.1.5 LASER UNIT.............................................................................................................. 3-2

3.1.6 CHARGE CORONA................................................................................................... 3-3

3.1.7 DEVELOPMENT........................................................................................................ 3-3

3.1.8 CLEANING.................................................................................................................3-4

3.1.9 FUSING UNIT ............................................................................................................ 3-4

3.1.10 PAPER FEED .......................................................................................................... 3-4

3.1.11 USED TONER ......................................................................................................... 3-4

3.2 SPECIAL TOOLS AND LUBRICANTS......................................................................... 3-5

3.2.1 SPECIAL TOOLS....................................................................................................... 3-5

3.2.2 LUBRICANTS ............................................................................................................ 3-5

3.3 OPERATION PANEL AND EXTERNAL COVERS .............................................................. 3-6

3.3.1 OPERATION PANEL................................................................................................. 3-6

3.3.2 FRONT DOOR........................................................................................................... 3-6

3.3.3 RIGHT COVERS........................................................................................................ 3-7

3.3.4 LEFT COVERS .......................................................................................................... 3-8

3.3.5 REAR COVERS......................................................................................................... 3-9

3.4 SCANNER.......................................................................................................................... 3-10

3.4.1 ADF AND TOP COVERS ........................................................................................ 3-10

ADF .............................................................................................................................3-10

Top Covers.................................................................................................................. 3-11

3.4.2 EXPOSURE GLASS................................................................................................ 3-12

3.4.3 SCANNER ORIGINAL SIZE SENSORS ................................................................. 3-13

3.4.4 LENS BLOCK .......................................................................................................... 3-14

3.4.5 EXPOSURE LAMP .................................................................................................. 3-15

3.4.6 LAMP REGULATOR................................................................................................ 3-16

3.4.7 SCANNER MOTOR DRIVE BOARD (SDRB).......................................................... 3-17

3.4.8 SCANNER MOTOR ................................................................................................. 3-18

3.4.9 SCANNER HP SENSOR ......................................................................................... 3-19

3.4.10 SCANNER WIRE REPLACEMENT....................................................................... 3-20

Preparation for Removal ............................................................................................. 3-20

Wire Removal: Back ................................................................................................... 3-21

Wire Removal: Front ................................................................................................... 3-22

Attaching the New Wire .............................................................................................. 3-23

3.4.11 SCANNER HEATER.............................................................................................. 3-25

3.5 LASER UNIT ...................................................................................................................... 3-26

3.5.1 CAUTION DECALS .................................................................................................3-26

3.5.2 LD UNIT AND POLYGON MOTOR ......................................................................... 3-27

3.5.3 LASER SYNCHRONIZATION DETECTOR REPLACEMENT ................................ 3-29

3.5.4 LASER UNIT ALIGNMENT...................................................................................... 3-30

3.6 DRUM UNIT ....................................................................................................................... 3-32

3.6.1 DEVELOPMENT UNIT REMOVAL.......................................................................... 3-32

Removal ...................................................................................................................... 3-32

Re-installation ............................................................................................................. 3-33

Replacement with a used Development Unit.............................................................. 3-33

3.6.2 CHARGE CORONA UNIT ....................................................................................... 3-34

3.6.3 CHARGE CORONA WIRE AND GRID.................................................................... 3-35

3.6.4 CHARGE CORONA WIRE CLEANING PADS........................................................ 3-36

3.6.5 OPC DRUM REMOVAL........................................................................................... 3-37

Dusting the Drum Surface........................................................................................... 3-38

3.6.6 PTL (B140 AND B246 SERIES ONLY) ................................................................... 3-39

3.6.7 QUENCHING LAMP ................................................................................................ 3-40

3.6.8 DRUM POTENTIAL SENSOR................................................................................. 3-40

3.6.9 CLEANING FILTER ................................................................................................. 3-41

3.6.10 CLEANING BLADE................................................................................................ 3-41

3.6.11 CLEANING BRUSH............................................................................................... 3-42

3.6.12 PICK-OFF PAWLS................................................................................................. 3-43

3.6.13 ID SENSOR ........................................................................................................... 3-43

3.6.14 DRUM MOTOR...................................................................................................... 3-44

3.6.15 TONER COLLECTION BOTTLE ........................................................................... 3-45

3.6.16 TONER SEPARATION UNIT................................................................................. 3-45

3.6.17 OZONE FILTERS .................................................................................................. 3-46

3.6.18 OPTICS DUST FILTER ......................................................................................... 3-46

3.6.19 INTERNAL DUST FILTER..................................................................................... 3-46

3.7 DEVELOPMENT UNIT....................................................................................................... 3-47

3.7.1 DEVELOPER REPLACEMENT............................................................................... 3-47

3.7.2 DEVELOPMENT FILTER ........................................................................................ 3-49

3.7.3 ENTRANCE SEAL AND SIDE SEALS .................................................................... 3-50

3.7.4 TD SENSOR ............................................................................................................ 3-51

3.7.5 TONER END SENSOR............................................................................................ 3-51

3.7.6 TONER SUPPLY MOTOR....................................................................................... 3-52

3.7.7 DEVELOPMENT MOTOR ....................................................................................... 3-53

3.8 TRANSFER BELT UNIT .................................................................................................... 3-54

3.8.1 TRANSFER BELT UNIT .......................................................................................... 3-54

3.8.2 TRANSFER BELT.................................................................................................... 3-55

3.8.3 TRANSFER ROLLER CLEANING BLADE.............................................................. 3-57

3.8.4 DISCHARGE PLATE ............................................................................................... 3-58

3.8.5 TRANSFER POWER PACK .................................................................................... 3-59

3.9 FUSING UNIT .................................................................................................................... 3-60

3.9.1 FUSING UNIT .......................................................................................................... 3-60

3.9.2 FUSING PRESSURE RELEASE MOTOR (B140/B246 SERIES)........................... 3-62

3.9.3 FUSING PRESSURE RELEASE HP SENSOR (B140/B246 SERIES)................... 3-63

3.9.4 FUSING UNIT THERMISTORS AND THERMOSTATS.......................................... 3-64

B064 Series................................................................................................................. 3-65

B140 Series................................................................................................................. 3-65

B246 Series................................................................................................................. 3-65

3.9.5 WEB CLEANING ROLLER...................................................................................... 3-67

Web Unit Disassembly................................................................................................ 3-67

Web Unit Assembly..................................................................................................... 3-68

3.9.6 WEB MOTOR AND WEB END SENSOR................................................................ 3-69

3.9.7 PRESSURE ROLLER CLEANING UNIT................................................................. 3-70

B064 Series................................................................................................................. 3-70

B140/B246 Series ....................................................................................................... 3-71

3.9.8 FUSING LAMPS, HOT ROLLER, AND PRESSURE ROLLER............................... 3-72

B064 Series: Fusing Lamps........................................................................................ 3-72

B140/B246 Series: Fusing Lamps .............................................................................. 3-73

Important Notes about Fusing Unit Assembly (B064 Series) ..................................... 3-78

3.9.9 PRESSURE ROLLER.............................................................................................. 3-79

3.9.10 STRIPPER PAWLS ............................................................................................... 3-80

B064 Series................................................................................................................. 3-80

B140/B246 Series ....................................................................................................... 3-81

3.9.11 NIP BAND WIDTH ADJUSTMENT........................................................................ 3-82

3.9.12 FUSING UNIT EXIT SENSOR............................................................................... 3-83

3.9.13 FUSING/EXIT MOTOR.......................................................................................... 3-84

3.9.14 FUSING EXIT AND EXIT UNIT ENTRANCE SENSORS...................................... 3-85

vii

3.10 DUPLEX UNIT ................................................................................................................. 3-86

3.10.1 DUPLEX UNIT REMOVAL .................................................................................... 3-86

3.10.2 DUPLEX UNIT SIDE-TO-SIDE ADJUSTMENT .................................................... 3-87

3.10.3 JOGGER FENCE ADJUSTMENT ......................................................................... 3-87

3.10.4 DUPLEX MOTORS................................................................................................ 3-88

Duplex Inverter Motor ................................................................................................. 3-88

Duplex Jogger and Transport Motors ......................................................................... 3-89

3.10.5 DUPLEX TRANSPORT CLUTCH/JOGGER HP SENSOR................................... 3-90

3.10.6 DUPLEX ENTRANCE SENSOR ........................................................................... 3-91

3.10.7 DUPLEX TRANSPORT SENSOR 3...................................................................... 3-92

3.10.8 INVERTER EXIT SENSOR, TRANSPORT SENSORS 1 & 2............................... 3-93

3.10.9 DUPLEX JOGGER BELT ADJUSTMENT............................................................. 3-94

3.11 PAPER FEED .................................................................................................................. 3-95

3.11.1 PAPER TRAY REMOVAL ..................................................................................... 3-95

3.11.2 REAR FENCE RETURN SENSOR REPLACEMENT ........................................... 3-97

3.11.3 REAR FENCE HP SENSOR REPLACEMENT ..................................................... 3-98

3.11.4 TANDEM RIGHT TRAY PAPER SENSOR REPLACEMENT ............................... 3-99

3.11.5 BOTTOM PLATE LIFT WIRE REPLACEMENT .................................................. 3-100

3.11.6 TANDEM TRAY PAPER SIZE CHANGE ............................................................ 3-102

3.11.7 PICK-UP, FEED, SEPARATION ROLLER REPLACEMENT.............................. 3-105

3.11.8 FEED UNIT .......................................................................................................... 3-106

3.11.9 SEPARATION ROLLER PRESSURE ADJUSTMENT ........................................ 3-108

3.11.10 RELAY SENSOR ............................................................................................... 3-109

3.11.11 BY-PASS PAPER SIZE DETECTION BOARD ................................................. 3-110

3.11.12 BY-PASS TRAY ROLLERS............................................................................... 3-111

3.11.13 BY-PASS SEPARATION ROLLER PRESSURE ADJUSTMENT .................. 3-112

3.11.14 REGISTRATION SENSOR................................................................................ 3-113

3.11.15 REGISTRATION AND BY-PASS UNIT REMOVAL .......................................... 3-114

3.12 PCBS AND HDD ............................................................................................................ 3-116

3.12.1 BCU BOARD (BASE ENGINE CONTROL UNIT) ............................................... 3-116

BCU: B064, B140 Series .......................................................................................... 3-116

BCU, IOB: B246 Series............................................................................................. 3-117

3.12.2 CONTROLLER BOARD....................................................................................... 3-118

B064 Series: Controller Board .................................................................................. 3-118

B140 Series: Controller Board .................................................................................. 3-119

B246 Series: Controller Board .................................................................................. 3-120

3.12.3 IPU BOARD ......................................................................................................... 3-121

B064 Series: IPU Board............................................................................................ 3-121

B140 Series: IPU, Mother Board............................................................................... 3-122

B246 Series: IPU ...................................................................................................... 3-125

B246 Series Motherboard......................................................................................... 3-126

3.12.4 DEVELOPMENT POWER PACK ........................................................................ 3-128

3.12.5 PSU, PFC BOARDS ............................................................................................ 3-129

B064 Series............................................................................................................... 3-129

B140 Series PSU ...................................................................................................... 3-129

B246 Series PSU ...................................................................................................... 3-130

3.12.6 HDD ..................................................................................................................... 3-131

B064 Series HDD...................................................................................................... 3-131

B140 Series HDD...................................................................................................... 3-132

B246 Series HDD...................................................................................................... 3-133

Disposal of HDD Units .............................................................................................. 3-134

Reinstallation............................................................................................................. 3-134

3.12.7 NVRAM ................................................................................................................ 3-135

NVRAM: B064 Series, B140 Series.......................................................................... 3-135

NVRAM: B246 Series ............................................................................................... 3-137

3.12.8 DIMMS ................................................................................................................. 3-139

viii

3.13 ADF ................................................................................................................................ 3-140

3.13.1 ADF COVERS...................................................................................................... 3-140

3.13.2 FEED UNIT .......................................................................................................... 3-141

3.13.3 FEED BELT AND PICK-UP ROLLER.................................................................. 3-142

3.13.4 SEPARATION ROLLER ...................................................................................... 3-143

3.13.5 REGISTRATION SENSOR.................................................................................. 3-144

3.13.6 ADF CONTROL BOARD ..................................................................................... 3-145

3.13.7 ORIGINAL WIDTH, INTERVAL, AND SKEW CORRECTION SENSORS........ 3-146

3.13.8 ORIGINAL LENGTH SENSORS ......................................................................... 3-147

3.13.9 DF POSITION AND APS SENSOR..................................................................... 3-148

3.13.10 OTHER ADF SENSORS ................................................................................... 3-149

3.13.11 BOTTOM PLATE LIFT MOTOR ........................................................................ 3-150

3.13.12 FEED MOTOR ................................................................................................... 3-150

3.13.13 EXIT MOTOR AND TRANSPORT MOTOR ...................................................... 3-151

3.13.14 PICK-UP ROLLER MOTOR AND HP SENSOR ............................................... 3-152

3.13.15 CIS POWER SUPPLY BOARD AND CIS UNIT ................................................ 3-153

3.13.16 ADF EXIT SENSOR........................................................................................... 3-154

3.14 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING ............................................. 3-155

3.14.1 PRINTING............................................................................................................ 3-155

Registration - Leading Edge/Side-to-Side ................................................................ 3-155

Blank Margin ............................................................................................................. 3-156

Registration Buckle Adjustment ................................................................................ 3-156

3.14.2 SCANNING .......................................................................................................... 3-157

Registration: Platen Mode......................................................................................... 3-157

Magnification............................................................................................................. 3-157

3.14.3 ADF SCANNING ADJUSTMENTS ...................................................................... 3-158

Vertical Black Lines................................................................................................... 3-158

DIP Switch Settings (ADF Main Board) .................................................................... 3-158

ADF Skew Correction ............................................................................................... 3-158

3.15 TOUCH SCREEN CALIBRATION ................................................................................. 3-160

4. TROUBLESHOOTING ................................................................................................................ 4-1

4.1 OVERVIEW.......................................................................................................................... 4-1

4.1.1 RECOVERY METHODS............................................................................................ 4-2

4.1.2 IMPORTANT SP CODES .......................................................................................... 4-2

4.1.3 DOWNLOAD ERROR CODES.................................................................................. 4-3

4.1.4 JAM DETECTION ...................................................................................................... 4-6

SENSOR LOCATIONS ................................................................................................. 4-6

4.1.5 TIMING CHARTS....................................................................................................... 4-7

Feed, Transport, Feed Out: Face-up ............................................................................ 4-7

Transport, Inverter, Feed Out: Face-down ................................................................... 4-8

Duplex Transport .......................................................................................................... 4-9

4.1.6 PROGRAM DOWNLOAD ........................................................................................ 4-10

4.2 B064 SERIES SERVICE MODE........................................................................................ 4-11

4.2.1 B064 SERIES SERVICE CALL CONDITIONS........................................................ 4-11

4.2.2 B064 SERIES SC CODE DESCRIPTIONS............................................................. 4-12

SC100: Scanning System ........................................................................................... 4-12

SC300: Image Development System (1) .................................................................... 4-15

SC400: Image Development System (2) .................................................................... 4-20

SC500: Feed, Transport, Duplexing, and Fusing Systems ........................................ 4-21

SC600: Data Communication ..................................................................................... 4-24

SC700: Peripherals..................................................................................................... 4-26

SC800: Overall System............................................................................................... 4-29

SC900: Miscellaneous ................................................................................................ 4-32

4.2.3 ADDITIONAL SC CODES PRINTED IN SMC REPORT......................................... 4-34

4.3 B140/B246 SERIES SERVICE MODE .............................................................................. 4-37

4.3.1 SERVICE MODE LOCK/UNLOCK .......................................................................... 4-37

4.3.2 B140/B246 SERIES SERVICE CALL CONDITIONS .............................................. 4-38

4.3.3 B140/B246 SERIES SC CODE DESCRIPTIONS ................................................... 4-39

SC100: Scanning System ........................................................................................... 4-40

SC200: Exposure........................................................................................................ 4-43

SC300: Image Development System (1) .................................................................... 4-44

SC400: Image Development System (2) .................................................................... 4-49

SC500: Feed, Transport, Duplexing, and Fusing Systems ........................................ 4-50

SC600: Data Communication ..................................................................................... 4-55

SC700: Peripherals..................................................................................................... 4-57

SC800: Overall System............................................................................................... 4-66

SC900: Miscellaneous ................................................................................................ 4-72

4.3.4 JAM CODES ............................................................................................................ 4-76

Main Unit: Paper Jam Errors....................................................................................... 4-76

Finisher B469 Jam Codes........................................................................................... 4-77

Finisher B468/B674 Jam Codes ................................................................................. 4-77

Finisher B478/B706 Jam Codes ................................................................................. 4-78

Mailbox B471 Jam Codes ........................................................................................... 4-78

Cover Interposer Tray B470 Jam Codes .................................................................... 4-78

Z-Folding Unit B660 Jam Codes................................................................................. 4-79

4.3.5 ADDITIONAL SC CODES PRINTED IN SMC REPORT......................................... 4-80

4.4 OTHER PROBLEMS (B064/B140/B246 SERIES) ............................................................ 4-83

4.4.1 BLOWN FUSE CONDITIONS ................................................................................. 4-83

4.4.2 COMMON PROBLEMS ........................................................................................... 4-83

4.4.3 FREQUENT PAPER JAMS ..................................................................................... 4-84

5. SERVICE TABLES ..................................................................................................................... 5-1

5.1 SERVICE PROGRAM MODE.............................................................................................. 5-1

5.1.1 SERVICE PROGRAM MODE OPERATION ............................................................. 5-1

Service Mode Lock/Unlock ........................................................................................... 5-1

To Enter and Exit the Service Mode ............................................................................. 5-2

To Enter and Exit the Super SP Mode.......................................................................... 5-2

To Switch to the Copy Window for Test Printing .......................................................... 5-2

Using the SP Mode ....................................................................................................... 5-3

SP Mode Button Summary ........................................................................................... 5-4

SP Mode Print (SMC Print) ........................................................................................... 5-5

5.2 RESETS............................................................................................................................... 5-6

5.2.1 MEMORY ALL CLEAR: SP5801 ............................................................................... 5-6

5.2.2 SOFTWARE AND SETTING RESET ...................................................................... 5-10

Software Reset ........................................................................................................... 5-10

Resetting the System.................................................................................................. 5-10

Resetting Copy/Document Server Features Only....................................................... 5-10

Resetting Scanner Features Only............................................................................... 5-10

5.3 TEST PATTERN PRINTING.............................................................................................. 5-11

5.3.1 PRINTING TEST PATTERN: SP2902-003.............................................................. 5-11

Test Pattern Table ...................................................................................................... 5-12

5.3.2 IPU FRONT/BACK TEST PATTERNS: SP2902-001,002 ....................................... 5-13

Test Pattern Table ...................................................................................................... 5-14

5.3.3 IPU PRINTING TEST PATTERN: SP2902-004 ...................................................... 5-15

5.4 SOFTWARE UPDATE ....................................................................................................... 5-16

5.4.1 SOFTWARE UPDATE PROCEDURE: B140/B246 SERIES................................... 5-16

Updating the LCDC for the Operation Panel .............................................................. 5-21

Downloading Stamp Data ........................................................................................... 5-21

NVRAM Data Upload/Download ................................................................................. 5-22

5.4.2 SOFTWARE UPDATE PROCEDURE: B064 SERIES............................................ 5-23

GW Controller/BCU Update ........................................................................................ 5-24

Forced Update ............................................................................................................ 5-25

Stamp Data Update .................................................................................................... 5-25

Operation Panel Software Update .............................................................................. 5-26

Scanner Update .......................................................................................................... 5-27

NIB Update.................................................................................................................. 5-27

NetFile Firmware Update............................................................................................ 5-27

NVRAM Update .......................................................................................................... 5-28

Firmware Update Notes .............................................................................................. 5-28

5.5 SERVICE PROGRAM MODE TABLES ............................................................................. 5-29

5.5.1 SERVICE TABLE KEY............................................................................................. 5-29

5.5.2 COPIER SERVICE TABLE...................................................................................... 5-30

SP1xxx Feed............................................................................................................... 5-30

SP2xxx Drum .............................................................................................................. 5-36

SP3xxx Processing ..................................................................................................... 5-55

SP4xxx Scanner ......................................................................................................... 5-58

SP5xxx Mode.............................................................................................................. 5-68

SP6xxx Peripherals................................................................................................... 5-120

SP7xxx Data Logs .................................................................................................... 5-131

SP8xxx: Data Log2 ................................................................................................... 5-148

5.5.3 PRINTER SERVICE TABLE.................................................................................. 5-177

5.5.4 SCANNER SERVICE TABLE ................................................................................ 5-178

5.6 INPUT/OUTPUT CHECK................................................................................................. 5-190

5.6.1 COPIER INPUT CHECK: SP5803......................................................................... 5-190

5.6.2 COPIER OUTPUT CHECK: SP5804..................................................................... 5-196

5.6.3 ADF INPUT CHECK: SP6007 ............................................................................... 5-198

5.6.4 ADF OUTPUT CHECK: SP6008 ........................................................................... 5-199

5.6.5 FINISHER INPUT CHECK: SP6117 (B478/B704) ............................................... 5-200

5.6.6 FINISHER OUTPUT CHECK: SP6118.................................................................. 5-202

5.6.7 FINISHER 1 INPUT CHECK: 6121........................................................................ 5-203

5.6.8 FINISHER 1 OUTPUT CHECK: 6124.................................................................... 5-204

5.6.9 FINISHER 2 INPUT CHECK: 6122........................................................................ 5-205

5.6.10 FINISHER 2 OUTPUT CHECK: 6125.................................................................. 5-206

5.7 USING THE DEBUG LOG (B140/B246).......................................................................... 5-207

5.7.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG ................................... 5-207

5.7.2 RETRIEVING THE DEBUG LOG FROM THE HDD ............................................. 5-210

5.7.3 RECORDING ERRORS MANUALLY.................................................................... 5-211

5.7.4 NEW DEBUG LOG CODES .................................................................................. 5-212

SP5857-015 Copy SD Card-to-SD Card: Any Desired Key .................................... 5-212

SP5857-016 Create a File on HDD to Store a Log.................................................. 5-212

SP5857-017 Create a File on SD Card to Store a Log............................................ 5-212

5.8 USER TOOLS .................................................................................................................. 5-213

5.8.1 OVERVIEW............................................................................................................ 5-213

5.8.2 SYSTEM SETTINGS ............................................................................................. 5-214

B064 Series System Settings ................................................................................... 5-214

B140 Series System Settings ................................................................................... 5-216

5.8.3 COPIER/DOCUMENT SERVER FEATURES ....................................................... 5-219

5.8.4 INQUIRY ................................................................................................................ 5-223

5.8.5 COUNTER ............................................................................................................. 5-223

5.9 DIP SWITCH TABLES ..................................................................................................... 5-224

5.9.1 BCU (BASE ENGINE CONTROL UNIT) ............................................................... 5-224

5.9.2 CONTROLLER BOARD......................................................................................... 5-224

6. DETAILED DESCRIPTIONS ...................................................................................................... 6-1

6.1 OVERVIEW.......................................................................................................................... 6-1

6.1.1 PAPER PATH (WITH COVER INTERPOSER TRAY) .............................................. 6-3

6.1.2 PAPER PATH (WITH 9-BIN MAILBOX) .................................................................... 6-4

6.1.3 DRIVE LAYOUT......................................................................................................... 6-5

6.2 BOARD STRUCTURE ......................................................................................................... 6-6

6.2.1 BLOCK DIAGRAM ..................................................................................................... 6-6

6.2.2 COMPONENT DESCRIPTIONS ............................................................................... 6-7

BCU (Base Engine Control Unit)................................................................................... 6-7

Controller Board............................................................................................................ 6-7

MB (Mother Board) ....................................................................................................... 6-7

IPU (Image Processing Unit) ........................................................................................ 6-7

SBU (Sensor Board Unit).............................................................................................. 6-8

PFC (Paper Feed Control)............................................................................................ 6-8

SDRB (Scanner Driver Board)...................................................................................... 6-8

VIB (Video Interface Board) .......................................................................................... 6-8

DRB (Drive Board) ........................................................................................................ 6-8

CNB (Connection Board) .............................................................................................. 6-8

HDD (Hard Disk Drive).................................................................................................. 6-9

6.3 COPY PROCESS OVERVIEW.......................................................................................... 6-10

6.4 ADF .................................................................................................................................... 6-12

6.4.1 OVERVIEW.............................................................................................................. 6-12

6.4.2 ADF DRIVE LAYOUT .............................................................................................. 6-13

6.4.3 PICK-UP ROLLER LIFT .......................................................................................... 6-14

6.4.4 BOTTOM PLATE LIFT............................................................................................. 6-15

6.4.5 ORIGINAL SEPARATION ....................................................................................... 6-16

6.4.6 ORIGINAL TRANSPORT ........................................................................................ 6-17

6.4.7 ORIGINAL SKEW CORRECTION........................................................................... 6-18

6.4.8 ORIGINAL SIZE DETECTION................................................................................. 6-20

6.4.9 ADF SCANNING...................................................................................................... 6-23

6.4.10 JAM DETECTION .................................................................................................. 6-24

6.5 SCANNING ........................................................................................................................ 6-25

6.5.1 OVERVIEW.............................................................................................................. 6-25

6.5.2 SCANNER DRIVE ................................................................................................... 6-26

6.5.3 ORIGINAL SIZE DETECTION................................................................................. 6-27

Sensors ....................................................................................................................... 6-27

Detection Timing ......................................................................................................... 6-28

6.5.4 SCANNING MAGNIFICATION ................................................................................ 6-29

Book Mode.................................................................................................................. 6-29

6.5.5 AUTO IMAGE DENSITY (ADS)............................................................................... 6-30

Xenon Lamp → CCD ADS.......................................................................................... 6-30

CIS ADS...................................................................................................................... 6-30

6.6 IMAGE PROCESSING....................................................................................................... 6-31

6.6.1 OVERVIEW.............................................................................................................. 6-31

6.6.2 IMAGE PROCESSING FLOW................................................................................. 6-32

6.6.3 IMAGE PROCESSING MODES .............................................................................. 6-33

6.6.4 IMAGE QUALITY SP ADJUSTMENTS ................................................................... 6-34

Custom Settings for Each Mode: Image Quality......................................................... 6-34

Custom Settings for Each Mode: Line Width Correction ............................................ 6-36

Custom Setting: Duplex Scanning Mode Original Image Quality Settings ................. 6-38

Settings Adjustable for Each Original Mode ............................................................... 6-39

6.6.5 RELATION BETWEEN THE SP AND UP SETTINGS ............................................ 6-40

6.6.6 IMAGE PROCESSING TROUBLESHOOTING....................................................... 6-42

Removing Background from Coarse Paper ................................................................ 6-42

Improving the Appearance of a Copy of a Color Document ....................................... 6-42

Removing Vertical White Lines During Duplex Scanning........................................... 6-43

Equalizing Duplex Scanned Image Quality of Front/Back Sides ................................ 6-44

Equalizing Image Quality of Front Sides for Duplex and Simplex Modes .................. 6-44

xii

6.7 LASER EXPOSURE .......................................................................................................... 6-45

6.7.1 OVERVIEW.............................................................................................................. 6-45

6.7.2 OPTICAL PATH ....................................................................................................... 6-46

6.7.3 FOUR-BEAM EXPOSURE ...................................................................................... 6-47

6.7.4 COOLING FAN ........................................................................................................ 6-48

6.7.5 LD SAFETY SWITCHES ......................................................................................... 6-49

B064 Series, B140 Series Safety Switches................................................................ 6-49

B246 Series Safety Switches...................................................................................... 6-50

6.8 DRUM UNIT ....................................................................................................................... 6-51

6.8.1 OVERVIEW.............................................................................................................. 6-51

6.8.2 OPC DRUM ............................................................................................................. 6-52

6.8.3 DRUM DRIVE .......................................................................................................... 6-52

6.8.4 DRUM CHARGE...................................................................................................... 6-53

6.8.5 CHARGE CORONA WIRE CLEANING................................................................... 6-54

6.8.6 DRUM PICK-OFF MECHANISM ............................................................................. 6-55

6.8.7 DRUM CLEANING................................................................................................... 6-56

6.8.8 DRUM VENTILATION AND OZONE FILTER.......................................................... 6-57

6.8.9 TONER RECYCLING .............................................................................................. 6-58

6.8.10 WASTE TONER COLLECTION ............................................................................ 6-59

Mechanism.................................................................................................................. 6-59

Error Detection............................................................................................................ 6-59

6.8.11 PROCESS CONTROL........................................................................................... 6-60

What Happens at Power On ....................................................................................... 6-60

Drum Potential Sensor Calibration.............................................................................. 6-61

Development Bias, Bias Grid, and LD Adjustment ..................................................... 6-62

ID Sensor Calibration (Vsg) ........................................................................................ 6-64

TD Sensor Calibration (Vref)....................................................................................... 6-64

6.9 DEVELOPMENT AND TONER SUPPLY .......................................................................... 6-65

6.9.1 OVERVIEW.............................................................................................................. 6-65

Development Unit ....................................................................................................... 6-65

Toner Supply............................................................................................................... 6-66

6.9.2 DEVELOPMENT UNIT ............................................................................................ 6-67

6.9.3 DEVELOPER/TONER MIXING (AGITATION) ........................................................ 6-68

6.9.4 DEVELOPMENT BIAS............................................................................................. 6-69

6.9.5 TONER SUPPLY ..................................................................................................... 6-70

6.9.6 DEVELOPMENT UNIT DRIVE AND VENTILATION............................................... 6-71

6.9.7 TONER END SENSOR............................................................................................ 6-72

6.9.8 SHUTTER MECHANISM......................................................................................... 6-72

6.9.9 TONER BOTTLE SUPPLY AND VENTILATION..................................................... 6-73

6.9.10 TONER SUPPLY CONTROL ................................................................................ 6-74

Sensor Control Mode .................................................................................................. 6-74

Pixel Count Toner Supply Mode ................................................................................. 6-75

TD Sensor Initialization ............................................................................................... 6-76

Determining Vref ......................................................................................................... 6-76

Toner Supply without ID Sensor and TD Sensors...................................................... 6-77

Abnormal TD Sensor Output....................................................................................... 6-77

Abnormal ID Sensor Output........................................................................................ 6-77

Toner End Detection ................................................................................................... 6-78

Toner End Recovery ................................................................................................... 6-78

xiii

6.10 IMAGE TRANSFER AND PAPER SEPARATION........................................................... 6-79

6.10.1 OVERVIEW............................................................................................................ 6-79

6.10.2 TRANSFER BELT LIFT ......................................................................................... 6-80

Mechanism.................................................................................................................. 6-80

Timing ......................................................................................................................... 6-81

6.10.3 TRANSFER BELT CHARGE ................................................................................. 6-82

6.10.4 TRANSFER CURRENT SETTINGS...................................................................... 6-83

6.10.5 TRANSFER CURRENT CIRCUIT ......................................................................... 6-84

6.10.6 TRANSFER BELT DRIVE AND PAPER TRANSPORT ........................................ 6-85

6.10.7 TRANSFER BELT CLEANING .............................................................................. 6-86

6.10.8 ANTI-CONDENSATION HEATER......................................................................... 6-87

6.11 PAPER FEED .................................................................................................................. 6-88

6.11.1 OVERVIEW............................................................................................................ 6-88

Tray Capacities ........................................................................................................... 6-89

Built-in Feed Stations.................................................................................................. 6-89

By-pass Feed.............................................................................................................. 6-89

Paper Registration ...................................................................................................... 6-89

Jam Removal .............................................................................................................. 6-89

6.11.2 DRIVE .................................................................................................................... 6-90

6.11.3 TRAY AND PAPER LIFT MECHANISM – TRAY 2,3 ............................................ 6-91

Bottom Plate Lift.......................................................................................................... 6-91

Lift Sensor................................................................................................................... 6-92

6.11.4 PAPER FEED AND SEPARATION MECHANISM ................................................ 6-93

Paper Feed and Separation: No Paper Present......................................................... 6-93

Paper Feed and Separation........................................................................................ 6-94

Separation Roller Release Mechanism ...................................................................... 6-95

6.11.5 PAPER NEAR-END AND PAPER END – TRAYS 2 AND 3.................................. 6-96

6.11.6 PAPER SIZE DETECTION.................................................................................... 6-97

Tandem Tray (Tray 1) ................................................................................................. 6-97

Universal Cassettes (Tray 2, 3) .................................................................................. 6-97

6.11.7 ANTI-CONDENSATION HEATERS ...................................................................... 6-98

6.11.8 TANDEM TRAY – TRAY 1 .................................................................................... 6-99

Overview ..................................................................................................................... 6-99

Connecting the Left and Right Sides of the Tray...................................................... 6-100

Paper Lift/Remaining Paper Detection ..................................................................... 6-101

Fence Drive............................................................................................................... 6-103

Rear Fence Drive...................................................................................................... 6-104

Tray Side-to-side Positioning .................................................................................... 6-105

6.11.9 TRAY POSITIONING MECHANISM – TRAYS 1 TO 3 ....................................... 6-106

6.11.10 BY-PASS TRAY................................................................................................. 6-107

By-pass Feed and Separation .................................................................................. 6-107

By-pass Tray Paper End Detection .......................................................................... 6-108

By-pass Paper Size Detection .................................................................................. 6-109

6.11.11 PAPER REGISTRATION................................................................................... 6-110

Overview ................................................................................................................... 6-110

Paper Registration Drive........................................................................................... 6-111

Jam Removal at Paper Registration ......................................................................... 6-112

xiv

6.12 IMAGE FUSING AND PAPER EXIT .............................................................................. 6-113

6.12.1 OVERVIEW.......................................................................................................... 6-113

B064 Series............................................................................................................... 6-113

B140/B246 Series ..................................................................................................... 6-114

All Series................................................................................................................... 6-114

6.12.2 FUSING MECHANISM ........................................................................................ 6-115

B064 Series............................................................................................................... 6-115

B140/B246 Series ..................................................................................................... 6-116

6.12.3 PRESSURE ROLLER.......................................................................................... 6-117

B064 Series............................................................................................................... 6-117

B140/B246 Series ..................................................................................................... 6-118

6.12.4 HOT ROLLER CLEANING .................................................................................. 6-119

Overview ................................................................................................................... 6-119

Web Drive ................................................................................................................. 6-120

Web Near-end........................................................................................................... 6-120

Web End ................................................................................................................... 6-120

6.12.5 FUSING UNIT ENTRANCE GUIDE..................................................................... 6-121

6.12.6 FUSING UNIT DRIVE.......................................................................................... 6-122

6.12.7 CPM DOWN MODE............................................................................................. 6-123

B140/B246 Series ..................................................................................................... 6-123

6.12.8 FUSING TEMPERATURE CONTROL ................................................................ 6-124

6.12.9 EXIT ..................................................................................................................... 6-126

6.12.10 EXIT JUNCTION GATE..................................................................................... 6-127

6.13 DUPLEX UNIT ............................................................................................................... 6-128

6.13.1 OVERVIEW.......................................................................................................... 6-128

6.13.2 DUPLEX DRIVE................................................................................................... 6-129

6.13.3 INVERTER OPERATION .................................................................................... 6-130

Inverter Feed-in and Jogging.................................................................................... 6-130

Inverter Feed-out ...................................................................................................... 6-131

6.13.4 DUPLEX TRAY FEED ......................................................................................... 6-132

6.13.5 DUPLEX INTERLEAVE FEED ............................................................................ 6-133

6.14 ENERGY SAVER MODES ............................................................................................ 6-135

6.14.1 OVERVIEW.......................................................................................................... 6-135

6.14.2 ENERGY SAVER MODE..................................................................................... 6-136

Entering the energy saver mode............................................................................... 6-136

What happens in energy saver mode ....................................................................... 6-136

Return to stand-by mode .......................................................................................... 6-136

6.14.3 LOW POWER MODE ..........................................................................................6-137

Entering the low power mode ................................................................................... 6-137

What happens in low power mode............................................................................ 6-137

Return to stand-by mode .......................................................................................... 6-137

6.14.4 AUTO OFF MODE............................................................................................... 6-138

Entering auto off mode.............................................................................................. 6-138

What happens in auto off mode................................................................................ 6-138

Returning to stand-by mode...................................................................................... 6-138

Disabling auto off mode ............................................................................................ 6-138

6.14.5 NIGHT MODE ...................................................................................................... 6-139

Entering night stand-by and night modes ................................................................. 6-139

What happens in night stand-by and night modes.................................................... 6-139

Returning to stand-by mode...................................................................................... 6-139

6.14.6 CHANGES FOR B140 AND B246....................................................................... 6-140

7. SPECIFICATIONS ................................................................................................................. 7-1

7.1 GENERAL SPECIFICATIONS...................................................................................... 7-1

7.1.1 COPIER ..................................................................................................................... 7-1

7.1.2 ADF............................................................................................................................ 7-2

7.1.3 POWER CONSUMPTION ......................................................................................... 7-3

7.2 MACHINE CONFIGURATION ............................................................................................. 7-6

7.3 OPTIONAL EQUIPMENT..................................................................................................... 7-7

7.3.1 A3/DLT KIT (B475) .................................................................................................... 7-7

7.3.2 LCT (LARGE CAPACITY TRAY) (B473)................................................................... 7-7

7.3.3 3000-SHEET FINISHER WITH SADDLE-STITCH

AND 50-SHEET STAPLER (B468)............................................................................ 7-8

7.3.4 3000-SHEET FINISHER WITH 50-SHEET STAPLER (B469)................................ 7-10

7.3.5 3000-SHEET FINISHER WITH SADDLE-STITCH

AND 50-SHEET STAPLER (B674).......................................................................... 7-11

7.3.6 PUNCH UNIT (B377) ............................................................................................... 7-14

7.3.7 COVER INTERPOSER TRAY (B470) ..................................................................... 7-15

7.3.8 3000 SHEET FINISHER (B478/B706)..................................................................... 7-16

7.3.9 PUNCH UNIT (B531) ............................................................................................... 7-17

7.3.10 PUNCH UNIT (A812)............................................................................................. 7-18

7.3.11 JOGGER UNIT (B513)........................................................................................... 7-19

7.3.12 9-BIN MAILBOX (B471)......................................................................................... 7-19

7.3.13 LG/B4 KIT (B474) .................................................................................................. 7-19

7.3.14 Z-FOLDING UNIT (B660) ...................................................................................... 7-19

7.3.15 3000-SHEET FINISHER B701 .............................................................................. 7-20

7.3.16 2000-SHEET FINISHER B700 .............................................................................. 7-22

7.3.17 PUNCH UNIT B702 ............................................................................................... 7-24

7.3.18 9-BIN MAILBOX B762 ............................................................................................ 7-24

xvi

30 June 2006 INSTALLATION REQUIREMENTS

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 OPERATING ENVIRONMENT

1. Temperature Range:

2. Humidity Range:

3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight or

4. Ventilation: Room air should turn over at least 3 times per hour

5. Ambient Dust: Less than 0.10 mg/m3

Humidity

80%

54%

Recommended: 15°C to 25°C (59°F to 77°F) Possible: 10°C to 32°C (50°F to 90°F)

15% to 80% RH (27°C 80%, 32°C 54%)

strong light.)

Operation range

Installation

15%

10°C

(50°F)

27°C

(80.6°F)

32°C

(89.6°F)

Temperature

B064I502.WMF

6. If the place of installation is air-conditioned or heated, do not place the machine where it will be:

1) Subjected to sudden temperature changes

2) Directly exposed to cool air from an air-conditioner

3) Directly exposed to heat from a heater

1-1

INSTALLATION REQUIREMENTS 30 June 2006

7. Do not place the machine where it will be exposed to corrosive gases.

8. Do not install the machine at any location over 2,000 m (6,500 feet) above sea level.

9. Place the copier on a strong and level base with the front and back of the machine within ±5 mm (0.2") of level.

10. Do not place the machine where it may be subjected to strong vibrations.

11. Do not connect the machine to a power source shared with another electrical appliance.

12. The machine can generate an electromagnetic field which could interfere with radio or television reception.

1.1.2 MACHINE LEVEL

1. Front to back:

2. Right to left:

Within ±5 mm (0.2") of level

The machine legs may be screwed up or down in order to level the machine. Set a carpenter’s level on the exposure glass.

1-2

30 June 2006 INSTALLATION REQUIREMENTS

1.1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing minimum clearance as shown below. The same amount of clearance is necessary when optional peripheral devices are installed.

50 mm (2") Back

100 mm (4") Left

700 mm (27.6") Front

B064I001.WMF

40 mm (1.6") Right

Installation

1-3

INSTALLATION REQUIREMENTS 30 June 2006

1.1.4 DIMENSIONS

B064 Series

480 mm (18.9")

425 mm (16.7")

1,098 mm (43.2")

1,165 mm (45.9")

1,014 mm (39.9")

620 mm (24.4")

90 mm (3.5")

734 mm (28.9")

690 mm (27.2")

314 mm (12.4")

B064I003.WMF

750 mm (29.5")

458 mm (18")

B064I002.WMF

1-4

30 June 2006 INSTALLATION REQUIREMENTS

B140 Series

480 mm (18.9")

425 mm (16.7")

Installation

1,098 mm (43.2")

1,014 mm (39.9")

620 mm (24.4")

90 mm (3.5")

734 mm (28.9")

177 mm (6.9")

690 mm (27.2")

1,165 mm (45.9")

314 mm (12.4")

B064I140.WMF

750 mm (29.5")

458 mm (18")

B064I002.WMF

1-5

INSTALLATION REQUIREMENTS 30 June 2006

B246 Series

480 mm (18.9")

425 mm (16.7")

1103 mm (43.4")

978 mm (38.5")

90 mm (3.5")

657mm (25.9")

177 mm (6.9")

690 mm (27.2")

314 mm (12.4")

B132I112.WMF

1165 mm (45.9")

790 mm (31.1")

613 mm (24.1")

458 mm (18")

B064I002.WMF

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30 June 2006 INSTALLATION REQUIREMENTS

1.1.5 PERIPHERAL/OPTION SUMMARY TABLE

The table below summarizes all the peripheral devices and controller options that can be installed with the B064, B140, and B246 Series machines. O: YES, X: NO

Bnnn Name

B328 Copy Connector Kit

Type 2105

B377 Punch Unit Type

1045

B452 Key Counter

Bracket Type 1027

B468 Booklet Finisher O X X 1 Punching, sorting, shifting,

B469 Booklet Finisher

SR850

B470 Cover Interposer

Tray

B471 9-Bin Mailbox O O X 2 Installed on the B468, B469,

B473 LCT RT43 O O O 1 Paper bank for LT/A4 paper B474 81/2"x 14" Paper

Size Tray Type 1075

B475 A3/11"x17" Tray

Unit Type 1075

B476 Copy Tray Type

1075

B478 3000 Sheet Finisher O X X 1 Punching, sorting, shifting,

B498 Card Reader

Bracket

B499 Tab Sheet Holder

Type 3260

B513 Output Jogger Unit

Type 1075 B515 IEEE 801.11b O X X 3 Board B519 File Format

Converter B525-08 Postscript 3 Type

1075 B525-15 Postscript 3 Type

2075 B525-44 Postscript 3 Type

7500 B525-01 USB 2.0 O O O 3 Board B531-27 Punch Unit Type

1075 EU 2/4 B531-17 Punch Unit Type

1075 NA 3/2 B581 IEEE 1394 Interface

Board Type B B585 Memory Unit Type

D 2075 256MB B594 Network Interface

Board Type 2105 B596-01 USB 2.0 Interface

Board Type B B609-04 File Format

Converter Type C B609-01 File Format

Converter Type B B659 Printer/Scanner Kit

Type 2075

B064 B140 B246

Series

X O X 1 Links two mainframes.

O O X 2 Installed in B468, B469, B674

O O O 1 Common option.

O O X 1 Punching, sorting, shifting,

O O X 2 Installed on B468, B469,

O O O 1 Paper bank for LG paper

O O O 1 Installed in Tray 1 (Tandem

O X X 2 Small output tray for

O O O 1 Connected directly to the

O O O 2 Installed in Tray 1 (Tandem

X O O 2 Installed in B478 or B706

O X X 3 Board

O X X 3 DIMM

X O X 3 SD card

X X O 3 SD card

O O O 2 Installed in B478 or B706.

X X O 3 Board

X O X 3 Memory

X O X 3 Board

X X O 3 Board

X O X 3 Board

X O X 3 SD card

Class*

corner/booklet stapling.

corner stapling only.

B674, or B478, B706

or B674.

Tray)

mainframe

corner stapling only.

mainframe.

Tray)

Comment

Installation

1-7

INSTALLATION REQUIREMENTS 30 June 2006

Bnnn Name

B660 Z-folding Unit ZF

4000 B674 Booklet Finisher X O X 1 Punching, sorting, shifting,

B679 IEEE1284 Interface

Board Type A B700 SR 4000 X X O 1 Punching, sorting, shifting,

B701 SR970 X X O 1 Punching, sorting, shifting,

B702-27 Punch Unit Type

3260 EU 2/4 B702-17 Punch Unit Type

3260 NA 2/3 B702-28 Punch Unit Type

3260 SC B703 Output Jogger Unit

Type 3260 B704 Cover Interposer

Type 3260 B706 SR841 X O O 1 Punching, sorting, shifting,

B735 Data Overwrite

Security Unit C

B736 Bluetooth Interface

Unit Type 3245 B756 Copy Tray Type

2075 B762 Mail Box CS391 X X O 2 Installed on B700 or B701 B782 VM Card Type B X O X 3 SD card B812 Punch Unit Type

850 SC B818 Remote

Communication

Gate Type CM1 B825 USB Host Interface

Unit Type A B826 Bluetooth Unit Type

3245 B828 Browser Unit Type

B B829 Copy Data Security

Unit Type C B841 Printer/Scanner Unit

Type 7500 B842 Copy Connector

Type MP 7500 B861 VM Card Type C X X O 3 SD card G336 IEEE 1394 O X X 3 Board G338 Printer/Scanner Kit O X X 3 DIMM G377 Bluetooth Interface

Unit G381 Gigabit Ethernet

Type 7300 G813 IEEE 802.11b

Interface Board

B064 B140 B246

Series

X O O 1 Installed with B674, B700, or

X X O 3 Board

X X O 2 Installed in B700 or B701

X X O 2 Installed on B700 or B701

X X O 2 Installed on the B700, B701,

X O O 3 SD card

X O X 3 Board

X O O 1 Small output tray for

O O O 2 Installed in B478/B706.

X X O 3 Board

X X O 3 SD card

X X O 3 IPU Board

X X O 3 SD Card

X O O 1 Links two mainframes

X O X 3 Board

X X O 3 Board

X O O 3 Board

Class*

B701.

corner/booklet stapling.

corner stapling only.

B706.

corner stapling only.

mainframe

Comment

*1 Class 1: Peripheral units connected directly to the mainframe Class 2: Components installed on or in peripheral units (punches, etc.) Class 3: MFP controller options (SD cards, boards)

1-8

30 June 2006 INSTALLATION REQUIREMENTS

1.1.6 POWER REQUIREMENTS

CAUTION

1. Make sure that the wall outlet is near the main machine and easily

accessible. Make sure the plug is firmly inserted in the outlet.

2. Avoid multi-wiring.

3. Be sure to ground the machine.

4. Never set anything on the power cord.

Input voltage level

Permissible voltage fluctuation

North America 120 V, 60 Hz: 20 A or more Europe/Asia 220 V ~ 240 V, 50 Hz/60 Hz: 10 A or more Taiwan 110V, 60 Hz, 20A or more ±10%

CAUTION

Never turn off the main power switch when the power LED is lit or flashing. To avoid damaging the hard disk or memory, press the operation power switch to switch the power off, wait for the power LED to go off, and then switch the main power switch off.

The Main Power LED () lights or flashes at the following times:

Installation

• While the platen cover or ADF is open

• While the main machine is communicating with the network server

• While the machine is accessing the hard disk or memory when reading or

writing data.

There are two power switches on the machine:

• Main Power Switch. Located on the front left corner of the machine and covered by a plastic cover. This switch should always remain on unless the machine is being serviced.

• Operation Power Switch. Located on the right side of the operation panel. This is the switch normally used by the customer to power the machine on and off.

1-9

MAIN MACHINE (B064 SERIES/B140 SERIES/B246 SERIES) 30 June 2006

1.2 MAIN MACHINE (B064 SERIES/B140 SERIES/B246

SERIES)

1.2.1 ACCESSORY CHECK

Check the accessories and their quantities against this list:

Description Q’ty

1. Model Name Decal (-29 Only) ............................................... 1

2. Operation Instructions (-17, -19, -29, -69 Only) ..................... 2

3. NECR with Envelope (-17 Only) ............................................ 1

4. Decal – Paper Size ................................................................ 1

5. Decal: Caution Chart: Paper Set: Direction ........................... 1

6. Stand Holder.......................................................................... 1

7. Operating Instructions Holder ................................................ 2

8. Decal – Original Table (Face Up) .......................................... 1

9. Decal – Cleaning - Multiple .................................................... 1

10. Cloth – DF Exposure Glass ................................................... 1

11. Cloth Holder........................................................................... 1

12. Decal – Toner Supply - Multiple ............................................ 1

13. Decal: Power Source: Off ...................................................... 1

14. Decal Exposure Glass: Multiple............................................. 1

15. Decal – D1/E1 Multiple .......................................................... 1

1-10

+ 840 hidden pages

Aficio B064, B065, B140, B141, B163 Service Manual

IMPORTANT SAFETY NOTICES

LASER SAFETY

TABLE OF CONTENTS

30 June 2006 INSTALLATION REQUIREMENTS

Installation

B064 Series

B140 Series

B246 Series

MAIN MACHINE (B064 SERIES/B140 SERIES/B246 SERIES) 30 June 2006