Gestetner A294, A295 Service Manual

A294/A295

SERVICE MANUAL

000902MIU

RICOH GROUP COMPANIES

CÓPIA NÃO CONTROLADA

A294/A295

SERVICE MANUAL

RICOH GROUP COMPANIES

CÓPIA NÃO CONTROLADA

A294/A295

SERVICE MANUAL

000902MIU

CÓPIA NÃO CONTROLADA

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NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY

FASHION AND DISTRIBUTED WITHOUT THE PRIOR

PERMISSION OF RICOH CORPORATION.

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

CÓPIA NÃO CONTROLADA

The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. User s of this manual should be either service trained or certified by successfully completing a Ricoh T echnical Training Program.

Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection.

Ricoh Corporation

WARNING

CÓPIA NÃO CONTROLADA

LEGEND

PRODUCT CODE COMPANY

GESTETNER RICOH SAVIN

A294-I

3285 Aficio 850 2085DP

A295-I

32105 Aficio1050 2105DP

A294-II

8502 Aficio 1085 2585

A295-II

10502 Aficio 1105 25105

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

* 1/2000 Original Printing

1 7/2000 A295 Addition 29/2001

A294-II/A295-II Addition

CÓPIA NÃO CONTROLADA

SM i A294A295

TABLE OF CONTENTS

OVERALL INFORMATION

1. OVERALL MACHINE INFORMATION........................................ 1-1

1.1 SPECIFICATIONS.....................................................................................1-1

1.1.1 COPIER ENGINE.............................................................................1-1

1.1.2 ADF ..................................................................................................1-4

1.2 MACHINE CONFIGURATION...................................................................1-5

1.3 COMPONENT LAYOUT............................................................................1-6

1.3.1 COPIER ENGINE.............................................................................1-6

1.3.2 ADF ..................................................................................................1-7

1.4 PAPER PATH............................................................................................1-8

1.5 COPY PROCESS......................................................................................1-9

1.6 DRIVE LAYOUT......................................................................................1-11

1.6.1 COPIER ENGINE...........................................................................1-11

1.6.2 ADF ................................................................................................1-12

1.7 ELECTRICAL COMPONENT DESCRIPTIONS......................................1-13

1.7.1 COPIER ENGINE...........................................................................1-13

1.7.2 ADF ................................................................................................1-19

DETAILED DESCRIPTIONS

2. DETAILED SECTION DESCRIPTIONS ...................................... 2-1

2.1 DOCUMENT FEEDER..............................................................................2-1

2.1.1 PICK-UP ROLLER RELEASE..........................................................2-1

2.1.2 BOTTOM PLATE LIFT......................................................................2-2

2.1.3 PICK-UP AND SEPARATION...........................................................2-3

2.1.4 ORIGINAL FEED..............................................................................2-4

2.1.5 ORIGINAL SIZE DETECTION..........................................................2-5

2.1.6 ORIGINAL TRANSPORT .................................................................2-6

2.1.7 ORIGINAL SKEW CORRECTION....................................................2-7

2.1.8 ORIGINAL INVERSION AND FEED-OUT........................................2-8

2.1.9 JAM CONDITIONS.........................................................................2-12

2.2 SCANNING..............................................................................................2-13

2.2.1 OVERVIEW....................................................................................2-13

2.2.2 SCANNER DRIVE..........................................................................2-14

2.2.3 ORIGINAL SIZE DETECTION IN BOOK MODE............................2-15

2.3 IMAGE PROCESSING............................................................................2-17

2.3.1 OVERVIEW....................................................................................2-17

2.3.2 SBU................................................................................................2-18

2.3.3 AUTO IMAGE DENSITY (ADS)......................................................2-19

2.3.4 IMAGE PROCESSING STEPS AND RELATED SP MODE...........2-20

2.3.5 AUTO SHADING ............................................................................2-26

2.3.6 BACKGROUND ERASE.................................................................2-27

2.3.7 INDEPENDENT DOT ERASE........................................................2-28

Rev. 10/2000

CÓPIA NÃO CONTROLADA

A294/A295 ii SM

2.3.8 FILTERING, MAIN SCAN MAGNIFICATION/REDUCTION ...........2-29

2.3.9 GAMMA (γ) CORRECTION............................................................2-31

2.3.10 GRADATION PROCESSING........................................................2-31

2.3.11 LINE WIDTH CORRECTION........................................................2-32

2.4 LASER EXPOSURE................................................................................2-33

2.4.1 OVERVIEW....................................................................................2-33

2.4.2 OPTICAL PATH..............................................................................2-34

2.4.3 AUTO POWER CONTROL (APC)..................................................2-35

2.4.4 FOUR BEAM LASER WRITING.....................................................2-36

2.4.5 LD SAFETY SWITCHES................................................................2-37

2.5 DRUM UNIT ............................................................................................2-38

2.5.1 PROCESS CONTROL....................................................................2-38

2.5.2 TONER DENSITY CONTROL........................................................2-43

2.5.3 DRUM UNIT COMPONENTS.........................................................2-46

2.5.4 DRIVE............................................................................................. 2-47

2.5.5 DRUM CHARGE.............................................................................2-48

2.5.6 DRUM CLEANING..........................................................................2-50

2.5.7 OTHERS.........................................................................................2-53

2.6 DEVELOPMENT .....................................................................................2-56

2.6.1 OVERVIEW....................................................................................2-56

2.6.2 DEVELOPMENT MECHANISM......................................................2-57

2.6.3 DRIVE............................................................................................. 2-58

2.6.4 CROSSMIXING..............................................................................2-59

2.6.5 DEVELOPMENT BIAS ...................................................................2-60

2.7 TONER SUPPLY AND RECYCLING.......................................................2-61

2.7.1 TONER BANK................................................................................2-61

2.7.2 SUPPLYING TONER TO THE DEVELOPMENT UNIT..................2-65

2.7.3 TONER HOPPER...........................................................................2-66

2.7.4 TONER RECYCLING AND WASTE TONER COLLECTION..........2-68

2.8 PAPER FEED..........................................................................................2-71

2.8.1 OVERVIEW....................................................................................2-71

2.8.2 DRIVE............................................................................................. 2-72

2.8.3 PAPER LIFT – TRAYS 2 & 3..........................................................2-73

2.8.4 PICK-UP AND FEED – TRAYS 1 TO 3..........................................2-75

2.8.5 REMAINING PAPER/

PAPER END DETECTION – TRAYS 2 & 3....................................2-79

2.8.6 PAPER SIZE DETECTION – TRAYS 2 & 3....................................2-80

2.8.7 TRAY LOCK – TRAYS 2 & 3..........................................................2-81

2.8.8 TANDEM FEED – TRAY 1 .............................................................2-82

2.8.9 VERTICAL TRANSPORT...............................................................2-89

2.8.10 PAPER REGISTRATION..............................................................2-90

2.9 IMAGE TRANSFER AND PAPER SEPARATION...................................2-93

2.9.1 OVERVIEW....................................................................................2-93

2.9.2 IMAGE TRANSFER AND PAPER SEPARATION..........................2-94

2.9.3 TRANSFER BELT UNIT LIFT.........................................................2-96

2.9.4 PAPER TRANSPORTATION AND BELT DRIVE...........................2-97

2.9.5 TRANSFER BELT CLEANING.......................................................2-98

2.9.6 TONER COLLECTION...................................................................2-99

2.9.7 TRANSFER ANTI-CONDENSATION HEATER............................2-100

Rev. 10/2000

CÓPIA NÃO CONTROLADA

SM iii A294A295

2.10 FUSING...............................................................................................2-101

2.10.1 OVERVIEW................................................................................2-101

2.10.2 FUSING ENTRANCE GUIDE.....................................................2-102

2.10.3 FUSING UNIT DRIVE.................................................................2-103

2.10.4 FUSING LAMP CONTROL.........................................................2-104

2.10.5 OIL SUPPLY AND CLEANING...................................................2-105

2.10.6 PAPER COOLING......................................................................2-106

2.10.7 FUSING PRESSURE .................................................................2-107

2.10.8 HOT ROLLER STRIPPER RELEASE........................................2-108

2.11 PAPER EXIT/DUPLEX........................................................................2-109

2.11.1 OVERVIEW................................................................................2-109

2.11.2 PAPER EXIT MECHANISM........................................................2-110

2.11.3 DUPLEX DRIVE MECHANISM...................................................2-111

2.11.4 INVERTER..................................................................................2-112

2.11.5 DUPLEX TRAY FEED MECHANISM .........................................2-114

2.11.6 BASIC DUPLEX FEED OPERATION.........................................2-115

2.12 ENERGY SAVER MODES..................................................................2-119

2.12.1 OVERVIEW................................................................................2-119

2.12.2 ENERGY SAVER (PANEL OFF) MODE ....................................2-120

2.12.3 LOW POWER MODE .................................................................2-121

2.12.4 OFF MODE.................................................................................2-122

2.12.5 SUMMARY .................................................................................2-124

2.13 OTHERS..............................................................................................2-125

2.13.1 OPERATION UNIT.....................................................................2-125

2.13.2 DOOR SAFETY SWITCH LOCK TOOLS...................................2-126

2.13.3 HDD CONTROL .........................................................................2-127

2.13.4 DATA PATH THROUGH THE INTERFACE BOARD.................2-129

INSTALLATION

3. INSTALLATION PROCEDURE................................................... 3-1

3.1 INSTALLATION REQUIREMENTS...........................................................3-1

3.1.1 ENVIRONMENT...............................................................................3-1

3.1.2 MACHINE LEVEL.............................................................................3-1

3.1.3 MINIMUM SPACE REQUIREMENTS...............................................3-2

3.1.4 POWER REQUIREMENTS..............................................................3-2

3.2 COPIER (A294).........................................................................................3-3

3.2.1 ACCESSORY CHECK......................................................................3-3

3.2.2 INSTALLATION PROCEDURE........................................................3-5

3.3 FINISHER INSTALLATION (B302)..........................................................3-13

3.3.1 ACCESSORY CHECK....................................................................3-13

3.3.2 INSTALLATION PROCEDURE......................................................3-14

3.4 LCT INSTALLATION (B303)....................................................................3-17

3.4.1 ACCESSORY CHECK....................................................................3-17

3.4.2 INSTALLATION PROCEDURE......................................................3-18

3.4.3 INSTALLATION PROCEDURE FOR THE TRAY HEATER KIT..3-19B

3.5 PUNCH UNIT INSTALLATION (A812)....................................................3-20

3.5.1 ACCESSORY CHECK....................................................................3-20

3.5.2 PUNCH UNIT INSTALLATION.......................................................3-21

Rev. 10/2000

CÓPIA NÃO CONTROLADA

A294/A295 iv SM

3.6 A3/DLT TRAY (B331)..............................................................................3-24

3.6.1 ACCESSORY CHECK....................................................................3-24

3.6.2 INSTALLATION PROCEDURE......................................................3-25

3.7 KEY COUNTER INSTALLATION............................................................3-28

3.8 INTERFACE BOARD

(CD-RW/TANDEM COPY KIT/PRINTER CONTROLLER)......................3-31

3.8.1 INSTALLATION PROCEDURE......................................................3-31

3.8.2 INSTALLATION NOTES FOR CD-R/RW .......................................3-32

3.9 TRANSPORTATION REMARKS.............................................................3-32

3.9.1 TONER TRANSPORT TUBE CLEANING ......................................3-32

SERVICE TABLES

4. SERVICE TABLES...................................................................... 4-1

4.1 GENERAL CAUTIONS..............................................................................4-1

4.1.1 DRUM............................................................................................... 4-1

4.1.2 DRUM UNIT......................................................................................4-1

4.1.3 TRANSFER BELT UNIT...................................................................4-2

4.1.4 SCANNER UNIT...............................................................................4-2

4.1.5 LASER UNIT.....................................................................................4-2

4.1.6 CHARGE CORONA..........................................................................4-3

4.1.7 DEVELOPMENT...............................................................................4-3

4.1.8 CLEANING.......................................................................................4-4

4.1.9 FUSING UNIT...................................................................................4-4

4.1.10 PAPER FEED.................................................................................4-4

4.1.11 USED TONER................................................................................4-4

4.2 SERVICE PROGRAM MODE....................................................................4-5

4.2.1 SERVICE PROGRAM MODE OPERATION.....................................4-5

4.2.2 SERVICE PROGRAM MODE TABLES..........................................4-10

4.2.3 TEST PATTERN PRINTING (SP2-902).........................................4-59

4.2.4 INPUT CHECK ...............................................................................4-60

4.2.5 OUTPUT CHECK ...........................................................................4-68

4.2.6 SYSTEM PARAMETER AND DATA LISTS (SMC LISTS) .............4-70

4.2.7 MEMORY ALL CLEAR (SP5-801)..................................................4-70

4.2.8 SOFTWARE RESET ......................................................................4-71

4.2.9 SYSTEM SETTING AND

COPY SETTING (UP MODE) RESET............................................4-71

4.3 PM COUNTER ........................................................................................4-72

4.3.1 PM COUNTER ACCESS PROCEDURE........................................4-72

4.4 PROGRAM DOWNLOAD........................................................................4-78

4.5 NVRAM DATA DOWNLOAD...................................................................4-80

4.6 LANGUAGE DATA DOWNLOAD............................................................4-81

4.7 STAMP DATA DOWNLOAD....................................................................4-81

4.8 USER PROGRAM MODE .......................................................................4-82

4.8.1 HOW TO ENTER AND EXIT UP MODE.........................................4-82

4.8.2 UP MODE TABLE...........................................................................4-82

4.8.3 IMAGE QUALITY SETTING BY UP MODE....................................4-85

4.8.4 LEDS..............................................................................................4-91

Rev. 9/2001

CÓPIA NÃO CONTROLADA

SM v A294A295

4.9 TEST POINTS/DIP SWITCHES/LEDS....................................................4-92

4.9.1 DIP SWITCHES..............................................................................4-92

4.9.2 TEST POINTS................................................................................4-93

4.9.3 FUSES............................................................................................4-93

4.9.4 VARIABLE RESISTORS ................................................................4-93

4.10 SPECIAL TOOLS AND LUBRICANTS..................................................4-94

4.10.1 SPECIAL TOOLS .........................................................................4-94

4.10.2 LUBRICANTS...............................................................................4-94

PREVENTIVE MAINTENANCE

5. PREVENTIVE MAINTENANCE SCHEDULE .............................. 5-1

5.1 PM PARTS................................................................................................5-1

REPLACEMENT AND ADJUSTMENT

6. REPLACEMENT AND ADJUSTMENT........................................ 6-1

6.1 EXTERIOR................................................................................................6-1

6.1.1 FRONT.............................................................................................6-1

6.1.2 RIGHT ..............................................................................................6-2

6.1.3 LEFT.................................................................................................6-3

6.1.4 REAR................................................................................................6-4

6.2 DOCUMENT FEEDER..............................................................................6-5

6.2.1 COVER REMOVAL ..........................................................................6-5

6.2.2 FEED UNIT REMOVAL AND

SEPARATION ROLLER REPLACEMENT .......................................6-7

6.2.3 FEED BELT REPLACEMENT..........................................................6-8

6.2.4 PICK-UP ROLLER REPLACEMENT................................................6-9

6.2.5 SENSOR REPLACEMENT.............................................................6-10

6.2.6 TRANSPORT BELT REPLACEMENT............................................6-14

6.2.7 MOTOR REPLACEMENT ..............................................................6-15

6.2.8 FEED-IN CLUTCH REPLACEMENT..............................................6-17

6.3 SCANNER UNIT......................................................................................6-18

6.3.1 EXPOSURE GLASS.......................................................................6-18

6.3.2 LENS BLOCK.................................................................................6-19

6.3.3 ORIGINAL SIZE SENSORS...........................................................6-20

6.3.4 EXPOSURE LAMP.........................................................................6-21

6.3.5 LAMP REGULATOR.......................................................................6-22

6.3.6 OPTICS DUST FILTER..................................................................6-23

6.3.7 SCANNER H.P. SENSOR..............................................................6-24

6.3.8 SCANNER MOTOR........................................................................6-25

6.3.9 SCANNER DRIVE WIRES .............................................................6-26

6.4 LASER UNIT ...........................................................................................6-29

6.4.1 CAUTION DECAL LOCATIONS.....................................................6-29

6.4.2 LDB AND LD FILTER REPLACEMENT .........................................6-30

6.4.3 POLYGON MIRROR MOTOR REPLACEMENT............................6-31

6.4.4 LASER SYNCHRONIZATION DETECTOR REPLACEMENT........6-32

Rev. 9/2001

CÓPIA NÃO CONTROLADA

A294/A295 vi SM

6.5 DRUM UNIT ............................................................................................6-33

6.5.1 DRUM UNIT REMOVAL AND DRUM REPLACEMENT .................6-33

6.5.2 QUENCHING LAMP REPLACEMENT ...........................................6-34

6.5.3 GRID PLATE/CHARGE CORONA WIRE/

WIRE CLEANER REPLACEMENT.................................................6-35

6.5.4 DRUM POTENTIAL SENSOR REPLACEMENT ............................6-37

6.5.5 CLEANING BLADE/ID SENSOR REPLACEMENT ........................6-38

6.5.6 CLEANING BRUSH REPLACEMENT............................................6-39

6.5.7 PICK-OFF PAWL REPLACEMENT................................................6-40

6.5.8 DRUM FILTER REPLACEMENT....................................................6-41

6.5.9 OPC DRUM CHANGE....................................................................6-41

6.6 DEVELOPMENT AND TONER SUPPLY ................................................6-42

6.6.1 DEVELOPMENT UNIT REMOVAL.................................................6-42

6.6.2 DEVELOPER REPLACEMENT......................................................6-43

6.6.3 DEVELOPMENT AND AIR DUST FILTER REPLACEMENT .........6-45

6.6.4 DEVELOPMENT ENTRANCE, FRONT, & REAR SIDE SEALS ...6-46

6.6.5 TONER DENSITY SENSOR REPLACEMENT...............................6-47

6.6.6 TONER HOPPER SENSOR REPLACEMENT ...............................6-48

6.6.7 DEVELOPMENT MOTOR REPLACEMENT...................................6-49

6.6.8 DEVELOPMENT ROLLER SHAFT CLEANING .............................6-50

6.7 TRANSFER BELT UNIT..........................................................................6-51

6.7.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION ....................6-51

6.7.2 TRANSFER BELT REPLACEMENT...............................................6-53

6.7.3 TRANSFER BELT CLEANING BLADE REPLACEMTNT...............6-55

6.7.4 TRANSFER BELT BIAS BRUSH REPLACEMENT ........................6-56

6.8 PAPER FEED..........................................................................................6-57

6.8.1 PAPER TRAY REMOVAL ..............................................................6-57

6.8.2 PAPER FEED ROLLER REPLACEMENT......................................6-60

6.8.3 PAPER FEED AND VERTICAL TRANSPORT CLUTCH, AND TRAY LIFT, PAPER FEED, AND

PAPER END SENSOR REMOVAL ...............................................6-61

6.8.4 REAR FENCE RETURN SENSOR REPLACEMENT.....................6-64

6.8.5 REAR FENCE HP SENSOR REPLACEMENT...............................6-65

6.8.6 RIGHT 1ST TRAY PAPER SENSOR REPLACMENT....................6-66

6.8.7 BOTTOM PLATE LIFT WIRE REPLACEMENT..............................6-67

6.8.8 PAPER DUST REMOVER CLEANING ..........................................6-69

6.8.9 REGISTRATION SENSOR CLEANING .........................................6-70

6.8.10 UNIVERSAL TRAY SIZE SWITCH REPLACEMENT ...................6-71

6.8.11 1ST TRAY LIFT MOTOR REMOVAL ...........................................6-72

6.8.12 LIFT MOTOR REMOVAL (2ND & 3RD TRAYS)...........................6-73

6.8.13 PAPER FEED MOTOR REMOVAL ..............................................6-74

6.8.14 RELAY MOTOR, UPPER RELAY CLUTCH,

LCT RELAY CLUTCH REMOVAL................................................6-75

6.8.15 REGISTRATION MOTOR REMOVAL..........................................6-76

6.8.16 COPIER FEED UNIT/DEVELOPMENT FAN MOTOR

REMOVAL....................................................................................6-77

6.8.17 LCT RELAY AND RELAY SENSOR REMOVAL ..........................6-78

6.8.18 TANDEM FEED TRAY PAPER SIZE CHANGE ...........................6-79

6.8.19 MECHANICAL SIDE REGISTRATION ADJUSTMENT ................6-82

Rev. 05/2004

CÓPIA NÃO CONTROLADA

SM vii A294A295

6.9 FUSING UNIT..........................................................................................6-83

6.9.1 OIL SUPPLY & CLEANING WEB UNIT REMOVAL.......................6-83

6.9.2 HOT ROLLER UNIT REMOVAL AND

PRESSURE ROLLER REPLACEMENT.........................................6-84

6.9.3 HOT ROLLER REPLACEMENT.....................................................6-86

6.9.4 OIL SUPPLY & CLEANING WEB REPLACEMENT.......................6-88

6.9.5 WEB CLEANING ROLLER REPLACEMENT.................................6-90

6.9.6 HOT ROLLER STRIPPER REPLACEMENT..................................6-91

6.9.7 PRESSURE ROLLER STRIPPER REPLACEMENT......................6-92

6.9.8 PRESSURE ROLLER CLEANING ROLLER REPLACEMENT ......6-93

6.9.9 FUSING AND EXIT UNIT REMOVAL.............................................6-94

6.9.10 FUSING PRESSURE ADJUSTMENT ..........................................6-95

6.10 PAPER EXIT/DUPLEX UNIT.................................................................6-96

6.10.1 EXIT SENSOR REPLACEMENT..................................................6-96

6.10.2 DUPLEX UNIT REMOVAL ...........................................................6-97

6.10.3 DUPLEX UNIT INNER COVER REMOVAL..................................6-98

6.10.4 JOGGER MOTOR REPLACEMENT............................................6-99

6.10.5 DUPLEX UNIT CLUTCH REPLACEMENT.................................6-100

6.10.6 DUPLEX ENTRANCE SENSOR REPLACEMENT.....................6-101

6.10.7 DUPLEX TRANSPORT SENSORS 2 & 3 ..................................6-102

6.10.8 DUPLEX TRANSPORT SENSOR 1/

DUPLEX INVERTER SENSOR..................................................6-103

6.11 TONER BANK.....................................................................................6-104

6.11.1 WASTE TONER BOTTLE REMOVAL........................................6-104

6.11.2 TONER BANK UNIT REMOVAL.................................................6-105

6.11.3 TONER SUPPLY MOTOR AND

TONER SUPPLY MOTOR SENSOR REMOVAL.......................6-108

6.11.4 ACCESS TO INSIDE THE TONER BANK..................................6-109

6.12 BOARDS AND OTHER ITEMS ...........................................................6-110

6.12.1 SICU BOARD.............................................................................6-110

6.12.2 HARD DISK DRIVE....................................................................6-111

6.12.3 BCU BOARD..............................................................................6-112

6.12.4 I/O BOARD.................................................................................6-113

6.12.5 PSU............................................................................................6-114

6.12.6 CHARGE/GRID/BIAS POWER PACK........................................6-115

6.12.7 FUSING/DUPLEX MOTOR REPLACEMENT.............................6-116

6.12.8 DRUM MOTOR REPLACEMENT...............................................6-117

6.13 COPY IMAGE ADJUSTMENT: PRINTING/SCANNING...................... 6-118

6.13.1 PRINTING...................................................................................6-118

6.13.2 PARALLELOGRAM IMAGE ADJUSTMENT ..............................6-121

6.13.3 SCANNING.................................................................................6-123

6.13.4 ADF IMAGE ADJUSTMENT.......................................................6-124

6.14 TOUCH SCREEN CALIBRATION.......................................................6-125

Rev. 2/2000

CÓPIA NÃO CONTROLADA

A294/A295 viii SM

TROUBLESHOOTING

7. TROUBLESHOOTING ................................................................ 7-1

7.1 SERVICE CALL CONDITIONS .................................................................7-1

7.1.1 SUMMARY.......................................................................................7-1

7.1.2 SC CODE DESCRIPTIONS .............................................................7-2

7.2 ELECTRICAL COMPONENT DEFECTS.................................................7-37

7.2.1 SENSORS......................................................................................7-37

7.2.2 SWITCHES.....................................................................................7-41

7.3 BLOWN FUSE CONDITIONS .................................................................7-42

7.4 FIRMWARE HISTORY............................................................................7-43

7.4.1 A294 / A295 FIRMWARE MODIFICATION HISTORY....................7-43

3,000-SHEET FINISHER B302

1. OVERALL MACHINE INFORMATION........................................ 8-1

1.1 SPECIFICATIONS.....................................................................................8-1

1.2 MECHANICAL COMPONENT LAYOUT....................................................8-3

1.3 ELECTRICAL COMPONENT DESCRIPTION...........................................8-4

1.4 DRIVE LAYOUT........................................................................................8-6

2. DETAILED DESCRIPTIONS ....................................................... 8-7

2.1 TRAY AND STAPLER JUNCTION GATE.................................................8-7

2.2 PAPER PRE-STACKING...........................................................................8-8

2.3 JOGGER UNIT PAPER POSITIONING.....................................................8-9

2.4 STAPLER UNIT MOVEMENT.................................................................8-10

2.5 STAPLER................................................................................................8-12

2.6 FEED-OUT..............................................................................................8-14

2.7 SHIFT TRAY UP/DOWN MOVEMENT....................................................8-15

2.8 SHIFT TRAY SIDE-TO-SIDE MOVEMENT.............................................8-16

2.9 PUNCH UNIT DRIVE ..............................................................................8-17

2.10 PUNCH WASTE COLLECTION............................................................8-18

2.11 JAM CONDITIONS................................................................................8-19

3. SERVICE TABLES.................................................................... 8-20

3.1 DIP SWITCHES.......................................................................................8-20

3.2 TEST POINTS.........................................................................................8-20

3.3 FUSES.....................................................................................................8-20

4. REPLACEMENT AND ADJUSTMENT...................................... 8-21

4.1 COVER REPLACEMENT........................................................................8-21

4.2 POSITIONING ROLLER REPLACEMENT..............................................8-24

4.3 ALIGNMENT BRUSH ROLLER REPLACEMENT...................................8-25

4.4 SENSOR REPLACEMENT......................................................................8-26

4.4.1 STACK HEIGHT 1, 2 AND EXIT GUIDE OPEN SENSOR.............8-26

4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR........................8-27

4.4.3 SHIFT TRAY EXIT SENSOR..........................................................8-28

Rev. 9/2001

CÓPIA NÃO CONTROLADA

SM ix A294A295

4.4.4 ENTRANCE AND

STAPLER TRAY ENTRANCE SENSORS .....................................8-29

4.4.5 PRE-STACK STOPPER SENSOR.................................................8-30

4.4.6 STAPLE WASTE HOPPER SENSOR............................................8-31

4.4.7 STAPLER ROTATION HP AND

STAPLER RETURN SENSORS.....................................................8-32

4.5 STAPLER REMOVAL..............................................................................8-33

4.6 PUNCH POSITION ADJUSTMENT.........................................................8-34

4.7 ROM HISTORY.......................................................................................8-35

4.7.1 FIRMWARE MODIFICATION HISTORY........................................8-35

LARGE CAPACITY TRAY B303

1. OVERALL MACHINE INFORMATION........................................ 9-1

1.1 SPECIFICATIONS.....................................................................................9-1

1.2 MECHANICAL COMPONENT LAYOUT....................................................9-2

1.3 ELECTRICAL COMPONENT DESCRIPTIONS........................................9-3

1.4 DRIVE LAYOUT........................................................................................9-5

2. DETAILED DESCRIPTIONS ....................................................... 9-6

2.1 PAPER FEED............................................................................................9-6

2.2 PICK-UP AND FEED.................................................................................9-7

2.2.1 OVERVIEW......................................................................................9-7

2.2.2 PICK-UP AND FEED........................................................................9-8

2.2.3 SEPARATION ROLLER RELEASE..................................................9-9

2.3 PAPER LIFT............................................................................................9-10

2.3.1 TRAY DETECTION ........................................................................9-10

2.3.2 LIFT MECHANISM .........................................................................9-10

2.3.3 LIFT SENSOR................................................................................9-11

2.4 PAPER SIZE DETECTION......................................................................9-12

2.5 PAPER END DETECTION......................................................................9-13

3. REPLACEMENT AND ADJUSTMENT...................................... 9-14

3.1 EXTERIOR COVER REMOVAL..............................................................9-14

3.2 INNER COVER REMOVAL.....................................................................9-15

3.3 PAPER FEED ROLLER REPLACEMENT............................................... 9-16

3.4 LCT MOTOR REPLACEMENT................................................................9-17

3.5 RELAY SENSOR REPLACEMENT.........................................................9-18

3.6 PAPER HEIGHT SENSOR AND

PAPER SIZE SWITCH REPLACEMENT.................................................9-19

3.7 MAIN DRIVE BELT REPLACEMENT......................................................9-20

3.8 SIDE REGISTRATION ADJUSTMENT...................................................9-21

Rev. 8/2000

CÓPIA NÃO CONTROLADA

A294/A295 x SM

A3/DLT TRAY KIT B331

1. OVERALL MACHINE INFORMATION...................................... 10-1

1.1 SPECIFICATIONS...................................................................................10-1

2. DETAILED DESCRIPTIONS ..................................................... 10-2

2.1 SECTIONAL DESCRIPTION...................................................................10-2

3. REPLACEMENT AND ADJUSTMENT...................................... 10-3

3.1 BOTTOM PLATE LIFT WIRE REPLACEMENT ......................................10-3

DIFFERENCES FROM THE A294 I / A295 I MODELS

1 DETAILED SECTION DESCRIPTIONS ..................................... 11-1

1.1 TONER AND DEVELOPER.....................................................................11-1

1.2 NEWLY ADDED: DEVELOPMENT SUCTION MOTOR AND

SUCKED TONER COLLECTION BOTTLE.............................................11-1

1.3 DEVELOPMENT UNIT............................................................................11-2

1.4 TONER BANK UNIT................................................................................11-3

1.5 CLEANING UNIT.....................................................................................11-3

1.6 FUSING UNIT..........................................................................................11-4

1.7 NEW ADDITIONS TO TRANSFER CURRENT CONTROL.....................11-5

1.8 CHARGE CORONA UNIT.......................................................................11-6

1.9 ELECTRICAL COMPONENTS................................................................11-6

1.10 SOFTWARE..........................................................................................11-8

2 SERVICE TABLES..................................................................... 11-9

2.1 SERVICE PROGRAM MODE..................................................................11-9

3 PREVENTIVE MAINTENANCE SCHEDULE ........................... 11-13

3.1 PM PARTS............................................................................................11-13

4 TROUBLESHOOTING ............................................................. 11-14

4.1 SERVICE CALL CONDITIONS .............................................................11-14

Rev. 9/2001

CÓPIA NÃO CONTROLADA

SM 1 A294/A295

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

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

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

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

HEALTH SAFETY CONDITIONS

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

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

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

CÓPIA NÃO CONTROLADA

A294/A295 2 SM

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:

CÓPIA NÃO CONTROLADA

OVERALL INFORMATION A294/A295

LARGE CAPACITY TRAY B303

DETAILED DESCRIPTIONS A294/A295

A3/DLT TRAY KIT B331

INSTALLATION A294/A295

DIFFERENCES FROM A294 I/A295 I

SERVICE TABLES A294/A295

PREVENTIVE MAINTENANCE A294/A295

REPLACEMENT AND ADJUSTMENT A294/A295

TROUBLESHOOTING A294/A295

3,000-SHEET FINISHER B302

TAB

POSITION 2

TAB

POSITION 1

TAB

POSITION 3

TAB

POSITION 4

TAB

POSITION 6

TAB

POSITION 5

TAB

POSITION 8

TAB

POSITION 7

Rev. 9/2001

CÓPIA NÃO CONTROLADA

OVERALL INFORMATION

CÓPIA NÃO CONTROLADA

SPECIFICATIONS

SM 1-1 A294/A295

Overall

Information

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS

1.1.1 COPIER ENGINE

Configuration: Console

Copy Process: Dry electrostatic transfer system

Originals: Sheet/Book

Original Size: Maximum: A3/11" x 17"

Minimum: A5, 5

1/2

"x 8

1/2

" (using ADF)

Original Alignment: Rear left corner

Paper Size/Weight:

Size: Mainframe, Tray 1 (Tandem Tray):

A4 sideways and LT sideways

Mainframe, Trays 2 and 3 (Universal Trays):

Europe/Asia:

A5 sideways - A3 lengthwise, 8-kai sideways, 16-kai

N. America:

1/2

" x 8

1/2

" sideways - 11" x 17" lengthwise

LCT, Trays 4 ~ 6:

A4 sideways, B5 sideways, LT sideways, A5, HLT

Duplex Tray: A5/HLT (lengthwise or sideways)

to A3/DLT, except that tab paper cannot be used

Weight: Mainframe, Trays 1 to 3:

52 to 163 g/m

16 to 40 lbs Bond 50 to 60 lbs Cover 90 lbs Index (no Tab)

LCT, Trays 4 and 5:

52 to 216 g/m

16 to 40 lbs Bond 50 to 80 lbs Cover 90 to 110 lbs Index

LCT, Tray 6:

Same as Mainframe, Trays 1 to 3

Duplex Tray:

64 to 163 g/m

20 to 40 lbs Bond 50 to 60 lbs Cover 90 lbs Index (no Tab)

CÓPIA NÃO CONTROLADA

SPECIFICATIONS

A294/A295 1-2 SM

Reproduction Ratios: 7 reduction and 5 enlargement

Metric Version Inch Version

Enlargement

400% 200% 141% 122% 115%

400% 200% 155% 129% 121%

Full Size 100% 100%

Reduction

93% 82% 75% 71% 65% 50% 25%

93% 85% 78% 73% 65% 50% 25%

Zoom: 25 ~ 400%

Copy Speed: A294: Max. 85 CPM (A4/8

1/2

" x 11" sideways)

A295: Max. 105 CPM (A4/8

1/2

" x 11" sideways)

Resolution: Scanning: 600 dpi

Printing: 600 dpi

Gradation: 256 levels

Warm-up Time: Less than 360 s (from Off mode)

First Copy Time: (1st Tray, A4 sideways)

Finisher upper tray: face down

A294: Less than 5.4 s A295: Less than 4.9 s

Finisher upper tray: face up

A294: Less than 4.1 s A295: Less than 3.8 s

Copier: face down

A294: Less than 4.5 s A295: Less than 4.2 s

Copier: face up

A294: Less than 3.2 s A295: Less than 2.9 s

Copy Number Input: Ten-key pad, 1 to 9999

Copy Paper Capacity: 1st Tray: 1,000 sheets (2,000 when used as a tandem

tray) 2nd/3rd Tray: 500 sheets each 4th/5th Tray (LCT): 1,000 sheets each 6th Tray (LCT): 2,500 sheets

Memory Capacity: A294: RAM: 48 MB x 2, HDD: 4.3 GB x 2

A295: RAM: 48 MB x 2, HDD: 6.8 GB x 2

Toner Replenishment: Cartridge exchange (1,450 g/cartridge)

Rev. 6/2000

CÓPIA NÃO CONTROLADA

+ 570 hidden pages

Gestetner A294, A295 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual