Ricoh C249, C264 Service Manual
C249/C264
SERVICE MANUAL
001780MIU
C249/C264
SERVICE MANUAL
C249/C264
SERVICE MANUAL
001780MIU
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within this document to maintain a level of confidentiality that is in the best
interest of Ricoh Corporation and its member companies.
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PERMISSION OF RICOH CORPORATION.
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only and for the benefit of such companies. No such use, or the use of
any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.
© 2006 RICOH Corporation. All rights reserved.
The Service Manual contains information
regarding service techniques, procedures,
p
rocesses and spare parts of office equipmen
t
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
r
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
g
information contained in this service manual to
repair or modify Ricoh equipment risk persona
l
injury, damage to property or loss of warrant
y
p
rotection.
Ricoh Corporation
WARNING
LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
C249 CP244 LDD145 JP4500 3560DNP
C264 CP6244 LDD245 DX4542 3270DNP
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*
10/2003 Original Printing
1 09/2006 C264 Addition
SM i C249/C264
C249/C264
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION............................................................................ 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................................1-1
1.1.1 OPTIMUM ENVIRONMENTAL CONDITION....................................1-1
1.1.2 ENVIRONMENTS TO AVOID...........................................................1-1
1.1.3 POWER CONNECTION ...................................................................1-1
1.1.4 MACHINE ACCESS .........................................................................1-2
1.2 INSTALLATION PROCEDURE .................................................................1-3
1.2.1 MAIN UNIT .......................................................................................1-3
1.2.2 BEFORE BEGINNING MACHINE OPERATION ..............................1-9
1.2.3 PLATEN COVER INSTALLATION (OPTION) ...................................... 1-10
1.2.4 ADF INSTALLATION (OPTION).....................................................1-11
1.2.5 TAPE MARKER (OPTION)..............................................................1-15
1.2.6 OPTIONAL DRUMS .......................................................................1-22
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE.................................................... 2-1
2.1 MAINTENANCE TABLE ............................................................................2-1
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1
3.1 GENERAL CAUTION ................................................................................3-1
3.2 PRINT KEY / START KEY......................................................................... 3-1
3.3 COVERS / BOARDS .................................................................................3-2
3.3.1 FRONT COVER / PANEL.................................................................3-2
3.3.2 REAR COVERS................................................................................3-3
3.3.3 MPU..................................................................................................3-3
3.3.4 PSU ..................................................................................................3-4
3.4 SCANNER .................................................................................................3-5
3.4.1 EXPOSURE GLASS / SCALES........................................................3-5
3.4.2 SBU AND LAMP STABILIZER / SCANNER MOTOR....................... 3-5
3.4.3 SCANNER H.P. SENSOR / PLATEN COVER SENSOR .................3-6
3.4.4 EXPOSURE LAMP (XENON LAMP) ................................................3-7
3.4.5 SCANNER WIRES ...........................................................................3-8
3.4.6 IMAGE ADJUSTMENT ...................................................................3-10
3.5 MASTER EJECT ..................................................................................... 3-11
3.5.1 MASTER EJECT UNIT ................................................................... 3-11
3.6 MASTER FEED ....................................................................................... 3-12
3.6.1 MASTER MAKING UNIT ................................................................ 3-12
Rev. 04/2004
C249/C264 ii SM
3.6.2 THERMAL HEAD............................................................................3-12
3.6.3 DUCT PLATE HP SENSOR / DUCT PLATE MOTOR.................... 3-16
3.6.4 CUTTER UNIT................................................................................ 3-17
3.6.5 THERMAL HEAD DRIVING UNIT ..................................................3-17
3.6.6 THERMAL HEAD VOLTAGE ADJUSTMENT................................. 3-18
3.6.7 DUCT JAM SENSOR ADJUSTMENT ............................................3-19
3.6.8 MASTER EDGE SENSOR ADJUSTMENT ....................................3-20
3.6.9 2ND DRUM MASTER SENSOR ADJUSTMENT............................ 3-21
3.6.10 MASTER END SENSOR ADJUSTMENT ..................................... 3-22
3.7 PAPER FEED..........................................................................................3-23
3.7.1 PICK-UP ROLLER / PAPER FEED ROLLER / FRICTION PAD..... 3-23
3.7.2 PAPER SEPARATION PRESSURE ADJUSTMENT......................3-24
3.7.3 PAPER WIDTH DETECTION BOARD ...........................................3-25
3.8 PRINTING ...............................................................................................3-26
3.8.1 PRESS ROLLER ............................................................................3-26
3.8.2 PRESS ROLLER RELEASE LEVER ADJUSTMENT ..................... 3-27
3.8.3 PRINTING PRESSURE ADJUSTMENT.........................................3-28
3.9 DRUM...................................................................................................... 3-29
3.9.1 PREPARATION..............................................................................3-29
3.9.2 CLOTH SCREEN............................................................................3-29
3.9.3 CLAMPER / METAL SCREEN .......................................................3-31
3.9.4 INK PUMP ADJUSTMENT .............................................................3-33
3.9.5 INK ROLLER UNIT / INK ROLLER ONE-WAY CLUTCH ............... 3-35
3.9.6 DOCTOR ROLLER GAP ADJUSTMENT ....................................... 3-36
3.9.7 INK DETECTION ADJUSTMENT...................................................3-37
3.9.8 MAIN MOTOR PULLEY POSITION................................................3-37
3.9.9 MAIN DRIVE TIMING BELT ADJUSTMENT ..................................3-37
3.9.10 INK IDLING MOTOR /INK IDLING ROLLER HP SENSOR .......... 3-38
3.9.11 EXIT PAWL ADJUSTMENT .........................................................3-39
3.10 PAPER DELIVERY................................................................................3-41
3.10.1 PAPER DELIVERY UNIT .............................................................3-41
3.10.2 DELIVERY BELT / PAPER EXIT SENSOR..................................3-41
3.10.3 EXIT PAWL ADJUSTMENT .........................................................3-42
3.10.4 AIR PUMP ADJUSTMENT ...........................................................3-44
3.11 SPECIAL TOOLS .................................................................................. 3-45
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 ERROR CODES........................................................................................4-1
4.2 ELECTRICAL COMPONENT DEFECTS ..................................................4-3
4.2.1 SENSORS ........................................................................................4-3
4.2.2 SWITCHES.......................................................................................4-5
4.2.3 LINES ...............................................................................................4-5
4.3 FUSE, LED, VR, DIP-SW, AND TP TABLES ............................................4-6
4.3.1 BLOWN FUSE CONDITIONS ..........................................................4-6
4.3.2 LED’S ...............................................................................................4-6
4.3.3 VR’S .................................................................................................4-6
4.3.4 DIP SWITCHES................................................................................ 4-7
SM iii C249/C264
4.3.5 TEST POINTS ..................................................................................4-7
4.4 OTHERS ...................................................................................................4-8
4.4.1 PAPER FEED PROBLEMS ..............................................................4-8
4.4.2 PAPER EJECTION ERRORS ........................................................4-10
4.4.3 MASTER FEED ERRORS..............................................................4-10
4.4.4 MASTER DELIVERY ERRORS...................................................... 4-11
4.4.5 DRUM ERRORS.............................................................................4-11
4.4.6 POOR IMAGE ................................................................................4-12
4.4.7 OTHERS.........................................................................................4-13
4.4.8 USER INSTRUCTIONS..................................................................4-14
SERVICE TABLES
5. SERVICE TABLES....................................................................... 5-1
5.1 USING SERVICE PROGRAM MODES.....................................................5-1
5.1.1 ACCESSING SP MODES.................................................................5-1
5.1.2 HOW TO SELECT A PROGRAM NUMBER.....................................5-2
5.2 MAIN MENU NO.1: COPY DATA ..............................................................5-3
5.2.1 SP TABLE ........................................................................................5-3
5.2.2 SP1-70: MAIN FIRMWARE PARTS NUMBER.................................5-3
5.2.3 SP1-80: ERROR CODE HISTORY...................................................5-3
5.3 MAIN MENU NO.2: BASIC SETTINGS .....................................................5-4
5.3.1 SP TABLE ........................................................................................5-4
5.3.2 SP2-7: CHINESE DISPLAY SETTING (CHINA MODEL ONLY) ......5-5
5.3.3 SP2-32: INK SUPPLY AFTER TRIAL...............................................5-5
5.3.4 SP2-33: RE - FEEDING SETTING ...................................................5-5
5.3.5 SP2-34: SLOW STARTING MODE ..................................................5-5
5.3.6 SP2-35: PRINTING PRESSURE ADJUSTMENT.............................5-5
5.3.7 SP2-36: INK IDLING ROLLER SETTING .........................................5-6
5.3.8 SP2-38: IDLING AFTER PRINT (SP2-28, 29) ..................................5-6
5.3.9 SP2-41, 2-42: THERMAL HEAD ENERGY CONTROL....................5-6
5.3.10 SP2-60: BOLD MODE: LETTER MODE ONLY ..............................5-6
5.3.11 SP2-100: MAKE A MASTER WITHOUT PRINTING.......................5-6
5.4 MAIN MENU NO.3: SYSTEM SETTINGS .................................................5-7
5.4.1 SP TABLE ........................................................................................5-7
5.4.2 SP3-1: INPUT THE PRESENT TIME ...............................................5-7
5.4.3 SP3-4: INPUT INSTALLATION DATE..............................................5-8
5.5 MAIN MENU NO.4: INPUT MODE ............................................................ 5-9
5.5.1 SP TABLE ........................................................................................5-9
5.6 MAIN MENU NO.5: OUTPUT MODE ......................................................5-10
5.6.1 SP TABLE ......................................................................................5-10
5.7 MAIN MENU NO.6: ADJUSTMENT.........................................................5-11
5.7.1 SP TABLE ......................................................................................5-11
5.7.2 SP6-40: INK DETECTION ADJUSTMENT .....................................5-14
5.7.3 IMAGE ADJUSTMENT (SP6-10, -21, -5, -3, AND -1).....................5-14
5.7.4 SP6-31: SBU CALIBRATION .........................................................5-17
5.7.5 SP6-32 TO 37: MTF FILTER ..........................................................5-17
5.7.6 SP6-20: REGISTRATION BUCKLE (NOT USED).......................... 5-18
5.7.7 SP6-60: MASTER RETURNING VALUE........................................5-18
Rev. 10/2004
C249/C264 iv SM
5.7.8 SP6-64: MASTER PUSHING VALUE (NOT USED).......................5-18
5.7.9 SP6-100 TO 107: PAPER REGISTRATION - EACH SPEED.........5-19
5.7.10 SP6-116 TO 123: PAPER MIDDLE BUCKLE (NOT USED) .........5-20
5.7.11 SP6-124 TO 131: PAPER FRONT BUCKLE (NOT USED) .......... 5-22
5.8 MAIN MENU NO.7: MEMORY CLEAR....................................................5-25
5.8.1 SP TABLE ......................................................................................5-25
5.8.2 SP7-1: FACTORY SETTINGS CLEAR...........................................5-25
5.9 MAIN MENU NO.8: SYSTEM TEST........................................................5-26
5.9.1 SP TABLE ......................................................................................5-26
5.9.2 SP8-1: DOWNLOAD MAIN FIRMWARE ........................................5-26
5.9.3 SP8-2: UPLOAD MAIN FIRMWARE...............................................5-27
5.9.4 SP8-10: TEST PATTERNS ............................................................5-27
5.9.5 SP8-21: PAPER FEED TEST (15 RPM).........................................5-27
5.9.6 SP8-22: FREE RUN PAPER FEED (15 RPM) ...............................5-27
5.9.7 SP8-18: TEMPORARY SECURITY................................................5-28
DETAILED DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 MECHANISM OVERVIEW ........................................................................6-1
6.1.1 COMPONENT LAYOUT ...................................................................6-1
6.1.2 ELECTRICAL COMPONENT LAYOUT ............................................6-2
6.1.3 DRIVE LAYOUT ...............................................................................6-7
6.2 MASTER EJECT UNIT..............................................................................6-8
6.2.1 OVERVIEW ......................................................................................6-8
6.2.2 MASTER CLAMPER OPENING MECHANISM ................................6-9
6.2.3 MASTER EJECT ROLLER MECHANISM ...................................... 6-10
6.2.4 PRESSURE PALTE MECHANISM.................................................6-11
6.3 SCANNER UNIT......................................................................................6-12
6.3.1 OVERVIEW ....................................................................................6-12
6.3.2 BOARD LAYOUT............................................................................6-13
6.3.3 AUTO BACKGROUND CORRECTION ..........................................6-14
6.3.4 MTF FILTER...................................................................................6-14
6.3.5 SMOOTHING FILTER .................................................................... 6-14
6.3.6 MAIN SCAN ENLARGEMENT/REDUCTION .................................6-14
6.3.7 BINARY PROCESSING .................................................................6-15
6.3.8 FINE MODE....................................................................................6-15
6.3.9 THERMAL HEAD............................................................................6-16
6.4 MASTER FEED ....................................................................................... 6-18
6.4.1 OVERVIEW ....................................................................................6-18
6.4.2 AUTO ADJUSTABLE MASTER SET..............................................6-19
6.4.3 THERMAL HEAD DRIVING MECHANISM.....................................6-20
6.4.4 MASTER BUFFER MECHANISM...................................................6-21
6.4.5 DETECTION OF MASTER IN THE LOWER MASTER TRAY........6-22
6.4.6 DUCT PLATE MECHANISM ..........................................................6-23
6.4.7 MASTER FEED MECHANISM .......................................................6-25
6.4.8 CLAMPER AND TENSION ROLLER MECHANISM.......................6-26
6.4.9 MASTER PUSH MYLAR ................................................................6-27
6.4.10 2ND DRUM MASTER SENSOR................................................... 6-28
Rev. 10/2004
SM v C249/C264
6.4.11 CUTTER MECHANISM ................................................................6-29
6.4.11 MASTER SET COVER SENSOR.................................................6-29
6.4.13 RE-CUTTING MECHANISM......................................................... 6-30
6.5 DRUM...................................................................................................... 6-31
6.5.1 OVERVIEW ....................................................................................6-31
6.5.2 DRUM DRIVE MECHANISM ..........................................................6-32
6.5.3 INK SUPPLY MECHANISM............................................................6-33
6.5.4 INK ROLLER MECHANISM ...........................................................6-34
6.5.5 INK SUPPLY CONTROL ................................................................6-35
6.5.6 DRUM IDLING MECHANISM .........................................................6-36
6.6 PAPER FEED..........................................................................................6-38
6.6.1 OVERVIEW ....................................................................................6-38
6.6.2 PAPER FEED MECHANISM ..........................................................6-39
6.6.3 PAPER FEED/SEPARATION PRESSURE MECHANISM .............6-40
6.6.4 REGISTRATION ROLLER MECHANISM.......................................6-41
6.6.5 PRINTING PRESSURE MECHANISM ........................................... 6-42
6.6.6 AUTO ADJUTABLE PRINTING PRESSURE MECHANISM .........6-43
6.6.7 PAPER TABLE MECHANISM .........................................................6-44
6.7 PAPER DELIVERY..................................................................................6-46
6.7.1 OVERVIEW ....................................................................................6-46
6.7.2 PAPER DELIVERY UNIT DRIVE MECHANISM............................. 6-46
6.7.3 PAPER SEPARATION FROM THE DRUM ....................................6-47
6.7.4 EXIT PAWL DRIVE MECHANISM..................................................6-48
6.8 TIMING CHART.......................................................................................6-49
6.8.1 MASTR EJECT/MASTER FEED ....................................................6-49
6.8.2 MASTER WRAPPING .................................................................... 6-51
6.8.3 PRINTING ......................................................................................6-53
6.9 JAM DETECTION....................................................................................6-55
6.9.1 MASTER EJECT JAM (B JAM LOCATION INDICATOR) ..............6-55
6.9.2 DF JAM (P JAM LOCATION INDICATOR).....................................6-56
6.9.3 MASTER FEED JAM (D JAM LOCATION INDICATOR)................6-57
6.9.4 DRUM JAM (B JAM LOCATION INDICATOR)...............................6-60
6.9.5 PAPER FEED JAM (A JAM LOCATION INDICATOR)................... 6-60
6.9.6 PAPER DELIVERY JAM (C JAM LOCATION INDICATOR)...........6-61
SPECIFICATIONS
SPECIFICATIONS............................................................................. 7-1
1. GENERAL SPECIFICATIONS.....................................................................7-1
C264
SEE SECTION C264 FOR DETAILED TABLE OF CONTENTS
DOCUMENT FEEDER C600
SEE SECTION C600 FOR DETAILED TABLE OF CONTENTS
Rev. 07/2004
C249/C264 vi SM
PRINTER SCANNER C624
SEE SECTION C624 FOR DETAILED TABLE OF CONTENTS
INSTALLATION C249
DOCUMENT FEEDER C600
PREVENTIVE MAINTENANCE C249
PRINTER/CONTROLLER C624
REPLACEMENT AND ADJUSTMENT C249
TROUBLESHOOTING C249
SERVICE TABLES C249
DETAILED DESCRIPTIONS C249
SPECIFICATIONS C249
C264
TAB
POSITION 2
TAB
POSITION 1
TAB
POSITION 3
TAB
POSITION 4
TAB
POSITION 6
TAB
POSITION 5
TAB
POSITION 8
TAB
POSITION 7
INSTALLATION
INSTALLATION REQUIREMENTS
SM 1-1 C249
Installation
1. INSTALLATION
1.1 INSTALLATION REQUIREMENTS
Carefully select the installation location. Environmental conditions greatly affect
machine performance.
1.1.1 OPTIMUM ENVIRONMENTAL CONDITION
1. Temperature 10 to 30 °C (50 to 86 °F)
2. Humidity 20 to 90 % RH
3. Install the machine on a strong and level base. The machine must be level
within 5 mm (0.2") both front to rear and left to right.
1.1.2 ENVIRONMENTS TO AVOID
1. Locations exposed to direct sunlight or strong light (more than 1,500 lux).
2. Dusty areas.
3. Areas containing corrosive gases.
4. Locations directly exposed to cool air from an air conditioner or reflected heat
from a space heater. (Sudden temperature changes from low to high or vice
versa may cause condensation within the machine.)
1.1.3 POWER CONNECTION
1. Securely connect the power cord to a power source.
2. Make sure that the wall outlet is near the machine and easily accessible.
3. Make sure the plug is firmly inserted in the outlet.
4. Avoid multi-wiring.
5. Do not pinch the power cord.
INSTALLATION REQUIREMENTS
C249 1-2 SM
1.1.4 MACHINE ACCESS
Place the machine near a power source, providing clearance as shown below.
C249I000.WMF
INSTALLATION PROCEDURE
SM 1-3 C249
Installation
1.2 INSTALLATION PROCEDURE
1.2.1 MAIN UNIT
Accessory Check
Make sure that you have all the accessories listed below:
Description Q'ty
1. Master Spool.............................................................................. 2
2. Operating Instructions................................................................ 1
3. NECR (Ricoh version only)........................................................ 1
4. Model Name Plates (C249-22, and -52 only)............................. 1 set
C249I019.WMF
INSTALLATION PROCEDURE
C249 1-4 SM
Installation Procedure
1. Unpack the box. When installing the optional table, mount the machine as
shown (there are 2 screws [A] packed with the table).
CAUTION
Only lift with the carrying handles on the bottom corners of the machine.
Secure the machine on the table with the 2 screws [A] provided. This
prevents the machine from falling from the table when the platen cover is
open.
Lock the casters of the table as shown [B], to prevent the machine from
moving (e.g. when the drum is set).
C249I014.WMF
[B]
[A]
INSTALLATION PROCEDURE
SM 1-5 C249
Installation
2. Remove the filament tape and string securing the covers and units as shown
above.
C249I907.WMF
C249I020.WMF
C249I908.WMF
C249I909.WMF
INSTALLATION PROCEDURE
C249 1-6 SM
3. Pull out the master making unit, and
take out the accessory bag [A].
4. Insert both spools into a new master
roll.
5. Install the master roll as shown to the right.
6. Insert the leading edge of the master
roll under the platen roller. The arrows
[B] indicate the correct position of the
master leading edge.
C249I038.WMF
C249I030.WMF
C249I032.WMF
C249I910.WMF
[B]
[A]
INSTALLATION PROCEDURE
SM 1-7 C249
Installation
7. Close the cover [C] using both hands.
8. Set the master-making unit.
9. Open the door, and insert a new ink
cartridge [D].
10. Open the paper table, and load a
stack of paper.
11. Make sure that the side plates [E]
touch the paper gently. Shift the lock
lever [F] in the direction of the arrow.
C249I031.WMF
C249I034.WMF
C249I028.WMF
[D]
[C]
[E]
[F]
INSTALLATION PROCEDURE
C249 1-8 SM
12. Raise the paper delivery table [G]
slightly, then gently lower it.
13. Lift the side plates and the end
plate, and adjust them to the
paper size.
14. Firmly insert the power plug in the
outlet.
15. Make sure that the wall outlet is near
the machine and easily accessible.
16. Turn on the main switch [H].
17. Press the “Economy mode” key while
holding down the “0” key, to supply
ink inside the drum.
18. Make some test copies.
C249I027.WMF
C249I026.WMF
[G]
[H]
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