SONY B S2 T S Service Manual

RICOH GROUP COMPANIES

A246/A247/A248

SERVICE MANUAL

PN: RCSMA246

SERVICE MANUAL

A246/A247/A248

RICOH GROUP COMPANIES

A246/A247/A248

SERVICE MANUAL

PN:RCSMA246

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NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY

FASHION AND DISTRIBUTED WITHOUT THE PRIOR

PERMISSION OF RICOH CORPORATION.

All product names, domain names or product illustrations, including desktop images, used in this document are trademarks, registered trademarks or the property of their respective companies.

They are used throughout this book in an informational or editorial fashion 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.



g o

WARNING

The Service Manual contains informatio regarding service techniques, procedures, processes and spare parts of office equipmen distributed by Ricoh Corporation. Users of thi manual should be either service trained o certified by successfully completing a Rico Technical Training Program.

Untrained and uncertified users utilizin information contained in this service manual t repair or modify Ricoh equipment risk persona injury, damage to property. or loss of warrant protection.

Ricoh Corporation

LEGEND

PRODUCT CODE COMPANY

GESTETNER RICOH SAVIN

A246 2851 FT7950 2050 A247 2860 FT7960 2060 A248 2870 FT7970 2070

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

12/98 Original Printing

A246/A247/A248 and A175/A176/A177

Product Comparison Chart

Refer to SM, pg. 2-113 for

After the last sheet of copy paper is stacked

detailed information.

in the duplex tray, the next job will start.

Refer to SM, pg. 2-85/89

for detailed information.

A246G507.WMF

Last sheet

First duplex sheet

The tandem tray (capacity: 500 x 2) is the 1st

tray for (A176/A177/A191/A192 copiers).

SERIES COPIERS.

Duplex copy control has been revised. The

duplex copy productivity has been increased

Duplex copy

productivity

Last sheet

First duplex sheet

in the simplex to duplex mode. Before the

last sheet of copy paper is stacked in the

duplex tray, the next job will start from the

bottom stacked sheet in simplex to duplex

mode.

1st tray for easier paper replenishment.

Tandem LCT The tandem LCT (capacity: 1,550 x 2) is the

1. THE FOLLOWING TABLE SHOWS THE MAJOR DIFFERENCES BETWEEN THE A246/A247/A248 AND A175/A176/A177

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

SM 1 A246/A247/A248

Refer to SM, pg. 2-31/35

for detailed information.

Around 10% of toner is collected to the used

toner collection bottle without transferring the

Refer to SM, pg. 2-65/67

for detailed information.

The A229 (digital copier)

does not have a transfer

belt cleaning blade.

Reason:

If the toner on the transfer

belt were scraped by a

cleaning blade, some of

the normally negatively

charged toner could be

charged positively by

friction.

The positively charged

toner then could not be

removed by the cleaning

bias roller.

A246G500.WMF

toner to the copy paper.

Bias Roller Blade

The toner from the drum cleaning unit and

transfer belt unit is collected and the filtering

Toner re-cycl i n g

system

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

Cleaning Bias Roller

equipment mechanism separates the re-

usable toner and unusable material (blocked

toner and paper dust). The re-usable toner is

returned to the toner tank and the unusable

material is collected in the used toner

collection bottle. About 3% of toner is

collected in the used toner collection bottle.

The estimated period before the toner

collection bottle is full has been extended

from 240 k to 1,500 k copies.

To improve the transfer belt function, a

cleaning bias roller and a bias roller blade

have been added to the transfer belt unit.

Even if the toner is not removed completely

by the transfer belt cleaning blade due to the

paper dust stuck on the transfer belt cleaning

blade, the toner is attracted to the negative

charged cleaning bias roller. The bias roller

blade scrapes off the toner on the cleaning

bias roller.

Transfer belt

cleaning bias

roller

Transfer Belt Cleaning Blade

SM 2 A246/A247/A248

Refer to SM, pg. 2-37 for

detailed information.

Refer to the Operating

Instructions.

The size of the LCD on the operation panel is

320 x 240 dots.

Refer to the Operating

Instructions

The operators have to input 2 actions of the

key operation to enter the UP mode (Clear

Refer to SM, pg. 4-8 and

SP 1-12-1 for detailed

information.

mode key and Clear/Stop key).

Additional original can be set on ADF table

during copying but the copy operation is not

continued

The process control only starts when the

fusing temperature is low. If the main switch

of the copier is not turned off during 24 hours,

the fusing temperature does not go down to

100°C. Process control cannot be carried

out.

To reduce the machine vibration while the

scanner is returning to the home position for

Optics/Scanner

return speed (70

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

70 cpm machines, the appropriate return

speed for each reproduction ratio is adapted

CPM machine)

so that the vibration of the machine is

added for easier access in the UP mode.

table during copying and the copy

operation is continued (totally 100

originals).

operation panel.

widened from 7 to 9. The number of

programs has been increased from 5 to

10. The digits of the user code has been

increased from 6 to 8.

SP mode.

reduced (to the 60 cpm machine level).

operation panel has been enlarged to 640 x

240 dots. For easier key operation, the layout

of the keys has been changed.

A175/A176/A177 machines have been

incorporated to facilitate machine operation.

1) The key top for the UP mode has been

2) Additional or iginals can be set on the ADF

Operation panel For easier operation, the LCD on the

Operation Improvements resulting from experience with

3) A sample copy key is added to the

4) T he range of the ID level has been

5) T he units (inch or mm) can be changed by

The process control auto start mode can be

selected in SP mode (Default: selected). To

maintain optimum copy quality, process

control occurs every 24 hours even if the

main switch is not turned off.

Process control

auto start mode

SM 3 A246/A247/A248

Refer to SM, pg. 2-99 for

detailed information.

Refer to SM, pg. 4-16 for

detailed information.

Developer, Type 9

EDP Code: 887797

Toner, Type 6105

EDP Code: 887801

See illustration. Refer to

SM, pg. 2-21 for detailed

information.

A246G503.WMF

A175/A176/A177A246/A247/A248

When the registration clutch turns on, the

main motor rotation may sometimes be

shocked. Jitter may appear at 80 mm from

the leading edge on small fine dotted images.

It takes longer to deliver severely curled

paper such as recycled paper or paper which

was fed as far as the duplex separation

section in the duplex unit. In latter case, the

paper guide is already up for next sheet of

paper. The paper guide cannot guide the

paper. To solve the problem, a program in

SP mode has been added.

For exit jam removal, it is necessary to open

the sorter stapler door first and then the

copier front door. Also, it is necessary to

close the copier front door first and then the

sorter stapler door.

The PM cycle for replacing developer is every

120 k.

The new type drum can be installed in the

A175/A176/A177 machines.

An independent stepping motor drives the

registration roller to ensure good copy

Drive for the

registration roller

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

speed has increased 1.6 times from the

A177 so that the positioning roller delivers

the paper to the duplex separation section

while the paper guide is down.

changed by SP mode (1-9-1).

quality.

the following modification has been applied.

Duplex To ensure good stacking in the duplex unit,

1) T he duplex positioning roller rotation

2) T he positioning ro ller on timing can be

Operators can open and close either the

Exterior/Front

copier or the sorter stapler door first because

the copier door swing to the right.

doors

New developer is used to stabilize the

triboelectric charge after a long copy run

Developer

(300 k). The new developer maintains the

triboelectric chargeability over a long time.

This reduces the possibility of low image

density or dirty background.

To prevent the drum temperature from

increasing in the continuous duplex mode,

the drum has 12 holes in each drum flange.

Drum

SM 4 A246/A247/A248

See illustration.

The key counter holder is installed at the

copier right rear position.

Refer to SM, pg. 2-91 for

Refer to SM, pg. 3-16/17

for detailed information.

A246G504.WMF

detailed information.

Refer to SM, pg. 4-18 for

detailed information.

Key Counter Holder

When removing misfed paper in the vertical

transport section, it is necessary to open the

upper and lower vertical transport guides.

The open angle of the upper vertical

transport guide is narrower than that of the

lower vertical transport guides.

The key counter holder is installed at the

Key counter

copier right front position for easier operation.

The upper and lower transport guides have

Vertical transport

been combined into one part for easier

operation of jam removal. The open angle of

guide

data can

+300(V)

= V

Thicker, N: Normal, H: Thinner, HH: Much

IDB

Thinner

the upper guide is the same as that of the

lower guide.

Vertical thin line may be thicker than original

after generation copy. Vertical thin lines can

Character Thin

Line Adjustment

be compensated by SP mode (SP1-13-4). L:

be made thinner by lowering the toner

density in the development unit. V

(Generation Copy

Mode)

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

SM 5 A246/A247/A248

See illustration.

When replacing the pressure roller and its

bearings without removing the hot roller, it is

Refer to SM, pg. 5-2 for

detailed information.

Refer to SM, pages 6 1 to

6-9 for details.

A246G501.WMF

Lever

necessary to remove the pressure levers,

retaining rings, and connector bracket.

Retaining Ring

The PM cycle for replacing the pressure roller

is every 240 k.

The Energy Star compliant, US version only. Refer to SM, pg. 2-115 for

To remove the right or the left cover, it is

necessary to remove the other parts (front

cover, rear cover, and inner cover).

The pressure levers securing method has

been changed. The levers are hooked by the

Fusing/Pressure

roller

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

High durability rubber is used for the

pressure roller (450 k).

The European version machine meets the

Energy Star guidelines for energy efficiency

as well as US version machines.

independently. The numbers of screws

required for removing following covers have

been reduced.

Operation panel (-4), Upper cover (-4), Right

upper cover (-4), Lower left & right cover (-2),

shaft and holes, and 2 retaining rings have

been eliminated. Thus, it is not necessary to

remove the connector bracket when

replacing the pressure roller and its bearings

without removing the hot roller.

Retaining Ring

Fusing

Energy star

compliant

Exterior covers The left and right covers can be removed

Lower rear cover (-4)

SM 6 A246/A247/A248

See illustration.

The two types of belt are

not interchangeable. The

two types of duplex unit

are also not interchange-

able because of the

different connectors.

A246G502.WMF

The bias terminal in the development roller

rotates in the bias receptacle. The bias

terminal must be lubricated.

A175/A176/A177

A246/A247/A248

Three separation belts are used for duplex

separation.

The bias terminal (development roller shaft)

does not rotate but the outside of the

Development/Bias

terminal

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

development roller shaft rotates. It is not

necessary to lubricate the development bias

terminal.

lubrication

The number of separation belts has been

reduced from 3 to 1.

Duplex/Separation

belt

SM 7 A246/A247/A248

See illustration.

The drum grounding plate contacts the drum

shaft rotated. Replacement and lubrication

A246G505.WMF

A246G506.WMF

Brush

A246/A247/A248

Brush

Bearing

every 1.2 M are necessary.

Drum Grounding Plate

As the drum grounding terminal, a conductive

brush and a conductive bearing are used. It

Drum grounding

terminal

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

A175/A176/A177

is not necessary to replace these parts at

regular PM.

SM 8 A246/A247/A248

Refer to SM, pg. 9-19/21

for detailed information.

There are 2 solenoids in the grip assembly.

One is used for opening and closing the grip

arms. The other is used for moving the grip

arms. The grip motor is used for moving the

Refer to SM, pg. 4-52 for

detailed information.

grip arms.

The operator can selects 4 staple positions

(top, bottom, slant, 2 staple).

Refer to SM, pg. 9-25 for

detailed information.

The capacity of the punch collection box is as

follows:

7 k sheets (2 holes/sheet) 5 k sheets (3

holes/sheet)

Refer to SM, pg. 9-8 for

In the proof mode the proof exit roller (driving

detailed information.

side) contacts the front side (image side) to

deliver the copy paper.

See Operating

Instruictions

When making more than 20 sets of copies,

operators have to divide the job. The

operator also has to input the settings after

each 20 sets of copies is finished.

is used for opening and closing the grip arms,

Sorter stapler/Grip There are 2 motors in the grip assembly. One

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

instead of solenoids. The other (Grip motor)

is used for moving the grip arms. This reduce

the operation noise in staple mode.

In addition to the 4 staple positions (top,

bottom, slant, 2 staple), the operator can

User

program/Three

select either the 2 or 3 staple position by user

program. When the 3 staple position is

staple position

selected, the indication on the operation

panel will be changed from 2-staple to 3-

staple.

The capacity of the punch waste collection

Sorter

box has been increased.

20 k sheets (2 holes/sheet)/13 k sheets (3

holes/sheet)

stapler/Punch

waste collection

box

For easier operation of the next job or in the

Sorter

platen mode, the original tray is added to the

stapler/Original

top of the proof tray in the sorter stapler.

To ensure good copy quality in proof mode,

the proof exit roller (driving side) contacts the

rear side (non-image side) to deliver the copy

paper.

When making more than 20 sets of copies,

operators just input the number of sets and

press the start key. The operator must then

remove every 20 sets of copies stacked in

the 20 bins. Then reset the originals, and

press the start key again. The operator can

have more than 20 sets of copies.

tray

Sorter

stapler/Proof exit

roller

Sorter

stapler/limitless

sort function:

software

SM 9 A246/A247/A248

Refer to SM, pg. 2-48/49

for detailed information.

There are three reflective type sensors to

detect the original size in platen mode.

Refer to SM, pg. 2-95 for

detailed information.

The APS sensor emits 2 beams (ultra red

light LED) to scan the original size. To

Optics/APS

sensor

No. Section/Item A246/A247/A248 A175/A176/A177 Remarks

distinguish between LT and LG paper sizes,

another APS sensor (usual reflective type) is

installed in the US version.

When the by-pass paper feed key is pressed

twice, the copier enters the thick paper mode.

By-pass tray/Thick

paper mode

In this mode the by-pass feed clutch turns on

twice, the fusing temperature is controlled in

a higher than normal mode, the continuous

copy speed is reduced, and higher transfer

current is applied to the transfer belt.

SM 10 A246/A247/A248

OVERALL INFORMATION

1. OVERALL MACHINE INFORMAT ION........................................ 1-1

1.1 SPECIFICATION...................................................................................... 1-1

1.2 MACHINE CONFIGURATION.................................................................. 1-6

1.2.1 COPIER OVERVIEW....................................................................... 1-6

1.2.2 SYSTEM OVERVIEW...................................................................... 1-6

1.3 COPY PROCESS AROUND THE DRUM................................................. 1-8

1.4 MECHANICAL COMPONENT LAYOUT................................................. 1-10

1.5 DRIVE LAYOUT ..................................................................................... 1-12

1.6 PAPER PATH......................................................................................... 1-13

1.6.1 STANDARD COPYING.................................................................. 1-13

1.6.2 MULTIPLE 2-SIDE COPYING....................................................... 1-14

1.7 ELECTRICAL COMPONENT DESCRIPTION........................................ 1-15

DETAILED DESCRIPTIONS

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

2.1 PROCESS CONTROL.............................................................................. 2-1

2.1.1 OVERVIEW ..................................................................................... 2-1

2.1.2 PROCESS CONTROL DATA INITIAL SETTING............................. 2-4

2.1.3 LATENT IMAGE CONTROL............................................................ 2-5

2.1.4 IMAGE DENSITY CONTROL........................................................ 2-12

2.2 DRUM UNIT............................................................................................ 2-18

2.2.1 OVERVIEW ................................................................................... 2-18

2.2.2 OPC DRUM CHARACTERISTICS................................................. 2-19

2.2.3 DRUM CHARGE............................................................................ 2-20

2.2.4 ERASE........................................................................................... 2-23

2.2.5 CLEANING..................................................................................... 2-25

2.2.6 QUENCHING................................................................................. 2-30

2.3 DRUM CLEANING AND TONER-RECYCLING...................................... 2-31

2.3.1 TONER TRANSPORT................................................................... 2-31

2.3.2 FILTERING.................................................................................... 2-32

2.3.3 PUMP MECHANISM...................................................................... 2-33

2.3.4 DRIVE MECHANISM..................................................................... 2-34

2.3.5 TONER COLLECTION BOTTLE.................................................... 2-35

2.4 OPTICS .................................................................................................. 2-36

2.4.1 OVERVIEW ................................................................................... 2-36

2.4.2 SCANNER DRIVE ......................................................................... 2-37

2.4.3 VERTICAL LENS DRIVE............................................................... 2-38

2.4.4 HORIZONTAL LENS DRIVE.......................................................... 2-39

2.4.5 HORIZONTAL LENS POSITIONING............................................. 2-40

2.4.6 3RD SCANNER DRIVE................................................................. 2-42

SM i A246/A247/A248

2.4.7 OPTICS CONTROL CIRCUIT........................................................ 2-43

2.4.8 AUTOMATIC IMAGE DENSITY CONTROL SYSTEM (ADS)........ 2-44

2.4.9 MANUAL IMAGE DENSITY CONTROL ........................................ 2-46

2.4.10 UNEVEN LIGHT INTENSITY CORRECTION.............................. 2-47

2.4.11 ORIGINAL SIZE DETECTION IN PLATEN MODE...................... 2-48

2.4.12 HALF TONE MODE..................................................................... 2-50

2.5 DEVELOPMENT..................................................................................... 2-51

2.5.1 OVERVIEW ................................................................................... 2-51

2.1.2 DEVELOPMENT MECHANISM..................................................... 2-52

2.1.3 DRIVE MECHANISM..................................................................... 2-53

2.1.4 CROSSMIXING ............................................................................. 2-54

2.1.5 DEVELOPMENT BIAS................................................................... 2-55

2.1.6 TONER SUPPLY........................................................................... 2-60

2.6 IMAGE TRANSFER................................................................................ 2-64

2.6.1 PRE-TRANSFER LAMP................................................................ 2-64

2.6.2 IMAGE TRANSFER AND PAPER SEPARATION OVERVIEW..... 2-65

2.6.3 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM... 2-66

2.6.4 TRANSFER BELT UNIT LIFT MECHANISM................................. 2-68

2.6.5 PAPER TRANSPORTATION AND BELT DRIVE MECHANISM....2-69

2.6.6 TRANSFER BELT CLEANING MECHANISM................................ 2-70

2.6.7 TONER COLLECTION MECHANISM............................................ 2-71

2.6.8 TRANSFER ANTI-CONDENSATION HEATER............................. 2-72

2.7 PAPER FEED......................................................................................... 2-73

2.7.1 OVERVIEW ................................................................................... 2-73

2.7.2 FRR FEED SYSTEM..................................................................... 2-74

2.7.3 SLIP CLUTCH MECHANISM......................................................... 2-76

2.7.4 FRR FEED DRIVE MECHANISM.................................................. 2-77

2.7.5 SEPARATION ROLLER RELEASE MECHANISM........................ 2-79

2.7.6 PAPER RETURN MECHANISM.................................................... 2-80

2.7.7 PAPER SKEW PREVENTION MECHANISM................................ 2-81

2.7.8 PAPER LIFT MECHANISM............................................................ 2-82

2.7.9 PAPER NEAR END/PAPER END DETECTION............................ 2-85

2.7.10 TANDEM FEED TRAY................................................................. 2-86

2.7.11 PAPER SIZE DETECTION.......................................................... 2-90

2.7.12 VERTICAL TRANSPORT MECHANISM ..................................... 2-91

2.7.13 TRAY POSITIONING MECHANISM............................................ 2-92

2.7.14 BY-PASS FEED TABLE .............................................................. 2-95

2.7.15 PAPER REGISTRATION............................................................. 2-98

2.7.16 REGISTRATION DRIVE MECHANISM....................................... 2-99

2.7.17 GUIDE PLATE RELEASE MECHANISM................................... 2-100

2.8 IMAGE FUSING.................................................................................... 2-101

2.8.1 OVERVIEW ................................................................................. 2-101

2.8.2 FUSING ENTRANCE GUIDE...................................................... 2-102

2.8.3 FUSING DRIVE MECHANISM..................................................... 2-103

2.8.4 FUSING LAMP CONTROL.......................................................... 2-104

2.8.5 INVERTER AND PAPER EXIT.................................................... 2-105

2.8.6 INVERTER AND EXIT DRIVE MECHANISM............................... 2-106

2.9 DUPLEX ............................................................................................... 2-107

2.9.1 OVERVIEW ................................................................................. 2-107

A246/A247/A248 ii SM

2.9.2 DRIVE MECHANISM................................................................... 2-108

2.9.3 DUPLEX ENTRANCE TO DUPLEX TRAY.................................. 2-109

2.9.4 DUPLEX STACKING................................................................... 2-110

2.9.5 DUPLEX PICK-UP ROLLER MECHANISM................................. 2-111

2.9.6 DUPLEX PAPER FEED............................................................... 2-112

2.10 ENERGY STAR COMPLIANT MACHINES

(ALL THE DESTIMATIONS)............................................................... 2-115

2.11 ENERGY SAVING INFORMATION.................................................... 2-117

2.11.1 ABOUT THE ENERGY SAVING FE ATURES OF

THIS COPIER............................................................................ 2-117

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 (A246/A247/A248)...................................................................... 3-3

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

3.2.2 INSTALLATION PROCEDURE........................................................ 3-4

3.2.3 GUIDANCE ROM INSTALLATION

(OPTION: EUROPE VERSION ONLY)......................................... 3-14

3.2.4 PLATEN COVER (OPTION) INSTALLATION................................ 3-15

3.2.5 KEY COUNTER HOLDER INSTALLATION (OPTION).................. 3-16

3.2.6 ORIGINAL TRAY INSTALLATION (OPTION)................................ 3-18

3.3 UNIVERSAL TRAY (TRAY 2)................................................................. 3-19

3.4 550 SHEETS PAPER TRAY (TRAY 3)................................................... 3-20

3.5 TANDEM FEED TRAY PAPER SIZE CHANGE (TRAY 1)..................... 3-22

3.6 DUAL JOB FEEDER (A610)................................................................... 3-25

3.6.1 ACCESSORY CHECK................................................................... 3-25

3.6.2 INSTALLATION PROCEDURE...................................................... 3-26

3.7 SORTER STAPLER (A821).................................................................... 3-29

3.7.1 ACCESSORY CHECK................................................................... 3-29

3.7.2 INSTALLATION PROCEDURE...................................................... 3-30

3.7.3 SORTER ADAPTER INSTALLATION (OPTION)........................... 3-34

3.8 20 BIN SORTER STAPLER (A658) (A246 ONLY) ................................. 3-36

3.8.1 ACCESSORY CHECK................................................................... 3-36

3.8.2 INSTALLATION PROCEDURE...................................................... 3-37

3.9 LCT (A822)............................................................................................. 3-41

3.9.1 ACCESSORY CHECK................................................................... 3-41

3.9.2 INSTALLATION PROCEDURE...................................................... 3-42

3.9.3 PAPER SIZE CHANGE ................................................................. 3-46

3.10 TRANSPORTATION REMARKS.......................................................... 3-49

3.10.1 TONER RECYCLING TUBE CLEANING..................................... 3-49

3.10.2 OTHER OPERATIONS................................................................ 3-49

SM iii A246/A247/A248

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 CHARGE CORONA......................................................................... 4-2

4.1.4 OPTICS ........................................................................................... 4-2

4.1.5 ERASE LAMP.................................................................................. 4-3

4.1.6 DEVELOPMENT UNIT .................................................................... 4-3

4.1.7 TRANSFER BELT UNIT .................................................................. 4-3

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

4.1.9 PRE-TRANSFER LAMP.................................................................. 4-4

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

4.1.11 FUSING UNIT................................................................................ 4-4

4.1.12 USED TONER ............................................................................... 4-5

4.2 SERVICE PROGRAM MODE................................................................... 4-6

4.2.1 SERVICE PROGRAM MODE OPERATION.................................... 4-6

4.2.2 SERVICE PROGRAM MODE TABLES........................................... 4-8

4.2.3 INPUT CHECK............................................................................... 4-45

4.2.4 OUTPUT CHECK........................................................................... 4-48

4.3 USER PROGRAM.................................................................................. 4-51

4.3.1 HOW TO ENTER AND EXIT UP MODE........................................ 4-51

4.3.2 UP MODE TABLE.......................................................................... 4-51

4.4 TEST POINTS/DIP SWITCHES/LEDS................................................... 4-53

4.4.1 DIP SWITCHES............................................................................. 4-53

4.4.2 TEST POINTS............................................................................... 4-53

4.4.3 FUSES........................................................................................... 4-54

4.4.4 LEDS ............................................................................................. 4-54

4.5 SPECIAL TOOLS AND LUBRICANTS ................................................... 4-54

4.5.1 SPECIAL TOOLS........................................................................... 4-54

4.5.2 LUBRICANTS................................................................................ 4-54

4.6 TOUCH PANEL DISPLAY POSITION ADJUSTMENT........................... 4-55

PREVENTIVE MAINTENANCE

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

5.1 PM TABLE................................................................................................ 5-1

5.2 PM PROCEDURE .................................................................................... 5-5

5.2.1 CLEARING PM COUNTER.............................................................. 5-5

5.2.2 PM PROCEDURE............................................................................ 5-6

REPLACEMENT AND ADJUSTMENT

6. REPLACEMENT AND AD JUSTMENT........................................ 6-1

6.1 EXTERIOR AND INNER COVER REMOVAL........................................... 6-1

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

A246/A247/A248 iv SM

6.1.2 REAR SIDE...................................................................................... 6-2

6.1.3 INNER COVER................................................................................ 6-3

6.1.4 RIGHT SIDE.................................................................................... 6-6

6.1.5 LEFT SIDE....................................................................................... 6-7

6.1.6 OPERATION PANEL....................................................................... 6-8

6.1.7 UPPER COVER............................................................................... 6-9

6.2 PAPER FEED......................................................................................... 6-10

6.2.1 PAPER TRAY UNIT REMOVAL.................................................... 6-10

6.2.2 PAPER TRAY REMOVAL.............................................................. 6-13

6.2.3 PAPER FEED ROLLERS REPLACEMENT................................... 6-16

6.2.4 PAPER FEED TIMING ADJUSTMENT.......................................... 6-17

6.2.5 PAPER FEED CLUTCH REMOVAL

(1ST TRAY PAPER FEED CLUTCH)........................................... 6-20

6.2.6 REAR FENCE RETURN SENSOR REPLACEMENT.................... 6-24

6.2.7 REAR FENCE HP SENSOR REPLACEMENT.............................. 6-25

6.2.8 BOTTOM PAPER SENSOR REPLACEMENT............................... 6-26

6.2.9 BY-PASS FEED TABLE REMOVAL.............................................. 6-27

6.2.10 BY-PASS FEED ROLLERS REPLACEMENT ............................. 6-28

6.2.11 BY-PASS PAPER SIZE SE NSOR REPLACEMENT ................... 6-29

6.2.12 BY-PASS FEED CLUTCH AND GUIDE PLATE SOLENOID

REMOVAL................................................................................... 6-31

6.2.13 REGISTRATION MOTOR REMOVAL......................................... 6-33

6.2.14 PAPER DUST CLEANER CLEANING......................................... 6-34

6.2.15 REGISTRATION SENSOR CLEANING....................................... 6-35

6.2.16 UNIVERSAL TRAY SIZE SWITCH REPLACEMENT.................. 6-36

6.2.17 550-SHEET TRAY SET SWITCH REPLACEMENT .................... 6-37

6.2.18 LIFT MOTOR REMOVAL............................................................. 6-38

6.2.19 PAPER FEED MOTOR REMOVAL ............................................. 6-39

6.2.20 COPIER FEED UNIT REMOVAL................................................. 6-40

6.2.21 BOTTOM PLATE LIFT WIRE REPLACEMENT........................... 6-42

6.2.22 550 SHEETS PAPER TRAY (TRAY 3)........................................ 6-44

6.2.23 TANDEM FEED TRAY PAPER SIZE CHANGE.......................... 6-46

6.3 OPTICS .................................................................................................. 6-49

6.3.1 EXPOSURE GLASS REMOVAL.................................................... 6-49

6.3.2 EXPOSURE LAMP REPLACEMENT............................................ 6-50

6.3.3 OPTICS THERMOSWITCH REPLACEMENT............................... 6-52

6.3.4 SCANNER HP SENSOR REPLACEMENT ................................... 6-53

6.3.5 ADS SENSOR REMOVAL............................................................. 6-54

6.3.6 SCANNER DRIVE MOTOR........................................................... 6-55

6.3.7 SCANNER DRIVE WIRES REPLACEMENT................................. 6-56

6.3.8 THIRD SCANNER REMOVAL....................................................... 6-72

6.3.9 THIRD SCANNER DRIVE MOTOR/HP SENSOR

REPLACEMENT............................................................................ 6-73

6.3.10 LENS HORIZONTAL DRIVE HP SENSOR REPLACEMENT...... 6-75

6.3.11 LENS HORIZONTAL DRIVE MOTOR REPLACEMENT ............. 6-77

6.3.12 APS SENSOR ADJUSTMENT (SENSITIVITY DOWN)............... 6-79

6.3.13 ARS SENSOR ADJUSTMENT.................................................... 6-80

6.4 TONER RECYCLING............................................................................. 6-81

6.4.1 TONER RECYCLING UNIT REMOVAL......................................... 6-81

SM v A246/A247/A248

6.4.2 TONER RECYCLING CLUTCH REPLACEMENT......................... 6-82

6.5 DEVELOPMENT AND TONER SUPPLY................................................ 6-83

6.5.1 DEVELOPMENT UNIT REMOVAL................................................ 6-83

6.5.2 DEVELOPER REPLACEMENT..................................................... 6-85

6.5.3 DEVELOPMENT ROLLERS REPLACEMENT .............................. 6-87

6.5.4 TONER DENSITY SENSOR REPLACEMENT.............................. 6-89

6.5.5 TONER BOTTLE DRIVE MOTOR REPLACEMENT..................... 6-90

6.5.6 DEVELOPMENT FILTER AND PRESSURE RELEASE FILTER

REPLACEMENT............................................................................ 6-91

6.5.7 DEVELOPMENT ROLLER SHAFT CLEANING............................. 6-92

6.6 DRUM UNIT............................................................................................ 6-93

6.6.1 DRUM UNIT REMOVAL AND OPC DRUM REPLACEMENT........ 6-93

6.6.2 QUENCHING LAMP REPLACEMENT .......................................... 6-94

6.6.3 GRID PLATE/CHARGE WIRE/WIRE CLEANER

REPLACEMENT............................................................................ 6-95

6.6.4 ERASE LAMP AND DRUM POTENTIAL SENSOR

REPLACEMENT............................................................................ 6-97

6.6.5 CLEANING BLADE REPLACEMENT............................................ 6-98

6.6.6 CLEANING BRUSH REPLACEMENT........................................... 6-99

6.6.7 PICK-OFF PAWL REPLACEMENT............................................. 6-100

6.6.8 OZONE FILTER REPLACEMENT............................................... 6-101

6.6.9 PRE-TRANSFER LAMP REMOVAL............................................ 6-102

6.7 TRANSFER BELT UNIT....................................................................... 6-103

6.7.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION ................. 6-103

6.7.2 TRANSFER BELT REPLACEMENT............................................ 6-105

6.7.3 CLEANING BLADE REPLACEMENT.......................................... 6-107

6.8 FUSING UNIT....................................................................................... 6-108

6.8.1 FUSING UNIT REMOVAL ........................................................... 6-108

6.8.2 FUSING THERMISTOR REPLACEMENT................................... 6-109

6.8.3 FUSING THERMOFUSE REPLACEMENT ................................. 6-110

6.8.4 FUSING LAMP REPLACEMENT................................................. 6-111

6.8.5 OIL SUPPLY/CLEANING ROLLER REPLACEMENT.................. 6-113

6.8.6 OIL SUPPLY CLEANING BRUSH REPLACEMENT................... 6-114

6.8.7 HOT ROLLER REPLACEMENT.................................................. 6-115

6.8.8 PRESSURE ROLLER AND BEARING REPLACEMENT ............ 6-117

6.8.9 FUSING STRIPPER PAWL REPLACEMENT.............................. 6-119

6.8.10 FUSING PRESSURE ADJUSTMENT........................................ 6-120

6.8.11 PAPER EXIT UNIT REMOVAL.................................................. 6-121

6.8.12 EXIT SENSOR AND FUSING EXIT SENSOR

REPLACEMENT........................................................................ 6-123

6.8.13 DUPLEX PAPER GUIDE SENSOR AND DUPLEX

TRANSPORT SENSOR REPLACEMENT................................. 6-124

6.8.14 PRESSURE ROLLER CLEANING ROLLER

REPLACEMENT........................................................................ 6-125

6.9 DUPLEX UNIT...................................................................................... 6-126

6.9.1 FEED ROLLER REPLACEMENT................................................ 6-126

6.9.2 SEPARATION BELT REPLACEMENT........................................ 6-128

6.9.3 DUPLEX UNIT REMOVAL........................................................... 6-131

A246/A247/A248 vi SM

Rev. 10/2000

6.9.4 SEPARATION CLUTCH/TRANSPORT CLUTCH REMOVAL ...... 6-132

6.9.5 JOGGER MOTOR REPLACEMENT ............................................6-133

6.10 COPY QUALITY ADJUSTMENT.........................................................6-138

6.10.1 SP ADJUSTMENT MODE ..........................................................6-138

6.10.2 SIDE-TO-SIDE REGISTRATION ADJUSTMENT.......................6-140

6.10.3 UNEVEN EXPOSURE ADJUSTMENT.......................................6-141

6.10.4 IMAGE DENSITY ADJUSTMENT...............................................6-143

6.10.5 SCANNER HEIGHT ADJUSTMENT...........................................6-144

6.10.6 APS SIZE CALIBRATION...........................................................6-145

6.10.7 FUSING EXIT COVER MAGNET POSITIONING

ADJUSTMENT ...........................................................................6-146

TROUBLESHOOTING

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

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

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

7.1.2 EXPOSURE......................................................................................7-3

7.1.3 SCANNER ........................................................................................7-5

7.1.4 LENS MAGNIFICATION................................................................... 7-8

7.1.5 OPTICS THERMISTOR..................................................................7-10

7.1.6 CHARGE CORONA UNIT ..............................................................7-10

7.1.7 DEVELOPMENT ............................................................................7-11

7.1.8 PROCESS CONTROL SENSORS .................................................7-12

7.1.9 TRANSFER CURRENT..................................................................7-15

7.1.10 DRUM...........................................................................................7-15

7.1.11 PAPER FEED...............................................................................7-16

7.1.12 DUPLEX .......................................................................................7-19

7.1.13 FUSING ........................................................................................7-20

7.1.14 SYSTEM CONTROL ....................................................................7-22

7.1.15 DUAL JOB FEEDER.....................................................................7-23

7.1.16 SORTER STAPLER .....................................................................7-24

7.1.17 OTHERS.......................................................................................7-28

7.2 ELECTRICAL COMPONENT DEFECTS ................................................7-30

7.2.1 SENSORS ......................................................................................7-30

7.2.2 SWITCHES.....................................................................................7-34

7.2.3 FUSES............................................................................................7-35

7.3 FIRMWARE HISTORY ............................................................................7-36

DUAL JOB FEEDER A610

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

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

1.2 COMPONENT LAYOUT............................................................................8-2

1.2.1 MECHANICAL COMPONENT LAYOUT...........................................8-2

1.2.2 ELECTRICAL COMPONENT LAYOUT............................................8-3

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

SM vii A246/A247/A248

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