C249/C264 SERVICE MANUAL

001780MIU

C249/C264 SERVICE MANUAL

001780MIU

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

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C249/C264 PARTS CATALOG TABLE OF CONTENTS

C249 PARTS LOCATION AND LIST LOCATION OF UNIT................................................ 3 1.EXTERIOR (C249) .............................................. 8 2.OPERATION PANEL (C249).............................. 10 3.SCANNER UNIT 1 (C249).................................. 12 4.SCANNER UNIT 2 (C249).................................. 14 5.SCANNER UNIT 3 (C249).................................. 16 6.PAPER TABLE SECTION (C249) ...................... 18 7.PAPER FEED SECTION (C249)........................ 20 8.PAPER REGISTRATION (C249) ....................... 22 9.PLOTTER UNIT 1 (C249)................................... 24 10.PLOTTER UNIT 2 (C249).................................. 26 11.PLOTTER UNIT 3 (C249).................................. 28 12.PRESS ROLLER SECTION (C249) .................. 30 13.DRUM UNIT 1 (C249)........................................ 32 14.DRUM UNIT 2 (C249)........................................ 34 15.DRUM UNIT 3 (C249)........................................ 36 16.DRUM UNIT 4 (C249)........................................ 38 17.VACUUM FAN UNIT (C249).............................. 40 18.DELIVERY TABLE (C249)................................. 42 19.MASTER EJECT UNIT (C249).......................... 44 20.DRIVE SECTION 1 (C249)................................ 46 21.DRIVE SECTION 2 (C249)................................ 48 22.ELECTRICAL SECTION 1 (C249) .................... 50 23.ELECTRICAL SECTION 2 (C249) .................... 52 24.ELECTRICAL SECTION 3 (C249 CHINA

MODEL ONLY) .................................................. 54

25.FRAME SECTION (C249).................................. 56 26.MPU BOARD (C249).......................................... 58 27.DECALS AND DOCUMENTS (C249) ................ 66 28.ACCESSORIES AND SPECIAL TOOLS (C249) 68 C249 PARTS INDEX PARTS INDEX .......................................................... 2 C264 PARTS LOCATION AND LIST LOCATION OF UNIT ................................................ 3 1.EXTERIOR (C264) ............................................... 8 2.OPERATION PANEL (C264) .............................. 10 3.SCANNER UNIT 1 (C264) .................................. 12 4.SCANNER UNIT 2 (C264) .................................. 14 5.SCANNER UNIT 3 (C264) .................................. 16 6.PAPER TABLE SECTION (C264)....................... 18 7.PAPER FEED SECTION (C264)......................... 20 8.PAPER REGISTRATION (C264) ........................ 22 9.PLOTTER UNIT 1 (C264) ................................... 24 10.PLOTTER UNIT 2 (C264) .................................. 26 11.PLOTTER UNIT 3 (C264) .................................. 28 12.PRESS ROLLER SECTION (C264)................... 30 13.DRUM UNIT 1 (C264) ........................................ 32 14.DRUM UNIT 2 (C264) ........................................ 34 15.DRUM UNIT 3 (C264) ........................................ 36 16.DRUM UNIT 4 (C264) ........................................ 38 17.VACUUM FAN UNIT (C264) .............................. 40

18. DELIVERY TABLE 1 (C264) ............................. 42

19. DELIVERY TABLE 2 (C264) ............................. 44 20.MASTER EJECT UNIT 1 (C264)........................ 46 21.MASTER EJECT UNIT 2 (C264)........................ 48 22.DRIVE SECTION 1 (C264) ................................ 50 23.DRIVE SECTION 2 (C264) ................................ 52 24.ELECTRICAL SECTION 1 (C264) ..................... 54 25.ELECTRICAL SECTION 2 (C264) ..................... 56 26.FRAME SECTION (C264).................................. 58 27.INTERFACE BOARD (C650) ............................. 60 28.MPU BOARD (C264).......................................... 62 29.DECALS AND DOCUMENTS (C264) ................ 74 30.ACCESSORIES AND SPECIAL TOOLS (C264) 78 C264 PARTS INDEX PARTS INDEX ......................................................... 2 PLATEN COVER UNIT TYPE 1018 B406 PARTS LOCATION AND LIST 1.PLATEN COVER TYPE 1018 (B406) ................. 2 PLATEN COVER UNIT TYPE 1018 B406 PARTS INDEX PARTS INDEX ......................................................... 2 DOCUMENT FEEDER C600 PARTS LOCATION AND LIST

1.EXTERIOR (C600) .............................................. 2 2.ORIGINAL TABLE (C600).................................... 4 3.PAPER FEED (C600)........................................... 6 4.TRANSFER SECTION (C600) ............................. 8 5.PAPER EXIT (C600) ........................................... 10 6.ELECTRICAL SECTION (C600) ......................... 12

7.FRAME SECTION (C600)................................... 14 DOCUMENT FEEDER C600 PARTS INDEX PARTS INDEX .......................................................... 2 TAPE DISPENSER TYPE 20 C651 PARTS LOCATION AND LIST 1.EXTERIOR (C651)............................................... 2 2.DECAL (C651) ..................................................... 4 TAPE DISPENSER TYPE 20 C651 PARTS INDEX PARTS INDEX .......................................................... 2