Model PT3

Machine Code: C275

Field Service Manual

2 November, 2009
Important Safety Notices
Responsibilities of the Customer Engineer

Customer Engineer
Maintenance shall be done only by trained customer engineers who have completed service training for
the machine and all optional devices designed for use with the machine.

Reference Material for Maintenance

• Maintenance shall be done using the special tools and procedures prescribed for maintenance of the
machine described in the reference materials (service manuals, technical bulletins, operating
instructions, and safety guidelines for customer engineers).
• In regard to other safety issues not described in this document, all customer engineers shall strictly
obey procedures and recommendations described the "CE Safety Guide".
• Use only consumable supplies and replacement parts designed for use of the machine.

Before Installation, Maintenance

Shipping and Moving the Machine

• Work carefully when lifting or moving the machine. If the machine is heavy, two or more customer
engineers may be required to prevent injuries (muscle strains, spinal injuries, etc.) or damage to the
machine if it is dropped or tipped over.
• Personnel moving or working around the machine should always wear proper clothing and footwear.
Never wear loose fitting clothing or accessories (neckties, loose sweaters, bracelets, etc.) or casual
footwear (slippers, sandals, etc.) when lifting or moving the machine.
• Always unplug the power cord from the power source before you move the product. Before you move
the product, arrange the power cord so it will not fall under the product.

1
 Power

• Always disconnect the power plug before doing any maintenance procedure. After switching off the
machine, power is still supplied to the main machine and other devices. To prevent electrical shock,
switch the machine off, wait for a few seconds, then unplug the machine from the power source.
• Before you do any checks or adjustments after turning the machine off, work carefully to avoid injury.
After removing covers or opening the machine to do checks or adjustments, never touch electrical
components or moving parts (gears, timing belts, etc.).
• After turning the machine on with any cover removed, keep your hands away from electrical
components and moving parts. Never touch the cover of the fusing unit, gears, timing belts, etc.

Installation, Disassembly and Adjustments

• After installation, maintenance, or adjustment, always check the operation of the machine to make
sure that it is operating normally. This ensures that all shipping materials, protective materials, wires
and tags, metal brackets, etc., removed for installation, have been removed and that no tools remain
inside the machine. This also ensures that all release interlock switches have been restored to normal
operation.
• Never use your fingers to check moving parts causing spurious noise. Never use your fingers to
lubricate moving parts while the machine is operating.

Special Tools

• Use only standard tools approved for machine maintenance.

• For special adjustments, use only the special tools and lubricants described in the service manual.
Using tools incorrectly, or using tools that could damage parts, could damage the machine or cause
injuries.

During Maintenance

General

• Before you begin a maintenance procedure:

• 1) Switch the machine off

2
 • 2) Disconnect the power plug from the power source.

Safety Devices

• Never remove any safety device unless it requires replacement. Always replace safety devices
immediately.
• Never do any procedure that defeats the function of any safety device. Modification or removal of a
safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the operation of
the machine to ensure that it is operating normally and safely after removal and replacement of any
safety device.
• For replacements use only the correct fuses or circuit breakers rated for use with the machine. Using
replacement devices not designed for use with the machine could lead to a fire and personal injuries.

Organic Cleaners

• During preventive maintenance, never use any organic cleaners (alcohol, etc.) other than those
described in the service manual.
• Make sure the room is well ventilated before using any organic cleaner. Use organic solvents in small
amounts to avoid breathing the fumes and becoming nauseous.
• Switch the machine off, unplug it, and allow it to cool before doing preventive maintenance. To avoid
fire or explosion, never use an organic cleaner near any part that generates heat.
• Wash your hands thoroughly after cleaning parts with an organic cleaner to contamination of food,
drinks, etc. which could cause illness.
• Clean the floor completely after accidental spillage of silicone oil or other materials to prevent slippery
surfaces that could cause accidents leading to hand or leg injuries. Use dry rags to soak up spills.

Power Plug and Power Cord

• Before serving the machine (especially when responding to a service call), always make sure that the
power plug has been inserted completely into the power source. A partially inserted plug could lead
to heat generation (due to a power surge caused by high resistance) and cause a fire or other
problems.
• Always check the power plug and make sure that it is free of dust and lint. Clean it if necessary. A
dirty plug can generate heat which could cause a fire.

3
 • Inspect the length of the power cord for cuts or other damage. Replace the power cord if necessary.
A frayed or otherwise damaged power cord can cause a short circuit which could lead to a fire or
personal injury from electrical shock.
• Check the length of the power cord between the machine and power supply. Make sure the power
cord is not coiled or wrapped around any object such as a table leg. Coiling the power cord can
cause excessive heat to build up and could cause a fire.
• Make sure that the area around the power source is free of obstacles so the power cord can be
removed quickly in case of an emergency.
• Make sure that the power cord is grounded (earthed) at the power source with the ground wire on
the plug.
• Connect the power cord directly into the power source. Never use an extension cord.
• When you disconnect the power plug from the power source, always pull on the plug, not the cable.

After Installation, Servicing

Points to Confirm with Operators

At the end of installation or a service call, instruct the user about use of the machine. Emphasize the following
points.
• Show operators how to remove jammed paper and troubleshoot other minor problems by following
the procedures described in the operating instructions.
• Point out the parts inside the machine that they should never touch or attempt to remove.
• Confirm that operators know how to store and dispose of consumables.
• Make sure that all operators have access to an operating instruction manual for the machine.
• Confirm that operators have read and understand all the safety instructions described in the operating
instructions.
• Demonstrate how to turn off the power and disconnect the power plug (by pulling the plug, not the
cord) if any of the following events occur: 1) something has spilled into the product, 2) service or
repair of the product is necessary, 3) the product cover has been damaged.
• Caution operators about removing paper fasteners around the machine. They should never allow
paper clips, staples, or any other small metallic objects to fall into the machine.

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Safety Instructions for this Machine

Prevention of Physical Injury

1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine
and peripheral power cords are unplugged.
2. The plug should be near the machine and easily accessible.
3. If any adjustment or operation check has to be made with exterior covers off or open while the main
switch is turned on, keep hands away from electrified or mechanically driven components.
4. The inside and the metal parts of the fusing unit become extremely hot while the machine is operating.
Be careful to avoid touching those components with your bare hands.
5. To prevent a fire or explosion, keep the machine away from flammable liquids, gases, and aerosols.

Health Safety Conditions

1. If you get ink in your eyes by accident, try to remove it with eye drops or flush with water as first aid.
If unsuccessful, get medical attention.
2. If you ingest ink by accident, induce vomiting by sticking a finger down your throat or by giving soapy
or strong salty water to drink.

Observance of Electrical Safety Standards

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

Safety and Ecological Notes for Disposal

1. Dispose of replaced parts in accordance with local regulations.
2. Used ink and masters should be disposed of in an environmentally safe manner and in accordance
with local regulations.

Symbols

This manual uses several symbols. The meanings of those symbols are as follows:

See or Refer to

Clip ring

5
 E-ring

Screw

Connector

Clamp

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TABLE OF CONTENTS
Important Safety Notices...................................................................................................................................1
Responsibilities of the Customer Engineer....................................................................................................1
Before Installation, Maintenance..................................................................................................................1
During Maintenance......................................................................................................................................2
After Installation, Servicing............................................................................................................................4
Safety Instructions for this Machine...............................................................................................................5
Symbols...........................................................................................................................................................5
1. Product Information
Specifications....................................................................................................................................................11
Guidance for Those Who are Familiar with Predecessor Products..............................................................12
Overview..........................................................................................................................................................14
Mechanical Component Layout.................................................................................................................14
Electrical Component Layout......................................................................................................................16
Drive Layout..................................................................................................................................................20
2. Installation
Installation Requirements.................................................................................................................................21
Optimum Environmental Condition............................................................................................................21
Environments to Avoid.................................................................................................................................21
Power Connection.......................................................................................................................................21
Minimum Space Requirements...................................................................................................................21
Dimensions...................................................................................................................................................22
Main Body and Peripherals........................................................................................................................23
Power Sockets for Peripherals....................................................................................................................24
Installation Procedure......................................................................................................................................25
Main Body....................................................................................................................................................25
Color Drum (Option)...................................................................................................................................35
ADF (Option)................................................................................................................................................36
Platen Cover (Option).................................................................................................................................39
Tape Dispenser (Option).............................................................................................................................40
Printer Unit VC-20 (Option)........................................................................................................................44
Printer Unit Type 4545A (Option)..............................................................................................................46
3. Preventive Maintenance
Maintenance Tables........................................................................................................................................51

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 4. Replacement and Adjustment
General Caution...............................................................................................................................................53
Special Tools....................................................................................................................................................54
Image Adjustment.............................................................................................................................................55
Overview......................................................................................................................................................55
SP6-10: Master Writing Speed..................................................................................................................55
SP6-21: Paper Regist Position.....................................................................................................................56
SP6-5: Scanning Speed – Platen and SP6-6: Scanning Speed – ADF mode.......................................56
SP6-3: Scanning Start Position – Platen and SP6-4: Scanning Start Position - ADF..............................56
SP6-1: Main Scan Position – Platen and SP6-2: Main Scan Position - ADF..........................................56
Covers...............................................................................................................................................................58
Front Cover and Front Door........................................................................................................................58
Operation Panel...........................................................................................................................................59
Rear Cover...................................................................................................................................................59
Upper Covers...............................................................................................................................................60
Boards...............................................................................................................................................................61
MPU..............................................................................................................................................................61
PSU................................................................................................................................................................61
Scanner.............................................................................................................................................................63
Exposure Glass, DF Exposure Glass and Scales......................................................................................63
Lens Block.....................................................................................................................................................64
Exposure Lamp and Lamp Stabilizer Board..............................................................................................65
Scanner Motor.............................................................................................................................................66
Scanner Home Position Sensor...................................................................................................................67
Platen Cover Sensor....................................................................................................................................68
Adjusting the Scanner Position....................................................................................................................68
Master Feed......................................................................................................................................................73
Master Making Unit.....................................................................................................................................73
Master Making Unit Set Switches...............................................................................................................73
Thermal Head..............................................................................................................................................75
Master Set Cover Sensor............................................................................................................................77
Master End Sensor.......................................................................................................................................77
Cutter Unit.....................................................................................................................................................78

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 Thermal Head Voltage Adjustment.............................................................................................................79
Master End Sensor Adjustment...................................................................................................................80
Master Eject......................................................................................................................................................82
Master Eject Unit..........................................................................................................................................82
Master Eject Rollers.....................................................................................................................................83
Master Eject Motor and Pressure Plate Motor..........................................................................................83
Drum Master Sensor, Master Eject Sensor and Eject Box Set Sensor.....................................................84
Pressure Plate HP Sensor and Pressure Plate Limit Sensor........................................................................85
Air Knife Fan Motor.....................................................................................................................................85
Master Eject Position Sensor.......................................................................................................................86
Master Clamper Opening Unit...................................................................................................................86
Paper Feed........................................................................................................................................................88
Pick-up Roller, Paper Feed Roller and Friction Pad...................................................................................88
Paper Table Lower Limit Sensor..................................................................................................................89
Paper Height Sensor 1 and 2.....................................................................................................................89
Paper End Sensor.........................................................................................................................................90
Paper Table Motor.......................................................................................................................................91
Paper Feed Clutch.......................................................................................................................................92
Paper Separation Pressure Adjustment......................................................................................................92
Printing...............................................................................................................................................................94
Press Roller...................................................................................................................................................94
Registration Sensor......................................................................................................................................95
Feed Start Timing Sensor.............................................................................................................................95
2nd Feed Timing Sensor..............................................................................................................................96
Registration Motor ......................................................................................................................................96
Registration Roller........................................................................................................................................97
Press Roller Release Solenoids...................................................................................................................99
Press Roller Release Lever Adjustment.....................................................................................................100
Printing Pressure Adjustment.....................................................................................................................101
Drum...............................................................................................................................................................103
Preparation................................................................................................................................................103
Cloth Screen..............................................................................................................................................103
Clamper and Metal Screen......................................................................................................................106

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 Ink Pump Unit.............................................................................................................................................108
Ink Roller Unit and Ink Roller One-Way Clutch......................................................................................109
Doctor Roller Gap Adjustment.................................................................................................................110
Ink Detection Adjustment .........................................................................................................................111
Paper Delivery................................................................................................................................................114
Paper Delivery Unit...................................................................................................................................114
Delivery Belt, Paper Exit Sensor, Vacuum Fan Motor and Paper Delivery Unit Bushings...................115
Paper Delivery Motor................................................................................................................................117
Exit Pawl Adjustment.................................................................................................................................117
Main Drive ....................................................................................................................................................121
Registration Motor.....................................................................................................................................121
Main Motor...............................................................................................................................................122
Main Drive Timing Belt Adjustment..........................................................................................................124
Main Motor Pulley Position......................................................................................................................124
5. System Maintenance
Service Program Mode.................................................................................................................................127
6. Troubleshooting
Troubleshooting Guide..................................................................................................................................129
7. Energy Saving
Energy Save...................................................................................................................................................131
Energy Saver Modes................................................................................................................................131
Paper Save.....................................................................................................................................................133
Effectiveness of the Combine Function.....................................................................................................133

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1. Product Information

Specifications 1
See "Appendices" for the "General Specifications":

11
 1. Product Information

Guidance for Those Who are Familiar with

Predecessor Products
1 Machine C275 is a successor model to Machine C267/C271. If you have experience with the
predecessor products, the following information will be of help when you read this manual.

Different Points from Predecessor Products

Item C267/C271 C275

Paper Delivery No Yes

Motor

Drum HP Lock No Yes

Mechanism

Optional Printer Unit No Yes

Type 4545A

First Print Time 33 seconds (A4 ) 34 seconds (A4 )

When setting an original on the When setting an original on the
exposure glass exposure glass

Depth 676 mm 681 mm

120 V, 60 Hz, 1.7 A 120 V, 60 Hz, 2.2 A

Power Source
220 V – 240 V, 50 – 60 Hz, 1.1 A 220 V – 240 V, 50 – 60 Hz, 1.2 A

120V, 60Hz: 120V, 60Hz:

Less than 150W (Printing) Less than 185W (Printing)
Less than 150W (Master making) Less than 210W (Master making)
Power Consumption
220V-240V, 50-60Hz: 220V-240V, 50-60Hz:
Less than 160W (Printing) Less than 185W (Printing)
Less than 160W (Master making) Less than 210W (Master making)

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 Guidance for Those Who are Familiar with Predecessor Products

Item C267/C271 C275

Sound Power Level Sound Power Level

Standby: 36 dB
Copying 80 cpm: 78 dB
Standby: 34 dB
Copying 80 cpm: 78 dB
1
Copying 100 cpm: 80 dB Copying 100 cpm: 80 dB
Copying 130 cpm: 84 dB Copying 130 cpm: 84 dB
Noise Emission
Operating Position Sound Power Level Operating Position Sound Power Level
Standby: 20 dB Standby: 20 dB
Copying 80 cpm: 63 dB Copying 80 cpm: 63 dB
Copying 100 cpm: 70 dB Copying 100 cpm: 66 dB
Copying 130 cpm: 72 dB Copying 130 cpm: 70 dB

13
 1. Product Information

Overview

1 Mechanical Component Layout

14
 Overview

1. Tension Roller
16. Paper Delivery Table
2. Master Feed Roller
17. Air Knife Fan Motor
3. Platen Roller
4. Thermal Head
18. Master Eject Box 1
19. Master Eject Rollers
5. Master Roll
20. 3rd Mirror
6. Paper Feed Roller
21. 2nd Mirror
7. Paper Pick-up Roller
22. 1st Mirror
8. Paper Table
23. DF Exposure Glass
9. Registration Rollers
24. 1st Transport Roller
10. Doctor Roller
25. Separation Roller
11. Press Roller
26. Original Feed Belt
12. Ink Roller
27. Pick-up Roller
13. Vacuum Fan Motor
28. 2nd Transport Roller
14. Exit Pawl
29. Original Exit Roller
15. Transport Belts

15
 1. Product Information

Electrical Component Layout

Boards

Index No. Name Function

18 LCD Displays messages for the operator

16
 Overview

Index No. Name Function

19 Operation Panel These boards control the operation panel.

Boards
1
21 Lamp Stabilizer This supplies power to the xenon lamp.

25 SBU Makes a video signal from the scanned original.

44 Main Processing Unit Controls all machine functions both directly and through other
(MPU) boards.

49 Power Supply Unit Provides dc power to the system.

Motors

Index No. Name Function

1 Scanner Motor Stepper motor drives the book scanner.

4 Master Feed Motor Feeds the master to the drum.

11 Paper Table Motor Raises and lowers the paper table.

15 Cutter Motor Cuts the master.

29 Master Eject Motor Sends used masters into the master eject box.

30 Air Knife Fan Motor Rotates the fan to provide air to separate the leading edge of
the paper from the drum.

32 Vacuum Fan Motor Provides suction so that paper is held firmly on the transport belt.

33 Paper Delivery Motor Drives the paper delivery unit.

35 Pressure Plate Motor Raises and lowers the pressure plate.

37 Clamper Motor Opens or closes the drum master clamper.

41 Main Motor Drives paper feed mechanisms and the drum.

42 Registration Motor Feeds the paper to align it with the master on the drum.

46 Original Feed Motor Stepper motor drives the book scanner.

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 1. Product Information

Solenoids

Index No. Name Function

1 13 Front Pressure Releases the press roller to apply printing pressure.

Release Solenoid

39 Rear Pressure Release Releases the press roller to apply printing pressure.
Solenoid

Switches

Index No. Name Function

9, 14 Master making unit The machine does not work until the two set switches turn on.
set switches

12 Paper Table Lowering Lowers the paper table.

Switch

16 Master eject unit Checks whether the master eject unit is properly closed.
safety switch

17 Door Safety Switches Checks whether the front door is properly closed.

24 Cutter HP Switch Detects when the cutter is at the home position

28 Main Switch Turns the power on or off.

Sensors

Index No. Name Function

3 Master End Sensor Informs the CPU when the master making unit runs out of master
roll.

6 Paper Height Sensor Detects when the paper table reaches the paper feed position.
1

7 Paper Height Sensor Detects when the paper table reaches the paper feed position.
2

8 Paper End Sensor Informs the CPU when the paper table runs out of paper.

18
 Overview

Index No. Name Function

10 Paper Registration Detects paper approaching the registration roller.

Sensor
1
24 Scanner Home Detects when the image sensor is at home position.
Position Sensor

25 Platen Cover Sensor Detects whether the platen cover is open or closed.

26 Master Eject Sensor Detects used master misfeeds.

27 Drum Master Sensor Detects if there is a master on the drum

31 Paper Exit Sensor Detects paper misfeeds at the exit.

34 Pressure Plate Limit Detects if the pressure plate is in the lowest position.
Sensor

36 2nd Feed start Timing Determines the paper misfeed check timing at the paper
Sensor registration area.

38 Clamper Open Detects if the clamper is in the open position.

Sensor

40 Clamper Close Detects if the clamper is in the closed position.

Sensor

43 Paper Table Lower Detects when the paper table is at its lower limit position.
Limit Sensor

47 Feed Start Timing Determines the paper feed start timing.

Sensor

48 Master Eject Position Detects when the drum is at the master eject position (this is the
Sensor home position)

50 Pressure Plate Home Detects if the pressure plate is at the home position.
Position Sensor

51 Eject Box Set Sensor Checks if the master eject box is set.

19
 1. Product Information

Others

Index No. Name Function

1 5 Thermal Head Burns the image onto the master.

20 Xenon Lamp Applies light to the original for exposure.

Transmits main motor drive to the paper feed roller at the

45 Paper Feed Clutch
appropriate time.

Drive Layout

1. Master Eject Motor 6. Registration Motor

2. Pressure Plate Motor 7. Paper Feed Clutch
3. Clamper Motor 8. Master Feed Motor
4. Paper Delivery Motor 9. Scanner Motor
5. Main Motor 10. Original Feed Motor

20
2. Installation

Installation Requirements
Carefully select the installation location because environmental conditions greatly affect machine
performance. 2
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 5mm (0.2") both
front to rear left to right.

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.)

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.

Minimum Space Requirements

Place the machine near a power source, providing minimum clearance as shown below.

21
 2. Installation

Dimensions

22
 Installation Requirements

Main Body and Peripherals

This is a list of the peripheral devices that can be installed with the digital duplicator.

No. Model Name Comments

1 C275 Digital duplicator Main Machine

2 C642 ADF Auto document feeder

3 B406 Platen cover

4 C643/C647/C648 Color drum Optional drum – A4/LG/B4

5 C651 Tape Dispenser

23
 2. Installation

No. Model Name Comments

6 C646 Printer unit VC-20 Printer controller unit

7 C654 Printer Unit Type 4545A

2 Power Sockets for Peripherals

CAUTION

Rating Voltage for Peripherals

Make sure to plug the cables into the correct sockets.

24
 Installation Procedure

Installation Procedure
Main Body

Accessory Check 2

Make sure that you have all the accessories listed below.

No. Description Quantity

1 Master Spool 2

2 Paper Delivery Table Side Plate Guide 2

3 Paper Feed Side Pad 2

4 Emblem Cover (C275-80, -83, -92, -93) 1

5 Emblem – Ricoh DX 3440 (C275-80) 1

6 Emblem – Gestetner DX 3440 (C275-80) 1

7 Warranty Letter on carton box (C275-76, -78) 1

8 Leaflet (C275-76, -78) 1

9 Operating Instructions (C275-61, -76, -78, -80, -92) 1

10 Easy Operation Guide (C275-61, -76, -78, -80, -92) 1

25
 2. Installation

No. Description Quantity

11 German Acoustic Statement – Ricoh (C275-83, -93) 1

12 German Acoustic Statement – Gestetner (C275-83, -93) 1

13 Bundled Items List (C275-76, -78) 1

2 14 NECR (C275-80, -92) 1

Installation Procedure

• To avoid serious injury, do not connect the power plug to the machine until you are instructed to do
so.

1. Unpack the machine and remove all the wrapping.

26
 Installation Procedure

2. When you install the optional table:

• Mount the machine on the table. There are two screws [A] packed with the table.
• Lock the caster [B]
• Fix the caster lock stays [C] and tighten the screws [D]
• Attach the stabilizing brackets [E] (these help to prevent the machine from falling over).

27
 2. Installation

28
 Installation Procedure

3. Remove the filament tape as shown above.

29
 2. Installation

4. Remove the string securing the covers and units as shown above.

5. Open the paper table.

6. Pull out the master making unit, and take out the accessory bag [A].
7. Remove the filament tape and string securing the covers and units.

8. Insert both spools into a new master roll.

30
 Installation Procedure

9. Install the master roll, and open the master making unit cover.

10. Insert the leading edge of the master roll under the platen roller. The arrows [B] indicate the correct
position of the master leading edge.

31
 2. Installation

11. Close the master making unit cover [C] using both hands until it clicks into place.
12. Close the master making unit [D].

13. Open the front door.

14. Release the ink holder lock lever [E] and pull out the ink holder [F].
15. Remove the cap of the new ink cartridge, and insert a new ink cartridge into the ink holder.
16. Set the ink holder [F].

32
 Installation Procedure

17. Load a stack of paper on the paper table.

18. Shift the lock lever [G] in the direction of the arrow. Make sure that the side plates [H] touch the paper
gently.
19. Shift the lock lever [G] to its original position.

• Two side fence friction pads [I] are included as accessories. They are not used normally, but if
paper multi-feed frequently occurs or thin paper is used, the side fence friction pads [I] can be
installed to apply stopping pressure to the paper.

20. Raise the paper delivery table slightly, then gently lower it.
21. Lift the side plates and the end plate, and attach the side plate guides [J] for both side plates.

33
 2. Installation

• When printing on A4 SEF, 81/2" SEF, B5 JIS LEF and SEF size paper and thin paper, you should
attach the side plate guides to the side plates of the paper delivery tray. Users can also attach
these guides.
22. Adjust the side and end fences of the paper delivery table to match the paper size.

2 23. Firmly insert the power plug in the outlet.

24. Turn on the main switch.
25. Make a master and make 30 prints with this master. Do this at least three times, until the image quality
is acceptable.

• This is a new drum. Because of this, before the first print is made, ink is supplied automatically.
This takes 2 minutes.

Changing the operation panel language

There are ten languages in the machine. If you need to change the language, use the User Tools menu to
set the language.
• On the operation panel, press the User Tools key.
• Select "2. System".
• Select "5. Language on LCD".
• Select the language.

Date/Time Setting
Use the User Tools menu to set the current date and time.
• On the operation panel, press the User Tools key.
• Select "2. System".
• Select "6. Date/Time".
• Enter the date and the time.

SP Codes Setting

SP No. Menu Function

SP3-2 Input TEL number Do this SP and input the contact numbers of the customer
engineer. These numbers are shown when a service call is
issued.

34
 Installation Procedure

Color Drum (Option)

Accessory Check
Check the quantity and condition of the accessories in the box against this list:

No. Description Quantity 2

1 Color Indicator Decal 5

Installation Procedure

• To avoid serious injury, do not connect the power plug to the machine until you are instructed to do
so.

1. Remove the protective sheets [A] from the drum.

2. Attach a color indicator decal to the drum case. The decal must be the same color as the ink in use.
3. Remove the drum from the machine.
4. Leave the master wrapped around the removed drum to protect the drum from dust and from drying.
5. Keep the removed drum in the drum case.
6. Install the color drum in the machine.

• The color drum indicator on the operation panel stays lit when a drum is mounted in the machine.
7. Remove the ink cartridge cap.
8. Insert the ink cartridge in the ink holder.

35
 2. Installation

9. After main body installation, firmly insert the power plug in the outlet.
10. Turn on the main switch.
11. Make a master and make 30 prints with this master. Do this at least three times, until the image quality
is acceptable.

2 • This is a new drum. Because of this, before the first print is made, ink is supplied automatically.
This takes 2 minutes.

ADF (Option)

Accessory Check

Check the quantity and condition of the accessories in the box against this list:

No. Description Quantity

1 Stepped Screw 2

2 Screws 2

3 Screwdriver Tool 1

4 DF Exposure Glass 1

5 Decal - Scale - mm 1

6 Decal - Scale - inch 1

7 Scale Guide 1

8 Attention Label 1

36
 Installation Procedure

Installation Procedure

• To avoid serious injury, do not connect the power plug to the machine until you are instructed to do
so.

1. Remove the strips of tape.

2. Remove the left scale [A] ( x 2).

3. Place the DF exposure glass [B] on the glass holder.

37
 2. Installation

• When installing the DF exposure glass, make sure that the white dot [C] is positioned at the front
side, as shown.
4. Peel off the backing [D] of the double-sided tape attached to the rear side of the scale guide [E], then
install the scale guide (2 screws removed in step 2).

2 5. Install the two stepped screws [F].

6. Mount the DF by aligning the holes [G] in the DF with the stepped screws, then slide the DF to the front
as shown.
7. Secure the DF unit with two screws [H].
8. Connect the cables [I] to the main body.

38
 Installation Procedure

9. Attach the scale decal [J] as shown.

10. Connect the power cord, then turn the main switch on.

Platen Cover (Option)

Accessory Check
Check the quantity and condition of the accessories in the box against this list:

No. Description Quantity

1 Stepped Screw 2

Installation Procedure

• To avoid serious injury, do not connect the power plug to the machine until you are instructed to do
so.

39
 2. Installation

1. Install the platen cover [A] ( x 2).

Tape Dispenser (Option)

Accessory Check
Check the quantity and condition of the accessories in the box against this list:

No. Description Quantity

Knob Screw (For C210, C217, C218, C219, C222, C223, C225, C228,
1 2
C238, C237, C238, C248, C249, C264 and C267, C271)

2 Screw M4 x 25 (For C211, C212, C213, C214, C216, C224 and C226) 2

3 Hexagon Nut M4 (For C211, C212, C213, C214, C216, C224 and C226) 2

4 Auxiliary Bracket (For C226 and C267, C271) 1

5 Auxiliary Bracket (For C238, C247 and C249) 1

6 Auxiliary Bracket (For C264) 1

7 Screw M4 x 8 (For C226, C238, C247, C249 and C267, C271) 4

8 Lock Washer (For C226 only) 1

40
 Installation Procedure

No. Description Quantity

9 Lock Washer (Without C267, C271) 1

10 Tape 1

Installation Procedure 2

1. Turn off the main switch and unplug the power cord.
2. Remove the paper delivery cover (s x 5).
3. Remove the cutout [A] from the rear cover, as shown.

4. Connect the harness from the tape dispenser to the connector [B].
5. Remove the screw [C] that is beside the connector [B]. Reuse the screw to secure the bracket [D], as
shown.

41
 2. Installation

6. Open the master eject unit.

7. Install the auxiliary bracket [E] on the tape dispenser with M4x8 screws (accessories) [F].
8. Install the tape dispenser on the main body with two M4x8 screws [G] (accessories) in the two outer
holes in the tape dispenser bracket.
9. Close the master eject unit. Reinstall the paper delivery cover.

10. Open the tape dispenser cover [H]. Then, insert the leading edge of the tape into the tape entrance
until it stops as shown in the illustration [I].

• Be sure that the tape is installed in the proper direction. If it is not, the tape dispenser will not
work correctly.

42
 Installation Procedure

11. Firmly insert the power plug in the outlet.

12. Turn on the main switch of the main body.
13. Turn on the tape dispenser switch [J].

14. Press the tape cut button [K] to cut off the leading edge of the tape.
15. Check the tape dispenser operation using the Memory/Class modes of the main body.

43
 2. Installation

Printer Unit VC-20 (Option)

Accessory Check
Make sure that you have all the accessories listed below.

No. Description Quantity

1 VC-20 Interface Board 1

2 Screws 3

3 Installation CD 1

4 Quick Install Guide 1

5 Safety Information 1

Installation Procedure

• To avoid serious injury, do not connect the power plug to the machine until you are instructed to do
so.

44
 Installation Procedure

1. Remove the small rear cover [A] in the rear cover. ( x 2)

2. Cut out the USB port cover [B] in the small rear cover.

3. Connect the VC-20 interface board [C] to CN114 of the MPU board and secure it using three screws.
4. Reinstall the small rear cover.

45
 2. Installation

Printer Unit Type 4545A (Option)

Components Check

No. Description Quantity

1 ACU Board (with Case) 1

2 Top Right Bracket 1

3 Bottom Bracket 1

4 Top Left Bracket 1

5 Short Harness 1

6 Long Harness 1

7 Ground Cable 1

8 Cover 1

46
 Installation Procedure

No. Description Quantity

9 Ferrite Core 1

10 Screw: M3x4 5

11 Screw: M3x6 4

12 Clamp 1 2
13 Attachment Kit for HP4R2.5*1 1

*1: This item is not used for this machine.

Installation Procedure
Preparation for Installing

1. Attach the top left bracket [A], top right bracket [B] and bottom bracket [C] to the case ( x 1 each)
2. Install the clamp [D].
3. Attach the long harness [E] to the left side of the case ( x 1).
4. Attach the ferrite core [F] to the long harness.
5. Attach the short harness [G] to the front side of the case.
6. Attach the cover [H] to the case ( x 2).
7. Check whether the "mm/inch" setting in the User Tools (System - mm/inch) is set to the correct value.
If necessary, change it to the correct "mm/inch" setting.

47
 2. Installation

8. Check whether "SP2-7" (Vendor Selection) is set to the correct value. If necessary, change it to the
correct vendor setting.
Installing the Controller in the Main Machine

1. Remove the controller cover [A] ( x 2).

2. Remove the rear cover [B] ( x 9).

3. Attach the controller [C] to the main machine ( x 4).

4. Connect the harness [D] to the main board.
5. Attach the ground cable [E] ( x 1).

48
 Installation Procedure

6. Reinstall the rear cover.

• After installing the printer unit, make sure that the board and cable are securely connected.

49
 2. Installation

50
3. Preventive Maintenance

Maintenance Tables
See "Appendices" for the "Maintenance Tables".

51
 3. Preventive Maintenance

52
4. Replacement and Adjustment

General Caution

• Turn off the main power switch and unplug the machine before attempting any of the procedures in
this section.

53
 4. Replacement and Adjustment

Special Tools
The followings are the special tools used for service.

Description Part number Note

Scanner positioning pins A0069104 p.68

(4 pins as a set)

Flash memory card – 4MB N8036701 "8. System Test" in the

Appendices

4 Alvamoa 2 (Alvania) Grease A0699502 -

54
 Image Adjustment

Image Adjustment
Overview

"Image Adjustment" adjusts the image position on prints by changing the SP settings.
Adjust the settings in the order:
• SP6-10 6-21 6-5 6-6 6-3 6-4 6-1 6-2
When correcting errors made when printing with the controller, use only the first two procedures. When
correcting errors made when printing with scanned originals, do all six adjustments in the given order.
This adjustment is required every time the RAM on the MPU has been replaced.
4
SP6-10: Master Writing Speed

1. Input SP8-10 (Test patterns) and enter "6", then press the Start key.
2. Exit the SP mode, print 10 copies at 100 rpm (speed 2). Use the 10th print for the adjustment.
3. The length of the 6 squares in the feed direction should be 130 mm, as shown above.
4. If it is not, calculate the reproduction ratio using the following formula.
{(130 - Value) / 130} x 100 = ± X.X % (Round off to one decimal place)
5. Example: If the value is 133, {(130 - 133) / 130} x 100 = - 2.3 %
6. Access SP6-10, input the calculated ratio, and press the Enter key.
7. Repeat the procedure to make sure that the ratio is correct.

55
 4. Replacement and Adjustment

SP6-21: Paper Regist Position

1. Input SP8-10 (Test patterns) and enter "6", then press the Start key.
2. Exit the SP mode, print 10 copies at 100 rpm (speed 2). Use the 10th print for the adjustment.
3. The space between the leading edge and the next line should be 8 mm, as shown above.
4. If it is not, access SP6-21, input the difference and press the Enter key.
Example: If the value is 7 mm, 7 - 8 = -1.0
5. Repeat the procedure to make sure that the gap is correct.

SP6-5: Scanning Speed – Platen and SP6-6: Scanning Speed – ADF mode
4
1. Make copies of the test pattern printed during the previous adjustments ( previous page), in platen
mode at speed 2. Use the 10th print for the adjustment.
2. The length of the 6 squares in the feed direction should be 130 mm.
3. If it is not, calculate the reproduction ratio using the following formula.
{(130 - Value) / 130} x 100 = ± X.X % (Round off to one decimal place)
Example: If the value is 133, {(130 - 133) / 130} x 100 = - 2.3 %
4. Access SP6-05, input the calculated ratio, and press the Enter key.
5. Check again to make sure that the ratio is correct.
6. Make copies of the test pattern in ADF mode and repeat the process using SP6-06.

SP6-3: Scanning Start Position – Platen and SP6-4: Scanning Start Position - ADF

1. Make copies of the test pattern printed during the previous adjustments ( previous page), in platen
mode at speed 2. Use the 10th print for the adjustment.
2. The space between the leading edge and the next line should be 8 mm.
3. If it is not, access SP6-03, input the gap value and press the Enter key.
Example: If the value is 7 mm, 7 - 8 = -1.0
4. Repeat the procedure to make sure that the gap is correct.
5. Make copies of the test pattern in ADF mode and repeat the process using SP6-04.

SP6-1: Main Scan Position – Platen and SP6-2: Main Scan Position - ADF

1. Make a copy in platen mode at speed 2.

2. Measure the difference between the center of the main-scan on the original and on the print.

56
 Image Adjustment

3. Access SP6-01, input the gap value and press the Enter key. (If you input a positive value, the image
moves towards the operation side.)
4. Repeat the procedure to make sure that there is no difference.
5. Make a copy in ADF mode and repeat the process using SP6-02.

57
 4. Replacement and Adjustment

Covers
Front Cover and Front Door

[A]: Front cover ( x 9)

[B] Front door ( x 4)

58
 Covers

Operation Panel

• Front cover ( p.58 "Front Cover and Front Door")

[A]: Operation panel ( x 5, x 2, x 3)

Rear Cover

[A]: Rear cover ( x 9)

59
 4. Replacement and Adjustment

Upper Covers

[A]: Left upper cover ( x 2)

[B]: Top rear cover ( x 1)
[C]: Right upper cover ( x 1)

60
 Boards

Boards
MPU

• Rear cover ( p.59)

[A]: MPU ( x 10, x 18, 2 ribbon cables)

• Take the NVRAM [B] from the old board and put it in the socket on the new board.
• Adjust the master end sensor ( p.77) after installing the new MPU.
• Adjust the ink detection ( p.110) after installing the new MPU.
• If you must replace the MPU RAM, you must then do the image adjustments after you install the new
RAM ( p.55).

PSU

• When the PSU is replaced, the thermal head voltage returns to the default. Adjust the thermal head
voltage ( p.79) after installing the new board.

61
 4. Replacement and Adjustment

PSU Board
• Rear cover ( p.59)
• PSU ( x 6, x 7)

• The split washer screw [B] is used for grounding. Do not use another type of screw here.

PSU Board with Bracket

• Rear cover ( p.59)
[A]: PSU ( x 5, x 7)

62
 Scanner

Scanner
Exposure Glass, DF Exposure Glass and Scales

Exposure Glass
[A]: Left scale ( x 2)
[B]: Rear scale ( x 3)
[C]: Exposure glass

• When reinstalling, make sure that the mark [E] is at the rear left corner, and that the left edge is aligned
with the support on the frame.

DF Exposure Glass
[A]: Left scale ( x 2)
[D]: DF exposure glass

• When reinstalling, make sure that the mark [F] is on the bottom.

63
 4. Replacement and Adjustment

Lens Block

• Do not touch the paint-locked screws on the lens block. The position of the lens assembly (black part)
is adjusted before shipment.
• Do not grasp the PCB or the lens assembly when handling the lens block. The lens assembly may slide
out of position.

• Exposure glass ( p.63)

[A]: Lens cover ( x 5)
[B]: Ribbon cable
[C]: Lens block ( x 4).

64
 Scanner

Exposure Lamp and Lamp Stabilizer Board

• Exposure glass ( p.63)

1. Slide the first scanner to a position where the front end of the lamp is visible.
2. Place one hand under the lamp stabilizer board [A] and release the hook [B].
3. Remove the lamp stabilizer board [A] ( x 2).
4. Press the plastic latch [C] and push the front end of the lamp toward the rear.
5. Remove the lamp [D] (with the cable).

65
 4. Replacement and Adjustment

Scanner Motor

• Rear cover ( p.59)

• Exposure glass ( p.63)
[A]: Scanner motor ( x 3, x 1, x 1, 1 spring, 1 belt)

• When reassembling, install the belt first, and set the spring next. Fasten the leftmost screw (viewed
from the rear), then fasten the other two screws.

66
 Scanner

Scanner Home Position Sensor

• Left upper cover ( p.60 "Upper Covers")

• Top rear cover ( p.60 "Upper Covers")
• Front cover ( p.58 "Front Cover and Front Door")
• Operation panel ( p.59)
• Exposure glass, DF exposure glass (if installed) ( p.63)
[A]: Scanner left lid ( x 7, x 1).
[B]: Sensor tape
[C]: Scanner home position sensor

67
 4. Replacement and Adjustment

Platen Cover Sensor

• Top rear cover ( p.60 "Upper Covers")

[A]: Platen cover sensor ( x 1).

Adjusting the Scanner Position

• Grasp the front and rear ends (not the middle) of the first scanner when you manually move it. The
first scanner may be damaged if you press, push, or pull the middle part of the scanner.

68
 Scanner

Overview

Adjust the scanner positions at these times:

• When the first scanner [C] and second scanner [B] are not parallel with the side frames [A]
• When you have replaced one or more of the scanner belts.
To adjust the scanner positions, do either of the following:
• To adjust the belt contact points on the first scanner ( Adjusting the Belt Contact Points for the First
Scanner)
• To adjust the belt contact points on the scanner bracket ( Adjusting the Belt Contact Points for the
Second Scanner)

The two actions above have the same objectives: to align the following holes.
1st scanner [D], frame [E], arm of second scanner [F], and frame [G]
The scanner positions are correct when these holes are all aligned.

69
 4. Replacement and Adjustment

Adjusting the Belt Contact Points for the First Scanner

• ADF or platen cover

• Front cover ( p.58 "Front Cover and Front Door")
• Operation panel ( p.59)
• Rear cover ( p.59)
• Top rear cover ( p.60 "Upper Covers")
• Left upper cover ( p.60 "Upper Covers")
• Exposure glass ( p.63)
1. Loosen the 2 screws [A] [F].
2. Slide the 1st and 2nd scanners to align the following holes and marks ( p.14 "Overview"):
• Align all four holes: 1st scanner, frame, arm of second scanner and frame
3. Insert the positioning tools [D] [E] through the holes.
4. Check that the scanner belts [B] [C] [G] [H] are properly set between the bracket and the 1st scanner.
5. Tighten the screws [A] [F].
6. Remove the positioning tools.
7. Reassemble the machine and check the operation.

70
 Scanner

Adjusting the Belt Contact Points for the Second Scanner

• ADF or platen cover

• Front cover ( p.58 "Front Cover and Front Door")
• Operation panel ( p.59)
• Rear cover ( p.59)
• Top rear cover ( p.60 "Upper Covers")
• Left upper cover ( p.60 "Upper Covers")
• Exposure glass ( p.63)
1. Disconnect the platen cover sensor connector [A].
2. Scale bracket [B] ( x 2)

• 1). Take off the scale bracket, otherwise the screws [D] cannot be loosened.
• 2). Take off the bracket [C] in order to take off the scale bracket.

71
 4. Replacement and Adjustment

3. Loosen the 2 screws [D].

4. Slide the 2nd scanner to align the following holes and marks ( p.14 "Overview"):
• Align all four holes: 1st scanner, frame, arm of second scanner and frame
5. Insert the positioning tools [E] [F] through the holes.
6. Check that the scanner belts are properly set in the brackets.
7. Remove the positioning tools.
8. Reassemble the machine and check the operation.

72
 Master Feed

Master Feed
Master Making Unit

[A]: Master making unit cover ( x 3)

[B]: Master making unit ( x 2, x 4, x 1, x 1)

Master Making Unit Set Switches

73
 4. Replacement and Adjustment

• Master making unit ( p.73)

[A]: Master making unit set switch ( x 1, x 1)

• Front cover ( p.58 "Front Cover and Front Door")

[B]: Master making unit set switch ( x 1, x 1)

• There are two master making unit set switches for safety. Both sensors must be on or the machine will
not start.

74
 Master Feed

Thermal Head

• Master making unit ( p.73)

[A]: Open the platen roller unit.
[B]: Thermal head upper cover ( x 2)
[C]: Thermal head side cover ( x 1)

• Close the platen roller unit.

[D]: Thermal head ( x 2)

75
 4. Replacement and Adjustment

Installation

If the following remarks are not followed, the thermal head will be installed incorrectly.
1. Fit the base's springs [A] over the protrusions [B] on the underside of the thermal head (5 points).
2. While fitting the tops of the springs [A] over the protrusions on the underside of the thermal head, hook
the lock pawls [C] of the thermal head onto the base (3 lock pawls). Make sure to set the front side
[D] (the paper table side) first.
3. Make sure that all protrusions are properly fitted into the springs.

• Adjust the thermal head voltage ( p.79) after installing the new thermal head.
• Do not touch the surface with bare hands. (If you touch it, clean the surface with alcohol.)
• Do not touch the terminals of the connectors with bare hands.

76
 Master Feed

Master Set Cover Sensor

4
• Master making unit ( p.73)
[A]: Master set cover sensor ( x 3, x 1)

Master End Sensor

• Master making unit ( p.73)

• Thermal head upper cover ( p.75 "Thermal Head")
• Thermal head side cover ( p.75 "Thermal Head")
[A]: Master end sensor ( x 2, x 1)

77
 4. Replacement and Adjustment

• Adjust the master end sensor ( p.80) after installing a new sensor.

Cutter Unit

• Master making unit ( p.73)

[A]: Bracket ( x 2)
[B]: Shaft ( x 2)
[C]: Bracket ( x 2)
[D]: Cutter unit ( x 3, x 1, x 1)

78
 Master Feed

• To remove the screw [E], you must slide the thermal head a small distance towards the paper feed
table.

Thermal Head Voltage Adjustment

• This adjustment is always required when the thermal head or PSU has been replaced.

Purpose To maintain master making quality and extend the lifetime of the thermal head.

Refer to the voltage value (X) printed on the thermal head. The value varies from 4
Standard one thermal head to another.
The adjustment voltage should be between X and X - 0.1 V.

Tools Circuit tester

• Rear cover ( p.59)

• Read the voltage value on the decal on the thermal head.

1. Connect the positive terminal of a circuit tester to TP1 and the negative terminal to TP2 on the PSU.

• If the output and ground terminals touch each other, the board will be damaged.
2. Connect the power plug, and turn on the main switch to access SP mode.
3. Select SP5-12 (Thermal head signal output).

79
 4. Replacement and Adjustment

4. Press the # key. Power is continuously supplied to the thermal head, which could damage the thermal
head, so press the clear/stop key if you cannot finish the adjustment quickly.
A beeper sounds while the power is being supplied.
5. Measure the voltage, and turn RV1 on the PSU until the value is between "+0" and "-0.1" volts from
the value on the thermal head decal.

Master End Sensor Adjustment

To ensure that the sensor detects the end mark (a solid black area) on the master
Purpose
roll.

4 Standard 2.0 ± 0.1 volts

Tools The core of a used master roll (the core just before a master end display appears)

• Rear cover ( p.59)

1. Place the core inside the master making unit, and close the master making unit.
2. Connect the power plug, and turn on the main switch.
3. Access SP6-50.

80
 Master Feed

4
4. Turn VR2 [A] on the MPU board until the display is 2.0 ± 0.1 volts.

81
 4. Replacement and Adjustment

Master Eject
Master Eject Unit

Open the master eject unit.

[A]: Master eject unit ( x 3, x 1)

82
 Master Eject

Master Eject Rollers

4
• Master eject unit ( p.82)
[A]: Gears ( x 1)
[B]: Lower master eject roller ( x 2)
[C]: Upper master eject roller ( x 2, 2 springs)

Master Eject Motor and Pressure Plate Motor

• Master eject unit ( p.82)

[A]: Gears ( x 1)
[B]: Master eject motor ( x 2, x 1, x 2)
[C]: Pressure plate motor ( x 2, x 1, x 2)

83
 4. Replacement and Adjustment

Drum Master Sensor, Master Eject Sensor and Eject Box Set Sensor

• Master eject unit ( p.82)

• Master eject box
[A]: Drum master sensor ( x 2, x 1)
[B]: Bracket ( x 2, x 1)
[C]: Master eject sensor ( x 1, x 1)
[D]: Eject box set sensor ( x 1)

84
 Master Eject

Pressure Plate HP Sensor and Pressure Plate Limit Sensor

• Master eject unit ( p.82)

• Master eject box
[A]: Pressure plate HP sensor ( x 1)
[B]: Gear ( x 1, 1 pin)
[C]: Pressure plate limit sensor ( x 1)

Air Knife Fan Motor

85
 4. Replacement and Adjustment

[A]: Air knife fan duct ( x 2)

[B]: Air knife fan motor ( x 1, x 1, x 2)

Master Eject Position Sensor

• Rear cover ( p.59)

[A]: Master eject position sensor ( x 1, x 1, x 1)

Master Clamper Opening Unit

86
 Master Eject

• Rear cover ( p.59)

[A]: Master clamper opening unit ( x 3, x 2)

87
 4. Replacement and Adjustment

Paper Feed
Pick-up Roller, Paper Feed Roller and Friction Pad

• Move the separation pressure slider [E] to position 1.

[A]: Pick-up roller ( x 1)
[B]: Paper guide ( x 1)
[C]: Paper feed roller ( x 1)
[D]: Friction pad
Do not change the position and direction of the paper guide [B].

88
 Paper Feed

Paper Table Lower Limit Sensor

• Rear cover ( p.59)

[A]: Paper table lower limit sensor ( x 1, x 1)

Paper Height Sensor 1 and 2

• Master making unit ( p.73)

[A]: Paper feed unit cover ( x 2)
[B]: Paper feed unit cover – small ( x 4, x 1)

89
 4. Replacement and Adjustment

4
[C]: Paper height sensor 1 ( x 1, x 1)
[D]: Paper height sensor 2 ( x 1, x 1)

Paper End Sensor

• Rear cover ( p.59)

[A]: Paper table ( x 1, x 2)

90
 Paper Feed

[B]: Paper table bottom plate ( x 5, 3 washers)

[C]: Paper end sensor ( x 2, x 1)

Paper Table Motor

• Front cover ( p.58 "Front Cover and Front Door")

[A]: Paper table motor ( x 2, x 1)

91
 4. Replacement and Adjustment

Paper Feed Clutch

• Rear cover ( p.59)

• MPU ( p.61)
[A]: Paper feed clutch bracket ( x 2)
[B]: Paper feed clutch ( x 1, x 1)

Paper Separation Pressure Adjustment

The position of the screw can be changed in order to change the amount of pressure exerted by the friction
pad.
This adjustment can be done:
• When feeding special paper, especially thick paper
• When the customer is experiencing feed problems.

92
 Paper Feed

• Move the separation pressure slider [A] to position 1.

Increase the paper separation pressure: Move up the screws [B]
Decrease the paper separation pressure: Move down the screws [B]
Default position: lowest position
The adjustment is automatically applied to all settings of the separation pressure slider.

93
 4. Replacement and Adjustment

Printing
Press Roller

• Take care to avoid possible injury. If the printing pressure release arms disengage, the press roller
will be pulled upwards suddenly.

• Remove the drum.

[A]: Press roller ( x 1)
The bearings on the rear and front differ. During installation, ensure that the bearing with the stopper [B]
is positioned towards the rear of the machine.

94
 Printing

Registration Sensor

[A]: Registration sensor ( x 2, x 1)

Feed Start Timing Sensor

[A]: Feed start timing sensor ( x 1, x 1)

95
 4. Replacement and Adjustment

2nd Feed Timing Sensor

• Open the master eject unit

[A]: 2nd feed timing sensor ( x 1, x 1)

Registration Motor

96
 Printing

• Rear cover ( p.59)

• MPU ( p.61)
[A]: Registration motor (spring, x3, belt, x 1)

• The side of the motor with the harness [B] should face downward, as shown in the diagram
• The flange of the gear should face towards the motor as shown in the diagram

Registration Roller

• Front cover ( p.58 "Front Cover and Front Door")

• Rear cover ( p.59)
[A]: Paper table ( x 1, x 2)

97
 4. Replacement and Adjustment

[B]: Plate ( x 4)
• MPU ( p.61)
• PSU ( p.61)
• Registration motor ( p.96)

[C]: Gear

• The flange of gear [C] should face towards the machine, as shown in the diagram.

98
 Printing

[D]: Bearing ( x 2)
[E]: Registration roller
4
Press Roller Release Solenoids

• Front cover ( p.58 "Front Cover and Front Door")

• Rear cover ( p.59)
[A]: Press roller release solenoid ( x 2, x 1)

• Adjust the press roller release lever ( p.100 "Press Roller Release Lever Adjustment") after installing
the new solenoid.

99
 4. Replacement and Adjustment

Press Roller Release Lever Adjustment

To maintain the correct clearance between the press roller arms and press
Purpose: roller lock levers. This ensures that the press roller is correctly released and
pressed against the drum when the press roller release solenoid is energized.

Standard: 0.7 to 1.2 mm

Tools: Thickness gauge

• Front cover ( p.58 "Front Cover and Front Door")

• Rear cover ( p.59)
1. Turn the drum manually until the drum master clamper on the drum moves into the lowest position.
(This is when the high points of the cams on the drum flanges meet with the cam followers on both
ends of the press roller.)
• To find out the correct position of the drum for the adjustment, look at the rear end of the drum
shaft. The recess on the drum drive gear meets the hole [A] in the bracket when the drum is in
the correct position.

100
 Printing

4
2. Using a thickness gauge, measure the clearance [B] between the press roller arm [C] and the press
roller lock lever [D] (rear side). It should be between 0.7 and 1.2 mm.
3. If it is not correct, adjust the position of the press roller lock lever after loosening the two screws [E].
4. Repeat steps 2 and 3 for the front side.

Printing Pressure Adjustment

Purpose: To make better print results without decreasing the run length.

Standard: Within 10 ± 0.5 mm

• Paper delivery unit ( p.114)

101
 4. Replacement and Adjustment

1. Adjust the distance [A] to 10 ± 0.5 mm by turning the adjusting bolt [B].
2. Repeat the same procedure for the printing pressure spring at the non-operation side.

102
 Drum

Drum
Preparation

Before attempting any of the procedures in this section, wipe off the ink around the ink roller. To do this,
set SP2-10 (ink detection) to off, and feed paper until ink ends.

Cloth Screen

• Remove the drum.

1. Remove the drum upper bracket ( x 4).
2. Release the stopper [A], then rotate the drum until the master clamper faces top.

103
 4. Replacement and Adjustment

3. Remove the cloth screen [B] ( x 4).

Installation

• Do not scratch the cloth screen or metal screen.

104
 Drum

• Properly insert the edge of the cloth screen [A] on the cloth screen under the mylar [B] on the metal
screen, as shown above. Otherwise, ink will leak from the trailing edge of the master on the drum
during a long printing run.

• Make sure that the correct side ([A]: Inside, [B]: Outside) of the screen is facing up. In addition, make
sure that the stays for securing the cloth screen are positioned correctly.

• When replacing the cloth screen, spread the screen around the metal screen while pulling the stay
[C]. Adjust the stay so that it is parallel to the master clamper, then tighten the screws.
• Make sure that the cloth screen is not wrinkled while spreading it around the drum.

105
 4. Replacement and Adjustment

Clamper and Metal Screen

4
• Remove the drum.
• Cloth screen ( p.103)
[A]: Clamper lever (1 hexagon screw)
[B]: Clamper - open the clamping plate [C], then remove the clamper.

• Do not allow ink to get on the inside of the clamping plate [C]. Otherwise, the master may slip off and
the image position on the prints will move toward the trailing edge of the prints during a printing run.
• Use a cloth dampened with water to clean the inside of the clamping plate [C]. Never use alcohol or
other solvents, or the clamping force of the magnet will be weakened.

[D]: Tape (do not lose it)

[E]: Metal screen ( x 12)

106
 Drum

Installation

• Make sure that the correct end of the metal screen is overlapping. (The right side overlaps, as viewed
from the non-operation side, as shown above.)
• The 4 screws holding the drum master clamper are longer than the 12 screws holding the metal screen,
although they are similar in appearance. Be careful not to mix them up or use the wrong screws.
• When installing the metal screen, secure the trailing edge first with the 2 screws. Then, tighten the
other screws while removing the slack from the screen. Make sure that the gap between the drum
flanges and the screen is 0.3 mm or less, as shown above. (The two holes [A] on the trailing side are
round holes and the other holes are long holes, to allow for the removal of the slack.)

107
 4. Replacement and Adjustment

• Position the springs [B] and [C] (one each at the front and rear) as shown when reinstalling the drum
master clamper [D].
• Do not scratch the cloth screen or metal screen.

• The side [E] with the part number printed on it must be on the top.

Ink Pump Unit

• Remove the drum.

• Cloth screen ( p.103)
• Clamper / Metal screen ( p.106)
[A]: Ink pump unit ( x 1, x 2)

108
 Drum

Ink Roller Unit and Ink Roller One-Way Clutch

• Wipe off the ink around the ink roller beforehand (use SP2-10).
• Remove the drum
• Cloth screen ( p.103)
• Clamper / Metal screen ( p.106)
[A]: Connector cover ( x 2, x 2)
[B]: Ink socket ( x 1)
[C]: Front drum bracket ( x 3)
[D]: Front drum flange

109
 4. Replacement and Adjustment

[E]: Drum rear plate ( x 2)

Loosen the screw [F] to take off the drum rear stoppers ( x 1)
[G]: Drum rear flange

4
[H]: Ink roller unit
[I]: Ink roller one-way clutch

Doctor Roller Gap Adjustment

Purpose: To control the ink thickness around the ink roller.

Standard: A 0.07mm gauge passes, but a 0.09mm gauge does not.

Tools: Thickness gauge

• Normally the doctor roller gap is not adjusted or changed. It tends to be difficult to change in the field.
If the gap is too narrow, an uneven image may appear on the prints. If it is too wide, too much ink
will be applied to the drum screens, resulting in ink leakage from the drum.

110
 Drum

• Wipe off the ink around the ink roller beforehand. (Use SP2-10.)
• Remove the drum
• Remove the Ink roller unit
1. Make sure that a 0.07 mm gap gauge goes through the gap [A] between the ink and doctor rollers,
and that a 0.09 mm gap gauge does not.

• The gap should be checked at both ends of the doctor roller. Insert a gap gauge at each end of
the roller. The gap tends to be larger for the center.
• While the gap gauge is inserted, hold the doctor and ink rollers with your fingers in order to stop
the rollers from rotating.
• While the gap gauge is inserted, hold the end of the gap gauge.
2. If the gap is out of the standard, loosen the screw [B] and adjust the gap by turning the cam bushing
[C] for the front and for the rear.

• Make sure to repeat the adjustment for both ends of the rollers.

Ink Detection Adjustment

Using an Oscilloscope

Purpose: To ensure that the CPU detects a no ink condition.

111
 4. Replacement and Adjustment

Standard: 4.0 ± 0.2 sec

• Before attempting this procedure, wipe off the ink around the ink roller. To do this, set SP2-10 (Ink
Detection) to OFF, and feed paper until ink ends.
• This adjustment is required every time the MPU has been replaced.
• Normally, the simple method is sufficient. But, the oscilloscope method is more accurate. Use the
oscilloscope method if you cannot adjust the sensor to the required value with the simple method, or
if ink flooding problems occur after adjustment with the simple method.

1. Turn off the main switch and disconnect the power plug.
2. Remove the rear cover.
3. Connect the CH1 probe of an oscilloscope to TP25 (INK1), the CH2 probe to TP23 (INK2). Select
the 2-microsecond range on the oscilloscope.
4. Connect the power plug and turn on the main switch.
5. Make sure that the waveform is as shown in the illustration while the ink end indicator lights.
6. If it is not correct, adjust the ON timing of the detection signal by turning VR1 beside the test pins.

• If the ink detection off mode has been selected with SP2-10, do not forget to return it to the default
(detection on).

Simple Method

Purpose: To ensure that the CPU detects a no ink condition.

Standard: 4.0 ± 0.2 sec

112
 Drum

• Before attempting this procedure, wipe off the ink around the ink roller. To do this, set SP2-10 (Ink
Detection) to OFF, and feed paper until ink ends.
• This adjustment is required every time the MPU has been replaced.
• Normally, the simple method is sufficient. But, the oscilloscope method is more accurate. Use the
oscilloscope method if you cannot adjust the sensor to the required value with the simple method, or
if ink flooding problems occur after adjustment with the simple method.

• Rear cover ( p.59)

1. Access SP6-40.
2. Turn VR1 [A] on the MPU board until the display is "4.0 ± 0.2 sec".
3. When the drum has ink inside, the machine displays "----". Do SP 2-10 again, then go back to step
1.

• If the simple method gives an inaccurate result (causing ink flooding, for example), it is possible that
too much ink will come out into the drum during printing. If this happens, repeat the adjustment, but
use the oscilloscope method, because this is more accurate.

113
 4. Replacement and Adjustment

Paper Delivery
Paper Delivery Unit

[A]: Paper table ( x 2)

[B]: Paper delivery cover ( x 5)

114
 Paper Delivery

[C]: Paper delivery unit ( x 2, x 3)

Delivery Belt, Paper Exit Sensor, Vacuum Fan Motor and Paper Delivery Unit
Bushings

• Remove the paper delivery unit ( p.114).

115
 4. Replacement and Adjustment

[A]: Vacuum fan motor bracket ( x 4)

[B]: Vacuum fan motor ( x 2, pin x 2)
[C]: Paper exit sensor ( x 1)

• Make sure that you install the vacuum fan [B] the correct way around.

[D]: Delivery belts ( x 1)

[E]: Paper delivery unit bushings

• Install the delivery belt [D] the correct way around. The writing must be on the outside surface of the
belt.
• The flat part of the "D" shaped cutout in the shaft [F] must face upwards.

116
 Paper Delivery

Paper Delivery Motor

• Remove the paper delivery unit ( p.114).

• Delivery belts ( p.115 "Delivery Belt, Paper Exit Sensor, Vacuum Fan Motor and Paper Delivery
Unit Bushings")
[A]: Paper delivery motor ( x 2)

• When installing the paper delivery motor in the paper delivery unit, make sure that the pulley of the
paper delivery motor hooks the timing belt [B], and the paper delivery motor is linked with the delivery
belts [C] of the paper delivery unit.

Exit Pawl Adjustment

To ensure that the exit pawls can move out of the way of the drum master clamper while
Purpose:
the drum is rotating.

Standard: Within 1.15 ± 0.15 mm

117
 4. Replacement and Adjustment

Clearance adjustment

• Front cover ( p.58 "Front Cover and Front Door")

• Rear cover ( p.59)
1. Turn the drum to the drum home position.

• The drum turns to home position automatically immediately after the power switch is turned on.
2. Loosen screw [A] then screw [B] in this order (do not remove them). Make sure that the bracket [C]
becomes free from engagement and the cam follower [D] contacts the drum flange.

118
 Paper Delivery

3. Using a gap gauge, measure the clearance [E] between the drum surface and the exit pawls. It should
be 1.15 ± 0.15 mm.
4. If the clearance is not correct, adjust the clearance by turning the bolt [F].
5. Reposition the bracket [C] and tighten the screws [A] and [B].

Timing adjustment
Do this after the clearance adjustment.
Standard: 0 or less than 0.5 mm

1. Turn the drum manually until the recess in the drum drive gear meets the positioning hole [A] in the
bracket, as shown.

119
 4. Replacement and Adjustment

2. Loosen screw [B] then screw [C] in that order (do not remove them). Make sure that the bracket [D]
becomes free from engagement and the cam follower [E] contacts the drum flange.
3. Measure the gap [F] between the cam follower and cam face (front drum flange). It should be 0 to
0.5 mm.
4. If the gap is not correct, loosen the two screws securing the cam follower bracket [G].
5. Re-tighten the two screws while pushing the cam follower against the cam face. Make sure that the
gap [F] is 0 or less than 0.5 mm.
6. Do not push the cam followers too strongly against the cam.
7. Re-position the bracket [D] and tighten the screws [B] and [C].

120
 Main Drive

Main Drive
Registration Motor

• Rear cover ( p.59)

• MPU ( p.61)
• PSU ( p.61)
[A]: Paper table ( x 1, x 2)

[B]: Plate ( x 4)

121
 4. Replacement and Adjustment

[C]: Registration motor (spring, x3, belt)

• The side of the motor with the harness [D] should face downward, as shown in the diagram.
• The flange of the gear should face towards the motor, as shown in the diagram.

Main Motor

122
 Main Drive

• Registration motor ( p.96)

[A]: Harnesses ( x 6)
[B]: Bracket ( x 2, bushing x 1)

[C]: Drive bracket ( x 8)

• If the drive bracket [C] is to be removed from the machine with the drum removed, return the drum
position to its home position [D].

123
 4. Replacement and Adjustment

[E]: Main motor ( x 1, x 4)

• Adjust the main drive timing belt ( p.124 "Main Drive Timing Belt Adjustment") after installing the
new main motor.

Main Drive Timing Belt Adjustment

After the timing belt is replaced, correct belt tension must be applied.

• Rear cover ( p.59)

• MPU ( p.61)
1. Loosen the screws [A], [B], and [C].
2. Move the tension roller [D] to the right with a screwdriver [E] as shown.
3. Tighten the screws [A], [B], and [C].
4. Remove the screwdriver.

Main Motor Pulley Position

After putting the pulley back on the main motor shaft, refer to the above illustration for the correct position
of the pulley.
Standard: 46.3 ± 0.3 mm

124
 Main Drive

• Tighten the screws alternately little by little. Do not tighten them completely one by one.

125
 4. Replacement and Adjustment

126
5. System Maintenance

Service Program Mode

See "Appendices" for the "Service Program Mode".

127
 5. System Maintenance

128
6. Troubleshooting

Troubleshooting Guide
See "Appendices" for the followings:
• "Service Call Conditions"
• "Electrical Component Defects"
• "DIP SW, LED, VR, TP and Fuse Tables"

129
 6. Troubleshooting

130
7. Energy Saving

Energy Save
Energy Saver Modes

Customers should use energy saver modes properly, to save energy and protect the environment.

The area shaded grey in this diagram represents the amount of energy that is saved when the timers are
at the default settings. If the timers are changed, then the energy saved will be different. For example, if
the timers are all set to 120 min., the grey area will disappear, and no energy is saved before 120 min.
expires.

Timer Settings
The user can set these timers with User Tools (System settings)
• Energy saver timer (1 – 120 min): Low Power Mode. Default setting: 3 minute
• Auto off timer (1 – 120 min): Off
Default settings:

131
 7. Energy Saving

PT3 3 min.

• The energy saver timer and the auto off timer cannot be used at the same time. Only one is available.

Recommendation
We recommend that the default settings should be kept.
• If the customer requests that these settings should be changed, please explain that their energy costs
could increase, and that they should consider the effects on the environment of extra energy use.
• If it is necessary to change the settings, please try to make sure that the Auto Off timer is not too long.
Try with a shorter setting first, such as 30 min., then go to a longer one (such as 60 min.) if the customer
is not satisfied.
• If the timers are all set to the maximum value, the machine will not begin saving energy until 120
minutes has expired after the last job. This means that after the customer has finished using the machine
for the day, energy will be consumed that could otherwise be saved.

132
 Paper Save

Paper Save
Effectiveness of the Combine Function

The combine function reduces the amount of paper used. This means that less energy overall is used for
paper production, which improves the environment.

Combine mode:
Reduce paper volume in half!

7
Recommendation
Please explain the above features to the customers, so that they can reduce their paper usage.

PT3
The following table shows paper savings and how the counters increase for some simple examples of
single-sided jobs.
If combine mode is used, the total counters work in the same way as explained previously. The following
table shows paper savings and how the counters increase for some simple examples of combine jobs.

2 in 1 mode:
Simplex Sheet Paper
Originals
used Saved

1 1 0

2 2 1

133
 7. Energy Saving

134
 Model PT3
Machine Code: C275
Appendices

2 November, 2009
TABLE OF CONTENTS
1. Appendix: General Specifications
General Specifications.......................................................................................................................................3
2. Appendix: PM Tables
Maintenance Tables...........................................................................................................................................9
Main Body......................................................................................................................................................9
ADF...............................................................................................................................................................10
3. Appendix: Service Call Conditions
Service Call Conditions...................................................................................................................................13
Service Call Codes......................................................................................................................................13
4. Appendix: Electrical Component Defects
Electrical Component Defects.........................................................................................................................17
Paper Feed and Exit.....................................................................................................................................17
Drum..............................................................................................................................................................18
Paper Eject....................................................................................................................................................18
Paper Feed...................................................................................................................................................18
Main Drive....................................................................................................................................................19
Scanner.........................................................................................................................................................19
Master Eject..................................................................................................................................................20
Master Making Unit.....................................................................................................................................20
Other.............................................................................................................................................................21
5. Appendix: DIP SW, LED, VR, TP and Fuse Tables
DIP SW, LED, VR, TP and Fuse Tables............................................................................................................23
Test Points.....................................................................................................................................................23
Potentiometers..............................................................................................................................................23
LEDs...............................................................................................................................................................24
Fuses..............................................................................................................................................................24
6. Appendix: Service Program Mode Tables
Service Program Mode....................................................................................................................................25
Using Service Program Modes...................................................................................................................25
How to Select a Program Number.............................................................................................................25
Main Menu Number List.............................................................................................................................26
1. Copy Data...............................................................................................................................................26
2. Basic Settings...........................................................................................................................................28

1
 3. System Settings........................................................................................................................................32
4. Input Mode..............................................................................................................................................34
5. Output Mode...........................................................................................................................................35
6. Adjustment................................................................................................................................................37
7. Memory Clear.........................................................................................................................................44
8. System Test...............................................................................................................................................45
9. Print Controller.........................................................................................................................................49

2
1. Appendix: General Specifications

General Specifications 1
Configuration Desktop

300 dpi x 300 dpi

Pixel Density
In Fine mode, 400 dpi in sub-scanning resolution

600 dpi x 300 dpi CCD

Scanning This model always reduces the amount of scanned data
in the main-scan direction by half before printing.

Master Process Digital with 300 dpi thermal head

Originals Sheet / Book

Printing Process Fully automatic one-drum system

Platen Mode:
Maximum A3 / DL size
Original Size ADF Mode:
Maximum 297 mm x 432 mm, 11.7" x 17.0"
Minimum 105 mm x 128 mm, 4.1" x 5.0"

Platen Mode:
Maximum 30 mm
Original Thickness / Weight
ADF Mode:
52 to 105 g/m2, 14 to 28 lb.

A4/ 8 1/2" x 11" or less:

40 sheets (80 g/m2 [20 lb.])
Original Stack Capacity (ADF)
More than A4/ 8 1/2" x 11":
30 sheets (80 g/m2 [20 lb.])

3
 1. Appendix: General Specifications

Maximum:
275 mm x 395 mm, 10.8" x 15.6"
Copy Paper Size 297 mm x 420 mm, 11.7" x 16.5" (A3 Printing Mode)
1 Minimum:
90 mm x 140 mm, 3.5" x 4.7"

China model:
35 to 127.9 g/m2 (Normal Printing Mode)
52.3 to 127.9 g/m2 (A3 Printing Mode)
B4/LG model (except China model):
47.1 to 209.3 g/m2 (Normal Printing Mode)
Copy Paper Weight
52.3 to 157 g/m2 (A3 Printing Mode)
A4 model:
47.1 to 209.3 or 127.9 g/m2 (Normal Printing Mode)
Note: 47.1 to 209.3g/m2 (A4 size and smaller), 47.1
to 127.9 g/m2 (More than A4 size)

80, 100 or 130 cpm (Normal Printing Mode)

Printing Speed
80 cpm (A3 Printing Mode)

Original Type Text, Text/Photo, Photo, Pale mode, Pencil mode

Master Making Density Lighter, Normal, Darker 1, Darker 2

Metric (%): 141, 122, 115, 93, 87, 82, 71

Reproduction Ratios
Inch (%): 155, 129, 121, 93, 77, 74, 65

Master Eject Box Capacity 30 masters

Copy Paper Capacity 1,000 sheets (64 g/m2, 17 lb.)

1,000 sheets (64 g/m2, 171 lb., Normal Printing

Paper Delivery Tray Capacity Mode)
500 sheets (64 g/m2, 17 lb., A3 Printing Mode)

120 V, 60 Hz, 2.2 A

Power Source
220 V – 240 V, 50 – 60 Hz, 1.2 A

4
 General Specifications

120V, 60Hz:
Less than 185W (Printing)
Less than 210W (Master making)
Power Consumption
220V-240V, 50-60Hz: 1
Less than 185W (Printing)
Less than 210W (Master making)

Sound Power Level

Standby: 34 dB
Copying 80 cpm: 78 dB
Copying 100 cpm: 80 dB
Copying 130 cpm: 84 dB
Noise Emission
Operating Position Sound Power Level
Standby: 20 dB
Copying 80 cpm: 63 dB
Copying 100 cpm: 66 dB
Copying 130 cpm: 70 dB

Stored:
750 x 681 x 633 mm, 29.5" x 26.8" x 24.9"
Stored with ADF:
750 x 681 x 686 mm, 29.5" x 26.8" x 27.0"
Dimensions (W x D x H)
Set up:
1224 x 681 x 633 mm, 48.2" x 26.8" x 24.9"
Set up with ADF:
1224 x 681 x 686 mm, 48.2" x 226.8" x 27.0"

69.0 kg (Main)
Weight 2 kg (Platen)
7 kg (ADF)

32 seconds (A4 , Platen)

Master Processing Time
35 seconds (A4 , ADF)

34 seconds (A4 , Platen)

First Print Time
37 seconds (A4 , ADF)

5
 1. Appendix: General Specifications

B4 Drum:
250 mm x 355 mm
LG Drum:
1 Printing Area
210 mm x 355 mm
A4 Drum:
210 mm x 288 mm

5 mm ± 3 mm (Normal Printing Mode)

Leading Edge Margin 15 mm (B4/LG model, A3 Printing Mode)
25 mm (A4 model, A3 Printing Mode)

Side Registration:
± 10 mm (Normal Printing Mode)
Fixed (A3 Printing Mode: -10 mm (B4/LG model) or -20
Side / Vertical Registration Adjustable Range mm (A4 model)
Vertical Registration:
± 10 mm or more (Normal Printing Mode)
Fixed at Center (A3 Printing Mode)

280 mm width (B4)

240 mm width (LG / A4)
Master Type
100 m / roll (China/ Korea)
125 m / roll (other destinations)

260 masters / roll (B4 / LG)

Master Yield 300 masters / roll (A4)
205 masters / roll (B4 China/ Korea)

Maximum run length per master 2000 prints / master

Storage Condition -10 to 40°C, 10 to 90 %RH

Storage Period 18 months after production date

6
 General Specifications

500 ml / pack (Black, China)

Ink Type 600 ml / pack (Black, Other destinations)
600 ml / pack (Other colors)

Black, Red, Blue, Green, Brown, Violet

1
Ink Available Colors
Yellow, Maroon, Navy, Orange, Hunter green

Storage Condition -5 to 40 C, 10 to 95 %RH

-5 to 40 C (12 months after production date)

Storage Period
15 to 25 C (18 months after production date)

Avoid locations exposed to direct sunlight.

7
 1. Appendix: General Specifications

8
2. Appendix: PM Tables

Maintenance Tables
The following items should be maintained periodically. There are two sets of intervals - one based on time
and the other based on print count or original count. For maintenance items with entries in both of them,
use whichever comes first.
2
Symbol Key: C: Clean, R: Replace, L: Lubricate

• Turn off the main power switch and unplug the machine before performing any procedure in this
section.

Main Body

Time Print Counter

30 EM Note
6M 1Y 2Y 5Y 600K 1.2M 3M
0K

Optics

Clean with
Exposure glass C C C C C
water.

Clean with
Platen cover C C C C C
water.

Clean with
White plate C C C C C
water.

Master Feed

Clean with
Thermal head C C C C C
alcohol.

Clean with
Platen roller C
alcohol.

Drum and Ink Supply

Ink nozzle C Damp cloth

Drum master sensor C Dry cloth

9
 2. Appendix: PM Tables

Black patches C C C C C Dry cloth

Cloth screen R

Ink roller one-way

R
clutch

2 Drum master sensor C Dry cloth

Clean with
Master clamper C C C C C
water.

Paper Feed

Dry or damp
Paper feed roller C C C C R C
cloth

Dry or damp
Pick-up roller C C C C R C
cloth

Clean with
Friction pad C C C C R C
alcohol.

Clean with
Registration rollers C
alcohol.

Feed start timing C Dry cloth

sensor

Dry or damp
Press roller C C C C R C
cloth

Grease
Drum drive gears L
(Alvania #2)

Paper feed clutch R

Paper delivery
R
motor

ADF

Time Print Counter

EM Note
6M 1Y 2Y 5Y 300K

10
 Maintenance Tables

Clean with water or

Feed belt C C C C R C
alcohol.

Clean with water or

Separation roller C C C C R C
alcohol.

Clean with water or

Pick-up roller C C C C R C
alcohol. 2
Clean with water or
White plate C C C C C
alcohol.

DF exposure glass C C C C C Clean with water.

Clean with water or

Platen cover C C C C C
alcohol.

11
 2. Appendix: PM Tables

12
3. Appendix: Service Call Conditions

Service Call Conditions

Service Call Codes

• If the problem concerns electrical circuit boards, first disconnect then reconnect the connectors before 3
replacing the PCBs.
• If the problem concerns a motor lock, first check the mechanical load before replacing motors or
sensors.

No. Description/Definition Points to Check

E-00 Clamper Motor Failure Clamper drive

The MPU cannot detect the clamper position Clamper sensors
sensor signal (open or closed) within 3.0 seconds
Clamper motor
after the clamper motor turns on.
MPU board
Main motor encoder
Master eject position sensor

E-01 Cutter error: Cutter drive

The cutter HP sensor does not turn on within 3.0 Cutter switch
seconds after the cutter motor turns on. Cutter motor

E-02 Paper Table Drive error: Paper table drive

The paper height sensor or the table lower limit Paper table motor
sensor does not turn on within 7.5 seconds after Paper height sensor 1 or 2
the table motor turns on.
Paper table lower limit sensor
Paper height sensor 1 or 2 does not turn on within
Gears
1 second after the paper height sensor 1 or 2 turn
on. Paper table spring

E-04 Thermal Head Overheat: Overheat (wait for the thermal head to
Temperature of the thermal head is greater than cool down)
65°C when the Start key is pressed. Thermal head

13
 3. Appendix: Service Call Conditions

No. Description/Definition Points to Check

E-06 Main Motor Lock: Main motor drive

The CPU cannot detect the master eject position Main motor
sensor (drum HP) signal within 5.0 seconds after Motor drive board
the main motor turns on.
Master eject position sensor

E-09 Thermal Head Thermistor Open: Thermal head thermistor

The thermistor output voltage is over 2.925 volts. Thermal head connector
3
E-10 Thermal Head Energy Pulse error: Thermal head connector
The CPU detects an abnormal ID signal from the Thermal head
thermal head energy control pulse. MPU

E-12 Pressure Plate error: Pressure plate drive

The pressure plate home position sensor does not Pressure plate motor
turn on within 6 seconds during initialization. Plate position sensors
Both the pressure plate home position and Master eject error
pressure plate limit sensors turn on when the main
SW is turned on.
The pressure plate home position sensor does not
turn off when the pressure plate limit sensor does
not turn on within 4.5 seconds when compressing
the ejected master.

E-13 Scanner error: Scanner drive

The scanner HP sensor does not turn on after the Scanner HP sensor
scanner motor has moved for more than 10 Scanner motor
seconds back to home position after scanning.
Scanner wire has come off
The scanner cannot leave the home position within
2.0 seconds of power on.
Just after switching the power on, the scanner
cannot return to the home position within 2.0
seconds of leaving.

E-22 2nd Feed Start Timing Sensor error: Drum sensors

The 2nd feed start timing sensor does not activate Feeler
before the master eject position sensor activates.

14
 Service Call Conditions

No. Description/Definition Points to Check

E-23 Master Eject Position Sensor (Drum HP) error: Drum sensors
The master eject position sensor does not activate Feeler
before the feed start timing sensor activates.

E-24 Feed Start Timing Sensor error: Drum sensors

The feed start timing sensor does not activate Feeler
before the 2nd feed timing sensor activates.

E-40 Thermal Head ID error: Different thermal head

3
The CPU detects an abnormal ID signal from the MPU
thermal head. Thermal head connector disconnected

E-44 MSU error Replace the MPU

E-50 NVRAM data version disagreement: Replace the MPU

Data for the uploading NVRAM is not expected
data for the machine.

E-51 Flash Rom error: Replace the MPU

The data in the flash ROM is not complete.

E-61 Auto Off Switch error: Auto off switch defective

The main switch does not turn off for more than Auto off switch connector disconnected
6.0 seconds.

15
 3. Appendix: Service Call Conditions

16
4. Appendix: Electrical Component
Defects

Electrical Component Defects

Paper Feed and Exit

Jam Type

Paper feed A Jam

Drum B Jam

Paper eject C Jam

Master feed D Jam

Master eject E Jam

ADF P Jam

Paper remaining A or B Jam

17
 4. Appendix: Electrical Component Defects

Drum

Name State Symptoms

2nd Feed Start Timing Open

E22 is displayed when the drum rotates.
Sensor Shorted

Master Eject Position Open

E23 is displayed when the drum rotates.
(HP) Sensor Shorted

Open
4 Feed Start Timing Sensor
Shorted
E24 is displayed when the drum rotates.

Setting Drum: Normal Operation

Set
Drum Set Sensor No Drum: E-06 is displayed when the main motor rotates.

OFF Displays "not drum".

ON Image will be patchy because ink will not be supplied.

Drum Ink Sensor
OFF Displays "Ink end".

Paper Eject

Name State Symptoms

Paper Exit Sensor Open The "C" jam indicator is lit.

Shorted The "B" jam indicator is lit when a copy is made.

Paper Feed

Name State Symptoms

Paper Registration Open The "AB" jam indicator is lit.

Sensor
Shorted The "A" jam indicator is lit when a copy is made.

18
 Electrical Component Defects

Name State Symptoms

Paper Table Lower limit Open The paper table does not go down.
Sensor
The paper table goes down below the sensor, and E-02
Shorted
is displayed.

Paper End Sensor Printing can begin even if there is no paper, and the "A"
Open
jam indicator will be lit.

Shorted The "load more paper" indicator is lit.

Paper height sensor 1 E-02 is displayed after 1 second from moving up the
Open
paper feed table during printing.
4
The paper table goes up over the sensor, and E-02 is
Shorted
displayed

Paper height sensor 2 E-02 is displayed after 1 second from moving up the
Open
paper feed table during printing.

The paper table goes up over the sensor, and E-02 is

Shorted
displayed

Main Drive

Name State Symptoms

Clamper Open Sensor Open E-00 is displayed.

Shorted E-00 is displayed when the clamper operates.

Clamper Close Sensor Open E-00 is displayed when the clamper operates.

Shorted E-00 is displayed.

Scanner

Name State Symptoms

Platen Cover Sensor The master is made normally, even if the platen cover is
Open
open. (Have to push the start button twice)

Shorted The image is treated using center/edge erase mode.

19
 4. Appendix: Electrical Component Defects

Name State Symptoms

Scanner HP Sensor Open E-13 is displayed.

Master Eject

Name State Symptoms

Drum Master Sensor On The "B" jam indicator is lit when print is started. (Print
without master)

4 Off Master does not eject

The "D" jam indicator is lit.

Pressure Plate Limit Open E-12 is displayed.

Sensor
Shorted The "Full eject master" indicator is lit.

Pressure Plate HP Open E-12 is displayed.

Sensor
Shorted E-12 is displayed.

Master Eject Box Sensor On The master is ejected, even if there is no master eject box

Off "No master eject box" is displayed.

"Full eject master" indicator is lit.

Master Eject Sensor Open The "B" and "E" jam indicator is lit.

Shorted The "B" jam indicator is lit

Master eject unit safety Open "Unit open" is displayed.

switch

Master Making Unit

Name State Symptoms

Master Set Cover Open The "D" jam indicator is lit.

Sensor
Shorted The "open cover" indicators are lit.

20
 Electrical Component Defects

Name State Symptoms

Cutter HP Sensor Open E-01 is displayed.

Shorted E-01 is displayed.

Master making unit set If both sensors work correctly, the machine operates
On
switches correctly.

Off "Not set making unit" is displayed

Master End Sensor Master making can start even if there is no master roll, but
White
the "D" jam indicator will be lit.

Black The "load new master roll" indicator is lit. 4

Thermal Head Open E-09 is displayed.
Temperature
Short E-04 is displayed.

Other

Name State Symptoms

Auto shut off Switch On Cannot shut off the main switch.
E-61 is displayed at auto shut off.

Off The main switch stays off

21
 4. Appendix: Electrical Component Defects

22
5. Appendix: DIP SW, LED, VR, TP and
Fuse Tables

DIP SW, LED, VR, TP and Fuse Tables

Test Points

MPU

No. Usage

TP7 GND-a 5
TP8 Standard Pulse

TP9 Ink Detection Pulse

TP11 +5VE

TP12 GND-a

Potentiometers

MPU

No. Usage

VR1 Ink detection adjustment

VR2 Master End Sensor Adjustment

Power Supply Unit

No. Usage

RV1 Thermal Head Voltage Adjustment

23
 5. Appendix: DIP SW, LED, VR, TP and Fuse Tables

LEDs

MPU

LED # OFF ON

LED 1 CPU2 (not use for service)

LED 2 Low Ink Condition Sufficient Ink Condition

LED 3 CPU1 (not use for service)

LED 4 CPU1 (not use for service)

5 Fuses

MPU

FUSE # Rated Current Voltage Related Devices

FU 1 2A 5 V DC UC2 PC Controller

PSU

FUSE # Rated Current Voltage Related Devices

FU 700 T6.3 A 120/230V AC Line

AC

FU 701 T6.3 A 24VDC Paper Transport Motor, Paper Feed Clutch, Paper Up-
Down Motor, Air Knife Fan Motor, Front/Rear Pressure
Release Solenoid, Vacuum Fan Motor, Ink Pump Motor,
Master Eject Motor, Optional Key Counter, Master
Counter, Paper Counter, Cutter Motor, Clamper Motor,
Scanner Motor

FU 702 T6.3 A 24V DC Not used

FU 703 T8 A 24V DC Main Motor

FU 704 T6.3 A 24V DC Optional Tape Dispenser

24
6. Appendix: Service Program Mode
Tables

Service Program Mode

• The Service Program Mode is for use by service representatives only so that they can properly maintain
product quality. If this mode is used by anyone other than service representatives for any reason, data
might be deleted or settings might be changed. In such case, product quality cannot be guaranteed
any more.

Using Service Program Modes

Use the service program modes (SP modes) to check electrical data, change operating modes, and adjust
values.
6
How to Select a Program Number

1. Using the number keys [A] or the keys [B], enter the desired main menu number, then press the
Enter key [C] or the OK key [D].
2. Using the number keys or the keys, enter the desired sub-menu number, then press the Enter key
or the OK key.
3. Enter the desired value or mode using the number keys (SP modes are listed in the service program
tables).

25
 6. Appendix: Service Program Mode Tables

• Use the Memory/Class [E] key to toggle between "+" and "-".
• To enter a decimal place, you do not have to enter a decimal point. For example, to enter "1.5"
just press "1" and "5" keys.
4. Press the Enter key or the OK key to store the displayed setting.

• To cancel the SP mode, press the Clear Modes/Energy Saver key [F] or the Cancel key [G].

Main Menu Number List

No. Main Menu

1 Copy Data

2 Basic Settings

6 3 System Settings

4 Input Mode

5 Output Mode

6 Adjustment

7 Memory Clear

8 System Test

1. Copy Data

SP Table (SP 1-xxx)

No. Menu Items

1 Total master counter

20 Total print counter

50 D - master clamp jam

26
 Service Program Mode

No. Menu Items

51 E - master eject jam

52 E - master compressing jam

53 A - paper non-feed jam

54 A - paper registration jam

55 B - paper wrapping jam

56 C - paper delivery jam

57 P - original feed - in jam

58 P - original feed - out jam

60 D - master cut jam

70 Main firmware part number 6

72 Serial number

73 Main firmware version

75 Serial number (Factory)

80 Error code history

81 Telephone number display

82 Jam history

83 PSU unusual voltage history

160 Japanese Display type (Japan only)

161 Key counter setting check

162 Key card setting check (Japan only)

SP1-70: Main Firmware Parts Number

Displays the main firmware parts number and the suffix.

27
 6. Appendix: Service Program Mode Tables

SP1-80: Error Code History

Displays the latest 40 SC codes. Use the keys to view the codes.
SP1-83: PSU Unusual Voltage History
Display the unusual power supply events in the machine history.

2. Basic Settings

SP Table (SP 2-xxx)

No. Menu Items Default Settings

1 Default print speed 2 1 to 3

2 Default image position 0 -10.0mm to +10.0mm (0.5mm interval)

4 Destination code
6 5 Not used (Ink) 0 0 / 2-

6 Image position display 1 0:Slow 1:Normal 2:Fast

7 Vender Selection - RICOH

TIE
KonicaMinolta
Edisys
NRG
Nashuatec
RexRotary
Gestetner
Lanier
Savin
Standard

10 Ink detection board On Off/On (Off is used for tests, and for
removing ink from the drum)

11 Paper end sensor On Off/On (Off is used for tests)

12 Drum master sensor On Off/On (Off is used for tests)

28
 Service Program Mode

No. Menu Items Default Settings

13 Platen cover sensor On Off/On (Off is used for tests)

14 ADF cover sensor On Off/On (Off is used for tests)

20 Destination setting Other Other/Japan

21 Ink setting (not used) 0 0 to 1

33 Re - Feeding setting On Off/On

34 Proof Print Adjustment Off Off/On

35 Number of Proof Prints 0 0 to 5

40 T/H energy control – B4/Black 7 0 to 50%

41 T/H energy control – B4/Color 7 0 to 50%

6
42 T/H energy control – A4/Black 7 0 to 50%

43 T/H energy control – A4/Color 7 0 to 50%

44 T/H energy control – LG/Black 7 0 to 50%

45 T/H energy control – LG Color 7 0 to 50%

50 T/H energy control - B4/Black eco 15 0 to 50%

51 T/H energy control - B4/Color eco 15 0 to 50%

52 T/H energy control - A4/Black eco 15 0 to 50%

53 T/H energy control - A4/Color eco 15 0 to 50%

54 T/H energy control – LG/Black eco 15 0 to 50%

55 T/H energy control – LG/Color eco 15 0 to 50%

60 Bold letter mode Off Off/On

61 T/H Swing Mode Off Off/On

62 T/H Swing Quantity 2 ± 1mm to ± 5mm

29
 6. Appendix: Service Program Mode Tables

No. Menu Items Default Settings

80 Auto off at unusual voltage On Off/On

95 Paper table standby position Low High / Low

100 Make master without print Off Off/On

SP2-6: Image Position Display

When the user moves the image position on the operation panel, this SP controls the length of time that the
adjustment value is shown on the display before the screen goes back to the previous display.
"Slow" means that the display is shown for the longest time possible.
SP2-33: Re-Feeding Setting
When the machine performs re-feeding, the paper registration position can be up to 5mm out of range. If
this incorrect position is not acceptable to the customer, change this SP mode to "OFF".

6 ON: Re- feeding is on (factory setting).

OFF: Re- feeding is off.
SP2-34: Proof Print Adjustment
This enables or disables the proof print adjustment mode (default: Off). The proof print adjustment mode
is designed to compensate for the low image density of the first few sheets. If the proof print adjustment is
enabled, the machine prints several sheets of paper, which can be adjusted by SP2-35, at 30 cpm.
• Off: No proof print adjustment
• On: The machine prints the first few sheets (up to 5) at 30 cpm.
For example:
Default setting (SP2-34: Off)

Number of sheets Idling 1 2 3 4 5

Speed (cpm) 80 100 100 100 100 100

Proof print mode enabled (SP2-34: ON)

Setting of SP2-35: "1"

Number of sheets 1 Idling 2 3 4 5

Speed (cpm) 30 80 100 100 100 100

30
 Service Program Mode

Setting of SP2-35: "5"

Number of sheets 1 2-5 Idling 6 7 8

Speed (cpm) 30 30 80 100 100 100

Proof print mode enabled (SP2-34: ON) and skip feed mode enabled (2 sheets)

Setting of SP2-35: "2"

Idling Idling Idling Idling Idling

Number of sheets 1 2 3
(Skip) (Skip) (Skip) (Skip) (Skip)

Speed (cpm) 30 30 30 30 80 100 100 100

SP2-35: Number of Proof Prints

This can set the number of sheets for the print proof adjustment mode.
• Default: 1
• Adjustable range: 1 to 5 (sheets)
6
For details about how to use this, see the description above (SP2-34).
SP2-40, 2-55: Thermal Head Energy Control

The default is 7%. This means that during normal printing mode, the thermal
2-40 to -45:
head energy is 93% of the maximum possible (100 – 7).

The default is 15%. This means that in economy printing mode, the thermal
2-50 to 55: head energy is reduced by another 15%. With the default settings, this
means that the thermal head energy is 85% of maximum power (100-15).

SP2-60: Bold Mode: Letter Mode Only

Makes a bold outline of a letter-mode image.
SP2-61: T/H Swing Mode
If this is set to "ON", the thermal head writing position is moved a small amount between masters. The
amount is set with SP2-61 (T/H Swing Amount) automatically. This changes the side-to-side margin on the
master.
This prevents the same parts of the thermal head from being used all the time, because if masters that contain
the same image (such as a logo) are made frequently, this can burn out the thermal head.
Default: OFF
SP2-62: T/H Swing Amount
Settings: ± 1 to± 5 mm

31
 6. Appendix: Service Program Mode Tables

Default: 2 mm
SP2-80: Auto off at Unusual Voltage
There is an automatic detection system for unexpected voltage surges, featuring automatic shut-off and
data logging features.
SP2-95: Paper Table Standby Position.
High: The paper table after printing is moved to a higher position than the standard position. This will reduce
the time for starting the first print when continuously making masters.
Low: The standard position

• If SP2-95 is "high", the machine goes to the standard position in the following situations.
• When the master end indicator lights and a message is displayed
• When a master eject jam (B jam location indicator) is displayed
• When a master feed jam (D jam location indicator) is displayed
• When the paper height sensor is actuated immediately after the main switch is turned on.

6 SP2-100: Make master without print

This function wraps a blank master around the drum. The ink on the drum may dry up at the following times:
• The machine is not used for a long time.
• The customer changes to a color drum that has not been used recently.
This might affect the print quality (Poor image: ghost image of the previous print).
Wrap a blank master around the drum after you print, to prevent ghost images of previous prints when the
machine is not used for a long time.
Procedure:
1. Access SP2-100 (Make master without printing). Then press "OK".
2. Press the "Start" key while holding down the "#" key.

3. System Settings

SP Table (SP 3-xxx)

No. Menu Items Default Settings

1 Input the present time (00/01/01 0:00) 99/12/31 23:59

2 Input TEL number -

3 Input serial number -

32
 Service Program Mode

No. Menu Items Default Settings

4 Input installation data (00/01/01) 99/12/31

9 Key counter setting No No/Yes

10 Key card setting (Japan only) No No/Yes

SP3-1: Input the present time

Input the year, the month / date, and the time in that order. Press the Enter key between each one.
Input the last two digits of the present year (two-digit number).
#
Input the present month (two-digit number).
#
Input the present date (two-digit number).
#
Input the present hour (two-digit number). 6
#
Input the present minute (two-digit number).
#
Input the present second (two-digit number).
#
Example: 2003/January/27th/13:00:00
03
#
01
#
27
#
13
#
00
#
00
OK

33
 6. Appendix: Service Program Mode Tables

SP3-4: Input installation date

Input installation date in that order. Press the Enter key between each one.
Input the last two digits of the present year (two-digit number).
#
Input the present month (two-digit number).
#
Input the present date (two-digit number).
#
Example: 2003/January/27th/13:00:00
03
#
01
#
27
6 OK

4. Input Mode

SP Table (SP 4-xxx)

No. Menu Items No. Menu Items

1 Scanner HP sensor 28 Drum size2 signal

2 Platen cover sensor

7 Master eject unit open SN 30 Table lowering switch

9 Master making unit set SW 1 31 Table lower sensor

33 Paper end sensor

10 Master making unit set SW 2 35 Paper pick-up roller sensor

11 Master set cover sensor 36 Paper height filler sensor

12 Cutter HP switch 41 Registration sensor

13 Master end sensor 42 Feed start timing sensor

34
 Service Program Mode

No. Menu Items No. Menu Items

14 Eject box set switch 43 2nd feed timing sensor

15 Master eject sensor 44 Paper exit sensor

16 Pressure plate HP sensor

17 Pressure plate limit Sensor 50 Door safety switch

18 Ink detection signal 60 ADF connecting signal

19 Color drum signal 61 ADF cover sensor

62 ADF registration sensor

21 Drum set signal 64 ADF original set sensor

22 Clamper open sensor 69 ADF open sensor

23 Clamper close sensor

24 Drum master sensor 70 Key counter signal

6
25 Master eject position SN 71 Key card signal (Japan only)

27 Drum size1 signal

28 Drum size2 signal

5. Output Mode

SP Table (SP 5-xxx)

No. Menu Items No. Menu Items

1 Exposure lamp (xenon lamp) 40 Registration motor - 30 rpm

2 Scanner motor - scan 41 Registration motor - 60 rpm

3 Scanner motor - return 42 Registration motor - 80 rpm

4 Scanner to HP 43 Registration motor - 100 rpm

8 Master feed motor – Forward 44 Registration motor - 130 rpm

9 Cutter motor – to HP

35
 6. Appendix: Service Program Mode Tables

No. Menu Items No. Menu Items

10 Cutter motor – reverse 46 Air knife fan motors

11 Cutter motor – forward 47 Vacuum fan motor

12 VHD signal 48 PSU fan motor

13 Master eject motor 49 Paper Delivery Motor

14 Pressure plate motor - limit 50 Paper counter

15 Pressure plate motor -to HP 51 Master counter

60 ADF motor

17 Main motor - 30 rpm 61 ADF feed clutch

18 Main motor - 60 rpm 62 ADF pick-up solenoid

19 Main motor - 80 rpm 63 Key counter signal

6 20 Main motor - 100 rpm 64 Not used

21 Main motor - 130 rpm 65 Key card (Japan only)

23 Clamper motor: to open 90 Main motor – to HP

24 Clamper motor: to close 91 Main motor – to Master clamp

25 Ink pump motor

26 Pressure release solenoids 100 All indicators on the panel

30 Table motor – down 111 Auto Off solenoid

31 Table motor – up

32 Paper feed clutch

36
 Service Program Mode

6. Adjustment

SP Table (SP 6-xxx)

No. Menu Items Default Settings

1 Main-scan position – platen 0 -5.0 to 5.0 mm

2 Main-scan position – ADF 0 -5.0 to 5.0 mm

3 Scan start position – platen 0 -2.0 to 5.0 mm

4 Scan start position - ADF 0 -5.0 to 5.0 mm

5 Scanning speed - platen 0 -5.0 to 5.0 %

6 Scanning speed - ADF mode 0 -5.0 to 5.0 %

10 Master writing speed 0 -5.0 to 5.0 % 6

11 Master writing length 0 -5.0 to 5.0 %

20 Registration buckle 0 0 to100 PLS

21 Paper regist position 0 -5.0 to 5.0 mm

26 Master making density - Pencil 1 0: Pale, 1: Normal, 2: Dark

27 Master making density - Tint 1 0: Pale, 1: Normal, 2: Dark

28 Master making density - Photo 1 0: Pale, 1: Normal, 2: Dark

29 Master making density - Letter/Photo 1 0: Pale, 1: Normal, 2: Dark

30 Master making density - Letter 1 0: Pale, 1: Normal, 2: Dark

32 MTF filter – Letter: Main 2 0 to 7

33 MTF filter – Letter: Sub 2 0 to 7

34 MTF filter – Letter/Photo: Main 2 0 to 7

35 MTF filter – Letter/Photo: Sub 2 0 to 7

36 MTF filter - Photo: Main 2 0 to 7

37
 6. Appendix: Service Program Mode Tables

No. Menu Items Default Settings

37 MTF filter – Photo: Sub 2 0 to 7

40 Ink detection adjustment –

50 Master end sensor voltage 2 0.5 to 3.5V

61 Master length – LG drum 4780 4200 to 6000 (0.1mm)

62 Master length – B4 drum 4780 4200 to 6000 (0.1mm)

63 Master length – A4 drum 4140 3000 to 6000 (0.1mm)

70 SBU VRT value –

71 SBU FBO value –

6 72 SBU FBE value –

100 Paper registration 30rpm 0 -40 to 40

101 Paper registration 60rpm 0 -40 to 40

102 Paper registration 80rpm 0 -40 to 40

103 Paper registration 100rpm 0 -40 to 40

104 Paper registration 130rpm 0 -40 to 40

108 Paper regist: skip: 30rpm 0 -40 to 40

109 Paper regist: skip: 60pm 0 -40 to 40

110 Paper Regist: skip: 80rpm 0 -40 to 40

111 Paper Regist: skip: 100rpm 0 -40 to 40

112 Paper Regist: skip: 130rpm 0 -40 to 40

116 Paper middle bulge 30rpm (Do not Adjust) 0 -100 to 100

117 Paper middle bulge 60rpm (Do not Adjust) 0 -100 to 100

118 Paper middle bulge 80rpm (Do not Adjust) 0 -100 to 100

38
 Service Program Mode

No. Menu Items Default Settings

119 Paper middle bulge 100rpm (Do not 0 -100 to 100

Adjust)

120 Paper middle bulge 130rpm (Do not 0 -100 to 100

Adjust)

124 Paper front bulge 30rpm (Do not Adjust) 0 -90 to 8

125 Paper front bulge 60rpm (Do not Adjust) 0 -90 to 8

126 Paper front bulge 80rpm (Do not Adjust) 0 -90 to 8

127 Paper front bulge 100rpm (Do not Adjust) 0 -90 to 8

128 Paper front bulge 130rpm (Do not Adjust) 0 -90 to 8

132 Paper Regist: A4 drum 30 rpm 0 -40 to 40

133 Paper Regist: A4 drum 60 rpm 0 -40 to 40

6
134 Paper Regist: A4 drum 80 rpm 0 -40 to 40

135 Paper Regist: A4 drum 100 rpm 0 -40 to 40

136 Paper Regist: A4 drum 130 rpm 0 -40 to 40

140 Paper Regist: skip: A4: 30 rpm 0 -40 to 40

141 Paper Regist: skip: A4: 60 rpm 0 -40 to 40

142 Paper Regist: skip: A4: 80 rpm 0 -40 to 40

143 Paper Regist: skip: A4: 100 rpm 0 -40 to 40

144 Paper Regist: skip: A4: 130 rpm 0 -40 to 40

148 Paper middle bulge A4 30rpm(Do not 0 -100 to 100

Adjust)

149 Paper middle bulge A4 60rpm(Do not 0 -100 to 100

Adjust)

150 Paper middle bulge A4 80rpm(Do not 0 -100 to 100

Adjust)

39
 6. Appendix: Service Program Mode Tables

No. Menu Items Default Settings

151 Paper middle bulge A4 100rpm(Do not 0 -100 to 100

Adjust)

152 Paper middle bulge A4 130rpm(Do not 0 -100 to 100

Adjust)

156 Paper front bulge A4 30rpm(Do not Adjust) 0 -90 to 8

157 Paper front bulge A4 60rpm(Do not Adjust) 0 -90 to 8

158 Paper front bulge A4 80rpm(Do not Adjust) 0 -90 to 8

159 Paper front bulge A4 100rpm(Do not 0 -90 to 8

Adjust)

160 Paper front bulge A4 130rpm(Do not 0 -90 to 8

Adjust)

6 SP6-10: Master Writing Speed

1. Input SP8-10 (Test patterns) and enter "6", then press the Start key.
2. Exit the SP mode, print 10 copies at 100 rpm (speed 2). Use the 10th print for the adjustment.
3. The length of the 6 squares in the feed direction should be 130 mm, as shown above.
4. If it is not, calculate the reproduction ratio using the following formula.
{(130 - Value) / 130} x 100 = ± X.X % (Round off to one decimal place)
Example: If the value is 133, {(130 - 133) / 130} x 100 = - 2.3 %
5. Access SP6-10, input the calculated ratio, and press the Enter key.
6. Repeat the procedure to make sure that the ratio is correct.

40
 Service Program Mode

SP6-21: Paper Regist Position

1. Input SP8-10 (Test patterns) and enter "6", then press the Start key.
2. Exit the SP mode, print 10 copies at 100 rpm (speed 2). Use the 10th print for the adjustment.
3. The space between the leading edge and the next line should be 8 mm, as shown above.
4. If it is not, access SP6-21, input the difference and press the Enter key.
5. Example: If the value is 7 mm, 7 - 8 = -1.0
6. Repeat the procedure to make sure that the gap is correct.
SP6-5: Scanning Speed – Platen and SP6-6: Scanning Speed – ADF mode
1. Make copies of the test pattern printed during the previous adjustments ( previous page), in platen
mode at speed 2. Use the 10th print for the adjustment.
2. The length of the 6 squares in the feed direction should be 130 mm.
3. If it is not, calculate the reproduction ratio using the following formula.
{(130 - Value) / 130} x 100 = ± X.X % (Round off to one decimal place)
Example: If the value is 133, {(130 - 133) / 130} x 100 = - 2.3 %
4. Access SP6-05, input the calculated ratio, and press the Enter key. 6
5. Check again to make sure that the ratio is correct.
6. Make copies of the test pattern in ADF mode and repeat the process using SP6-06.
SP6-3: Scanning Start Position – Platen and SP6-4: Scanning Start Position - ADF
1. Make copies of the test pattern printed during the previous adjustments ( previous page), in platen
mode at speed 2. Use the 10th print for the adjustment.
2. The space between the leading edge and the next line should be 8 mm.
3. If it is not, access SP6-03, input the gap value and press the Enter key.
Example: If the value is 7 mm, 7 - 8 = -1.0
4. Repeat the procedure to make sure that the gap is correct.
5. Make copies of the test pattern in ADF mode and repeat the process using SP6-04.
SP6-1: Main Scan Position – Platen and SP6-2: Main Scan Position - ADF
1. Make a copy in platen mode at speed 2.
2. Measure the difference between the center of the main-scan on the original and on the print.
3. Access SP6-01, input the gap value and press the Enter key. (If you input a positive value, the image
moves towards the operation side.)
4. Repeat the procedure to make sure that there is no difference.
5. Make a copy in ADF mode and repeat the process using SP6-02.
SP6-20: Registration Buckle
Adjusts the paper skew and the paper registration slippage.

41
 6. Appendix: Service Program Mode Tables

6 [A]: Increase the value

The occurrence of paper skew will be reduced, but the paper is more likely to slip and the registration
position may be incorrect.
[B]: Decrease the value
The paper registration position will be correct.
SP6-32 to 37: MTF filter
Sharpens the image, but moiré can become more apparent.
Refer to the following table for the relationship between this SP mode value and filter strength (the
relationship is not linear).

Value Strength of Filter

7 X4

6 X2

0 X1

5 X 1/2

4 X 1/4

3 X 1/8

2 X 1/16

42
 Service Program Mode

Value Strength of Filter

1 X 1/32

SP6-40: Ink detection adjustment

Ensures that the CPU detects a no ink condition.

• Before attempting this procedure, wipe off the ink around the ink roller. To do this, set SP2-10 (ink
detection) to OFF, and feed paper until ink ends. After finishing the procedure, do not forget to return
SP2-10 to the default (ink detection on).

Access SP6-40, and open the door cover. Then turn the VR1 [A] on the MPU board until the display
becomes "4.0 ± 0.2 " (4 s).

• When the drum has ink inside, the machine displays "----".
SP6-100 to 104: Paper registration - each speed
The following procedure allows the image position to be adjusted for each speed (30, 60, 80, 100 and
130 rpm)

• If you want to adjust the image position for all the speed at the same time, use SP6-21 (Paper
registration position).
1. Set SP8-10 (Test patterns) to a value of "6", then press the Start key.
2. Make 3 copies at speed 3 (finishing with 130 rpm). Perform the adjustment below for all 3 copies.
Trial print: 30 rpm

43
 6. Appendix: Service Program Mode Tables

1st print: 60 rpm

2nd print: 80 rpm
3rd print: 100 rpm
4th print: 130 rpm
3. The distance between the leading edge and first line should be 8mm, as shown below.

6
4. If this distance is not 8mm, access SP6-101 to 104 and then input a value to adjust the distance
(range: -40 to 40, step: 1) for each of 3 copies samples (i.e. 30, 60, 80, 100 and 130 rpm samples).
The higher the value, the narrower the distance between the leading edge and 1st line becomes (and
vice-versa). Also, each step corresponds to approximately 0.5mm. Input the value that will bring the
distance to 8mm.
5. Perform the adjustment again for any of the samples that are still outside the 8mm standard.

• Adjust SP6-108 to 112, 132 to 144 in the same way.

7. Memory Clear

SP Table (SP 7-xxx)

No. Menu Items

1 Factory settings clear

3 Total counter clear

4 Jam/Error data clear

44
 Service Program Mode

No. Menu Items

11 Protect Code clear

SP7-1: Factory settings clear

This resets all SP and User tool settings except for the following SP and User tool numbers.
• User tool 1: Counter Display (Masters and Prints)
• User tool 2-4: mm/inch
• User tool 2-5: Language on LCD
• User tool 2-6: Date/Time
• SP2-4: Destination code
• SP2-20: Destination setting
• SP2-80: Auto off at unusual voltage
• SP3-3: Input serial number
• SP6-All: Adjustments
SP7-3: Total counter clear
6
This resets the following SP numbers
• SP1-1 Total master counter
• SP1-20 Total print counter

• The counters for "User tool 1: Counter Display" are unresettable counters
SP7-11: Protect Code clear
This clears the settings of the "User Tools Protect (Administrator Setting)".
• User Tools Protect: Off
• User Tools Protect PW (Password): null

8. System Test

SP Table (SP 8-xxx)

No. Menu Items Default Settings

1 Download main firmware - Start with # key

2 Upload main firmware - Start with # key

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 6. Appendix: Service Program Mode Tables

No. Menu Items Default Settings

3 Data printout – Basic/SC/Jam -

4 Data printout – Adjustment -

5 Data printout – Input/Output -

9 Data printout – Power failure -

10 Test patterns 6 1 to 9 A4 start with #

19 Free run - ADF 100% 65%~155%

20 Free run - scanner 100% 65%~155%

21 Paper feed at 30rpm Off Off/On

22 Free run - Paper feed Off Off/On

6
30 All indicators on panel - Active when start press

31 LCD data download (Do not use) Off Off/On

100 Drum size/type check

SP8-1: Download Main Firmware

Updates the main firmware using a flash memory card [A].

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1. Before downloading new firmware, check the current version with SP1-70
2. Prepare a flash memory card with the latest firmware.
3. Turn off the main switch and disconnect the power cord.
4. Remove the rear card cover [B].
5. Plug the flash memory card into the connector on the MPU.
6. Connect the power cord, then turn on the main switch.
7. Access SP8-1 and press the OK key. Press the "Enter(#)" key.
8. Press the Enter key. (It takes about 2.0 minutes to complete.)
9. Check that the "Completed" is displayed.
10. Turn off the main switch, and remove the flash memory card.
SP8-2: Upload main firmware
Writes firmware to a flash memory card (P/N' #A2309352 or N8036701) from the machine.
1. Refer to steps 3 to 5 of section (download main firmware).
2. Connect the power cord, then turn on the main switch while holding the Clear Modes key.
3. Access SP8-2 and press the OK key. Press the "Enter(#)" key. 6
Refer to steps 8 and 10 in section (download main firmware).

SP8-9: Data printout – Power failure

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 6. Appendix: Service Program Mode Tables

[A]: Momentary Voltage Drop

[B]: Over voltage
[C]: Low voltage
[D]: High voltage
The machine collects information about unusual voltages from the power outlet and you can check this
data with SP 8-9 Data printout – Power failure
SP8-10: Test patterns

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Makes prints without using the scanner.

Access SP8-10 and select the number "6", then press the "Enter(#)" key.
Other numbers are as shown below
1: Grid, 2: Vertical, 3: Horizontal gray, 4: Vertical gray, 5: 16 grays,
6: Cross, 7: Diagonal grid, 8: 256 grays, 9: 64 grays
SP8-21: Paper feed test (30 rpm)
Feeds paper at the lowest speed (30 rpm), and applies printing pressure.
1. Set a stack of paper on the paper feed table.
2. Access SP8-21 and press the OK key.
3. Exit the SP mode and enter the number of sheets that you want to feed.
4. Press the Print key.
5. To exit this mode, turn off the main switch.
SP8-22: Free run paper feed (30 rpm)
Drives the paper feed mechanism at the lowest speed (30 rpm) without paper.
1. Access SP8-22 and press the OK key. 6
2. Exit the SP mode and enter the number of times that you want to repeat the paper feed cycle.
3. Press the Print key.
4. To exit this mode, turn off the main switch.

9. Print Controller

These SPs are displayed after installing C654 (Printer Unit Type 4545A).

SP Table (SP 9-xxx)

No. Menu Items Default Settings

0:Normal, 1:Hex dump,

9-1 Output Data Print 0
2:SD Card

9-2 Service Summary Print - -

9-3 NIB Summary Print - -

9-4 Firmware Part Number - -

9-5 Firmware Version - -

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 6. Appendix: Service Program Mode Tables

No. Menu Items Default Settings

9-30 Clear Printer Setting - -

9-31 Clear NIB NVRAM – System - -

Load Program - System -

9-40

SP9-1: Output Data Print

In normal operation, an image that is sent from the computer is printed out. But with this SP mode, the image
is changed to hex data and then output on paper or to an SD card.
There are three settings:
0: Normal (Default setting)
6 1: Hex Dump
2: SD card
Hex Dump:
The image is changed to hex data, and the hex data is printed out on paper.

• This mode continues until main power is shut off.

• In some cases, there will be a large quantity of data, and many masters will be consumed to print out
the hex dump. Be careful when you use this mode.

SD Card:
The image is changed to hex data, and the hex data is transferred to an SD card.
Procedure:
1. Turn off the main switch.
2. Put the SD card in the SD card slot.
3. Turn on the main switch.
4. Set SP 9-1 to "1: SD card" and get out from the SP mode.
5. Send the data from the computer
6. The "data in" LED on the machine blinks during the data transfer, and the LED turns off when the data
transfer is finished (the transfer takes a few seconds).
7. Set SP 9-1 to "0: Normal".

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8. Turn off the main switch.

9. Remove the SD card from the machine.

• Do not take out the SD card before you turn off the main switch and set the SP Mode to "Normal".

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 6. Appendix: Service Program Mode Tables

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