Ricoh Aficio Color 6010 User manual

Aficio Color 6010/6110
(Cattleya, A257/A269)
Service Manual
Issued March 30, 1999, Ricoh CO., LTD.

øIMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the copier power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that some components of the copier and the paper tray unit are
supplied with electrical voltage even if the main power switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers off
or open while the main switch is turned on, keep hands away from electrified
or mechanically driven components.
5. If the Start key is pressed before the copier completes the warm-up period
(the Start key starts blinking red and green alternatively), keep hands away
from the mechanical and the electrical components as the copier starts
making copies as soon as the warm-up period is completed.
6. The inside and the metal parts of the fusing unit become extremely hot while
the copier is operating. Be careful to avoid touching those components with
your bare hands.
HEALTH SAFETY CONDITIONS
1. Never operate the copier without the ozone filters installed.
2. Always replace the ozone filters with the specified ones at the specified
intervals.
3. Toner and developer are non-toxic, but if you get either of them in your eyes
by accident, it may cause temporary eye discomfort. Try to remove with eye
drops or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on
those models.
2. The NVRAM on the system control board has a lithium battery which can
explode if replaced incorrectly. Replace the NVRAM only with an identical
one. The manufacturer recommends replacing the entire NVRAM. Do not
recharge or burn this battery. Used NVRAM must be handled in accordance
with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly
when exposed to an open flame.
2. Dispose of used toner, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, do not
put more than 100 batteries per sealed box. Storing larger numbers or not
sealing them apart may lead to chemical reactions and heat build-up.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of
laser-based optical units in the field. The optical housing unit can only be repaired
in a factory or at a location with the requisite equipment. The laser subsystem is
replaceable in the field by a qualified Customer Engineer. The laser chassis is not
repairable in the field. Customer engineers are therefore directed to return all
chassis and laser subsystems to the factory or service depot when replacement of
the optical subsystem is required.
øWARNING
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
øWARNING
Turn off the main switch before attempting any of the procedures in the
Laser Unit section. Laser beams can seriously damage your eyes.
CAUTION MARKING:

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TABLE OF CONTENTS
1. OVERALL MACHINE INFORMATION........................................1-1
1.1 SPECIFICATIONS.................................................................................... 1-1
1.1.1 MAJOR UNITS................................................................................. 1-1
1.1.2 BASIC SPECIFICATIONS ............................................................... 1-2
1.1.3 PLATEN/ARDF ORIGINAL SIZE DETECTION................................ 1-6
1.1.4 COPY PAPER SIZES...................................................................... 1-7
1.1.5 NOISE EMISSION........................................................................... 1-8
1.1.6 POWER CONSUMPTION................................................................ 1-8
1.2 MECHANISM OVERVIEW ....................................................................... 1-9
1.2.1 IMAGE GENERATION PROCESS.................................................. 1-9
1.2.2 MAJOR UNITS AND PAPER PATH .............................................. 1-11
1.3 PARTS LAYOUT .................................................................................... 1-13
1.3.1 MAJOR UNIT LAYOUT DIAGRAM................................................ 1-13
1.4 DRIVE LAYOUT ..................................................................................... 1-14
1.5 AIR FLOW .............................................................................................. 1-15
1.5.1 AIR FLOW SYSTEM 1................................................................... 1-15
1.5.2 AIR FLOW SYSTEM 2................................................................... 1-16
1.6 ELECTRICAL PARTS LAYOUT ............................................................. 1-17
1.6.1 ELECTRICAL PARTS LAYOUT 1.................................................. 1-17
1.6.2 ELECTRICAL PARTS LAYOUT 2.................................................. 1-18
1.6.3 ELECTRICAL PARTS LAYOUT 3.................................................. 1-19
1.6.4 ELECTRICAL PARTS LAYOUT 4.................................................. 1-20
1.6.5 ELECTRICAL PARTS LAYOUT 5.................................................. 1-21
1.6.6 ELECTRICAL PARTS LAYOUT 6.................................................. 1-22
1.6.7 ELECTRICAL PARTS LAYOUT 7.................................................. 1-23
1.7 ELECTRICAL PARTS DESCRIPTIONS................................................. 1-24
2. DETAILED SECTION DESCRIPTIONS.......................................2-1
2.1 PROCESS CONTROL.............................................................................. 2-1
2.1.1 OVERVIEW ..................................................................................... 2-1
2.1.2 POTENTIAL CONTROL .................................................................. 2-2
Overview.............................................................................................. 2-2
Potential Control Timing....................................................................... 2-2
2.1.3 PROCESS CONTROL γCORRECTION ......................................... 2-4
What is process control γ? ................................................................... 2-4
How is it done?..................................................................................... 2-4
Process Control γCorrection Timing.................................................... 2-5
Relationship Between Process Control γCorrection, ACC,
and Other γCorrections.................................................................... 2-5
2.1.4 PROCESS CONTROL SELF CHECK OPERATION FLOW............ 2-6
Step 1: VSG Adjustment...................................................................... 2-7
Step 2: Generating ID Sensor Patch Patterns...................................... 2-7

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Step 3: Sensor Pattern Potential Detection.......................................... 2-8
Step 4: Sensor Pattern Density Detection............................................ 2-9
Process................................................................................................ 2-9
Step 5: Toner Amount Calculation ..................................................... 2-11
Step 6: Development Potential Calculation........................................ 2-11
Step 7: Selecting the Optimum VD, VB, VL ....................................... 2-12
2.1.5 TONER SUPPLY CONTROL......................................................... 2-13
Toner Supply Control Modes ............................................................. 2-13
TD Sensor Output.............................................................................. 2-14
Toner Supply Calculation................................................................... 2-14
Detecting VSP for Toner Supply Control............................................ 2-14
Calculating the Amount of Toner on the Drum................................... 2-15
Toner Near End/Toner End Detection................................................ 2-15
2.2 DRUM UNIT............................................................................................ 2-17
2.2.1 MAJOR COMPONENTS................................................................ 2-17
2.2.2 DRUM UNIT DRIVE....................................................................... 2-18
Drum Drive......................................................................................... 2-18
Cleaning Drive.................................................................................... 2-18
2.2.3 CHARGE CORONA UNIT ............................................................. 2-19
2.2.4 CHARGE CORONA UNIT CLEANER............................................ 2-20
2.2.5 CLEANING MECHANISM.............................................................. 2-21
Cleaning............................................................................................. 2-21
Lubricant Application.......................................................................... 2-21
2.2.6 PRE-CLEANING CORONA (PCC) ................................................ 2-21
2.2.7 QUENCHING................................................................................. 2-22
2.2.8 CARRIER CATCHER .................................................................... 2-22
2.3 SCANNER UNIT..................................................................................... 2-23
2.3.1 OVERVIEW ................................................................................... 2-23
2.3.2 SCANNER ..................................................................................... 2-24
2.3.3 SCANNER DRIVE ......................................................................... 2-25
2.3.4 COLOR CCD ................................................................................. 2-26
2.3.5 WHITE PLATE SCANNING........................................................... 2-27
2.3.6 SCANNER IPU .............................................................................. 2-27
2.3.7 ORIGINAL SIZE DETECTION....................................................... 2-28
2.3.8 OTHERS........................................................................................ 2-30
Anti-condensation Heater................................................................... 2-30
Fans................................................................................................... 2-30
2.4 IMAGE PROCESSING ........................................................................... 2-31
2.4.1 OVERVIEW ................................................................................... 2-31
2.4.2 SCANNER SECTION BLOCK DIAGRAM...................................... 2-32
2.4.3 SCANNER FUNCTIONS ............................................................... 2-33
Photoelectric Conversion ................................................................... 2-33
Signal Processing (Analog ASIC)....................................................... 2-33
A/D Conversion.................................................................................. 2-33
Shading Compensation Circuit........................................................... 2-34
D/A Conversion.................................................................................. 2-35
Scan Line Correction Circuit .............................................................. 2-35
2.4.4 IPU SECTION BLOCK DIAGRAM................................................. 2-36
2.4.5 IPU FUNCTIONS........................................................................... 2-37

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Scanner γConversion and Picture Element Correction...................... 2-37
ACS (Auto Color Selection)................................................................ 2-39
Automatic Original Type Selection..................................................... 2-40
Image Separation............................................................................... 2-41
Filtering and Color Conversion........................................................... 2-42
Magnification Processing................................................................... 2-46
Image Creation................................................................................... 2-47
Gradation Processing......................................................................... 2-49
Area Manipulation Functions.............................................................. 2-52
CPU ................................................................................................... 2-52
IPU Board Test................................................................................... 2-52
2.5 LASER EXPOSURE............................................................................... 2-53
2.5.1 OVERVIEW ................................................................................... 2-53
2.5.2 LD UNIT......................................................................................... 2-54
LD Safety Switch................................................................................ 2-54
LD Unit Configuration......................................................................... 2-55
Auto Power Control (APC)................................................................. 2-56
2.5.3 LASER OPTICS SYSTEM............................................................. 2-57
Cylindrical Lens.................................................................................. 2-57
Polygon Mirror.................................................................................... 2-57
f θLenses and the BTL...................................................................... 2-58
Laser Synchronization Mechanism .................................................... 2-58
Laser Exposure Control ..................................................................... 2-59
Multibeam Laser Exposure ................................................................ 2-60
Laser Diode Control Board Functions................................................ 2-60
2.6 DEVELOPMENT UNIT ........................................................................... 2-61
2.6.1 OVERVIEW ................................................................................... 2-61
2.6.2 REVOLVER MECHANISM............................................................. 2-62
Revolver Drive.................................................................................... 2-63
Revolver Home Position Detection..................................................... 2-64
2.6.3 DEVELOPMENT MECHANISM..................................................... 2-65
2.6.4 DEVELOPMENT DRIVE................................................................ 2-66
2.6.5 DEVELOPER AGITATION............................................................. 2-66
2.6.6 TONER AGITATION...................................................................... 2-67
2.6.7 DEVELOPMENT BIAS................................................................... 2-67
2.6.8 TD SENSOR NONCONTACT COUPLER ..................................... 2-68
2.6.9 TONER SUPPLY MECHANISM .................................................... 2-69
2.6.10 TONER CARTRIDGE DETECTION............................................. 2-70
2.6.11 TONER CARTRIDGE SHUTTER LOCK PIN............................... 2-70
2.6.12 INCORRECT TONER INSTALLATION PREVENTION ............... 2-70
2.6.13 TONER END SENSOR................................................................ 2-71
2.6.14 TONER END RECOVERY........................................................... 2-72
2.6.15 TONER LOOSENING.................................................................. 2-73
2.6.16 REVOLVER LOCK MECHANISM................................................ 2-74
2.7 TRANSFER BELT UNITS....................................................................... 2-75
2.7.1 OVERVIEW ................................................................................... 2-75
2.7.2 IMAGE TRANSFER BELT SECTION............................................ 2-76
Image Transfer Belt Drive Mechanism............................................... 2-76
Belt Tension Release Mechanism...................................................... 2-77

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Image Transfer Belt Bias.................................................................... 2-78
Belt Mark Sensor Mechanism ............................................................ 2-78
Belt Cleaning Mechanism .................................................................. 2-79
Cleaning Vacuum............................................................................... 2-81
Toner Collection Mechanism.............................................................. 2-81
2.7.3 PAPER TRANSFER BELT SECTION............................................ 2-82
Paper Transfer Unit Contact/Release Mechanism............................. 2-82
Paper Transfer Belt Drive................................................................... 2-82
Paper Transfer Belt Cleaning............................................................. 2-83
Paper Transfer Bias........................................................................... 2-84
Paper Transfer Belt Discharge........................................................... 2-85
Paper Separation Mechanism............................................................ 2-85
2.8 PAPER FEED AND REGISTRATION SECTION.................................... 2-86
2.8.1 MAJOR COMPONENTS................................................................ 2-86
Diagram ............................................................................................. 2-86
2.8.2 PAPER TRAY SECTION ............................................................... 2-87
Paper Feed/Separation Mechanism................................................... 2-87
Reverse Roller Release Mechanism.................................................. 2-87
Paper Feed Operation........................................................................ 2-87
Paper Lift Mechanism ........................................................................ 2-88
Paper End Detection.......................................................................... 2-89
Paper Near End Detection................................................................. 2-89
2.8.3 BY-PASS PAPER FEED SECTION............................................... 2-90
By-pass Feed Table........................................................................... 2-90
By-pass Feed Unit.............................................................................. 2-90
By-pass Paper End Sensor................................................................ 2-90
By-pass Pick-up Roller Pressure........................................................ 2-91
By-pass Pick-up/Reverse Solenoid Timing Chart............................... 2-92
2.8.4 PAPER FEED DRIVE.................................................................... 2-93
Tray Feed Unit Drive.......................................................................... 2-93
Registration Roller Drive .................................................................... 2-93
By-pass Feed Unit Drive.................................................................... 2-93
2.9 TRANSPORT, FUSING, AND EXIT........................................................ 2-94
2.9.1 MAJOR COMPONENTS................................................................ 2-94
2.9.2 DRIVE MECHANISM..................................................................... 2-95
2.9.3 FUSING OVERVIEW..................................................................... 2-96
2.9.4 FUSING TEMPERATURE CONTROL........................................... 2-97
2.9.5 FUSING PRESSURE..................................................................... 2-97
2.9.6 OIL SUPPLY.................................................................................. 2-98
2.9.7 CLEANING MECHANISM.............................................................. 2-98
2.9.8 PAPER EXIT AND PAPER INVERSION ....................................... 2-99
Paper Exit Mechanism....................................................................... 2-99
Junction Gate Mechanism.................................................................. 2-99
Paper Exit Cover................................................................................ 2-99
2.10 DUPLEX TRAY................................................................................... 2-100
2.10.1 OVERVIEW ............................................................................... 2-100
2.10.2 DRIVE MECHANISM................................................................. 2-101
2.10.3 PAPER FEED INTO THE DUPLEX TRAY................................. 2-102
Duplex Stacking............................................................................... 2-102

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Paper Feed from the Duplex Tray.................................................... 2-102
Duplex Entrance to Duplex Tray ...................................................... 2-103
2.10.4 JOGGER MECHANISM............................................................. 2-104
2.10.5 PAPER FEED FROM THE DUPLEX TRAY............................... 2-105
Bottom Plate Lift Mechanism ........................................................... 2-105
2.10.6 PAPER FEED-OUT MECHANISM............................................. 2-106
2.11 SYSTEM CONFIGURATION.............................................................. 2-107
2.11.1 CONFIGURATION..................................................................... 2-107
2.11.2 NORMAL COPY MODE............................................................. 2-108
Main Power Switch Off State ........................................................... 2-108
Power-off (Sleep) State.................................................................... 2-108
Copier Modes................................................................................... 2-109
2.11.3 OPERATION PANEL................................................................. 2-110
2.11.4 PRINTER CONTROLLER INTERFACE .................................... 2-111
3. INSTALLATION PROCEDURES................................................. 3-1
3.1 INSTALLATION REQUIREMENTS .......................................................... 3-1
3.1.1 DIMENSIONS.................................................................................. 3-1
3.1.2 ENVIRONMENT .............................................................................. 3-2
Environmental Requirements............................................................... 3-2
Minimum Space Requirements............................................................ 3-3
Power Requirements............................................................................ 3-4
3.2 COPIER.................................................................................................... 3-5
3.2.1 ACCESSORY CHECK..................................................................... 3-5
3.2.2 PREPERATION............................................................................... 3-6
3.2.3 DEVELOPER INSTALLATION....................................................... 3-10
3.2.4 LOADING TONER CARTRIDGES................................................. 3-14
3.2.5 FUSING UNIT................................................................................ 3-16
3.2.6 DEFAULT SETTINGS AND OPERATION CHECKS..................... 3-17
3.2.7 HEIGHT ADJUSTMENT ................................................................ 3-19
3.2.8 COUNTER DISPLAY SETTING...................................................... 3-19
3.2.9 RESETTING THE ELECTRONIC TOTAL COUNTER................... 3-19
3.2.10 PREPARATION FOR TRANSPORT............................................ 3-20
3.3 PLATEN COVER (A749-01)................................................................... 3-21
3.3.1 INSTALLATION ............................................................................. 3-21
3.4 ARDF (A663).......................................................................................... 3-22
3.4.1 ACCESSORY CHECK................................................................... 3-22
3.4.2 INSTALLATION ............................................................................. 3-23
3.5 SORTER STAPLER (A831).................................................................... 3-24
3.5.1 INSTALLATION ............................................................................. 3-24
3.6 LCT (A683)............................................................................................. 3-29
3.6.1 INSTALLATION ............................................................................. 3-29
3.7 LCT ADAPTER (A840)........................................................................... 3-30
3.7.1 INSTALLATION ............................................................................. 3-30
3.8 FILM PROJECTOR TABLE (A702-19) ................................................... 3-36
3.8.1 INSTALLATION ............................................................................. 3-36

vi
3.9 FILM PROJECTOR UNIT(A846) ............................................................ 3-38
3.9.1 ACCESSORY CHECK................................................................... 3-38
3.9.2 INSTALLATION ............................................................................. 3-39
3.10 KEY COUNTER HOLDER.................................................................... 3-46
3.11 USER CODE SETTING........................................................................ 3-47
4. SERVICE TABLES......................................................................4-1
4.1 SERVICE PROGRAM (SP) MODES........................................................ 4-1
4.1.1 HOW TO ENTER AN SP MODE...................................................... 4-1
4.1.2 SP MODE TYPES............................................................................ 4-3
4.1.3 SP MODE CHART........................................................................... 4-3
4.1.4 SP4-301 APS OPERATION CHECK DETAILS ............................... 4-3
4.1.5 TEST PATTERN.............................................................................. 4-5
4.1.6 SP5-803 INPUT CHECK.................................................................. 4-6
4.1.7 SP5-804 OUTPUT CHECK.............................................................. 4-9
4.1.8 SP5-955 PRINTER INTERNAL PATTERN.................................... 4-11
5-955-018: Internal Pattern Types...................................................... 4-11
4.2 USER TOOLS......................................................................................... 4-11
4.2.1 HOW TO ENTER USER TOOLS................................................... 4-11
4.2.2 DETAILED DESCRIPTION OF USER TOOLS.............................. 4-12
4.3 TP/SW/LED/FUSE.................................................................................. 4-12
4.3.1 MAIN CONTROL BOARD TEST PINS.......................................... 4-12
4.3.2 LD MAIN CONTROL BOARD TEST PINS..................................... 4-13
4.3.3 I/O CONTROL BOARD TEST PINS .............................................. 4-13
4.3.4 FUSE SPECIFICATIONS .............................................................. 4-19
4.3.5 LED/SW SPECIFICATIONS OF SCANNER IPU BOARD............. 4-20
LED Specifications............................................................................. 4-20
SW Specifications.............................................................................. 4-20
5. PREVENTIVE MAINTENANCE...................................................5-1
5.1 PM PROCEDURES.................................................................................. 5-1
5.1.1 PM-RELATED COUNTERS............................................................. 5-1
SP7-803 (PM Counter Display)............................................................ 5-1
5.1.2 REGULAR PREVENTIVE MAINTENANCE FLOW DIAGRAM........ 5-4
5.2 REGULAR PM ITEMS.............................................................................. 5-7
5.2.1 REGULAR PM TABLE..................................................................... 5-7
Peripherals......................................................................................... 5-11

vii
6. REPLACEMENT AND ADJUSTMENT........................................6-1
6.1 PM-RELATED COUNTERS...................................................................... 6-1
6.2 SERVICE REMARKS ............................................................................... 6-1
6.3 COVERS AND FILTERS .......................................................................... 6-2
6.3.1 UPPER AND LOWER FRONT COVER........................................... 6-2
6.3.2 RIGHT-SIDE FRONT COVER AND RIGHT EDGE COVER............ 6-2
6.3.3 INNER COVERS.............................................................................. 6-3
6.3.4 REAR COVERS............................................................................... 6-3
6.3.5 LEFT COVERS................................................................................ 6-4
6.3.6 EXPOSURE GLASS........................................................................ 6-4
6.3.7 OPERATION PANEL....................................................................... 6-5
6.3.8 USED TONER TANK....................................................................... 6-5
6.3.9 CHARGE CORONA FILTER............................................................ 6-6
6.3.10 DUST AND OZONE FILTERS....................................................... 6-6
6.3.11 SCANNER FILTER........................................................................ 6-7
6.3.12 REVOLVER FILTER...................................................................... 6-7
6.3.13 INNER COVER FILTER................................................................. 6-8
6.3.14 FUSING UNIT FILTER................................................................... 6-8
6.4 UNIT REMOVAL....................................................................................... 6-9
6.4.1 REVOLVER/DRUM DRAWER......................................................... 6-9
6.4.2 DRUM UNIT REMOVAL ................................................................ 6-10
6.4.3 REINSTALLING THE REVOLVER/DRUM DRAWER.................... 6-11
6.4.4 IMAGE TRANSFER BELT UNIT REMOVAL ................................. 6-12
Reinstalling the Image Transfer Belt Unit........................................... 6-13
6.4.5 PAPER TRANSFER UNIT REMOVAL........................................... 6-14
6.4.6 REMOVING THE FUSING UNIT ................................................... 6-15
6.5 DRUM UNIT............................................................................................ 6-16
6.5.1 DRUM REPLACEMENT ................................................................ 6-16
Post-replacement Procedure ............................................................. 6-17
6.5.2 CLEANING BLADE REPLACEMENT............................................ 6-18
6.5.3 CLEANING BRUSH REPLACEMENT ........................................... 6-19
6.5.4 LUBRICANT BAR REPLACEMENT .............................................. 6-19
6.5.5 BIAS ROLLER BLADE REPLACEMENT....................................... 6-20
6.5.6 CHARGE GRID AND CORONA WIRE REPLACEMENT.............. 6-20
6.5.7 PCC REPLACEMENT ................................................................... 6-21
6.5.8 DRUM POTENTIAL SENSOR REPLACEMENT ........................... 6-22
6.5.9 ID SENSOR REPLACEMENT ....................................................... 6-23
6.6 SCANNER UNIT..................................................................................... 6-24
6.6.1 EXPOSURE LAMP REPLACEMENT ............................................ 6-24
6.6.2 SBU REPLACEMENT.................................................................... 6-25
6.6.3 OPENING THE SCANNER UNIT .................................................. 6-26
6.6.4 SCANNER IPU MAIN/SUB BOARD REPLACEMENT................... 6-28
6.6.5 SCANNER WIRE REPLACEMENT............................................... 6-29
6.6.6 APS AND H.P. SENSOR REPLACEMENT ................................... 6-32
6.7 COPY IMAGE ADJUSTMENT................................................................ 6-33
6.7.1 PRINTER γADJUSTMENT............................................................ 6-33
Auto Color Calibration (ACC)............................................................. 6-33
KCMY Color Balance Adjustment ...................................................... 6-33

viii
ACC Target Modification.................................................................... 6-36
6.7.2 MAIN SCAN POSITION DOT CORRECTION ............................... 6-37
6.8 LASER OPTICS SECTION..................................................................... 6-40
6.8.1 POLYGON MIRROR MOTOR REPLACEMENT............................ 6-40
6.8.2 LASER SYNCHRONIZING DETECTOR REPLACEMENT............ 6-42
6.8.3 LD UNIT REPLACEMENT............................................................. 6-42
LD Pitch Check and Adjustment]........................................................ 6-43
6.8.4 SQUARENESS ADJUSTMENT..................................................... 6-47
6.8.5 LD CONTROL BOARD REPLACEMENT...................................... 6-49
6.9 DEVELOPMENT UNIT ........................................................................... 6-50
6.9.1 DEVELOPER REPLACEMENT..................................................... 6-50
Developer Collection.......................................................................... 6-50
6.9.2 DEVELOPER INSTALLATION....................................................... 6-53
6.9.3 DEVELOPMENT UNIT REPLACEMENT....................................... 6-58
6.9.4 TONER CATCH COVER CLEANING............................................ 6-59
6.9.5 REVOLVER MOTOR REPLACEMENT ......................................... 6-60
6.9.6 TONER DENSITY SENSOR REPLACEMENT.............................. 6-61
6.9.7 TD SENSOR NONCONTACT COUPLER REPLACEMENT.......... 6-62
Main Unit Element.............................................................................. 6-62
TD Sensor Interface (I/F) Board......................................................... 6-63
6.8 IMAGE TRANSFER SECTION............................................................... 6-65
6.8.1 IMAGE TRANSFER BELT REPLACEMENT ................................. 6-65
6.8.2 IMAGE TRANSFER BELT BLADE REPLACEMENT..................... 6-67
6.8.3 TRANSFER BELT LUBRICANT BAR AND LUBRICANT
BRUSH REPLACEMENT .............................................................. 6-68
6.8.4 PAPER TRANSFER BELT REPLACEMENT................................. 6-69
6.8.5 PAPER TRANSFER BELT BLADE/CLEANING BRUSH
REPLACEMENT............................................................................ 6-69
6.8.6 BACK BRUSH REPLACEMENT.................................................... 6-70
6.8.7 PAPER TRANSFER BELT DISCHARGE CORONA WIRE
REPLACEMENT............................................................................ 6-70
6.8.8 PAPER DISCHARGE CORONA WIRE REPLACEMENT.............. 6-71
6.9 PAPER FEED AND REGISTRATION SECTION.................................... 6-72
6.9.1 BY-PASS FEED TABLE REMOVAL.............................................. 6-72
6.9.2 BY-PASS FEED PAPER WIDTH SENSOR REPLACEMENT....... 6-73
6.9.3 BY-PASS PICK-UP ROLLER REPLACEMENT............................. 6-74
6.9.4 BY-PASS FEED ROLLER REPLACEMENT.................................. 6-74
6.9.5 BY-PASS SEPARATION ROLLER REPLACEMENT.................... 6-75
6.9.6 BY-PASS PAPER FEED UNIT REMOVAL.................................... 6-75
6.9.7 BY-PASS PAPER FEED UNIT INSTALLATION............................ 6-76
6.9.8 REGISTRATION SENSOR REPLACEMENT................................ 6-78
6.9.9 PAPER TRAY ROLLER REPLACEMENT..................................... 6-78
6.9.10 PAPER FEED UNIT AND PAPER FEED CLUTCH
REPLACEMENT.......................................................................... 6-79
6.9.11 COPY IMAGE AREA ADJUSTMENT .......................................... 6-80
PAPER TRANSPORT, FUSING, AND PAPER EXIT......................... 6-83
6.10.1 TRANSPORT UNIT REMOVAL................................................... 6-83
6.10.2 FUSING UNIT TOP COVER REMOVAL ..................................... 6-83
6.10.3 OIL SUPPLY UNIT REPLACEMENT AND CLEANING............... 6-84

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6.10.4 HOT ROLLER BLADE REPLACEMENT ..................................... 6-85
6.10.5 CLEANING THE CLEANING ROLLER SCRAPER...................... 6-86
6.10.6 FUSING THERMOFUSE AND THERMISTOR REPLACEMENT 6-86
6.10.7 FUSING UNIT DISASSEMBLY.................................................... 6-87
6.10.8 FUSING LAMP REPLACEMENT................................................. 6-88
6.10.9 HOT ROLLER REPLACEMENT.................................................. 6-88
6.10.10 HOT ROLLER CLEANING ROLLER CLEANING...................... 6-89
6.10.11 PRESSURE ROLLER LAMP/ROLLER REPLACEMENT.......... 6-89
6.10.12 PRESSURE THERMOFUSE AND THERMISTOR
REPLACEMENT........................................................................ 6-90
6.10.13 PRESSURE CLEANING ROLLER CLEANING ......................... 6-90
6.10.14 NIP BAND WIDTH ADJUSTMENT............................................ 6-91
6.10.15 CAUTIONS TO BE TAKEN WHEN USING A FUSING UNIT
THAT HAS BEEN IN STOCK FOR A LONG PERIOD .............. 6-92
6.11 DUPLEX UNIT...................................................................................... 6-93
6.11.1 DUPLEX UNIT REMOVAL........................................................... 6-93
6.11.2 SEPARATION ROLLER REPLACEMENT................................... 6-93
6.11.3 FEED ROLLER REPLACEMENT................................................ 6-94
6.11.4 DUPLEX FEED MOTOR REPLACEMENT.................................. 6-95
6.12 SYSTEM AND ELECTRONICS............................................................ 6-97
6.12.1 SOFTWARE UPDATE USING AN IC CARD............................... 6-97
Care of the IC Card............................................................................ 6-97
Upgrading the Main Control Board Software...................................... 6-97
Upgrading the Scanner IPU Software................................................ 6-98
NV-RAM Uploading and Downloading............................................. 6-101
Upload/download procedure ............................................................ 6-101
6.12.2 RAM CLEAR.............................................................................. 6-102
RAM Clear Procedure...................................................................... 6-102
6.12.3 MAIN CONTROL BOARD.......................................................... 6-103
Main Control Board Replacement Procedure................................... 6-103
6.12.4 COUNTERS............................................................................... 6-104
About the Total Counter................................................................... 6-104
Mechanical Counter......................................................................... 6-104
NV-RAM Replacement Procedure ................................................... 6-105
6.12.5 TOUCH PANEL CALIBRATION................................................. 6-106
7. TROUBLESHOOTING.................................................................7-1
7.1 PROCESS CONTROL ERROR CONDITIONS ........................................ 7-1
7.1.1 PROCESS CONTROL SELF CHECK RESULTS (SP3-975-00)...... 7-1
7.1.2 DEVELOPER SETUP RESULTS (SP3-964-00).............................. 7-2
“Developer Agitation (SP2-225)”OPERATION FLOW........................ 7-3
7.1.3 TD SENSOR INITIALIZATION RESULTS (SP3-005-006)............... 7-3
7.1.4 SELF-CHECK PROCESS CONTROL RELATED SCS ................... 7-4
SC385: Vsg Adjustment Error.............................................................. 7-4
7.2 SC CODE TABLE..................................................................................... 7-4
7.3 DRUM LIGHT FATIGUE............................................................................ 7-5

x
OPTIONS
ARDF (A663)
1. SPECIFICATIONS.................................................................A663-1
2. COMPONENT LAYOUT........................................................A663-2
2.1 MECHANICAL COMPONENTS..........................................................A663-2
2.2 ELECTRICAL COMPONENTS...........................................................A663-3
3. ELECTRICAL COMPONENT DESCRIPTION.......................A663-4
4. DETAILED DESCRIPTIONS .................................................A663-5
4.1 ORIGINAL PICK-UP MECHANISM....................................................A663-5
4.2 SEPARATION AND PAPER FEED MECHANISM..............................A663-6
4.3 FRICTION BELT DRIVE MECHANISM..............................................A663-7
4.4 ORIGINAL SIZE DETECTION............................................................A663-8
4.5 PAPER TRANSPORT MECHANISM..................................................A663-9
4.6 THICK/THIN ORIGINAL MODES .....................................................A663-10
4.7 ORIGINAL FEED-OUT MECHANISM...............................................A663-11
4.8 TWO-SIDED ORIGINAL FEED MECHANISM..................................A663-12
5. TIMING CHARTS ................................................................A663-13
5.1 A4 SIDEWAYS: 1 SIDED ORIGINAL ...............................................A663-13
5.2 COMBINE 2 ORIGINAL MODE........................................................A663-14
5.3 A4 SIDEWAYS: DUPLEX.................................................................A663-15
6. SERVICE TABLES..............................................................A663-16
6.1 DIP SWITCHES................................................................................A663-16
6.2 VARIABLE RESISTORS...................................................................A663-17
6.3 LED...................................................................................................A663-17
6.4 FUSE................................................................................................A663-17
7. REPLACEMENT AND ADJUSTMENT................................A663-18
7.1 TRANSPORT BELT REPLACEMENT..............................................A663-18
7.2 FEED ROLLER REPLACEMENT.....................................................A663-19
7.3 FRICTION BELT REPLACEMENT...................................................A663-20
7.4 ORIGINAL SET AND WIDTH SENSOR REPLACEMENT................A663-21
7.5 VERTICAL REGISTRATION ADJUSTMENT ...................................A663-22
7.5.1 ONE SIDED THIN ORIGINAL MODE......................................A663-22
7.5.2 TWO SIDED ORIGINAL MODE...............................................A663-23
7.6 SIDE-TO-SIDE REGISTRATION (DF POSITIONING)
ADJUSTMENT..................................................................................A663-24

xi
LCT (A683)
1. OVERALL MACHINE INFORMATION..................................A683-1
1.1 SPECIFICATIONS..............................................................................A683-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A683-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A683-3
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A683-4
1.5 DRIVE LAYOUT .................................................................................A683-5
2. DETAILED DESCRIPTIONS .................................................A683-6
2.1 PAPER FEED MECHANISM..............................................................A683-6
2.2 TRAY LIFT AND PAPER HEIGHT DETECTION MECHANISM.........A683-7
Tray lifting conditions .....................................................................A683-7
Tray lowering conditions ................................................................A683-7
2.3 TRAY UNIT SLIDE MECHANISM.......................................................A683-8
3. SERVICE TABLES................................................................A683-9
3.1 DIP SWITCHES..................................................................................A683-9
3.2 TEST POINTS....................................................................................A683-9
3.3 SWITCHES.........................................................................................A683-9
3.4 FUSES................................................................................................A683-9
4. REPLACEMENT AND ADJUSTMENT................................A683-10
4.1 COVER REPLACEMENT.................................................................A683-10
Tray Cover ...................................................................................A683-10
Front Cover..................................................................................A683-10
Rear Cover...................................................................................A683-10
Right Lower Cover .......................................................................A683-10
Upper Cover.................................................................................A683-10
4.2 ROLLER REPLACEMENT................................................................A683-11
4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ......A683-11
Pick-up Roller...............................................................................A683-11
Paper Feed Roller........................................................................A683-11
Separation Roller .........................................................................A683-11
4.3 TRAY LIFT AND PAPER END SENSOR REPLACEMENT..............A683-12
Tray Lift Sensor............................................................................A683-12
Paper End Sensor........................................................................A683-12
4.4 RELAY SENSOR REPLACEMENT..................................................A683-13
4.5 SIDE FENCE POSITION CHANGE..................................................A683-14
SORTER STAPLER (A831)
1. OVERALL MAHCINE INFORMATION..................................A831-1
1.1 SPECIFICATIONS..............................................................................A831-1
1.2 COMPONENT LAYOUT.....................................................................A831-3
1.2.1 MECHANICAL COMPONENT LAYOUT....................................A831-3
1.2.2 DRIVE LAYOUT.........................................................................A831-4

xii
2. DETAILED DESCRIPTION....................................................A831-5
2.1 BASIC OPERATION...........................................................................A831-5
2.1.1 NORMAL (PROOF MODE) AND SORT/STACK MODE............A831-5
Normal (Proof) Mode (From the Turn Gate Section
to the Proof Tray) ...............................................................A831-5
Sort Mode (From the Turn Gate Section to the Bins).....................A831-6
Stack Mode (From the Turn Gate Section to the Bins)...................A831-7
Reverse Mode (From the Turn Gate Section to the Bins)..............A831-8
2.1.2 STAPLE MODE .........................................................................A831-9
2.2 TURN GATE SECTION....................................................................A831-11
2.3 BIN DRIVE MECHANISM.................................................................A831-12
2.4 BIN HOME POSITION......................................................................A831-13
2.5 JOGGER SECTION..........................................................................A831-14
2.6 BIN REAR PLATE DRIVE SECTION................................................A831-15
2.7 GRIP ASSEMBLY.............................................................................A831-16
2.7.1 GRIP MOTOR..........................................................................A831-17
2.7.2 GRIP SHIFT MOTOR ..............................................................A831-18
2.8 STAPLE UNIT...................................................................................A831-19
2.8.1 STAPLE UNIT DRIVE MECHANISM.......................................A831-19
2.8.2 STAPLER ................................................................................A831-20
Staple Prohibit Conditions............................................................A831-21
2.8.3 STAPLE UNIT PULLED-OUT MECHANISM ...........................A831-22
3. REPLACEMENTS AND ADJUSTMENTS...........................A831-23
3.1 EXTERIOR COVER REMOVAL.......................................................A831-23
3.2 STAPLER REMOVAL AND REINSTALLATION...............................A831-24
3.3 JOGGER PLATE REMOVAL AND INSTALLATIOIN........................A831-25
Removal.......................................................................................A831-25
Installation....................................................................................A831-25
3.4 BINS REMOVAL...............................................................................A831-26
Removal.......................................................................................A831-26
Installation....................................................................................A831-28
3.5 MAIN MOTOR REMOVAL................................................................A831-30
3.6 GRIP ASSEMBLY REMOVAL..........................................................A831-31
3.7 UPPER GRIP ASSEMBLY REMOVAL.............................................A831-32
3.8 GRIP SHIFT MOTOR REMOVAL.....................................................A831-33
3.9 HELICAL WHEELS REMOVAL........................................................A831-34
Removal.......................................................................................A831-34
Front Helical Wheel......................................................................A831-34
Rear Helical Wheel ......................................................................A831-35
Installation....................................................................................A831-36
Rear Helical Wheel ......................................................................A831-36
Front Helical Wheel......................................................................A831-37
Alignment of the 2 Helical Wheels................................................A831-38
3.10 GRIP MOTOR AND SENSORS REMOVAL...................................A831-39
3.10.1 GRIP MOTOR/GRIP MOTOR HP SENSOR/GRIP
SHIFT MOTOR HP SENSOR REMOVAL.............................A831-39
3.11 MAIN CONTROL BOARD REPLACEMENT...................................A831-40

xiii
4. SP MODE AND STAPLE POSITION ADJUSTMENT..........A831-41
4.1 SERVICE TABLES (MAIN CONTROL BOARD)...............................A831-41
4.1.1 DIP SWITCHES.......................................................................A831-41
DIP 1 (Mode) SP Mode................................................................A831-41
DIP 2 (Staple) Staple Position Adjustment (A) DIP 3 (Chuck)
Staple Position Adjustment (B).................................................A831-41
FPU (A846)
1. SPECIFICATIONS..................................................................A846-1
2. ELECTRICAL COMPONENT LAYOUT
AND DESCRIPTIONS ...........................................................A846-2
3. SECTIONAL DESCRIPTIONS................................................ A846-3
3.1 OVERVIEW ........................................................................................A846-3
3.2 SHADING ...........................................................................................A846-4
3.3 MIRROR UNIT....................................................................................A846-5
APPENDIX
APPENDIX-1
SC CODE TABLE
APPENDIX-2
SP MODE
APPENDIX-3
POP-UP DISPALYS
APPENDIX-4
TIMING CHARTS

30 March 1999 SPECIFICATIONS
1-1
Overall
Information
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.1.1 MAJOR UNITS
•A257 copier: Basic model
•A269 copier: Editing model
1. Original tray (A430)
2. FPU (A846)
3. FPU table (A702-19)
4. LCT (A683) + LCT adapter (A840-01)
5. 20 bin sorter stapler (A831)
6. ARDF (A663)
Other options
•Platen cover (A749-01)
•Controller interface (A839)
A269V001.PCX
5
3
2
1
4
6

SPECIFICATIONS 30 March 1999
1-2
1.1.2 BASIC SPECIFICATIONS
Type: Console type
Copy process: Dry electrostatic transfer system
Number of scans: 1 (image memory for A3/DLT full color copy is
installed)
Pre-scan: Only when Auto Original Type mode is used
Resolution: Copy mode (read/write): 400 dpi/600 dpi
Print mode (write): 600 dpi
Gradations: 256 gradations (8 bits)
Original types: Sheet, book, object
Maximum original size: A3/11" x 17"
Original reference position: Left rear corner
Maximum print size: 323 mm x 473 mm
Copy paper size: First tray
Maximum: A4 (S/L)/81/2" x 11" (S/L)
Minimum: A5 (S)/ 81/2" x 51/2" (S)
Other trays
Maximum: A3/11" x 17"
Minimum: A5 (S)/ 81/2" x 51/2" (S)
By-pass
Maximum: 13" x 19" (330 x 483 mm)
Minimum: Postcard (100 x 148 mm)
Auto/duplex
Maximum: A3/11" x 17"
Minimum: A5 (S)/ 81/2" x 51/2" (S)
Paper thickness: Tray feed (including duplex):
64 to 105 g/m2, 17 to 28 lb
By-pass feed:
64 to 256 g/m2, 17 to 68 lb
Thick paper 1 (105 ~ 157 g/m2, 28 ~ 42 lb)
Thick paper 2 (157 ~ 256 g/m2, 42 ~ 68 lb)
Non-reproduction area: Leading edge: 4±2 mm
Left and right: 2±2 mm (4 mm or less in total)
Trailing edge: 2±2 mm

30 March 1999 SPECIFICATIONS
1-3
Overall
Information
Copying speed (cpm):
Full
color C/M/ Y/K B, G R K+M K+Y K+C
A4/81/2" x 11" or less 10 40 13.5 10 13.5 10
Normal paper/
normal mode A3/11"x17" 5207575
A4/81/2" x 11" or less 4.5 7 5 4.5 5 4.5
OHP/thick
paper A3/11" x 17" 2 3.5 2.5 2 2.5 2
A4/81/2"x11"orless8318888
ARDF 1 to 1 A3/11"x17" 5155554
A4/81/2" x 11" or less 10 35 13.5 10 13.5 10
Duplex feed A3/11"x17"T 5207575
Warm-up time: 8 minutes and 30 seconds or less
First copy time (A4/81/2" x 11") Normal Paper:
Full color: 16.5 seconds or less
K, C, M, Y: 8 seconds or less
B, G: 14 seconds or less
R: 16.5 seconds or less
Thick paper/OHP:
Full color: 29 seconds or less
Paper feed capacity: Tray:
500-sheet paper tray: 3 trays
By-pass feed:
50 sheets
Duplex tray:
50-sheets (30 sheets for A3/11" x 17"
20 sheets (Full color)
Paper feed system: Tray:
FRR system (Stack height: 53 mm max.)
By-pass feed:
FRR system (Stack height: 6 mm max.)
Duplex tray:
Friction roller separation system
Reproduction Ratios:
81/2" x 11"LT/11" x 17"DLT version A4/A3 version
Enlargement 121, 129, 155, 200, 400% 115, 122, 141, 200, 400%
Full size 100% 100%
Reduction 25, 50, 65, 73, 78, 85, 93% 25, 50, 65, 71, 75, 82, 93%
Programmable 2 user ratios 2 user ratios
Zoom 25% to 400% in 1% steps 25% to 400% in 1% steps

SPECIFICATIONS 30 March 1999
1-4
Number of continuous copies: 1 to 999 sheets
Scanning system: 3-line 1-chip CCD sensor (400 dpi/5,000 pixels)
Light source: 1-halogen-lamp indirect lighting (frosted surface)
Print system: Twin laser beam, 600 dpi
Development system: 2-component magnetic brush
Drum cleaning system: Counter blade
Image Transfer system: Belt transfer system
Fusing system: Heat and pressure roller system with oil application
Dimensions:
1. Copier
730 mm (W1) x 780 mm (D) x 980 mm (H1)
2. Copier + Platen Cover + Paper Exit Tray + By-pass Tray
1,643 mm (W2) x 780 mm (D) x 1,045 mm (H2)
A269V155.WMF
A269V156.WMF