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Ricoh Aficio AP2700 Service Manual

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Russian Printer
Aficio AP2700
SERVICE MANUAL
October 1st, 1999
Subject to change

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Summary of Contents for Ricoh Aficio AP2700

  • Page 1 Russian Printer Aficio AP2700 SERVICE MANUAL October 1st, 1999 Subject to change...
  • Page 2 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the printer power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. Note that some components of the printer and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off.
  • Page 3 1. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 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.
  • Page 4 Trademarks ® ® ® Microsoft , Windows , and MS-DOS are registered trademarks of Microsoft Corporation in the United States and /or other countries. ® PostScript is a registered trademark of Adobe Systems, Incorporated. ® is a registered trademark of Hewlett-Packard Company. ®...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. OVERALL MACHINE INFORMATION ........1-1 1.1 SPECIFICATIONS ..................1-1 1.1.1 GENERAL SPECIFICATIONS ............1-1 1.1.2 SUPPORTED PAPER SIZES ............1-3 1.2 SOFTWARE ACCESSORIES..............1-4 1.2.1 PRINTER DRIVERS ................ 1-4 1.2.2 UTILITY SOFTWARE ..............1-4 1.2.3 SERVICE TOOLS ................1-4 1.3 MACHINE CONFIGURATION ..............
  • Page 6 2.6 PAPER FEED ..................2-24 2.6.1 OVERVIEW ................... 2-24 2.6.2 PAPER FEED DRIVE MECHANISM ..........2-25 2.6.3 PAPER FEED AND SEPARATION MECHANISM......2-26 2.6.4 PAPER LIFT MECHANISM............2-27 2.6.5 PAPER END DETECTION............. 2-28 2.6.6 PAPER HEIGHT DETECTION............2-29 2.6.7 PAPER SIZE DETECTION ............2-30 2.6.8 SPECIAL PAPER SETTING ............
  • Page 7 4. SERVICE TABLES ..............4-1 4.1 GENERAL CAUTION................4-1 4.1.1 PCU ....................4-1 4.1.2 TRANSFER ROLLER UNIT ............. 4-1 4.1.3 LASER UNIT..................4-1 4.1.4 FUSING UNIT .................. 4-2 4.1.5 PAPER FEED .................. 4-2 4.1.6 OTHERS ..................4-2 4.2 SERVICE PROGRAM MODE..............4-3 4.2.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ..
  • Page 8 6.2 PHOTOCONDUCTOR UNIT (PCU)............6-6 6.2.1 PCU ....................6-6 6.3 TRANSFER UNIT ..................6-7 6.3.1 TRANSFER ROLLER UNIT ............. 6-7 6.4 ID SENSOR ....................6-8 6.5 PAPER EXIT..................6-9 6.5.1 PAPER EXIT AND OVERFLOW SENSORS ........6-9 6.6 PAPER FEED AND REGISTRATION............. 6-10 6.6.1 PAPER LIFT MOTORS..............
  • Page 9 OPTIONS PAPER TRAY UNIT (A860) 1. OVERALL MACHINE INFORMATION ........A860-1 1.1 SPECIFICATIONS ................A860-1 1.2 MECHANICAL COMPONENT LAYOUT..........A860-2 1.3 ELECTRICAL COMPONENT LAYOUT ..........A860-3 1.4 ELECTRICAL COMPONENT DESCRIPTION ........A860-4 1.5 DRIVE LAYOUT ................. A860-5 2. DETAILED DESCRIPTIONS ..........A860-6 2.1 PAPER FEED AND SEPARATION MECHANISM......
  • Page 10 2.4 PAPER HEIGHT DETECTION ..............10 2.5 PAPER SIZE DETECTION .................12 2.6 SIDE AND END FENCES................13 3. REPLACEMENT AND ADJUSTMENT......... 14 3.1 FEED ROLLER REPLACEMENT ...............14 3.2 TRAY MAIN BOARD REPLACEMENT............15 3.3 TRAY MOTOR REPLACEMENT ..............15 3.4 TRAY MOTOR REPLACEMENT ..............16 3.5 LIFT MOTOR REPLACEMENT ..............17 3.6 PAPER END SENSOR REPLACEMENT ...........18 3.7 PAPER SIZE SWITCH REPLACEMENT............18...
  • Page 11 BY-PASS UNIT (A899) 1 OVERALL MACHINE INFORMATION ........A899-1 1.1 SPECIFICATIONS ................A899-1 1.2 MECHANICAL COMPONENT LAYOUT..........A899-1 1.3 ELECTRICAL COMPONENT LAYOUT ..........A899-2 1.4 ELECTRICAL COMPONENT DESCRIPTION ........A899-2 2 DETAILED DESCRIPTIONS ..........A899-3 2.1 BASIC OPERATION................A899-3 2.2 PAPER SIZE DETECTION ..............A899-4 3 REPLACEMENT AND ADJUSTMENT........A899-5 3.1 PAPER FEED ROLLER/FRICTION PAD/PAPER END SENSOR..
  • Page 12 2. DETAILED DESCRIPTIONS ..........G529-6 2.1 BASIC OPERATION................G529-6 Larger than A4 lengthwise/LT Lengthwise ........G529-6 Up to A4 Lengthwise/LT lengthwise ..........G529-7 2.2 FEED IN AND EXIT MECHANISM .............G529-8 When Paper is Fed Into Duplex Unit: ..........G529-8 Inversion and Exit:................G529-8 3. REPLACEMENT AND ADJUSTMENT......... G529-9 3.1 COVER REMOVAL ................G529-9 3.2 ENTRANCE SENSOR REPLACEMENT ..........G529-10 3.3 EXIT SENSOR REPLACEMENT............G529-11...
  • Page 13 2. DETAILED DESCRIPTIONS ..........A681-7 2.1 JUNCTION GATE MECHANISM ............A681-7 Staple Mode ................... A681-7 No staple Mode ................A681-7 2.2 JOGGER UNIT PAPER POSITIONING MECHANISM ....... A681-8 2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM ......A681-9 2.4 STAPLER ..................A681-10 2.5 FEED OUT MECHANISM..............A681-11 2.6 SHIFT TRAY UP/DOWN MECHANISM..........
  • Page 14 MAILBOX (G518) 1. OVERALL MACHINE INFORMATION ......... G518-1 1.1 SPECIFICATIONS ................G518-1 1.2 COMPONENT LAYOUT ..............G518-2 1.2.1 MECHANICAL COMPONENT LAYOUT ........G518-2 1.2.2 DRIVE LAYOUT.................G518-2 1.3 ELECTRICAL COMPONENT DESCRIPTIONS........G518-3 2. DETAILED DESCRIPTIONS ..........G518-5 2.1 BASIC OPERATION................G518-5 2.2 PAPER OVERFLOW DETECTION ............G518-6 2.2.1 OVERVIEW ................G518-6 2.2.2 DETECTION TIMING..............G518-6 2.3 PAPER MISFEED DETECTION TIMING..........G518-7...

  • Page 15: Overall Machine Information

    1 October, 1999 SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS 1.1.1 GENERAL SPECIFICATIONS Printing Speed: Maximum 27 pages per minute (A4/LT LEF) (22 pages: duplex printing) Printer Language: PCL6/PCL5e PostScript Level 3 TIFF (rev 6.0 compatible) Resolution: 600 dpi (PCL 6/PCL5e/PS3) 300 dpi (PCL 5e/PS3) Resident Fonts: PCL:...
  • Page 16 SPECIFICATIONS 1 October, 1999 Standard 16 MB, up to 80 MB with optional DIMM. Memory: Power Source: 120 V, 60 Hz: More than 10 A (for North America) 220 V - 240 V, 50/60 Hz: More than 6.0 A (for Europe) Power Consumption: 120V 230V...

  • Page 17: Supported Paper Sizes

    1 October, 1999 SPECIFICATIONS 1.1.2 SUPPORTED PAPER SIZES Trays Duplex By-pass/ Paper Size (W x L) Tray 2 Ledger 11 x 17” Legal 8.5 x 14“ Letter SEF 8.5 x 11” Letter LEF 11 x 8.5” Half Letter 5.5 x 8.5” Half Letter LEF 8.5 x 5.5”...

  • Page 18: Software Accessories

    SOFTWARE ACCESSORIES 1 October, 1999 1.2 SOFTWARE ACCESSORIES The printer drivers and utility software are provided on one CD-ROM. An auto-run installer allows you to select which components to install. The service tools are not provided on the CD-ROM. 1.2.1 PRINTER DRIVERS Printer Language Windows 3.1x Windows 95/98 Windows NT4.0 Macintosh PCL 6...

  • Page 19: Machine Configuration

    1 October, 1999 MACHINE CONFIGURATION 1.3 MACHINE CONFIGURATION 1.3.1 SYSTEM COMPONENTS G038V502.WMF...
  • Page 20 MACHINE CONFIGURATION 1 October, 1999 Machine Item Remarks Code User installable Main Unit G038 Option Paper Tray Unit - 1 tray A861 Used in common with Stinger-C (See note 1) User installable Paper Tray Unit - 2 trays A860 Used in common with Stinger-C/Russian-C (See note 1) User installable...

  • Page 21: Paper Path

    1 October, 1999 PAPER PATH 1.4 PAPER PATH G038V101.WMF [A]: Optional interchange unit [B]: Optional duplex unit [C]: Optional by-pass tray [D]: Optional paper tray unit (2 trays) [E]: Optional 1000-sheet finisher [F]: Optional bridge unit...

  • Page 22: Mechanical Component Layout

    MECHANICAL COMPONENT LAYOUT 1 October, 1999 1.5 MECHANICAL COMPONENT LAYOUT G038V503.WMF 1. Exit roller 10. Friction pad 2. Hot roller 11. Paper feed roller 3. Fusing pressure roller 12. Paper size sensor 4. Cleaning unit 13. Special paper sensor 5. Drum 14.

  • Page 23: Electrical Component Descriptions

    1 October, 1999 ELECTRICAL COMPONENT DESCRIPTIONS 1.6 ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout on the reverse side of the point-to-point diagram for the location of the components. Symbol Name Function Motors Polygonal Mirror Turns the polygonal mirror. Main Motor Drives the main unit components.
  • Page 24 ELECTRICAL COMPONENT DESCRIPTIONS 1 October, 1999 Symbol Name Function Lower Relay Detects misfeeds. Detects misfeeds and controls registration clutch Registration off-on timing. Detects when the paper in the 1st paper tray is at 1st Paper Lift the feed height. Detects when the paper in the 2nd paper tray is 2nd Paper Lift at the feed height.

  • Page 25: Printing Process

    1 October, 1999 PRINTING PROCESS 1.7 PRINTING PROCESS Overview G038V504.WMF 1. DRUM CHARGE The charge roller gives a negative charge to the organic photoconductive (OPC) drum. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark. 2.
  • Page 26 PRINTING PROCESS 1 October, 1999 5. IMAGE TRANSFER Paper is fed to the area between the drum surface and the transfer roller at the proper time for aligning the print paper and the developed image on the drum surface. Then, the transfer roller applies a high positive charge to the reverse side of the paper.

  • Page 27: Board Structure

    1 October, 1999 BOARD STRUCTURE 1.8 BOARD STRUCTURE 1.8.1 OVERVIEW Standard Operation components Panel Network Optional Interface components Printer Laser Controller PS DIMM Synch. Board DRAM DIMM Power Polygon Motors L D D R H D D Motor Pack Engine Board Fusing Lamp Thermistor Paper Tray...

  • Page 28: Descriptions

    BOARD STRUCTURE 1 October, 1999 1.8.2 DESCRIPTIONS 1. Engine Board The engine board controls the following functions: • Engine sequence • Machine control, printer engine control • Timing control for peripherals • Video control • Drive control for the sensors, motors, solenoids, and high voltage supply board 2.

  • Page 29: Detailed Section Descriptions

    1 October, 1999 LASER EXPOSURE 2. DETAILED SECTION DESCRIPTIONS 2.1 LASER EXPOSURE 2.1.1 OVERVIEW G038D523.WMF The LD unit [A] outputs a laser beam to the polygon mirror [B] through the cylindrical lens [C]. The shield glass [D] prevents dust from reaching the polygon mirror.

  • Page 30: Auto Power Control (Apc)

    LASER EXPOSURE 1 October, 1999 2.1.2 AUTO POWER CONTROL (APC) LD LEVEL + 5 V LD ON LD OFF LD Driver LD OFF Controller VIDEO VIDEO VREF Monitor Reference Circuit LD Drive Board G038D510.WMF The LD driver IC drives the laser diode. To prevent the intensity of the laser beam from changing because of the temperature, the machine monitors the current passing through the laser diode (LD).

  • Page 31: Ld Safety Switch

    1 October, 1999 LASER EXPOSURE 2.1.3 LD SAFETY SWITCH Interlock LDD: LD Drive Board + 5 V L D + 5 V L D P S U Engine V C C Board Laser B e a m Optical Path LD Control IC O P C Drum G038D501.WMF...

  • Page 32: Photoconductor Unit (Pcu)

    PHOTOCONDUCTOR UNIT (PCU) 1 October, 1999 2.2 PHOTOCONDUCTOR UNIT (PCU) 2.2.1 OVERVIEW G038D201.WMF The PCU consists of the components shown in the above illustration. An organic photoconductor (OPC) drum (diameter: 30 mm) is used in this machine. 1. Cleaning Blade 6.

  • Page 33: Drive Mechanism

    1 October, 1999 PHOTOCONDUCTOR UNIT (PCU) 2.2.2 DRIVE MECHANISM G038D202.WMF The main motor [A] drives the drum [B] through a series of gears, a timing belt [C], and the drum drive shaft [D]. The main motor assembly includes a drive controller, which outputs a motor lock signal when the rotation speed is out of the specified range.

  • Page 34: New Pcu Detection Mechaninsm

    PHOTOCONDUCTOR UNIT (PCU) 1 October, 1999 2.2.3 NEW PCU DETECTION MECHANINSM G038D206.WMF When the PCU counter reaches 60K, the “Replace PCU” message is displayed. The new PCU detect switch [A] detects when a new PCU is installed. Each PCU has an actuator [B]. When a new PCU is installed in the machine, the actuator [B] pushes the new PCU detect switch.

  • Page 35: Drum Charge

    1 October, 1999 DRUM CHARGE 2.3 DRUM CHARGE 2.3.1 OVERVIEW G038D203.WMF This machine uses a drum charge roller to charge the drum. The drum charge roller [A] always contacts the surface of the drum [B] to give it a negative charge of -900V.

  • Page 36: Charge Roller Voltage Correction

    DRUM CHARGE 1 October, 1999 2.3.1 CHARGE ROLLER VOLTAGE CORRECTION Correction for Environmental Conditions 28.9 cm 2 cm 2 cm ID Sensor Pattern Sub Scan Direction -1650 V Charge Voltage -1450 V Laser Diode Drum Potential -900 V -700 V Development Bias -600 V -400 V...

  • Page 37: Id Sensor Pattern Production Timing

    1 October, 1999 DRUM CHARGE If the humidity drops, the drum potential goes up (to a higher –ve voltage) even if the charge roller voltage supply stays the same (efficiency of voltage transfer is higher with lower humidity). As a result, less toner is transferred to ID sensor pattern [B].

  • Page 38: Drum Charge Roller Cleaning

    DRUM CHARGE 1 October, 1999 2.3.3 DRUM CHARGE ROLLER CLEANING G038D205.WMF Because the drum charge roller [A] always contacts the drum, it gets dirty easily. So, the cleaning pad [B] also contacts the drum charge roller all the time to clean the surface of the drum charge roller.

  • Page 39: Development

    1 October, 1999 DEVELOPMENT 2.4 DEVELOPMENT 2.4.1 OVERVIEW G038D301.WMF The development unit consists of the following parts. 1. Development roller 4. Mixing auger 1 2. Mixing auger 2 5. Doctor blade 3. TD sensor This machine uses a single-roller development system. Two mixing augers mix the developer.

  • Page 40: Drive Mechanism

    DEVELOPMENT 1 October, 1999 2.4.2 DRIVE MECHANISM G038D304.WMF The main motor [A] drives the development roller [B] and mixing augers [C] through a train of gears and the development drive shaft [D]. When the PCU is pushed in, the development drive shaft engages the development roller gear. The development drive gears (except for the gears in the development unit) are helical gears.

  • Page 41: Developer Mixing

    1 October, 1999 DEVELOPMENT 2.4.3 DEVELOPER MIXING G038D302.WMF This machine uses 2 mixing augers, [A] and [B], to keep the developer evenly mixed. Mixing auger 2 [A] transports excess developer, scraped off the development roller [C] by the doctor blade [D], towards the front of the machine. Mixing auger 1 [B] returns the excess developer, along with new toner, to the rear of the mixing assembly.

  • Page 42: Development Bias

    DEVELOPMENT 1 October, 1999 2.4.4 DEVELOPMENT BIAS G038D303.WMF This machine uses a negative-positive development system, in which black areas of the latent image are at a low negative charge (about -150 ± 50 V) and white areas are at a high negative charge (about -900 V). To attract negatively charged toner to the black areas of the latent image on the drum, the high voltage supply board applies a bias of -600 volts to the development rollers throughout the image development process.

  • Page 43: Toner Supply

    1 October, 1999 DEVELOPMENT 2.4.5 TONER SUPPLY Toner bottle replenishment mechanism G038D507.WMF When a toner bottle is placed in the bottle holder unit [A] and the unit is pushed in completely, pin [B] moves against the side [C] of the PCU, and the toner shutter [D] is pulled out to open the bottle.
  • Page 44 DEVELOPMENT 1 October, 1999 Toner supply mechanism G038D508.WMF G038D306.WMF The toner supply motor [A] drives the toner bottle [B] and the mylar blades [C]. First, the toner falls down into the toner bottle holder. The toner supply mylar blades transfer the toner to the slit [D]. When the PCU is installed in the machine, the shutter [E] above the PCU is opened by the machine frame.

  • Page 45: Toner Density Control

    1 October, 1999 DEVELOPMENT 2.4.6 TONER DENSITY CONTROL Overview There are four modes for controlling toner supply as shown in the following tables. The mode can be changed with by the printer service mode (Service Menu 2: Toner supply). The factory setting is P+T control mode. Basically, toner density is controlled using the standard TD sensor voltage (Vts), toner supply reference voltage (Vref), actual TD sensor output voltage (Vt), and ID sensor output data (Vsp/Vsg).
  • Page 46 DEVELOPMENT 1 October, 1999 There are four toner density control modes: Mode P+T Control (Normally use this setting only) Toner supply decision Compare Vt with a reference voltage (Vts or Vref) Toner control process Toner is supplied to the development unit when Vt is higher than the reference voltage (Vts or Vref).
  • Page 47 1 October, 1999 DEVELOPMENT Toner density sensor initial setting The TD sensor initial setting procedure is performed automatically when the new PCU is installed in the machine. During TD sensor initial setting, the TD sensor is set to the TD sensor output to the value programmed in the printer service mode (T sensor set: default: 2.3V).
  • Page 48 DEVELOPMENT 1 October, 1999 Toner Supply Motor On Time Determinations For sensor control modes 1 and 2, the toner supply motor on time is decided by the following factors. • Vt • Vref • TD sensor sensitivity (coefficient: S, value is 0.4) There are seven levels for toner supply motor on time as shown below.

  • Page 49: Toner Near End/End Detection And Recovery

    1 October, 1999 DEVELOPMENT 2.4.7 TONER NEAR END/END DETECTION AND RECOVERY The toner near end and end conditions are detected using the Vt and Vref values, in a similar way to toner density control. This is done in all toner supply modes except for fixed quantity 2, when toner end is not detected.

  • Page 50: Drum Cleaning And Toner Recycling

    DRUM CLEANING AND TONER RECYCLING 1 October, 1999 DRUM CLEANING AND TONER RECYCLING 2.5.1 DRUM CLEANING G038D201.WMF The cleaning blade [A] removes any toner remaining on the drum after the image is transferred to the paper. This model uses a counter blade system. The cleaning blade scrapes off toner remaining on the drum.

  • Page 51: Toner Recycling

    1 October, 1999 DRUM CLEANING AND TONER RECYCLING 2.5.2 TONER RECYCLING G038D205.WMF G038D306.WMF Toner picked up by the toner collection coil [A], is transported to the opening [B] at the side of the PCU. Then, this toner falls into the development unit with new toner coming from the toner bottle and it is all mixed together by mixing auger 1 [C] and used again.

  • Page 52: Paper Feed

    PAPER FEED 1 October, 1999 2.6 PAPER FEED 2.6.1 OVERVIEW G038D701.WMF There are two paper trays, each of which can hold 500 sheets. The paper tray feed stations use a friction pad system. The two relay sensors are used for paper jam detection. The components of the paper feed station are as follows.

  • Page 53: Paper Feed Drive Mechanism

    1 October, 1999 PAPER FEED 2.6.2 PAPER FEED DRIVE MECHANISM G038D702.WMF The main motor [A] drives the pick-up and feed mechanism of both the first and second paper trays. The paper feed clutches [B] transfer drive from this motor to the paper feed rollers [C].

  • Page 54: Paper Feed And Separation Mechanism

    PAPER FEED 1 October, 1999 2.6.3 PAPER FEED AND SEPARATION MECHANISM A860D104.WMF The paper feed roller [A] drives the top sheet of paper from the paper tray. The friction pad [B] allows only one sheet to feed at a time. The friction pad applies pressure to the feed roller with a spring [C].

  • Page 55: Paper Lift Mechanism

    1 October, 1999 PAPER FEED 2.6.4 PAPER LIFT MECHANISM G038D521.WMF G038D522.WMF The paper size switch detects when the tray is pushed in. When the paper tray is pushed into the machine, the pin [A] for the lift motor pressure shaft engages the lift motor coupling [B] and the pin [C] for the bottom plate lift shaft in the tray engages the bottom plate pressure lever coupling [D].

  • Page 56: Paper End Detection

    PAPER FEED 1 October, 1999 For A4-width paper or wider, a projection [H] on the side fence engages the secondary pressure spring [J] through a lever [I]. Then, the secondary pressure spring [J] applies paper feed pressure in addition to the main pressure spring [K], to ensure that extra pressure is applied to wider paper.

  • Page 57: Paper Height Detection

    1 October, 1999 PAPER FEED 2.6.6 PAPER HEIGHT DETECTION G038D522.WMF The amount of paper in the tray is detected by the combination of on/off signals from two paper height sensors [A] and [B]. When the amount of paper decreases, the bottom plate pressure lever [C] moves the actuator up.

  • Page 58: Paper Size Detection

    PAPER FEED 1 October, 1999 2.6.7 PAPER SIZE DETECTION Size 9 9 9 9 9 9 9 9 9 9 9 9 A4 LEF 9 9 9 9 9 9 9 9 A4 SEF A5 SEF, 9 9 9 9 9 9 9 9 "...

  • Page 59: Special Paper Setting

    1 October, 1999 PAPER FEED 2.6.8 SPECIAL PAPER SETTING G038D703.WMF When feeding thick paper and envelopes, the user must use the 2nd paper tray (if the optional by-pass table is not installed), and turn lever [A] to the right. Then, when sliding the tray into the machine, the lever does not push the special paper switch [B] (it stays off), and the machine detects that there is special paper in the 2nd paper tray.

  • Page 60: Side And End Fences

    PAPER FEED 1 October, 1999 2.6.9 SIDE AND END FENCES A860D110.WMF A860D109.WMF Side Fences If the tray is full of paper and it is pushed in strongly, the fences may deform or bend. This may cause the paper to skew or the side-to-side registration to be incorrect.

  • Page 61: Paper Registration

    1 October, 1999 PAPER FEED 2.6.10 PAPER REGISTRATION G038D702.WMF G038D704.WMF The drive from the main motor [A] is transmitted to the registration roller through the registration clutch gear [B]. The registration sensor [C] is used for correcting paper skew and for detecting paper misfeeds.

  • Page 62: Image Transfer And Paper Separation

    IMAGE TRANSFER AND PAPER SEPARATION 1 October, 1999 IMAGE TRANSFER AND PAPER SEPARATION 2.7.1 OVERVIEW G038D403.WMF G038D401.WMF G038D402.WMF The machine uses a transfer roller [A], which touches the surface of the drum [B]. The high voltage supply board supplies a positive current to the transfer roller, which attracts the toner from the drum onto the paper.

  • Page 63: Image Transfer Mechanism

    1 October, 1999 IMAGE TRANSFER AND PAPER SEPARATION 2.7.2 IMAGE TRANSFER MECHANISM There are two transfer current levels: low transfer current level and high transfer current level. The image transfer procedure is as follows: 1. When the CPU receives the image writing start signal, the CPU instructs the high voltage supply board to supply +10µA (low transfer current level) to the roller.

  • Page 64: Transfer Roller Cleaning

    IMAGE TRANSFER AND PAPER SEPARATION 1 October, 1999 2.7.3 TRANSFER ROLLER CLEANING If the paper size is smaller than the image, or if a paper jam occurs during printing, toner may be transferred to the roller surface. To prevent the toner from transferring to the back side of the printouts, the transfer roller requires cleaning before the next printing run.

  • Page 65: Image Fusing And Paper Exit

    1 October, 1999 IMAGE FUSING AND PAPER EXIT 2.8 IMAGE FUSING AND PAPER EXIT 2.8.1 OVERVIEW G038D521.WMF The fusing unit and paper exit area consist of the following parts. 1. Paper exit roller 7. Fusing lamp 2. Fusing exit sensor 8.

  • Page 66: Fusing Drive And Release Mechanism

    IMAGE FUSING AND PAPER EXIT 1 October, 1999 2.8.2 FUSING DRIVE AND RELEASE MECHANISM G038D504.WMF G038D505.WMF The main motor [A] drives the fusing unit through a gear train and drives the paper exit rollers [B] through a timing belt [C]. The fusing unit release mechanism automatically disengages the fusing unit drive gear [D] when the right cover [E] is opened.

  • Page 67: Fusing Entrance Guide Shift Mechanism

    1 October, 1999 IMAGE FUSING AND PAPER EXIT 2.8.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM G038D506.WMF The entrance guide [A] is adjustable for paper thickness to prevent creasing. The left screw holes [B] on each side are used as the default setting. If creasing occurs frequently in the fusing unit, adjust the entrance guide to the right, by securing it with the other holes [C].

  • Page 68: Pressure Roller

    IMAGE FUSING AND PAPER EXIT 1 October, 1999 2.8.4 PRESSURE ROLLER G038D502.WMF The pressure springs [A] constantly apply pressure between the hot roller [B] and the pressure roller [C]. Applied pressure can be changed by adjusting the position of the pressure springs. The spring is positioned at the top [D] as the default setting.

  • Page 69: New Fusing Unit Detection

    1 October, 1999 IMAGE FUSING AND PAPER EXIT 2.8.6 NEW FUSING UNIT DETECTION G038D500.WMF When the PM (fusing) counter reaches 120K, "Replace Maintenance Kit" is displayed. The machine detects when the new maintenance fusing unit is installed by checking the circuit through the detector hook [A]. The detector hook is hooked on the edge of the fusing pressure roller shaft [B].

  • Page 70: Fusing Temperature Control

    IMAGE FUSING AND PAPER EXIT 1 October, 1999 2.8.7 FUSING TEMPERATURE CONTROL ºC Idling Enabled Power On 1 job or 11 pages G038D511.WMF Temperature Control When the main power switch is turned on, the CPU turns on the fusing lamp to maintain the fusing temperature of 180°C for the first job, or for the first 11 consecutive pages of printing.
  • Page 71 1 October, 1999 IMAGE FUSING AND PAPER EXIT Fusing Lamp Control Turning on and off the fusing lamp power causes fluorescent light in the room to flicker. To reduce the flickering, use the following printer service modes. Fusing temperature detection cycle (Fusing period) The CPU checks the output from the fusing thermistor once a second (default setting).

  • Page 72: Overheat Protection

    IMAGE FUSING AND PAPER EXIT 1 October, 1999 2.8.8 OVERHEAT PROTECTION If the hot roller temperature becomes higher than 231°C, the CPU cuts off the power to the fusing lamp. At the same time, SC543 is generated. Even if the thermistor overheat protection fails, there is a thermofuse in series with the common ground line of the fusing lamp.

  • Page 73: Energy Saver Modes

    1 October, 1999 ENERGY SAVER MODES 2.9 ENERGY SAVER MODES When the machine is not used, the energy saver feature reduces power consumption by lowering or switching off the fusing lamp. This machine has two types of energy saver mode. •...

  • Page 74: Controller Functions

    CONTROLLER FUNCTIONS 1 October, 1999 2.10 CONTROLLER FUNCTIONS 2.10.1 PAPER SIZE/TYPE DETECTION AND SELECTION The controller uses the paper sizes detected by the print engine for trays 1, 2, 3 and 4. For the by-pass tray, the user has to specify a paper size using the Job Control menu in the Printer User Tools.
  • Page 75 1 October, 1999 CONTROLLER FUNCTIONS Manual Tray Select Tray 1 Start of Tray Search Tray 2 (Tray selected by the driver) Tray 3 (optional) Tray 4 (optional) G038D542.WMF When the printer driver specifies a tray, the selected tray becomes the first tray checked at the start of the tray search.

  • Page 76: Output Tray Selection

    CONTROLLER FUNCTIONS 1 October, 1999 Paper Size Mismatch When the controller could not find the specified paper size and paper type in any of the trays, the machine displays an error message. Then the user can either load the requested paper size and paper type in a tray or select another tray, e.g., a tray that contains A4 size paper, by pressing the “Form Feed”...

  • Page 77: Collation (Sort)

    1 October, 1999 CONTROLLER FUNCTIONS 2.10.4 COLLATION (SORT) When the controller has either an optional SDRAM DIMM or an optional HDD installed, collation is enabled. If the memory or HDD becomes full while storing a job that uses collation, the controller prints the pages that have been stored for collation, empties the memory or HDD, then continues printing the rest of the pages with collation.

  • Page 78: Duplex Printing

    CONTROLLER FUNCTIONS 1 October, 1999 2.10.5 DUPLEX PRINTING NOTE: Duplex printing requires installation of the memory option Duplex printing is available with all output bin options but not all paper sizes (refer to the specifications section). If a job specifies duplex but the paper size to be used is not usable in the duplex unit, the job will be printed single-sided.

  • Page 79: Proof Print

    1 October, 1999 CONTROLLER FUNCTIONS 2.10.7 PROOF PRINT H D D Controller Collate Partition Proof Partition Host Computer Engine G038D543.WMF The Proof Print function gives users a chance to check the print results before starting a multiple-set print run. When printing from a host computer, a print job is sent to the controller with a user ID and the current time.

  • Page 80: Reset Operations

    CONTROLLER FUNCTIONS 1 October, 1999 2.10.8 RESET OPERATIONS Job Reset This resets the job being processed and ignores all incoming data until a data end is received. If a collate job or a proof print job is being printed, the controller stops printing and deletes the file from the RAM or HDD.

  • Page 81: Installation

    1 October, 1999 INSTALLING THE MACHINE 3. INSTALLATION 3.1 INSTALLING THE MACHINE Refer to the Setup Guide for information about the installation environment and instructions on how to install and set up the machine. Installation procedures for the following equipment are described. •...

  • Page 82: Installing Optional Units

    INSTALLING OPTIONAL UNITS 1 October, 1999 3.2 INSTALLING OPTIONAL UNITS ø CAUTION Before installing this option, do the following: 1. Print out all data in the printer buffer. 2. Turn off the switch and disconnect the power cord. 3.2.1 BRIDGE UNIT Accessory Check Check the quantity and condition of the accessories with the following list.
  • Page 83 1 October, 1999 INSTALLING OPTIONAL UNITS 7 Attach the securing plate [E], as shown. NOTE: Do not attach it with a screw; this is done when securing the front stand for the optional finisher. 8. Install the optional finisher (A681) (refer to the 1000- sheet finisher installation procedure).

  • Page 84: 1,000-Sheet Finisher

    INSTALLING OPTIONAL UNITS 1 October, 1999 3.2.2 1,000-SHEET FINISHER NOTE: The following options must be installed before installing this finisher: • Bridge Unit (A897) • Paper Tray Unit (A860/A861) or LCT (A862) Installation Procedure 1. Unpack the finisher and remove the tapes. A681I503.WMF A681I504.WMF 2.
  • Page 85 1 October, 1999 INSTALLING OPTIONAL UNITS 6. Pull out the stapler unit [D]. 7. Draw out the locking lever [E] (1 screw). 8. Align the finisher on the stands, and lock it in place by pushing the locking lever. 9. Secure the locking lever (1 screw) and push the stapler unit into the finisher.

  • Page 86: Hard Disk (Hdd)

    INSTALLING OPTIONAL UNITS 1 October, 1999 3.2.3 HARD DISK (HDD) 1. Remove the controller cover [A] (6 screws), and the rear cover [B] (5 screws). G038R765.WMF 2. Remove the cover bracket [C] (2 screws). 3. Install the hard disk unit [D] to the upper socket of the printer controller.

  • Page 87: Service Tables

    1 October, 1999 GENERAL CAUTION 4. SERVICE TABLES 4.1 GENERAL CAUTION Do not turn off the main switch while any of the electrical components are active. Doing so might cause damage to units, such as the PCU, when they are pulled out of or put back into the machine.

  • Page 88: Fusing Unit

    GENERAL CAUTION 1 October, 1999 4.1.4 FUSING UNIT 1. After installing the fusing thermistor, make sure that they contact the hot roller and that the roller rotates freely. 2. Be careful not to damage the edges of the hot roller strippers or their tension springs.

  • Page 89: Service Program Mode

    1 October, 1999 SERVICE PROGRAM MODE 4.2 SERVICE PROGRAM MODE ø CAUTION Before accessing the service menu, do the following: Confirm that there is no print data in the printer buffer (the Data In LED must not be lit or blinking). If there is some data in the buffer, wait until all data has been printed.

  • Page 90: Service Program Mode Menu Tree

    SERVICE PROGRAM MODE 1 October, 1999 4.2.2 SERVICE PROGRAM MODE MENU TREE The following diagram shows the service mode menu tree. SERVICE MODE Service Menu 1 BitSw#1 Set (Controller Service BitSw#2 Set Mode) BitSw#3 Set BitSw#4 Set NVRAM Clear 1 NVRAM Clear 2 NVRAM Clear 3 Couter Clear...

  • Page 91: Printer Controller Service Mode

    1 October, 1999 PRINTER CONTROLLER SERVICE MODE 4.3 PRINTER CONTROLLER SERVICE MODE Service Mode Table (Service Menu 1) Title Description BitSw#1 Set Adjusts bit switch settings. Note: Currently, the bit switches are not being used. BitSw#2 Set BitSw#3 Set BitSw#4 Set NVRAM Clear 1 Initializes the controller NVRAM except bit switches, NIB settings, and log data.

  • Page 92: Nvram Reset

    PRINTER CONTROLLER SERVICE MODE 1 October, 1999 4.3.2 NVRAM RESET ø CAUTION Print the service summary report, controller configuration page, and NIB configuration page before resetting the NVRAM(s). DIAG. ERROR LOG AND PAPER TRAY SETTINGS RESET This initializes the following settings in the controller NVRAM. •...

  • Page 93: Power-On Diagnostics Error Display

    1 October, 1999 PRINTER CONTROLLER SERVICE MODE COUNTER RESET This initializes all the print counters in the controller NVRAM. Refer to the service summary report for the counters in the controller NVRAM. 1. Enter the Printer SP mode, and select “1. Service Menu”. 2.
  • Page 94 PRINTER CONTROLLER SERVICE MODE 1 October, 1999 Model Number / System Version / Unit Number Lists the machine’s Plug&Play name, controller firmware version, and the controller part number. Program List Lists the firmware module version. Bit Switch List the current bit switch settings. NOTE: Currently the bit switches are not being used.

  • Page 95: Printer Engine Service Mode

    1 October, 1999 PRINTER ENGINE SERVICE MODE 4.4 PRINTER ENGINE SERVICE MODE 4.4.1 SERVICE MODE MENU Service Mode (Service Menu 2) Notes Title Description (SP Mode) Prn EngMainte Prints the engine information Service regist Man/sub scan registration 1-001/002 Regist sag Paper feed timing 1-003 Fusing times...

  • Page 96: Service Mode Tables

    PRINTER ENGINE SERVICE MODE 1 October, 1999 4.4.2 SERVICE MODE TABLES Menu Level Function Settings Level 1 Level 2 Description Prints the The following items are engine printed. maintenance · Engine serial number information · Firmware version (Engine/Duplex unit/Finisher) · Maintenance Counter (Total counter/PCU counter/Motor counter)
  • Page 97 1 October, 1999 PRINTER ENGINE SERVICE MODE Menu Level Function Settings Level 1 Level 2 Description M-Scan Side-to-Side Adjusts the printing side-to- -9.0 to +9.0 Registration side registration from paper Tray1 (Paper Tray 1) tray 1 using the test pattern. mm/step 0.0 mm Use the...
  • Page 98 PRINTER ENGINE SERVICE MODE 1 October, 1999 Menu Level Function Settings Level 1 Level 2 Description Fusing Adjusts the fusing temperature 100 to 190 Temperature for printing. 1°C/step Adjustment 180°C First, the current fusing Fusing temperature is displayed. Use heat keys to scroll to the temperature adjustment menu.
  • Page 99 1 October, 1999 PRINTER ENGINE SERVICE MODE Menu Level Function Settings Level 1 Level 2 Description Tailing Shifts the image across the Correction page at the interval specified (Shift Value) by the following SP mode (N: Tailing papers). When making many copies of 0.0 to 5.0 an original that contains Tailing...
  • Page 100 PRINTER ENGINE SERVICE MODE 1 October, 1999 Menu Level Function Settings Level 1 Level 2 Description Memory All Resets all software counters Clear and returns all modes and adjustments to the default settings. However, the following items are not reset. •...
  • Page 101 1 October, 1999 PRINTER ENGINE SERVICE MODE Menu Level Function Settings Level 1 Level 2 Description Engine Displays the firmware ROM Firm number. Duplex Displays the Firm ROM Number version Finisher Firm Serial Number Use to input the machine serial Engine Programming number.

  • Page 102: Input Check Table

    PRINTER ENGINE SERVICE MODE 1 October, 1999 4.4.3 INPUT CHECK TABLE Reading Number Description Not used Front cover safety switch Closed Opened Front cover safety switch - LD5 V Closed Opened Right cover switch Closed Opened Right lower cover switch Closed Opened Tray Cover (optional paper tray unit)
  • Page 103 1 October, 1999 PRINTER ENGINE SERVICE MODE Reading Number Description Lower paper end sensor Paper not detected Paper detected (Optional paper tray unit) Upper paper size switch See Table 1 (for paper tray unit) (Optional paper tray unit or LCT) 01: A4, 02: LT (for LCT - there is no sensor) Lower paper size switch...
  • Page 104 PRINTER ENGINE SERVICE MODE 1 October, 1999 Reading Number Description LD error No error Error 83 - 99 Not used Table 1: Paper Size Switch (Main Unit) S W N o . 1 G038M503.WMF Number SW 1 SW 2 SW 3 SW 4 SP Value Paper Size...
  • Page 105 1 October, 1999 PRINTER ENGINE SERVICE MODE Table 4: Paper Tray Unit Set Sensor Number SP Value Unit Installed None Paper tray unit (2 trays) 4-19...

  • Page 106: Output Check Table

    PRINTER ENGINE SERVICE MODE 1 October, 1999 4.4.4 OUTPUT CHECK TABLE NOTE: Pull out the tray before performing the output checks from 29 to 32. Number Description Not used Main motor (forward) Main motor (Reverse) Do not use this mode. Registration clutch Not used Toner supply motor...
  • Page 107 1 October, 1999 PRINTER ENGINE SERVICE MODE Number Description Not used Bridge cooling fan motor (Optional bridge unit) Bridge unit drive motor (Optional bridge unit) Junction gate solenoid (Optional bridge unit) 48 - 50 Not used Polygonal mirror motor Polygonal mirror motor and laser diode Laser diode - Do not use this mode 54 - 79 Not used Duplex unit free run (without paper)

  • Page 108: Engine Board Program Download

    PRINTER ENGINE SERVICE MODE 1 October, 1999 4.4.5 ENGINE BOARD PROGRAM DOWNLOAD The engine board program software can be upgraded using the flash memory card. G038R765.WMF G038M505.WMF 1. Turn off the main switch. 2. Remove the controller cover [A] and the rear cover [B]. 3.

  • Page 109: Service Tools

    1 October, 1999 SERVICE TOOLS 4.5 SERVICE TOOLS 4.5.1 SERVICE TOOL MENU Service Mode (Service Tool) Title Description HDD Test Verifies the FAT and directory entries on the HDD. HDD format Partitions and formats the HDD. NIB read/write Backs up the NIB NVRAM and restores it. NOTE: Items related to the HDD will not be displayed if the HDD is not installed.

  • Page 110: Hdd Format

    SERVICE TOOLS 1 October, 1999 4.5.3 HDD FORMAT This creates partitions on the HDD and formats them. 1. Enter the SP mode, and select “3. Service Tool”. 2. Select “HDD Format”, then press [Enter]. 3. Check the HDD capacity, then press [Enter]. 4.
  • Page 111 1 October, 1999 SERVICE TOOLS 6. Turn off the machine and replace the NIB. 7. Turn on the machine, and ensure that the target NIB is correctly installed. 8. Enter the SP mode, and select “3. Service Tool”. 9. Select “NIB read/write”, then press [Enter]. 10.

  • Page 112: Controller Firmware Update

    CONTROLLER FIRMWARE UPDATE 1 October, 1999 4.6 CONTROLLER FIRMWARE UPDATE 4.6.1 FIRMWARE DOWNLOAD This procedure is for upgrading the firmware for the controller, the network interface board, and the PS3 DIMM module. To update the PS3 firmware, the target DIMM module must already contain a version of the PS3 firmware.

  • Page 113: Error Recovery

    1 October, 1999 CONTROLLER FIRMWARE UPDATE 4.6.2 ERROR RECOVERY CONTROLLER If the controller does not start up after a failed firmware download, use the following procedure. This procedure will force the controller to boot from the IC card. 1. Prepare an IC card with the required controller firmware version on it. 2.

  • Page 114: Power-On Self Test

    POWER-ON SELF TEST 1 October, 1999 4.7 POWER-ON SELF TEST 4.7.1 PARALLEL LOOP-BACK TEST This tests the standard IEEE1284 parallel interface using a loop-back connector. The loop-back connector (P/#: G0219350) is required for this test. NOTE: Do not use the loop-back connector (P/#: G0109350). This loop-back connector causes the “Timeout error”.

  • Page 115: Preventive Maintenance

    1 October, 1999 USER MAINTENANCE 5. PREVENTIVE MAINTENANCE 5.1 USER MAINTENANCE All PM items can be done by the customer, using the maintenance kit. The maintenance kit contains the following items. When the maintenance counter reaches 120K, "Replace Maintenance Kit" is displayed.

  • Page 116: Service Maintenance

    SERVICE MAINTENANCE 1 October, 1999 5.2 SERVICE MAINTENANCE 5.2.1 PM TABLE The following tables describe the PM items when the PM is done by service. NOTE: Make sure to clear the PM (fusing) counter by the SP mode (Service Menu 2: FuserCount clr) when you replace the fusing parts. Cross-reference: Section 4.2 Service Program Mode L: Lubricate, I: Inspect Symbol key: C: Clean, R: Replace,...
  • Page 117 1 October, 1999 SERVICE MAINTENANCE 120K NOTE Paper Feed Roller Pick-up Roller Separation Roller Transport Rollers Clean with water Bottom Plate Pad Clean with water Relay Clutch Replace if necessary Paper Feed Clutch Replace if necessary 120K NOTE Finisher Rollers Clean with water or alcohol.

  • Page 118: Replacement And Adjustment

    1 October, 1999 LASER UNIT 6. REPLACEMENT AND ADJUSTMENT 6.1 LASER UNIT ø WARNING Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. 6.1.1 CAUTION DECAL LOCATIONS Caution decal is located in the laser section as shown below.

  • Page 119: Laser Unit

    LASER UNIT 1 October, 1999 6.1.2 LASER UNIT G038R161.WMF G038R162.WMF ø WARNING Turn off the main switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. 1. Remove the optional finisher and/or bridge unit, if these units have been installed.
  • Page 120 1 October, 1999 LASER UNIT G038R503.WMF 6. Release the lock lever [A] and slide out the toner bottle [B]. 7. Remove the laser unit [C] (2 screws, 2 connectors).

  • Page 121: Polygonal Mirror Motor

    LASER UNIT 1 October, 1999 6.1.3 POLYGONAL MIRROR MOTOR G038R504.WMF NOTE: When performing the following steps, take care not to damage the mirror surface with the tip of the screw driver. Also, do not touch the mirror surface with bear fingers. 1.

  • Page 122: Laser Synchronization Detector

    1 October, 1999 LASER UNIT 6.1.5 LASER SYNCHRONIZATION DETECTOR G038R506.WMF G038R507.WMF 1. Remove the laser unit. (See Laser Unit Replacement). 2. Remove the heat sink [A] (4 screws). 3. Remove the laser upper cover [B] (3 screws). 4. Remove the holding bracket [C] (1 screw). 5.

  • Page 123: Photoconductor Unit (Pcu)

    PHOTOCONDUCTOR UNIT (PCU) 1 October, 1999 6.2 PHOTOCONDUCTOR UNIT (PCU) 6.2.1 PCU G038R569.WMF 1. Open the right cover [A] and front cover [B]. 2. Pull the PCU [C] out slightly while pushing the release lever [D]. NOTE: Do not touch the drum surface with bare hands.

  • Page 124: Transfer Unit

    1 October, 1999 TRANSFER UNIT 6.3 TRANSFER UNIT 6.3.1 TRANSFER ROLLER UNIT G038R570.WMF 1. Open the right cover [A]. 2. Remove the transfer roller unit [B] (1 hook). NOTE: Do not touch the transfer roller surface.

  • Page 125: Id Sensor

    ID SENSOR 1 October, 1999 6.4 ID SENSOR G038R261.WMF G038R502.WMF 1. Remove the optional duplex unit, if it has been installed. 2. Open the right cover [A]. 3. Lift up the right cover band [B] and slide it to the left. 4.

  • Page 126: Paper Exit

    1 October, 1999 PAPAPER EXIT 6.5 PAPER EXIT 6.5.1 PAPER EXIT AND OVERFLOW SENSORS G038R661.WMF 1. Remove the optional 4-bin mailbox unit if it has been installed. 2. Open the right cover [A]. 3. Open the paper exit guide cover [B] and remove the upper cover [C] (1 screw). 4.

  • Page 127: Paper Feed And Registration

    PAPER FEED AND REGISTRATION 1 October, 1999 6.6 PAPER FEED AND REGISTRATION 6.6.1 PAPER LIFT MOTORS G038R765.WMF G038R768.WMF 1. Disconnect the interface harness of the optional paper tray unit of LCT. 2. Remove the controller cover [A] (6 screws). 3. Remove the rear cover [B] (5 screws). 4.

  • Page 128: Registration Clutch

    1 October, 1999 PAPER FEED AND REGISTRATION 6.6.2 REGISTRATION CLUTCH G038R771.WMF 1. Remove the rear cover. (See Paper Lift Motors.) 2. Remove the fly-wheels [A] (1 screw). 3. Remove the registration clutch [B] (1 connector, 1 E-ring). 6.6.3 PAPER FEED CLUTCHES G038R772.WMF 1.

  • Page 129: Upper Paper Transport Clutch

    PAPER FEED AND REGISTRATION 1 October, 1999 6.6.4 UPPER PAPER TRANSPORT CLUTCH G038R774.WMF 1. Remove the rear cover. (See Paper Lift Motors.) 2. Remove the connector bracket [A] (2 screws). NOTE: The connector bracket also functions to hold the registration clutch [B] in place.

  • Page 130: Registration Sensor

    1 October, 1999 PAPER FEED AND REGISTRATION 6.6.6 REGISTRATION SENSOR G038R901.WMF 1. Remove the right cover. (See Image Density Sensor.) 2. Remove the registration guide plate [A] (2 screws). 3. Remove the paper support roller [B] (2 snap rings, 2 bushings). 4.

  • Page 131: Upper Relay Sensor

    PAPER FEED AND REGISTRATION 1 October, 1999 6.6.7 UPPER RELAY SENSOR G038R900.WMF G038R519.WMF 1. Remove the optional duplex and by-pass tray unit, if these unit have been installed. 2. Remove the right cover. (See ID Sensor.) 3. Remove the right lower cover [A] (2 screws). 4.

  • Page 132: Lower Relay Sensor

    1 October, 1999 PAPER FEED AND REGISTRATION 6.6.8 LOWER RELAY SENSOR G038R520.WMF 1. Open the paper transport cover [A] (1 clip). 2. Remove the guide plate [B]. 3. Remove the transport stay [C] (2 screws). 4. Remove the sensor bracket [D] (1 screw). 5.

  • Page 133: Upper Paper Size Sensor

    PAPER FEED AND REGISTRATION 1 October, 1999 6.6.9 UPPER PAPER SIZE SENSOR G038R521.WMF 1. Pull out the paper tray. 2. Remove the optional duplex unit and by-pass tray unit, if these units have been installed. 3. Remove the right lower cover [A]. 4.

  • Page 134: Lower Paper Size Sensor/Special Paper Sensor

    1 October, 1999 PAPER FEED AND REGISTRATION 6.6.10 LOWER PAPER SIZE SENSOR/SPECIAL PAPER SENSOR G038R522.WMF 1. Pull out the paper tray. 2. Remove the sensor bracket [A] (1 screw). 3. Remove the lower paper size sensor [B] (1 connector). 4. Remove the special paper sensor [C] (1 connector). 6-17...

  • Page 135: Feed Rollers

    PAPER FEED AND REGISTRATION 1 October, 1999 6.6.11 FEED ROLLERS G038R568.WMF 1. Remove the paper tray [A]. 2. Pull the lever [B]. 3. Replace the feed roller [C]. NOTE: Do not touch the roller surface with bare hands. After reinstalling the feed roller, return the lever [B]. 6-18...

  • Page 136: Paper End Sensor (1St And 2Nd Paper Feed Trays)

    1 October, 1999 PAPER FEED AND REGISTRATION 6.6.12 PAPER END SENSOR (1ST AND 2ND PAPER FEED TRAYS) G038R524.WMF Remove the paper tray [A]. Remove the sensor bracket [B] (1 screw, 1 connector). Remove the paper end sensor [C]. 6-19...

  • Page 137: Fusing

    FUSING 1 October, 1999 6.7 FUSING 6.7.1 FUSING UNIT ø CAUTION Allow time for the unit to cool before doing the following procedure. G038R561.WMF 1. Release the duplex unit, if it has been installed, and open the right cover. 2. Remove the fusing unit [A] (2 screws). 6.7.2 THERMISTOR G038R562.WMF 1.

  • Page 138: Thermofuse

    1 October, 1999 FUSING 6.7.3 THERMOFUSE G038R563.WMF G038R564.WMF 1. Remove the fusing unit. (See Fusing Unit.) 2. Remove the fusing upper cover [A] (4 screws). 3. Remove the pressure springs [B]. 4. Remove the hot roller stripper bracket [C] (3 screws). 5.

  • Page 139: Hot Roller And Fusing Lamp

    FUSING 1 October, 1999 6.7.4 HOT ROLLER AND FUSING LAMP G038R565.WMF G038R566.WMF 1. Remove the fusing unit. (See Fusing Unit.) 2. Remove the fusing upper cover. (See Thermofuse.) 3. Remove the pressure springs. (See Thermofuse.) 4. Remove the hot roller stripper bracket. (See Thermofuse.) 5.

  • Page 140: Pressure Roller/Cleaning Roller

    1 October, 1999 FUSING 6.7.5 PRESSURE ROLLER/CLEANING ROLLER G038R567.WMF 1. Remove the fusing lamp and hot roller assembly. (See Hot Roller and Fusing Lamp.) 2. Replace the pressure roller [A] (1 E-ring, 2 bushings, 1 spring). 3. Replace the cleaning roller [B]. NOTE: Do not touch the surface of the rollers.

  • Page 141: Pcbs And Motors

    PCBS AND MOTORS 1 October, 1999 6.8 PCBS AND MOTORS 6.8.1 PSU G038R761.WMF G038R902.WMF 1. Remove the left cover [A] (6 screws). 2. Remove the bracket [B] (3 screws). 3. 230 V machine only: Remove the coil [C] (1 screw, 1 connector). 4.

  • Page 142: Engine Board

    1 October, 1999 PCBS AND MOTORS 6.8.2 ENGINE BOARD G038R765.WMF G038R766.WMF G038R767.WMF 1. Disconnect the interface harness for the optional paper tray unit or LCT. 2. Remove the controller cover [A] (6 screws). 3. Remove the rear cover [B] (5 screws). 4.

  • Page 143: Printer Controller / Nib

    PCBS AND MOTORS 1 October, 1999 6.8.3 PRINTER CONTROLLER / NIB G038R510.WMF Printer Controller 1. Remove the controller cover [A] (6 screws). 2. Remove the network interface board [B] (2 screws). 3. Remove the printer controller board [C] (6 screws, 1 connector). 4.

  • Page 144: High Voltage Supply Board

    1 October, 1999 PCBS AND MOTORS 6.8.4 HIGH VOLTAGE SUPPLY BOARD G038R769.WMF 1. Remove the rear cover. (See Engine Board.) 2. Remove the fly-wheels [A] (1 screw). 3. Remove the high voltage supply board [B] (5 connectors, 2 screws, 2 locking supports).

  • Page 145: Toner Bottle Motor

    PCBS AND MOTORS 1 October, 1999 6.8.6 TONER BOTTLE MOTOR G038R571.WMF G038R777.WMF 1. Remove the optional finisher and/or bridge unit, if these units have been installed. 2. Remove the front cover [A] (2 pins). 3. Swing up the toner bottle lever. Then, remove the inner cover [B] (5 screws). 4.

  • Page 146: Troubleshooting

    1 October, 1999 SERVICE CALL CONDITIONS 7. TROUBLESHOOTING 7.1 SERVICE CALL CONDITIONS 7.1.1 PRINTER ENGINE SC CODES SUMMARY There are 3 levels of service call conditions. Level Definition To prevent the machine from being damaged, the SC can only be reset by a service representative (see the note below this table).

  • Page 147: Printer Engine Sc Codes

    SERVICE CALL CONDITIONS 1 October, 1999 7.1.2 PRINTER ENGINE SC CODES SC302: High voltage power supply error Definition: [B] A charge roller current leak signal is detected. Possible causes • Charge roller damaged • Charge high voltage supply board defective •...
  • Page 148 1 October, 1999 SERVICE CALL CONDITIONS SC324: LD drive current over Definition: [B] The LD drive board applies more than 100 mA to the LD. Possible causes: • LD unit defective (not enough power, due to aging) • Poor connection between the LD unit and the engine board •...
  • Page 149 SERVICE CALL CONDITIONS 1 October, 1999 SC401/402: Transfer roller leak error 1/2 Definition: [B] Transfer current leak signal is detected. Transfer current feedback signal is not detected. Possible causes: • High voltage supply board defective • Poor connection of the PCU •...
  • Page 150 1 October, 1999 SERVICE CALL CONDITIONS SC506: Paper tray motor lock (optional paper tray unit) Definition: [C] A motor lock signal is not detected for more than 1.5 s or the lock signal is not detected for more than 1.0 s during rotation. Possible causes: •...
  • Page 151 SERVICE CALL CONDITIONS 1 October, 1999 SC541: Fusing temperature warm-up error Definition: [A] The fusing temperature detected by the thermistor was below 13 °C for 10 seconds Possible causes: • Fusing thermistor defective or out of position • Fusing lamp open •...
  • Page 152 1 October, 1999 SERVICE CALL CONDITIONS SC546: Unstable fusing temperature Definition: [A] Fusing temperature more than 60 °C: The fusing temperature does not rise 2°C or more within 6 seconds after the fusing lamp has been on. Fusing temperature 60 °C or less: The fusing temperature does not rise 2°C or more during a 6 second interval (the 6 s timer starts 14 s after the fusing lamp turned on).
  • Page 153 SERVICE CALL CONDITIONS 1 October, 1999 SC692: Communication error between the engine board and the printer controller Definition: [B] The engine board cannot communicate with the printer controller properly. Possible causes: • Poor connection between the engine board and the printer controller board. •...
  • Page 154 1 October, 1999 SERVICE CALL CONDITIONS SC726: Finisher shift motor error Definition: [B] Tray shift is not detected within a certain period after the shift motor is turned on. Possible causes: • Shift motor defective • Shift tray half-turn sensor defective SC730: Finisher stapler position motor error Definition: [B] 1) The stapler does not return to its home position within a certain period after...
  • Page 155 SERVICE CALL CONDITIONS 1 October, 1999 SC735: Finisher exit guide motor error Definition: [B] The exit guide plate open sensor or exit guide plate HP sensor does not activate within a certain time after the exit guide plate motor turned on. Possible causes: •...

  • Page 156: Printer Controller Error

    1 October, 1999 PRINTER CONTROLLER ERROR 7.2 PRINTER CONTROLLER ERROR 7.2.1 ERROR CODES Code Description Required Action 0201 On-board SDRAM read/verify Replace the controller if this error is failed. frequent. 0301 SDRAM DIMM (option) Replace the SDRAM DIMM if this error is read/verify failed.

  • Page 157: Controller Led Display

    CONTROLLER LED DISPLAY 1 October, 1999 7.3 CONTROLLER LED DISPLAY 7.3.1 LOCATION The controller uses two LEDs to display error status even while the LCD message is not active. L E D 2 L E D 1 G038T501.WMF 7.3.2 FATAL ERROR If the controller detected a fatal error during the power-on self-test, it uses two LEDs to notify the cause of the error.
  • Page 158 1 October, 1999 CONTROLLER LED DISPLAY SDRAM Error LED2 (Upper) LED1 (Lower) O F F G038T503.WMF Turn off the machine and turn it back on. If the controller detects the same error, replace the controller. CPU Error LED2 (Upper) LED1 (Lower) O F F G038T504.WMF...
  • Page 159 CONTROLLER LED DISPLAY 1 October, 1999 APIP Error LED2 (Upper) LED1 (Lower) O F F G038T507.WMF Turn off the machine, check the connection to the engine board, then turn on the machine. If the controller detects the same error, replace the controller, or engine board.

  • Page 160: Electrical Component Defects

    1 October, 1999 ELECTRICAL COMPONENT DEFECTS 7.4 ELECTRICAL COMPONENT DEFECTS 7.4.1 SENSORS NOTE: The CN numbers describes the connector number on the engine board. Component Condition Symptom (Symbol) Open SC390 is displayed Toner Density 302-3 Shorted The Paper End indicator lights even if Open paper is placed in the 1st paper tray.
  • Page 161 ELECTRICAL COMPONENT DEFECTS 1 October, 1999 Component Condition Symptom (Symbol) Open The CPU cannot determine the paper 1st Paper 308-2 near-end condition properly. Height - 1 Shorted Open The CPU cannot determine the paper 1st Paper 308-5 near-end condition properly. Height - 2 Shorted Open...

  • Page 162: Switches

    1 October, 1999 ELECTRICAL COMPONENT DEFECTS 7.4.2 SWITCHES Component Condition Symptom (Symbol) Open The machine does not turn on. 281-1,2 Main (PSU) Shorted The machine does not turn off. The Cover Open indicator is not lit even Open if the right upper cover is opened. Right Upper 324-8 Cover...

  • Page 163: Blown Fuse Conditions

    BLOWN FUSE CONDITIONS 1 October, 1999 7.5 BLOWN FUSE CONDITIONS Rating Symptom when turning on the Fuse main switch 115 V 220 - 240 V Power Supply Board 15 A/250 V ---- No response 8 A/125 V 3.15 A/250 V No response 3.15 A/125 V 3.15 A/250V...
  • Page 164 Paper Tray Unit (A861) Engine Baord (PCB 1) CN231 CN232 CN105 CN101 (30P) CN233 CN234 CN220 Optional Duplex Unit (G529) Optional Interchange Unit (G531) Optional CN8-12 CN503-1 CN501-12 By-pass Tray [ 5] IN 1 [24/0] A1 Transport [24/0] /A1 Motor +24V +24V [24/0] B1...
  • Page 165 ,QGH[ý1Rï 3ýWRý3 35,17(5ýõ*íêåôý(/(&75,&$/ý&20321(17ý/$<287 6\PERO 1DPH 0RWRUV 0ì 3RO\JRQDOý0LUURU ì %ê 0ë 0DLQý0RWRU ëè *ë 0ê ([KDXVWý)DQ éê %ì 0é ìVWý3DSHUý/LIW êæ %ì 0è ëQGý3DSHUý/LIW êè %ì 0ç 7RQHUý6XSSO\ ëé %ì ëé é éí ê 0DJQHWLFý&OXWFKHV ë è 0&ì ìVWý3DSHUý)HHG ëå &ì...

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