Ricoh G035 Service Manual

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G035

SERVICE MANUAL

000872MIU

RICOH GROUP COMPANIES

Table of Contents

Troubleshooting

Summary of Contents for Ricoh G035

Page 1 G035 SERVICE MANUAL 000872MIU RICOH GROUP COMPANIES...
Page 3 ® ® RICOH GROUP COMPANIES...
Page 5 G035 SERVICE MANUAL MIU000872...
Page 7 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
Page 9 WARNING The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.
Page 11 LEGEND PRODUCT CODE COMPANY GESTETNER RICOH SAVIN G035 P7045 AP4500 SLP45 DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 10/99 Original Printing 08/2000 A683, G909/G912, A688, A681, A697 Addition...
Page 13: Table Of Contents
2.3 PHOTOCONDUCTOR UNIT (PCU) ............2-16 2.3.1 OVERVIEW ..................2-16 2.3.2 DRIVE MECHANISM..............2-17 2.4 DRUM CHARGE ..................2-18 2.4.1 OVERVIEW ..................2-18 2.4.2 CHARGE ROLLER VOLTAGE CORRECTION......2-19 2.4.3 ID SENSOR PATTERN PRODUCTION TIMING ......2-21 2.4.4 DRUM CHARGE ROLLER CLEANING.......... 2-21 G035...
Page 14 2.10.6 FUSING TEMPERATURE CONTROL ......... 2-58 2.10.7 OVERHEAT PROTECTION ............2-59 2.11 DUPLEX....................2-60 2.11.1 BASIC OPERATION..............2-60 2.11.2 FEED IN AND EXIT MECHANISM ..........2-62 2.12 ENERGY SAVER MODE ..............2-63 2.13 NEW UNIT DETECTION MECHANISM ..........2-64 G035...
Page 15 3.10.1 ACCESSORY CHECK ..............3-40 3.10.2 INSTALLATION PROCEDURE ............ 3-41 3.11 DRAM SIMM ..................3-44 3.11.1 ....................... 3-44 3.11.2 ....................... 3-44 SERVICE TABLES 4. SERVICE TABLES ..............4-1 4.1 GENERAL CAUTIONS................4-1 4.1.1 DRUM....................4-1 4.1.2 TRANSFER BELT UNIT..............4-2 G035...
Page 16 4.8.1 SPECIAL TOOLS ................4-37 4.8.2 LUBRICANTS................. 4-37 PREVENTIVE MAINTENANCE 5. PREVENTIVE MAINTENANCE SCHEDULE ....... 5-1 5.1 PM TABLE ....................5-1 REPLACEMENT AND ADJUSTMENT 6. REPLACEMENT AND ADJUSTMENT ........6-1 6.1 LASER UNIT ..................... 6-1 6.1.1 CAUTION DECAL LOCATIONS............6-1 G035...
Page 17 6.8.3 RELAY/UPPER PAPER FEED/LOWER PAPER FEED CLUTCHES ..................6-33 6.8.4 UPPER PAPER FEED UNIT ............6-34 6.8.5 LOWER PAPER FEED UNIT ............6-35 6.8.6 PAPER END/PAPER HEIGHT/RELAY SENSORS ......6-36 6.8.7 REGISTRATION SENSOR ............6-37 6.9 FUSING....................6-39 6.9.1 FUSING UNIT ................6-39 G035...
Page 18 1.5 DRIVE LAYOUT ..................8-5 2. DETAILED DESCRIPTIONS............8-6 2.1 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM.... 8-6 2.2 PAPER LIFT MECHANISM............... 8-7 2.3 PAPER END DETECTION................ 8-9 2.4 PAPER HEIGHT DETECTION ..............8-10 2.5 PAPER SIZE DETECTION ..............8-11 G035...
Page 19 4.2.3 RESOURCE CONFLICT ..............9-8 4.3 INVALID DYNAMIC LINK CALL FROM SWAPENUM ERROR....9-9 4.4 SWAPFTL PROBLEM WITH NOTEBOOK COMPUTERS......9-9 4.4.1 WINDOWS AND PC CARD DRIVER VERSION ....... 9-9 4.4.2 SYSTEM SUMMERY ................ 9-9 4.5 COMPLETE UNINSTALL................. 9-10 G035...
Page 20 3.4 FUSES ....................11-9 4. REPLACEMENT AND ADJUSTMENT ........11-10 4.1 COVER REPLACEMENT..............11-10 Tray Cover..................11-10 Front Cover..................11-10 Rear Cover ..................11-10 Right Lower Cover ................11-10 Upper Cover ..................11-10 4.2 ROLLER REPLACEMENT ..............11-11 G035 viii...
Page 21 1.2 BRIDGE UNIT FOR MAILBOX (G912)..........12-15 1.2.1 ACCESSORY CHECK ..............12-15 1.2.2 INSTALLATION PROCEDURE ............ 12-16 4. REPLACEMENT AND ADJUSTMENT ........12-21 4.1 PROOF TRAY UNIT................12-21 4.1.1 PROOF TRAY SENSOR AND PAPER OVERFLOW SENSORS ............... 12-21 4.1.2 PROOF TRANSPORT UNIT ............12-21 G035...
Page 22 1.3 ELECTRICAL COMPONENT LAYOUT........... 14-3 1.4 ELECTRICAL COMPONENT DESCRIPTIONS ........14-4 1.5 DRIVE LAYOUT ..................14-6 2. DETAILED DESCRIPTIONS............14-7 2.1 JUNCTION GATE MECHANISM............. 14-7 Staple mode ..................14-7 No staple mode .................. 14-7 2.2 JOGGER UNIT PAPER POSITIONING MECHANISM ......14-8 G035...
Page 23 1.4 ELECTRICAL COMPONENT DESCRIPTION ........15-5 1.5 DRIVE LAYOUT ..................15-7 2. DETAILED DESCRIPTIONS............15-8 2.1 TRAY AND STAPLER JUNCTION GATE MECHANISM ......15-8 Normal mode ..................15-8 Sort/stack mode.................. 15-8 Staple mode ..................15-8 2.2 JOGGER UNIT PAPER POSITIONING MECHANISM ......15-9 G035...
Page 24 4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR...... 15-27 Upper Tray Paper Limit Sensor ............15-27 Upper Tray Exit Sensor ..............15-27 4.4.3 SHIFT TRAY EXIT SENSOR ............15-28 4.4.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSOR..15-29 Entrance Sensor................15-29 G035...
Page 25 4.6 PUNCH POSITION ADJUSTMENT ............15-32 Right to left ..................15-32 Front to rear..................15-32 4.7 STACK FEED-OUT MOTOR SPEED ADJUSTMENT......15-33 4.8 ROM HISTORY ..................15-34 APPENDIX APPENDIX 1..............APPENDIX-1 1.1 JAM HISTORY ................APPENDIX-1 1.1.1 JAM CONDITION TABLE..........APPENDIX-1 xiii G035...
Page 27 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the printer power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components.
Page 28: Laser Safety
NOTES SAFETY AND ECOLOGICAL 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.
Page 29 OVERALL MACHINE INFORMATION G035 SWAPBOX AND SWAPFTL INSTALLATION MANUAL DETAILED SECTION DESCRIPTIONS G035 SWAPFTL BINARY UTILITY OPERATION MANUAL INSTALLATION PROCEDURE G035 LARGE CAPACITY TRAY (A683) SERVICE TABLES G035 NINE-TRAY MAILBOX AND BRIDGE UNIT (G909/G912) PREVENTIVE MAINTENANCE G035 BRIDGE UNIT (A688)
Page 31: Overall Machine Information
OVERALL MACHINE INFORMATION...
Page 33: Specifications
8 MB (Standard) 2 DRAM SIMM slots (up to 64 MB) Maximum Total: Up to 72 MB Printer Driver: PCL5e Printer Driver for Windows 3.1/95/98/NT PCL6 Printer Driver for Windows 3.1/95/98/NT PS3 Printer Driver for Windows 3.1/95/98/NT and Macintosh G035...
Page 34 50 sheets (up to 5.5 mm, 0.2") LCT: 1,500 sheets Tray Capacity: A4/11" x 8.5": 500 sheets A3/B4/8.5" x 14"/11" x 17": 250 sheets Standard tray Toner Replenishment: Cartridge exchange (700 g/cartridge) ⇒ Toner Yield: 30 k sheets printed (A4 sideways, 5% full black) G035...
Page 35 Less than 1.0 kW ⇒ Energy Saver Mode Less than 45 W/h Noise Emission: Mainframe Only System Sound Power Level Printing 70 dB(A) 74 dB(A) Stand-by 42 dB(A) — NOTE: The above measurements were made in accordance with ISO 7779. G035...
Page 36: Network Interface Board
• MAP (Management Access Protocol) Utility Software: • IPX peer-to-peer printing • IP peer-to-peer printing • BOOTP (16-bit and 32-bit) • NetWare setup utility • Built-in web server Other: • Built-in Telnet server • Firmware update over an IPX or IP network G035...
Page 37: Paper Exit Tray Selection
Bridge unit & Finisher (1,000-sheet) Internal Tray [A] Bridge unit & Finisher (3,000-sheet) External Tray [B]: The finisher upper tray Bridge unit and Mailbox [C]: The mail box tray Bridge unit and Mailbox and Finisher 3000 [C]: The mail box tray G035...
Page 38: Machine Configuration
MACHINE CONFIGURATION 1.3 MACHINE CONFIGURATION 1.3.1 SYSTEM COMPONENTS G035V502.WMF Version Item Machine Code Printer G035 LCT (Option) A683 RAM SIMM (Option) — Hard Disk (Option) A853 Paper Tray Unit (Option) G520 3,000-sheet Finisher (Option) A697 Printer 1,000-sheet Finisher (Option) A681...
Page 39: Installable Option Table
Requires the paper tray unit and bridge unit. 3,000-sheet Finisher Requires the paper tray unit and bridge unit. Punch Unit Requires the 3000-sheet finisher. Mailbox Requires the bridge unit and the paper tray unit Mailbox Bridge Unit Requires the Mailbox G035...
Page 40: Mechanical Component Layout
27. Charge roller 12. Transfer belt 28. Fθ mirror 13. Registration roller 29. Polygonal mirror motor 14. Lower transport roller 30. Laser unit 15. Exit sensor 31. Barrel toroidal lens (BTL) 16. Paper end sensor 32. Toner supply bottle holder G035...
Page 41: Paper Path
PAPER PATH 1.5 PAPER PATH G035V500.WMF 1. Bridge unit 2. Duplex unit 3. By-pass feed unit 4. LCT 5. Paper tray unit 6. Mailbox 7. 3,000-sheet finisher 8. Mailbox bridge unit G035...
Page 42: Electrical Component Descriptions
Drives the upper and lower transport rollers. Sensors LD Unit Home Informs the CPU when the LD unit is at the Position home position. Toner Density (TD) Detects the amount of toner inside the development unit. Paper Exit Detects misfeeds. G035 1-10...
Page 43 Detects whether the cover guide is opened. Paper End (By-pass) Informs the copier when the by-pass tray runs out of paper. Paper Size Sensor Detects the paper width. Board (By-pass) Switches Right Lower Cover Detects whether the right lower cover is open or closed. 1-11 G035...
Page 44 Fusing Monitors the temperature at the central area of the hot roller. Thermofuse Fusing Provides back up overheat protection in the fusing unit. Other Laser Detects the laser beam at the start of the Synchronization main scan. Detector G035 1-12...
Page 45: Drive Layout
DRIVE LAYOUT 1.7 DRIVE LAYOUT PCU Drive Fusing Transfer Development G035V108.WMF 1. Transfer belt clutch 4. Lower paper feed clutch 2. Registration clutch 5. Relay clutch 3. Upper paper feed clutch 6. Main motor 1-13 G035...
Page 46 DRIVE LAYOUT Duplex G035V002.WMF 1. Inverter roller 4. Transport motor 2. Inverter motor 5. Lower transport roller 3. Upper transport roller G035 1-14...
Page 47: Print Process
PRINT PROCESS PRINT PROCESS 1.8.1 OVERVIEW G035V101.WMF 1-15 G035...
Page 48 7. CLEANING The drum cleaning blade removes any toner remaining on the drum surface after the image is transferred to the paper. 8. QUENCHING The light from the quenching lamp electrically neutralizes the charge on the drum surface. G035 1-16...
Page 49: Board Structure
Mirror Motor LD Posi- High LD H.P Bridge Unit tioning Operation Voltage Sensor Motor Panel Supply Paper Sensors Feed Main Finisher/ Sensors Fans Clutches Duplex Controller Motor Mailbox Clutches (PFB) Paper Tray Unit : Standard : Option G035V501.WMF 1-17 G035...
Page 50: Descriptions
7. IOB (Input/Output Board) The IOB handles the following functions. • Drive control for the sensors, motors, and solenoids of the printer • PWM control for high voltage supply board • Serial interface with peripherals • Fusing control G035 1-18...
Page 51: Detailed Descriptions
DETAILED DESCRIPTIONS...
Page 53: Detailed Section Descriptions
CPU and the co-processor. 2. Co-processor The co-processor performs the following functions. • ROM control • I/O control • DRAM control • Printer video interface • Printer communication interface • IEEE 1284 compliant bi-directional parallel port interface • Interrupt control G035...
Page 54 This HDD interface is provided to support storage of fonts downloaded from a 7. IC Card Interface The flash memory card for updating the controller and PostScript firmware is connected to this flash memory card slot. 8. Power-on Self-diagnostic When the controller is turned on, the controller performs a self-diagnostic test. G035...
Page 55: Image Printing
LD unit through the IPU on the BICU board. At that time, the data is also sent to the hard disk for multiple printing and sorting, as well as backup in case of paper jams. G035...
Page 56: Image Data Processing
Toner saving is done by reducing the laser power, not by varying the development bias. In toner saving mode, the image data is filtered through a matrix. Passing through the filter uses less toner to create the latent image on the drum, and black areas print as gray. G035...
Page 57: Features
2) Proof print is available with PCL drivers, Windows 95/98 PostScript drivers, and Macintosh PostScript drivers (with the Proof Print plug-in). The PostScript drivers for Windows 3.x and Windows NT 4.0 do not support the proof print function. G035...
Page 58 There is a limit for the number of sheets that each finisher can staple. If a job that specifies stapling has more than this number of sheets, it will not be stapled. G035...
Page 59 If any errors are detected, the operation panel displays an error message. Test Items Devices always tested • Co-processor • Flash ROM • Resident RAM • NVRAM • Engine I/F • Network interface board I/F Devices tested when they are installed • DRAM SIMM • HDD I/F G035...
Page 60: Hard Disk
If you press the “Ignore” button, the machine determines that there is no optional printer hard disk. Engine HDD (Standard) The hard disk in the main machine, used for printer functions, has two partitions: for printer and proof print files. G035...
Page 61: Paper Overflow Detection
250 sheets. If a print job of more than 250 sheets is executed, the machine will print up to 250 pages, then the print job stops. Once the output stack is removed, the printing job automatically continues from where it let off. G035...
Page 62: Laser Exposure
In previous models, the mirror speed increased for higher resolutions. However, for this machine, the line cycle (time taken to output one main scan line of data to the laser diode) also varies, so a simple relationship does not exist between the resolution and the mirror speed. G035 2-10...
Page 63: Optical Path
F-theta mirror [E], mirror [F], and BTL (barrel toroidal lens) [G]. Then these laser beams go to the drum through the toner shield glass [H]. The laser synchronizing detector [I] determines the main scan starting position. 2-11 G035...
Page 64: Auto Power Control (Apc)
This auto power control is done just after the machine is turned on and during printing while the laser diode is active. The reference levels are adjusted on the production line. Do not touch the variable resistors on the LDDR in the field. G035 2-12...
Page 65: Dual Beam Writing
0.06 mm (at 400 dpi) in the sub-scan direction (see the next page). The reason for the two-mm difference in the main scan direction is so that the machine can detect a laser synchronization signal for each beam. 2-13 G035...
Page 66: Laser Beam Pitch Change Mechanism
However, when the number of times that the resolution has changed reaches 100 times, the LD unit moves to the home position (the home position sensor activates), and then it moves to the proper position. This recalibrates the LD unit positioning mechanism. G035 2-14...
Page 67: Ld Safety Switches
These four switches are in series on the LD5 V line that comes from the power supply unit (PSU) through the BICU board. When opening either the front or upper right covers, the power supply to the laser diode is interrupted. 2-15 G035...
Page 68: Photoconductor Unit (Pcu)
(OPC) drum (diameter: 60 mm) is used in this machine. 1. Toner Collection Coil 6. OPC Drum 2. Toner Collection Plate 7. Transfer Entrance Guide 3. ID Sensor 8. Charge Roller Cleaning Pad 4. Spur 9. Charge Roller 5. Pick off Pawl 10. Cleaning Blade G035 2-16...
Page 69: Drive Mechanism
The flywheel [E] on the end of the drum drive shaft stabilizes the rotation speed preventing banding and jitters from appearing on sheets printed. This machine has two flywheels because it operates at a higher speed. 2-17 G035...
Page 70: Drum Charge
The high voltage supply board [C] gives a negative DC voltage to the drum charge roller through the charge roller terminal [D], bias plate [E], and the rear roller bushing [F]. This gives the drum surface a negative charge of –950 V. G035 2-18...
Page 71: Charge Roller Voltage Correction
The ID sensor measures the density of this pattern [B], and the output voltage is known as Vsdp. This voltage is comparable to Vsg (read from the bare drum at the same time). 2-19 G035...
Page 72 Paper width from 150 mm to 216 mm: SP2-5-1 + 50 V (adj. with SP2-13-2) Paper width below 150 mm: SP2-5-1 + 250 V (adj. with SP2-13-1) Similar voltage adjustments are available for development bias and transfer current. G035 2-20...
Page 73: Id Sensor Pattern Production Timing
The cam gear [D] moves the pin [C] at the rear of the cleaning pad holder, and also moves the cleaning pad from side to side. This movement improves the cleaning process. 2-21 G035...
Page 74: Development
G035D401.WMF This machine uses a single-roller development system. A dual mixing roller mechanism is used for developer mixing. 1. Drum 5. Mixing Auger 2. Development Roller 6. Development Filter 3. Paddle Roller 7. Doctoring Blade 4. TD Sensor G035 2-22...
Page 75: Drive Mechanism
The main motor [A] drives the development roller [B] through a train of gears and the paddle roller gear [C]. The development drive gears are helical, making them quieter than normal gears. When the development unit is pushed in, the development drive shaft engages the paddle roller gear. 2-23 G035...
Page 76: Developer Mixing
New toner from the toner bottle and recycled toner from the toner collection coil both enter the development unit at the top [D] G035 2-24...
Page 77: Development Bias
Paper width from 150 mm to 216 mm: SP2-5-1 + 50 V (adj. with SP2-13-4) Paper width below 150 mm: SP2-5-1 + 200 V (adj. with SP2-13-3) Similar voltage adjustments are available for charge roller input voltage and transfer current. 2-25 G035...
Page 78: Toner Supply
When the bottle holder unit is pulled out to add a new toner bottle, the following events happen automatically to prevent toner from scattering. • The chuck releases the toner bottle cap into its proper position. • The toner shutter shuts to block the opening because of pressure from a spring. G035 2-26...
Page 79 [D]. When the PCU is installed into the machine, the development unit opens the shutter [E] under the PCU. Then the toner falls down into the development unit through the slit and the shutter. 2-27 G035...
Page 80: Toner Density Control
Image pixel count mode: GAIN = 1 Toner supply motor on Vsp/Vsg detection time calculation Have 10 or more sheets printed New Vtref determination been made since the last Vtref change and is the Print job finished? G035D540.WMF G035 2-28...
Page 81 “K” is decided in a similar way as for the previous condition. GAIN Determination GAIN is another factor in the toner supply motor on time calculation. It is decided using the following data. • Vtref – Vt(10) • Ten most recent Vt values 2-29 G035...
Page 82 ID sensor output, is also used as one of the factors for deciding the new Vtref, which is used for toner density control. The new Vtref is determined using the following data. • Vtref – Vt(10) • Vsp/Vsg From this point, toner density control is done using the new Vtref. G035 2-30...
Page 83: Toner Near End/End Detection
40 times? Toner supply motor turns while main motor turns ID sensor check: Vsp ≤ 2.0 V? Vtref ≤ Vt(10) been detected 20 more times? Have 90 sheets printed been made since toner near-end detection? Toner end G035D538.WMF 2-31 G035...
Page 84 If Vsp is bigger than 2.0V, the density of the ID sensor pattern is very light, so the machine detects a toner end condition. However, if Vsp stays less than 2.0V but 90 sheets printed have been made after toner near end was determined, the machine enters the toner end condition. G035 2-32...
Page 85: Toner End Recovery
2 s. Is the toner concentration still low? Has the motor turned on 8 times? Is this the 4th Vtp' detection? Clear the toner end/near- end condition and reset the value of "K" to 3.0. Toner End G035D539.WMF 2-33 G035...
Page 86: Toner Supply In Abnormal Sensor Conditions
SC code and requires repair. If this happens during a print job, Vtref is not changed, the print job is allowed to finish, and then the SC code is generated. Details of how the machine determines abnormal sensor detection are in section 7 (Troubleshooting). G035 2-34...
Page 87: Drum Cleaning And Toner Recycling
To remove the toner and other particles that have accumulated at the edge of the cleaning blade, the drum turns in reverse for about 5 mm at the end of every print job. 2-35 G035...
Page 88: Toner Recycling
Toner transferred to the toner collection coil [A] is transported to the opening [B] in the bottom of the PCU. Then, it falls into the development unit with the new toner coming from the toner bottle, which the paddle roller [C] mixes together. G035 2-36...
Page 89: Paper Feed
6. Upper separation roller 15. Lower paper height 2 sensor 7. Lower relay sensor 16. Lower paper height 1 sensor 8. Lower relay roller 17. Upper paper size switch 9. Lower paper feed roller 18. Lower paper size switch 2-37 G035...
Page 90: Paper Feed Drive Mechanism
Mechanism for more detail). When the paper feed clutch turns on, the pick-up, paper feed, and separation rollers start rotating to feed the paper. The paper feed clutch stays on until shortly after the registration sensor [C] activates. G035 2-38...
Page 91: Pick-Up And Separation Roller Release Mechanism
When the paper tray is placed in the machine, it pushes the release lever [E]. This causes the pick-up roller [D] to move down and the separation roller [B] to move up and contact the paper feed roller. 2-39 G035...
Page 92: Paper Lift Mechanism
When the machine detects that the paper tray is in the machine, the tray lift motor [C] rotates and the coupling gear [D] on the tray lift motor engages the pin [E] on the lift arm shaft [F]. Then the tray lift arm [G] lifts the tray bottom plate [H]. G035 2-40...
Page 93 The tray lift motor turns on again until this sensor is activated again. When the tray is drawn out of the machine, the tray lift motor coupling gear disengages the pin on the lift arm shaft, and the tray bottom plate then drops under its own weight. 2-41 G035...
Page 94: Paper End Detection
When the paper tray runs out of paper, the paper end feeler drops into the cutout [C] in the tray bottom plate activating the paper end sensor. When the paper tray is drawn out, the pick-up roller supporter [D] lifts up the paper end feeler. G035 2-42...
Page 95: Paper Height Detection
Paper Height Paper Sensor [A] Sensor [B] Full Near Full Near End 1 35 11 33 34 35 Near End 2 Near End 1 35 11 33 34 35 Near End 2 35 11 33 34 36 G035D707.WMF 2-43 G035...
Page 96: Paper Registration
The registration and relay rollers feed the paper to the image transfer section. The registration sensor is also used for paper misfeed detection. G035 2-44...
Page 97: Paper Size Detection
A4 Portrait A4 Portrait 11" x 17" Portrait A5 Portrait " x 14" Portrait 8" x 13" Portrait " x 11" Portrait " x 11" Portrait " x 11" Landscape " x 11" Landscape ON: Pushed OFF: Not Pushed 2-45 G035...
Page 98: Paper Feed And Jam Timing
T4: The registration clutch turns off 150 ms after the registration sensor. J1: Checks whether the sensors are activated within 0.3 seconds after the designated time for these sensors. J2: Checks whether the sensors are deactivated within 0.3 seconds after the designated time for these sensors. G035 2-46...
Page 99: By-Pass Feed
When printing starts, the pick-up solenoid [B] turns on and the pick-up roller [C] moves onto the paper. When the by-pass tray runs out of paper, the paper end feeler [D] drops into the cutout in the by-pass tray activating the paper end sensor [E]. 2-47 G035...
Page 100: Image Transfer And Paper Separation
The pick-off pawl ensures that the paper separates from the drum. The transfer belt cleaning blade removes toner from the transfer belt to prevent the back side of the paper from being stained. G035 2-48...
Page 101: Belt Drive Mechanism
[A] at the correct time to synchronize the leading edge of the developed latent image on the drum [B] with the leading edge of the paper. The transfer belt [C] is not in contact with the drum at this time. G035D522.WMF 2-49 G035...
Page 102 4. After receiving the image from the drum, the paper is fed by the belt. 5. The paper moves to the end of the transfer belt unit, where it separates from the belt as the belt curves away. Then, the paper goes to the fusing unit. G035 2-50...
Page 103: Transfer Belt Unit Contact Mechanism
• To prevent the ID sensor pattern on the drum from being rubbed off by the transfer belt. • To prevent a change in the drum’s characteristics because of the influence of additives inside the rubber belt. 2-51 G035...
Page 104: Transfer Belt Charge
If this current is not maintained, the efficiency of the toner transfer and paper separation processes will vary with paper thickness, type, environmental condition, or changes in transfer belt surface resistance. G035 2-52...
Page 105: Transfer Belt Cleaning Mechanism
[B], which is in the transfer belt unit. This toner is not recycled. When the toner overflow sensor [C] in the transfer belt unit detects toner overflow, the toner overflow indicator lights. After this, 999 printed sheets can be made before machine operation stops. 2-53 G035...
Page 106: Image Fusing And Paper Exit
11. Fusing lamp(s) ( see the note 5. Pressure spring 12. Thermistor 6. Pressure roller strippers 13. Thermofuse 7. Pressure roller 14. Hot roller strippers NOTE: For 115 V machines: One lamp. For 230 V machines: Two lamps. G035 2-54...
Page 107: Fusing Drive And Release Mechanism
When the right cover is opened, the actuator plate [E] pulls release wire [F]. The wire pulls the fusing drive gear bracket [G] and the fusing unit drive disengages. 2-55 G035...
Page 108: Fusing Entrance Guide Shift Mechanism
This prevents thick paper from buckling against the hot roller, which can cause blurring at the leading edge of the print. This setting also aids in preventing thick paper from bending easily, making it less likely to crease. G035 2-56...
Page 109: Pressure Roller
The cleaning roller [A] is always in contact with the pressure roller [B]. It collects toner and paper dust adhering to the surface of the pressure roller. This is because the cleaning roller is made of metal and collects matter more easily than the pressure roller, which has a Teflon coating. 2-57 G035...
Page 110: Fusing Temperature Control
15°C or less and the temperature reaches the value of SP2-4-1 (Fusing temperature adjustment): –20°C The fusing idling time is as follows. Fusing idling time Power-up temperature 30 seconds 15°C or less Not performed Higher than 15°C G035 2-58...
Page 111: Overheat Protection
If the temperature of the thermofuse reaches 169°C, the thermofuse opens, removing power from the fusing lamp. At the same time, the copier stops operating. At this time, an SC542 is generated. 2-59 G035...
Page 112: Duplex
Example: 8 pages. The number [A] in the illustration shows the order of pages. The number [B] in the illustration shows the order of sheets of paper (if shaded, this indicates the second side). ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ G035D013.WMF G035D014.WMF G035 2-60...
Page 113 Example: 8 pages. The number [A] in the illustration shows the order of pages. The number [B] in the illustration shows the order of sheets of paper (if shaded, this indicates the second side). ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ G035D015.WMF G035D016.WMF 2-61 G035...
Page 114: Feed In And Exit Mechanism
[G]. As a result, the inverter gate [D] opens and the inverter roller rotates counterclockwise. The paper passes through the upper and lower transport rollers [E, F] to the copier. G035 2-62...
Page 115: Energy Saver Mode
Leaving Energy Saver Mode The machine leaves energy saver mode when one of the following happens. • The print command is received from a PC • Any key on the operation panel is pressed 2-63 G035...
Page 116: New Unit Detection Mechanism
Then the machine goes in the initialize mode, the actuating cam is turned [C] by the main motor, therefore, the new unit sensor turns off. If the actuation cam turns once, it never returns the initial position. G035 2-64...
Page 117: Installation 3. Installation Procedure
INSTALLATION PROCEDURE...
Page 119: Installation Requirements
5 mm.) 10. Do not place the machine where it may be subjected to strong vibrations. 3.1.2 MACHINE LEVEL Front to back: Within 5 mm (0.2") of level Right to left: With in 5 mm (0.2") of level G035...
Page 120: Minimum Space Requirements
600 mm (23.6") 1320 mm (52") G035I003.WMF NOTE: The 75 centimeters recommended for the space at the front is for pulling out the paper tray only. If an operator stands in front of the printer, more space is required. G035...
Page 121: Power Requirements
1. Input voltage level: 120 V, 60 Hz: More than 10 A 220 V ~ 240 V, 50/60 Hz: More than 6 A 2. Permissible voltage fluctuation: ±10% 3. Make sure nothing is on or presses against the power cord. G035...
Page 122: Printer Installation
2) Press the “Enter #” key to print the configuration page. The machine automatically prints the printer configuration page. NOTE: For more detailed information about the operation panel settings, refer to the operating instructions. The printer configuration page is similar to that shown on the next page. G035...
Page 123: Configuration Page
PRINTER INSTALLATION Configuration Page RICOH Aficio AP4500 Reference Options Printer ID 4H65110303 Printer Hard Disk Drive Installed Firmware Version 1.73 500x2 Sheets Paper Bank Installed PCL 5e Emulation 1.4.10 Finisher 1000 Not Installed PCL 6 Emulation 1.1.10 Finisher 3000 Not Installed Adobe PostScript 3 92.01...
Page 124 NOTE: If the machine does not print the status sheet, check the Network menu in printer user tools menu. If any problem occurs with the above check, reinstall the printer controller and other options. Then set up the machine again and redo the test. G035...
Page 125: Hard Disk Drive Installation (A853)
6. Install the printer controller in the printer. 7. After turning on the main switch and format the hard disk using “SP 1(Controller SP) - 4 (Format Disk)”. 8. After formatting the hard disk, turn the main switch off and on. G035...
Page 126: Network Interface Board (Nib) Installation
Keep the status sheet with the machine, because it has the following information. • Unit serial number • Firmware version • Network (MAC) address • Network/Protocol information G035...
Page 127: Programming Network/Protocol Parameters
(Default = Auto-Sense) Disable Bindery Optional (Default = No) (Uncheck the box) NOTE: The preferred NDS context must be typed in without a starting dot ( . ). • OU=Development.O=Corp [OK] • .OU=development.O=Corp [NG] • Develoment.Corp [OK] • .Develoment.Corp [NG] G035...
Page 128 NIB is reset. The assigned IP address may not be the same all the time. LPD Parameters Enable LPD Enables or disables the LPD Banner banner (Default = No) Available PDLs Available printer languages are for NIC Port automatically selected. G035 3-10...
Page 129 Apple Printer Utility can change the printer name only. 2) Even if the printer name and zone name are changed using a utility, the changed names will be reset to the default at the next power-on, due to NIB-to-Controller interface limitations. 3-11 G035...
Page 130: Setup For Various Network Types
• Name or address of the server providing lpd: IP Address of the NIB • Name of the printer or print queue on that server: PORT1 (uppercase) After installing a printer connected to the LPR port, share the printer for other workgroup members. G035 3-12...
Page 131 1. Login to the NIB as “port1” (ASCII/PCL) user name. 2. Put a file to print. Using NetScape Navigator (Version 2.0 or Later) 1. Open one of the following addresses: • ftp://port1@<IP Address> (ASCII/PCL) 2. Select [File] – [Upload] to put a print file. 3-13 G035...
Page 132: Bridge Unit Installation (A688)
Check the quantity and condition of the accessories in the box against the following list: Description Quantity 1. Stepped screw................2 2. Connector cover ................ 1 3. Entrance mylar ................2 4. Exit mylar................... 2 5. NECR ..................1 6. Installation procedure ..............1 G035 3-14...
Page 133: Installation Procedure
BRIDGE UNIT INSTALLATION (A688) 3.4.2 INSTALLATION PROCEDURE A688I401.WMF CAUTION Unplug the main machine power cord before starting the following procedure. 1. Unpack the bridge unit. Then remove the tapes. 3-15 G035...
Page 134 6. Open the right cover [E] of the bridge unit and peel off the black tape [F]; then pull out the connector [G]. 7. Install the paper sensor [H] (which is packed along with the printer itself as an accessory) (1 screw, 1 connector). G035 3-16...
Page 135 10. Remove the cover [C]. 11. Install the bridge unit (2 screws) [D]. 12. Connect the bridge unit I/F harnesses [E]. 13. Install the connector cover. 14. Turn on the AC switch and check the bridge unit operation. 3-17 G035...
Page 136: Lct Installation (A683)
Check the quantity and condition of the accessories in the box against the following list: Description Quantity 1. Joint pin ..................2 2. Stepped screw - M3 x 18 ............4 3. Magnet cover................1 4. NECR (-17, -27 machines) ............1 5. Installation procedure ..............1 G035 3-18...
Page 137: Installation Procedure
3. Open the lower right cover [B] and cut the holding band [C]. NOTE: When cutting the holding band, the upper part of the band should be cut as shown. Otherwise, paper jams may occur. 4. Remove the lower right cover. 3-19 G035...
Page 138 7. Hang the LCT [C] on the joint pins, then secure the brackets [D] (4 screws). 8. Return the LCT to the previous position and connect the LCT cable [E]. 9. Open the LCT cover and load the paper. 10. Turn on the AC switch and check the LCT operation. G035 3-20...
Page 139: 1,000-Sheet Finisher Installation (A681)
Check the quantity and condition of the accessories in the box against the following list: Description Quantity 1. Front stand ................1 2. Rear stand ................. 1 3. Knob screw................1 4. Screw - M4 x 12................. 6 5. NECR (-17, -27 machines) ............1 6. Installation procedure ..............1 3-21 G035...
Page 140: Installation Procedure
A681I504.WMF CAUTION Unplug the main machine power cord before starting the following procedure. NOTE: If this finisher will be installed on the G035 printer, the following options should be installed. • Bridge unit (A688) • Paper tray unit (G520) 1. Unpack the finisher and remove the tapes.
Page 141 6. Draw out the locking lever [E] (1 screw). 7. Align the finisher on the stands, and lock it in place by pushing the locking lever. 8. Secure the locking lever (1 screw) and push the stapler unit into the finisher. 3-23 G035...
Page 142 11. Install the shift tray [B] (1 snap ring). NOTE: Make sure that the three pegs [C] fit into the slots [D] properly. 12. Connect the finisher cable [E] to the main machine. 13. Turn on the AC switch and check the finisher operation. G035 3-24...
Page 143: 3,000-Sheet Finisher Installation (A697)
8. Screw - M4 x 14................. 4 9. Screw - M3 x 8................4 10. Cushion ..................1 11. Upper grounding plate ............... 1 12. Lower grounding plate ............... 2 13. NECR (-17 machine) ..............1 14. Installation procedure ..............1 3-25 G035...
Page 144: Installation Procedure
Unplug the main machine power cord before starting the following procedure. NOTE: To install this finisher with the printer, the bridge unit (A688) and paper tray unit (G520) must be installed. 1. Unpack the finisher and remove the tapes. G035 3-26...
Page 145 2. Install the front joint bracket [A] and rear joint bracket [B] (2 screws each). 3. Peel off the backing of the double-sided tape that is attached to the lower grounding plate [C]. 4. Attach one lower grounding plate to the center position of the paper tray unit as shown. 3-27 G035...
Page 146 3,000-SHEET FINISHER INSTALLATION (A697) A697I559.WMF 5. Attach the cushion [A] on the position [B]. 6. Install the entrance guide plate [C] (2 screws). G035 3-28...
Page 147 50, from 3000 to 2950. 12. Install the shift tray [F] (4 screws). 13. Connect the finisher cable [G] to the main machine. 14. Turn on the main power switch and check the finisher operation. 3-29 G035...
Page 148: Mailbox Installation (G909)
3.8.2 REQUIREMENT OPTIONS FOR MAIN MACHINE When the mailbox is going to be installed with the printer, the following options for main machine must be required. • Bridge unit type 450 (A688) • Paper tray unit - PS430 (G520) G035 3-30...
Page 149: Installation Procedure
3. Peel off the backing of the double-sided tape that is attached to the lower grounding plate [C]. 4. Attach one lower grounding plate to the center of the bottom edge of the paper tray unit as shown. 3-31 G035...
Page 150 MAILBOX INSTALLATION (G909) G909I550.WMF 5. Attach the cushion to [A] the position [B]. 6. Open the front cover [C] of the mailbox, and remove the screw [D] that secures the locking lever [E]. Then pull the locking lever. G035 3-32...
Page 151 10. Peel off the backing of the double-sided tape that is attached to the proof tray attachment [C]. 11. Install the proof tray attachment on the proof tray. 12. Turn on the main switch and check the mailbox operation. 3-33 G035...
Page 152: Bridge Unit For Mailbox Installation (G912)
2. Cable ..................1 3. Cover switch ................1 4. Grounding bracket ..............1 5. Finisher shielding plate .............. 1 6. Screw - M4 x 8................9 7. Screw - M4 x 4................4 8. Screw - M3 x 6................2 G035 3-34...
Page 153: Installation Procedure
NOTE: Do not remove the protective sheet [B] at this time. 2. Remove the mailbox if it has been installed. 3. Remove the rear cover [C] of the mailbox (8 screws). 4. Remove the proof tray unit [D] (6 screws, 1 connector). 5. Remove the cover [E]. 3-35 G035...
Page 154 8. Route the cable [D] and clamp it as shown. 9. Connect the cover switch [E] to the cable then install the cover switch (2 screws - M4 x 8). 10. Remove the paper guide plate [F] (2 screws). G035 3-36...
Page 155 13. Remove the tape [F] for the protective sheet. 14. Open the upper paper guide [G] then pull out the protective sheet [H]. NOTE: Check that all mylars are set into the gap between the paper guides. 3-37 G035...
Page 156 When the 3,000-sheet finisher (A697) is going to be installed, do steps 21 to 21. Install the front joint bracket [E] and rear joint bracket [F] which are contained in the finisher’s accessory box. G035 3-38...
Page 157 24. Attach the shielding plate [C] to the finisher (2 screws - M3 x 8). 25. Attach the finisher to the mailbox (refer to the finisher installation procedure). 26. Turn on the main switch of the main machine and check the bridge unit operation. (Select a print mode that uses the finisher.) 3-39 G035...
Page 158: Punch Unit Installation
8. Harness - Short ................. 1 9. Hopper..................1 10. Punch position decal ..............1 11. Tapping screw - M4 x 10 ............2 12. Screw with flat washer - M4 x 6 ..........1 13. NECR ..................1 G035 3-40...
Page 159: Installation Procedure
1. Unpack the punch unit and remove the shipping retainers [A] (4 screws) and [B] (1 screw). 2. Open the front door and remove the hopper cover [C] (2 screws). 3. Remove the finisher rear cover (2 screws) and remove the transport guide plate [D] (4 screws). 3-41 G035...
Page 160 (1-mm) because they are used for adjusting the punch hole position. 5. Install the punch unit [B] and secure it with a long stepped screw [C]. 6. Install the punch unit knob [D] (1 screw). 7. Secure the rear of the punch unit (2 screws). G035 3-42...
Page 161 10. When a three-punch-hole unit is installed: Turn on switch 1 of DIP SW 100 on the finisher control board. 11. Slide the hopper [F] into the finisher. 12. Reassemble the finisher and attach the 3,000-sheet finisher to the copier, then check the punch unit function. 3-43 G035...
Page 162: Installation Procedure
3. Remove the optional hard disk unit [B] (4 screws, 1 connector). 4. Install the DRAM SIMM [C], as shown. NOTE: Make sure that the DRAM SIMM is installed properly. 5. Reinstall the printer controller in the main machine. G035 3-44...
Page 163: Service Tables
SERVICE TABLES...
Page 165: General Cautions
2) Make sure that the charge roller voltage supply is at the standard value (SP2-5-1). 3) Do the ID Sensor Initial Setting procedure (SP2-14). 12. When installing the PCU, make sure that the PCU is set in the machine properly. G035...
Page 166: Transfer Belt Unit
4. Clean the drive gears after removing used developer. 5. Dispose of used developer in accordance with local regulations. G035...
Page 167: Fusing Unit
1. The used toner in the transfer belt unit should be emptied at every PM cycle, but we recommend checking the amount of used toner at every EM. 2. Dispose of used toner in accordance with local regulations. Never throw toner into an open flame, for toner dust may ignite. G035...
Page 168: Service Program Mode
The service program (SP) mode is used to check electrical data, change modes, and adjust values. Operation Panel Please refer to the illustrations for the key names and their locations. On line Job Reset Escape Form Feed Menu Enter Power Error D ata In G035M007.WMF G035M006.WMF G035...
Page 169 NOTE: The setting appearing initially on the display is the current setting. 2. Select the required setting using the key (increasing) or the (decreasing), then press the “Enter” key. NOTE: The previous value remains if the “Enter” key is not pressed. 3. Exit service mode. G035...
Page 170: Service Program Mode Tables
1st paper feed 0.1 mm/step (Tray 1) station using the trimming area [+3.0 mm] pattern (SP2-12, No.10). Use the key to toggle between + and - before entering the value. The specification is 2 ± 1.5 mm. G035...
Page 171 (Duplex) Paper Feed Timing (By-pass) Fusing Selects the fusing temperature control On/Off or Temperature mode. Phase Control [On/Off] Fusing Adjusts the fusing temperature for 170 ~ 200 Temperature paper fed from a paper tray. 1°C/step Adjustment [185°C] (Paper Tray) G035...
Page 172 SP must be performed. Beam Pitch Resets the values of current LD unit Execute Data Reset position and laser beam pitch change counter. Press “Enter #” to reset. After replacing the LD unit, this SP mode must be done. G035...
Page 173 TD sensor output about 4.0 V. Press “Enter #” to start. After finishing this, the TD sensor output voltage is displayed. E.g. 4.00 V Use this mode only after changing the TD sensor and developer, or adding new developer. G035...
Page 174 10 V/step Setting - from the by-pass tray. [50 V] Charge-b Use this SP when an image problem (see 2-13-1) occurs when paper with a small width is fed from the by-pass feed tray. G035 4-10...
Page 175 No or Yes Double Count doubled for A3/11"x17" paper. Press [No] key to select “No” or “Yes”. If "Yes" is selected, the total counter and the current user code counter count up twice when A3/11"x17" paper is used. 4-11 G035...
Page 176 See the "System Parameter and Data Lists" section for how to print the lists. SMC Printing - Prints the SP mode data list. Execute SP Mode Data See the "System Parameter and Data Lists" section for how to print the lists. G035 4-12...
Page 177 (see the “auto power control” section (2.2.3)) is done. User If the engineer will execute the No or Yes Maintenance preventive maintenance, select “No”. [No] When “No” is selected for this menu, the machine will not display “Change Maint. Kit”. 4-13 G035...
Page 178: Test Pattern Printing (Sp2-12)
16 Grayscales (Vert./Hor.) Horizontal Line (2-dot) 16 Grayscales (Vert./Hor Overlay) Grid Pattern (Single-dot) Not used Grid Pattern (Double-dot) Horizontal Line (1-dot) Alternating Dot Pattern Grid Pattern (Single-dot) Full Dot Pattern Grid Pattern (Double-dot) Black Band Alternating Dot Pattern Trimming Area G035 4-14...
Page 179: Input Check
Paper Size Sensor 1 Switch pressed Switch not pressed Zero Cross Signal Detected Not detected Transfer Belt Unit H.P Not at home At home position (Registration Sensor position & others) Exhaust Fan Lock Signal Not locked Locked 4-15 G035...
Page 180 Not used Right Lower Cover Switch Switch not Switch pressed pressed 2nd Tray Height Sensor Paper not at Paper at upper (Paper End) upper limit limit 1st Tray Height Sensor Paper not at Paper at upper upper limit limit G035 4-16...
Page 181 Dip Switch - 1 Not used Exit Sensor Paper detected Paper not detected (Duplex) Entrance Sensor Paper detected Paper not detected Cover Guide Sensor Cover guide Cover guide opened closed Duplex Unit Switch Switch pressed Switch not (cover closed) pressed 4-17 G035...
Page 182: Output Check
Not used Toner Supply Motor Main Motor Transfer Belt Clutch Transport Motor (Duplex) 58 ~ 61 Not used Inverter Motor – Reverse (Duplex) Quenching Lamp Inverter Motor - Forward Charge Roller Bias (Duplex) 64 ~ 66 Not used G035 4-18...
Page 183: System Parameter And Data Lists (Smc Lists)
1. Print out all SMC Data Lists (SP mode 2-22). 2. Access SP mode 2-18. 3. Press the "Enter #" key twice. 4. Turn the main power switch off and back on. 5. Do the laser beam pitch adjustment. 4-19 G035...
Page 184: Software Reset
4.2.9 PRINTER RESTART AND MENU RESET (USER MENU) The following parameters are user menu. See section 4.6 User menu. Printer Restart This parameter initializes the printer. Menu Reset This parameter resets the user menu settings to the default value. G035 4-20...
Page 185: Downloading New Firmware
7. Print the “Printer Configuration Page” to check the new firmware version ([Menu] – [List Print] – [Config. Page]). The firmware version number is printed in the “Printer Details” section of the configuration page. 4-21 G035...
Page 186: Firmware Update From Parallel Port
PC (and the printer controller does not start up), any attempts thereafter to download from the card or PC will not be possible. In addition, it will not be possible to return the machine to operating condition. G035 4-22...
Page 187 Downloading from the controller to ROM DIMM 1. Remove the printer controller. 2. Install the ROM DIMM on the controller. 3. Install the printer controller and turn on the machine. 4. Enter SP mode. 5. Choose “1-3 – Copy ROM”. 4-23 G035 4-22A...
Page 188: Formating The Hard Disk (Sp1-4)
2. Choose “1-4 – Format Disk”. 3. Press “Enter #” in reply to the confirmation message. Hard disk formatting will take several minutes. 4. After confirming that formatting was successful, turn the machine off and back on again. G035 4-24 4-22B...
Page 189: Parallel Loop Back Test (Sp1-9)
G N D G N D G N D G N D G N D G N D G N D /INIT / F A U L T / S E L E C T I O N G035M003.WMF 4-23 G035...
Page 190: Downloading New Software
NOTE: 1) The machine does not display any message during the download procedure. 2) This procedure takes about 3 minutes. 5. After 3 minutes pass, turn off the machine, remove the card from the slot, and turn the machine back on. G035 4-24...
Page 191: Network Interface Board
3. The green LED flashes 3 times, then the amber and green LEDs light alternately (once per second). 4. Turn off the machine and remove the network interface board. 5. Reset the OP2 jumper setting to the default, and put the board back in the machine. 6. Turn on the machine. 4-25 G035...
Page 192: Flash Rom Update
FTPDL utility. IPX Network No NetWare server Not possible NetWare 2.x server Use FlashUP NetWare 3.x server Use FlashUP NetWare 4.x server Bindery Enabled Use FlashUP Bindery Disabled Not possible TCP/IP Network Use FTPDL NetBEUI Network Not possible G035M005.WMF G035 4-26...
Page 193 4. In the “Destination Location” dialog box, choose a folder (directory) to install the software, then click “Next >”. 5. Confirm the program folder (group) name, then click “Next >”. 6. After the software has been installed, click “Finish” in the “Setup Complete” dialog box. 4-27 G035...
Page 194 5. If you do not see the desired unit in the list, click “Show All” to display all network interface cards that are currently logging in to the server. If you still cannot see the unit, click “Cancel”, restart the machine (printer), and try again. G035 4-28...
Page 195 Even if firmware download has failed, firmware download is still possible. The NIB in “down” status appears as DWN_xxx_xxxxxx in the dialog box in step 4 above. Download the firmware again to the NIB in “down” status using FlashUp utility. 4-29 G035...
Page 196 4. In the “Destination Location” dialog box, choose a folder (directory) to install the software, then click “Next >”. 5. Confirm the program folder (group) name, then click “Next >”. 6. After the software has been installed, click “Finish” in the “Setup Complete” dialog box. G035 4-30...
Page 197 1. Start the FTPDL utility. 2. Choose [File] - [Download]. 3. Choose a new firmware file and click “OK”. 4. Enter the IP address of the network interface card in which you wish to update firmware, then click “OK”. 4-31 G035...
Page 198 CAUTION: Do not turn off the machine until after it prints a status sheet. Recovery from Failed Download If firmware download using FTPDL has failed, use the FlashUP utility to recover the NIB. This is because the NIB may not have IP parameters anymore after failed download. G035 4-32...
Page 199: User Menu
Auto Tray SW Paper Output Output Tray Duplex Sort Staple Punch Print Quality Edge Smoothing Resolution Image Density Toner Saving System Copies Print PS Errors Energy Saver Auto Continue PCL Menu Orientation Form Lines Font Source Font Number Point Size 4-33 G035...
Page 200 Network Setup I/O Timeout IP Address Subnet Mask Gateway Address Maintenance Printer Restart Menu Reset Registration Tray3 Width Tray4 Width List Print Config. Page Menu List PCL Font List PS Font List PCL Demo Page PS Demo Page Language G035 4-34...
Page 201: Test Points/Dip Switches/Leds
Keep at “OFF” Not used Keep at “OFF” Destination Japan On N. America Off Europe On Not used Not used Keep at “OFF” NOTE: 1) Disabling the jam detection is effective only for the main machine (not for the options). 4-35 G035...
Page 202: Jumper Pins
Do not change this setting. Keep at “UN-PROT”. 4.7.3 TEST POINTS I/O Board Number Monitored Signal TP103 Ground TP104 +24V TP136 TP154 Ground TP156 +12 V TP158 –12 V TP159 +5VE BICU Number Monitored Signal TP105 TP125 F-gate signal G035 4-36...
Page 203: Leds
Positioning Pin – Laser Unit A2309352 Flash Memory Card – 4MB A2309351 Case – Flash Memory Card A0299387 Digital Multimeter – FLUKE 87 4.8.2 LUBRICANTS Part Number Description Q’ty A0289300 Grease Barrierta JFE 5 5/2 52039501 Silicone Grease G-501 4-37 G035...
Page 205: Preventive Maintenance
PREVENTIVE MAINTENANCE...
Page 207: Preventive Maintenance Schedule
(By-pass feed table) Paper Feed Guides Clean with water or alcohol. Relay Rollers Clean with water or alcohol. Bottom Plate Pad Clean with water or alcohol. Bottom Plate Pad Clean with water or alcohol. (By-pass feed) Registration Sensor Blower brush G035...
Page 208 Paper Exit Guide Ribs Clean with water or alcohol. DUPLEX UNIT Inverter Roller Clean with water or alcohol Upper Transport Roller Clean with water or alcohol Lower Transport Roller Clean with water or alcohol OTHERS Drive Belts Replace if necessary G035...
Page 209 EM 150k 300k 450k NOTE 1,000-SHEET/3,000-SHEET FINISHERS Rollers Clean with water or alcohol. Brush Roller Replace if necessary. Discharge Brush Clean with a dry cloth Sensors Blower brush Jogger Fences Replace if necessary. Punch Waste Hopper Empty the hopper. G035...
Page 211: Replacement And Adjustment
REPLACEMENT AND ADJUSTMENT...
Page 213: Laser Unit
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 Two caution decals are located in the laser section as shown below. G035...
Page 214: Laser Unit
5. Remove the laser unit [E] (2 screws, 5 connectors, 1 flexible harness). NOTE: 1) When disconnecting the harnesses from the LD unit, hold on to the LD unit. 2) When sliding out the laser unit, do not hold the LD unit. G035...
Page 215: Polygon Mirror Motor
LASER UNIT 6.1.3 POLYGON MIRROR MOTOR G035R203.WMF G035R204.WMF 1. Remove the laser unit (see Laser Unit). 2. Remove the laser unit cover [A] (4 screw, 2 pawls). 3. Remove the polygon mirror motor [B] (4 screws, 1 connector). G035...
Page 216: Laser Synchronization Detector
2. Remove the LD unit [A] (3 screws, 1 connector) NOTE: When disconnecting the harness, hold on to the LD unit. 3. After replacing the LD unit, perform SP 2-6-5, then the laser beam pitch adjustment (see the following procedure). G035...
Page 217 600 dpi, using the same procedure as for 400 dpi (use the SP modes for 600 dpi). When starting the adjustment for 600 dpi, input a value for SP2-6-2 between 24 and 48 higher than the final result for 400 dpi. Feed Direction Feed Direction G035R512.WMF G035R513.WMF Adjustment not complete Adjustment complete G035...
Page 218: Photoconductor Unit (Pcu) And Development Unit
6.3 PHOTOCONDUCTOR UNIT (PCU) 6.3.1 PCU G035R552.WMF 1. Pull out the PCU and development unit. (See Photoconductor Unit and Development Unit.) 2. Remove the PCU [A] (2 screws) from the development unit [B]. G035...
Page 219: Drum
SP2-5-1. NOTE: If this is not done, the carrier will be attracted to the drum because the charge roller voltage will be too high. 6. After replacing the drum, perform the ID sensor initial setting using SP2-14. G035...
Page 220: Pick-Off Pawls
If a line has appeared on the drum surface because of the pick-off pawl, the pick- off pawl position can be adjusted using either or both of the following: • Changing the spur position. • Changing the pick-off pawl assembly position G035...
Page 221: Charge Roller/Charge Roller Cleaning Pad
5. After replacing the charge roller, check the value of SP2-5-1. If it is not at the standard value, change it to the standard value using SP2-5-1. NOTE: If this is not done, the carrier will be attracted to the drum because the charge roller voltage will be too high. Standard value: -1620V G035...
Page 222: Drum Cleaning Blade
3. Remove the PCU rail [A] (2 screws, 1 connector). 4. Remove the ID sensor bracket [B] (1 screw, 1 connector). 5. Remove the ID sensor [C] (1 screw). 6. Perform the ID sensor initial setting using SP2-14. G035 6-10...
Page 223: Development
NOTE: Be careful not to nick or scratch the development roller. If you are temporarily installing a used development unit for test purposes for a long time, perform 2-11 after installation (see the SP mode table for details). 6-11 G035...
Page 224: Development Filter
3. Remove the development filter [B] NOTE: 1) Make sure that the surface with a red mark is facing up. 2) These seals [C] are for protection during transportation. Do not use these sheets after pealing them off (take off the sheets). G035 6-12...
Page 225: Development Roller
2. Remove the gear [A] (1 snap ring) and the joint bracket [B]. 3. Remove the development roller [C] (2 screws). NOTE: 1) Be careful not to nick or scratch the development roller. 2) When re-installing the development roller, the side seals [D] should be inside the development unit case. 6-13 G035...
Page 226: Developer
NOTE: 1) Dispose of the used developer in accordance with local regulations. 2) Be careful not to nick or scratch the development roller. 4. Pour all the new developer [C] into the development unit. Then, rotate the gear [D] to distribute the developer evenly. G035 6-14...
Page 227: Td Sensor
3. Pour new developer into the development unit and perform the TD sensor initial setting using SP2-10. NOTE: When performing the TD sensor initial setting, cover the toner entrance hole with a piece of paper (see the above illustration). 6-15 G035...
Page 228: Duplex
1. Open the by-pass feed table [A]. 2. Remove the connector cover [B] (1 screw). 3. Open the duplex unit. 4. Remove the link [C] from the pin [D] (1 snap ring). 5. Remove the duplex unit [E] (2 connectors). G035 6-16...
Page 229: Duplex Unit Cover
2. Remove the duplex unit cover [A] (4 screws). 6.5.3 ENTRANCE SENSOR G035R001.WMF 1. Remove the duplex unit cover (See Duplex Unit Cover). 2. Remove the sensor holder [A] (1 screw). 3. Replace the entrance sensor [B] (1 connector). 6-17 G035...
Page 230: Exit Sensor
DUPLEX 6.5.4 EXIT SENSOR G035R002.WMF 1. Remove the duplex unit. (See Duplex Unit.) 2. Remove the sensor bracket [A] (1 screw). 3. Replace the exit sensor [B] (1 connector). G035 6-18...
Page 231: Transfer Unit
3. Open the right cover [A]. 4. Release the release lever [B] then remove the transfer unit [C]. 5. Remove the springs [D]. 6. Remove the transfer belt unit [E] (1 hook). NOTE: Do not touch the transfer belt surface. 6-19 G035...
Page 232: Transfer Belt
3) When re-installing the transfer belt, make sure that the belt is under the pin [E]. 4) When re-installing, to avoid damage to the transfer belt, manually turn the rollers and check that the new transfer belt is not running over the edge of any of the rollers. G035 6-20...
Page 233: Transfer Belt Cleaning Blade/Toner Overflow Sensor
2. Turn over the transfer unit and empty the used toner in the transfer unit. 3. Remove the toner overflow sensor [B] (1 screw, 3 terminal wires). NOTE: When re-installing the terminal wires, the wire color order is red, purple, and blue, from the top. 6-21 G035...
Page 234: Right Cover
2. Remove the transfer belt unit. (See Transfer Belt Unit.) 3. Remove the screw [A] that secures the link [B]. 4. Remove the unit band [C]. 5. Remove the clip [D] and bushing [E]. 6. Remove the right cover [F] (1 connector). G035 6-22...
Page 235: By-Pass Feed
BY-PASS FEED 6.7 BY-PASS FEED 6.7.1 BY-PASS FEED UNIT G035R003.WMF 1. Remove the duplex unit. (See Duplex Unit.) 2. Remove the front cover [A] and rear cover [B]. 3. Remove the by-pass feed unit [C] (4 screws, 2 connectors). 6-23 G035...
Page 236: By-Pass Feed Unit Covers
1. Remove the hinge cover [C] (1 screw). Upper Cover 1. Remove the hinge cover. 2. Open the duplex unit. 3. Remove two screws for the upper cover. 4. Close the duplex unit and pull out the upper cover [D]. G035 6-24...
Page 237: Paper Feed And Pick-Up Roller
Paper Feed Roller 3. Replace the paper feed roller [B] (1 snap ring). Pick-up Roller 3. Replace the pick-up roller [C] (1 snap ring). 6-25 G035...
Page 238: Separetion Roller
BY-PASS FEED 6.7.4 SEPARETION ROLLER G035R006.WMF 1. Close the by-pass table. 2. Remove the separation roller [A] from the bottom (1 snap ring). G035 6-26...
Page 239: Paper End Sensor And Pick-Up Selenoid
NOTE: When lifted, the paper end feeler locks into position. Therefore, make sure to move it back to its original position before re-installing the upper cover. 3. Replace the paper end sensor [B] (1 connector). Pick-up Solenoid 2. Remove the pick-up solenoid [C] (1 screw, 1 spring, 1 connector). 6-27 G035...
Page 240: Paper Size Sensor Board
6.7.6 PAPER SIZE SENSOR BOARD G035R008.WMF 1. Release hooks [A] and remove the by-pass table [B] (1 connector). 2. Replace the paper size sensor board [C]. NOTE: When removing the paper size sensor board, be careful not to break its hook. G035 6-28...
Page 241: By-Pass Table
3. Remove the two screws [B] 4. Hold the spring bracket [C] and remove the by-pass table [D]. CAUTION: Pressure is applied to the spring bracket, so when removing the by- pass tray, hold the spring bracket by hand as shown. 6-29 G035...
Page 242: Paper Feed Clutch
1. Remove the by-pass table. (See By-pass Table.) 2. Remove the paper feed unit [A] (2 screws, 1 connector). 3. Remove the rear bracket [B] (3 screws, 1 clip, 1 bushing). 4. Replace the paper feed clutch [C] (1 connector) G035 6-30...
Page 243: Paper Feed
2. Remove the pick-up roller [A]. 3. Remove the feed [B] and separation rollers [C] (1 clip each). NOTE: Do not touch the roller surface with bare hands. After installing the new rollers, do SP2-25-2 for the appropriate paper tray. 6-31 G035...
Page 244: Lower Right Cover/Lower Rear Cover
3. Remove the upper connector cover [A] and lower connector cover [B] then disconnect the harnesses [C]. 4. Remove the lower rear cover [D] (4 screws). 5. Remove the unit band [E] (1 clip) and remove the vertical transport cover [F]. 6. Remove the lower right cover [G] (5 screws). G035 6-32...
Page 245: Relay/Upper Paper Feed/Lower Paper Feed Clutches
4. Remove the drive bracket [C] (2 screws, 1 spring, 1 bearing, 4 harness clamps). 5. Remove the relay clutch [D] (1 connector). 6. Remove the upper paper feed clutch [E] (1 connector). 7. Remove the lower paper feed clutch [F] (1 connector). 6-33 G035...
Page 246: Upper Paper Feed Unit
2. Remove the upper paper feed clutch [A]. (See Relay/Upper Paper Feed/Lower Paper Feed Clutches.) 3. Remove three relay gears [B]. 4. Remove the lower right cover. (See Lower Right Cover/Lower Rear Cover.) 5. Remove the upper paper feed unit [C] (2 screws, 1 connector). G035 6-34...
Page 247: Lower Paper Feed Unit
3. Remove the paper trays. 4. Remove the lower right cover. (See Lower Right Cover/Lower Rear Cover.) 5. Remove the cover [C] (2 screws). 6. Remove the gear [D]. 7. Remove the lower paper feed unit [E] (2 screws, 1 connector). 6-35 G035...
Page 248: Paper End/Paper Height/Relay Sensors
1. Remove the appropriate paper feed unit. (See Upper or Lower Paper Feed Unit.) 2. Remove the paper height sensor [A] (1 connector). 3. Remove the paper end sensor [B] (1 connector). 4. Remove the relay sensor bracket [C] (1 screw, 1 connector). 5. Remove the relay sensor [D]. G035 6-36...
Page 249: Registration Sensor
8. Remove the registration roller bushing [C] and front registration roller gear [D] (1 E-ring, 1 spring). 9. Remove the right cover switch bracket [E]. 10. Remove the rear registration holder [F] (1 screw). 11. Remove the registration roller bushing [G] (1 E-ring, 1 spring). 6-37 G035...
Page 250 NOTE: When re-installing the clip [C], its position must be as shown. 13. Remove the registration guide plate [D] (2 screws, 1 connector). 14. Remove the sensor bracket [E] (1 screw). 15. Remove the registration sensor [F] (1 screw, 1 connector). G035 6-38...
Page 251: Fusing
1. Open the front cover and right cover. 2. Open the duplex unit. 3. Remove the screw [A]. 4. Release the fusing lever [B] and slide out the fusing unit [C]. NOTE: After removing the fusing unit, close the right cover. 6-39 G035...
Page 252: Hot Roller Strippers And Fusing Lamp
5. Remove the front lamp holder [F] (1 screw). 6. Remove the fusing lamp [G] (1 lamp for 115 V machines, 2 lamps for 230 V machines). NOTE: Do not touch the glass part of the fusing lamp with bare hands. G035 6-40...
Page 253: Thermistor And Thermofuse
1. Remove the fusing upper cover. (See Hot Roller Strippers and Fusing Lamp.) 2. Remove the thermistor [A] (1 screw, 1 connector). 3. Remove the thermofuse [B] (2 screws). Route the cable of the thermistor and thermofuse as shown. 6-41 G035...
Page 254: Cleaning Roller
[B] 3. Remove the lower fusing cover [C] (1 screw). NOTE: When removing the lower fusing cover, be careful not to drop the cleaning roller onto the hot roller. 4. Replace the cleaning roller [D]. G035 6-42...
Page 255: Hot Roller And Pressure Roller
5) When re-installing the hot roller assembly and pressure roller assembly, make sure that the flange position of the bushings is as shown. 6) When re-installing the C-rings [G] of the hot roller, make sure that the position of the C-rings is as shown. 6-43 G035...
Page 256: Drive Area
4. Remove the power pack bracket [D] (2 screws, 6 connectors). 5. Remove 2 flywheels [E] (3 screws). 6. Remove the registration clutch [F] (1 E-ring, 1 connector). 7. Remove the transfer belt clutch assembly [G] (2 screws, 2 connectors). G035 6-44...
Page 257: Main Motor
2. Remove the power pack bracket and fly wheels. (See Registration Clutch and Transfer Belt Clutch.) 3. Remove the bracket [C] (3 screws). 4. Remove the timing belt [D]. 5. Remove the main motor [E] (3 screws, 2 connectors). 6-45 G035...
Page 258: Toner Bottle Motor
3. Remove the stopper [C] for the holder, then take out the toner bottle holder. 4. Remove the motor harness from the two wire clamps [D]. 5. Remove the toner bottle motor [E] (2 hooks). 6. Disconnect the harness from the motor. G035 6-46...
Page 259: Covers
COVERS 6.11 COVERS G035R539.WMF G035R526.WMF Connector Cover and Rear Cover 1. Remove the connector cover [A] and rear cover [B] (4 screws). Operation Panel Cover 1. Remove the operation panel cover [C] (2 caps, 2 screws). 6-47 G035...
Page 260 3. Remove the operation panel cover. (See Operation Panel Cover.) 4. Remove the small upper cover and upper cover. (See Upper Cover.) 5. Remove the printer controller cover [C] (4 screws) and the left cover [D] (4 screws). G035 6-48...
Page 261: Pcbs
1. Open the front cover. 2. Remove the operation panel, connector, rear, upper and left covers. (See Covers.) 3. For 230 V machines: Remove the circuit breaker [A] (1 screw, 1 connector). 4. Remove the PSU [B] (4 screws, all connectors). 6-49 G035...
Page 262: Printer Control Board And Nib
3. Remove the optional hard disk unit [B] (4 screws, 1 connector) and DRAM SIMMs that have been installed. 4. Remove the NIB [C] (4 screws, 1 connector). 5. Remove the NVRAM [D] from the old printer control board and install it on the new printer control board. G035 6-50...
Page 263: Hard Disk
G035R532.WMF 1. Remove the printer controller cover. (See Covers.) 2. Pull the hard disk assembly [A] (2 connectors). 3. Remove the hard disk unit [B] (8 screws). 4. After replacing the HDD, perform SP2-15-2 “Bad Sector Information Reset”. 6-51 G035...
Page 264: I/O Board
4. Remove the I/O board bracket [B] (2 screws, all connectors). 5. Remove the I/O board (4 screws). NOTE: Make sure that the DIP switch settings on the new board are the same as those on the old board. G035 6-52...
Page 265: Bicu Board
4. Remove the I/O board bracket. (See I/O Board.) 5. Remove the BICU board [A] (5 screws, 1 stud, all connectors). 6. Remove the NV RAM [B] from the old BICU board and install it on the new board. ⇒ 6-53 G035...
Page 266: Print Image Adjustments
By-pass feed SP2-1-5 SP2-1-6 NOTE: The default setting (2.0 mm) for the side-to-side registration of the 3rd and 4th paper feeds cannot be changed because the SP mode is unavailable. A: Leading Edge Registration B: Side-to-Side Registration G035R506.WMF G035 6-54...
Page 267 7. Tighten the adjustment bracket. 8. Print the trimming area pattern to check the image. If it is still the same, repeat steps 6 to 8. 6-55 G035...
Page 269: Troubleshooting
TROUBLESHOOTING...
Page 271: Service Call Conditions
SP mode. 7.1.2 SC CODE DESCRIPTIONS SC302: Charge Roller Current Leak Definition [B] A charge roller current leak signal is detected. Possible Causes • Charge roller damaged • High voltage supply board defective • Poor PCU connection G035...
Page 272 Possible Causes • Poor connection between the laser synchronization detector board and the LD unit. • Laser synchronization detector board out of position • Laser synchronization detector board defective • LD unit defective G035...
Page 273 The LD unit home position sensor does not detect an off condition when the LD unit moves from its home position. Possible Causes • LD unit home position sensor defective • LD positioning motor defective • LD unit movement blocked because of incorrect connector routing G035...
Page 274 • ID sensor defective • ID sensor connector defective • Poor ID sensor connector connection • I/O board (IOB) defective • High voltage supply board defective • Dirty ID sensor • Defect at the ID sensor pattern writing area of the drum G035...
Page 275 • ID sensor defective • ID sensor connector defective • Poor ID sensor connector connection • I/O board (IOB) defective • High voltage supply board defective • Dirty ID sensor • Defect at the ID sensor pattern writing area of the drum G035...
Page 276 The TD sensor output voltage is less than 0.5 V or more than 4.0 V 10 times consecutively during printing. Possible Causes • TD sensor abnormal • Poor connection between the TD sensor and the I/O board (IOB) • I/O board (IOB) defective G035...
Page 277 SC405: Transfer Belt Error Definition [B] The transfer belt does not move away from the drum during ID sensor pattern checking. Possible Causes • Main motor/drive malfunction • Transfer belt position sensor defective • Poor transfer belt position sensor connection G035...
Page 278 A bridge unit cooling fan motor lock signal is not detected within 5 seconds after the bridge unit cooling fan motor turns on. Possible Causes • Too much load on the drive mechanism • Bridge unit cooling fan motor defective • Poor fan motor connector connection G035...
Page 279 If it does not deactivate within 5 seconds four times consecutively, this SC will be generated. Possible Causes • 2nd tray upper limit sensor defective • Tray lift motor defective • Too much paper in the tray G035...
Page 280 If it does not deactivate within 5 seconds four times consecutively, this SC will be generated. Possible Causes • 4th tray upper limit sensor defective • Tray lift motor defective • Too much paper in the tray G035 7-10...
Page 281 Possible Causes • LCT lift motor defective • Pick-up solenoid defective • Poor motor connector connection • Poor pick-up solenoid connector connection • Paper end sensor defective • LCT lift sensor defective • LCT lower limit sensor defective 7-11 G035...
Page 282 145 seconds after the main power switch is turned on. Possible Causes • Fusing thermistor defective or out of position • Fusing lamp open • Fusing thermofuse open • BICU defective • Power supply board defective • Poor fusing unit connection G035 7-12...
Page 283 • Noise on the ac power line SC548: Fusing Unit Installation Error Definition [A] The machine cannot detect the fusing unit when the front cover and right cover are closed. Possible Causes • Fusing unit is not installed • Poor fusing unit connection 7-13 G035...
Page 284 SC624: Communication Error between BICU and LCT Definition [B] The BICU cannot communicate with the LCT properly. Possible Causes • Poor connection between the BICU board and the LCT main board • LCT main board defective • BICU board defective G035 7-14...
Page 285 1) Tray shift does not finish within a certain time after the shift motor turned on. 2) The stack height sensor does not activate within a certain time after the shift tray lift motor turned on. Possible Causes • Shift motor defective • Shift tray lift motor defective 7-15 G035...
Page 286 Possible Causes • Stapler motor defective • Stapler H.P sensor defective • Poor stapler motor connection SC900: Electrical Total Counter Error Definition [A] The total counter contains a character that is not a number. Possible Causes • NVRAM defective G035 7-16...
Page 287 Definition [B] The IPU sends the Page Print Complete signal back to the engine software, but the signal does not contain the correct response code to the original command. Possible Causes • BICU Software defective • BICU Board defective 7-17 G035...
Page 288 The print ready signal is not generated for more than 17 seconds after the IPU received the print start signal. Possible Causes • Software defective SC980: HDD Access Error Definition [B] Incorrect parameter sent to the HDD controller. Possible Causes • Software defective • Poor connection between BICU and HDD. G035 7-18...
Page 289 NOTE: 1) When this SC occurs, the file name, address, and data will be stored in the NVRAM. These data can be checked by SMC printing-logging data (SP2-22-3). 2) Note the above data and the situation in which this SC occurs. Then report the data and conditions to your technical control center. 7-19 G035...
Page 290: Printer Controller
This error occurred during • A complex page is printed printing. • The DRAM SIMM is board The language has sent a file that is too complex to interpret in defective • The controller is defective the available memory. G035 7-20...
Page 291 1 = LED is lit, 0 = LED is off LEDs Description LED2 LED3 LED4 LED5 ROM error RAM (resident, SIMM) error: NOTE 1) NVRAM error: NOTE 1) Fatal error Debug trap error: NOTE 2) NOTE: 1) SC2000 is also displayed. 2) SC2002 is also displayed. 7-21 G035...
Page 292: Network Interface Board
Two LEDs visible from the outside, one amber and one green, indicate the status of the network interface board (NIB). Refer to the diagram on the right for their location. A m b e r G r e e n G035T501.WMF G035 7-22...
Page 293 Blinks rapidly Error • Check the cable connection and the NetWare server status. • The NIB has reset its NVRAM to the Blink alternately NVRAM reset factory defaults. (Refer to section 4.5.1 for how to reset the NVRAM.) 7-23 G035...
Page 294: Electrical Component Defects
The Paper Jam indicator will light whenever a printed Open (S11) sheet is made. 236-5 (PFB) The Paper Jam indicator lights even if there is no Shorted paper. Transfer Belt Open No symptom 203-A8 Position (S12) (IOB) Shorted SC403 is displayed G035 7-24...
Page 295: Switches
4 A/125 V 4 A/250 V Paper end condition 6.3 A/125 V 6.3 A/250 V One of SC302, or SC403, or SC405 is displayed FU101 15 A/125 V — No response FU102 8 A/125 V 5 A/250 V No response 7-25 G035...
Page 296: Rom History
Energy Saver Mode, an SC990 may occur (Software Performance error) before the machine reaches Stand-by temperature. If this happens an SC542 occurs (Fusing Temperature Warm-up error). The correction turns off the Fusing Temperature control whenever an SC990 occurs. G035 7-26...
Page 297 The firmware has been modified to allow downloading of document formats. • The firmware has been modified to support Page Count MIB. • An SC2001 sometimes occurs during a print job if Auto Tray Select has been selected. 7-27 G035...
Page 299: Paper Tray Unit G520
PAPER TRAY UNIT G520...
Page 301: Overall Machine Information
120 Vac: 115 V version (from the copier) 220 ~ 240 Vac: 224/240 V version (from the copier) Power Consumption: 50 W Weight: 25 kg Size (W x D x H): 540 mm x 600 mm x 270 mm G035...
Page 302: Mechanical Component Layout
1. Upper pick-up roller 6. Lower paper feed roller 2. Upper paper feed roller 7. Lower separation roller 3. Upper relay roller 8. Lower pick-up roller 4. Upper separation roller 9. Lower tray 5. Lower relay roller 10. Upper tray G035...
Page 303: Electrical Component Layout
6. Tray lift motor 15. Lower paper height 1 sensor 7. Lower paper feed clutch 16. Upper paper height 2 sensor 8. Vertical guide switch 17. Upper paper height 1 sensor 9. Lower paper lift sensor 18. Tray paper size switch G035...
Page 304: Electrical Component Description
Magnetic Clutches Upper Paper Feed Starts paper feed from the upper tray. Lower Paper Feed Starts paper feed from the lower tray. Relay Drives the transport rollers. PCBs Main Controls the paper tray unit and PCB1 communicates with the copier. G035...
Page 305: Drive Layout
8. Lower pick-up roller 3. Upper paper feed clutch 9. Upper separation roller 4. Lower paper feed clutch 10. Upper relay roller 5. Lower relay roller 11. Upper paper feed roller 6. Lower separation roller 12. Upper pick-up roller G035...
Page 306: Detailed Descriptions
When the paper tray is put into the paper tray unit, it pushes the release lever [E]. This causes the pick-up roller to move down (top diagram) and the separation roller to move into contact with the paper feed roller (bottom diagram). G035...
Page 307: Paper Lift Mechanism
When the machine detects that the paper tray is in the machine, the tray lift motor [C] rotates and the coupling gear [D] on the tray lift motor engages the pin [E] on the lift arm shaft [F]. Then the tray lift arm [G] lifts the tray bottom plate [H]. G035...
Page 308 The tray lift motor turns on again until this sensor is activated again. When the tray is drawn out of the machine, the tray lift motor coupling gear disengages the pin on the lift arm shaft, and the tray bottom plate then drops under its own weight. G035...
Page 309: Paper End Detection
When the paper tray runs out of paper, the paper end feeler drops into the cutout [C] in the tray bottom plate and the paper end sensor is activated. When the paper tray is drawn out, the pick-up roller supporter [D] lifts up the paper end feeler. G035...
Page 310: Paper Height Detection
Paper Height Paper Sensor [A] Sensor [B] Full Near Full Near End 1 35 11 33 34 35 Near End 2 Near End 1 35 11 33 34 35 Near End 2 35 11 33 34 36 G520D505.WMF G035 8-10...
Page 311: Paper Size Detection
A4 Portrait A4 Portrait 11" x 17" Portrait A5 Portrait " x 14" Portrait 8" x 13" Portrait " x 11" Portrait " x 11" Portrait " x 11" Landscape " x 11" Landscape ON: Pushed OFF: Not Pushed 8-11 G035...
Page 312: Service Tables
TXD to the copier TP104 (RXD) RXD from the copier TP105 (5 V) +5 V TP106 (GND) Ground 3.3 SWITCHES Function SW101 Starts the free run SW102 Stops the free run 3.4 FUSES Function FU101 Protects the 24 V line. G035 8-12...
Page 313: Replacement And Adjustment
COVER REPLACEMENT 4. REPLACEMENT AND ADJUSTMENT 4.1 COVER REPLACEMENT G520R500.WMF Right Cover 1. Remove the right cover [A] (2 screws). Rear Cover 1. Remove the rear cover [B] (2 screws). 8-13 G035...
Page 314: Roller Replacement
4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS G520R501.WMF 1. Remove the paper tray. Pick-up Roller 2. Replace the pick-up roller [A]. Paper Feed Roller 2. Replace the paper feed roller [B] (1 snap ring). Separation Roller 2. Replace the separation roller [C]. G035 8-14...
Page 315: Tray Motor Replacement
TRAY MOTOR REPLACEMENT 4.3 TRAY MOTOR REPLACEMENT G520R502.WMF 1. Remove the rear cover. 2. Remove the tray motor [A] (1 connector, 3 screws). 8-15 G035...
Page 316: Paper Feed And Relay Clutch Replacement
4. Remove the gear holder [C] (3 screws, 1 spring, 1 bearing). 5. Replace the relay clutch [D] (1 connector). 6. Replace the upper feed clutch [E] (1 bushing, 1 connector). 7. Replace the lower feed clutch [F] (1 connector). G035 8-16...
Page 317: Paper Feed Unit Replacement
1. Remove the rear cover. 2. Remove the upper and lower paper feed clutch holder. 3. Remove the gear holder. 4. Remove the upper feed clutch [A] or lower feed clutch [B]. 5. Remove the upper or lower gear [C, D]. 8-17 G035...
Page 318 8. Remove the upper paper feed unit [C] (2 screws, 1 connector). Lower Paper Feed Unit 6. Remove the docking bracket [D] (1 screw). 7. Remove the vertical transport guide [E] (2 screws). 8. Remove the lower paper feed unit [F] (2 screws, 1 connector). G035 8-18...
Page 319: Paper End, Tray Lift, And Relay Sensor Replacement
2. Replace the paper end sensor [A] (1 connector). Tray Lift Sensor 2. Replace the paper lift sensor [B] (1 connector). Relay Sensor 2. Remove the sensor bracket [C] (1 screw). 3. Replace the relay sensor [D] (1 connector). 8-19 G035...
Page 321 SwapBox and SwapFTL Installation Manual...
Page 323: Introduction
Before you use the software, you must agree to the SCM software license agreement that is enclosed in either the SwapBox or the software. Users must be responsible for the agreement with SCM Microsystems Inc. Ricoh Co., Ltd. is not responsible for any legal problems caused by user’s actions contrary to the agreement.
Page 324: Windows 95 Version Confirmation
4.00.950a, install “Service Pack 1” into the current Windows operating system. Refer to the next page for how to get “Service Pack 1”. 4.00.950a If the version is 4.00.950B or 4.00.950C, install SwapBox and SwapFTL without updating Windows. G035...
Page 325 Finnish http://www.microsoft.com/windows/software/localize/fin-eu.htm German http://www.microsoft.com/windows/software/localize/frn-eu.htm Greek http://www.microsoft.com/windows/software/localize/ger-eu.htm Hungarian http://www.microsoft.com/windows/software/localize/grk-eu.htm Italian http://www.microsoft.com/windows/software/localize/itn-eu.htm Japanese (PCAT) http://www.microsoft.com/windows/software/localize/jpcat-eu.htm Korean http://www.microsoft.com/windows/software/localize/kr-eu.htm Norwegian http://www.microsoft.com/windows/software/localize/nor-eu.htm Pan-European http://www.microsoft.com/windows/software/localize/pan-eu.htm Polish http://www.microsoft.com/windows/software/localize/pl-eu.htm Portuguese http://www.microsoft.com/windows/software/localize/brz-eu.htm (Brazilian) Portuguese (Iberian) http://www.microsoft.com/windows/software/localize/pt-eu.htm Russian http://www.microsoft.com/windows/software/localize/ru-eu.htm Slovenian http://www.microsoft.com/windows/software/localize/slv-eu.htm Spanish http://www.microsoft.com/windows/software/localize/spa-eu.htm Swedish http://www.microsoft.com/windows/software/localize/swe-eu.htm Thai http://www.microsoft.com/windows/software/localize/thai2.htm Turkish http://www.microsoft.com/windows/software/localize/trk-eu.htm G035...
Page 326: Swapbox Installation
6. Choose “Device Manager” and confirm that “SCM SwapBox Family Plug and Play PCMCIA Controller” is listed in the PCMCIA socket category. 7. Double-click “SCM SwapBox Family Plug and Play PCMCIA Controller” and confirm that the SwapBox is working properly. G035...
Page 327: Software (Swapftl) Installation
6. Reboot the computer after installation has finished. VERIFICATION 3.2.1 SOFTWARE VERSION 1. Choose “SwapFTL Binary Utility” from the “SCMSwapFTL” program group. 2. After the utility starts, choose [Help] – [About SwapUti..]. 3. Confirm that the version information is as follows: G035...
Page 328: Flash Memory Card Automatic Detection
SWAPBOX INSTALLATION 3.2.2 FLASH MEMORY CARD AUTOMATIC DETECTION 1. Insert the 4MB flash memory card supplied from Ricoh into a card slot. 2. Windows 95 automatically detects the card, if this is the first time a flash card has been used, Windows 95 installs the necessary drivers, and the “Found new hardware”...
Page 329: Troubleshooting
4. Adjust the settings so that the BIOS does not allocate the SwapBox memory range to PCI devices. Example: Award BIOS 1. Press the “DEL” key during boot-up to gain access to BIOS setup. 2. Choose “PNP AND PCI SETUP” from the main menu. G035...
Page 330: Failed To Open Pccard Errors
4.2.3 RESOURCE CONFLICT If you receive a “Failed to open PCCard” error even if the SwapBox looks correctly configured in the device manager, a memory address conflict is causing the error. Refer to section 4.1.2 to solve the problem. G035...
Page 331: Swapftl Problem With Notebook Computers
4. Click the “Print” button. 5. Choose the PostScript printer using the “Setup” button, choose “All devices and system summary” as the report type, and check the “Print to file” box. 6. Click OK to make a PostScript print file. G035...
Page 332: Complete Uninstall
3. Delete “SCM SwapBox Family Plug and Play PCMCIA Controller” from the Windows device manager. (Choose ‘System” from the Control panel to access the device manager.) 4. Shutdown and restart Windows. Windows starts the plug & play process again to install the SwapBox. G035 9-10...
Page 333 SwapFTL Binary Utility Operation Manual...
Page 335: Overview
SPC. You cannot use other types of flash memory card. 4. After downloading ROM data to one machine, you can use the same card with another machine of the same type. Machine (e.g., NAD Copier) 10-1 G035...
Page 336: Operation
200000 1FFFFF 1FFFFF Copy Copy (BICU) (BICU) 000000 000000 Start Address (Hex) 2 0 0 0 0 0 Length (Hex) 2 0 0 0 0 0 2 0 0 0 0 0 Size (kB) 2,000 (2MB) 2,000 (2MB) G035 10-2...
Page 337 2 0 0 0 0 0 2 0 0 0 0 0 Length (Hex) 4 0 0 0 0 2 0 0 0 0 A 0 0 0 0 Size (kB) 2 5 6 1 2 8 128 + 512 10-3 G035...
Page 338: Downloading To A Machine
Some machines can upload an internal flash ROM image to a flash memory card. To save the image on the flash memory card as a computer file, read the card with a specific address range setting that was mentioned in section 2.1.2, and save the read data as a file. G035 10-4...
Page 339: Functions
An 8-bit checksum is displayed at the lower left corner of the opened file. 3.1.2 [FILE] – [CLOSE] This closes an active file that has been opened. 3.1.3 [FILE] – [SAVE] This saves an active file with the same name. 10-5 G035...
Page 340 3.1.4 [FILE] – [SAVE AS] This saves an active file with a different name from the original. VIEW MENU 3.2.1 [VIEW] – [TOOLBAR] This switches on the toolbar display. 3.2.2 [VIEW] – [STATUS BAR] This switches on the status bar display. G035 10-6...
Page 341: Image Menu
To erase the whole card, do not change the setting Base of Address/ Do not change the settings. Length The default setting is “Hex”. NOTE: If the specified start address and length do not coincide with block boundaries on the flash memory card, the message below appears. 10-7 G035...
Page 342 A “0 (zero)” appears at default. Change this setting if necessary. Length Hexadecimal length of the card appears at default. Change this setting if necessary. Base of Address/ Do not change the settings. Length The default setting is “Hex”. G035 10-8...
Page 343 Do not change the settings. Length The default setting is “Hex”. After writing the data to a flash memory card, an 8-bit checksum pops up, so that you can compare it with the checksum of the source file. 10-9 G035...
Page 344 Do not change the settings. Length The default setting is “Hex”. If verification was successful, a ‘Verification OK!” message pops up. If verification was not successful, a “Compare error !” message pops up with the source and target addresses. G035 10-10...
Page 345 FUNCTIONS 3.4 HELP MENU 3.4.1 [HELP] – [ABOUT SWAPUTI…] 10-11 G035...
Page 347 LARGE CAPACITY TRAY A683...
Page 349: Overall Machine Information
Remaining Paper Detection: 5 steps (100%, 75%, 50%, 25%, Near end) Power Source: 24 Vdc, 5 Vdc (from copier) Power Consumption: 40 W Weight: 17 kg Size (W x D x H): 390 mm x 500 mm x 390 mm 11-1 G035...
Page 350: Mechanical Component Layout
MECHANICAL COMPONENT LAYOUT 1.2 MECHANICAL COMPONENT LAYOUT A683V500.WMF 1. Relay Roller 5. Paper End Sensor 2. Relay Sensor 6. Paper Tray 3. Paper Feed Roller 7. Separation Roller 4. Pick-up Roller G035 11-2...
Page 351: Electrical Component Layout
13. Down Switch 5. Paper Height 2 Sensor 14. Relay Sensor 6. Paper Height 3 Sensor 15. Paper End Sensor 7. Main Board 16. Lift Sensor 8. Side Fence Position Sensor 17. Pick-up Solenoid 9. Lower Limit Sensor 11-3 G035...
Page 352: Electrical Component Description
Lowers the LCT bottom plate if pressed by the user. Solenoids Controls up-down movement of the pick-up Pick-up SOL1 roller. Magnetic Clutches Paper Feed Drives the paper feed roller. Relay Drives the relay roller. PCBs Main Controls the LCT and communicates with the PCB1 copier. G035 11-4...
Page 353: Drive Layout
1.5 DRIVE LAYOUT A683V502.WMF 1. Relay Clutch 6. Tray Drive Belts 2. Paper Feed Clutch 7. Lift Motor 3. LCT Motor 8. Separation Roller 4. Tray Bottom Plate 9. Paper Feed Roller 5. Pick-up Roller 10. Relay Roller 11-5 G035...
Page 354: Detailed Descriptions
This machine uses the FRR (Feed and Reverse Roller) paper feed system (paper feed roller [A], separation roller [B], pick-up roller [C]). When the start key is pressed, the pick-up solenoid [D] energizes and the pick-up roller touches the paper. G035 11-6...
Page 355: Tray Lift And Paper Height Detection Mechanism
Sensor 1 Sensor 2 Sensor 3 Near end On (High) Off (Low) Off (Low) Off (Low) On (High) Off (Low) Off (Low) On (High) On (High) Off (Low) Off (Low) On (High) 100% Off (Low) Off (Low) Off (Low) 11-7 G035...
Page 356: Tray Unit Slide Mechanism
[A] and can slide the LCT away from the copier to remove the jammed paper. When sliding the LCT back into position, the LCT is secured against the copier in the correct position by the docking pins [B] on the LCT. G035 11-8...
Page 357: Service Tables
TXD to the copier TP104 (RXD) RXD from the copier TP105 (5 V) +5 V TP106 (GND) Ground 3.3 SWITCHES Function SW101 Starts the free run SW102 Stops the free run 3.4 FUSES Function FU101 Protects the 24 V line. 11-9 G035...
Page 358: Replacement And Adjustment
3. Remove the rear cover [D] (3 screws). Right Lower Cover 1. Remove the right lower cover [E] (2 screws). Upper Cover 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the upper cover [F]. G035 11-10...
Page 359: Roller Replacement
3. Replace the pick-up roller [A] (1 snap ring). Paper Feed Roller 3. Replace the paper feed roller [B] (1 snap ring). Separation Roller 3. Remove the guide plate [C] (2 screws). 4. Replace the separation roller [D] (1 snap ring). 11-11 G035...
Page 360: Tray Lift And Paper End Sensor Replacement
1. Remove the front and rear cover. 2. Remove the upper cover. 3. Remove the sensor bracket [A] (1 screw). Tray Lift Sensor 3. Replace the tray lift sensor [B] (1 connector). Paper End Sensor 3. Replace the paper end sensor [C] (1 connector). G035 11-12...
Page 361: Relay Sensor Replacement
RELAY SENSOR REPLACEMENT 4.4 RELAY SENSOR REPLACEMENT A683R503.WMF 1. Pull out the LCT. 2. Remove the joint guide [A] (4 screws). 3. Remove the sensor bracket [B] (1 screw). 4. Replace the relay sensor [C] (1 connector). 11-13 G035...
Page 362: Side Fence Position Change
1. Push the down switch to lower the tray bottom plate until it reaches its lowest position. 2. Remove the tray cover. 3. Remove the front and rear side fences [A, B] (1 screw each). 4. Install the side fences in the correct position. G035 11-14...
Page 363 NINE-TRAY MAILBOX AND BRIDGE UNIT G909/G912...
Page 365: Overall Machine Information
BRIDGE UNIT BRIDGE UNIT BRIDGE UNIT TYPE 460 TYPE 460 TYPE 460 NOTE: The installation of the G909 MailBox requires that the A688 Bridge Unit Type 450 and the A682 Paper Tray Unit (PS360) must also be installed. 12-1 G035...
Page 366: Component Layout
7. Proof Tray Paper Overflow Sensor 19. Paper Overflow Sensor 8. Proof Tray Exit Roller 20. Paper Sensor 9. Proof Tray Exit Sensor 21. 9th Tray 10. Proof Tray Junction Gate 22. 1st Tray 11. Entrance Roller 23. Bridge Unit 12. Entrance Sensor G035 12-2...
Page 367: Drive Layout
COMPONENT LAYOUT 1.2.2 DRIVE LAYOUT G909V501.WMF G909V502.WMF G909V503.WMF 1. Proof Tray Exit Roller 5. Entrance Roller 2. Proof Tray Transport Motor 6. Vertical Transport Motor 3. Bridge Exit Roller 7. Tray Feed-out Roller 4. Transport Motor 12-3 G035...
Page 368: Electrical Component Descriptions
Informs the CPU when there is paper on Paper 6 the 6th tray. Informs the CPU when there is paper on Paper 7 the 7th tray. Informs the CPU when there is paper on Paper 8 the 8th tray. G035 12-4...
Page 369 Switches Cuts the +24 V power line and detects Bridge Cover when the bridge cover is opened. Cuts the +24 V power line and detects Front Cover when the front cover is opened. 12-5 G035...
Page 370: Detailed Descriptions
When the proof tray is selected as the output tray, the transport motor and the vertical transport motor energize. Each tray gate [C] is individually controlled by a solenoid. When a solenoid is energized, the tray gate opens and the paper goes into the tray. G035 12-6...
Page 371: Proof Tray Sensors
When this occurs, a message will be displayed on the operation panel and the machine stops printing until the paper stack on the proof tray is removed. 12-7 G035...
Page 372: Tray Sensors
9th tray contains only a phototransistor. The machine detects paper leaving trays 1 to 3 using the sensor above tray 1 and the one on tray 3. When paper passes between those sensors, the light from the LED above tray 1 is interrupted. G035 12-8...
Page 373: Timing Chart And Misfeed Detection
Relay Sensor 100 pulses Vertical Transport Motor 1st Tray Sol. Tray Exit Sensor G909D502.WMF A4 Sideways (to Proof Tray) Transport Motor Proof Transport Motor Entrance Sensor Proof Junction Gate Sol. Relay Junction Gate Sol. Proof Exit Sensor G909D500.WMF 12-9 G035...
Page 374 2. Off check J6: A sensor does de-activate within the specified number of pulses after that sensor has been activated. Number of pulses = Paper length (in the paper feed direction) x 1.5 1 pulse = 0.1707 mm G035 12-10...
Page 375: Installation Procedure
3.1.2 REQUIREMENT OPTIONS FOR MAIN MACHINE When the mailbox is going to be installed to the A230, A231, or A232 machines, the following options for the main machine are required. 1. Bridge Unit Type 450 (A688) 2. Paper Tray Unit – PS360 (A682) 12-11 G035...
Page 376: Installation Procedure
4. Peel off the backing of the double sided tape that is attached to the lower grounding plate [D]. 5. Attach one lower grounding plate to the center of the bottom edge of the paper tray unit as shown. Go to step 7. G035 12-12...
Page 377 NOTE: When attaching the cushion to position [H], cut about 40 mm (1.6 inches) off one edge of the cushion. 8. Open the front cover [I] of the mailbox, and remove the screw [J] that secures the locking lever [K]. Then pull the locking lever. 12-13 G035...
Page 378 13. Install the proof tray attachment on the proof tray. 14. A229 machines only: Install the exit guide mylar [D] on the upper cover just above the anti-static brush. 15. Power on the main switch and check the mailbox operation. G035 12-14...
Page 379: Bridge Unit For Mailbox (G912)
Check the accessories in the box against the following list. Description Q’ty Guide Plate Bracket Cable Cover Switch Grounding Bracket Finisher Shielding Plate Screw - M4 x 8 Screw - M4 x 4 Screw - M3 x 6 G912I500.WMF 12-15 G035...
Page 380: Installation Procedure
NOTE: Do not remove the protective sheet [B] at this time. 2. Remove the mailbox if it has been previously installed. 3. Remove the rear cover [C] of the mailbox (8 screws). 4. Remove the proof tray unit [D] (6 screws, 1 connector). 5. Remove the cover [E]. G035 12-16...
Page 381 8. Route the cable [D] and affix it to the clamp as shown. 9. Connect the cover switch [E] to the cable then install the cover switch (2 screws – M4 x 8). 10. Remove the paper guide plate [F] (2 screws). 12-17 G035...
Page 382 13. Remove the tape [F] of the protective sheet. 14. Open the upper paper guide [G] then pull out the protective sheet [H]. NOTE: Check that all mylars are set into the gap between the paper guides. G035 12-18...
Page 383 If the 3000 sheet finisher (A697) is going to be installed, perform steps 21 to 25. 21. Install the front joint bracket [E] and rear joint bracket [F] which are contained in the finisher’s accessory box. 12-19 G035...
Page 384 24. Attach the shielding plate [C] to the finisher (2 screws – M3 x 8). 25. Attach the finisher to the mailbox (refer to the Finisher Installation Procedure). 26. Power-on the main switch of the main machine and check the bridge unit operation. (Select a copy mode that uses the finisher.) G035 12-20...
Page 385: Replacement And Adjustment
6. Remove the proof tray paper overflow sensor [F]. 4.1.2 PROOF TRANSPORT UNIT 1. Remove the proof tray unit [B] and remove two screws [C]. 2. Carefully turn over the proof tray unit and remove the proof transport unit [G] (2 screws). 12-21 G035...
Page 386: Tray Unit
4. Open the front cover [D] and remove the cover bracket [E] (1 screw), then remove the front cover. 5. Remove the two screws [F] which secure the tray. 6. Remove the tray [G]. (First move the tray to the left and gently flex it, then remove the tray.) G035 12-22...
Page 387: Paper Sensor, Paper Overflow Sensor And Tray Exit Sensor
7. After replacing the tray exit sensor, perform the tray exit sensor adjustment (see Tray Exit Sensor Adjustment). NOTE: After replacing the tray exit sensor, do not put the rear cover back on the mailbox, because the tray exit sensor adjustment must be performed first. 12-23 G035...
Page 388: Main Control Board
G909R508.WMF G909R509.WMF 1. Remove the rear cover [A] (8 screws). 2. Remove the main control board [B] (all connectors). 3. After replacing the main control board, perform the tray exit sensor adjustment procedure (see Tray Exit Sensor Adjustment). G035 12-24...
Page 389: Tray Exit Sensor Adjustment
6. Make sure that the interface cable is connected to the main machine and turn the main switch on. 7. Fully turn the appropriate variable resistor (VR) [D] clockwise, then check that the appropriate LED [E] has turned off (the relationship between tray, VR, and LED are shown in the table below). 12-25 G035...
Page 390 VR No. LED No. TP No. Trays 1 to 3 LED 2 Trays 4 to 6 LED 3 Trays 7 to 9 LED 4 TP13 NOTE: The DIP switches to change are the same regardless of the adjusted sensor. G035 12-26...
Page 391: Service Tables
When the 2nd paper overflow sensor is activated, LED3 will light. When the 3rd paper overflow sensor is activated, LED4 will light. Paper Overflow Sensor When the 4th paper overflow Check (4th to 6th trays) sensor is activated, LED2 will light. 12-27 G035...
Page 392: Variable Resistors
Adjusts the tray exit sensor sensitivity between trays 7 and 9 5.1.3 LEDS Number Monitored Signal LED1 Monitors the software operation. Blinking: Normal operation Others: Abnormal operation LED2 The LED lights when the appropriate sensor is activated. (Refer to the DIP switch table for more details.) LED3 LED4 G035 12-28...
Page 393 BRIDGE UNIT A688...
Page 395: Overall Machine Information
1.1 SPECIFICATIONS Standard sizes Paper Size: A6 lengthwise to A3 HLT to DLT Non-standard sizes Width: 100 to 305 mm Length: 148 to 432 mm Paper Weight: 52 g/m ~ 135 g/m , 16 lb ~ 42 lb G035 13-1...
Page 396: Mechanical Component Layout
MECHANICAL COMPONENT LAYOUT 1.2 MECHANICAL COMPONENT LAYOUT A688V500.WMF 1. Upper Exit Roller 5. Relay Sensor 2. Junction Gate Solenoid 6. 2nd Transport Roller 3. Junction Gate 7. Left Exit Roller 4. 1st Transport Roller G035 13-2...
Page 397: Electrical Component Layout
Detects when the tray exit unit is opened. Right Guide Detects when the right guide is opened. Left Guide Detects when the left guide is opened. Solenoids Junction Gate Moves the junction gate to direct the SOL1 paper to the upper or left tray. G035 13-3...
Page 398: Drive Layout
DRIVE LAYOUT 1.5 DRIVE LAYOUT A688V502.WMF 1. Left Exit Roller 3. Upper Exit Roller 2. 2nd Transport Roller 4. 1st Transport Roller G035 13-4...
Page 399: Detailed Description
[C]. When the left tray or the finisher is selected, the junction gate stays off and the paper is sent to the left tray or the finisher through the transport rollers [D] and the left exit roller. G035 13-5...
Page 400: Replacement And Adjustment
2. Remove the rear upper cover [A] (1 screw). 3. Remove the upper cover unit [B] (2 screws, 2 connectors, Timing Belt). 4. Remove the exit guide plate [C] (2 screws). 5. Replace the exit sensor [D] (1 connector). G035 13-6...
Page 401 1,000-SHEET FINISHER A681...
Page 403: Overall Machine Information
A3, B4, DLT, LG — Staple Positions: Staple Replenishment: Cartridge (3,000 staples/cartridge) Power Source: 24 Vdc, 5 Vdc (from the copier) Power Consumption: 48 W Weight: 21 kg Dimensions (W x D x H): 568 x 520 x 625 mm G035 14-1...
Page 404: Mechanical Component Layout
1. Shift Tray 7. Lower Transport Roller 2. Exit Roller 8. Entrance Roller 3. Exit Roller Release Cam 9. Stapler Unit 4. Upper Transport Roller 10. Positioning Roller 5. Middle Transport Roller 11. Stack Feed-out Belt 6. Junction Gate G035 14-2...
Page 405: Electrical Component Layout
24. Jogger Fence Motor 11. Transport Motor 25. Jogger Unit Paper Sensor 12. Positioning Roller Solenoid 26. Rear Fence Motor 13. Shift Tray Lower Limit Sensor 27. Rear Fence HP Sensor 14. Entrance Sensor 28. Stack Feed-out Motor G035 14-3...
Page 406: Electrical Component Descriptions
Detects the lower limit position of the shift Lower Limit tray. Shift Tray Detects the stop position of the shift tray Half-turn during the side-to-side movement. Solenoids SOL1 Junction Gate Drives the junction gate. Positioning Moves the positioning roller. SOL2 Roller G035 14-4...
Page 407 Cuts the dc power when the right cover is Safety opened. Cartridge Set Detects whether a staple cartridge is installed. Staple End Detects staples in the cartridge. PCBs Main Controls the finisher and communicates with PCB1 the copier. G035 14-5...
Page 408: Drive Layout
4. Shift Tray Lift Motor 13. Stack Feed-out Motor 5. Shift Motor 14. Rear Fence Motor 6. Lower Transport Roller 15. Jogger Fence Motor 7. Positioning Roller Drive Roller 16. Jogger Fence 8. Transport Motor 17. Stack Feed-out Belt 9. Entrance Roller G035 14-6...
Page 409: Detailed Descriptions
When the exit sensor of the copier turns on, the junction gate solenoid is energized. The paper is sent to the jogger unit. No staple mode The junction gate solenoid stays off and the paper is sent to the shift tray directly. G035 14-7...
Page 410: Jogger Unit Paper Positioning Mechanism
20 mm against the rear fence to align the paper horizontally. Then the jogger fence moves back to the previous position. The stapler is mounted on the rear fence. G035 14-8...
Page 411: Exit Guide Plate Open/Close Mechanism
When the exit guide plate open sensor [E] turns on, the motor stops. When stapling is finished, the exit guide plate motor turns on again to close the exit guide plate. When the exit guide plate HP sensor [F] turns on, the motor stops. G035 14-9...
Page 412: Stapler
[B]. Therefore, the jammed staple can be removed easily after pulling out the staple cartridge. If there is no staple cartridge in the stapler unit or no staples in the staple cartridge, staple end is indicated on the operation panel. This machine has only one stapling position. G035 14-10...
Page 413: Feed Out Mechanism
Shortly afterwards, the stack feed-out motor stops, and the exit motor feeds out the stack. When the stack has been fed out to the shift tray, the stack feed-out motor turns on again. When the stack feed-out belt HP sensor [C] turns on, the stack feed-out motor turns off. G035 14-11...
Page 414: Shift Tray Up/Down Mechanism
The shift tray upper limit switch [F] prevents the drive gears from being damaged if the stack height sensor fails. When the shift tray turns on the shift tray upper limit switch, the switch cuts the power to the shift tray lift motor. G035 14-12...
Page 415: Shift Tray Side-To-Side Mechanism
[F] and the shift motor stops. The next set of copies is then delivered. The motor turns on, repeating the same process and moving the tray back to the previous position. G035 14-13...
Page 416: Jam Conditions
2. When the exit sensor does not turn off within 1,000 ms after it turns on. 3. When the exit sensor does not turn on in no staple mode within 1,250 ms after the entrance sensor turns on. G035 14-14...
Page 417: Timing Charts
O F F O F F O F F Copier Finisher Shift Motor ON Exit Completed Exit Completed Exit Completed Exit Completed Exit Completed Exit Completed Finisher Copier Transport Motor Exit Motor Entrance Sensor Exit Sensor Shift Motor A681D508.WMF G035 14-15...
Page 418: Staple Mode (A4 Sideways, 2 Sheets/2 Sets)
Solenoid Entrance Sensor Exit Sensor Positioning Roller Solenoid Jogger Fence Motor R e a r F e n c e Motor S t a p l e H a m m e r Motor Stack Feed-out Motor A681D509.WMF G035 14-16...
Page 419: Service Table
3.1 DIP SWITCH TABLE DPS101 Description Default Free run: staple mode Free run: no-staple mode 3.2 TEST POINTS Label Monitored Signal TP100 (5 V) +5 V TP101 (GND) Ground 3.3 FUSES Function FU100 Protects the 24 V line. G035 14-17...
Page 420: Replacement And Adjustment
2. Remove the front cover [B] (2 screws). Rear Cover 1. Remove the rear cover [C] (2 screws). Upper Cover 1. Remove the front door. 2. Remove the front cover. 3. Remove the rear cover. 4. Remove the upper cover [D] (2 screws). G035 14-18...
Page 421: Lower Left Cover
Front Shift Tray Cover 1. Remove the front shift tray cover [B] (1 screw). Rear Shift Tray Cover 1. Remove the rear shift tray cover [C] (1 screw). Shift Tray 1. Remove the shift tray [D] (1 snap ring). G035 14-19...
Page 422: Entrance Sensor Replacement
ENTRANCE SENSOR REPLACEMENT 4.2 ENTRANCE SENSOR REPLACEMENT A681R501.WMF 1. Remove the finisher from the copier. 2. Replace the entrance sensor [A] (1 connector). G035 14-20...
Page 423: Exit Sensor Replacement
EXIT SENSOR REPLACEMENT 4.3 EXIT SENSOR REPLACEMENT A681R502.WMF 1. Remove the upper cover. 2. Remove the exit sensor bracket [A] (1 screw). 3. Replace the exit sensor [B] (1 screw, 1 connector). G035 14-21...
Page 424: Stack Height Sensor Replacement
7. Remove the end fence [F] (1 snap ring). 8. Remove the stack height sensor cover [G] (1 screw). 9. Remove the stack height sensor bracket [H] (1 screw). 10. Replace the stack height sensor [I] (1 connector). G035 14-22...
Page 425: Positioning Roller Replacement
POSITIONING ROLLER REPLACEMENT 4.5 POSITIONING ROLLER REPLACEMENT A681R506.WMF 1. Pull out the jogger unit. 2. Remove the snap ring [A]. 3. Release the rubber belt [B]. 4. Remove the positioning roller [C]. G035 14-23...
Page 426: Stapler Replacement
3. Remove the lower cover screw [B]. 4. Remove the upper cover [C] (2 screws). 5. Remove the stapler with the lower cover [D] (2 screws). 6. Release the harness from the lower cover. 7. Replace the stapler. G035 14-24...
Page 427: Rom History
A681 can also be used with the A265 and A267. This change has no effect on the A232 series. Corrects the following: A6815103F • Stapled paper did not stack straight. Corrects the following: A6815103E • Paper rolling on the shift tray. G035 14-25...
Page 429 3,000-SHEET FINISHER A697...
Page 431: Overall Machine Information
2 to 9 B5, A4 lengthwise LT lengthwise 10 to 40 150 to 37 2 to 9 A4 sideways LT sideways 10 to 40 250 to 63 2 to 9 Other sizes 10 to 25 150 to 60 G035 15-1...
Page 432 (Front, Rear, Rear-Oblique) 2 staple: 1 position Staple Replenishment: Cartridge (5,000 staples) Power Source: 24 Vdc (from copier) Power Consumption: 48 W Weight: 45 kg Size (W x D x H): 625 mm x 545 mm x 960 mm G035 15-2...
Page 433: Mechanical Component Layout
13. Positioning Roller 5. 1st Entrance Roller 14. Stack Feed-out Belt 6. Punch Unit 15. Middle Transport Roller 7. 2nd Entrance Roller 16. Shift Tray Exit Roller 8. Punch Waste Hopper 17. Shift Tray 9. Stapler Junction Gate G035 15-3...
Page 434: Electrical Component Layout
16. Shift Tray Lower Limit 2 Sensor 35. Shift Tray Upper Limit Switch 17. Stapler Motor 36. Stapler Junction Gate Solenoid 18. Stapler Rotation Motor 37. Upper Tray Paper Limit Sensor 19. Stapler Rotation HP Sensor 38. Upper Tray Exit Sensor G035 15-4...
Page 435: Electrical Component Description
Checks for misfeeds at the upper tray. Exit Upper Tray Detects when the paper stack height in the Paper Limit upper tray is at its upper limit. Shift Tray Detects the return position for side-to-side Half-turn movement of the shift tray. G035 15-5...
Page 436 SOL2 Junction Gate Positioning Moves the positioning roller against the SOL3 Roller stapling tray. PCBs Main Controls the finisher and communicates with PCB1 the copier. Punch Passes signals between the punch unit and PCB2 the finisher main board. G035 15-6...
Page 437: Drive Layout
7. Lower Transport Motor 18. Jogger Motor 8. Middle Transport Roller 19. Jogger Fence 9. Lower Transport Roller 1 20. Stack Feed-out Belt 10. Shift Tray Exit Motor 21. Stapler Motor 11. 2nd Entrance Roller 22. Stapler Rotation Motor G035 15-7...
Page 438: Detailed Descriptions
The tray junction gate solenoid and the stapler junction gate solenoid remain off. The copies are sent to the shift tray directly. Staple mode The tray junction gate solenoid remains off and the stapler junction gate solenoid turns on. The copies go downwards to the jogger unit. G035 15-8...
Page 439: Jogger Unit Paper Positioning Mechanism
70 ms to move the jogger fences 5 mm towards the paper. After a short time, the jogger motor turns on again approximately for 60 ms for the horizontal paper alignment then goes back to the waiting position. G035 15-9...
Page 440: Stapler Unit Movement Mechanism
After the job is completed, the stapler moves back to its home position. This is detected by the stapler HP sensor [C]. Rotation: In the oblique staple position mode, the stapler rotation motor [D] rotates the stapler 45° after it moves to the stapling position. G035 15-10...
Page 441: Stapler
If this condition is detected during a copy job, the indication will appear, but the copy job will not stop. The staple cartridge has a clinch area [I], in which jammed staples are left. Operators can remove the jammed staples from this area. G035 15-11...
Page 442: Feed-Out Mechanism
600 ms to wait until the exit rollers have completely fed the stapled stack out to the shift tray. Then, the stack-feed-out motor turns on again until the pawl actuates the stack feed-out belt home position sensor [F]. G035 15-12...
Page 443: Shift Tray Up/Down Mechanism
The shift tray upper limit switch [J] prevents the drive gear from being damaged if stack height sensor 1 fails. When the shift tray pushes up the shift tray positioning roller [K], the switch will cut the power to the shift tray lift motor. G035 15-13...
Page 444: Shift Tray Side-To-Side Mechanism
[F] and the shift motor stops. The next set of copies is then delivered. The motor turns on, repeating the same process and moving the tray back to the previous position. G035 15-14...
Page 445: Punch Unit Drive Mechanism
The home position is detected by the punch HP sensor [C]. When the cut-out on the punch shaft gear disk [D] enters the punch HP sensor, the punch motor stops. The punch position is adjusted as follows: Right to left: SP mode Front to rear: Spacers G035 15-15...
Page 446: Punch Waste Collection Mechnism
The hopper sensor also works as the hopper set sensor. If the punch waste hopper is not set, the hopper sensor moves away from the hole in the hopper holder [D] and a message is displayed. This message is the same as for the hopper full condition. G035 15-16...
Page 447: Jam Conditions
9. In staple mode, the stapler tray paper sensor does not turn off within 250 pulses of the stack feed-out motor after it starts. 10. In staple mode, the shift tray exit sensor does not turn off within 1,260 ms after the stack feed-out motor starts. G035 15-17...
Page 448: Timing Charts
(Exit Sensor On) Motor On (Exit Sensor On) Motor Off Finisher > Copier Exit Finisher Entrance Sensor Punch HP Sensor Shift Tray Exit Sensor Punch Motor Upper Transport Motor 7 8 m s Punch Motor Tray Junction Gate Solenoid A697D513.WMF G035 15-18...
Page 449: A4 Sideways (2 Sheets): Sort/Stack And Punch Mode
(Exit Sensor On) Motor Off Finisher > Copier Exit Finisher Entrance Sensor Punch HP Sensor Shift Tray Exit Sensor Shift Tray Half Turn Upper Transport Motor Shift Tray Exit Motor 7 8 m s Punch Motor Shift Motor A697D514.WMF G035 15-19...
Page 450: A4 Sideways (2 Sheets): Staple And Punch Mode
Stapler HP Sensor Stapler Junction Gate Solenoid 4 0 m s Positioning Roller Solenoid Staple Hammer Motor Staple Hammer HP Sensor Stack Feed-out Motor Stack Feed-out Belt HP 1 0 0 m s Sensor Shift Tray Exit Motor A697D515.WMF G035 15-20...
Page 451: Service Tables
NOTE: Do not use any other settings. 3.2 TEST POINTS Label Monitored Signal TP101 (GND) Ground 3.3 LED Function LED100 Monitors the stack feed-out motor speed. 3.4 VARIABLE RESISTORS Function VR100 Adjust the stack feed-out motor speed. 3.5 FUSES Function FU100 Protects 24 V. G035 15-21...
Page 452: Replacement And Adjustment
3. Remove the upper bracket [D] (1 screw). 4. Remove the front door [E]. Left Front Cover 1. Remove the rear cover. 2. Remove the upper cover. 3. Remove the front door. 4. Remove the left front cover [F] (2 screws). G035 15-22...
Page 453: Shift Tray
Right Cover 1. Remove the right cover [H] (2 screws). Front Shift Tray Cover 1. Remove the front shift tray cover [I] (1 screw). Rear Shift Tray Cover 1. Remove the rear shift tray cover [J] (1 screw). G035 15-23...
Page 454: Positioning Roller Replacement
POSITIONING ROLLER REPLACEMENT 4.2 POSITIONING ROLLER REPLACEMENT A697R501.WMF 1. Open the front door. 2. Remove the snap ring [A]. 3. Release the rubber belt [B]. 4. Replace the positioning roller [C]. G035 15-24...
Page 455: Alignment Brush Roller Replacement
5. Remove the front side E-ring [E] and bushing [F]. 6. Remove the alignment brush roller assembly. 7. Remove the timing pulley [G] (1 E-ring). 8. Replace the alignment brush roller [H] (1 spacer, 1 bushing). G035 15-25...
Page 456: Sensor Replacemnt
1. Remove the upper left cover. 2. Remove the upper cover. 3. Remove the sensor feeler [A] (1 screw, 1 connector). 4. Remove the sensor bracket [B] (1 screw). 5. Replace the stack height sensor 1 [C] or 2 [D]. G035 15-26...
Page 457: Upper Tray Paper Limit And Exit Sensor
3. Remove the sensor bracket [A] (1 screw). 4. Replace the upper tray paper limit sensor [B] (1 connector). Upper Tray Exit Sensor 3. Remove the sensor bracket [C] (1 screw). 4. Replace the upper tray exit sensor [D] (1 connector). G035 15-27...
Page 458: Shift Tray Exit Sensor
4. Open the front door and remove the upper exit guide [A] (1 plastic clip). 5. Remove the guide stay [B] (2 screws). 6. Remove the discharge brush [C] (2 screws). 7. Replace the shift tray exit sensor [D] (1 screw, 1 connector). G035 15-28...
Page 459: Entrance And Stapler Tray Entrance Sensor
2. Remove the sensor bracket [A] (1 screw). 3. Replace the entrance sensor [B] (1 screw, 1 connector). Stapler Tray Entrance Sensor 2. Remove the sensor bracket [C] (1 screw). 3. Replace the stapler tray entrance sensor [D] (1 screw, 1 connector). G035 15-29...
Page 460: Stapler Rotation Hp Sensor
4.4.5 STAPLER ROTATION HP SENSOR 1. Remove the stapler unit. 2. Remove the screw [A] and rotate the stapler bracket [B]. 3. Remove the sensor bracket [C] (1 screw). 4. Replace the stapler rotation HP sensor [D] (1 connector). G035 15-30...
Page 461: Stapler Removal
STAPLER REMOVAL 4.5 STAPLER REMOVAL A697R509.WMF 1. Open the front door and pull out the jogger unit. 2. Move the stapler to the front. 3. Remove the stapler [A] (1 screw, 1 connector). G035 15-31...
Page 462: Punch Position Adjustment
The optional punch units have the following 3 spacers as accessories. 1 mm thickness: 2 pcs 2 mm thickness: 1 pc The punch position can be adjusted by up to 4 mm by combinations of the 3 spacers. G035 15-32...
Page 463: Stack Feed-Out Motor Speed Adjustment
1. Set the DIP switches on the finisher main board as follows. DIP SW DIP100 DIP101 2. If LED100 remains lit, turn VR100 counterclockwise until LED100 starts blinking. 3. Turn VR100 clockwise until the LED stops blinking and remains lit. G035 15-33...
Page 464: Rom History
Jam codes were not defined for paper jams at or before the entrance sensor. Corrects the following: A6975656 H Not Available • The stack height sensor mis-detects the height, which causes the exit motor to stop and a paper jam occurs. G035 15-34...
Page 465 Level Prod. Date Ver. ⇒ Corrects the following: A6975656 J Not Available • If a finisher job is initiated from 5 to 105 seconds after the copier recovers from “Energy Saver Mode”, SC990 or a paper jam occurs. G035 15-35...
Page 467 APPENDIX...
Page 469: Appendix 1
Mail box sensor: paper does not activate the sensor LCT: paper doe not activate the sensor 1st paper tray: paper stays at the sensor 2nd paper tray: paper stays at the sensor 3rd paper tray: paper stays at the sensor APPENDIX-1 G035...
Page 470 Exit sensor: paper stays at the sensor Bridge exit sensor: paper stays at the sensor Bridge relay sensor: paper stays at the sensor Duplex entrance sensor: paper stays at the sensor Registration sensor: paper stays at the sensor G035 APPENDIX-2...
Page 471 TECHNICAL SERVICE BULLETINS...
Page 473 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G035 – 001 12/06/99 APPLICABLE MODEL: GESTETNER – P7045 RICOH – AP4500 SAVIN – SLP45 SUBJECT: SERVICE MANUAL CORRECTIONS GENERAL: The Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 1 set of replacement pages.
Page 474: Specifications
8 MB (Standard) 2 DRAM SIMM slots (up to 64 MB) Maximum Total: Up to 72 MB Printer Driver: PCL5e Printer Driver for Windows 3.1/95/98/NT PCL6 Printer Driver for Windows 3.1/95/98/NT PS3 Printer Driver for Windows 3.1/95/98/NT and Macintosh G035...
Page 475 50 sheets (up to 5.5 mm, 0.2") LCT: 1,500 sheets Tray Capacity: A4/11" x 8.5": 500 sheets A3/B4/8.5" x 14"/11" x 17": 250 sheets Standard tray Toner Replenishment: Cartridge exchange (700 g/cartridge) ⇒ Toner Yield: 30 k sheets printed (A4 sideways, 5% full black) G035...
Page 476 Less than 1.0 kW ⇒ Energy Saver Mode Less than 45 W/h Mainframe Only System Noise Emission: Sound Power Level Printing 70 dB(A) 74 dB(A) Stand-by 42 dB(A) — NOTE: The above measurements were made in accordance with ISO 7779. G035...
Page 477 “K” is decided in a similar way as for the previous condition. GAIN Determination GAIN is another factor in the toner supply motor on time calculation. It is decided using the following data. • Vtref – Vt(10) • Ten most recent Vt values 2-29 G035...
Page 478 ID sensor output, is also used as one of the factors for deciding the new Vtref, which is used for toner density control. The new Vtref is determined using the following data. • Vtref – Vt(10) • Vsp/Vsg From this point, toner density control is done using the new Vtref. G035 2-30...
Page 479 GESTETNER – P7045 RICOH – AP4500 SAVIN – SLP45 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all G035 Parts Catalogs. • UPDATE 1: Page 10. Add index number 34 as follows REFERENCE PART NO.
Page 480 Tech Service Bulletin No. G035 – 002 Page 2 of 2 • UPDATE 3 : Page 46. Correct index number from 108 to 101. REFERENCE PART NO. DESCRIPTION PAGE ITEM 04513006B Tapping screw M3x6 • UPDATE 4: Page 52. Add NV-RAM (index number 26) and part number as follows Page 52 •...
Page 481 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G035 - 003 03/01/2000 APPLICABLE MODEL: GESTETNER – P7045 RICOH – AP4500 SAVIN – SLP45 SUBJECT: SERVICE MANUAL - INSERT GENERAL: The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages.
Page 482 7. IOB (Input/Output Board) The IOB handles the following functions. • Drive control for the sensors, motors, and solenoids of the printer • PWM control for high voltage supply board • Serial interface with peripherals • Fusing control G035 1-18...
Page 483 This HDD interface is provided to support storage of fonts downloaded from a 7. IC Card Interface The flash memory card for updating the controller and PostScript firmware is connected to this flash memory card slot. 8. Power-on Self-diagnostic When the controller is turned on, the controller performs a self-diagnostic test. G035...
Page 484 The cam gear [D] moves the pin [C] at the rear of the cleaning pad holder, and also moves the cleaning pad from side to side. This movement improves the cleaning process. 2-21 G035...
Page 485 See the "System Parameter and Data Lists" section for how to print the lists. SMC Printing - Prints the SP mode data list. Execute SP Mode Data See the "System Parameter and Data Lists" section for how to print the lists. G035 4-12...
Page 486 3. Remove the optional hard disk unit [B] (4 screws, 1 connector) and DRAM SIMMs that have been installed. 4. Remove the NIB [C] (4 screws, 1 connector). 5. Remove the NVRAM [D] from the old printer control board and install it on the new printer control board. G035 6-50...
Page 487 4. Remove the I/O board bracket. (See I/O Board.) 5. Remove the BICU board [A] (5 screws, 1 stud, all connectors). 6. Remove the NV RAM [B] from the old BICU board and install it on the new board. ⇒ 6-53 G035...
Page 488 • Noise on the ac power line SC548: Fusing Unit Installation Error Definition [A] The machine cannot detect the fusing unit when the front cover and right cover are closed. Possible Causes • Fusing unit is not installed • Poor fusing unit connection 7-13 G035...
Page 489 New Information (ROM History - BICU) The PCB ROM revision B (file name G035BICU_REVB.EXE) can be downloaded through the Ricoh Technical Services FTP Site http://tsc.ricohcorp.com. NOTE: Refer to Facts Line Bulletin # FL002 for more information about the FTP Internet Web Site.
Page 490 1.5 DRIVE LAYOUT ..................8-5 2. DETAILED DESCRIPTIONS ............8-6 2.1 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM ... 8-6 2.2 PAPER LIFT MECHANISM ..............8-7 2.3 PAPER END DETECTION ............... 8-9 2.4 PAPER HEIGHT DETECTION ............... 8-10 2.5 PAPER SIZE DETECTION ..............8-11 G035...
Page 491 G0355113 B From Dec. 8, 99 • SC546 occurs during warm-up, when the machine is Prod. turned on or brought out of Energy Saver Mode and the surrounding environment is relatively cold. Initial Production G0355113 A 1st Prod. G035 7-26...
Page 492 The Toner Supply Shutter (P/N A2322321) returns to the closed position when the PCD Unit (PCU and Development Unit) is set into the G035. Normally, the Shutter is not in the closed position when the G035 is shipped. If the technician removes the PCD Unit from the G035 and attempts to separate the PCU from the...
Page 493 ITEM AA062303 Tension Spring A2322321 Shutter – Toner Supply UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style Shutter - Toner Supply installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 P1891100001...
Page 494 Hot Roller Stripper AA060701 AA060837 Tension Spring UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style Hot Roller Strippers and Tension Springs installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 P1891200023...
Page 495 PCU UNIT 1 SEALS GENERAL: The PCU Unit Seals have been registered as service parts. The following parts additional parts are being issued for all G035 Parts Catalogs. Please update your Parts Catalogs with the following information. REFERENCE PART NUMBER...
Page 496 Stepped Screw – M2.5 A2325402 A2845520 DC Harness – Front Upper UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new micro switch and harness installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045...
Page 497 [D]. The Grounding Plate Pawls for the rear groove should be set first, followed by the setting of those for the front groove. Continued…     2000 RICOH Corporation. All rights reserved. CONTROL NO. 049ABW...
Page 498 Tech Service Bulletin No. G035 - 009 Page 2 of 4 Install the Bushing [B]. Remove the Bushing [E] (1 E-ring). Attach the edge of the Grounding Plate [F] (A2844462) to the back of the attachment projection of the Exit Unit Frame.
Page 499 Tech Service Bulletin No. G035 - 009 Page 3 of 4 5. Route the Harness under the Drive Belt as shown in the illustration, taking up any slack. 6. Secure the other end of the Harness with the Screw [E] that secures the Stay.
Page 500 Tech Service Bulletin No. G035 - 009 Page 3 of 4 GENERAL: The following parts updates are being issued for all G035 Parts Catalogs. Please update your Parts Catalogs with the following information. REFERENCE OLD PART NO. NEW PART NO.
Page 501 SAVIN – SLP45 SAVIN – SLP45 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following parts updates are being issued for all G035 Parts Catalogs. • UPDATE 1: Quenching Lamp Magnet – To standardize with other models the quenching lamp magnet has been changed.
Page 502 Tech Service Bulletin No. G035 – 010 Page 2 of 2 • UPDATE 2: Hard Disk Drive – Due to a vender change the part number for the Hard Disk Drive has been changed. REFERENCE OLD PART NO. NEW PART NO.
Page 503 1 set of replacement pages. PAGES: ⇒ The revised areas have been highlighted by an arrow • 7-6, 7 Updated Information (SC Tables) • 7-26 Updated Information (ROM History)     CONTROL NO. 050ABW 2000 RICOH Corporation. All rights reserved.
Page 504 The TD sensor output voltage is less than 0.5 V or more than 4.0 V 10 times consecutively during printing. Possible Causes • TD sensor abnormal • Poor connection between the TD sensor and the I/O board (IOB) • I/O board (IOB) defective G035...
Page 505 SC405: Transfer Belt Error Definition [B] The transfer belt does not move away from the drum during ID sensor pattern checking. Possible Causes • Main motor/drive malfunction • Transfer belt position sensor defective • Poor transfer belt position sensor connection G035...
Page 506 Energy Saver Mode, an SC990 may occur (Software Performance error) before the machine reaches Stand-by temperature. If this happens an SC542 occurs (Fusing Temperature Warm-up error). The correction turns off the Fusing Temperature control whenever an SC990 occurs. G035 7-26...
Page 507 Updated Information (Photoconductor Unit) • 2-44 Updated Information (Paper Registration) • Updated Information (Photoconductor Unit and Development Unit) • 7-17 and 18 Updated Information (Service Call Conditions)     CONTROL NO. 053ABW 2000 RICOH Corporation. All rights reserved.
Page 508 (OPC) drum (diameter: 60 mm) is used in this machine. 1. Toner Collection Coil 6. OPC Drum 2. Toner Collection Plate 7. Transfer Entrance Guide 3. ID Sensor 8. Charge Roller Cleaning Pad 4. Spur 9. Charge Roller 5. Pick off Pawl 10. Cleaning Blade G035 2-16...
Page 509 The registration and relay rollers feed the paper to the image transfer section. The registration sensor is also used for paper misfeed detection. G035 2-44...
Page 510 6.3 PHOTOCONDUCTOR UNIT (PCU) 6.3.1 PCU G035R552.WMF 1. Pull out the PCU and development unit. (See Photoconductor Unit and Development Unit.) 2. Remove the PCU [A] (2 screws) from the development unit [B]. G035...
Page 511 Definition [B] The IPU sends the Page Print Complete signal back to the engine software, but the signal does not contain the correct response code to the original command. Possible Causes • BICU Software defective • BICU Board defective 7-17 G035...
Page 512 The print ready signal is not generated for more than 17 seconds after the IPU received the print start signal. Possible Causes • Software defective SC980: HDD Access Error Definition [B] Incorrect parameter sent to the HDD controller. Possible Causes • Software defective • Poor connection between BICU and HDD. G035 7-18...
Page 513 The developer has a tendency to spill out during transport. The factory will only supply this unit with developer. • The Development Unit for the A232 Series (P/N A2327460) can also be used with the G035 if the three components listed below are installed.
Page 514 DESCRIPTION PAGE ITEM A2325310 A2935310 Laser Sync. Detector UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style Laser Sync. Detector installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 P1890900001 Ricoh AP4500...
Page 515 DESCRIPTION PAGE ITEM AB017429 AB014189 Gear – 27Z UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style Gear – 27Z installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 P18008xxxx Ricoh AP4500...
Page 516 Driven Roller – M9 A2324491 A2844491 Guide Plate – Fusing Unit UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style Driven Roller and Guide Plate installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045...
Page 517 NEW PART NO. DESCRIPTION PAGE ITEM A2325130 A2325135 PFB Board UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style PFB Board installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 P18008xxxx Ricoh AP4500 P1800800001...
Page 518 4-22 Updated Information (Copy Flash ROM) • 4-22A & B New Information (Copy Flash ROM) • 4-23 Updated Information (Parallel Loop Back Test) • Updated Information (SC442)     CONTROL NO. 066ABW 2000 RICOH Corporation. All rights reserved.
Page 519 PC (and the printer controller does not start up), any attempts thereafter to download from the card or PC will not be possible. In addition, it will not be possible to return the machine to operating condition. G035 4-22...
Page 520 Downloading from the controller to ROM DIMM 1. Remove the printer controller. 2. Install the ROM DIMM on the controller. 3. Install the printer controller and turn on the machine. 4. Enter SP mode. 5. Choose “1-3 – Copy ROM”. 4-23 G035 4-22A...
Page 521 2. Choose “1-4 – Format Disk”. 3. Press “Enter #” in reply to the confirmation message. Hard disk formatting will take several minutes. 4. After confirming that formatting was successful, turn the machine off and back on again. G035 4-24 4-22B...
Page 522: Operation Panel
G N D G N D G N D G N D G N D G N D G N D /INIT / F A U L T / S E L E C T I O N G035M003.WMF 4-23 G035...
Page 523 A bridge unit cooling fan motor lock signal is not detected within 5 seconds after the bridge unit cooling fan motor turns on. Possible Causes • Too much load on the drive mechanism • Bridge unit cooling fan motor defective • Poor fan motor connector connection G035...
Page 524 NEW PART NO. DESCRIPTION PAGE ITEM A2322374 B0042310 Spur UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style Spurs installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 Ricoh AP4500 P18010xxxx Savin SLP45 Continued…...
Page 525 DESCRIPTION PAGE ITEM A2324498 A2844498 Copy Tray Guide UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style Copy Tray Guide installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 Ricoh AP4500 P18010xxxx...
Page 526 1 set of new pages. PAGES: ⇒ The revised areas have been highlighted by an arrow • 7-27 New Information (ROM History – Controller Board)     CONTROL NO. 074ABW 2000 RICOH Corporation. All rights reserved.
Page 527 The firmware has been modified to allow downloading of document formats. • The firmware has been modified to support Page Count MIB. • An SC2001 sometimes occurs during a print job if Auto Tray Select has been selected. 7-27 G035...
Page 528 The shape of the end fence has been changed to help the end user to correctly position the end fence into the tray and to prevent breakage. Also, the material of the end fence has changed to a stronger type. The following part correction is being issued for all G035 Parts Catalogs. REFERENCE OLD PART NO.
Page 529 Tech Service Bulletin No. G035 – 020 Page 2 of 2 UNITS AFFECTED: All G035 printers manufactured after the Serial Numbers listed below will have the new style end fence installed during production. MODEL NAME SERIAL NUMBER Gestetner P7045 P18012XXXX...
Page 530 The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages. PAGES: ⇒ The revised areas have been highlighted by an arrow • 15-34 & 15-35 A697 Firmware History  Copyright 2002 RICOH Corporation. All rights reserved.
Page 531 Jam codes were not defined for paper jams at or before the entrance sensor. Corrects the following: A6975656 H Not Available • The stack height sensor mis-detects the height, which causes the exit motor to stop and a paper jam occurs. G035 15-34...
Page 532 Level Prod. Date Ver. ⇒ Corrects the following: A6975656 J Not Available • If a finisher job is initiated from 5 to 105 seconds after the copier recovers from “Energy Saver Mode”, SC990 or a paper jam occurs. G035 15-35...
Page 533 The Doctor Blade Gap has been narrowed from 0.4±0.05 mm to 0.38±0.03 mm to ensure that toner does not stick to the operator side of the Development Roller. The following part update is being issued for all G035 Parts Catalogs. Please update your parts catalog with the following information. REFERENCE OLD PART NO.

Ricoh G035 Service Manual

Overall Information

Overall Machine Information

Detailed Descriptions

Detailed Section Descriptions

Installation 3. Installation Procedure

3 Installation Procedure

Service Tables

Preventive Maintenance

Preventive Maintenance Schedule

Replacement and Adjustment

Troubleshooting

Paper Tray Unit G520

Overall Machine Information

Detailed Descriptions

SwapboxAnd SwapftlInstallation Manual

Introduction

Swapbox Installation

Software (Swapftl) Installation

Troubleshooting

1 Overview

Operation

Functions

Quick Links

Troubleshooting

Related Manuals for Ricoh G035

Summary of Contents for Ricoh G035