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Ricoh A-P3 Service Manual

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Model A-P3
(Machine Code: G065)
SERVICE MANUAL
November 6th, 2001
Subject to change

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Summary of Contents for Ricoh A-P3

  • Page 1 Model A-P3 (Machine Code: G065) SERVICE MANUAL November 6th, 2001 Subject to change...
  • Page 2 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. Note that some components of the printer and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off.
  • Page 3 LASER SAFETY The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer.
  • Page 4 Lithium Batteries (Memory Back-up) CAUTION The danger of explosion exists if a battery of this type is incorrectly replaced. Replace only with the same or an equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer’s instructions. Warning Concerning Copyright Many documents are copyrighted.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. INSTALLATION ................1-1 1.1 INSTALLATION REQUIREMENTS ............1-1 1.1.1 ENVIRONMENT ................1-1 1.1.2 MACHINE LEVEL ................1-1 1.1.3 MACHINE SPACE REQUIREMENTS ..........1-2 1.1.4 POWER REQUIREMENTS ..............1-3 1.2 MACHINE INSTALLATION ...............1-3 1.3 OPTIONAL UNIT INSTALLATION.............1-3 1.4 SYMBOLS USED IN TEXT ...............1-3 1.5 LCT INSTALLATION (A683)..............1-4 1.5.1 ACCESSORY CHECK..............1-4 1.5.2 INSTALLATION PROCEDURE ............1-5...
  • Page 6 3.2.3 SYMBOLS USED IN TEXT...............3-2 3.3 FRONT DOOR ..................3-3 3.4 DUPLEX UNIT...................3-3 3.5 UPPER RIGHT COVER ................3-4 3.6 BY-PASS TRAY UNIT ................3-5 3.7 REAR COVERS ..................3-6 3.7.1 REAR UPPER COVER..............3-6 3.7.2 REAR LOWER COVER..............3-6 3.8 LEFT COVERS..................3-7 3.8.1 LEFT UPPER COVER..............3-7 3.8.2 OPERATION PANEL................3-8 3.8.3 PAPER OUTPUT TRAY ..............3-9 No Bridge Unit Installed ................3-9...
  • Page 7 3.13.8 TRAY LIFT MOTOR ..............3-38 3.13.9 FEED/DEVELOPMENT MOTOR..........3-39 3.14 FUSING ....................3-40 3.14.1 FUSING UNIT................3-40 3.14.2 FUSING UNIT EXIT GUIDE ............3-41 3.14.3 HOT ROLLER STRIPPERS ............3-41 3.14.4 FUSING LAMPS ................3-42 Left Side....................3-42 Right Side ...................3-43 3.14.5 THERMISTORS AND THERMOSTATS ........3-44 3.14.6 HOT ROLLER/PRESSURE ROLLER...........3-45 3.15 BY-PASS TRAY ..................3-47 3.15.1 COVER REPLACEMENT .............3-47 3.15.2 BY-PASS FEED/PICK-UP ROLLER..........3-48...
  • Page 8 BICU ....................4-15 4.5 TEST POINTS ..................4-15 Controller Board..................4-15 5. SERVICE TABLES..............5-1 5.1 SERVICE PROGRAM MODE..............5-1 5.1.1 ENTERING AND LEAVING THE SERVICE PROGRAM MODE ..5-1 5.2 PRINTER CONTROLLER SERVICE MODE ..........5-2 5.2.1 CONTROLLER SERVICE MODE MENUS........5-2 5.2.2 BIT SWITCH PROGRAMMING ............5-2 5.2.3 PRINTER CONTROLLER BIT SWITCH SETTINGS ......5-3 5.3 PRINTER ENGINE SERVICE MODE............5-4 Leaving the SP Mode ................5-5...
  • Page 9 6.3 PRINTING PROCESS OVERVIEW............6-8 Drum Charge ..................6-8 Laser Exposure..................6-8 Development..................6-8 Image Transfer ..................6-9 Separation ....................6-9 ID Sensor....................6-9 Cleaning....................6-9 Quenching ....................6-9 6.4 LASER EXPOSURE................6-10 6.4.1 OVERVIEW ..................6-10 6.4.2 AUTO POWER CONTROL (APC) ..........6-11 6.4.3 DUAL BEAM WRITING ..............6-12 6.4.4 LASER BEAM PITCH CHANGE MECHANISM......6-13 6.4.5 LD SAFETY SWITCHES ..............6-14 6.5 PHOTOCONDUCTOR UNIT (PCU) ............6-15 6.5.1 OVERVIEW ..................6-15...
  • Page 10 6.9.1 OVERVIEW ..................6-31 6.9.2 PAPER FEED DRIVE ..............6-32 6.9.3 PICK-UP/SEPARATION ROLLER RELEASE ........6-32 6.9.4 PAPER LIFT ...................6-33 6.9.5 PAPER END DETECTION .............6-34 6.9.6 PAPER REGISTRATION..............6-34 6.9.7 PAPER SIZE DETECTION.............6-35 6.9.8 PAPER HEIGHT DETECTION ............6-36 6.10 BY-PASS TRAY ..................6-37 6.10.1 OVERVIEW ..................6-37 6.10.2 BY-PASS TRAY OPERATION .............6-38 6.10.3 BY-PASS PAPER SIZE DETECTION ..........6-39 6.11 DUPLEX UNIT..................6-40...
  • Page 11 SPECIFICATIONS..............SPEC-1 1. GENERAL SPECIFICATIONS............. SPEC-1 2. SUPPORTED PAPER SIZES.............. SPEC-2 3. SOFTWARE ACCESSORIES ............. SPEC-3 3.1 PRINTER DRIVERS ..............SPEC-3 3.2 UTILITY SOFTWARE ..............SPEC-3 4. MACHINE CONFIGURATION ............. SPEC-4 4.1 SYSTEM COMPONENTS ............SPEC-4 4.2 INSTALLABLE OPTION TABLE..........SPEC-5 5.

  • Page 12: Installation

    6 November, 2001 INSTALLATION REQUIREMENTS 1. INSTALLATION 1.1 INSTALLATION REQUIREMENTS 1.1.1 ENVIRONMENT 1. Temperature Range: 10°C to 32°C (50°F to 89.6°F) 2. Humidity Range: 15 % to 80 % RH 3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight). 4.

  • Page 13: Machine Space Requirements

    INSTALLATION REQUIREMENTS 6 November, 2001 1.1.3 MACHINE SPACE REQUIREMENTS Place the printer near the power source, providing clearance as shown: A: In Front: > 75 cm (29.6") B: Left: > 10 cm (4") C: To Rear: > 10 cm (4") D: Right: >...

  • Page 14: Power Requirements

    6 November, 2001 MACHINE INSTALLATION 1.1.4 POWER REQUIREMENTS CAUTION 1. Make sure the plug is firmly inserted in the outlet. 2. Connect the printer to an independent power source. Avoid connecting the printer to a power supply shared with another machine. 3.

  • Page 15: Lct Installation (A683)

    LCT INSTALLATION (A683) 6 November, 2001 1.5 LCT INSTALLATION (A683) 1.5.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Joint Pin ................. 2 2. Stepped Screw - M3x18............4 3.

  • Page 16: Installation Procedure

    6 November, 2001 LCT INSTALLATION (A683) 1.5.2 INSTALLATION PROCEDURE A683I501.WMF A683I604.WMF A683I500.WMF CAUTION Switch off the main machine and unplug its power cord before starting the following procedure. NOTE: The Paper Tray Unit (G520) must be installed before installing the LCT. 1.
  • Page 17 LCT INSTALLATION (A683) 6 November, 2001 A683I503.WMF 5. Install the joint pins [A]. 6. Push the release lever [B] and slide the LCT to the right (front view). 7. Hang the LCT [C] on the joint pins, then secure the brackets [D] (! x 4). 8.

  • Page 18: Bridge Unit Installation (B397)

    6 November, 2001 BRIDGE UNIT INSTALLATION (B397) 1.6 BRIDGE UNIT INSTALLATION (B397) 1.6.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Stepped Screw ..............2 2. Connector Cover..............1 3.

  • Page 19: Installation Procedure

    BRIDGE UNIT INSTALLATION (B397) 6 November, 2001 1.6.2 INSTALLATION PROCEDURE B397I401.WMF B397I407.WMF B397I500.WMF CAUTION Switch off the main machine and unplug its power cord before starting the following procedure. 1. Unpack the bridge unit [A] and remove all tapes and shipping retainers. 2.
  • Page 20 6 November, 2001 BRIDGE UNIT INSTALLATION (B397) B397I402.WMF B397I444.WMF 8. If an optional finisher is to be installed, attach two mylars [A] to the bridge unit. 9. Remove the cover [B]. 10. Install the bridge unit [C] (! x 2). 11.

  • Page 21: 1000-Sheet Finisher Installation (A681)

    1000-SHEET FINISHER INSTALLATION (A681) 6 November, 2001 1.7 1000-SHEET FINISHER INSTALLATION (A681) 1.7.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Front Stand ................1 2. Rear Stand................1 3.

  • Page 22: Installation Procedure

    6 November, 2001 1000-SHEET FINISHER INSTALLATION (A681) 1.7.2 INSTALLATION PROCEDURE A681I701.WMF A681I702.WMF CAUTION Switch off the main machine and unplug its power cord before starting the following procedure. NOTE: The bridge unit (B397) and paper tray unit (G520) must be installed before installing this finisher.
  • Page 23 1000-SHEET FINISHER INSTALLATION (A681) 6 November, 2001 A681I704.WMF A681I705.WMF 2. Fasten [A] (! x 2) loosely. 3. Hang the front stand [B] and rear stand [C] on the screws installed in step 2. 4. To secure the front and rear stands tighten [A] (! x 2) and secure the stands (! x 4).
  • Page 24 6 November, 2001 1000-SHEET FINISHER INSTALLATION (A681) A681I706.WMF 9. Secure the finisher [A] (! x 1). 10. Adjust the securing knobs [B] under the front and rear stands until the finisher is perpendicular to the floor. 11. Install the shift tray [C] (snap ring x 1). NOTE: Make sure that the three pegs [D] fit into the slots [E] properly.

  • Page 25: 3000-Sheet Finisher Installation (A697)

    3000-SHEET FINISHER INSTALLATION (A697) 6 November, 2001 1.8 3000-SHEET FINISHER INSTALLATION (A697) 1.8.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Front joint bracket ..............1 2. Rear joint bracket..............1 3.

  • Page 26: Installation Procedure

    6 November, 2001 3000-SHEET FINISHER INSTALLATION (A697) 1.8.2 INSTALLATION PROCEDURE A697I506.WMF A697I507.WMF CAUTION Unplug the main machine power cord before starting the following procedure. NOTE: The bridge unit (B397) and paper tray unit (G520) must be installed before installing this finisher. If the mailbox (G909) will be installed, first install the mailbox, then the bridge unit for the mailbox (G912), and finally install the finisher.
  • Page 27 3000-SHEET FINISHER INSTALLATION (A697) 6 November, 2001 A697I558.WMF 2. Install the front joint bracket [A] and rear joint bracket [B] (! x 2 ea.). 3. Peel off the backing of the double-sided tape that is attached to the lower grounding plate [C]. 4.
  • Page 28 6 November, 2001 3000-SHEET FINISHER INSTALLATION (A697) A697I559.WMF 5. Attach the cushion [A] at the position [B]. 6. Install the entrance guide plate [C] (! x 2). 1-17...
  • Page 29 3000-SHEET FINISHER INSTALLATION (A697) 6 November, 2001 A697I534.WMF A697I550.WMF 7. If the customer requires the punch unit, install it now, before attaching the finisher to the machine. See ‘Punch Unit Installation’. 8. Open the front door of the finisher, and remove the screw [A] that secures the locking lever [B].

  • Page 30: Punch Unit Installation (A812)

    6 November, 2001 PUNCH UNIT INSTALLATION (A812) 1.9 PUNCH UNIT INSTALLATION (A812) 1.9.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Spacer - 2 mm ............... 1 2. Spacer - 1 mm ............... 2 3.

  • Page 31: Installation Procedure

    PUNCH UNIT INSTALLATION (A812) 6 November, 2001 1.9.2 INSTALLATION PROCEDURE A812I761.WMF A812I763.WMF CAUTION Unplug the copier power cord and remove the 3,000-sheet finisher from the copier before starting the following procedure. 1. Unpack the punch unit and remove the shipping retainers [A] (! x 4) and [B] (! x 1).
  • Page 32 6 November, 2001 PUNCH UNIT INSTALLATION (A812) A812I510.WMF A812I765.WMF 4. Install the spacer [A] (thickness = 2 mm). NOTE: There are three spacers in the accessory box. Do not lose the other two spacers (1-mm) because they are used for adjusting the punch hole position.
  • Page 33 PUNCH UNIT INSTALLATION (A812) 6 November, 2001 A812I767.WMF A812I511.WMF A812I512.WMF 8. Install the sensor bracket [A] (! x 1, spring x1). 9. Connect the harnesses [B]. NOTE: 1) The harness binders [C] must not be between the harness clamps [D]. 2) The harness binder [E] must be positioned to the left of the harness clamp.

  • Page 34: Mailbox Installation (G909)

    6 November, 2001 MAILBOX INSTALLATION (G909) 1.10 MAILBOX INSTALLATION (G909) 1.10.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Front joint bracket ..............1 2. Rear joint bracket..............1 3.

  • Page 35: Installation Procedure

    MAILBOX INSTALLATION (G909) 6 November, 2001 1.10.3 INSTALLATION PROCEDURE G909I500.WMF G909I559.WMF CAUTION Unplug the main machine power cord before starting the following procedure. NOTE: If a finisher will be installed, first install this mailbox, then the bridge unit for the mailbox (G912), and finally install the finisher. 1.
  • Page 36 6 November, 2001 MAILBOX INSTALLATION (G909) G909I550.WMF 5. Attach the cushion [A] to 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. 1-25...
  • Page 37 MAILBOX INSTALLATION (G909) 6 November, 2001 G909I503.WMF G909I552.WMF 7. Align the mailbox on the joint brackets, and lock it in place by pushing the locking lever [A]. 8. Secure the locking lever (! x 1) and close the front door. 9.

  • Page 38: Bridge Unit For Mailbox Installation (G912)

    6 November, 2001 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) 1.11 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) 1.11.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty 1. Guide plate bracket ............... 1 2.

  • Page 39: Installation Procedure

    BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) 6 November, 2001 1.11.2 INSTALLATION PROCEDURE G912I506.WMF G909I508.WMF CAUTION Unplug the main machine power cord before starting the following procedure. NOTE: The bridge unit for the mailbox must be installed when both the mailbox and a finisher will be installed.
  • Page 40 6 November, 2001 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) G912I503.WMF G912I504.WMF G912I505.WMF 6. Open the left front cover [A] of the mailbox, and remove the inner plate [B] (! x 7. Install the guide plate bracket [C] (! x 4 - M4x4). 8.
  • Page 41 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) 6 November, 2001 G912I501.WMF G912I507.WMF G912I508.WMF 11. Pull up the tab [A] of the protective sheet. NOTE: 1) Do not remove the protective sheet at this time. 2) Make sure that all mylars are held between the two folded halves of the protective sheet.
  • Page 42 6 November, 2001 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) G912I509.WMF G912I513.WMF G912I510.WMF 15. Secure the bridge unit [A] (! x 4 - M4x8). 16. Route the cables [B] through the openings [C]. 17. Route the solenoid harness [D] through the opening [E]. 18.
  • Page 43 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) 6 November, 2001 G912I502.WMF G912I512.WMF 22. Remove the seal [A]. 23. Attach the grounding bracket [B] (! x 3 - M4x8). 24. Attach the shielding plate [C] to the finisher (! x 2 - M3x8). 25.

  • Page 44: Preventive Maintenance Schedule

    6 November, 2001 PM TABLES 2. PREVENTIVE MAINTENANCE SCHEDULE 2.1 PM TABLES 2.1.1 PM TABLES FOR THE PRINTER Two maintenance kits are provided for customers. NAME CONTENTS Maintenance Kit Type 4510A PCDU (Photo Conductor Cleaning/Development Unit) Maintenance Kit Type 4510B Fusing Unit and Transfer Unit Components marked with an asterisk (*) should be inspected, serviced, and replaced without the maintenance kits.
  • Page 45 PM TABLES 6 November, 2001 150K 300K 450K NOTE PAPER FEED Registration Roller Water or alcohol. Check counter value for each Paper Feed Roller* (SP7204). If ≥ 150 K, replace Separation Roller* roller. After replacing the roller, Pick-up Roller* do SP7816 to reset counter. Paper Feed Roller (By-pass feed table)* Separation Roller...

  • Page 46: Pm Tables For Options

    6 November, 2001 PM TABLES 2.1.2 PM TABLES FOR OPTIONS NOTE: Amounts mentioned as the PM interval indicate the number of prints. Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect 150K 300K 450K NOTE PAPER TRAY UNIT G520 Paper Feed Rollers Check counter with SP7204.

  • Page 47: Replacement And Adjustment

    6 November, 2001 GENERAL CAUTIONS 3. REPLACEMENT AND ADJUSTMENT 3.1 GENERAL CAUTIONS CAUTION To avoid damage to the transfer belt, drum, or development unit when it is removed or re-installed, never turn off either power switch while electrical components are active. CAUTION Turn off the main power switch and unplug the machine before attempting any of the procedures in this section.

  • Page 48: Special Tools And Lubricants

    SPECIAL TOOLS AND LUBRICANTS 6 November, 2001 3.2 SPECIAL TOOLS AND LUBRICANTS 3.2.1 SPECIAL TOOLS Part Number Description Q’ty A2309003 Adjustment Cam – Laser Unit A2309004 Positioning Pin – Laser Unit A2309352 Flash Memory Card – 4MB A2309351 Case – Flash Memory Card G0219350 Parallel Loopback Connector 3.2.2 LUBRICANTS...

  • Page 49: Front Door

    6 November, 2001 FRONT DOOR 3.3 FRONT DOOR G065R951.WMF 1. Open front door. 2. Front door. Left pin [A], right pin [B]. 3.4 DUPLEX UNIT G065R003.WMF 1. Connector cover [A] (! x 1) 2. Duplex connectors [B] (" x 2) 3.

  • Page 50: Upper Right Cover

    UPPER RIGHT COVER 6 November, 2001 3.5 UPPER RIGHT COVER G065R945.WMF NOTE: Work carefully to avoid damaging the development roller. 1. Duplex unit (☛ 3.4) 2. Transfer belt unit (☛ 3.12.1) 3. Metal support arm [A] (! x 1) 4. Band support arm [B] (loop fastener) 5.

  • Page 51: By-Pass Tray Unit

    6 November, 2001 BY-PASS TRAY UNIT 3.6 BY-PASS TRAY UNIT G065R952.WMF Use this procedure to remove the complete by-pass tray unit from the machine. If you wish to remove only the table, or some of the components of this unit, ☛ 3.15. 1.

  • Page 52: Rear Covers

    REAR COVERS 6 November, 2001 3.7 REAR COVERS 3.7.1 REAR UPPER COVER G065R953.WMF 1. Left corner cover [A] (! x 2) 2. Rear upper cover [B] (! x 2) 3.7.2 REAR LOWER COVER G065R954.WMF 1. Rear lower cover [A] (! x 4)

  • Page 53: Left Covers

    6 November, 2001 LEFT COVERS 3.8 LEFT COVERS 3.8.1 LEFT UPPER COVER G065R955.WMF 1. Rear left corner cover [A] (! x 2) 2. Left upper cover [B] (! x 4)

  • Page 54: Operation Panel

    LEFT COVERS 6 November, 2001 3.8.2 OPERATION PANEL G065R919.WMF WARNING The fusing unit below the cover is hot. Allow the machine to cool for a few minutes before you begin the procedure. 1. Fusing unit cover [A] (caps x 2, ! x 2) NOTE: Insert the tip of a screwdriver into the slot to release the plastic hook and lift.

  • Page 55: Paper Output Tray

    6 November, 2001 LEFT COVERS 3.8.3 PAPER OUTPUT TRAY G065R920.WMF G065R921.WMF No Bridge Unit Installed 1. Sub copy tray [A] 2. Paper sensor ass’y [B] (! x 2) 3. Cover [C] (! x 1) 4. Paper output tray [D] (! x 3) 5.

  • Page 56: Laser Unit

    LASER UNIT 6 November, 2001 3.9 LASER UNIT WARNING Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. 3.9.1 CAUTION DECAL LOCATIONS Two caution decals are located in the laser section as shown below. (See the next page for removal instructions.) G060R951.WMF LASER-3.WMF...

  • Page 57: Laser Unit

    6 November, 2001 LASER UNIT 3.9.2 LASER UNIT G065R211.WMF G065R962.WMF WARNING Turn off the main power switch and unplug the machine before attempting this procedure. Laser beams can seriously damage your eyes. 1. Open the front door and raise the toner bottle holder handle [A]. 2.

  • Page 58: Polygon Mirror Motor

    LASER UNIT 6 November, 2001 3.9.3 POLYGON MIRROR MOTOR G065R994.WMF G065R201.WMF 1. Laser unit (☛ 3.9.2) 2. Laser unit cover [A] (! x 4, 2 hooks) 3. Polygon mirror motor [B] (! x 4, " x 1) 4. After replacing the motor, do the image adjustment. (☛ 3.20) 3-12...

  • Page 59: Laser Synchronization Detector

    6 November, 2001 LASER UNIT 3.9.4 LASER SYNCHRONIZATION DETECTOR G065R206.WMF 1. Laser unit (☛ 3.9.2) 2. Laser synchronization detector [A] (! x 1, " x 1). 3.9.5 LD UNIT G065R513.WMF 1. Laser unit (☛ 3.9.2) 2. LD unit [A] (! x 3, " x 1) NOTE: To avoid damaging the LD board, hold it securely when disconnecting the connectors.

  • Page 60: Laser Beam Pitch Adjustment

    LASER UNIT 6 November, 2001 Laser Beam Pitch Adjustment After replacing the LD board, do the laser beam pitch adjustment. There are two procedures: one for 400 dpi, and one for 600 dpi. These use the following SPs. SP2110 Test Mode Dpi (0: 400 dpi, 8: 600 dpi) SP2109-01 LD Beam Pitch Adjustment –...

  • Page 61: Pcdu

    6 November, 2001 PCDU 3.10 PCDU 3.10.1 PHOTOCONDCUTOR CLEANING/DEVELOPMENT UNIT G065R905.WMF G065R906.WMF 1. Open the front door. 2. Lower the by-pass tray, open the duplex unit, and open the transfer unit right cover. 3. Release the PCDU lock [A]. 4. Hold the PCDU by the handle [B] and pull out slowly. 5.

  • Page 62: Drum

    PCDU 6 November, 2001 3.10.2 DRUM G065R907.WMF G065R908.WMF G065R304.WMF 1. PCDU (☛ 3.10.1) CAUTION: Never touch the drum surface with bare hands. 2. Remove the toner cap [A] and use it to cover the toner port [B]. 3. Turn the PCU upside down and remove the lower cover [C] (! x 2, pawls x 3) ➀...

  • Page 63: Pick-Off Pawls

    6 November, 2001 PCDU 3.10.3 PICK-OFF PAWLS G065R305.WMF 1. Remove the drum. (☛ 3.10.2) 2. Pawl assembly [A] 3. Pick-off pawl [B] (spring x 1, spur x 1) Pick-off pawl position adjustment If the pick-off pawl has marked the drum with a line, adjust the position by: •...

  • Page 64: Charge Roller And Cleaning Roller

    PCDU 6 November, 2001 3.10.4 CHARGE ROLLER AND CLEANING ROLLER G065R500.WMF 1. Remove the drum. (☛ 3.10.2) 2. Two snap rings [A] (# x 2) 3. Charge roller holder [B] 4. Charge roller [C] NOTE: Do not touch the charge roller. 5.

  • Page 65: Drum Cleaning Blade

    6 November, 2001 PCDU 3.10.5 DRUM CLEANING BLADE G065R307.WMF 1. Remove the drum. (☛ 3.10.2) 2. Remove the charge roller. (☛ 3.10.4) 3. Remove the drum cleaning blade [A] (! x 2). 3-19...

  • Page 66: Id Sensor

    PCDU 6 November, 2001 3.10.6 ID SENSOR G065R991.WMF 1. PCDU (☛ 3.10.1) 2. Fusing unit (☛ 3.14.1) 3. Development unit (☛ 3.11.1) 4. PCDU rail [A] (! x 2, " x 1) 5. ID sensor bracket [B] (! x 1, " x 1) 6.

  • Page 67: Development

    6 November, 2001 DEVELOPMENT 3.11 DEVELOPMENT 3.11.1 DEVELOPMENT UNIT G065R202.WMF 1. PCDU. (☛ 3.10.1) NOTE: Spread paper on a clean flat surface that is free of pins, paper clips, staples, screws or any other metal objects. 2. Separate the PCU [A] and development unit [B] (! x 3). 3.

  • Page 68: Development Filter

    DEVELOPMENT 6 November, 2001 3.11.2 DEVELOPMENT FILTER G065R909.WMF 1. Development unit (☛ 3.11.1) 2. Upper development cover [A] (# x 2) 3. Development filter [B]. NOTE: Make sure that the surface with the red mark is facing up. 3-22...

  • Page 69: Development Roller

    6 November, 2001 DEVELOPMENT 3.11.3 DEVELOPMENT ROLLER G065R910.WMF 1. Development unit (☛ 3.11.2) 2. Upper development cover (☛ 3.11.2) 3. Gear [A] (# x 1) 4. Joint bracket [B] 5. Development roller [C] (! x 2) NOTE: 1) Work carefully to avoid scratching or nicking the development roller. 2) Make sure that the part is grounded (earthed) correctly.

  • Page 70: Developer

    DEVELOPMENT 6 November, 2001 3.11.4 DEVELOPER G065R404.WMF G065R405.WMF 1. Development unit (☛ 3.11.1) 2. Remove the development roller (☛ 3.11.3) 3. Tip out the old developer [A] 4. Turn drive gear [B] to ensure that no developer remains in the unit or on the developer roller.
  • Page 71 6 November, 2001 DEVELOPMENT G065R518.WMF Reassemble the development unit 8. Cover the toner entrance hole [A] with a piece of paper. 9. Install the development unit in the machine. 10. Turn on the main power switch, make sure that the machine has warmed up, then perform the TD sensor initial setting using SP2801.

  • Page 72: Td Sensor

    DEVELOPMENT 6 November, 2001 3.11.5 TD SENSOR G065R975.WMF 1. Remove the development unit (☛ 3.11.1) 2. Empty all developer from the development unit (☛ 3.11.4) 3. TD sensor [A] (! x 1) NOTE: The TD sensor is attached to the casing with double-sided tape. Pry it off with the flat head of a screwdriver.

  • Page 73: Transfer Unit

    6 November, 2001 TRANSFER UNIT 3.12 TRANSFER UNIT 3.12.1 TRANSFER BELT UNIT G065R501.WMF G065R522.WMF NOTE: To avoid exposing the PCU drum to strong light, cover it with paper if the right cover will be open for a long period. 1. Lower the by-pass tray, open the duplex unit, and open the right cover. 2.

  • Page 74: Transfer Belt

    TRANSFER UNIT 6 November, 2001 3.12.2 TRANSFER BELT G065R524.WMF 1. Remove the transfer belt unit. (☛ 3.12.1) 2. Belt drive gear [A] 3. Set screws [B] (! x 2) 4. Lay on a flat, clean surface and fold the unit to release the tension on the belt [C].

  • Page 75: Cleaning Blade/Toner Overflow Sensor

    6 November, 2001 TRANSFER UNIT 3.12.3 CLEANING BLADE/TONER OVERFLOW SENSOR G065R911.WMF Transfer Belt Cleaning Blade 1. Transfer belt unit. (☛ 3.12.1) 2. Transfer belt. (☛ 3.12.2) 3. Transfer belt cleaning blade [A] (! x 3) NOTE: Avoid touching the edge of the new blade. Check the new blade for dust or damage.

  • Page 76: Paper Feed

    PAPER FEED 6 November, 2001 3.13 PAPER FEED 3.13.1 PICK-UP, SEPARATION, AND FEED ROLLERS G065R918.WMF 1. Paper tray 2. Pick-up roller [A] 3. Feed roller [B] (# x 1) 4. Separation roller [C] (# x 1) NOTE: Do not touch the roller surface with bare hands. After installing the new rollers, do SP7816 for the appropriate paper tray.

  • Page 77: Lower Right Cover

    6 November, 2001 PAPER FEED 3.13.2 LOWER RIGHT COVER G065R904.WMF 1. Duplex unit (☛ 3.4) 2. By-pass tray (☛ 3.6) 3. LCT (if installed) 4. Lower right cover [A] (! x 5) 5. Vertical transport cover [B] NOTE: Push the cover completely to the left and then press in on the right tab to release the peg from the hole.

  • Page 78: Relay/Upper Paper Feed And Lower Paper Feed Clutches

    PAPER FEED 6 November, 2001 3.13.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED CLUTCHES G065R973.WMF 1. Rear lower cover (☛ 3.7.2) 2. First paper feed clutch bracket [A] (! x 2, bushing x 1) 3. Second paper feed clutch bracket [B] (! x 2, bushing x 1) 4.

  • Page 79: Upper Paper Feed Unit For Tray 1

    6 November, 2001 PAPER FEED 3.13.4 UPPER PAPER FEED UNIT FOR TRAY 1 G065R900.WMF G065R941.WMF 1. Upper paper tray 2. Right lower cover (☛ 3.13.2) 3. Upper right cover (☛ 3.5) 4. Upper paper feed clutch [A] (☛ 3.13.3) 5. 3 relay gears [B] 6.

  • Page 80: Lower Paper Feed Unit For Tray 2

    PAPER FEED 6 November, 2001 3.13.5 LOWER PAPER FEED UNIT FOR TRAY 2 G065R974.WMF G065R943.WMF 1. Lower the paper trays 2. Lower right cover (☛ 3.13.2) 3. Lower paper feed clutch [A] (☛ 3.13.3) 4. Relay gears [B] (x 3) 5.

  • Page 81: Paper End/Paper Lift/Relay Sensors

    6 November, 2001 PAPER FEED 3.13.6 PAPER END/PAPER LIFT/RELAY SENSORS G065R944.WMF 1. Appropriate paper feed unit (☛ 3.13.4, 3.13.5) 2. Paper lift sensor [A] (" x 1) 3. Paper end sensor [B] (" x 1) 4. Relay sensor bracket [C] (! x 1, " x 1) 5.

  • Page 82: Registration Sensor

    PAPER FEED 6 November, 2001 3.13.7 REGISTRATION SENSOR G065R992.WMF G065R922.WMF G065R993.WMF 1. Front door (☛ 3.3 ) 2. Rear upper cover (☛ 3.7.1) 3. Right door and transfer belt unit (☛ 3.5, 3.12.1) 4. PCU (☛ 3.10.1) 5. Development unit (☛ 3.12.1) 6.
  • Page 83 6 November, 2001 PAPER FEED G065R934.WMF G065R935.WMF 16. Guide plate [A] and registration roller [B] (spring x 1, # x 1) 17. Registration guide plate [C] (! x 2, " x 1) 18. Sensor bracket [D] (! x 1) 19. Registration sensor [E] (! x 1, " x 1) 3-37...

  • Page 84: Tray Lift Motor

    PAPER FEED 6 November, 2001 3.13.8 TRAY LIFT MOTOR G065R964.WMF 1. Rear lower cover (☛ 3.7.2) 2. Bracket [A] (! x 2) 3. Motor control board [B] (! x 2, " x 13) 4. Tray lift motor [C] (! x 2) 3-38...

  • Page 85: Feed/Development Motor

    6 November, 2001 PAPER FEED 3.13.9 FEED/DEVELOPMENT MOTOR G065R982.WMF 1. Rear lower cover (! x 4) (☛3.7.2) 2. Rear upper cover (! x 4) (☛3.7.1) 3. Tray lift motor (☛ 3.13.8) 4. Support [A] (! x 2, harnesses x 2) 5.

  • Page 86: Fusing

    FUSING 6 November, 2001 3.14 FUSING 3.14.1 FUSING UNIT CAUTION Allow the unit to cool before doing the following procedure. G065R901.WMF 1. Open the front door, duplex unit, and right door. 2. Set screw [A] (! x 1) 3. Fusing unit release lever [B] 4.

  • Page 87: Fusing Unit Exit Guide

    6 November, 2001 FUSING 3.14.2 FUSING UNIT EXIT GUIDE G065R912.WMF 1. Fusing unit (☛ 3.14.1) 2. Exit guide [A] NOTE: Press the guide to the left and then press on the right end to release the peg from the hole. 3.14.3 HOT ROLLER STRIPPERS G065R913.WMF 1.

  • Page 88: Fusing Lamps

    FUSING 6 November, 2001 3.14.4 FUSING LAMPS G065R914.WMF G065R915.WMF 1. Fusing unit (☛ 3.14.1) 2. Fusing unit cover (☛  3 .14.3) 3. Fusing entrance guide [A] (! x 2) 4. Lower cover [B] (! x 1) Left Side 5. Two terminals [C] (! x 2) 6.

  • Page 89: Right Side

    6 November, 2001 FUSING G065R607.WMF Right Side 1. Two terminals [A] (! x 2) 2. Spring [B] 3. Connector bracket [C] (! x 2) 4. Bracket [D] (! x 2) NOTE: To avoid breaking the fusing lamps, handle them with care. Avoid touching the lamps with your fingers.

  • Page 90: Thermistors And Thermostats

    FUSING 6 November, 2001 3.14.5 THERMISTORS AND THERMOSTATS G065R917.WMF G065R916.WMF 1. Fusing unit (☛ 3.14.1) 2. Fusing upper and lower cover (☛ 3.14.3, 3.14.4) 3. Center thermistor [A] (! x 1, " x 1, holder x 1) 4. End thermistor [B] (! x 1, " x 1, holder x 1) CAUTION: The thermistors are thinly coated and extremely fragile.

  • Page 91: Hot Roller/Pressure Roller

    6 November, 2001 FUSING 3.14.6 HOT ROLLER/PRESSURE ROLLER G065R902.WMF 1. Fusing unit (☛ 3.14.1) 2. Fusing upper and lower cover (☛ 3.14.3, 3.14.4) 3. Fusing lamp. (☛ 3.14.4) 4. Springs x 2 [A] (both sides) 5. Arms x 2 [B] (both sides) 6.
  • Page 92 FUSING 6 November, 2001 G065R903.WMF 7. Hot roller [A] CAUTION: The hot roller is easily damaged. Always handle it carefully. 8. C-rings x 2 [B] (both ends) 9. Drive gear [C] 10. Bushings x 2 [D] (both ends) 11. Pressure roller [E] 12.

  • Page 93: By-Pass Tray

    6 November, 2001 BY-PASS TRAY 3.15 BY-PASS TRAY 3.15.1 COVER REPLACEMENT G065R540.WMF 1. Rear cover [A] (! x 1) 2. Front cover [B] (! x 1) 3. Hinge cover [C] (! x 1) 4. Upper cover [D] (! x 2) 5.

  • Page 94: By-Pass Feed/Pick-Up Roller

    BY-PASS TRAY 6 November, 2001 3.15.2 BY-PASS FEED/PICK-UP ROLLER G065R541.WMF 1. Upper cover (☛ 3.15.1) 2. Lift up paper end feeler [A] to lock feeler in position. NOTE: Before reinstalling the upper cover, return the paper end feeler to its original position.

  • Page 95: By-Pass Separation Roller Replacement

    6 November, 2001 BY-PASS TRAY 3.15.3 BY-PASS SEPARATION ROLLER REPLACEMENT G065R542.WMF 1. Close the by-pass table. 2. Remove the separation roller [A] from the bottom (# x 1) NOTE: Do not touch the roller surface with bare hands. After installing the new rollers, do SP7816 for the bypass tray.

  • Page 96: Paper End Sensor/Pick-Up Solenoid

    BY-PASS TRAY 6 November, 2001 3.15.4 PAPER END SENSOR/PICK-UP SOLENOID G065R543.WMF 1. Upper cover (☛ 3.15.1) 2. Lift paper end feeler [A]. NOTE: Before reinstalling the upper cover, return the paper end feeler to its original position. 3. Paper end sensor [B] (" x 1). 4.

  • Page 97: Paper Size Sensor Board Replacement

    6 November, 2001 BY-PASS TRAY 3.15.5 PAPER SIZE SENSOR BOARD REPLACEMENT G065R544.WMF 1. Hook [A] 2. Paper tray [B] (" x 1). 3. Size sensor board [C]. NOTE: To avoid breaking the hook of the paper size sensor board, handle it carefully during removal.

  • Page 98: By-Pass Table Removal

    BY-PASS TRAY 6 November, 2001 3.15.6 BY-PASS TABLE REMOVAL G065R505.WMF Note: To remove the entire by-pass tray unit, and not just the table, ☛ 3.6 1. Hinge cover (☛ 3.15.1) 2. Harness [A] (" x 1). 3. Screws [B] (! x 2) 4.

  • Page 99: Paper Feed Clutch Replacement

    6 November, 2001 BY-PASS TRAY 3.15.7 PAPER FEED CLUTCH REPLACEMENT G065R546.WMF G065R547.WMF 1. By-pass tray 2. Paper feed unit [A] (! x 2, " x 1) 3. Rear bracket [B] (! x 3, clip x 1, bushing x 1) 4. Paper feed clutch [C] (" x 1) 3-53...

  • Page 100: Duplex Unit

    DUPLEX UNIT 6 November, 2001 3.16 DUPLEX UNIT 3.16.1 DUPLEX COVER REMOVAL G065R101.WMF 1. Duplex unit cover [A] (! x 4) 3-54...

  • Page 101: Duplex Entrance Sensor Replacement

    6 November, 2001 DUPLEX UNIT 3.16.2 DUPLEX ENTRANCE SENSOR REPLACEMENT G065R102.WMF 1. Duplex unit cover (☛ 3.16.1) 2. Sensor holder [A] (! x 1) 3. Entrance sensor [B] (" x 1) 3-55...

  • Page 102: Duplex Exit Sensor Replacement

    DUPLEX UNIT 6 November, 2001 3.16.3 DUPLEX EXIT SENSOR REPLACEMENT G065R103.WMF 1. Duplex unit (☛3.4) 2. Sensor bracket [A] (! x 1) 3. Exit sensor [B] (" x 1) 3-56...

  • Page 103: Drive Area

    6 November, 2001 DRIVE AREA 3.17 DRIVE AREA 3.17.1 REGISTRATION/TRANSFER BELT CONTACT CLUTCHES G065R965.WMF G065R923.WMF 1. Rear upper cover (! x 2) 2. High voltage supply board [A] (" x 6, ! x 6) NOTE: Make sure that you re-connect the wires in the correct order.

  • Page 104: Main Motor

    DRIVE AREA 6 November, 2001 3.17.2 MAIN MOTOR G065R924.WMF 1. Rear upper cover, high voltage power supply, flywheels (☛ 3.17.1) 2. Remove the main cooling fan [A] (! x 2). 3. Timing belt [B] x 1 4. Bracket [C] (! x 2) 5.

  • Page 105: Fusing/Exit Motor

    6 November, 2001 DRIVE AREA 3.17.3 FUSING/EXIT MOTOR G065R925.WMF G065R926.WMF G065R927.WMF 1. Rear upper cover (☛3.7.1) 2. Fusing unit cover (☛3.8.2) (Do not disconnect.) 3. Paper output tray (☛3.8.3) 4. Harnesses [A] (x 3) 5. Connector bracket [B] (! x 1, harness x 1) 6.

  • Page 106: Fusing/Exit Clutch

    DRIVE AREA 6 November, 2001 3.17.4 FUSING/EXIT CLUTCH G065R928.WMF G065R929.WMF 1. Rear upper cover (☛3.7.1) 2. Fusing unit fan (harnesses x 2, ! x 2, " x 1) (☛3.17.3) NOTE: You may need to loosen the screws of the right upper cover to see the right screw of the fan bracket.

  • Page 107: Toner Supply Motor

    6 November, 2001 DRIVE AREA 3.17.5 TONER SUPPLY MOTOR G065R971.WMF G065R972.WMF 1. Open the front door. 2. Raise holder handle [A]. 3. Push the holder lever [B] to the right. 4. Stopper [C] 5. Toner bottle holder and bottle [D] 6.

  • Page 108: Printed Circuit Boards

    PRINTED CIRCUIT BOARDS 6 November, 2001 3.18 PRINTED CIRCUIT BOARDS 3.18.1 HIGH VOLTAGE POWER SUPPLY G065R965.WMF 1. Rear upper cover (☛ 3.7.1) 2. High voltage power supply [A] (! x 3, " x 6) 3-62...

  • Page 109: I/O Board

    6 November, 2001 PRINTED CIRCUIT BOARDS 3.18.2 I/O BOARD G065R930.WMF G065R968.WMF 1. Rear upper cover (☛ 3.7.1) 2. Expansion box [A] (! x 5, " x 1) 3. I/O board [B] (! x 2, " x all) NOTE: Make sure that the DIP switch settings on the new board are the same as those on the old board.

  • Page 110: Bicu Board

    PRINTED CIRCUIT BOARDS 6 November, 2001 3.18.3 BICU BOARD G065R931.WMF 1. I/O board (☛ 3.18.2) 2. BICU board [A] (! x 4, " x all) 3.18.4 PSU G065R970.WMF 1. Left upper cover (☛ 3.8.1) 2. PSU [A] (! x 5, " x all) 3-64...

  • Page 111: Hard Disk/Controller Board

    6 November, 2001 HARD DISK/CONTROLLER BOARD 3.19 HARD DISK/CONTROLLER BOARD G065R933.WMF G065R932.WMF 1. Left rear corner cover (☛ 3.8.1) 2. Expansion spacer [A] (! x 2) 3. HDD unit bracket [B] (" x 2) 4. HDD unit [C] (! x4) NOTE: Work carefully to avoid dropping or hitting the HDD.

  • Page 112: Printing Adjustments

    PRINTING ADJUSTMENTS 6 November, 2001 3.20 PRINTING ADJUSTMENTS Perform the appropriate adjustments after replacing any of the following items: • Polygon mirror motor • Paper side fence • Memory all clear • Rollers and gears • Paper feed unit For details about how to perform the adjustments, refer to the Operating Instructions.

  • Page 113: Parallelogram Image Adjustment

    6 November, 2001 PARALLELOGRAM IMAGE ADJUSTMENT 3.21 PARALLELOGRAM IMAGE ADJUSTMENT Do the following procedure if a parallelogram prints while adjusting the printing registration or printing margin using a trimming area pattern. The following procedure should be done after adjusting the side-to-side registration for each paper tray station.

  • Page 114: Troubleshooting

    6 November, 2001 SERVICE CALL CONDITIONS 4. TROUBLESHOOTING CAUTION To avoid damaging the hard disk or memory, never turn off the main power switch when the Data In LED is lit or flashing. 4.1 SERVICE CALL CONDITIONS 4.1.1 SUMMARY There are 4 levels of service call conditions. Level Definition Reset Procedure...

  • Page 115: Service Call Conditions

    SERVICE CALL CONDITIONS 6 November, 2001 4.1.2 SC CODE DESCRIPTIONS Level Symptom Possible Cause HARGE OLLER • Charge roller damaged Charge roller current leak • High voltage supply board A charge roller current leak signal was detected. defective • PCU harness defective or disconnected •...
  • Page 116 6 November, 2001 SERVICE CALL CONDITIONS Level Symptom Possible Cause • H.P. sensor/harness defective LD unit H.P. error 1 • LD unit home position sensor The LD unit H.P. sensor does not detect the on condition when the LD defective •...
  • Page 117 SERVICE CALL CONDITIONS 6 November, 2001 Level Symptom Possible Cause • ID sensor defective LED current abnormal at initialization • ID sensor harness defective during ID sensor adjustment • ID sensor connector defective At ID sensor initialization, one of the •...
  • Page 118 6 November, 2001 SERVICE CALL CONDITIONS Level Symptom Possible Cause • Main motor/drive malfunction Transfer belt H.P. abnormal • Transfer belt contact clutch H.P. is not detected after the T/S clutch is switched on twice. defective • Transfer belt position sensor defective •...
  • Page 119 SERVICE CALL CONDITIONS 6 November, 2001 Level Symptom Possible Cause APER • Lift motor malfunction or 1st tray lift malfunction disconnected Paper height sensor does not • Height sensor abnormal, or activate after the tray lift motor is on for 10 s. If the main power switch is connector loose •...
  • Page 120 6 November, 2001 SERVICE CALL CONDITIONS Level Symptom Possible Cause • Tray lift motor defective or 4th tray lift malfunction (optional paper tray unit) disconnected • Height sensor defective or Paper height sensor does not activate after the tray lift motor is on disconnected for 13 s.
  • Page 121 SERVICE CALL CONDITIONS 6 November, 2001 Level Symptom Possible Cause • Fusing lamp defective Fusing temperature warm-up error • Poor fusing unit connector • Fusing temperature does not • Thermistor warped or broken reach fusing standby temperature • Thermostat has tripped of 45°C (113°F) within 14 s at •...
  • Page 122 6 November, 2001 SERVICE CALL CONDITIONS Level Symptom Possible Cause • Serial line connecting BICU and Communication timeout error between BICU and finisher or finisher unstable • External noise mailbox A break (low) signal is received from the finisher or the mailbox. •...
  • Page 123 SERVICE CALL CONDITIONS 6 November, 2001 Level Symptom Possible Cause • I2C bus on BICU defective CDIC GAVD block I C bus error An error is detected in the CDIC communication I C control register of the GABIC2. • Jogger H.P. sensor defective Finisher jogger motor error •...
  • Page 124 6 November, 2001 SERVICE CALL CONDITIONS Level Symptom Possible Cause • Finisher exit guide open/close Finisher exit guide open/close motor error motor defective • Open/close sensor defective After the finisher exit guide open/close motor is turned on, the open/close sensor does not activate within the specified time.
  • Page 125 SERVICE CALL CONDITIONS 6 November, 2001 Level Symptom Possible Cause • Software defective F-GATE error at write request • BICU defective After the IPU receives an F-GATE signal, it receives another F-GATE signal (software timeout error) • Software defective Printer setting error The IPU does not respond with the settings required to start printer image processing.

  • Page 126: Electrical Component Defects

    6 November, 2001 ELECTRICAL COMPONENT DEFECTS 4.2 ELECTRICAL COMPONENT DEFECTS 4.2.1 SENSORS Component Condition Symptom (Symbol) LD Unit Home SC328 is displayed when the laser beam Open Position (S6) pitch is changed. 220-2 (IOB) SC327 is displayed when the laser beam Shorted pitch is changed.

  • Page 127: Switches

    ELECTRICAL COMPONENT DEFECTS 6 November, 2001 4.2.2 SWITCHES Component Condition Symptom (Symbol) Right Lower Cover “Doors/Covers Open” is displayed even if the Open (SW1) right lower cover is closed. 232-3 (PFB) LCD goes blank when the lower cover is Shorted opened.

  • Page 128: Blown Fuse Conditions

    6 November, 2001 BLOWN FUSE CONDITIONS 4.3 BLOWN FUSE CONDITIONS Rating Fuse Symptom at power on 115 V 210 ~ 230 V Power Supply Board 6.3 A/125 V 6.3 A/250 V “Doors/Covers Open” is displayed 6.3 A/125 V 6.3 A/250 V “Doors/Covers Open”...

  • Page 129: Service Tables

    6 November, 2001 SERVICE PROGRAM MODE 5. SERVICE TABLES 5.1 SERVICE PROGRAM MODE CAUTION Before entering the service menu, make sure that the Data In lamp is off. If the Data In lamp is lit or flashing, wait for it to go off. It will remain on until the current print job has completed.

  • Page 130: Printer Controller Service Mode

    PRINTER CONTROLLER SERVICE MODE 6 November, 2001 5.2 PRINTER CONTROLLER SERVICE MODE 5.2.1 CONTROLLER SERVICE MODE MENUS The controller service mode menu (1.Service) is the first item on the menu. Item What It Does Bit Switch Adjusts the bit switch settings. Clear Setting Initializes the settings for the “System”...

  • Page 131: Printer Controller Bit Switch Settings

    6 November, 2001 PRINTER CONTROLLER SERVICE MODE 5.2.3 PRINTER CONTROLLER BIT SWITCH SETTINGS Position: Display: Bit Switch 1 Default Do not change. Bit Switch 2 Do not change. Bit Switch 3 Do not change. Bit Switch 4 Do not change.

  • Page 132: Printer Engine Service Mode

    PRINTER ENGINE SERVICE MODE 6 November, 2001 5.3 PRINTER ENGINE SERVICE MODE The Printer Engine Service mode is used to check electrical data, change modes, and adjust values. Here is a quick summary of how to enter and use the Printer Engine Service mode to change the settings listed in the Service Program Mode Tables.

  • Page 133: Leaving The Sp Mode

    6 November, 2001 PRINTER ENGINE SERVICE MODE • To change a multiple-digit number setting Press to move the cursor to the digit that you want to change. " Press #(Enter). A number replaces the cursor. Press to increase or decrease the number. "...

  • Page 134: Service Program Mode Tables

    PRINTER ENGINE SERVICE MODE 6 November, 2001 5.3.1 SERVICE PROGRAM MODE TABLES Service Table Key Notation What it means [range / default / step] Example: [–9 ~ +9 / +3.0 / 0.1 mm step]. The setting can be adjusted in the range ±9, value reset to +3.0 after an NVRAM reset, and the value can be changed in 0.1 mm steps with each key press.
  • Page 135 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 1012* Exit Junction Solenoid Timing Adjusts the operation timing of the solenoids at the entrance and exit of the paper exit section to accommodate the increased speed of the duplex unit.
  • Page 136 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] [120°C ~ 220°C / 190° ° ° ° C / 1°C step] 1105* Ends (By-pass) Center (Reload) Adjusts the temperature for re-heating the center of the hot roller: Reload Temp.
  • Page 137 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 1109* Fusing Nip Band Check 1111* Switchback Timing Adjusts the reverse timing of paper in the duplex unit (stopping the rotation of the reverse roller after the trailing edge of the paper passes the duplex entrance sensor).

  • Page 138: Drum (Sp2000-00)

    PRINTER ENGINE SERVICE MODE 6 November, 2001 2. Drum (SP2000-00) Mode Number Function and [Setting] 2001* Charge Roller Bias Adjustment Image Pattern Adjusts the voltage applied to the charge roller for the image area to maintain a charge of –800 V on the OPC drum surface.
  • Page 139 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 2101* Back Side – Right Adjusts the right side erase margin in the reverse side of duplex prints. [0 ~ 9.0 / 0.3 / 0.1 mm step] Recommend: 2 ± 1.5 mm Back Side –...
  • Page 140 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] 2109* LD Unit Position Displays the current LD unit position (number of pulses from home position). If this is different from the value of SP2109-01 or SP2109-02, LD unit positioning has failed.
  • Page 141 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 2208* Toner Supply Mode Selects the toner mode. 0: Sensor control 1: Image pixel count. If you select 1, set SP2209-02 to its default value. Use image pixel count mode only as a temporary measure if the ID or TD sensor is defective and a replacement is not available.
  • Page 142 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] 2210* Large Job Sets the interval between ID sensor pattern prints with the halftone pattern added. The ID sensor reads the halftone pattern and outputs it as Vsm to the CPU. The Vsm value is used in the calculation Vsm/Vsg to adjust the power to the LD.
  • Page 143 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 2301* Image Back Printing the second side of the paper (image (2nd Side of Paper) area) during duplex printing. [20 ~ 100 µA / 45 / 1 µA step] Leading Edge.
  • Page 144 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] 2801* TD Sensor Initial Setting Performs the TD sensor initial setting. This SP mode controls the voltage applied to the TD sensor to make the TD sensor output about 4.0 V.
  • Page 145 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 2912 Drum Reverse Rotation Adjusts the time the drum and belt are reversed Interval in order to prevent paper dust and toner from collecting at the blade. DFU [0 ~ 10 /3 / 1 step] Example 1: If you enter 3, then: 3/2 = 2 (rounded up) x 10 + 10 = 30 ms...
  • Page 146 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] 2964* Transfer Cleaning Blade Applies a pattern of toner to the transfer belt at a Forming defined interval between sheets on the transfer belt in order to reduce friction between the belt surface and the cleaning blade.
  • Page 147 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 2975 Toner End Time Sets a time limit for issuing the toner near end warning on the operation panel. The time may need to be shortened for customers who run especially large print jobs to ensure earlier warning of the toner near end condition.

  • Page 148: Process (Sp3000-00)

    PRINTER ENGINE SERVICE MODE 6 November, 2001 3. Process (SP3000-00) Mode Number Function and [Setting] 3001* ID Sensor Initial Setting ID Sensor PWM Setting Allows you to reset the PWM (Pulse Width Modulation) of the ID sensor LED to avoid a service call error after clearing NVRAM or replacing the NVRAM.

  • Page 149: Hdd (Sp4000-00)

    6 November, 2001 PRINTER ENGINE SERVICE MODE 4. HDD (SP4000-00) Mode Number Function and [Setting] 4911 Format HDD Formats the hard disk. After execution, you must cycle the machine off and on with the power switch. 5. Mode (SP5000-00) Mode Number Function and [Setting] 5024* mm/inch Display...
  • Page 150 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] 5802* Printer Free Run Performs a free run. The printer prints the number of blank prints requested for testing. [0 ~ 1 /0 / 1 step] 0: Free run mode off. 1: Free run mode on.
  • Page 151 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] 5828* Network Job Analysis Sets the Centronics job analysis timeout for the Timeout Setting (Centronics) network. [0 ~ 4,200 s / 3 s / 1 sec. step] Network Job Timeout Setting Sets the Centronics job timeout for the network.
  • Page 152 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] 5907* Plug & Play Sets the brand name and the production name for Windows Plug & Play. This information is stored in NVRAM. If the NVRAM is defective or has been replaced, these names should be registered again.

  • Page 153: Peripherals (Sp6000-00)

    6 November, 2001 PRINTER ENGINE SERVICE MODE 6. Peripherals (SP6000-00) Mode Number Function and [Setting] 6105* Staple Adjustment Adjusts the staple position in the main scan direction when using the 3000-sheet f inisher. [–3.5 ~ +3.5 / 0 / 0.5 mm step] A larger value shifts the staple toward the edge of the paper.

  • Page 154: Data Log (Sp7000-00)

    PRINTER ENGINE SERVICE MODE 6 November, 2001 7. Data Log (SP7000-00) Mode Number Function and [Setting] 7001* Main Motor Operation Time The number of prints and drive time for drum revolutions can be obtained by counting the main motor revolution time. If the amount of the time required for the drum to revolve to print 1 copy increases, this data combined with the number of prints can be used to analyze...
  • Page 155 6 November, 2001 PRINTER ENGINE SERVICE MODE Mode Number Function and [Setting] Displays the total number of copy jams by 7504* Jam Count by Location location. Display range: 0000 ~ 9999 A “Paper Late” error occurs when the paper fails to activate the sensor at the precise time.
  • Page 156 PRINTER ENGINE SERVICE MODE 6 November, 2001 Mode Number Function and [Setting] Jam Count by Copy Size 7506* Displays the total number of copy jams by paper A4 H (Sideways) size. A5 H (Sideways) B5 H (Sideways) LT H (Sideways) HLT H (Sideways) A3 V (Lengthwise) A4 V (Lengthwise)

  • Page 157: Test Pattern Printing

    6 November, 2001 PRINTER ENGINE SERVICE MODE 5.3.2 TEST PATTERN PRINTING Enter the SP mode and select SP2902. 1. Press !" together (5s), release, then press #(Enter). System Ver.1.00 1. Service 2. Press " System Ver. 1.00 2. Engine 3. Press #(Enter). <Engine>...

  • Page 158: Test Pattern Table: Sp2902-03 Printing Test Patterns

    PRINTER ENGINE SERVICE MODE 6 November, 2001 Test Pattern Table: SP2902-03 Printing Test Patterns Test Pattern None Vertical Line (1-dot) Horizontal Line (1-dot) Vertical Line (2-dot) Horizontal Line (2 dot) Grid Pattern (1-dot) Grid Pattern (1-dot pair) (not used) (not used) Full Dot Pattern Black band Trimming Area...

  • Page 159: Input Check

    6 November, 2001 PRINTER ENGINE SERVICE MODE 5.3.3 INPUT CHECK Enter the SP mode and select SP5803. 1. Press !" together (5s), release, then press #(Enter). System Ver.1.00 1. Service 2. Press ". System Ver. 1.00 2. Engine 3. Press #(Enter). <Engine>...
  • Page 160 PRINTER ENGINE SERVICE MODE 6 November, 2001 Reading Number Description Fusing Exit Sensor Activated Deactivated Paper Height Sensor 2 Activated Deactivated Paper Height Sensor 1 Activated Deactivated SP5803-001 Not used — — Paper Feed 1 Paper Size Sensor 4 Activated Deactivated (Upper Tray) Paper Size Sensor 3...
  • Page 161 6 November, 2001 PRINTER ENGINE SERVICE MODE Reading Number Description Feed Motor Lock F-Gate Signal Active Not active Height Sensor Feed height Not feed height SP5803-006 Paper Exit Sensor Paper detected Paper not detected Unit Set Fusing Unit Detected Not detected (Detection) Total Counter Not detected...
  • Page 162 PRINTER ENGINE SERVICE MODE 6 November, 2001 Reading Number Description By-pass Yes/No Bit 2 Bit 1 Bit 0 Capacity Not used Full Not used SP5803-011 80% or more Not used Remainder of 50% or more Not used Feed Tray 2 30% or more LCT: Bit 2 10% or more...

  • Page 163: Output Check

    6 November, 2001 PRINTER ENGINE SERVICE MODE 5.3.4 OUTPUT CHECK NOTE: Motors keep turning in this mode regardless of upper or lower limit sensor signals. To prevent mechanical or electrical damage, do not keep an electrical component on for a long time. Enter the SP mode and select SP5804.

  • Page 164: Sp5804 Output Check Table

    PRINTER ENGINE SERVICE MODE 6 November, 2001 SP5804 Output Check Table Description Description 1st Paper Feed CL 43 ~ 44 Not used 2nd Paper Feed CL Duplex Junction Gate SOL 3rd Paper Feed CL (PTU) Not used 4th Paper Feed CL (PTU) Relay Junction Gate SOL By-pass Feed CL 48 ~ 49...

  • Page 165: Memory All Clear: Sp5801

    6 November, 2001 PRINTER ENGINE SERVICE MODE 5.3.5 MEMORY ALL CLEAR: SP5801 Executing Memory All Clear resets all the settings stored in the NVRAM to their default settings except the following: SP7003-1: Electrical total counter value SP5811-1: Machine serial number SP5907: Plug &...

  • Page 166: Smc Print Out Lists: Sp5990

    PRINTER ENGINE SERVICE MODE 6 November, 2001 5.3.6 SMC PRINT OUT LISTS: SP5990 1. Enter the SP Engine Mode. <Engine> 1.Feed 2. Press until you see “5.Mode”. " <Engine> 5.Mode 3. Press #(Enter). SP5024 mm/inch Display 4. Press to select SP5990. SP5990 >>...

  • Page 167: Software Download

    6 November, 2001 SOFTWARE DOWNLOAD 5.4 SOFTWARE DOWNLOAD 5.4.1 DOWNLOADING THE SOFTWARE Before downloading the software, please note: • If you are downloading the Engine software for the BICU, 1 card is required. • If you are downloading the Controller software, 2 cards are required. •...

  • Page 168: Power Failure During Software Download

    SOFTWARE DOWNLOAD 6 November, 2001 5.4.2 POWER FAILURE DURING SOFTWARE DOWNLOAD If a power failure occurs before downloading is completed, you will not be able to continue downloading with the Controller cards or the Engine card using the operation panel. 1.

  • Page 169: Self-Diagnostic Mode

    6 November, 2001 SELF-DIAGNOSTIC MODE 5.5 SELF-DIAGNOSTIC MODE 5.5.1 SELF-DIAGNOSTIC MODE AT POWER ON As soon as the main machine is powered on, the controller waits for the initial settings of the copy engine to take effect and then starts an independent self- diagnostic test program.

  • Page 170: Detailed Self-Diagnostic Mode

    SELF-DIAGNOSTIC MODE 6 November, 2001 5.5.2 DETAILED SELF-DIAGNOSTIC MODE In addition to the self-diagnostic test initiated every time the main machine is powered on, you can set the machine in a more detailed diagnostic mode manually in order to test other components or conditions that are not tested during self- diagnosis after power on.

  • Page 171: Dip Switches

    6 November, 2001 DIP SWITCHES 5.6 DIP SWITCHES Controller: DIP SW2 DIP SW No. IC Card Boot System ROM Boot Keep at “OFF” I/O Board: DIP SW101 DIP SW No. Function Not used. Off (Do not change) Jam Detection (see Note) SC Generation Disabled Enabled Not used...

  • Page 172: Detailed Section Descriptions

    6 November, 2001 OVERVIEW 6. DETAILED SECTION DESCRIPTIONS 6.1 OVERVIEW 6.1.1 COMPONENT LAYOUT G065D022.WMF 1. Exit Roller 17. By-pass Paper End Sensor 2. Paper Exit Sensor 18. By-pass Paper Feed Roller 3. Hot Roller 19. By-pass Separation Roller 4. Entrance Sensor 20.

  • Page 173: Paper Path

    OVERVIEW 6 November, 2001 Paper Path G065D551.WMF 1. Interchange unit 2. Duplex unit 3. By-pass tray 4. Large capacity tray (LCT) 5. Paper tray unit 6. Bridge unit 7. 1-bin shift tray 8. Mailbox bridge unit 9. Mailbox 10. Finisher...

  • Page 174: Drive Layout

    6 November, 2001 OVERVIEW 6.1.2 DRIVE LAYOUT PCU Drive Fusing Development Transfer G065D002.WMF 1. Transfer Belt Contact Clutch 6. Paper Feed/Development Motor 2. Registration Clutch 7. Development Clutch 3. Upper Paper Feed Clutch 8. Main Motor 4. Lower Paper Feed Clutch 9.

  • Page 175: Board Structure

    BOARD STRUCTURE 6 November, 2001 6.2 BOARD STRUCTURE 6.2.1 BLOCK DIAGRAM BICU Operation Panel PFCB HVPS DUPLEX G065D998.WMF This machine employs the GW (Grand Workware) architecture, which allows the printer to be expanded by installing simple modular components (ROM DIMMs) on the controller board.
  • Page 176 6 November, 2001 BOARD STRUCTURE Mother Board Interfaces the BICU and Controller. The operation panel connects directly to the Mother Board. Operation Panel Controls the LCD user interface and button controls. PSU (Power Supply Unit) Provides dc power to the system and ac power to the fusing lamp. HVPS (High Voltage Power Supply) Supplies high voltage to the drum charge roller, development roller, and transfer belt.

  • Page 177: Controller

    BOARD STRUCTURE 6 November, 2001 6.2.2 CONTROLLER OPTION OPTION OPTION OPTION 3.5" HDD 100Base-TX IEEE1284 IC Card (64/128/ IEEE1394 More than 10Base-T 256 MB) 10 GB IEEE1284 Network IC Card ROM DIMM RAM DIMM System Resident Font ROM NVRAM CELLO Flash ROM SDRAM (4MB)
  • Page 178 6 November, 2001 BOARD STRUCTURE 1. CPU. Employs RM7000A-300. Clock frequency: 300 MHz. 2. ASIC: CELLO. Uses a dedicated chip developed for use with GW architecture. These components perform CPU and I/F control and also control: memory, local bus, interrupts, PCI bus, video data, HDD, network, operation panel, and IEEE1284.

  • Page 179: Printing Process Overview

    PRINTING PROCESS OVERVIEW 6 November, 2001 6.3 PRINTING PROCESS OVERVIEW G065D111.WMF Drum Charge The charge roller [A] gives a negative charge to the organic photoconductive (OPC) drum. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark. Laser Exposure The image data is projected onto the drum by two laser beams [B], which form an electrostatic latent image on the drum surface.

  • Page 180: Image Transfer

    6 November, 2001 PRINTING PROCESS OVERVIEW Image Transfer Paper is fed into the area between the drum surface and the transfer belt [D] at the proper time to align it with the image on the drum. The transfer bias roller applies a high positive charge to the reverse side of the paper through the transfer belt.

  • Page 181: Laser Exposure

    LASER EXPOSURE 6 November, 2001 6.4 LASER EXPOSURE 6.4.1 OVERVIEW G065D541.WMF 1. LD unit 6. Laser synchronization detector 2. Cylindrical lens 7. BTL (Barrel Toroidal Lens) 3. Polygonal mirror 8. F-theta mirror 4. Shield glass 9. Toner shield glass 5. Mirror This machine uses two laser diodes to produce electrostatic images on an OPC drum.

  • Page 182: Auto Power Control (Apc)

    6 November, 2001 LASER EXPOSURE 6.4.2 AUTO POWER CONTROL (APC) The LD board drives the laser diode. Even if a constant electric current is applied to the laser diode, the intensity of the output light changes with the temperature. The intensity of the output decreases as the temperature increases.

  • Page 183: Dual Beam Writing

    LASER EXPOSURE 6 November, 2001 6.4.3 DUAL BEAM WRITING This LD unit employs two laser diodes [A] (LD) and [B] (L2). Each face of the polygon mirror writes two main scan lines, and twelve main scans are produced when the polygon mirror rotates once.

  • Page 184: Laser Beam Pitch Change Mechanism

    6 November, 2001 LASER EXPOSURE 6.4.4 LASER BEAM PITCH CHANGE MECHANISM G065D543.WMF When the LD positioning motor [A] turns, the metal block [B] in contact with the LD unit housing [C] moves up and down and changes the position of L2 (L1 does not move).

  • Page 185: Ld Safety Switches

    LASER EXPOSURE 6 November, 2001 6.4.5 LD SAFETY SWITCHES Upper Right BICU LDDR Cover Switch CN402-4 CN312-1 CN403-1 LD5V CN403-3 Front Cover Safety Switch G065D505.WMF To ensure personal safety and to prevent the laser beam from inadvertently switching on during servicing, power to the laser diode is switched off when the front cover or upper right cover is opened.

  • Page 186: Photoconductor Unit (Pcu)

    6 November, 2001 PHOTOCONDUCTOR UNIT (PCU) 6.5 PHOTOCONDUCTOR UNIT (PCU) 6.5.1 OVERVIEW G065D301.WMF 1. Toner Collection Coil 6. Transfer Entrance Guide 2. Toner Collection Plate 7. Charge Roller 3. Spur 8. Brush Roller 4. Pick off Pawl 9. Cleaning Blade 5.

  • Page 187: Drive Mechanism

    PHOTOCONDUCTOR UNIT (PCU) 6 November, 2001 6.5.2 DRIVE MECHANISM The drive from the main motor [A] is transmitted to the drum [B] through a series of gears, a timing belt [C], and the drum drive shaft [D]. The main motor has a drive controller, which outputs a motor lock signal when the rotation speed is out of the specified range.

  • Page 188: Drum Charge

    6 November, 2001 DRUM CHARGE 6.6 DRUM CHARGE 6.6.1 OVERVIEW G065D525.WMF This machine uses a drum charge roller to charge the drum. The drum charge roller [A] contacts the surface of the drum [B] to give it a negative charge. The high voltage supply board [C] supplies a negative dc voltage to the drum charge roller through the charge roller terminal [D], bias plate [E], and the rear roller bushing [F] to give the drum surface a negative charge of –950V.

  • Page 189: Charge Roller Voltage Correction

    DRUM CHARGE 6 November, 2001 6.6.2 CHARGE ROLLER VOLTAGE CORRECTION Correction for Environmental Conditions 3 cm 3 cm 3 cm ID Sensor Pattern Sub Scan Direction Charge Voltage –1480V Laser Diode –950V Drum Potential –540V Development Bias –550V –380V –150V Vsg (4.00V) ID Sensor Output Vsdp (3.50V)

  • Page 190: Correction For Paper Width And Thickness (By-Pass Tray Only)

    6 November, 2001 DRUM CHARGE Correction for Paper Width and Thickness (By-pass Tray only) The by-pass tray can be used for non-standard paper narrower than sizes accepted by the paper trays. Thicker paper, OHP sheets, etc. can also be loaded in the by-pass tray but adjustments must be performed with the SP modes listed below in order to avoid jams and quality problems.

  • Page 191: Id Sensor Pattern Production Timing

    DRUM CHARGE 6 November, 2001 6.6.3 ID SENSOR PATTERN PRODUCTION TIMING At certain times, an ID sensor pattern is created on the drum. The ID sensor reads the sensor pattern and outputs this reading as Vsp and sends it to the CPU where it is used to calculate Vref (Vsp/Vsg = Vref).

  • Page 192: Drum Charge Roller Cleaning

    6 November, 2001 DRUM CHARGE 6.6.4 DRUM CHARGE ROLLER CLEANING G065D901.WMF The drum charge roller [A], always in contact with the drum, get dirty easily, so the brush roller [B] also remains in contact with the charge roller to clean it. 6-21...

  • Page 193: Development

    DEVELOPMENT 6 November, 2001 6.7 DEVELOPMENT 6.7.1 OVERVIEW G065D401.WMF 1. Drum 5. Mixing Auger 2. Development Roller 6. Development Filter 3. Paddle Roller 7. Doctor Blade 4. TD Sensor 6-22...

  • Page 194: Drive Mechanism

    6 November, 2001 DEVELOPMENT 6.7.2 DRIVE MECHANISM The feed/development motor [A] drives the development roller [B] through the gears and the paddle roller gear [C]. The drive shaft engages and disengages the paddle roller gear when the development unit is inserted into and removed from the machine.

  • Page 195: Development Bias

    DEVELOPMENT 6 November, 2001 6.7.4 DEVELOPMENT BIAS Mechanism Black areas of the latent image are at a low negative charge (about -150 V) and white areas are at a high negative charge (about –950 V). To attract negatively charged toner to the black areas of the latent image on the drum, the high voltage supply board [A] applies a bias of –540 volts to the...

  • Page 196: Toner Supply

    6 November, 2001 DEVELOPMENT 6.7.5 TONER SUPPLY Toner Bottle Replenishment Mechanism G065D504.WMF When the toner bottle is installed in the bottle holder [A], pin [B] slides up the side of the PCU [C], pulling out the toner shutter [D]. When the toner bottle holder lever [E] is returned to its original position, the cap [F] pulls away and is kept in place by the chuck [G].

  • Page 197: Toner Supply Mechanism

    DEVELOPMENT 6 November, 2001 Toner Supply Mechanism The toner supply motor [A] rotates the toner bottle [B] and the mylar blades [C] (see below). G065D545.WMF Toner falls into the toner bottle holder, and the toner supply mylar blades [C] transfer the toner to slit [D]. Installing the PCU opens the shutter [E].

  • Page 198: Sensor Control Mode

    6 November, 2001 DEVELOPMENT Sensor Control Mode In the sensor control mode, the amount of toner required to print the page is calculated by the CPU; it adds up the image data value of each pixel and converts the sum to a value between 0 and 255. (255 would mean a completely black page.) The machine must vary toner supply for each print in order to maintain the correct amount of toner in the developer and to account for changes in drum reflectivity due to changes in temperature and humidity.

  • Page 199: Toner Near End/End Detection

    DEVELOPMENT 6 November, 2001 6.7.6 TONER NEAR END/END DETECTION Standard Method The toner near-end condition is detected based on the Vt(10) output from the TD sensor. If the difference between Vref (toner supply reference voltage) and Vt (10) is less than or equal to –0.45, then toner concentration is judged be very low and K (the toner supply coefficient) is set to 0.25, the machine enters the toner near end condition and the machine switches on the toner supply motor.

  • Page 200: Toner End Recovery

    6 November, 2001 DEVELOPMENT 6.7.7 TONER END RECOVERY If the front door is opened and then closed while a toner near end/end condition exists, the machine will attempt to recover. When the front door is closed, the toner supply motor turns on to supply toner. The machine checks the TD sensor output 2 seconds after the main motor turns on (Vtp), and the sensor is checked again every 1 second (Vtp The machine detects the toner concentration using Vref, Vt (10), Vtp, and Vtp...

  • Page 201: Drum Cleaning And Toner Recycling

    DRUM CLEANING AND TONER RECYCLING 6 November, 2001 6.8 DRUM CLEANING AND TONER RECYCLING 6.8.1 DRUM CLEANING This machine employs a counter blade system. After the image is transferred to paper, a cleaning blade [A] removes any toner remaining on the drum. The toner collection coil [B] carries scraped off toner to the toner collection plate [C].

  • Page 202: Paper Feed

    6 November, 2001 PAPER FEED 6.9 PAPER FEED 6.9.1 OVERVIEW G065D701.WMF 1. Upper pick-up roller 9. Lower paper feed roller 2. Upper paper lift sensor 10. Lower separation roller 3. Upper paper feed roller 11. Lower paper lift sensor 4. Upper relay sensor 12.

  • Page 203: Paper Feed Drive

    PAPER FEED 6 November, 2001 6.9.2 PAPER FEED DRIVE The feed/development motor [A] drives the pick-up and feed mechanism of both the upper and second paper feed stations through gears and the paper feed clutches [B]. When the paper feed clutch turns on, the pick-up roller, paper feed roller, and separation roller start rotating to feed the paper.

  • Page 204: Paper Lift

    6 November, 2001 PAPER FEED 6.9.4 PAPER LIFT The paper size switch [A] detects when the paper tray [B] is set in the machine, and 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].

  • Page 205: Paper End Detection

    PAPER FEED 6 November, 2001 6.9.5 PAPER END DETECTION If there is paper in the paper tray, the paper end feeler [A] is raised by the paper stack, and the paper end sensor [B] is deactivates. 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.

  • Page 206: Paper Size Detection

    6 November, 2001 PAPER FEED 6.9.7 PAPER SIZE DETECTION The paper size switch includes four microswitches. Actuators behind the paper size dial actuate the sensors. Each paper size has its own actuator, with a unique combination of notches. To determine the paper size, the CPU reads which switches the actuator has turned off.

  • Page 207: Paper Height Detection

    PAPER FEED 6 November, 2001 6.9.8 PAPER HEIGHT DETECTION Two paper height sensors [A] and [B], working in combination, detect the Full amount of paper in the tray. When the amount of paper decreases, the bottom plate pressure lever [C] moves up and the actuator [D] mounted on the same drive shaft as the pressure lever rotates.

  • Page 208: By-Pass Tray

    6 November, 2001 BY-PASS TRAY 6.10 BY-PASS TRAY 6.10.1 OVERVIEW G065D510.WMF 1. Paper feed roller 2. Paper end sensor 3. Pick-up roller 4. By-pass tray 5. Separation roller 6-37...

  • Page 209: By-Pass Tray Operation

    BY-PASS TRAY 6 November, 2001 6.10.2 BY-PASS TRAY OPERATION G065D500.WMF G065D501.WMF The by-pass unit is directly driven by the machine through gear [A]. When the print key is pressed, 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 and the paper end sensor [E] is activated.

  • Page 210: By-Pass Paper Size Detection

    6 November, 2001 BY-PASS TRAY 6.10.3 BY-PASS PAPER SIZE DETECTION G065D522.WMF 11" " " G065D523.WMF The paper size sensor board [A] monitors the paper width. The rear side fence is connected to the terminal plate. The pattern for each paper width is unique.

  • Page 211: Duplex Unit

    DUPLEX UNIT 6 November, 2001 6.11 DUPLEX UNIT 6.11.1 OVERVIEW G065D101.WMF 1. Entrance sensor 2. Inverter gate 3. Inverter roller 4. Upper transport roller 5. Lower transport roller 6. Exit sensor 6-40...

  • Page 212: Duplex Drive Layout

    6 November, 2001 DUPLEX UNIT 6.11.2 DUPLEX DRIVE LAYOUT G065D103.WMF 1. Inverter roller 2. Inverter motor 3. Upper transport roller 4. Transport motor 5. Lower transport roller 6-41...

  • Page 213: Duplex Basic Operation

    DUPLEX UNIT 6 November, 2001 6.11.3 DUPLEX BASIC OPERATION To increase the productivity of the duplex unit, copies are printed as follows. Larger than A4 Lengthwise/LT Lengthwise (SEF) The duplex unit can store only one sheet of paper. 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).

  • Page 214: Duplex Unit Feed In And Exit Mechanism

    6 November, 2001 DUPLEX UNIT 6.11.4 DUPLEX UNIT FEED IN AND EXIT MECHANISM G065D104.WMF G065D105.WMF Feed-in The inverter gate solenoid [A] stays off and the inverter rollers [B] rotate clockwise. A sheet of paper is sent to the inverter section [C]. NOTE: The cover guide has been eliminated in order to accommodate paper sizes longer than A4/LT in the reverse feed path which has been lengthened in the design of this machine.

  • Page 215: Image Transfer And Paper Separation

    IMAGE TRANSFER AND PAPER SEPARATION 6 November, 2001 6.12 IMAGE TRANSFER AND PAPER SEPARATION 6.12.1 OVERVIEW G065D561.WMF 1. Transfer belt 6. OPC 2. Drive roller 7. Pick-off pawls 3. Transfer belt cleaning blade 8. ID sensor 4. Transfer roller 9. Contact lever 5.

  • Page 216: Belt Drive Mechanism

    6 November, 2001 IMAGE TRANSFER AND PAPER SEPARATION 6.12.2 BELT DRIVE MECHANISM After the main motor switches on during printing, the transfer belt contact clutch [A] switches on after a specified interval and the cam [F] makes a half-turn to raise the contact lever [E] and bring the transfer belt [D] into contact with the drum.

  • Page 217: Image Transfer And Paper Separation Mechanism

    IMAGE TRANSFER AND PAPER SEPARATION 6 November, 2001 6.12.4 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM When the registration clutch switches on to align the leading edge of the paper [A] with the image on the drum [B], the transfer belt is [C] is away from the drum.

  • Page 218: Transfer Belt Charge

    6 November, 2001 IMAGE TRANSFER AND PAPER SEPARATION 6.12.5 TRANSFER BELT CHARGE Mechanism G065D564.WMF The high voltage supply board [A] applies a positive current to the transfer belt [B] through the terminal block [C], terminal plate [D], and the bias roller [E]. The high voltage supply board adjusts the current to the roller to keep a small but constant current flow to ground through the belt, paper, and drum.

  • Page 219: Correction For Paper Width And Thickness

    IMAGE TRANSFER AND PAPER SEPARATION 6 November, 2001 Correction for Paper Width and Thickness A range of SP modes is available in order to adjust the machine so it can handle papers of non-standard size and thickness. For paper width, there are two thresholds. The factory settings are 150 mm (5.9”) and 216 mm (8.5”).

  • Page 220: Transfer Currents To Leading Edge And Image Areas

    6 November, 2001 IMAGE TRANSFER AND PAPER SEPARATION Transfer Currents to Leading Edge and Image Areas Transfer current can also be adjusted for the leading edge and the image area, and for by-pass feed. The timing for starting to apply leading edge current, for the switchover from leading edge current to image area current, and for switching off at the trailing edge can also be changed.

  • Page 221: Transfer Belt Cleaning Mechanism

    IMAGE TRANSFER AND PAPER SEPARATION 6 November, 2001 6.12.6 TRANSFER BELT CLEANING MECHANISM G065D524.WMF The cleaning blade [A], always in contact with the transfer belt, scrapes off toner and paper dust remaining on the transfer belt. Scraped off toner and paper dust falls into the toner collection tank [B] in the transfer belt unit.

  • Page 222: Image Fusing And Paper Exit

    6 November, 2001 IMAGE FUSING AND PAPER EXIT 6.13 IMAGE FUSING AND PAPER EXIT 6.13.1 OVERVIEW G065D601.WMF 1. Paper exit sensor 10. Cleaning roller 2. De-curler rollers 11. Entrance guide 3. Junction gate 12. Fusing lamp (center) 4. Idle roller (duplex unit) 13.

  • Page 223: Fusing Drive

    IMAGE FUSING AND PAPER EXIT 6 November, 2001 6.13.2 FUSING DRIVE The fusing/paper exit motor [A] drives the fusing unit through the clutch [B] and the gears [C], and also drives the paper exit rollers [D] through a gear and a timing belt [E]. G065D903.WMF 6.13.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM The entrance guide [A] has two...

  • Page 224: Exit Guide Plate And De-Curler Rollers

    6 November, 2001 IMAGE FUSING AND PAPER EXIT 6.13.4 EXIT GUIDE PLATE AND DE-CURLER ROLLERS The exit guide plate [A] also functions as a pressure roller stripper. The exit guide plate can be moved in order to remove jammed paper. Stacking has been improved by mounting a face-curl correction mechanism at the paper exit roller.

  • Page 225: Fusing Temperature Control

    IMAGE FUSING AND PAPER EXIT 6 November, 2001 6.13.7 FUSING TEMPERATURE CONTROL There are two fusing lamps: the first fusing lamp (center: 650 W) [A] heats the center of the hot roller, and the second fusing lamp (ends: 550 W) [B] heats both ends of the hot roller.

  • Page 226: Fusing Idling Temperature

    6 November, 2001 IMAGE FUSING AND PAPER EXIT Fusing Idling Temperature If copies are not sufficiently fused soon after the main power switch is turned on, fusing idling should be enabled with SP1103-01. When fusing idling is enabled, it is done when the temperature reaches the re-load temperature.

  • Page 227: Energy Saver Mode

    ENERGY SAVER MODE 6 November, 2001 6.14 ENERGY SAVER MODE If the printer remains idle for the selected time interval, the machine automatically enters the energy saver mode and switches off the fusing lamps to reduce power consumption. The customer can select the idle time interval or switch the energy saver mode off. The Energy Saver selector setting is in the System menu, which can be accessed at the printer operation panel.

  • Page 228: Specifications

    6 November, 2001 SPECIFICATIONS SPECIFICATIONS 1. GENERAL SPECIFICATIONS Configuration: Desktop Print Process: Laser beam scanning and electro-photographic printing Dual component development Printing Speed: Max. 45 ppm, A4, 8 " x 11", LEF, simplex/duplex Parallel Interface: I/F: 36-pin connector, standard Mode: IEEE 1284 compatible, ECP, Nibble Network: Topology: Ethernet 10BASE-T/100BASE-TX Protocol: IPX/SPX, TCP/IP, AppleTalk, IPP, NetBEUI...

  • Page 229: Supported Paper Sizes

    SPECIFICATIONS 6 November, 2001 2. SUPPORTED PAPER SIZES Paper Tray Unit By-pass Tray Duplex Name Feed Size (W x L) NA/EU NA\EU 297 x 420 mm 257 x 364 mm 210 x 297 mm 297 x 210 mm 182 x 257 mm 257 x 182 mm 148 x 210 mm 210 x 148 mm...

  • Page 230: Software Accessories

    6 November, 2001 SPECIFICATIONS 3. SOFTWARE ACCESSORIES Printer drivers and utility software are provided on one CD-ROM. An automatic run installer allows you to select which components to install. 3.1 PRINTER DRIVERS Printer Language Windows 95/98/Me Windows NT4.0 Windows 2000 Macintosh PCL6 PCL5e...

  • Page 231: Machine Configuration

    SPECIFICATIONS 6 November, 2001 4. MACHINE CONFIGURATION 4.1 SYSTEM COMPONENTS G065V502.WMF Item Machine Code Printer G035 LCT (option) A683 Paper Tray Unit (option) G520 Nine-bin Mailbox (option) G909 3000-sheet Finisher (option) A697 1000-sheet Finisher (option) A681 Mailbox Bridge Unit (option) G912 Punch Unit (option for 3000-sheet Finisher) A812-17 (3-hole)

  • Page 232: Installable Option Table

    6 November, 2001 SPECIFICATIONS 4.2 INSTALLABLE OPTION TABLE Option Note " Paper Tray Unit Large Capacity Tray (LCT) Requires Paper Tray Unit. ❍ By-pass Feed Unit ❍ Duplex Unit " Bridge Unit 1000-Sheet Finisher Requires Paper Tray Unit, Bridge Unit (also Mailbox Bridge Unit if Mailbox is present) 3000-Sheet Finisher Requires Paper Tray Unit, Bridge Unit...

  • Page 233: 1000-Sheet Finisher

    SPECIFICATIONS 6 November, 2001 5. OPTIONS 5.1 BRIDGE UNIT Standard: Paper Size: A6 Lengthwise (SEF) to A3, HLT to DLT Non-Standard: Width: 100 to 305 mm Length: 148 to 432 mm Paper Weight: 52 g/m ~ 135 g/m , 16 lb. ~ 42 lb. 5.2 1000-SHEET FINISHER Paper Size: Staple Mode Off: A3 to A6 (L)

  • Page 234: 3000-Sheet Finisher

    6 November, 2001 SPECIFICATIONS 5.3 3000-SHEET FINISHER Paper Size: Punch Mode Off: Shift Tray: A3 to B5/DLT to LT (B6 lengthwise (SEF), shift mode off, staple mode off) Upper Tray: A3 to A6 lengthwise (SEF)/DLT to HLT Punch Mode On: 2 holes: A3 to A5/DLT to LT 3 holes: A3, B4, A4, B5, DLT, LT all sideways (LEF) Paper Weight:...

  • Page 235: Large Capacity Tray (Lct)

    SPECIFICATIONS 6 November, 2001 5.4 LARGE CAPACITY TRAY (LCT) A4 sideways (LEF)/LT sideways (LEF) Paper Size: Paper Weight: 60 g/m ~ 105 g/m , 16 lb. ~ 28 lb. Tray Capacity: 1,500 sheets (80 g/m , 20 lb.) Remaining Paper Detection: 5 steps (100%, 75%, 50%, 25%, Near end) Power Source: 24 Vdc, 5 Vdc (from copier)

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