Ricoh PD-D1 Field Service Manual
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Ricoh PD-D1 Field Service Manual

Ricoh PD-D1 Field Service Manual

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Model PD-D1
Machine Code: C279
Field Service Manual
3 February, 2012

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Summary of Contents for Ricoh PD-D1

  • Page 1 Model PD-D1 Machine Code: C279 Field Service Manual 3 February, 2012...

  • Page 3: Important Safety Notices

    Important Safety Notices Responsibilities of the Customer Engineer Customer Engineer Maintenance shall be done only by trained customer engineers who have completed service training for the machine and all optional devices designed for use with the machine. Reference Material for Maintenance •...

  • Page 4: Installation, Disassembly And Adjustments

    shock, switch the machine off, wait for a few seconds, then unplug the machine from the power source. • Before you do any checks or adjustments after turning the machine off, work carefully to avoid injury. After removing covers or opening the machine to do checks or adjustments, never touch electrical components or moving parts (gears, timing belts, etc.).

  • Page 5: Safety Devices

    Safety Devices • Never remove any safety device unless it requires replacement. Always replace safety devices immediately. • Never do any procedure that defeats the function of any safety device. Modification or removal of a safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the operation of the machine to ensure that it is operating normally and safely after removal and replacement of any safety device.

  • Page 6: After Installation, Servicing

    • Inspect the length of the power cord for cuts or other damage. Replace the power cord if necessary. A frayed or otherwise damaged power cord can cause a short circuit which could lead to a fire or personal injury from electrical shock. •...

  • Page 7: Safety Instructions For This Machine

    Safety Instructions for this Machine Prevention of Physical Injury 1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine and peripheral power cords are unplugged. 2. The plug should be near the machine and easily accessible. 3.
  • Page 8 • Therefore, removal of such components must always be with the consent of the customer. Do not remove them at your own judgment.

  • Page 9: Symbols And Trademarks

    Symbols and Trademarks Symbols This manual uses several symbols. The meanings of those symbols are as follows: See or Refer to Clip ring E-ring Screw Connector Clamp [A]: Short Edge Feed (SEF) [B]: Long Edge Feed (LEF) Trademarks ® ® ®...

  • Page 10: Table Of Contents

    TABLE OF CONTENTS Important Safety Notices...........................1 Responsibilities of the Customer Engineer....................1 Customer Engineer..........................1 Reference Material for Maintenance....................1 Before Installation, Maintenance........................1 Shipping and Moving the Machine.....................1 Power..............................1 Installation, Disassembly and Adjustments..................2 Special Tools............................2 During Maintenance............................2 General..............................2 Safety Devices............................3 Organic Cleaners..........................3 Power Plug and Power Cord........................3 After Installation, Servicing..........................4 Points to Confirm with Operators......................4 Safety Instructions for this Machine.......................5...
  • Page 11 2. Installation Procedure Installation Requirements..........................29 Optimum Environmental Condition......................29 Environments to Avoid..........................29 Power Connection............................29 Machine Access............................29 Power Sockets for Peripherals........................30 Optional Unit Combinations..........................32 Machine Options............................32 Machine Installation............................33 Accessory Check............................33 Installation Procedure..........................34 Brand Setting..............................41 Platen Cover (D593)............................43 Accessory Check............................43 Installation Procedure..........................43 Auto Document Feeder (D578)........................47 Accessory Check............................47 The Aim of Anti-tip Components and Precautions................48 Installation Procedure..........................48...
  • Page 12 4. Replacement and Adjustment Beforehand...............................65 Special Tools..............................66 Image Adjustment.............................67 SP6-10: Master Writing Speed........................67 SP6-100 to 107: Paper Registration ......................68 SP6-05, 6-06: Scanning Speed – Platen, ADF..................68 SP6-03, 6-04: Scanning Start Position – Platen, ADF................68 SP6-01, 6-02: Main Scan Position – Platen, ADF..................69 SP6-20: Standard White Execution......................69 Covers and Boards............................70 Front Cover, Operation Panel........................70...
  • Page 13 Master Eject Unit............................96 Master Eject Safety Switch.........................96 Eject Box Set Switch ...........................97 Master Feed..............................102 Master Making Unit..........................102 Plotter Safety Switch..........................102 Thermal Head............................103 Installation............................105 Duct Plate HP Sensor, Duct Plate Motor....................106 Cutter Unit..............................109 Thermal Head Driving Unit........................109 Duct Jam Sensor Adjustment........................110 Master Edge Sensor Adjustment......................111 2nd Drum Master Sensor Adjustment......................112 Master End Sensor Adjustment.........................113...
  • Page 14 Ink Roller Unit, Ink Roller One-Way Clutch....................132 Idling Roller Motor, Idling Roller HP Sensor...................133 Doctor Roller Gap Adjustment.........................134 Ink Detection Adjustment...........................135 Main Motor Pulley Position........................135 Main Drive Timing Belt Adjustment......................136 Paper Delivery ...............................137 Paper Delivery Unit...........................137 Fan Motor, Exit Sensor..........................137 Exit Pawl Adjustment..........................138 Timing Adjustment..........................138 Clearance Adjustment........................139...
  • Page 15 Controller Board..........................150 Test Points..............................151 MPU..............................151 PSU..............................151 5. System Maintenance Reference Service Program Mode..........................153 Using Service Program Modes........................153 How to Select a Program Number....................153 6. Troubleshooting Firmware Update............................155 Type of Firmware............................155 Before You Begin............................155 Preparing To Download Firmware......................156 Download Main/ADF firmware......................157 Download FV-Lt firmware.........................158 Electrical Component Defects........................161 Sensors...............................161...

  • Page 17: Product Information

    1. Product Information Specifications See "Appendices" for the following information: • Main Frame • Supported Paper Sizes • Software Accessories • Optional Equipment...

  • Page 18: Overview

    1. Product Information Overview Component Layout...

  • Page 19: Electrical Component Layout

    Overview 1. Scanner HP sensor 16. Paper table 2. 2nd carriage 17. Registration rollers 3. 1st carriage 18. Doctor roller 4. Original length sensor 19. Ink roller 5. Lens 20. Press roller 6. Blower fan motor 21. Idling roller 7. Reverse roller 22.
  • Page 20 1. Product Information...
  • Page 21 Overview...
  • Page 22 1. Product Information Boards Component Function CCD and SBU Outputs a video signal to the MPU. Paper Width Detection Board Sends data about the paper width on the paper table to the MPU.
  • Page 23 Overview Component Function Ink Detection Board Checks if there is ink in the drum. Operation Panel Boards These boards control the operation panel. Power Supply Unit (PSU) Provides dc power to the machine. Main Motor Board Controls the main motor speed. Main Processing Unit (MPU) Controls all machine functions, both directly and through other boards.
  • Page 24 1. Product Information Component Function Clamper Motor Opens or closes the master clamper on the drum. Duct plate motor Opens or closes the duct plate at entrance of the duct. Cutter Motor Cuts the master. Duct fan motors Provides suction to guide the master into the duct. Master Feed Motor Feeds the master to the drum.
  • Page 25 Overview Component Function Front Door Switching Sensor Detects if the Front Cover is in the closed position. Master Eject Sensor Detects used master misfeeds. Drum Master Sensor Detects if there is a master on the drum. Pressure Plate HP Sensor Detects when the pressure plate is at the home position.
  • Page 26 1. Product Information Solenoids Component Function Front Pressure Release Solenoid Releases the press roller to apply printing pressure. Rear Pressure Release Solenoid Releases the press roller to apply printing pressure. Switches Component Function Master Making Unit Set Switch Checks if the master making unit is installed. Table Lowering Switch Lowers the paper table.

  • Page 27: Drive Layout

    Overview Component Function Drum thermistor Detects the temperature inside the drum to adjust various processes. Ink detection pins Detect if ink is present in the drum Drive Layout 1. Pressure plate motor 7. Table motor 2. Clamper motor 8. Paper feed motor 3.

  • Page 28: Machine Codes And Peripherals Configuration

    1. Product Information Machine Codes and Peripherals Configuration Item Machine Code Remarks C279 -11/-17/-27/-29 Mainframe -61/-65 Platen Cover D593 One from No.2 or No.3 Auto Document Feeder D578 Network Controller C654 Tape Dispenser C651 Optional Drum C618/C619/C620...

  • Page 29: Guidance For Those Who Are Familiar With Predecessor Products

    Guidance for Those Who are Familiar with Predecessor Products Guidance for Those Who are Familiar with Predecessor Products Machine C279 is a successor model to Machine C264. If you have experience with the predecessor products, the following information will be of help when you read this manual. Different Points from Predecessor Products C279 C264...
  • Page 30 1. Product Information...

  • Page 31: Installation Procedure

    2. Installation Procedure Installation Requirements Carefully select the installation location because environmental conditions greatly affect machine performance. Optimum Environmental Condition 1. Temperature: 10 to 30 °C (50 to 86 °F) 2. Humidity: 20 to 90 %RH 3. Install the machine on a strong and level base. The machine must be level within 5mm (0.2") both front to rear left to right.

  • Page 32: Power Sockets For Peripherals

    2. Installation Procedure Power Sockets for Peripherals • Rating Voltage for Peripherals • Make sure to plug the cables into the correct sockets.
  • Page 33 Installation Requirements...

  • Page 34: Optional Unit Combinations

    2. Installation Procedure Optional Unit Combinations Machine Options Options Remarks Platen Cover (D593) One from No.1 or No.2 Auto Document Feeder (D578) Tape Dispenser (C651) Network Controller (C654) Optional Drums (C618/C619/C620)

  • Page 35: Machine Installation

    Description Quantity Master Spool Carrying Handle Stoppers Operating Instructions (CD-ROM) Easy Operation Guide Manuals & Safety Information for this machine NECR Emblem Cover Emblem (RICOH) Operation Panel Logo Plate (RIC/SAV/LAN) 1×3 Sheet & Pocket for the Exposure Glass Power Cable...

  • Page 36: Installation Procedure

    2. Installation Procedure Installation Procedure 1. Unpack the box. When installing the optional table, mount the machine as shown (there are 2 screws [A] packed with the table). • Only lift with the carrying handles on the bottom corners of the machine. •...
  • Page 37 Machine Installation 2. Push the carrying handles [C] into the machine, and attach the carrying handle stoppers[D].
  • Page 38 2. Installation Procedure 3. Remove the filament tape and string securing the covers and units as shown above.
  • Page 39 Machine Installation 4. Remove the front tape [A], the tag [B], and the rear tape [C]. • To remove the rear tape, pull the portion shown in the diagram toward the front of the machine.
  • Page 40 2. Installation Procedure 5. Pull out the master making unit, and take out the accessory bag [A]. 6. Insert both spools into a new master roll. 7. Install the master roll as shown above.
  • Page 41 Machine Installation 8. Insert the leading edge of the master roll under the platen roller. The arrows [A] indicate the correct position of the master leading edge. 9. Close the cover [A] using both hands. 10. Set the master-making unit.
  • Page 42 2. Installation Procedure 11. Open the door, and insert a new ink cartridge [A]. 12. Open the paper table, and load a stack of paper. 13. Make sure that the side plates [A] touch the paper gently. Shift the lock lever [B] in the direction of the arrow.

  • Page 43: Brand Setting

    Machine Installation 18. Turn on the main switch [A]. 19. Press the “Economy mode” key while holding down the “0” key, to supply ink inside the drum. 20. Make some test copies. Brand Setting If the machine was not set with the correct brand in the factory, you need to do this now. 1.
  • Page 44 2. Installation Procedure • When you set up the Ricoh brand model, install the emblem plate insted of the emblem and emblem cover. 2. Select your brand in the SP mode. Access SP2-7 (Vendor Selection) and choose your brand. (...

  • Page 45: Platen Cover (D593)

    Platen Cover (D593) Platen Cover (D593) Accessory Check Check the quantity and condition of the accessories in the box against the following list: Description Quantity Stepped Screw Guard Rail Filler Installation Procedure 1. Remove the strips of tape.
  • Page 46 2. Installation Procedure 2. Insert the two stepped screws [A] on the top of the machine. 3. Peel off the double sided tape from the guard rail filler [A] and place it by the platen cover sensor [B].
  • Page 47 Platen Cover (D593) 4. Mount the platen cover [A] by aligning the screw keyholes over the stud screws. 5. Slide the platen cover toward the right of the machine. 6. Remove the platen sheet [B] from the platen cover [A]. 7.
  • Page 48 2. Installation Procedure • When placing the platen sheet on the exposure glass, make sure to align it with the front left corner. 10. Turn on the main switch. 11. Place an original on the exposure glass and confirm that it can be printed properly. •...

  • Page 49: Auto Document Feeder (D578)

    Auto Document Feeder (D578) Auto Document Feeder (D578) Accessory Check Check the quantity and condition of the accessories in the box against the following list: Description Quantity Stepped Screw Screw Thumbscrew Stabilizer Bracket ADF exposure glass cleaning decal EMC ADDRESS:RIC...

  • Page 50: The Aim Of Anti-Tip Components And Precautions

    2. Installation Procedure The Aim of Anti-tip Components and Precautions The anti-tip components are necessary for meeting the requirements of IEC60950-1, the international standard for safety. The aim of these components is to prevent the products, which are heavy, from toppling as a result of people running into or leaning on the products, which can lead to serious accidents such as persons becoming trapped under the product.
  • Page 51 Auto Document Feeder (D578) 2. Insert the two stud screws [A] on the top of the machine.

  • Page 52: Adf Stabilizer Installation

    2. Installation Procedure 3. Mount the ADF [A] by aligning the screw keyholes [B] of the ADF support plate over the stud screws. 4. Slide the ADF toward the front of the machine. 5. Secure the ADF with the two knob screws [C]. 6.

  • Page 53: Configuration Of Options

    Auto Document Feeder (D578) 1. Attach the two stabilizer brackets [A] to the back of the table using the thumbscrews ( x 4). • This procedure must be done to prevent the machine from falling backwards when the ADF is open. Configuration of Options SP6-2 Main-scan position - ADF Adjust the image position of the ADF in the main scanning direction.

  • Page 54: Tape Dispenser (C651)

    2. Installation Procedure Tape Dispenser (C651) Accessory Check Check the quantity and condition of the accessories in the box against the following list: Description Quantity Knob Screw (For C210, C217, C218, C219, C222, C223, C225, C228, C238, C237, C238, C248, C249, C264, C267, C272, C276, C278, and C279) Screw M4 x 25 (For C211, C212, C213, C214, C216, C224, and C226) Hexagon Nut M4 (For C211, C212, C213, C214, C216, C224, and...

  • Page 55: Installation Procedure

    Tape Dispenser (C651) Installation Procedure 1. Turn off the main switch and unplug the power cord. 2. Remove the paper delivery plate. 3. Install the auxiliary bracket [B] on the tape dispenser[A] with M4 x 8 screws (accessories). 4. Cut off the cover [C] in the rear cover, as shown. 5.
  • Page 56 2. Installation Procedure 9. Open the tape dispenser cover [A]. Then, insert the leading edge of the tape into the tape entrance until it stops as shown in the illustration [B]. • Be sure that the tape is installed in the proper direction. If it is not, the tape marker will not work correctly.
  • Page 57 Tape Dispenser (C651) 12. Press the tape cut button [A] to cut off the leading edge of the tape. 13. Check the tape dispenser operation using the Memory/Class modes of the main body.

  • Page 58: Network Controller (C654)

    2. Installation Procedure Network Controller (C654) Accessory Check Check the quantity and condition of the accessories in the box against the following list: Description Quantity ACU Board (with Case) Top Right Bracket Bottom Bracket Top Left Bracket Short Harness...

  • Page 59: Installation Procedure

    Network Controller (C654) Description Quantity Long Harness Ground Cable Cover Ferrite Core Screw: M3x4 Screw: M3x6 Clamp Attachment Kit for HP4R2.5*1 *1This item is not used for this machine. • This circuit operates on a +5V circuit. Installation Procedure Prepare to install the board: Stage 1...
  • Page 60 2. Installation Procedure 1. Attach the three brackets [A], [B], [C] ( ×3). 2. Install the clamps [D] ( × 3). 3. Attach the harness [E] ( × 2, × 1). Prepare to install the board: Stage 2 1. Check whether the “mm/inch” setting in the User Tools (System – mm/inch) is set to the correct value.
  • Page 61 Network Controller (C654) 2. Open the two clamps to release this part of the harness [A], which will be connected to the controller. 3. Remove the bracket [B] ( × 1).
  • Page 62 2. Installation Procedure 4. Attach the board [A] ( × 3).
  • Page 63 Network Controller (C654) 5. Connect the harness [A][B] ( × 2, × 3). • After installing the printer controller unit, make sure that the board and the cable are securely connected.

  • Page 64: Optional Drums (C618/C619/C620)

    2. Installation Procedure Optional Drums (C618/C619/C620) There are three types of optional drum units: A3 Size: Color drum B4 Size: Color drum A4 Size: Black drum (Black ink only) 1. Remove the protective sheet [A] and the lock [B] from the drum unit. 2.

  • Page 65: Preventive Maintenance

    3. Preventive Maintenance Maintenance Tables See “Appendices” for the following information. • Appendix: PM Tables • Appendix: Service Call Conditions • Appendix: Service Program Mode...
  • Page 66 3. Preventive Maintenance...

  • Page 67: Replacement And Adjustment

    4. Replacement and Adjustment Beforehand • Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Before you start to work on the machine, please do the following: If there are printer jobs in the machine, print out all jobs in the printer buffer. Turn off the main switch and disconnect the power cord and the network cable.

  • Page 68: Special Tools

    4. Replacement and Adjustment Special Tools The following are the special tools used for service. Part Number Description Quantity B645 5010 SD Card B645 6705 PCMCIA Card Adapter B645 6830 USB Reader/Writer A006 9104 Scanner positioning pins (4 pins as a set) A0699502 Alvania 2 Grease...

  • Page 69: Image Adjustment

    Image Adjustment Image Adjustment Adjusts the image position on prints by changing the SP settings. Adjust the following in the given order. SP6-10: Master writing speed SP6-100 to 107: Paper registration SP6-05: Scanning speed - platen SP6-06: Scanning speed - ADF mode SP6-03: Scan start position - platen SP6-04: Scan start position - ADF SP6-01: Main scan position - platen...

  • Page 70: Sp6-100 To 107: Paper Registration

    4. Replacement and Adjustment 4. If it is not, calculate the reproduction ratio using the following formula. {(130 - Value) / 130} x 100 = ± X.X % (Round off to one decimal place) Example: If the value is 133, {(130 - 133) / 130} x 100 = - 2.3 % 5.

  • Page 71: Sp6-01, 6-02: Main Scan Position - Platen, Adf

    Image Adjustment 4. Repeat the procedure to make sure that the gap is correct. 5. Make copies of the test pattern in ADF mode and repeat the process using SP6-04. SP6-01, 6-02: Main Scan Position – Platen, ADF 1. Make a copy in platen mode at 90 rpm (speed 3). 2.

  • Page 72: Covers And Boards

    4. Replacement and Adjustment Covers and Boards Front Cover, Operation Panel Right cover ( p.72 "Right Cover") Left cover ( p.73 "Left Cover")
  • Page 73 Covers and Boards Remove the screws on the front door [A] ( x 2). Remove the screws on the operation panel [A] and the connectors on the back side of the operation panel. ( ×2 × 4) • It might be difficult to remove the panel due to projections inside the front cover. Be careful not to damage the cover or other parts when removing the cover from inside the front cover.

  • Page 74: Right Cover

    4. Replacement and Adjustment Right Cover Rear cover. ( p.74 "Rear Cover") Master Making Unit ( p.102 "Master Making Unit") Right cover [A]. ( × 2)

  • Page 75: Left Cover

    Covers and Boards Left Cover Rear cover. ( p.74 "Rear Cover") Left cover [A]. ( × 2)

  • Page 76: Rear Cover

    4. Replacement and Adjustment Rear Cover [A]: Rear cover ( × 8) Front Door Safety Switch Front Cover. ( p.70 "Front Cover, Operation Panel")
  • Page 77 Covers and Boards Front Door Safety Switches. ( × 3, × 2)

  • Page 78: Mpu

    4. Replacement and Adjustment Rear cover. ( p.74 "Rear Cover")
  • Page 79 Covers and Boards MPU [A] ( × 25, × 11, × 9) NVRAM [A]...

  • Page 80: Psu

    4. Replacement and Adjustment • Adjust the master end sensor, duct jam sensor, master edge sensor, and 2nd drum master sensor Master Feed –p.110 "Duct Jam Sensor Adjustment", p.111 "Master Edge Sensor Adjustment", p.112 "2nd Drum Master Sensor Adjustment" and p.113 "Master End Sensor Adjustment") after installing the new MPU.

  • Page 81: Scanner Unit

    Scanner Unit Scanner Unit Exposure Glass 1. Open the ADF or platen cover. 2. Glass cover [A] ( × 4) 3. Disconnect the DF I/F cable [A]...
  • Page 82 4. Replacement and Adjustment 4. ADF exposure glass [A] • Position the white marker [B] at the rear left corner when you reattach the ADF exposure glass. 5. Rear scale [A] ( × 3)

  • Page 83: Original Length Sensors

    Scanner Unit 6. Exposure glass [A] with left scale • Position the marker at the front left corner when you reattach the exposure glass. Original Length Sensors 1. Exposure glass with left scale ( p.79 "Exposure Glass") 2. SBU cover [A] ( × 6) •...

  • Page 84: Exposure Lamp

    4. Replacement and Adjustment Exposure Lamp 1. Rear cover( p.74 "Rear Cover") 2. Operation panel ( p.70 "Front Cover, Operation Panel") 3. Exposure glass ( p.79 "Exposure Glass") 4. Scanner rear cover [A] ( × 1) 5. Disconnect the connector [A] from the lamp stabilizer [B].
  • Page 85 Scanner Unit 6. Move the carriage unit [A] to the cutout position [B]. 7. Cable guide [A] (hooks) • Keep the cable guide for reassembling. 8. Adjustor clamp [B] ( × 1) 9. Pulley [C]...

  • Page 86: Reassembling

    4. Replacement and Adjustment 10. Release the cable clamp [A] (one hook under the cable clamp) at the rear edge of the exposure lamp. 11. Hold down the snap [B], and then slide the exposure lamp [C] to the front side. 12.

  • Page 87: Scanner Motor

    Scanner Unit Run the cable so there is no slack. Slide the adjustor clamp [A] to adjust the cable slack. • [B]: Good • [C]: Not good Scanner Motor 1. Rear cover ( p.74 "Rear Cover") 2. Scanner motor assembly [A] ( × 2, spring × 1, ×...

  • Page 88: Sensor Board Unit (Sbu)

    4. Replacement and Adjustment Sensor Board Unit (SBU) 1. Exposure glass ( p.79 "Exposure Glass") 2. Original length sensor assembly ( × 2, ×2, × 2) 3. Sensor board unit [A] ( × 4, ground screw × 1, × 2) Exposure Lamp Stabilizer 1.

  • Page 89: Platen Cover Sensor

    Scanner Unit 2. Scanner rear cover ( p.82 "Exposure Lamp") 3. Move the 1st scanner carriage [A] to the right side by rotating the scanner motor [B] clockwise. 4. Remove the mylar [A]. 5. Remove the scanner HP sensor [B] ( ×...

  • Page 90: Front Scanner Wire

    4. Replacement and Adjustment 2. Holder bracket [A] ( × 1) 3. Platen cover sensor [B] ( × 1) Front Scanner Wire 1. Rear cover ( p.74 "Rear Cover") 2. Operation panel ( p.70 "Front Cover, Operation Panel") 3. Exposure glass ( p.79 "Exposure Glass") 4.
  • Page 91 Scanner Unit 7. Take aside the connector bracket [A] ( × 2). 8. Scanner rear frame [B] ( × 8, × all, × all) 9. Scanner motor assembly ( p.85 "Scanner Motor") 10. Rear scanner drive pulley [A] ( × 1)

  • Page 92: Reinstalling The Front Scanner Wire

    4. Replacement and Adjustment 11. Front scanner wire clamp [A] 12. Loosen the front scanner wire bracket [B] ( × 1) 13. Front scanner wire. 14. Move the shaft [C] in the red arrow direction ( × 1: at front), and remove the scanner drive pulley [D] ( ×...
  • Page 93 Scanner Unit 1. Position the center ball [A] in the middle of the forked holder. 2. Pass the right end (with the ball) [B] through the square hole. Pass the left end (with the ring) through the notch. 3. Wind the right end counterclockwise (shown from the machine’s front) five times. Wind the left end clockwise three times.
  • Page 94 4. Replacement and Adjustment 6. Hook the right end onto the front scanner wire bracket [A]. The end should go via the rear track of the right pulley [B] and the rear track of the movable pulley [C]. • Do not attach the scanner wire bracket with the screw at this time. 7.

  • Page 95: Rear Scanner Wire

    Scanner Unit 8. Insert a scanner positioning pin [A] through the 2nd carriage hole [B] and the left holes [C] in the front rail. Insert another scanner positioning pin [D] through the 1st carriage hole [E] and the right holes in the front rail [F]. 9.

  • Page 96: Reinstalling The Rear Scanner Wire

    4. Replacement and Adjustment Reinstalling the Rear Scanner Wire 1. Position the center ball [A] in the middle of the forked holder. 2. Pass the left end (with the ball) [B] through the drive pulley notch. Pass the right end (with the ring) through the drive pulley hole.
  • Page 97 Scanner Unit • When removing the rear scanner wire, removing the timing pulley [A] is required before moving the shaft ( × 1).

  • Page 98: Master Eject Unit

    4. Replacement and Adjustment Master Eject Unit Master Eject Unit [A]: Master eject unit ( ×1, × 2, × 1) Master Eject Safety Switch 1. Master Eject Unit( p.96 "Master Eject Unit").

  • Page 99: Eject Box Set Switch

    Master Eject Unit 2. Remove the Master Eject Safety Switch. ( × 1, × 1) Eject Box Set Switch 1. Remove the Master Eject Unit. ( p.96 "Master Eject Unit").
  • Page 100 4. Replacement and Adjustment 2. Remove the cover. ( × 4)
  • Page 101 Master Eject Unit 3. Remove the face plates ( × 5) 4. Remove the Air Knife Fan [A]. ( × 1, × 2)
  • Page 102 4. Replacement and Adjustment 5. Remove the plate [A].( × 1) 6. Remove the Eject Box Set Switch( × 1, × 1).
  • Page 103 Master Eject Unit...

  • Page 104: Master Feed

    4. Replacement and Adjustment Master Feed Master Making Unit [A]: Master making unit ( × 2) Plotter Safety Switch 1. Master Making Unit ( p.102) 2. Remove the Plotter safety switch. ( × 4, × 1)

  • Page 105: Thermal Head

    Master Feed Thermal Head 1. Remove the master making unit ( p.102 "Master Making Unit")
  • Page 106 4. Replacement and Adjustment 2. Open the platen roller unit [1]. 3. Remove the following: [A]: T/H upper cover ( × 2) [B]: T/H side cover ( × 1) 4. Close the platen roller unit [1]. 5. Remove the thermal head [C] ( ×...

  • Page 107: Installation

    Master Feed 8. Remove the thermal head slowly. • If you cannot access SP modes, open the master making unit and loosen the 2 screws [D]. Installation 1. Insert the tabs (1) at the operation side and the middle. 2. Turn the thermal head counterclockwise and insert the tab (2) at the front.

  • Page 108: Duct Plate Hp Sensor, Duct Plate Motor

    4. Replacement and Adjustment 3. Turn the thermal head clockwise and insert the tab (3) at the non-operation side. Make sure to follow the above procedure or the thermal head will not be installed correctly. • Fit the base’s springs [A] over the protrusions [B] on the underside of the thermal head (6 points). •...
  • Page 109 Master Feed 3. Remove the duct plate HP sensor ( × 1) 4. Remove the rear rail bracket [A] ( × 2, × 1)
  • Page 110 4. Replacement and Adjustment 5. Remove the duct plate motor [A] ( × 3, × 2, × 2)

  • Page 111: Cutter Unit

    Master Feed Cutter Unit [A]: Cutter unit ( × 1, × 1) Thermal Head Driving Unit • Thermal head ( p.103 "Thermal Head") • Rear cover ( p.74 "Rear Cover") • Cutter unit ( p.109 "Cutter Unit")

  • Page 112: Duct Jam Sensor Adjustment

    4. Replacement and Adjustment [A]: Anti-static roller [B]: Thermal head driving unit ( × 2, × 2) Duct Jam Sensor Adjustment Ensures that the sensor detects when a master remains in the duct. Standard: 0.5 volts (within “+0.1” and “-0.1”volts) Tools: Circuit tester •...

  • Page 113: Master Edge Sensor Adjustment

    Master Feed Standard Value Standard Value Threshold level (SP6-52) Master present Master not present Above 2.0V 2.0V 0.5 +-0.1V Master Edge Sensor Adjustment Ensures that the sensor detects the leading edge of the master. Standard: 2.0 volts (within “+0.1” and “-0.1”volts) Tools: Circuit tester •...

  • Page 114: 2Nd Drum Master Sensor Adjustment

    4. Replacement and Adjustment Standard Value Standard Value Threshold level (SP6-51) Master present Master not present RTB 10 Modified 3.0V+-0.1V 2.8V Above 3.0V 2nd Drum Master Sensor Adjustment Ensures that the sensor detects if there is a master on the drum. Standard: 2.2 volts (within “+0.1”...

  • Page 115: Master End Sensor Adjustment

    Master Feed • When the voltage cannot be adjusted to the standard value, adjust the threshold level of the 2nd drum master sensor. (SP6-53: 2nd drum master sensor voltage) Standard Value Standard Value Threshold level (SP6-53) Master present Master not present 2.2V+-0.1V 1.0V Below 0.8V...

  • Page 116: Thermal Head Voltage Adjustment

    4. Replacement and Adjustment 5. Measure the voltage with the circuit tester, and turn VR101 until the value becomes between “-0.1” and “+0.1” volts from the standard value (1.8 volts). • Please refer to the following table for the standard voltages. •...
  • Page 117 Master Feed • Left cover ( p.73 "Left Cover") • Read the voltage value on the decal on the thermal head. 1. Slide out the master making unit. • Never turn VR1 clockwise rapidly while the master making unit is connected. The T/H will be damaged if too much voltage is supplied suddenly.

  • Page 118: Paper Feed

    4. Replacement and Adjustment Paper Feed Pick-Up Roller, Paper Feed Roller, Friction Pad • Lower the paper table. [A]: Pick-up roller ( × 1) [B]: Paper guide ( × 1) [C]: Feed roller ( × 1) [D]: Friction pad Paper Feed Safety Cover Pick-Up Roller.
  • Page 119 Paper Feed MPU. ( p.76 "MPU")
  • Page 120 4. Replacement and Adjustment MPU Cover. ( ×7) Remove the Wire [A]. Remove the Pulley [B]( ×1) Loosen the screws [A].
  • Page 121 Paper Feed Remove the Shaft [B] by sliding it to the right. Remove the paper feed safety cover. ( ×2)

  • Page 122: Paper Separation Pressure Adjustment

    4. Replacement and Adjustment Paper Separation Pressure Adjustment Purpose: To ensure that the friction pad exerts sufficient pressure for smooth printing paper separation. Default: The next position to the top. Adjust the separation pressure by loosening and moving the screw [A] up or down. •...

  • Page 123: Paper Width Detection Board

    Paper Feed Paper Width Detection Board • Lower the paper table. [A]: Paper table ( × 1, × 2) [B]: Table cover ( ×5, 3 washers) [C]: Sensor cover ( × 2) [D]: Paper width detection board ( × 1, ×...

  • Page 124: Printing

    4. Replacement and Adjustment Printing Press Roller • Take care to avoid possible injury. If the printing pressure release arms disengage, the press roller will be pulled upwards suddenly • Remove the drum. [A]: Press roller ( × 1) The bearings on the rear and front differ. During installation, ensure that the bearing with the stopper [B] is positioned towards the rear of the machine.

  • Page 125: Printing Pressure Adjustment

    Printing • Front cover ( p.70 "Front Cover, Operation Panel") • Rear cover ( p.74 "Rear Cover") 1. Turn the drum manually until the drum master clamper on the drum moves into the lowest position. (This is when the high points of the cams on the drum flanges meet with the cam followers on both ends of the press roller.) •...
  • Page 126 4. Replacement and Adjustment • Paper delivery unit ( p.137 "Paper Delivery ") 1. Adjust the distance [A] to 17 +-0.2 mm by turning the adjusting bolt [B]. 2. Repeat the same procedure for the printing pressure spring at the non-operation side. •...

  • Page 127: Drum

    Drum Drum Preparation Before attempting any of the procedures in this section, wipe off the ink around the ink roller. To do this, set SP2-10 (ink detection board) to OFF, and feed paper until ink ends. After finishing the required procedures in this section, do not forget to return SP2-10 to the default (Ink detection board ON).

  • Page 128: Installation

    4. Replacement and Adjustment Installation • Do not scratch the cloth screen or metal screen. • Properly insert the edge of the belt cloth [A] on the cloth screen under the mylar [B] on the metal screen, as shown above. Otherwise, ink will leak from the trailing edge of the master on the drum during a long printing run.

  • Page 129: Clamper, Metal Screen

    Drum Clamper, Metal Screen • Remove the drum Cloth screen ( p.125 "Cloth Screen") [A]: Clamper lever (1 hexagon screw) [B]: Clamper - open the clamping plate [C], then remove the clamper. • Do not allow ink to get on the inside of the clamping plate [C]. If it is dirty with ink, the master may slip off and the image position on the prints will move toward the trailing edge of the prints during a printing run.

  • Page 130: Installation

    4. Replacement and Adjustment Installation • Make sure that the correct end of the metal screen is overlapping. (The right side overlaps, as viewed from the non-operation side, as shown above.) • The 4 screws holding the drum master clamper are longer than the 12 screws holding the metal screen, although they are similar in appearance.

  • Page 131: Mylar Seal

    Drum Mylar Seal [A]: -0.5 to 0.5 mm [B]: 5.6 to 7.2 mm [C]: 4.9 to 6.5 mm Attach the mylar seal at the attachment position on the metal screen as shown above. • Clean the attachment position using isopropyl alcohol. Ink Pump Adjustment Purpose: To ensure the smooth operation of the ink pump plunger by properly positioning its holder.
  • Page 132 4. Replacement and Adjustment • Remove the drum [A]: Lower pump cover ( × 2) [B]: Upper pump cover ( × 3) 1. Remove the E-ring [C] to free the plunger from the pump drive slider [D]. 2. Loosen the two screws securing the holder [E]. (Do not remove the holder.) 3.
  • Page 133 Drum 4. Check that the piston motion is smooth. 5. If the motion is stiff, loosen the pump screws [G] and adjust the pump position. 6. After tightening, repeat step 4 and step 3. 7. Re-tighten the two screws [H]. 8.

  • Page 134: Ink Roller Unit, Ink Roller One-Way Clutch

    4. Replacement and Adjustment Ink Roller Unit, Ink Roller One-Way Clutch • Metal screen ( p.127 "Clamper, Metal Screen") • Pump covers ( p.129 "Ink Pump Adjustment") [A]: Board cover ( × 2) [B]: Front stay ( × 2, × 3) [C]: Front flange [D]: Rear stay ( ×...

  • Page 135: Idling Roller Motor, Idling Roller Hp Sensor

    Drum [G]: Rear flange [H]: Ink roller unit [I]: Ink roller one-way clutch Idling Roller Motor, Idling Roller HP Sensor • Cloth Screen ( p.125 "Cloth Screen") • Clamper, Metal Screen ( p.127 "Clamper, Metal Screen") [A]: Idling roller HP sensor ( ×...

  • Page 136: Doctor Roller Gap Adjustment

    4. Replacement and Adjustment Doctor Roller Gap Adjustment Controls ink thickness around the ink roller. Standard: 0.07 mm gauge passes, 0.09 mm gauge does not. Tools: Thickness gauge • Normally, the doctor roller gap is not adjusted or changed. It tends to be difficult to change in the field.

  • Page 137: Ink Detection Adjustment

    Drum Ink Detection Adjustment Purpose: To ensure that the CPU detects a no-ink condition. • Before attempting this procedure, wipe off the ink around the ink roller. To do this, set SP2-10 (ink detection board) to OFF, and feed paper until ink ends. •...

  • Page 138: Main Drive Timing Belt Adjustment

    4. Replacement and Adjustment Main Drive Timing Belt Adjustment Purpose: After the timing belt is replaced, correct belt tension must be applied. • Rear covers ( p.74 "Rear Cover") • MPU ( p.76 "MPU") 1. Loosen the screws [A], [B], and [C]. 2.

  • Page 139: Paper Delivery

    Paper Delivery Paper Delivery Paper Delivery Unit [A]: Paper delivery cover ( ×4) [B]: Paper delivery unit ( × 3, × 2) Fan Motor, Exit Sensor • Paper delivery unit ( p.137 "Paper Delivery ") [A]: Paper guide ( × 2)

  • Page 140: Exit Pawl Adjustment

    4. Replacement and Adjustment [B]: Delivery belts [C]: Vacuum fan motor ( × 1, × 4) [D]: Paper exit sensor ( × 1) Exit Pawl Adjustment Ensures that the exit pawls can move out of the way of the drum master clamper while the drum is rotating.

  • Page 141: Clearance Adjustment

    Paper Delivery 3. Loosen screws [D] and [E]. Then measure the gap between the cam follower and cam face (front drum flange). It should be 0 to 0.5 mm. Then re-tighten the two screws while pushing the cam follower against the cam face. 4.
  • Page 142 4. Replacement and Adjustment • Rear covers ( p.74 "Rear Cover") 1. Check the recess in the drum drive gear meets the positioning hole [A] in the bracket, as shown. 2. Check whether the hole [B] in the pump drive gear is aligned with the hole [C] in the air pump unit bracket.

  • Page 143: Chocks

    Paper Delivery Chocks [A]: Chocks ( × 2)
  • Page 144 4. Replacement and Adjustment [B]: Buffer fin bracket ( × 2 [C]) – Normally, do not disassemble parts [B] to [E] in the field. [D]: Buffer fin [E]: Buffer fin link...

  • Page 145: Network Printer Controller

    Network Printer Controller Network Printer Controller Printer Board 1. Rear cover ( p.74 "Rear Cover") 2. Remove the printer board with case. ( × 3, × 2, × 3).
  • Page 146 4. Replacement and Adjustment 3. Remove the printer board [A] from the case ( × 7, × 1). • Remove the SD card [B] before you remove the printer board, if there is an SD card in the board. • When you replace the printer board, remove the NVRAM [C] from the old printer board and install it on the new printer board.

  • Page 147: Sound-Proofing Cushions

    Sound-proofing Cushions Sound-proofing Cushions The following are the attachment positions of the soundproofing cushions. Paper Feed Left, Paper Feed Right [A]: 10.0 mm to 12.0 mm [B]: 0.0 mm...

  • Page 148: Paper Exit

    4. Replacement and Adjustment Paper Exit [C]: 0.0 mm Master Eject Cover Master eject cover ( × 4)

  • Page 149: Base

    Sound-proofing Cushions [D]: 0.0mm to 2.0mm Base Paper delivery cover ( × 4) ( p.137 "Paper Delivery ") • Insert the soundproofing cushion from the paper delivery side, and push it towards the inside of the machine. • The cushion has a short side and a long side, as shown above. Insert the cushion from the short side, and secure the cushion inside the machine at [E].

  • Page 150: Fuse, Led, Vr, Dip-Sw, And Tp Tables

    4. Replacement and Adjustment Fuse, LED, VR, DIP-SW, AND TP Tables Blown Fuse Conditions Rate Symptom FU700 6.3 A The machine does not turn on E-41 is displayed, and the output mode in SP mode does FU701, 6.3 A not turn anything on except the main motor. E-12 is displayed, and the output mode in SP mode does FU702 6.3 A...

  • Page 151: Controller Board

    Fuse, LED, VR, DIP-SW, AND TP Tables Function Monitors the duct jam sensor. When the sensor detects a master, LED6 this LED is lit. ( p.110 "Duct Jam Sensor Adjustment") LED7 Not used. Monitors the GATC2:FPGA. Usually, this LED is blinking at intervals LED8 of 1 second.

  • Page 152: Ink Detection Board

    4. Replacement and Adjustment Ink detection board Function Adjustment for the ink detection. ( p.129 "Ink Pump Adjustment") Dip Switches Ink detection board Normal drum Color drum A4 black drum Controller Board ROM boot SD card boot Normal machine operation Boot only ROM monitor Not used Not used...

  • Page 153: Test Points

    Fuse, LED, VR, DIP-SW, AND TP Tables Test Points Function TP101 Measures the master end sensor voltage. ( p.113 "Master End Sensor Adjustment") TP102 Measures the duct jam sensor voltage. ( p.110 "Duct Jam Sensor Adjustment") Measures the master edge sensor voltage. ( p.111 "Master Edge Sensor TP103 Adjustment")
  • Page 154 4. Replacement and Adjustment...

  • Page 155: System Maintenance Reference

    5. System Maintenance Reference Service Program Mode • Make sure that the data-in LED ( ) is not on before you go into the SP mode. This LED indicates that some data is coming to the machine. When the LED is on, wait for the copier to process the data.
  • Page 156 5. System Maintenance Reference 5. Output mode, 6. Adjustment, 7. Memory clear, 8. System test 2. Using the number keys or the keys or the zoom keys, enter the desired sub-menu number, then press the Enter key or the OK key. 3.

  • Page 157: Troubleshooting

    6. Troubleshooting Firmware Update To update the firmware for the machine, you must have the new version of the firmware. There are three types of firmware: Main, ADF and controller (FV-Lt). Type of Firmware There are two types of main firmware. One type is for A3 models, and the other is for B4 models. Download the firmware that corresponds to the model you are using.

  • Page 158: Preparing To Download Firmware

    6. Troubleshooting • Make sure that the machine is disconnected from the network to prevent a print job for arriving while the firmware update is in progress before you start the firmware update procedure. Preparing To Download Firmware Create a folder named “romdata” on the SD card (this step is only necessary when the SD card is used for the first time).

  • Page 159: Download Main/Adf Firmware

    Firmware Update Compare the size of the file on the PC and the file on the SD card. If the sizes are different, the data was not transferred completely. • Do not take out the SD card until after you turn off the PC or disconnect the USB Reader/ Writer.

  • Page 160: Download Fv-Lt Firmware

    6. Troubleshooting After downloading the firmware, turn on the main power and enter SP mode to confirm that the download is complete. Download FV-Lt firmware Before downloading new firmware, check the firmware version number with SP9-5 ( Appendices - Main SP Tables). Turn off the main switch.
  • Page 161 Firmware Update Enter the SP mode (SP9-40: Load Program – System). On the left [B], you can see the firmware version that is now in the machine. On the right [C], you can see the firmware version on the SD card. More than one version can be stored on the card.
  • Page 162 6. Troubleshooting After downloading the firmware, turn on the main power and enter SP mode to confirm that the download is complete. • Do not insert or extract the SD card when the machine power is on. • Do not shut off the power when the firmware is downloading.

  • Page 163: Electrical Component Defects

    Electrical Component Defects Electrical Component Defects Jams which occur because of a sensor error are shown below. error Paper feed error “A” jam Drum error “B” jam Paper Exit error “C” jam 2nd drum error “D” jam Eject Box error “E”...
  • Page 164 6. Troubleshooting Component Condition Symptom 2nd Feed Timing Sensor Open E-22 is displayed whenever the drum rotates. Shorted No display even if the drum is extracted and Connect E-06 is displayed when printing or master making. Drum Sensor (connecter) “No drum” is displayed when initialization is OPEN finished.
  • Page 165 Electrical Component Defects Component Condition Symptom 2nd Feed Sensor reflected The “C” jam indicator is lit. light / There is a paper The “B” jam indicator is lit whenever a copy is No paper made. Master Eject Sensor Open The “B” jam indicator is lit. Shorted The “BE”...
  • Page 166 6. Troubleshooting Component Condition Symptom Original Length / Width Sensor The correct original size is undetectable if original does not match the sensor pattern of the original size. Depending on the set paper when a master is made in this state, there may be a size disagreement warning, auto rotation or Reduce/Enlarge Master Set Cover Sensor...
  • Page 167 Electrical Component Defects Component Condition Symptom Cutter HP Sensor E-01 is displayed. The correct paper size is undetectable if paper does not match the paper size sensor pattern. A size different from the set paper or "*" is Paper Size Sensor displayed.
  • Page 168 6. Troubleshooting Component Condition Symptom Duct Jam Sensor There is a The “D” jam indicator is lit. master on the drum. There is a master in the lower master tray, but the duct jam sensor does not detect a master, the No master master vacuum fans do not pull the master, and E-01 is displayed.
  • Page 169 Electrical Component Defects Component Condition Symptom reflected The “P” jam indicator is lit. light ADF Skew Correction OFF: No The “P” jam indicator is lit when paper is fed-in reflected from ADF. light reflected The “P” jam indicator is lit. light ADF Registration OFF: No...

  • Page 170: Switches

    6. Troubleshooting Switches Component Condition Symptom Front Door Safety Switch The “open cover” indicator is lit. The “open Open cover” LED is on. Main unit error (“A”,”B”,”C” jam and No ink) cannot be canceled. Drum information is not updated even if drums are exchanged with the main switch on.

  • Page 171: Power Supplies

    Electrical Component Defects Component Condition Symptom Can operate the Vacuum fan, clamper, Blower fan motor, Eject roller, Pressure plate and drum if there is no Eject box. Interlock Switch An SC is displayed for the clamper, pressure plate, or drum when the main switch is turned Power Supplies Component Condition...

  • Page 172: Controller

    6. Troubleshooting Controller Component Condition Symptom Count Registration Error CPU error Cashless error TLB error ASIC DMA error ASIC error Timer error Registration error SDRAM ROM monitor usage area error RAM error 1 bit shift error All area error SSCG ACK error ASIC error NVARM...

  • Page 173: Energy Saving

    7. Energy Saving Energy Save Energy Save Customers should use energy saver modes properly, to save energy and protect the environment. The area shaded grey in this diagram represents the amount of energy that is saved when the timers are at the default settings.
  • Page 174 7. Energy Saving • If the customer requests that these settings should be changed, please explain that their energy costs could increase, and that they should consider the effects on the environment of extra energy use. • If it is necessary to change the settings, please try to make sure that the Auto Off timer is not too long.

  • Page 175: Paper Save

    Paper Save Paper Save Effectiveness of the Combine Function The combine function reduces the amount of paper used. This means that less energy overall is used for paper production, which improves the environment. Combine mode Reduce paper volume in half! Recommendation Please explain the above features to the customers, so that they can reduce their paper usage.
  • Page 176 MEMO...
  • Page 177 Model PD-D1 Machine Code: C279 Appendices 3 February, 2012...
  • Page 179 TABLE OF CONTENTS 1. Appendix: General Specifications Specifications..............................3 Main frame..............................3 Supported Paper Sizes..........................6 Paper Feed (mainly Europe and Asia)....................6 Paper Feed (mainly North America)....................7 Software Accessories.............................8 Printer Drivers............................8 Utility Software............................8 Optional Equipment............................9 Auto Document Feeder.........................9 Tape Dispenser............................9 Network Printer Controller (Printer Unit Type 4545A)..............10 2.

  • Page 181: Appendix: General Specifications

    1. Appendix: General Specifications Specifications Main frame Configuration: Stand-alone Digital with 400 dpi thermal head Master Process: (Fine mode: 400 × 600 dpi) 600 × 400 dpi Scanning (Pixel Density): (Fine mode: 600 × 600 dpi) Originals: Sheet/Book Printing process: Fully automatic one-drum stencil system Original Size: Maximum 297 ×...
  • Page 182 1. Appendix: General Specifications 3 enlargements and 4 reductions A3 version DLT version 141% 155% Enlargement 122% 129% 115% 121% Reproduction Ratios: Full Size 100% 100% Reduction Zoom: 50 to 200%, in 1% steps America: 120 V, 60 Hz Power Source: Europe, Asia: 220 –...
  • Page 183 Specifications Tables closed: 805 × 705 × 638 mm (31.7" × 27.8" × 25.1") Tables opened: 1370 × 705 × 638 mm (53.9" × 27.8" × 25.1") Dimensions (W x D x H) • Measurement Conditions • 1) Without the ADF •...

  • Page 184: Supported Paper Sizes

    1. Appendix: General Specifications Thermal master roll type: 320 mm width, 110 m/roll (A3 master roll) 280 mm width, 110 m/roll (B4 master roll) Yield: Master Type: 200 masters/roll (A3 Drum) 220 master/roll (B4 Drum) 315 masters/roll (A4 Drum) Maximum run length per master: 4,000 prints Temperature: 0 to 40 °C Humidity: 10 to 95% RH Master Storage Conditions:...

  • Page 185: Paper Feed (Mainly North America)

    Specifications Size Paper sizes (W × L) A4 LEF 297 × 210 mm A4 SEF 210 × 297 mm B5 JIS LEF 257 × 184 mm B5 JIS SEF 184 × 257 mm A5 SEF 148 × 210 mm B6 JIS SEF 128 ×...

  • Page 186: Software Accessories

    1. Appendix: General Specifications Software Accessories The printer drivers and utility software are provided. Printer Drivers The following OS are supported (Only 32 bit) • Windows XP Professional Edition (*) • Windows XP Home Edition • Windows 2003 Server Standard Edition (*) •...

  • Page 187: Optional Equipment

    Specifications Software Description • Display the printer status / settings • Check print job status and history, or deleting the print job Web Image Monitor • Make printer settings • Network protocol settings • Security settings • Peer-to-Peer print function •...

  • Page 188: Network Printer Controller (Printer Unit Type 4545A)

    1. Appendix: General Specifications Power Consumption Power Source From mainframe 155 × 105 × 60mm Dimension(WxDxH) 6.1" × 4.1" × 2.4" 700 g Weight 1.5lb Network Printer Controller (Printer Unit Type 4545A) Printer language RPCS Host interface USB 2.0 Network interface 100Base-TX/10Base-T Protocol TCP/IP...

  • Page 189: Appendix: Pm Tables

    2. Appendix: PM Tables PM Tables The following items should be maintained periodically. There are two sets of intervals - one based on time and the other based on print count. For maintenance items with entries in both of them, use whichever comes first.

  • Page 190: Other Yield Parts

    2. Appendix: PM Tables Time Interval NOTE Print Item Counter time Paper Feed Feed Start Timing Alcohol and dry cloth Sensor Registration Roller Alcohol and dry cloth Separation Pad 1200k Alcohol and dry cloth Paper Table Alcohol and dry cloth Paper Pick-up Roller/ 1200k Dry cloth...

  • Page 191: Adf (D578)

    PM Tables ADF (D578) Item NOTE (Original) Pick-up Roller Clean with water Feed Belt Clean with water Separation Roller Clean with water Other Rollers Clean with water Gears Lubricate, if necessary Platen Sheet Clean with water or alcohol...
  • Page 192 2. Appendix: PM Tables...

  • Page 193: Appendix: Service Call Conditions

    3. Appendix: Service Call Conditions Service Call Conditions Service Call Symptom Possible cause E-00 Clamper error Clamper drive The MPU cannot detect the clamper position sensor signal Clamper sensors (open or closed) within 3.0 seconds after the clamper motor Clamper motor turns on.
  • Page 194 3. Appendix: Service Call Conditions Symptom Possible cause E-10 Thermal Head Energy Pulse error Thermal head connector The CPU detects an abnormal ID signal from the thermal head Thermal head energy control pulse. E-12 Pressure Plate error Pressure plate drive The pressure plate home position sensor signal is not detected Pressure plate motor within 6.0 seconds after the pressure plate motor turn on.
  • Page 195 Service Call Conditions Symptom Possible cause E-24 Feed Start Timing Sensor error Drum sensors The feed start timing sensor does not activate before the 2nd Feeler feed timing sensor activates. E-40 Thermal Head ID error Thermal head The CPU detects an abnormal ID signal from the thermal head. Thermal head connector disconnected E-41...
  • Page 196 3. Appendix: Service Call Conditions Symptom Possible cause E-52 Registration motor Drive IC error Registration motor If the Driver IC detects an over-current or overheating condition, the machine outputs the FAULT signal. If the FAULT signal is detected, this SC appears on the display. If the same SC repeatedly appears on the display, the Driver IC may be damaged.

  • Page 197: Program Download Error Codes

    Service Call Conditions (*)When this error occurs, the Energy Saving mode LED blinks at intervals of 0.1 seconds. An error code is not displayed. Program Download Error Codes Display Symptom Possible cause SD Card Access error. 1. Re-insert the SD card 2.
  • Page 198 3. Appendix: Service Call Conditions...

  • Page 199: Appendix: Service Program Mode Tables

    4. Appendix: Service Program Mode Tables SP Table Service Program Mode Reading SP mode tables SP table reads as follows. SP name SP No Detailed explanation of SP No. Menu item Category* [Max to Min / Default / variation] Branch number Detailed explanation of branch number.
  • Page 200 4. Appendix: Service Program Mode Tables 1-24 C/O 6 to 10 1-25 C/O 11 to 20 1-26 C/O 21 to 50 1-27 C/O 51 to 70 1-28 C/O 71 to 100 1-29 C/O 101 to 200 1-30 C/O 201 to 500 1-31 C/O 501 to 1000 1-32 C/O 1001 to 2000 1-33 C/O 2001 to 3000...
  • Page 201 SP Table C - paper delivery jam 1-56 Display frequency and incidence. P - original feed-in jam 1-57 Display frequency and incidence.(Using ADF) P - original feed-out jam 1-58 Display frequency and incidence.(Using ADF) D - master feed jam 1-59 Display frequency and incidence.
  • Page 202 4. Appendix: Service Program Mode Tables SBU hard error location display This function shows where a SBU error has occurred. • bit 7: 0 (not used) • bit 6: 0 (not used) • bit 5: GASBU-N Id error 1-83 • bit 4: VSP5100 reset error •...
  • Page 203 SP Table 1-160 Not used 1-161 Key counter setting check 1-162 Key card setting check Basic setting Set the initial value of printing speed, ink detection, and international machine settings. Default print speed [1 to 5 / 3 / 1] Set the initial value of printing speed when you turn on and mode clear.
  • Page 204 Brands depend on the destination. *1 Displays only brand that can be set. RICOH / TTEC / KMBJ / NRG / Nashuatec /RexRotary / Gestetner / Lanier / Savin / Standard *2 If the model code has not been set, if there are multiple brands of a single model code, "RICOH"...
  • Page 205 SP Table 2-21 Ink setting [0 to 1 / 0 / 1] Double count-up (A3) [0 to 2 / 0 / 1] When using A3 Drum, electromagnetic counter (master, paper) count up every 2 / print. 2-22 • 0: As usual, one count increase. •...
  • Page 206 4. Appendix: Service Program Mode Tables Idling after how many prints [1 to 5 / 3 / 1 Print] • If SP 2-28 is set to 'YES', the idling motor turns if 3 or more prints were made. 2-29 • If SP 2-28 is set to 'NO', the idling motor turns if the number of prints made is the same as or more than the setting of SP 2-29.
  • Page 207 SP Table 2-36 Print pressure in fixing mode [1 to 5 / 4 / 1] When the print pressure point for SP2-35 is set to fixed, this field is used to specify the value at which it is fixed. 2-37 Printing pressure adjust [-2 to 2 / 0 / 1] Changes the printing pressure of all printing speeds (60 to 130 rpm).
  • Page 208 4. Appendix: Service Program Mode Tables T/H energy control [0 to 50% / 7 / 1%] 2-43 The default is 7%. This means that during normal printing mode, the thermal head energy is 93% of the maximum possible (100 – 7). T/H energy control - eco [0 to 50% / 15 / 1%] The default is 10%.
  • Page 209 SP Table T/H Energy Control: (Fine) [ 0 to 50% / 7 / 1%-] 2-54 Initial value is 7%.In this case, that means thermal head energy can be up to 93% in printing mode(density) (100-7=93%). T/H Energy Control -Eco (Fine) [0 to 50 / 15 / 1%] Initial value is 15%.In this case, in economy printing mode (density) means that an 2-55...
  • Page 210 4. Appendix: Service Program Mode Tables Paper table standby pos [fall slightly/ normal / normal / -] High: The paper table after printing is moved to a higher position than the standard position. This will reduce the time for starting the first print when continuously making masters.
  • Page 211 SP Table 2-115 Reg Improvement for 1st Prt [ ON-OFF / OFF / -] 2-120 Master Compression Time - A3 [ 0-3 / 0 / -] 2-121 Master Compression Time - B4 [ 0-3 / 0 / -] 2-122 Master Compression Time - A$ [ 0-3 / 0 / -] 5th Speed Paper Limit [ ON-OFF / OFF / -]...
  • Page 212 4. Appendix: Service Program Mode Tables Input the present time [yy.mm.dd hh.mm.ss / - / -] Input the year, the month / date, and the time in the following order. Press the Enter (#) key between each one. 1. Input the last two digits of the present year (two-digit number). 2.
  • Page 213 SP Table Input installation date [yy.mm.dd / 00.1.1 / -] Input the installation date as shown below. Press the Enter (#) key between each one. 1. Input the last two digits of the present year (two-digit number). 2. Input the present month (two-digit number). 3.
  • Page 214 4. Appendix: Service Program Mode Tables 4-11 Duct plate HP sensor 4-12 Lower master tray switch 4-13 Duct jam sensor 4-14 Eject box set switch 4-15 Master eject sensor 4-16 Pressure plate HP sensor 4-17 Pressure plate limit SN 4-18 Ink detection signal 4-19 Color drum signal 4-20 A4 drum signal 4-21 Drum set signal...
  • Page 215 SP Table 4-36 Paper width signal 1 4-37 Paper width signal 2 4-38 Paper width signal 3 4-39 Paper width signal 4 4-40 Paper width signal 5 4-41 Registration sensor 4-42 Feed start timing sensor 4-43 2nd feed timing sensor 4-44 Paper exit sensor 4-50 Door safety sensor 4-51 Main motor error signal...
  • Page 216 4. Appendix: Service Program Mode Tables 4-129 ADF Skew Correction 4-130 ADF Registration 4-131 ADF Org Exit 4-132 ADF Org Feed Cover 4-133 ADF Lift Up Output mode Checks the output of motors. Check the output of the selected operation is performed while pressing the Start key. 5-1 Exposure lamp (xenon lamp) 5-2 Scanner motor - scan 5-3 Scanner motor - return...
  • Page 217 SP Table 5-18 T/H driving motor - up 5-19 T/H driving motor - down 5-20 Master eject motor 5-21 Pressure plate motor:limit 5-22 Pressure plate motor:to HP 5-23 Main motor: 15 rpm 5-24 Main motor: 30 rpm 5-25 Main motor: 45 rpm 5-26 Main motor: 60 rpm 5-27 Main motor: 75 rpm 5-28 Main motor: 90 rpm...
  • Page 218 4. Appendix: Service Program Mode Tables 5-42 Paper feed motor: 15 rpm 5-43 Paper feed motor: 30 rpm 5-44 Paper feed motor: 45 rpm 5-45 Paper feed motor: 60 rpm 5-46 Paper feed motor: 75 rpm 5-47 Paper feed motor: 90 rpm 5-48 Paper feed motor: 105 rpm 5-49 Paper feed motor: 130 rpm 5-50 Registration motor: 15 rpm...
  • Page 219 SP Table 5-66 Key card signal 5-80 Printing pressure motor HP 5-81 Move to pressure 1 5-82 Move to pressure 2 (HP) 5-83 Move to pressure 3 5-84 Move to pressure 4 5-85 Move to pressure 5 5-100 All indicators on the panel 5-101 Drum Home Position LED 5-111 Auto OFF solenoid 5-120 ADF Feed Motor Forward...
  • Page 220 4. Appendix: Service Program Mode Tables Main-scan position - ADF [-5.0 to 5.0 mm / 0.0 / 0.1mm] Adjust the image position of the ADF to the main scanning direction. Main Scan Position - Platen, ADF 1. Make a copy in platen mode at 90 rpm (speed 3). 2.
  • Page 221 SP Table Adjust the scanning speed of the ADF. Scanning speed (platen/ADF) 1. Make copies of the test pattern printed during the previous adjustments ( previous page), in platen mode at 90 rpm (speed 3). Use the 10th print for the adjustment. 2.
  • Page 222 4. Appendix: Service Program Mode Tables Registration buckle 60 to 105rpm [0 to 100 / 18 / PLS] Adjust the flexible volume of the paper feed. The larger the number, the greater the amount 6-12 of deflection flexible volume. • ON: Detection of the ADF. •...
  • Page 223 SP Table Standard white confirmation Check the adjustment of the standard white execution. 6-21 Press the Enter key to start the check. Results after adjustment (success / failure) are displayed. Standard white adjusted value [-128 to 127PLS / 0 / -] 6-22 Display/Change the standard white adjusted value.
  • Page 224 4. Appendix: Service Program Mode Tables Sharpens the image, but moiré can become more apparent. Refer to the following table for the relationship between this SP mode value and filter strength (the relationship is not linear). • 0:*0 • 1:*1/32 •...
  • Page 225 SP Table 6-50 Master end sensor voltage [0.5 to 3.5 / 1.90 / V] 6-51 Master edge sensor voltage [1.5 to 3.5 / 2.80 / V] 6-52 Duct jam sensor voltage [0.5 to 3.5 / 2.00 / V] 6-53 2nd drum master sensor voltage [0.5 to 3.5 / 1.00 / V] Master returning value [0 to 200 / 100 / 0.1mm]...
  • Page 226 4. Appendix: Service Program Mode Tables 6-77 60rpm pressure:normal temp [1 to 5 / 1 / -] 6-78 75rpm pressure:normal temp [1 to 5 / 2 / -] 6-79 90rpm pressure:normal temp [1 to 5 / 3 / -] 6-80 105rpm pressure:normal temp [1 to 5 / 4 / -] 6-81 130rpm pressure:normal temp [1 to 5 / 5 / -]...
  • Page 227 SP Table 6-100 Paper registration 15rpm 6-101 Paper registration 30rpm 6-102 Paper registration 45rpm 6-103 Paper registration 60rpm [-40 to 40 / 0 / pulse] 6-104 Paper registration 75rpm 6-105 Paper registration 90rpm 6-106 Paper registration 105rpm 6-107 Paper registration 130rpm Paper registration 1.
  • Page 228 4. Appendix: Service Program Mode Tables 6-108 Paper Regist:skip:15rpm 6-109 Paper Regist:skip:30rpm 6-110 Paper Regist:skip:45rpm 6-111 Paper Regist:skip:60rpm [-40 to 40 / 0 / mm] 6-112 Paper Regist:skip:75rpm 6-113 Paper Regist:skip:90rpm 6-114 Paper Regist:skip:105rpm 6-115 Paper Regist:skip:130rpm 6-116 Paper middle bulge: 15rpm 6-117 Paper middle bulge: 30rpm 6-118 Paper middle bulge: 45rpm 6-119 Paper middle bulge: 60rpm...
  • Page 229 SP Table Paper middle bulge...
  • Page 230 4. Appendix: Service Program Mode Tables Adjusts doubled [A] or blurred [B] images (e.g. bold lines, text) for each printing speed (15, 30, 60,75, 90, 105, 130 rpm), by changing SP settings. 1. Set SP2-34 (Printing pressure adjust) to a value of "30 rpm" (print from 30rpm). 2.
  • Page 231 SP Table 6-124 Paper front bulge: 15rpm 6-125 Paper front bulge: 30rpm 6-126 Paper front bulge: 45rpm 6-127 Paper front bulge: 60rpm [-90 to 8 / 0 / mm] 6-128 Paper front bulge: 75rpm 6-129 Paper front bulge: 90rpm 6-130 Paper front bulge: 105rpm 6-131 Paper front bulge: 130rpm Paper front bulge...
  • Page 232 4. Appendix: Service Program Mode Tables 1. Set SP2-34 (Printing pressure adjust) to a value of "30 rpm" (print from 30rpm). 2. Set SP8-10 (Test patterns) to a value of "6", then press the Start key. 3. Access SP4-91 (Ink temperature), then check the ink temperature. 4.
  • Page 233 SP Table 6-132 Paper Regist:A4drum:15 6-133 Paper Regist:A4drum:30 6-134 Paper Regist:A4drum:45 6-135 Paper Regist:A4drum:60 [-40 to 40 / 0 / pulse] 6-136 Paper Regist:A4drum:75 6-137 Paper Regist:A4drum:90 6-138 Paper Regist:A4drum:105 6-139 Paper Regist:A4drum:130 6-140 Paper Regist:skip:A4:15 6-141 Paper Regist:skip:A4:30 6-142 Paper Regist:skip:A4:45 6-143 Paper Regist:skip:A4:60 [-40 to 40 / 0 / pulse] 6-144 Paper Regist:skip:A4:75...
  • Page 234 4. Appendix: Service Program Mode Tables 6-156 Paper front bulge:A4:15 6-157 Paper front bulge:A4:30 6-158 Paper front bulge:A4:45 6-159 Paper front bulge:A4:60 [-90 to 8 / 0 / mm] 6-160 Paper front bulge:A4:75 6-161 Paper front bulge:A4:90 RTB 1a, 2a SP 6-170 to 6-162 Paper front bulge:A4:105 6-180 added...
  • Page 235 SP Table System test Program download test, Reproduction test pattern. Download main firmware Download the program from the SD card into the machine. Start by pressing the "# "key. 8-2 Download DF firmware Download the program from the SD card into the machine. 8-3 Report(LOG DATA/SC/JAM) 8-4 Report(BASIC SETTING 8-5 Report(ADJUSTMENT VALUES)
  • Page 236 4. Appendix: Service Program Mode Tables Temporary security off [ ON-OFF / OFF / -] This function cancels "Security Mode" when the engineer repairs/inspects the machine. The technician must cancel security mode in order to take out the drum. It is not necessary to cancel security mode in order to make prints; put an original on the exposure glass and make a new master.
  • Page 237 SP Table Free run-Paper feed(15rpm) [ ON-OFF / OFF / -] Drives the paper feed mechanism at the lowest speed (15 rpm) without paper. 1. Access SP8-22 and press the OK key. 8-22 2. Exit the SP mode and enter the number of times that you want to repeat the paper feed cycle.
  • Page 238 4. Appendix: Service Program Mode Tables In normal operation, an image that is sent from the computer is printed out. But with this SP mode, the image is changed to hex data and then output on paper or to an SD card. There are three settings: •...
  • Page 239 SP Table Firmware part number Display the firmware numbers on the operation panel. Firmware version Display the firmware versions on the operation panel. Clear Printer setting 9-30 Initialization the printer system settings. Clear NIB NVRAM setting 9-31 Initialization the NIB NVRAM setting. Load Program - system 9-40 Select and run programs that can be downloaded from the SD card.
  • Page 240 MEMO...

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