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Ricoh A-P4 Service Manual

G147
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Model A-P4
Machine Code: G147

SERVICE MANUAL

May. 12th, 2006
Subject to change

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Summary of Contents for Ricoh A-P4

  • Page 1: Service Manual

    Model A-P4 Machine Code: G147 SERVICE MANUAL May. 12th, 2006 Subject to change...

  • Page 2: Conventions Used In This Manual

    Conventions Used in This Manual This manual uses several symbols. Symbol What It Means Screw Connector E-ring Clip ring Clamp Pawls (sensors) Spring Throughout this service manual, "SEF" denotes "Short Edge Feed" and "LEF" denotes "Long Edge Feed". Warnings, Cautions, Notes In this manual, the following important symbols and notations are used.
  • Page 3 • A Caution indicates a potentially hazardous situation. Failure to obey a Caution could result in minor or moderate injury or damage to the machine or other property. • Obey these guidelines to avoid problems such as misfeeds, damage to originals, loss of valuable data and to prevent damage to the machine •...

  • Page 4: Safety Instructions

    Safety Instructions For your safety, please read this manual carefully before you service machine. Always keep this manual handy for future reference. - Safety Information - Always obey the these safety precautions when using this product. - Switches and Symbols - Where symbols are used on or near switches on machines for Europe and other areas, the meaning of each symbol conforms with IEC60417.

  • Page 5: Before Installation Or Maintenance

    Before Installation or Maintenance - Shipping and Moving the Machine - • Work carefully when lifting or moving the machine. If the machine is heavy, two or more customer engineers may be required to prevent injuries (muscle strains, spinal injuries, etc.) or damage to the machine if it is dropped or tipped over.

  • Page 6: During Maintenance

    • For special adjustments, use only the special tools and lubricants described in the service manual. Using tools incorrectly, or using tools that could damage parts, could damage the machine or cause injuries. During Maintenance - General - • Before you begin a maintenance procedure always switch the machine off. •...

  • Page 7: After Installation

    • Always replace a lithium battery on a PCB with the same type of battery prescribed for use on that board. Replacing a lithium battery with any type other than the one prescribed for use on the board could lead to an explosion or damage to the PCB. •...
  • Page 8 • Ink is flammable. Never attempt to incinerate empty ink cartridges. • Always dispose of used items in accordance with the local laws and regulations regarding the disposal of such items. • To protect the environment, never dispose of this product or any kind of waste from consumables at a household waste collection point.

  • Page 9: Safety Instructions For Toner And Ink

    Safety Instructions for Toner and Ink This section describes information for users in regard to the use of toner and ink. Accidental Physical Exposure - PPC Toner Exposure - • Work carefully when removing paper jams or replacing toner bottles or cartridges to avoid spilling toner on clothing or the hands.

  • Page 10: Toner And Ink Disposal

    • Always store toner and developer supplies such as toner and developer packages, cartridges, and bottles (including used toner and empty bottles and cartridges) out of the reach of children. • Always store fresh toner supplies or empty bottles or cartridges in a cool, dry location that is not exposed to direct sunlight.

  • Page 11: Safety Precautions For This Machine

    Safety Precautions for This Machine 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.

  • Page 12: Table Of Contents

    TABLE OF CONTENTS Conventions Used in This Manual........................1 Safety Instructions...............................3 Responsibilities of the Service Technician....................3 Before Installation or Maintenance......................4 During Maintenance............................5 After Installation..............................6 Safety Instructions for Toner and Ink.........................8 Accidental Physical Exposure........................8 Handling and Storing Toner and Ink......................8 Toner and Ink Disposal..........................9 Safety Precautions for This Machine.......................10 Laser Safety..............................10 Caution Labels..............................10...
  • Page 13 Punch Unit (B377)............................39 Accessory Check: Punch Unit........................39 Installation Procedure: Punch Unit......................39 Data Overwrite Security Unit (B735)......................43 Before You Begin…............................43 Seal Check and Removal..........................43 Installation Procedure: DOS Unit........................44 Controller Options............................47 Boards and Slots............................47 Installing SD Cards............................48 Merging Applications on One SD Card....................49 Location of SD Card Slots........................49 Merging Applications.........................50 Undo Merging.............................51...
  • Page 14 Duplex Unit..............................67 Right Upper Cover............................68 By-Pass Tray Unit............................69 Rear Covers..............................70 Rear Upper Cover..........................70 Rear Lower Cover..........................70 Left Covers..............................71 Operation Panel...............................72 Paper Output Tray............................73 Laser Unit................................75 Caution Decal Locations..........................75 Laser Unit Removal............................76 Polygon Mirror Motor..........................77 Laser Synchronization Detector........................78 LD Unit................................79 LD Unit Replacement...........................79 Laser Beam Pitch Adjustment......................79 PCDU.................................82 Photoconductor Cleaning/Development Unit...................82...
  • Page 15 Transfer Belt Cleaning Blade and Toner Overflow Sensor..............97 Transfer Belt Cleaning Blade......................97 Toner Overflow Sensor........................97 Paper Feed................................98 Pick-Up, Separation, and Feed Rollers......................98 Lower Right Cover............................98 Relay/Upper Paper Feed and Lower Paper Feed Clutches..............99 Upper Paper Feed Unit for Tray 1......................100 Lower Paper Feed Unit For Tray 2......................101 Paper End/Paper Height/Relay Sensors....................103 Registration Sensor............................103...
  • Page 16 Duplex Exit Sensor............................129 Drive Mechanisms............................130 Registration Clutch, Transfer Belt Contact Clutch..................130 Main Motor...............................131 Fusing/Exit Motor.............................132 Toner Supply Motor..........................134 Boards................................136 NVRAM..............................136 Uploading NVRAM Data (SP5-824).....................136 Replacing NVRAM...........................137 Downloading NVRAM Data (SP5825)..................138 HVPS................................140 IOB................................141 BICU Board..............................142 PSU................................142 HDD and Controller Board........................143 Parallelogram Image Adjustment.........................145 4.
  • Page 17 Printer Controller Bit Switch Settings....................183 Printer Engine Service Mode........................184 Leaving the SP Mode..........................185 Service Program Mode Tables........................186 Service Table Key............................186 Service Tables............................186 SP1-xxx: Feed...........................186 SP2-xxx: Drum..........................191 SP3-xxx: Process..........................203 SP5-xxx: Mode..........................206 SP6-xxx: Peripherals.........................238 SP7-xxx: Data Log..........................238 SP8XXX: Data Log 2.........................244 Test Pattern Printing............................260 Selecting the Test Pattern..........................260 Printing the Test Pattern..........................261 SP2902-03 Printing Test Patterns......................262...
  • Page 18 DIP Switches..............................290 Controller: DIP SW2..........................290 I/O Board: DIP SW101...........................290 Using Debug Log............................291 Setting Up "Save Debug Log"........................291 To Switch Debug Log On.........................291 To Select the Target for the Debug Log File..................292 To Select Events..........................293 To select one or more memory modules for recording in the debug log file.......295 Retrieving the Debug Log from the HDD....................297 More About Debug Log..........................298 SP5857-015: SD to SD (Any)......................298...
  • Page 19 Drum Toner Seals............................316 New PCDU Unit Detection ........................316 New Unit Detection Mechanism.....................316 What Happens When a New Unit Is Detected................318 Drum Charge..............................319 Overview of Drum Charge........................319 Charge Roller Voltage Correction......................320 Correction for Environmental Conditions..................320 Correction for Paper Width and Thickness (By-pass Tray only)...........321 ID Sensor Pattern Production Timing......................321 Drum Charge Roller Cleaning........................323 Development..............................324...
  • Page 20 Toner Recycling............................334 Paper Feed..............................335 Overview of Paper Feed...........................335 Paper Feed Drive............................336 Pick-Up and Separation Roller Release Mechanism................336 Paper Lift..............................337 Paper End Detection..........................338 Paper Registration.............................339 Paper Size Detection..........................339 Paper Height Detection..........................340 By-Pass Tray..............................342 Overview of By-Pass Tray.........................342 By-Pass Tray Operation..........................343 By-Pass Paper Size Detection........................344 Duplex Unit..............................345 Overview of Duplex Unit..........................345 Duplex Drive Layout..........................346...
  • Page 21 Image Fusing and Paper Exit........................358 Overview Image Fusing and Paper Exit....................358 Fusing Drive...............................359 Fusing Drive Release Mechanism......................359 Fusing Entrance Guide Shift Mechanism....................360 Exit Guide Plate and De-Curler Rollers....................361 Pressure Roller............................361 Cleaning Mechanism..........................362 Fusing Temperature ..........................362 Fusing Temperature Components....................362 Fusing Temperature Control......................363 Fusing Idling Temperature........................364 Overheat Protection..........................364 Energy Save Mode............................365...

  • Page 22: Installation

    1. Installation Cautions • To avoid damaging the hard disk or memory, never turn off the power switch when the power LED is lit or flashing. • The power LED lights or flashes while the machine is communicating with the network server, or while the machine is accessing the hard disk or memory to read and write data.

  • Page 23: Installation Requirements

    1. Installation Installation Requirements Environment 1. Temperature Range: 10 °C to 32 °C (50 °F to 90 °F) 2. Humidity Range: 15% to 80% RH 3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight.) 4. Ventilation: Room air should turn over at least 30 m /hr/person 5.

  • Page 24: Power Requirements

    Installation Requirements A: Front: >75 cm (29.6") B: Left: > 10 cm (4") C: Rear: > 10 cm (4") D: Right > 10 cm (4") • The 75 cm (29.5") recommended for the space at the front is for pulling out the paper tray only. If the operator stands at the front of the main machine, more space is required.
  • Page 25 1. Installation • Avoid multi-wiring. • Be sure to ground the machine. 1. Input voltage level: • North America 120 V, 60 Hz: More than 12.5 A • Europe/Asia 220 V ~ 240V, 50 Hz/60 Hz: more than 8 A 2.

  • Page 26: Main Machine Installation

    Main Machine Installation Main Machine Installation Installation Overview The installation procedures of the following items are in the Operating Instructions: • Printer G147 (main machine) Installation • Paper Tray G839 (Option) • The Paper Tray G839 must be installed before the Finisher 3000 G838 can be installed. The installation procedures of the following options are in this service manual: Hardware Options •...

  • Page 27: Installation Flowchart

    1. Installation Installation Flowchart...

  • Page 28: Lct (B543)

    LCT (B543) LCT (B543) Accessory Check: LCT Check the quantity and condition of the accessories in the box against the following list: Description Q’ty Joint Pin Stepped Screw M3 x 18 Installation Procedure Installation Procedure: LCT • Unplug the main machine power cord before starting the following procedure. •...
  • Page 29 1. Installation Open the cover [3] and remove the tape and shipping material [4] from inside. Open the right cover of the paper tray unit [5]. Open the lower right cover [6]. Cut the band [7] and remove the lower right cover. •...
  • Page 30 LCT (B543) Install the joint pins [8]. Push the release lever [9] and slide the LCT to the right (front view). Hang the LCT [10] on the joint pins, then secure the brackets [11] ( x 4). Return the LCT to the previous position and connect the LCT cable [12]. Open the LCT cover and load the paper.

  • Page 31: Bridge Unit (B538)

    1. Installation Bridge Unit (B538) Accessory Check: Bridge Unit Check the quantity and condition of the accessories in the box against the following list: Description Q’ty Stepped Screw Connector Cover Exit Mylar Installation Procedure Installation Procedure: Bridge Unit • Unplug the main machine power cord before starting the following procedure. Unpack the bridge unit and remove all tapes and shipping retainers.
  • Page 32 Bridge Unit (B538) Remove the tray full sensor cover [1] ( x2, x1). Insert the loose connector [2] into the hole.
  • Page 33 1. Installation Remove the inner tray [3]. On the side of the machine, remove the three small covers [4]. Remove the two larger covers [5]. Remove the cover [6] ( x 1). Remove the cap [7]. If an optional finisher is to be installed, attach two mylars [8] to the bridge unit.
  • Page 34 Bridge Unit (B538) Remove the cover [9]. Install the bridge unit [10] ( x 2). Connect the bridge unit I/F harnesses [11] ( x 2). Install the connector cover [12]. Open the cover to expose the sensor connector [13]. Attach the paper sensor [14] (provided) ( x1, x1).
  • Page 35 1. Installation Turn on the main switch and check the bridge unit operation (make sure that there are no paper jams).

  • Page 36: Two-Tray Finisher (G838)

    Two-Tray Finisher (G838) Two-Tray Finisher (G838) Accessory Check: Two Tray Finisher Check the quantity and condition of the accessories in the box against the following list: Description Q’ty Front Joint Bracket Rear Joint Bracket Shift Tray Screw – M4 x 8 Screw –...
  • Page 37 1. Installation Unpack the finisher and remove all tapes and shipping retainers from outside the unit [1]. Open the front door [2] and remove all tapes and shipping materials from inside the finisher unit. Save the retainer [3] and other shipping material. •...
  • Page 38 Two-Tray Finisher (G838) Install the left joint bracket [4] ( x 2, M4 x 12) and right joint bracket [5] ( x 2, M4 x 12). Attach the ground plate [6] ( x 1, M4 x 12) to the center of the paper tray unit as shown. Open the front door of the finisher, and pull out the locking lever [7] ( x 1).
  • Page 39 1. Installation Install two trays [8] ( x 1 each). Connect the finisher cable [9] to the main machine below the right, rear handle. Turn on the main switch and check the finisher operation.

  • Page 40: Punch Unit (B377)

    Punch Unit (B377) Punch Unit (B377) Accessory Check: Punch Unit Check the quantity and condition of the accessories in the box against the following list: Description Q’ty Punch unit Sensor arm Hopper Step screw Spring Spacer (2 mm) Spacer (1 mm) Tapping screw Tapping screw Installation Procedure: Punch Unit...
  • Page 41 1. Installation Open the front door and remove the rear cover [1] ( x4). Remove the bracket [2] ( x2) and paper guide [3] ( x 1).
  • Page 42 Punch Unit (B377) Remove the hopper cover [4] ( x 2). Install the sensor bracket [5] (Stepped x 1). Install the spring [6]. Install the 2 mm spacer [7]. Install the punch unit [8] ( x 2, Stepped x 1)
  • Page 43 1. Installation Connect the harnesses [9] and clamp them as shown. • No special DIP switch settings are required for this punch unit. • The punch unit has a unique ID that the machine detects automatically so it knows what type of punch unit is installed.

  • Page 44: Data Overwrite Security Unit (B735)

    Data Overwrite Security Unit (B735) Data Overwrite Security Unit (B735) Before You Begin… 1. Confirm that the Data Overwrite Security unit SD card is the correct type for the machine. The correct type for this machine is type "C". • If the NVRAM is replaced then the data overwrite security feature must be replaced with the new data overwrite security option.

  • Page 45: Installation Procedure: Dos Unit

    1. Installation If the surfaces of the tapes do not show “VOID”, remove them from the corners of the box. • If you see “VOID” on the tapes, do not install the components in the box. Stop the procedure and contact your Sales Division. When you remove each seal, the “VOID”...
  • Page 46 Data Overwrite Security Unit (B735) If the machine is on, turn off the power switch. Disconnect the network cable. Turn the power switch on. Turn the power switch off. Remove the SD card slot cover [1] ( x1). With the printed side of the SD card [2] facing the rear of the machine, install the SD card in SD card slot C1.
  • Page 47 1. Installation • Under "[ Loading Program ]" you should see "GW1a_zoffy: B7355050/0.04". This completes the installation. • The Data Overwrite Security SD card must remain in SD card slot C1. • If the SD card is removed from C1 while the machine is operating, this will cause SC867 (SD Card Removed).

  • Page 48: Controller Options

    Controller Options Controller Options Boards and Slots The machine controller box has two board slots and three SD card slots. Make sure that each board and SD card is put in the correct slot. - Boards - Slot 1, Slot 2. The optional boards are inserted here. - SD Card Slots - Data Overwrite Security B735.

  • Page 49: Installing Sd Cards

    1. Installation Slot Board 1 or 2 IEEE802.11b G813 – Wireless LAN 1 or 2 IEEE1284 Interface Board B679 – Centronics 1 or 2 USB Host Interface Unit Type G819 1 or 2 Gigabit Ethernet Board B874 *Only one of these boards can be installed at one time. Installing SD Cards •...

  • Page 50: Merging Applications On One Sd Card

    Controller Options To remove an SD card, push the SD card in carefully to release it, and then remove it from the slot. • To prevent damage to the SD card or the slot lock, always push the card in to release it and then remove it.

  • Page 51: Merging Applications

    1. Installation • The SD card is the only evidence that the customer is licensed to use the application program. The service technician may occasionally need to check the SD card and its data to solve problems. SD cards must be stored in a safe location at the work site.A licensing agreement prohibits copying of the PostScript SD card.

  • Page 52: Undo Merging

    Controller Options Go into the SP mode and select SP5873 001. Push [#Enter]. Read the instruction on the display then push [#Enter] to start copying. When the display tells you copying is completed, push [#Enter]. Turn the machine off. Remove the Source SD card from C3. Leave the target SD card in C1. Turn the machine on.

  • Page 53: Installing Controller Options

    1. Installation Installing Controller Options 256 MB Memory (G818) or 128 MB Memory (B584) - Accessories - Check the accessories and their quantities against the following list: Description Q'ty Paper Sensor Paper Limit Sensor Unit Tapping Screws M3 x8 Pan Head Screw M3 x 8 Ferrite Core Stamp CD-ROM (Printer)
  • Page 54 Controller Options Remove the rear upper cover [A] ( x2) Remove the controller cover [B] ( x2) Remove the controller board faceplate [C] ( x 2). Remove the controller board [D] ( x 4) Remove the HDD unit bracket [E] ( x 4, x 2)

  • Page 55: Ieee 1284 (B679)

    1. Installation Install the memory DIMM [F]. Reinstall the controller board. IEEE 1284 (B679) - Accessories - Check the accessories and their quantities against the following list: Description Q'ty 1. IEEE 1284 Interface Board B679 - Procedure - • Turn off the power switch and disconnect the power supply cord.

  • Page 56: Ieee 802.11B Interface Kit (G813)

    Controller Options • You can only install one of these network interfaces: IEEE 802.11b (Wireless LAN), IEEE1284 (Cen- tronics), or Gigabit Ethernet Board. Remove the cover [1] of board Slot 1 or 2 ( x1) Install the interface board [2] ( x2 knob screws) •...
  • Page 57 1. Installation - Procedure - • Turn off the power switch and disconnect the power supply cord. • You can only install one of these network interfaces: IEEE 802.11b (Wireless LAN), IEEE1284 (Cen- tronics), or Gigabit Ethernet Board. Remove the cover [1] of board Slot 1 or 2 ( x1) Attach the interface board [2] to the controller board ( x1 knob screw).

  • Page 58: Usb Host Interface Unit Type 7300 (G819)

    Controller Options Sets the minimum range of the channels settings allowed for your 5840 007 Channel MIN country. 5840 011 WEP Key Select Used to select the WEP key (Default: 00). USB Host Interface Unit Type 7300 (G819) - Accessories - Check the accessories and their quantities against the following list: Description Q'ty...
  • Page 59 1. Installation Reattach the application cover ( x1)

  • Page 60: Preventive Maintenance

    2. Preventive Maintenance PM Tables PM Tables for the Printer Two maintenance kits are provided for customers. Name Contents Maintenance Kit SP 8100A PCDU (Photo Conductor Cleaning/Development Unit) Maintenance Kit SP8100B Fusing Unit and Transfer Unit • Components marked with an asterisk (*) must be inspected, serviced, and replaced without the main- tenance kits.
  • Page 61 2. Preventive Maintenance 150K 300K 450K Note Cleaning Unit Drum Cleaning Blade* Cleaning Entrance Seal Blower brush, replace if re- quired. Side Seal Development Development Drive Gears Replace every 5 PM (750 K) Development Filter* Developer* Entrance Seal Side Seal Development Roller Dry cloth Paper Feed...
  • Page 62 PM Tables 150K 300K 450K Note Pick-up Roller (By-pass feed table) Relay Rollers Water or alcohol. Paper Feed Roller Gear Silicone Grease G-501.* (By-pass feed) Duplex Unit Inverter Roller Water Upper Transport Roller Water Lower Transport Roller Water Transfer Belt Unit User replaceable Transfer Belt* Dry cloth...

  • Page 63: Pm Tables For Options

    2. Preventive Maintenance 150K 300K 450K Note Exit Sensor Blower brush Drive Drive Belts Replace if necessary PM Tables for Options Amounts mentioned as the PM interval indicate the number of prints. Symbol Key: C: Clean, R: Replace, L: Lubricate, I: Inspect 150K 300K 450K...

  • Page 64: Lubrication

    Lubrication Lubrication Lubricate the paper feed clutch gear [A] with Silicone Grease G501 every PM visit.
  • Page 65 2. Preventive Maintenance...

  • Page 66: Replacement And Adjustment

    3. Replacement and Adjustment Precautions General Precautions • To avoid damage to the transfer belt, drum, or development unit, never turn off the power switch while electrical components are active. • Always turn off the power switch and unplug the machine before attempting any of the procedures in this section.

  • Page 67: Special Tools And Lubricants

    3. Replacement and Adjustment Special Tools and Lubricants Special Tools Part Number Description Q’ty VSSM9000 Digital Multimeter – FLUKE 187 A2309003 Adjustment Cam – Laser Unit A2309004 Positioning Pin – Laser Unit B6455010 SD Card B6456820 USB Read/Writer Lubricants Part Number Description Q’ty A2579300...

  • Page 68: Covers And Common Procedures

    Covers and Common Procedures Covers and Common Procedures Front Door Open the front door. To remove the front door, remove left pin [A], and right pin [B]. Duplex Unit...

  • Page 69: Right Upper Cover

    3. Replacement and Adjustment Connector cover [A] ( x1) Duplex connectors [B] ( Duplex support arm [C] ( Duplex unit [D] • Grip the duplex unit with both hands, slowly rotate it towards you and then lift up. Right Upper Cover •...

  • Page 70: By-Pass Tray Unit

    Covers and Common Procedures By-Pass Tray Unit 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, see ‘By-Pass Tray’. Duplex unit (See ‘Duplex Unit’.) Left cover [A] ( x1) Right cover [B] ( x1) Connectors [C] (...

  • Page 71: Rear Covers

    3. Replacement and Adjustment Rear Covers Rear Upper Cover Rear upper cover [A] ( x2) Controller cover [B] ( x2) Rear Lower Cover Rear lower cover [A] ( x4)

  • Page 72: Left Covers

    Covers and Common Procedures Left Covers Left upper cover [A] ( x4) Controller cover [B] ( x2)

  • Page 73: Operation Panel

    3. Replacement and Adjustment Operation Panel • The fusing unit below the cover is hot. Allow the machine to cool for 10 minutes before you begin the procedure. Fusing unit cover [A] (caps x 2, x 2) Insert the tip of a screwdriver into the slot to release the plastic hook and lift. Exert very little pressure to avoid breaking the hooks.

  • Page 74: Paper Output Tray

    Paper Output Tray Paper Output Tray No Bridge Unit Installed Sub copy tray [A] Paper sensor ass’y [B] ( x 2) Cover [C] ( x 1) Paper output tray [D] ( x 3)
  • Page 75 3. Replacement and Adjustment If the duct on the bottom of the paper output tray base hangs up on the vertical support [E] below, reach under and pull the duct up over the support. Bridge Unit Installed Bridge unit [A] ( x 2, x 2) Paper output tray [B] ( x 3) If the duct on the bottom of the paper output tray base hangs up on the vertical support [E]...

  • Page 76: Laser Unit

    Laser Unit Laser Unit • Turn off the power switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage the eyes. Caution Decal Locations Two caution decals are located in the laser section as shown below.

  • Page 77: Laser Unit Removal

    3. Replacement and Adjustment Laser Unit Removal • Turn off the power switch and unplug the machine before attempting this procedure. Laser beams can seriously damage your eyes. Open the front door. Raise the toner bottle holder handle [A]. Remove front door [B] (Pins x2) Remove toner collection plate [C] (...

  • Page 78: Polygon Mirror Motor

    Laser Unit Shield plate [A] ( x 2) While holding the LD board securely, disconnect the laser unit [B] ( x 6, Flat film cable Hold the laser unit [C] by its casing, slide it out of the machine ( x 2) Polygon Mirror Motor Laser unit (See ‘Laser Unit’) Laser unit cover [A] ( x 4, Hooks x 2)

  • Page 79: Laser Synchronization Detector

    3. Replacement and Adjustment Polygon mirror motor [B] ( x 4, x 1) After replacing the motor, do the image adjustment. (See ‘Copy Adjustments: Printing/ Scanning’. Laser Synchronization Detector Laser unit (See ‘Laser Unit’) Laser synchronization detector [A] ( x1, x1).

  • Page 80: Ld Unit

    Laser Unit LD Unit LD Unit Replacement Laser unit (See ‘Laser Unit’) LD unit [A] ( x 3, x 1) • To avoid damaging the LD board, hold it securely when disconnecting the connectors. Hold the laser unit casing. After replacing the LD board, do SP 2-109 to adjust the laser beam pitch (described below). Laser Beam Pitch Adjustment After replacing the LD board, do the laser beam pitch adjustment.
  • Page 81 3. Replacement and Adjustment If you do not have an SMC Report for reference, do SP5990-002 to print the SMC Report so you can look up and match the SP numbers below with the correct name. Set SP2110 to "0" (for 400 dpi), or to "8" (for 600 dpi). Execute SP2109-08 to reset all the beam pitch data.
  • Page 82 Laser Unit...

  • Page 83: Pcdu

    3. Replacement and Adjustment PCDU Photoconductor Cleaning/Development Unit Open the front door. Lower the by-pass tray, open the duplex unit, and open the transfer unit right cover. Release the PCDU lock [A]. Hold the PCDU by the handle [B] and pull out slowly. Remove the screws [C] (...

  • Page 84: Drum

    PCDU With the PCU slightly offset, set it on top of the development unit, then carefully slide it horizontally to ensure that the end of the toner supply shutter at the toner supply port opens. Check the exposed spring on the back of the PCDU. •...

  • Page 85: Pick-Off Pawls

    3. Replacement and Adjustment Press at to release the charge roller [D], release the charge roller , press the drum [E] to the front, and then remove the drum - SP Adjustments - Set to the standard value to ensure Charge Roller Bias Adjustment 2001-01 carrier is not attracted to the drum.

  • Page 86: Charge Roller And Cleaning Roller

    PCDU Pawl assembly [A] 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, the pick-off pawl position can be adjusted using either method: •...
  • Page 87 3. Replacement and Adjustment Two snap rings [A] ( x 2). Charge roller holder [B] Charge roller [C] • Do not touch the charge roller. Cleaning roller [D]. SP Adjustment: Set to the standard value Charge Roller Bias Adjustment 2001-01 (–1,480 V) to ensure carrier is not attracted to the drum.

  • Page 88: Drum Cleaning Blade

    PCDU Drum Cleaning Blade Remove the drum. (See "Drum") Remove the charge roller. (See "Charge Roller") Remove the drum cleaning blade [A] ( x 2). ID Sensor Remove: • PCU (See ‘PCU’.) • Fusing unit (See “Fusing Unit’.) • Development unit (See ‘Development – Development Unit’.)
  • Page 89 3. Replacement and Adjustment Remove the PCU rail [A] ( x2, Remove the ID sensor bracket [B] ( x1, Remove the ID sensor [C] ( x1) Do SP3-001-2 to initialize the ID sensor.

  • Page 90: Development

    Development Development Development Unit PCDU. (See "PCDU") Spread paper on a clean flat surface that is free of pins, paper clips, staples, screws or any other metal objects. Separate the PCU [A] and development unit [B] ( x 3). Set the development unit on the spread paper, and cover the exposed drum with a clean piece of paper.

  • Page 91: Development Filter

    3. Replacement and Adjustment Development Filter Development unit (See ‘Development Unit’.) Upper development cover [A] ( Development filter [B] • Make sure that the surface with the red mark is facing up. Development Roller Development unit (See ‘Development Unit’.) Upper development cover (See ‘Development Filter’) Gear [A] (...

  • Page 92: Developer

    Development Joint bracket [B]. Development roller [C] ( x2) • Work carefully to avoid scratching or nicking the development roller. Developer Development unit (See ‘Development Unit’.) Remove the development roller (See ‘Development Roller’.) Tip out the old developer [A]. Turn drive gear [B] to ensure that no developer remains in the unit or on the development roller.
  • Page 93 3. Replacement and Adjustment Pour approximately 1/3 of the developer [C] evenly along the length of the development unit. Rotate the drive gear [D] to work the developer into the unit. Repeat [C] and [D] until all toner is in the unit and level with the edges. Reassemble the development unit Cover the toner entrance hole with a piece of paper [E].

  • Page 94: Td Sensor

    Development • When performing this setting, cover the toner entrance hole with a piece of paper. This prevents used toner falling from the PCU into the development unit during the TD sensor initial setting and interfering with the Vref setting (toner density reference voltage). Install the development unit in the machine.
  • Page 95 3. Replacement and Adjustment Pour new developer into the development unit and do the TD sensor initial setting using SP2-801. • When performing the TD sensor initial setting, cover the toner entrance hole with a piece of paper.

  • Page 96: Transfer Unit

    Transfer Unit Transfer Unit Transfer Belt Unit • To avoid exposing the PCU drum to strong light, cover it with paper if the right cover will be open for a long period. Lower the by-pass tray, open the duplex unit, and open the right cover. Transfer unit [A] (Hook x1) Transfer belt [B] (springs x2, Hook x1)

  • Page 97: Transfer Belt

    3. Replacement and Adjustment • Avoid touching the transfer belt surface. Transfer Belt Remove the transfer belt unit. (See ‘Transfer Belt Unit’.) Belt drive gear [A] Set screws [B] ( x2) Lay on a flat, clean surface and fold the unit to release the tension on the belt [C]. Transfer belt [D] •...

  • Page 98: Transfer Belt Cleaning Blade And Toner Overflow Sensor

    Transfer Unit Transfer Belt Cleaning Blade and Toner Overflow Sensor Transfer Belt Cleaning Blade Transfer belt unit. (See ‘Transfer Belt Unit’.) Transfer belt. (See ‘Transfer Belt’.) Transfer belt cleaning blade [A] ( x3) • Avoid touching the edge of the new blade. Check the new blade for dust or damage. Toner Overflow Sensor Transfer belt unit.

  • Page 99: Paper Feed

    3. Replacement and Adjustment Paper Feed Pick-Up, Separation, and Feed Rollers Paper tray Pick-up roller [A] ( x 1) Feed roller [B] ( x 1) Separation roller [C] ( x 1) Lower Right Cover Duplex unit (See ‘Covers and Common Units – Duplex Unit’)

  • Page 100: Relay/Upper Paper Feed And Lower Paper Feed Clutches

    Paper Feed By-pass tray (See ‘Covers and Common Units – By-pass Tray Unit’) LCT (if installed) Lower right cover [A] ( x5) Vertical transport cover [B] • Push the cover completely to the left and then press in on the right tab to release the peg from the hole.

  • Page 101: Upper Paper Feed Unit For Tray 1

    3. Replacement and Adjustment Relay clutch [D] ( Upper paper feed clutch [E] ( Lower paper feed clutch [F] ( Upper Paper Feed Unit for Tray 1 Upper paper tray Lower right cover. (See ‘Lower Right Cover’.) Right upper cover (See ‘Covers and Common Units – Right Upper Cover’.) Upper paper feed clutch [A] (See ‘Relay/Upper Paper Feed And Lower Paper Feed Clutch- es’.) 3 relay gears [B]...

  • Page 102: Lower Paper Feed Unit For Tray 2

    Paper Feed Upper paper feed unit [C] ( x2, Lower Paper Feed Unit For Tray 2 Lower the paper trays Lower right cover. (See ‘Lower Right Cover’.) Lower paper feed clutch [A] (See ‘Relay/Upper Paper Feed And Lower Paper Feed Clutch- es’.) Relay gears [B] (x3)
  • Page 103 3. Replacement and Adjustment Cover [C] ( x2) Gear [D] (x1) Lower paper feed unit [E] ( x2,...

  • Page 104: Paper End/Paper Height/Relay Sensors

    Paper Feed Paper End/Paper Height/Relay Sensors Remove the appropriate paper feed unit. (See ‘Upper Paper Feed Unit’ or ‘Lower Paper Feed Unit’.) Paper height sensor [A] ( Paper end sensor [B] ( x1). Relay sensor bracket [C] ( x1, Relay sensor [D] Registration Sensor Remove: •...
  • Page 105 3. Replacement and Adjustment • Development unit (See ‘Development’.) Inner cover [1] ( x2) Front registration holder [2] ( x1) Front registration roller gear [3] ( x1) Registration roller bushing [4] (spring x 1) High voltage power supply board [5] ( x3, Flywheels [6] ( x3) Right rear cover [7] ( x3)
  • Page 106 Paper Feed Right cover switch bracket [8] ( x1) Rear registration holder [9] ( x1) Registration roller bushing [10] ( x1, spring x1) Guide plate [11] and registration roller [12] (spring x1, x 1)
  • Page 107 3. Replacement and Adjustment Registration guide plate [13] ( x2, Sensor bracket [14] ( x1) Registration sensor [15] ( x1,...

  • Page 108: Tray Lift Motor

    Paper Feed Tray Lift Motor Rear lower cover (See ‘Covers and Common Units – Rear Covers’.) Remove the IOB (See ‘Printed Circuit Boards – IOB’.) Bracket [A] ( x2, Tray lift motor [B] ( x2)

  • Page 109: Feed/Development Motor

    3. Replacement and Adjustment Feed/Development Motor Remove: See "IOB" • Center plate of rear lower cover ( x1,  x1) • Rear lower cover ( x4) Remove the IOB [A] ( x4,  x24)
  • Page 110 Paper Feed Rear lower cover ( x4) (See ‘Covers and Common Units – Rear Covers’.) Rear upper cover ( x4) (See ‘Covers and Common Units – Rear Covers’.) Tray lift motor (See ‘Tray Lift Motor’.) Support [A] ( x2, harnesses x2) Timing belt [B] (Raise arm to release tension on belt.) Feed/development motor [C] ( x3,...

  • Page 111: Idle Roller Dust Blade

    3. Replacement and Adjustment Idle Roller Dust Blade Open the duplex unit and right door. Detach the dust blade [A]. Spread some paper on a flat surface. Tap the dust blade gently to remove paper dust col- lected in its dust box. Registration Roller Dust Blade Open the front door.
  • Page 112 Paper Feed Release the PCU lock [A]. Hold the PCU by the handle [B] and pull out slowly. Press the top of the blade [C] to unlock it and open it to the left. Remove the dust blade [D] from the machine.

  • Page 113: Fusing Unit

    3. Replacement and Adjustment Fusing Unit • Allow time for the unit to cool before doing the following procedure. Fusing Unit Removal Open the front door, duplex unit, and right door. Remove set screw [A] ( x 1) Fusing unit release lever [B] Slide out the fusing unit [C] •...

  • Page 114: Fusing Unit Exit Guide

    Fusing Unit Fusing Unit Exit Guide Fusing unit (See ‘Fusing Unit Removal’.) Exit guide [A]. Press the guide to the left and then press on the right end to release the peg from the hole. Hot Roller Strippers Fusing unit (See ‘Fusing Unit Removal’.) Fusing unit cover [A] ( x4) •...

  • Page 115: Fusing Lamps

    3. Replacement and Adjustment Hot roller strippers x7 and springs x7 Fusing Lamps Fusing unit (See ‘Fusing Unit Removal’.) Fusing unit upper cover (See ‘Hot Roller Strippers’.) Fusing entrance guide [A] ( x2) Fusing unit lower cover [B] ( x1)
  • Page 116 Fusing Unit Left side Two terminals [C] ( x2) Center fusing lamp lead [D] (Clamps x3) Bracket [E] ( x1) Right side...

  • Page 117: Thermistors And Thermostats

    3. Replacement and Adjustment Two terminals [F] ( x2) Spring [G] Connector bracket [H] ( x2) Bracket [I] ( x2) Remove both fusing lamps. • To avoid breaking the fusing lamps, handle them with care. • Avoid touching the lamps with bare hands. •...

  • Page 118: Hot Roller/Pressure Roller

    Fusing Unit Center thermostat [C] ( x2) End thermostat [D] ( x2) Hot Roller/Pressure Roller Fusing unit (See ‘Fusing Unit Removal’.) Fusing unit upper cover (See ‘Hot Roller Strippers’. Fusing unit lower cover. (See ‘Fusing Lamps’.) Fusing lamps. (See ‘Fusing Lamps’.)
  • Page 119 3. Replacement and Adjustment Springs x2 [A] (both sides) Arms x2 [B] (both sides) Pawl bracket [C] ( x4)
  • Page 120 Fusing Unit Hot roller [D] • The hot roller is easily damaged. Always handle it carefully. C-rings x2 [E] (both ends) Drive gear [F] Bushings x2 [G] (both ends) Pressure roller [H] Fusing knob [I] ( x1) Bushings x2 [J] (both ends) •...

  • Page 121: By-Pass Tray

    3. Replacement and Adjustment By-Pass Tray Covers Rear cover [A] ( x 1) Front cover [B] ( x 1) Hinge cover [C] ( x 1) Upper cover [D] ( x 2) Close the duplex unit and pull out the upper cover.

  • Page 122: By-Pass Paper Feed And Pick-Up Roller Replacement

    By-Pass Tray By-Pass Paper Feed and Pick-Up Roller Replacement Upper cover (See ‘Covers’.) Lift up paper end feeler [A] to lock the feeler in position. • Before reinstalling the upper cover, return the paper end feeler to its original position. Replace the paper feed roller [B] ( Replace the pick-up roller [C].

  • Page 123: By-Pass Separation Roller

    3. Replacement and Adjustment By-Pass Separation Roller Close the by-pass table. Remove the separation roller [A] from the bottom (...

  • Page 124: Paper End Sensor, Pick-Up Solenoid

    By-Pass Tray Paper End Sensor, Pick-Up Solenoid Upper cover (See ‘Covers’.) Lift the paper end feeler [A]. • Before reinstalling the upper cover, return the paper end feeler to its original position. Replace the paper end sensor [B] ( x1). Pick-up solenoid [C] ( x1, x1, spring x1)

  • Page 125: Paper Size Sensor Board

    3. Replacement and Adjustment Paper Size Sensor Board Hook [A] Paper tray [B] ( x1). Size sensor board [C]. • To avoid breaking the hook of the paper size sensor board, handle it carefully during removal.

  • Page 126: By-Pass Table Removal

    By-Pass Tray By-Pass Table Removal • The entire by-pass tray unit can be removed, not just the table. (See ‘Covers and Common Units – By-Pass Tray Unit’.) Hinge cover (See ‘Covers’.) Harness [A] ( x1). Screws [B] ( x2) By-pass table [C]. •...
  • Page 127 3. Replacement and Adjustment Paper feed unit [A] ( x2, Rear bracket [B] ( x4, x1, bushing x1) Paper feed clutch [C] (...

  • Page 128: Duplex Unit

    Duplex Unit Duplex Unit Duplex Cover Removal Duplex unit cover [A] ( x4)

  • Page 129: Duplex Entrance Sensor

    3. Replacement and Adjustment Duplex Entrance Sensor Duplex unit cover (See ‘Duplex Cover Removal’.) Sensor holder [A] ( x1) Entrance sensor [B] (...

  • Page 130: Duplex Exit Sensor

    Duplex Unit Duplex Exit Sensor Duplex unit (See ‘Covers and Common Units – Duplex Unit’.) Sensor bracket [A] ( x1) Exit sensor [B] (...

  • Page 131: Drive Mechanisms

    3. Replacement and Adjustment Drive Mechanisms Registration Clutch, Transfer Belt Contact Clutch Rear upper cover ( x 2) (See 'Covers and Common Units – Rear Covers') High voltage supply board [A] ( x 6, x 3) Make sure that you re-connect the wires in the correct order. They are labeled: 1 > 2 > B >...

  • Page 132: Main Motor

    Drive Mechanisms Flywheels [B] ( x 3) Registration clutch [C] ( x1, x 1) Transfer belt contact clutch [D] ( x 2, x 2) Main Motor Remove: • Rear upper cover (See 'Covers and Common Units – Rear Covers'.) • High voltage power supply, flywheel (See 'Registration Clutch, Transfer Belt Contact Clutch'.)

  • Page 133: Fusing/Exit Motor

    3. Replacement and Adjustment Remove the main cooling fan [A] ( x 2) Timing belt [B] x 1 Bracket [C] ( x 3) Main motor [D] ( x 2, x 3) Fusing/Exit Motor Remove: • Rear upper cover (See 'Covers and Common Units – Rear Covers') •...
  • Page 134 Drive Mechanisms Remove: • [A]: Harness clamps ( x 3) • [B]: Connector bracket ( x 1, x 1) • [C]: Main fan ( x 1, x 1) • [D]: Motor assembly ( x 4, x 2)

  • Page 135: Toner Supply Motor

    3. Replacement and Adjustment • [E]: Fusing/exit motor ( x 4) Toner Supply Motor Open the front door Raise holder handle [A] Push the holder lever [B] to the right Stopper [C] Toner bottle holder and bottle [D]...
  • Page 136 Drive Mechanisms Motor harness [E] (clamps x 2) Toner supply motor [F] (hooks x 2, x 1) • Press both sides of the motor to release it.

  • Page 137: Boards

    3. Replacement and Adjustment Boards NVRAM The following data cannot be downloaded from the SD card. • Total count categories (SP7002*** Copy Counter) • C/O, P/O Counter (SP7006*** C/O, P/O Count Display) • Duplex, A3/DLT/Over 420 mm, Staple and Scanner application scanning counters (system settings). •...

  • Page 138: Replacing Nvram

    Boards To enter the SP mode, press  together (5 seconds), release, then press [#Enter]. Select SP5824. SP5824 NVRAMUpload Push [#Enter]. When the message prompts you to execute, push [#Enter]. <NVRAMUpload> Processing <NVRAMUpload> result = OK Remove the SD card. Switch the machine off and on.

  • Page 139: Downloading Nvram Data (Sp5825)

    3. Replacement and Adjustment HDD unit bracket [C] ( x 4, x 2) Remove the NVRAM [D] from the controller board and replace it with the new chip. • Make sure that the notch of the new NVRAM is aligned properly as shown above before you try to install it.
  • Page 140 Boards Turn off the main switch. Remove the SD card cover [A]. Plug the SD card [B] into SD card slot C3.. Turn on the main switch. To enter the SP mode, press together (5 seconds), release, then press [#Enter]. Select SP5824.

  • Page 141: Hvps

    3. Replacement and Adjustment • If the correct SD card for the NVRAM data is not inserted in the SD card slot, after you press [#Enter] a message will tell you that downloading cannot proceed. HVPS Rear upper cover (See ‘Covers and Common Units – Rear Covers’) High voltage power supply [A] ( x3,...

  • Page 142: Iob

    Boards Remove the center plate [A] ( x1,  x1) Remove the rear lower cover [B] ( x 4). Remove the IOB [C] ( x 24, x 4).

  • Page 143: Bicu Board

    3. Replacement and Adjustment BICU Board IOB (See ‘IOB’) BICU board [A] ( x 5, x all) Left cover (See ‘Covers and Common Units – Left Cover’) PSU [A] ( x4, x all)

  • Page 144: Hdd And Controller Board

    Boards HDD and Controller Board Remove the controller cover ( x 2). (See ‘Covers and Common Units – Rear Covers’) Controller board faceplate [A] ( x 2). Controller board [B] ( x 4) HDD unit bracket [C] ( x 4, x 2) Format the HDD.
  • Page 145 3. Replacement and Adjustment HD Format Press # to start • Press [#Enter]. Formatting… Completed Restart printer • Turn the main power switch off/on.

  • Page 146: Parallelogram Image Adjustment

    Parallelogram Image Adjustment Parallelogram Image Adjustment Do the following procedure if a parallelogram prints while adjusting the printing registration or printing margin using the trim pattern. The following procedure should be done after adjusting the side-to-side registration for each paper tray station.
  • Page 147 3. Replacement and Adjustment Adjust the laser unit position by turning the adjustment cam. (See the illustration above.) Tighten the adjustment bracket. Print the trim pattern again with SP2902-010 to check the image. If the results are not sat- isfactory, repeat this procedure until the pattern is perfectly rectangular.

  • Page 148: Troubleshooting

    4. Troubleshooting Service Call Conditions There are 4 levels of service call conditions. Level Definition Reset Procedure To prevent damage to the machine, the main machine Enter SP mode, and then turn the cannot be operated until the SC has been reset by a power switch off and on.
  • Page 149 4. Troubleshooting • The power LED lights or flashes while machine is communicating with the network server, or while the machine is accessing the hard disk or memory. Charge roller current leak • Charge roller damaged Charge leak detected when charge was •...
  • Page 150 Service Call Conditions • LD unit home position sensor defective • LD positioning motor connector or har- The LD unit home position sensor did not ness loose, broken, defective detect the ON condition when the LD unit moved to its home position. •...
  • Page 151 4. Troubleshooting • Polygon motor defective Polygon motor error 3: XSCRDY signal er- • Polygon motor drive board I/F har- ness loose, disconnected, or dam- aged The XSCRDY signal did not go HIGH (In- • Polygon motor drive board defective active) after the polygon motor had been •...
  • Page 152 Service Call Conditions • ID sensor defective The ID sensor pattern edge voltage was not • IOB defective equal to 2.5 V and two samplings within • HVPS defective 800 ms. • ID sensor dirty ID sensor, LED current abnormal at initial- ization •...
  • Page 153 4. Troubleshooting • Toner supply defective (confirm that more than 4.8V during TD sensor initial set- the toner seal strip has been removed ting. from toner cartridge) Development output abnormal • Poor connection at the development bias terminal A development bias leak signal was de- •...
  • Page 154 Service Call Conditions New PCU error • New unit detection sensor defective • New PCU defective The new unit detection sensor switched ON Note: Normally the new unit detection sen- for 2 sec. to detect a new PCU while the sor goes on after a new PCU is installed and main motor was operating but the sensor then goes off after the ID sensor and TD...
  • Page 155 4. Troubleshooting • Pick-up solenoid connector or harness loose, broken, or defective • Pick-up solenoid defective 2nd tray lift malfunction The paper height sensor did not activate after the tray lift motor was on for 10 sec. Note: Normally, if the power switch is turned on when the paper is already at the feed height, the paper height position is detected again.
  • Page 156 Service Call Conditions Note: Normally, if the power switch is turned on when the paper is already at the feed height, the paper height position is detected again. At this time, the paper height sensor should de-activate within 5 seconds after the paper bottom plate starts to drop. If it does not deactivate within 5 s after four attempts, the tray lift motor halts.
  • Page 157 4. Troubleshooting • LCT lift motor connector or harness loose, broken, or defective, or LCT lift motor defective • Upper limit sensor connector or harness loose, broken, or defective, or sensor is defective. • Pick-up solenoid connector or harness loose, broken, or defective or solenoid is defective •...
  • Page 158 Service Call Conditions Fusing overheat error (software detection) • Check harnesses and connectors of PSU, IOB, BICU • PSU defective A fusing temperature of over 230°C • IOB defective (446 F) is detected for 5 seconds by the fusing thermistors at the center or at either •...
  • Page 159 4. Troubleshooting The machine cannot detect the fusing unit • Fusing unit connection loose when the front cover and right cover are closed. Zero-cross frequency over The applied power ac frequency was de- • Noise on the ac power line tected less than 66 Hz more than 10 times, or less than 44 Hz one time.
  • Page 160 Service Call Conditions • BICU board and finisher main board connection defective or loose A break (low) signal was received from the • Finisher main board defective finisher. • BICU board defective Communication timeout error between • Serial line connecting BICU and pa- BICU and paper tray unit per tray unit unstable •...
  • Page 161 4. Troubleshooting • LCT interface board defective • BICU board defective Engine startup error • Connections between BICU and controller board are loose, discon- The BICU failed to respond with the pre- nected, or damaged scribed time when the machine was turned •...
  • Page 162 Service Call Conditions Finisher stack feed-out motor error • Stack feed-out HP sensor defective The stack feed-out belt HP sensor did not ac- • Stack feed-out motor overload tivate within 4550 pulses after the stack • Stack feed-out motor defective feed-out motor turned on.
  • Page 163 4. Troubleshooting Finisher exit guide motor error • Finisher exit guide motor defective harness or connector loose, broken, defective After the finisher exit guide motor turned on, the exit guide sensor did not activate within • Finisher exit guide motor defective 800 ms.
  • Page 164 Service Call Conditions The bus is being held by another de- • System program defective; switch off/on, vice, or a CPU-device infinite loop has or change the controller firmware if the occurred. A module that the watchdog problem cannot be solved is monitoring has not closed properly •...
  • Page 165 4. Troubleshooting • For more details about this SC code error, execute SP5990 to print an SMC report so you can read the error code. The error code is not displayed on the operation panel. Self-diagnostic error 3: HDD The check that is done when the HDD is in- stalled revealed the following: •...
  • Page 166 Service Call Conditions Self-diagnostic error 7: ROM Measuring the CRC for the boot monitor and • Software defective operating system program results in an error. • Controller board defective A check of the CRC value for ROMFS of the • ROM defective entire ROM area results in an error.
  • Page 167 4. Troubleshooting • Wireless LAN card defective An error was detected on the wireless LAN card. • Wireless LAN card connection incorrect Wireless LAN (802.11b)error 4 • Wireless LAN card defective An error was detected on the wireless LAN card. •...
  • Page 168 Service Call Conditions During HDD operation, the HDD can- not respond to an CRC error query. Data transfer did not execute normally • HDD defective while data was being written to the HDD. HDD access error HDD responded to an error during op- eration for a condition other than those •...
  • Page 169 4. Troubleshooting Address book data on the hard disk was detected as abnormal when it • Software defective. Turn the machine off/ was accessed from either the opera- on. If this is not the solution for the problem, tion panel or the network. The ad- then replace the controller firmware.
  • Page 170 Service Call Conditions • HDD defective Delete All error 2: Data area An error occurred while the machine deleted data from the HDD. The source • Turn the main switch off/on and try the of this error is the Data Overwrite Se- operation again.
  • Page 171 4. Troubleshooting Net File function error The NetFile file management on the HDD cannot be used, or a NetFile management file is corrupted and op- eration cannot continue. The HDDs are defective and they cannot be de- bugged or partitioned, so the Scan •...
  • Page 172 Service Call Conditions Procedure 1 If the machine shows SC codes for HDD errors (SC860 ~ SC865) with SC 925, do the recovery procedures for SC860 ~ SC865. Procedure 2 If the machine does not show one of the five HDD errors (SC860 ~ SC865), turn the machine power off and on.
  • Page 173 4. Troubleshooting 980 D NVRAM Error A critical SP code setting is not within range. If the machine is allowed to operate • See description below this table. in this condition, this could lead to toner overflow and damage the machine. SP Code Acceptable Range SP Code...
  • Page 174 Service Call Conditions SP No. Name Range SP2802 002 TD Sensor Manual Setting – VTMAX SP2802 003 TD Sensor Manual Setting – VTMIN Print image data transfer error • Controller board defective • BICU defective • Connectors between BICU The image transfer from the controller to the engine via and controller loose or de- the PCI bus does not end within 15 s after starting.
  • Page 175 4. Troubleshooting Software error 3: Undefined • Software defective An error not controlled by the system • Turn the machine power off and on. The occurred (the error does not come un- machine cannot be used until this error is der any other SC code).
  • Page 176 Service Call Conditions If the machine loses power while downloading, or if for some other reason the download does not end normally, this could damage the controller board or the PCB targeted for the download and prevent subsequent downloading. If this problem occurs, the damaged PCB must be replaced.

  • Page 177: Electrical Component Defects

    4. Troubleshooting Electrical Component Defects Sensors Component Condition Symptom SC328 is displayed when the laser beam pitch is Open changed. 204-B2 LD Unit Home Position (IOB) SC327 is displayed when the laser beam pitch is Shorted changed. The Add Toner indicator blinks even if there is toner Open 222-11 in the development unit.

  • Page 178: Switches

    Electrical Component Defects The Paper End indicator lights even if paper is Open placed in the upper paper tray. 220-8 Upper Paper End (IOB) The Paper End indicator does not light even if there Shorted is no paper in the upper paper tray. The Paper End indicator lights even if paper is Open placed in the lower paper tray.

  • Page 179: Blown Fuse Conditions (Psu)

    4. Troubleshooting “Doors/Covers” Open is not displayed even if Shorted the front cover is opened. Blown Fuse Conditions (PSU) Rating Fuse Symptom at Power On 115V 210~230V 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 180 Electrical Component Defects — — +3.3 VCG DB0 RXD DB0 TXD TP10 TP11 +5 VE TP12 TP13 +5 V TP14 +5 VE TP15 TP16 R.FGATE TP17 W.FGATE TP18 +2.5 V TP19 +1.65 VCP TP20 +3.3 V...
  • Page 181 4. Troubleshooting...

  • Page 182: Service Tables

    5. Service Tables Service Program Mode Operation General Notes The service program (SP) mode is used to check electrical data, change modes, and adjust values. • Never turn off the power switch when the power LED is lit or flashing. •...

  • Page 183: Printer Controller Service Mode

    5. Service Tables 1.Service Controller service settings. 2.Engine Engine service settings. 3.End Leave the SP mode and return to normal operation. With the item that you want to open displayed in the LCD, press[#Enter]. Press  or  to display all the menus on the same level, then press [#Enter] to open the submenus.

  • Page 184: Printer Controller Bit Switch Settings

    Service Program Mode Operation bit0 _ Select the “0” or “1” for each position. The leftmost digit is 7 and the rightmost is 0. • Press  or  to move the cursor to the right or left to position the it at the digit to change. •...

  • Page 185: Printer Engine Service Mode

    5. Service Tables 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 186: Leaving The Sp Mode

    Service Program Mode Operation • Press to return to the previous level. To change a multiple-digit number setting • Press  or  to move the cursor to the digit that you want to change. • Press [#Enter]. A number replaces the cursor. •...

  • Page 187: Service Program Mode Tables

    5. Service Tables Service Program Mode Tables Service Table Key Notation What it means 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 [range / default / step] be changed in 0.1 mm steps with each key press.
  • Page 188 Service Program Mode Tables 004 Tray-4 [–9~ +9/ +2.0 mm / 0.1 mm/step] 005 Duplex Tray [–9 ~ +9/ +0.0 mm / 0.1 mm/step] 006 Bypass Tray [–9 ~ +9/ +3.0 mm / 0.1 mm/step] 007 LCT [–9 ~ +9/ +1.5 mm / 0.1 mm/step] Regis Buckle Adj Registration Buckle Adjustment 1003...
  • Page 189 5. Service Tables Switches fusing idling on/off. When on, printing will not start until enough time has elapsed so the hot roller can reach optimum temperature. This ensures even heat on the hot roller. Switch on if fusing on the 1st and 2nd copies is incomplete (this may occur if the room is cold.) You must switch SP1103-1 ON before you set the fusing interval with SP1103-2.
  • Page 190 Service Program Mode Tables 003 Ctr (Bypass) [120°C ~ 220°C / 190°C / 1°C step] 004 Ends (By-pass) [120°C ~ 220°C / 190°C / 1°C step] Adjusts the temperature for re-heating the center of the hot roller: Reload Temp. = Fusing. Temp – SP Value [0°C ~ 60°C / 30°C / 1°C step] 005 Ctr (Reload) When the fusing temperature exceeds this setting, the machine can...
  • Page 191 5. Service Tables [0°C ~ 60°C / 5°C / 1°C step] When the fusing temperature exceeds this setting, the machine can operate. Do not set a reload temperature (Spec. Temp – SP Value) higher than the SP1105-02 setting. 1106 Fusing T Disp. Fusing Temperature Display 001 Roller Center Displays the fusing temperature for the center of the hot roller.

  • Page 192: Sp2-Xxx: Drum

    Service Program Mode Tables [0~1/0/1] 0:OFF, 1:ON SP2-xxx: Drum 2001 Charge Roll Bias Charge Roller Bias Adjustment Adjusts the voltage applied to the charge roller for the image area to 001 Image Pattern maintain a charge of –800 V on the OPC drum surface. [–1,000 ~ –2,000 / –1570 V / 10 V step] Adjusts the voltage applied to the charge roller when making the ID sensor pattern (for charge roller voltage correction).
  • Page 193 5. Service Tables Adjusts the left side erase margin in the reverse side of duplex prints. 007 Back Side Left [0 ~ 4.0 / 0.3 / 0.1 mm step] Recommended: 2 +2.5/–1.5 mm LD Power Adj DFU LD Power Adjustment 2103 Adjusts the intensity of the laser for the printer.
  • Page 194 Service Program Mode Tables 400dpi Init Set 400 dpi Initial Setting Initializes the laser beam pitch for 400 dpi using the value for SP2-109-1. After entering a value for SP2-109-1, this SP must be used. 600dpi Init Set 600 dpi Initial Setting Initializes the laser beam pitch for 600 dpi using the value for SP2-109-2.
  • Page 195 5. Service Tables Polyg MO Off T. Polygon Motor Off Timer [0 ~ 60 s / 10 s / 5 s step] Input the time that the polygon motor is to switch off after the printer has remained idle for the 2112 specified time and entered the standby mode.
  • Page 196 Service Program Mode Tables 2210 ID Sensor Pattern Interval Sets the interval between ID sensor pattern prints for toner control. This setting allows adjustment for customers who do not make many prints daily. Selecting zero cancels creation of the ID sensor pattern.
  • Page 197 5. Service Tables (1) Check the value of SP2-220 in both the machine containing the test unit and the machine that you are going to move it to. (2) Install the test development unit, and then input the VREF for this unit into SP2-220. (3) After the test, put back the old development unit, and change SP2-220 back to the original value.
  • Page 198 Service Program Mode Tables Printing at leading edge of the paper. Increase the current to separate the paper from the drum properly in high humidity and high temperature conditions. [20 ~ 100 μA / 45 / 1 μA step] Img Face Bypass Image Face By-pass (By-pass Feed) Printing from the by-pass tray (image area).
  • Page 199 5. Service Tables 04 Beta (Tray) Adjusts the transfer current correction coefficient used if the paper width is less than the setting of SP2309-02. DFU [1.0 ~ 3 / 1.2 / 0.1 mm step] 05 Gamma (By-pass) Adjusts the transfer current correction coefficient used if the paper width is less than the setting of SP2309-01.
  • Page 200 Service Program Mode Tables Init. Pro.Ctrl Developer Initialization 2805 Performs the developer initialization. Press [#Enter] to start. This SP should be performed after doing SP2801-1 at installation and after replacing the drum. 2902 Print T Pattern Print Test Pattern Use this SP to select a print test pattern. After you select any pattern other than "0:None", this puts the printer in the Print Test Pattern mode.
  • Page 201 5. Service Tables 10/2 = 5 x 10 + 10 = 60. However, the limit is 50 ms so in this case, 60 ms is reduced to 50 Tst Pattern Den Print Density for Test Pattern 2913 [0 ~ 15 / 15 / 1] Sets the print density for the patterns printed with SP2-902-3.
  • Page 202 Service Program Mode Tables [0 = No, 1 = Yes] Selects whether or not the toner overflow sensor is activated. Transfer Cleaning Blade Forming [0 ~ 30/ 3 / 1 sheets] Applies a pattern of toner to the transfer belt at a defined interval between sheets on the transfer belt in order to reduce friction between the belt surface and the cleaning blade.
  • Page 203 5. Service Tables [0 ~ 100 / 85 / 1 step] Defines the upper limit for grayscale. A larger value allows a wider range of halftones at the pale end of the scale. If the image contains pale areas with fuzzy borders surrounded by dark areas, reduce this value to make the borders clearer.

  • Page 204: Sp3-Xxx: Process

    Service Program Mode Tables When SP2975 is set to any value other than “0”, this value is displayed when it matches the setting of SP2975. When SP2975 is set to “0”, SP2976 is disabled. SP2976 is automatically set to zero by toner end recovery.) Charge Counter [0 ~ 1000000 / 0 / 1 step] Sets the number of pages to print after toner and carrier initialization before the charge input is...
  • Page 205 5. Service Tables Presents on the display the current values of Vsg, Vsp, Vpdp, and grayscale control. If the ID sensor does not detect the ID pattern, “VSP = 5.0 V/VSG = 5.0 V” is displayed and an SC code is generated. If the ID sensor does not detect the bare area of the drum, “VSP = 0.0 V/VSG =0.0 V”...
  • Page 206 Service Program Mode Tables Toner and carbon clinging to the hot roller strippers can cause poor print quality. To prevent this, toner and carbon are dislodged from the hot roller strippers by switching the fusing motor on/off after every print job. These SPs set up the operation of this feature. Number of Rotati Number Rotations This SP sets the number of times the 1st Cleaning is done after the number of pages prescribed...

  • Page 207: Sp5-Xxx: Mode

    5. Service Tables This SP prescribes the number of times that the cleaning pattern of SP3905 004 is repeated for jobs that are longer than the number of pages prescribed by SP3905 004. [0~5/0/1] Unless you change this setting, the cleaning pattern of SP3904 (1st Cleaning, then the 2nd Cleaning after 35 sec.) is not repeated.
  • Page 208 Service Program Mode Tables Display IP add Display IP Address Switches the banner display of the IP address off and on. (Default: *Off) [OFF] ON 5055 For example, if this SP is switched on, the IP address will be displayed below "Ready" while the printer is in standby mode: Ready 169.254.187.055...
  • Page 209 5. Service Tables [0~1/0/1] 0: Off 1: On Set Time DFU Sets the time clock for the local time. This setting is done at the factory before delivery. The setting is GMT expressed in minutes. [–1440~1440/1 min.] JA: +540 (Tokyo) 5302 NA: -300 (NY) EU: +6- (Paris)
  • Page 210 Service Program Mode Tables If the time change is not a whole number (1.5 hours for example), digit 8should be 3 (30 minutes). Enables/disables the settings for 002 and 003. [0~1/1] 001 Setting 0: Disable 1: Enable Rule Set The start of summer time. (Start) 004 Rule Set (End) The end of summer time.
  • Page 211 5. Service Tables 3: High (6K jams) Error Alarm 5505 Sets the error alarm level. Japan only DFU [0~255 / 50 / 100 copies per step] 5507 Supply Alarm 0:Off 1:On Switches the control call on/off for the paper supply. DFU 0: Off, 1: On 001 Paper Supply Ala(rm) 0: No alarm.
  • Page 212 Service Program Mode Tables 142 Interval: B5 160 Interval: DLT 164 Interval: LG 166 Interval: LT 172 Interval: HLT 5515 SC Call Setting Japan Only With NRS (New Remote Service) in use, these SP codes can be set to issue an SC call when an SC error occurs.
  • Page 213 5. Service Tables Initializes all registration settings for the engine and copy 002 Clear Engine process settings. Initializes default system settings, SCS (System Control Ser- 003 SCS vice) settings, operation display coordinates, and ROM up- date information. Initializes the image file system. 004 IMH (IMH: Image Memory Handler) Initializes the automatic delete time setting for stored docu-...
  • Page 214 Service Program Mode Tables 0:Free run mode off. 1:Free run mode on. Input Check 5803 Displays the signals received from sensors and switches. (See "Input Check") Output Check 5804 Turns on the electrical components individually for test purposes. (See "Output Check") 5807 Option Connect Chk Option Connection Check 002 Bank (Paper Tray Unit)
  • Page 215 5. Service Tables [0~2/1] 0: Remote diagnostics off. 1: Serial (CSS or NRS) remote diagnostics on. 2: Network remote diagnostics. CE Call Lets the service technician start or end the remote machine check with CSS or NRS; to do this, push the center report key Function Flag Enables and disables remote diagnosis over the NRS network.
  • Page 216 Service Program Mode Tables Port 80 Enable Controls if permission is given to get access to the SOAP method over Port 80 on the NRS network. [0~1/1] 0: No. Access denied 1: Yes. Access granted. RCG – C Registed This SP displays the Cumin installation end flag. 1: Installation completed 2: Installation not completed RCG –...
  • Page 217 5. Service Tables The certification update is completed and the GW URL is being notified of the successful update. The certification update failed, and the GW URL is being notified of the failed update. The period of the certification has expired and new request for an update is being sent to the GW URL.
  • Page 218 Service Program Mode Tables Notification that GW URL does not exist. CERT: Up ID The ID of the request for certification. Firmware Up Status Displays the status of the firmware update. Non-HDD Firm Up This setting determines if the firmware can be updated, even without the HDD installed. Firm Up User Che Firmware Up User Check This SP setting determines if the operator can confirm the previous version of the firmware before...
  • Page 219 5. Service Tables Displays the common name of the issuer of the NRS certification. CN = the following 30 bytes. Asteriskes (****) indicate that no DESS exists. CERT: Valid Start Displays the start time of the period for which the current NRS certification is enabled. CERT: Valid End Displays the end time of the period for which the current NRS certification is enabled.
  • Page 220 Service Program Mode Tables Inquiry number error Registration in progress Proxy error (proxy enabled) Proxy error (proxy disabled) Proxy error (Illegal user name or password) Communication error Certification update error Other error Inquiry executing Confirm Place Displays the result of the notification sent to the device from the GW URL in answer to the inquiry request.
  • Page 221 5. Service Tables Displays a number that describes the error code that was issued when either SP5816 204 or SP5816 207 was executed. Cause Code Meaning -11001 Chat parameter error Illegal Modem Parameter -11002 Chat execution error -11003 Unexpected error Inquiry, registration attempted without acquir- -12002 ing device status.
  • Page 222 Service Program Mode Tables Prints the communication log. Remote Service A Remote Service Address Japan Only Sets the PI device code. After you change this setting, you 001 CSS-PI Device C(ode) must turn the machine off and on. Sets the IP address of the RCG (Remote Communication Gate) destination for call processing at the remote service 002 RCG IP Address center.
  • Page 223 5. Service Tables For example, if the 8-bit entry is "255.255.255.00" this is read "FFFFFF00h". This SP allows you to confirm and reset the IPv4 default gateway used by the network for Ethernet and wireless LAN (802.11b): 003 IPv4 DefaultGate aaa.bbb.ccc.ddd For example, if the 8-bit entry is "192.169.000.001"...
  • Page 224 Service Program Mode Tables Switches job spooling spooling on and off. 065 Job Spool 0: No spooling 1: Spooling enabled This SP determines whether the job interrupted at power off is resumed at the next power on. This SP operates only when SP5828 065 is set to 1.
  • Page 225 5. Service Tables ActIPv6Sttles4 The IPv6 address consists of a total 128 bits configured in 8 blocks of 16 bits each. 155 ActIPv6Sttles5 This SP is the IPv6 manually set address referenced on the Eth- ernet or wireless LAN (802.11b) in the format: "Manual Set Address"...
  • Page 226 Service Program Mode Tables fe80:0:0:0207:40ff:0:340e 4. Sections where only zeros exist can be abbreviated with double colons (::). This abbreviation can be done also where succeeding sections contain only zeros (but this can be done only at one point in the address).
  • Page 227 5844 Transfer Rate Sets the speed for USB data transmission. [Full Speed] [Auto Change] Vendor ID Sets the vendor ID: Initial Setting: 0x05A Ricoh Company [0x0000~0xFFFF/1] DFU Product ID Sets the product ID. [0x0000~0xFFFF/1] DFU DevReleaseNum Device Release Number Sets the device release number of the BCD (binary coded decimal) display.
  • Page 228 Service Program Mode Tables Delivery Srv Delivery Server 5845 These are delivery server settings. Retry Interval Sets the time interval before the machine tries again when it goes back to standby after an error occurs during an image transfer with the SMTP server. [60~900/1] No.
  • Page 229 5. Service Tables This SP uses bit switches to set up the fuzzy search options for the UCS local address book. Meaning Checks both upper/lower case characters Japan Only --- Not Used --- --- Not Used --- --- Not Used --- --- Not Used --- Complexity Opt1 Complexity Option 1...
  • Page 230 Service Program Mode Tables • This SP is enabled only after the system administrator has set up a group password policy to control access to the address book. Complexity Opt4 Complexity Option 4 Use this SP to set the conditions for password entry to access the local address book. Specifically, this SP limits the password entry to symbols and defines the length of the password.
  • Page 231 5. Service Tables The “Counter Clear Day” has been changed to “Installation Date” or 001 Display “Inst. Date”. Determines whether the installation date is printed on the printout for the total counter. [0~1/1] 003 Total Counter 0: No Print 1: Print Bluetooth Mode Sets the operation mode for the Bluetooth Unit.
  • Page 232 Service Program Mode Tables [2~3 /1] 2: HDD 3: SD Card Save to HDD Specifies the decimal key number of the log to be written to the hard disk. Save to SD Specifies the decimal key number of the log to be written to the SD Card. Copy HDD to SD (4 MB) Takes the most recent 4 MB of the log written to the hard disk and copies them to the SD Card.
  • Page 233 5. Service Tables This SP copies the log on an SD card (the file that contains the information written directly from shared memory) to a log specified by key number. Make HDD LogFile This SP creates a 32 MB file to store a log on the HDD. Make SD LogFile This SP creates a 4 MB file to store a log on an SD card.
  • Page 234 Service Program Mode Tables 008 Key 8 009 Key 9 010 Key 10 5860 SMTP/POP3/IMAP SMTP/POP3/IMAP4 SMTP Svr Port No. SMTP Server Port Number This SP sets the number of the SMTP server port. [1~65535/1] SMTP Auth SMTP Certification This setting switches SMTP certification on and off for mail sending. 0: Off 1: On SMTP Auth Encryp...
  • Page 235 5. Service Tables 1: POP3 protocol POP Auth Encrypt POP3/IMAP4 Certification Encryption This SP specifies whether password encryption is done for POP3/IMAP4 certification. 0: Automatic 1: No encryption done 2: Encryption done POP Srv Port No POP3 Server Port Number This SP sets the number of the POP3 server port.
  • Page 236 Service Program Mode Tables Determines whether RFC2298compliance is switched on for MDN reply mail. [0~1/1] 0: No 1: Yes SMTPAut FieldRep SMTP Auth. From Field Replacement Determines whether the FROM item of the mail header is switched to the validated account after the SMTP server is validated.
  • Page 237 5. Service Tables This SP determines whether the RAM disk is used for either the mail function or PDL Storage. [0~1/0/1] 0:Used 1:Not used 001 Mail Function Sets the amount of RAM disk used for PDL storage. The size of the RAM disk may need adjustment, depending on the amount of mem- 002 PDL Storage ory in the machine.
  • Page 238 Service Program Mode Tables ROM Update 5886 The setting of this SP allows or prohibits updating the ROM. *0:YES, 1:NO Plug/Play Plug & Play Maker/Model Name 5907 Selects the brand name and the production name for Windows Plug & Play. This information is stored in the NVRAM.

  • Page 239: Sp6-Xxx: Peripherals

    5. Service Tables 007 NIB Summary NIB (Network Interface Board) Summary SP6-xxx: Peripherals Staple Adj Staple Position Adjustment 6105 [–3.5~+3.5 / 0.0 / 0.5 mm step] Adjusts the staple position in the main scan direction when using the two-tray finisher. Punch Pos Adj Punch Hole Position Adjustment Adjusts the punch hole position.
  • Page 240 Service Program Mode Tables 003 Latest 2 004 Latest 3 005 Latest 4 006 Latest 5 007 Latest 6 008 Latest 7 009 Latest 8 010 Latest 9 Total Jam Total Paper Jam Counter 7502 Displays the total number of copy jams. Display range: 0000~9999 Total Jam by Location Displays the list of possible locations where a jam could have occurred.
  • Page 241 5. Service Tables 010 Feed Sensor 3:ON Relay Sensor 3 013 Registration: ON Registration Sensor:Paper Late 014 Fusing Sensor:ON 016 Exit Sensor:ON 017 Relay Exit:ON 018 Relay Feed:ON 019 Duplex: ON Duplex Entrance Sensor 023 Duplex Exit: ON Duplex Exit Sensor 025 Finisher Entrance Finisher Entrance Sensor 026 Finisher Proof...
  • Page 242 Service Program Mode Tables Displays the total number of jams by paper size. 005 A4 LEF 006 A5 LEF 014 B5 LEF 038 LT LEF 044 HLT LEF 132 A3 SEF 133 A4 SEF 134 A5 SEF Displays the total number of jams by paper size. 141 B4 SEF 142 B5 SEF 160 DLT SEF...
  • Page 243 5. Service Tables Latest 8 DATE is the date the jams occurred. 010 Latest 9 Size Code Size Code Size Code A4 (S) A3 (L) DLT (L) A5 (S) A4 (L) LG (L) B5 (S) A5 (L) LT (L) LT (S) B4 (L) HLT (L) HLT (S)
  • Page 244 Service Program Mode Tables 001 Last Pages Last Pages 0% to 100%. 002 Average Pages Average Pages 0% to 100%. 003 Toner Bottle In Toner Bottles In Use 0 to 65,535 copies 004 Copy Count: Prev Print Count: Previous Toner Bottle 0 to 999,999 copies Print Count: Toner Bottle Before Previ- 005 Copy Count:Tone...

  • Page 245: Sp8Xxx: Data Log 2

    5. Service Tables Engine RPGL FONT3 Finisher Factory Bank (PTU) RTIFF Net File Printer PCXL Test Suite HDD Format Optio MSIS Bluetooth MSIS(OPTION) Web System RPCS SDK1 BMLinks SDK2 RPDL FONT SDK3 FONT1 SP8XXX: Data Log 2 The SPs in this group are prefixed with a letter that indicates the mode of operation. The mode of operation is referred to as an ‘application’.
  • Page 246 Service Program Mode Tables Group 8 SP codes are limited to 17 characters, forced by the necessity of displaying them on the small LCDs of printers and faxes that also use these SPs. Read over the list of abbreviations below and refer to it again if you see the name of an SP that you do not understand.
  • Page 247 5. Service Tables Abbreviation What It Means GenCopy Generation Copy Mode Get Print Counter. For jobs 10 pages or less, this counter does not count up. For jobs larger than 10 pages, this counter counts up by the number that is in excess of 10 (e.g., for an 11-page job, the counter counts up 11-10 =1) IFax Internet Fax...
  • Page 248 Service Program Mode Tables Abbreviation What It Means Red (Toner Remaining). Applies to the wide format model A2 only. This machine is under development and currently not available. Resolution Service Code (Error SC code displayed) Scan Sim, Simplex Simplex, printing on 1 side. S-to-Email Scan-to-E-mail SMC report printed with SP5990.
  • Page 249 5. Service Tables • When an image received from Palm 2 is received and stored, the L: counter increments. 8021 T:Pjob/LS These SPs reveal how files printed from the document server were stored on the document server originally. 8024 P:Pjob/LS [0~9999999/ 0 / 1] 8027 O:Pjob/LS...
  • Page 250 Service Program Mode Tables Number of jobs started in Booklet mode. If the machine is in staple mode, the Staple 806x 4 Booklet counter also increments. Number of jobs started In any mode other than the Booklet mode and set for folding 806x 5 Z-Fold (Z-fold).
  • Page 251 5. Service Tables 8381 T:Total PrtPGS These SPs count the number of pages printed by the cus- tomer. The counter for the application used for storing 8384 P:Total PrtPGS the pages increments. [0~9999999/ 0 / 1] The L: counter counts the number of pages stored from 8387 O:Total PrtPGS within the document server mode screen at the operation...
  • Page 252 Service Program Mode Tables O:PrtPGS/Dup Comb [0~9999999/ 0 / 1] 8427 These SPs count by binding and combine, and n-Up settings the number of pages processed for printing by Other applications 842x 1 Simplex> Duplex 842x 4 Simplex Combine 842x 5 Duplex Combine 842x 6 2>...
  • Page 253 5. Service Tables The number of pages printed in series (one side) or printed as a book 843x 2 Series/Book with booklet right/left pagination. The number of pages printed where stamps were applied, including 843x 3 User Stamp page numbering and date stamping. T:PrtPGS/Ppr Size [0~9999999/ 0 / 1] 8441...
  • Page 254 Service Program Mode Tables PrtPGS/Ppr Tray [0~9999999/ 0 / 1] 8451 These SPs count the number of sheets fed from each paper feed station. 001 Bypass Tray Bypass Tray 002 Tray 1 Main Machine 003 Tray 2 Main Machine 004 Tray 3 Paper Tray Unit (Option) 005 Tray 4 Paper Tray Unit (Option)
  • Page 255 5. Service Tables 846x 6 Thick (Back) 846x 7 OHP 846x 8 Other PrtPGS/Mag [0~9999999/ 0 / 1] 8471 These SPs count by magnification rate the number of pages printed. (The magnification settings are done in the printer driver.) 001 ~49% 002 50%~99% 003 100% 004 101%~200%...
  • Page 256 Service Program Mode Tables P:PrtPGS/Emul [0~9999999/ 0 / 1] 8514 These SPs count by printer emulation mode the total number of pages printed. 001 RPCS 002 RPDL 003 PS3 004 R98 005 R16 006 GL/GL2 007 R55 008 RTIFF 009 PDF 010 PCL5e/5c 011 PCL XL 012 IPDL-C...
  • Page 257 5. Service Tables 852x 4 Booklet 852x 5 Z-Fold 852x 6 Punch 852x 7 Other • If stapling is selected for finishing and the stack is too large for stapling, the unstapled pages are still counted. • The counts for staple finishing are based on output to the staple tray, so jam recoveries are counted. This SP counts the number of staples used by the machine.
  • Page 258 Service Program Mode Tables Pixel Coverage Ratio 8781 This SP displays the count for the number of toner bottles used. The count is done based on the assumption that one toner bottle yields about 1,000 printed pages. Toner Remain [0~100/ 0 / 1] This SP displays (as a percentage) the amount of toner remaining.
  • Page 259 5. Service Tables 8921 Dot Coverage Count Total These counters count the percentage of dot coverage for K toner. (This machine uses only black toner) 001 Coverage (%):BK 002 Coverage/P:BK Machine Status [0~9999999/ 0 / 1] These SPs count the amount of time the machine spends in each operation mode. These SPs 8941 are useful for customers who need to investigate machine operation for improvement in their compliance with ISO Standards.
  • Page 260 Service Program Mode Tables 013 Duplex (SP8411 001) Total output of duplexed sheets. 015 Cvg:BW% (SP8601 001) Total output of K pages. Cvg:BW Pages (SP8601 Total output of K pages. 011)

  • Page 261: Test Pattern Printing

    5. Service Tables Test Pattern Printing Test pattern printing is a two-step operation. First, you must do SP2902 to select the pattern that you want to print. If you select any pattern other than "0:None" under SP2902, this sets the printer in the Test Pattern Print mode.

  • Page 262: Printing The Test Pattern

    Test Pattern Printing Press  to display “Test T Pattern” SP2902 Print T Pattern Press [#Enter]. <Print Pattern> *0:None • The asterisk (*) shows the current selection. Press  to display the name of the pattern that you want to print. <Print Pattern>...

  • Page 263: Sp2902-03 Printing Test Patterns

    5. Service Tables SP5990>> Print Mode Push  [#Enter]. SP5990-001 All Data List Push  to select "Diagnostic Report". SP5990-005 Diagnostic Repor Push [#Enter]. Diagnostic Repor ex- ecute? Push [#Enter] to print the pattern. Diagnostic Repor Processing… You can repeat this procedure for as many test prints as you need. •...
  • Page 264 Test Pattern Printing Test Pattern Test Pattern 5:Grid Pat. 1 19:Grayscale (H) 6:Ind. Pat. 1 20:Grayscale (V) 7:Ind. Pat. 2 21:Grayscale (VH) 8:Full Dot Pat. 22:Grayscale-Gr 9:Black Band 23:Grayscale HM 10:Trim Area 24:Grayscalel VM 11:Argyle Pat. 25:Grayscale VHM 12:Hound's Tooth 26:White Pat.

  • Page 265: Input Check

    5. Service Tables Input Check Enter the SP mode and select SP5803. Press  together (for 5 seconds), release, then press [#Enter]. System Ver.1.00 1. Service Press . System Ver. 1.00 2. Engine Press [#Enter]. <Engine> 1. Feed Press  to display “5. Mode”. <Engine>...
  • Page 266 Input Check Full Exit Tray 2 (7)00001010(0) 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 267 5. Service Tables Reading Number Description Cover Open Cover closed Cover opened Registration Sensor Paper detected Paper not detected Duplex reverse path door Closed Open Paper End Sensor Paper detected Paper not detected Not used — — Paper Size Sensor 4 - By-pass Activated Deactivated SP5803-004...
  • Page 268 Input Check Reading Number Description Fusing Unit Detected Not detected Total Counter Not detected Detected Key Counter Detected Not detected Key Card Present Detected Not detected Front cover/open closed Open Closed Vertical feed path Clear Not clear Paper not at up- 2nd Tray Lift Sensor Paper at upper limit per limit...
  • Page 269 5. Service Tables Reading Number Description Right cover open/closed Closed Open 1-Bin Unit Set Detected Not detected LD, H.P. sensor Positioned Not positioned Exit Sensor (Jam) Paper detected Paper not detected Entrance Sensor (Jam) Paper detected Paper not detected Paper End Sensor Paper detected Paper not detected Duplex Unit Switch...
  • Page 270 Input Check Reading Number Description Not used Not full or no tray Full Not used Not full or no tray Full Not used — — Not used Not full or no tray Full SP5803-012 Full Exit Tray 1 Finisher: Shift Tray Not full or no tray Full Not used...

  • Page 271: Output Check

    5. Service Tables Output Check • Motors keep turning in this mode regardless of upper or lower limit sensor signals. To prevent me- chanical or electrical damage, do not keep an electrical component on for a long time. Enter the SP mode and select SP5804. Press ...
  • Page 272 Output Check Fuser Exit Motor Press [#Enter]. <Fuser Exit Motor> Press [#Enter] to switch the component on, then press [#Enter] to switch it off. Fuser Exit Motor Fuser Exit Motor Press [Escape], then repeat Steps 8 to 11 to check other items. When you are finished, press [Escape] until you see “2.Engine”, then select “3.End”.
  • Page 273 5. Service Tables Operation Panel More Detail Bank Motor Bank Motor Paper Tray Unit Fuser Exit Motor Fusing/Exit Motor Main Motor Main Motor DuplexTransportM Duplex Transport (Motor) DuplexInv(back) Duplex Inverter Motor – Reverse DuplexInv(forward) Duplex Inverter Motor – Forward Developer Motor Development Motor Bank Relay Cl.
  • Page 274 Output Check Operation Panel More Detail ID Sensor LED ID Sensor LED ExhaustFanMotor Exhaust Fan Motor CoolingFanMotor Cooling Fan Motor Relay Fan Motor Bridge Unit Fan Motor Total Counter Total Counter Not Used. PatLigh(Red) PatLigh(Green) Japan Only PatLigh(Buzzer) ShiftLiftMotor Shift Lift Motor - Finisher Jogger Motor Jogger Motor - Finisher StaplerUnitMotor...

  • Page 275: Memory Clear: Sp5801

    5. Service Tables Memory Clear: SP5801 Executing Memory Clear resets all the settings stored in the NVRAM to their default settings, except the following: SP5811-1: Machine serial number SP5907: Plug & Play Brand Name and Production Name Setting • This procedure restores all SP code settings to their factory default settings. •...
  • Page 276 Memory Clear: SP5801 Item What It Initializes Network Control Service. IP addresses, SmartNetMonitor for 011 NCS Admin., Web Status Monitor settings, TELNET settings 014 DCS Setting DCS (Delivery Control Service) settings 015 Clean UCS Settings User Information Control Service) settings MIRS Settings Machine Information Report Service settings Certification and Charge-control Service settings.

  • Page 277: Smc Report

    5. Service Tables SMC Report To enter the SP mode, push and hold down  for 5 sec. then push [#Enter]. <Engine> 1.Feed Press  or  until you see “5.Mode”. <Engine> 5.Mode Press [#Enter]. SP5024 mm/inch Display Press  to select SP5990. SP5990 >>...
  • Page 278 SMC Report <SP Mode Data L execute? Press [#Enter]. <SP Mode Data L Processing The report prints. Repeat from Step 6 to select and print any other report.

  • Page 279: Updating The Firmware

    Insert the SD card [B] that contains the firmware in SD card slot C3. Turn on the machine. RICOH Aficio SP 8100 DN Wait about 60 sec. for the ‘Power’, ‘Error’, and ‘Data In’ LEDs on the operation panel to light, and for the first module selection to appear.

  • Page 280: Reviewing The Module Statuses

    Updating the Firmware Reviewing the Module Statuses With the machine in the firmware update mode, follow this procedure to review the status of the firmware modules. Web Support Push [Menu] to display the name of the first module. ROM : G1475933 NEW: G1475933 •...
  • Page 281 5. Service Tables Set the machine in the firmware update mode. (See "Setting the Machine in the Firmware Update Mode" above.) Web Support Push  or  to select the module that you want to update (Web Support, Network Support, Onboard Sys, Onboard Prn, Engine, or NetworkDocBox).

  • Page 282: Printing The Self-Diagnosis Report

    Updating the Firmware If firmware update does not complete successfully, try to update it again. If firmware update always fails, replace the controller board. Turn the machine off. If you are finished, remove the SD card from the slot and turn the machine on. -or- If you need to update another module, leave the SD card in place, turn the machine on again and repeat this procedure from Step 1.
  • Page 283 5. Service Tables SP5990-001 All (Data List) Push  three times to select SP5990-005 then push [#Enter]. <Diagnostic Repo execute? Push [#Enter] to print the report. The firmware module names and version numbers are listed in the report. The actual numbers will be different for your installation. Name/Ver.
  • Page 284 Updating the Firmware Name/Ver. No. in Report Module Name on Op- eration Panel Name (Sample) Ver. No. (Sample) NetworkDocBox G1475934 1.02...

  • Page 285: Uploading/Downloading Nvram Data

    5. Service Tables Uploading/Downloading NVRAM data The content of the NVRAM can be uploaded to and downloaded from an SD card. Uploading NVRAM Data Turn off the power switch. Remove the SD card cover [A]. Insert the SD card [B] into SD card slot C3. Turn on the machine.

  • Page 286: Downloading Nvram Data

    Uploading/Downloading NVRAM data result = OK Remove the SD card. Switch the machine off and on. Downloading NVRAM Data The following data are not downloaded from the SD card: • C/O, P/O Counter (SP7-006-** C/O, P/O Count Display) • Duplex, A3/DLT/Over 420 mm. Turn off the machine.
  • Page 287 5. Service Tables <NVRAMDownload> Processing <NVRAMDownload> result = OK Remove the SD card. Switch the machine off and on. • If the SD card is not installed properly, a message will tell you that downloading cannot proceed. • If the correct SD card for the NVRAM data is not inserted in the SD card slot, after you press [#Enter] a message will tell you that downloading cannot proceed.

  • Page 288: Self-Diagnostic Mode

    Self-Diagnostic Mode Self-Diagnostic Mode 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. The self-diagnostic test follows the path of the flow chart shown below and checks the CPU, memory, HDD, and so on.

  • Page 289: Self-Diagnostic Test Flow

    5. Service Tables Self-Diagnostic Test Flow...

  • Page 290: Detailed Self-Diagnostic Mode

    Self-Diagnostic Mode 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 291: Dip Switches

    5. Service Tables DIP Switches Controller: DIP SW2 DIP SW No. SD Card 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 OFF (Do not change)

  • Page 292: Using Debug Log

    Using Debug Log Using Debug Log This machine provides a debug log feature that allows the service technician to save and retrieve error information for analysis. Every time an error occurs, debug information is recorded in RAM but this information is lost when the machine is switched off and on.

  • Page 293: To Select The Target For The Debug Log File

    5. Service Tables Push [#Enter]. <On/Off> Push [Esc]. SP5857-001 On/Off Do the next procedure to select the target. To Select the Target for the Debug Log File You can select either the HDD (default) or the SD card as the target. This procedure shows you how to select the SD card.

  • Page 294: To Select Events

    Using Debug Log Do the next procedure to select the events that you want to record in the debug log file. To Select Events Push . SP5858 >> DebugSaveWhen Push [#Enter]. SP5858-001 EngineSC Error Here is a list of the events that you can select. Any number of events can be selected. SP No.
  • Page 295 5. Service Tables <EngineSC Error> Push [#Enter]. <EngineSC Error> Push [Esc]. SP5858-001 EngineSC Error Repeat this procedure to select either 002 or 004. - Example 2: To set an SC code with 003 - This example shows you how to enter "672" for SC672. •...

  • Page 296: To Select One Or More Memory Modules For Recording In The Debug Log File

    Using Debug Log 0000002 Push  or  to move the cursor to the next digit. . 0000002 Repeat Steps 2 to 6 to enter the "7". . 0000072 Repeat Steps 2 to 6 to enter the "6". . 0000672 Push [Esc] twice.
  • Page 297 5. Service Tables • The default settings for Keys 1 to 10 are all zero (“0”). Select the number from the table below, then use these key presses to enter the number. 0002222 Key Press What It Does  or  Moves the cursor to select the digit in the line above.

  • Page 298: Retrieving The Debug Log From The Hdd

    Enter the SP mode and execute SP5857 009 (HDD for SD (4MB)) to write the debugging data to the SD card. Use a card reader to copy the file and send it for analysis to your local Ricoh representative by email, or just send the SD card by mail.

  • Page 299: More About Debug Log

    5. Service Tables More About Debug Log SP5857-015: SD to SD (Any) This SP copies the log on an SD card (the file that contains the information written directly from shared memory) to a log specified by key number. The copy operation is executed in the log directory of the SD card inserted in the same slot.

  • Page 300: Details

    6. Details Machine Overview Component Layout Exit Roller By-pass Paper End Sensor Paper Exit Sensor By-pass Paper Feed Roller Hot Roller By-pass Separation Roller Entrance Sensor Upper Relay Roller Inverter Gate Feed Roller Inverter Roller Separation Roller Pressure Roller Pick-up Roller...

  • Page 301: Paper Path

    6. Details Transfer Belt Cleaning Blade Bottom Plate Upper Transport Roller Development Unit Transfer Belt Charge Roller OPC Drum Fθ Mirror Registration Roller Barrel Toroidal Lens (BTL) Lower Transport Roller Polygonal Mirror Motor Duplex Exit Sensor Laser Unit By-pass Tray Toner Bottle Holder By-pass Pick-up Roller Exit Junction Gate...

  • Page 302: Drive Layout

    Machine Overview Large Capacity Tray (LCT) Paper tray unit Two-Tray Finisher Bridge unit Drive Layout Transfer Belt Contact Clutch Paper Feed/Development Motor Registration Clutch Development Clutch Upper Paper Feed Clutch Main Motor Lower Paper Feed Clutch Fusing/Exit Motor Relay Clutch...
  • Page 303 6. Details In this machine, the development unit is provided with its own motor, separate from the main motor.

  • Page 304: Board Layout

    Board Layout Board Layout Board Block Diagram This machine employs the GW (Grand Workware) architecture, which allows the printer to be expanded by installing simple modular components (ROM DIMMs) in the controller board or installing optional boards in the two controller board slots. Here is a brief summary of the boards and their functions.
  • Page 305 6. Details • IEEE1284 (Centronics) • IEEE802.11b (Wireless LAN) • Gigabit Ethernet Board 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 printer system and ac power to the fusing lamp.

  • Page 306: Controller Block Diagram

    Board Layout Controller Block Diagram...
  • Page 307 6. Details The controller controls all applications. To add the optional applications, an SD card must be inserted in the SD card slot of the controller. Trumpet ASIC: Contains the dedicated GW controller chips of the shared resources (the CPU, memory, and HDD hardware) for the printing function.
  • Page 308 Board Layout At Power Max. Max. Item Space Files Pages Job Log Job log data 10 MB Saved Swap, Log Swap, debug, debug log 364 MB Saved Used by SDK applications 1 GB Saved 10000 SDK Log SDK log data 200 MB Saved ROM Update Data...

  • Page 309: Printing Process Overview

    6. Details Printing Process Overview Drum Charge The charge roller [1] 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 [2], which form an electrostatic latent image on the drum surface.
  • Page 310 Printing Process Overview Separation Paper separates from the drum as a result of the electrical attraction between the paper and the transfer belt. Pick-off pawls [5] help separate the paper from the drum. ID Sensor The ID sensor [6] measures the reflectivity of the pattern formed by the laser on the surface of the drum. This output signal is used for toner supply control and also measures the drum surface reflectivity, which is used for charge roller voltage control.

  • Page 311: Laser Exposure

    6. Details Laser Exposure Laser Exposure Overview LD unit Synchronization detector Cylindrical lens BTL (Barrel Toroidal Lens) Polygonal mirror F-theta mirror Shield glass Toner shield glass Mirror This machine uses two laser diodes to produce electrostatic images on an OPC drum. The laser diode unit converts image data from the BICU board into laser pulses, and the optical components direct these pulses to the drum.

  • Page 312: Auto Power Control (Apc)

    Laser Exposure Each surface of the polygon mirror reflects two full main scan lines. The laser beams go to the F-theta mirror, mirror, and BTL (barrel toroidal lens). Then these laser beams go to the drum through the toner shield glass. The laser synchronization detector determines the main scan starting position.

  • Page 313: Laser Beam Pitch Change Mechanism

    6. Details polygon motor rotation speed, reduces noise generated by the polygon motor, and reduces the frequency of the image data clock. The two laser beams follow the path: collimating lenses [C] > prism [D] >polygon mirror [E]. The two laser beams arrive on the drum surface about 2 mm apart in the main scan direction and about 0.06 mm apart (at 400 dpi) in the sub scan direction.

  • Page 314: Ld Safety Switches

    Laser Exposure Both LD unit positions are at fixed distances from the LD unit home position sensor [D]. Usually, the LD unit moves directly to the proper position. However, when the number of times that the resolution has changed reaches the value of SP2109 05, the LD unit moves to the home position, and this re-calibrates the LD unit positioning mechanism.

  • Page 315: Photoconductor Unit (Pcdu)

    6. Details Photoconductor Unit (PCDU) Overview of the PCDU Toner Collection Coil Transfer Entrance Guide Toner Collection Plate Charge Roller Spur Brush Roller Pick off Pawl Cleaning Blade OPC Drum (φ60 mm)

  • Page 316: Drum Drive Mechanism

    Photoconductor Unit (PCDU) Drum 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 317: Drum Toner Seals

    6. Details Drum Toner Seals Seals have been added to the structure of the PCU (photoconductor unit) to further prevent toner leakage. New PCDU Unit Detection New Unit Detection Mechanism This printer uses a push-switch to trigger the initialization of a new PCU.
  • Page 318 Photoconductor Unit (PCDU) When the PCU is removed from the maintenance kit, the trip lever is in the down position [1]. After the new PCU is installed in the machine, the trip lever is forced into the up position [2]. This triggers the initialization procedure shown below (Please refer to the flow chart below, "What Happens When a New Unit Is Detected".) This event is triggered only once after the new PCU is installed.

  • Page 319: What Happens When A New Unit Is Detected

    6. Details What Happens When a New Unit Is Detected...

  • Page 320: Drum Charge

    Drum Charge Drum Charge Overview of Drum Charge 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 –800 V.

  • Page 321: Charge Roller Voltage Correction

    6. Details Charge Roller Voltage Correction Correction for Environmental Conditions The voltage transferred from roller to drum could vary with the temperature and humidity around the drum charge roller. The lower the temperature or humidity, the higher the applied voltage required. The ID sensor measures the effects of ambient conditions, and any small change in drum potential caused by changes in temperature/humidity is reflected in the amount of toner transferred to the drum.

  • Page 322: Correction For Paper Width And Thickness (By-Pass Tray Only)

    Drum Charge transfers to the drum. The ID sensor measures the density of pattern [B], and Vsdp, the output voltage, is compared with Vsg which was read from the bare drum at the same time. 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.
  • Page 323 6. Details • After 100 prints • After 200 prints After 10 prints 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 324: Drum Charge Roller Cleaning

    Drum Charge Drum Charge Roller Cleaning The drum charge roller [A] (always in contact with the drum) becomes dirty easily. The brush roller [B] remains in contact with the charger roller to clean the charge roller.

  • Page 325: Development

    6. Details Development Overview of Development Drum Mixing Auger Development Roller Development Filter Paddle Roller Doctor Blade TD Sensor...

  • Page 326: Drive Mechanism

    Development 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 327: Development Bias

    6. Details The outer paddle moves developer to the front Ê and supplies it to the development roller. Developer that spills off by the doctor blade Ë passes through the holes [C] in the outer paddle, and is transported to the rear Ì...
  • Page 328 Development SP Mode SP Name SP2201-01 Developer Bias – Image Dev. Bias Default: -540 V SP2309-01 Paper Lower Width [a] Width limit. Default: 150 mm SP2309-02 Paper Upper Width [b] Width limit. Default: 216 mm SP2914-03 Process Ctrl Set – B gamma Adjust 10 V/step.

  • Page 329: Toner Supply

    6. Details Toner Supply Toner Bottle Replenishment Mechanism 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 330: Toner Supply Mechanism

    Development Toner Supply Mechanism The toner supply motor [A] rotates the toner bottle [B] and the mylar blades [C]. 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]. The toner falls into the development unit through the slit. Toner Density Control There are two modes for controlling and maintaining constant toner supply: sensor control (both direct and indirect) and image pixel count control.

  • Page 331: Sensor Control Mode

    6. Details • The factory setting is sensor control mode. Image pixel count mode should only be used temporarily until a defective TD or ID sensor can be replaced. Sensor Control Mode In the sensor control mode, the amount of toner required to print the page is calculated by the CPU. The CPU adds up the image data value of each pixel and converts the sum to a value between 0 and 255.

  • Page 332: Toner Near End/End Detection

    Development changed over to image pixel count mode with SP2208-01 (Toner Supply Mode) remain in effect and cannot be changed. Toner Near End/End Detection Standard Method for Toner Near-End/End Condition Detection The toner near-end condition is detected based on the Vt(10) output from the TD sensor. •...

  • Page 333: Toner Supply With Abnormal Sensors

    6. Details The machine detects the toner concentration using Vref, Vt (10), Vtp, and Vtp1. If the toner concentration is still too low, the toner supply motor remains on for another 10 seconds while the machine checks Vt. If toner concentration is judged to be at the standard level, then the toner near end/end condition is cancelled and K (toner supply coefficient) is reset.

  • Page 334: Drum Cleaning And Toner Recycling

    Drum Cleaning and Toner Recycling Drum Cleaning and Toner Recycling 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 excess toner to the toner collection plate [C].

  • Page 335: Toner Recycling

    6. Details Toner Recycling Toner collected by the toner collection coil [A] is transported to the opening [B]. This toner falls into the development unit with new toner coming from the toner bottle. The paddle roller [C] mixes the collected toner with the new toner.

  • Page 336: Paper Feed

    Paper Feed Paper Feed Overview of Paper Feed Upper pick-up roller Lower paper feed roller Upper paper height sensor Lower separation roller Upper paper feed roller Lower paper height sensor Upper relay sensor Lower pick-up roller Upper relay roller Lower paper size dial Upper separation roller Lower paper size switch Lower relay sensor...

  • Page 337: Paper Feed Drive

    6. Details 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 338: Paper Lift

    Paper Feed When the paper tray is set into the machine, it pushes the release lever [E]. This causes the pick-up roller [D] to go down and the separation roller [B] to move up and contact the paper feed roller. Paper Lift The paper size switch [1] detects when the paper tray [2] is set in the machine, and the tray lift motor [3] rotates, and the coupling gear [4] on the tray lift motor engages the pin [5] on the lift arm shaft [6].

  • Page 339: Paper End Detection

    6. Details When the paper tray is set in the machine, the pick-up roller [9] lowers. When the top sheet of paper reaches the proper height for paper feed, the paper pushes up the pick-up roller, and the actuator [10] on the pick-up roller supporter activates the paper height sensor [11] to stop the tray lift motor.

  • Page 340: Paper Registration

    Paper Feed 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. Paper Registration The registration drive roller [A] and idle roller [B] correct the skew of the paper to ensure that the leading edge of the paper is positioned correctly at the drum.

  • Page 341: Paper Height Detection

    6. Details 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. The CPU disables paper feed from a tray if the paper size cannot be detected. If the paper size actuator is broken, or if there is no tray installed, the printer control board recognizes that the paper tray is not installed.
  • Page 342 Paper Feed 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. The following combinations of sensor signals are sent to the printer controller. Amount of Paper Paper Height Sensor [A] Paper Height Sensor [B]...

  • Page 343: By-Pass Tray

    6. Details By-Pass Tray Overview of By-Pass Tray Paper feed roller Paper end sensor Pick-up roller By-pass tray Separation roller...

  • Page 344: By-Pass Tray Operation

    By-Pass Tray By-Pass Tray Operation 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 345: By-Pass Paper Size Detection

    6. Details By-Pass Paper Size Detection 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. Therefore, the machine determines which paper has been placed in the by-pass tray by the signal output from the board.

  • Page 346: Duplex Unit

    Duplex Unit Duplex Unit Overview of Duplex Unit Entrance sensor Upper transport roller Inverter gate Lower transport roller Inverter roller Exit sensor...

  • Page 347: Duplex Drive Layout

    6. Details Duplex Drive Layout Inverter roller Transport motor Inverter motor Lower transport roller Upper transport roller Duplex Basic Operation To increase the productivity of the duplex unit, copies are printed as follows. Paper Length Longer than A4/LT SEF The duplex unit can store only one sheet of copy paper. - Example: 8 pages - The number [A] in the illustration shows the order of pages.

  • Page 348: Paper Length Up To A4/Lt Sef

    Duplex Unit Paper Length Up to A4/LT SEF The duplex unit can store two sheets of copy 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 copy paper (if shaded, this indicates the second side).

  • Page 349: Duplex Unit Feed In And Exit Mechanism

    6. Details Duplex Unit Feed In and Exit Mechanism Paper Feed into Duplexer 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]. • 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 350: Paper Inversion And Exit From Duplexer

    Duplex Unit Paper Inversion and Exit from Duplexer The inverter gate solenoid turns on and the inverter motor turns on in reverse shortly after the trailing edge of the paper passes through the entrance sensor [D]. As a result, the inverter gate [E] is opened and the inverter roller rotates counterclockwise.

  • Page 351: Image Transfer And Paper Separation

    6. Details Image Transfer and Paper Separation Overview of Transfer and Separation Transfer belt Drive roller Pick-off pawls Transfer belt cleaning blade ID sensor Transfer roller Contact lever Idle roller Transfer belt contact clutch/cam...

  • Page 352: Transfer Belt Drive Mechanism

    Image Transfer and Paper Separation Transfer 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 353: Transfer Belt Unit Contact Mechanism

    6. Details Transfer Belt Unit Contact Mechanism The belt contact and release mechanism consists of the belt contact clutch [A], cam [B], and contact lever [C]. The belt contact clutch turns on and the cam attached to the clutch rotates half a complete rotation. The contact lever, riding on the cam, is lifted up and the springs [D] push the belt into contact with the drum.

  • Page 354: Image Transfer And Paper Separation Mechanism

    Image Transfer and Paper Separation 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 355 6. Details At the designated time after the main motor switches on, the transfer belt contact clutch switches on and the transfer belt touches the drum at [D]. When the paper enters the gap between the belt and the drum, the high voltage supply board [E] applies a high positive current to the belt to transfer the image to the paper.

  • Page 356: Transfer Belt Charge

    Image Transfer and Paper Separation Transfer Belt Charge Transfer Belt Charge Mechanism 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 357: Currents Applied To Leading Edge, Image Areas, And By-Pass Feed

    6. Details tendency of the current to flow directly from the transfer belt to the drum and not through the paper which could cause an insufficient amount of toner to transfer to narrow width paper. Thick paper must be fed from the by-pass tray because SP modes are available only for the by-pass tray in order to accommodate thick paper.

  • Page 358: Transfer Belt Cleaning Mechanism

    Image Transfer and Paper Separation Switch Timing (from leading edge to SP2-911-2 image area current SP2-911-3 Off Timing (at trailing edge) Transfer Belt Cleaning Mechanism The cleaning blade [A], always in contact with the transfer belt, scrapes off toner and paper dust remaining on the transfer belt.

  • Page 359: Image Fusing And Paper Exit

    6. Details Image Fusing and Paper Exit Overview Image Fusing and Paper Exit Paper exit sensor Cleaning roller De-curler rollers Entrance guide Junction gate Fusing lamp (center) Idle roller (duplex unit) Fusing lamp (ends) Fusing unit exit sensor Thermistors (center/end) Spring Thermostats (center/end) Fusing exit guide plate...

  • Page 360: Fusing Drive

    Image Fusing and Paper Exit Fusing Drive The fusing exit motor [A] drives the fusing unit through the gears [B] and also drives the paper exit rollers [C] through a gear and a timing belt [D]. Fusing Drive Release Mechanism...

  • Page 361: Fusing Entrance Guide Shift Mechanism

    6. Details The fusing unit drive release mechanism automatically disengages the fusing unit drive gear [A] when the right door [B] is opened. When the right cover is opened, the actuator plate [C] pulls release wire [D]. The wire pulls the fusing drive gear bracket [E] and the fusing unit drive is disengaged.

  • Page 362: Exit Guide Plate And De-Curler Rollers

    Image Fusing and Paper Exit 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. Two de-curler rollers [B] and [C] have been added under the exit roller [D] to correct the curl that paper acquires during transport through the fusing unit.

  • Page 363: Cleaning Mechanism

    6. Details the normal setting, and the right position [E] increases the pressure to prevent insufficient fusing by the fusing unit. Cleaning Mechanism The cleaning roller [A], in constant contact with the pressure roller [B], collects toner and paper dust from the surface of the pressure roller.

  • Page 364: Fusing Temperature Control

    Image Fusing and Paper Exit The fusing unit has two fusing lamps: the first fusing lamp (center: 650W) [A] heats the center of the fusing roller, and the second fusing lamp (ends: 550W) [B] heats both ends of the hot roller. This arrangement ensures even heat on all surfaces of the roller.

  • Page 365: Fusing Idling Temperature

    6. Details Fusing Idling Temperature If copies are not sufficiently fused soon after the 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. The re- load temperature can be adjusted with SP1105-05, 06.

  • Page 366: Energy Save Mode

    Energy Save Mode Energy Save 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: [Menu]>...
  • Page 367 6. Details...

  • Page 368: Specifications

    7. Specifications Printer Printer Hardware 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 Printing Speed By Paper Size A3/DLT 22 ppm 27 ppm 30 ppm A4/LT LEF 45 ppm...
  • Page 369 7. Specifications Drum Charge: Charge roller system Drum Cleaning: Counter blade (x1) Drum Quenching: QL LED Fusing Method: Hot roller (fusing lamps x 2), pressure roller Exposure Method: Dual laser beam system PCU (PCDU) Combined unit (PCU + Development Unit) Development Method: Dual component toner using 1-step SLIC development method (with toner recycling)

  • Page 370: Supported Paper Sizes

    Printer Bypass tray open 850 x 650 mm (33.5 x 25.6 in.) Bypass tray support extended 980 x 650 mm (38.6 x 25.6 in.) Temperature: Operating: 10°~32°C (50°~89.6°F), 15%~80% rH (no condensation) Storage: 30°C ~ 40°C (22°~104°F), less than 80% rH (no condensation) Weight: Less than 63 kg (138.9 lb.) Warm-up Time:...
  • Page 371 7. Specifications Paper Tray Unit By-pass Tray Duplex Name Feed Size (W x L) 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 128 x 182 mm 182 x 128 mm 105 x 148 mm...

  • Page 372: Software Accessories

    Printer Paper Tray Unit By-pass Tray Duplex Name Feed Size (W x L) Com10 Monarch 3.875 x 7.5 in. 114 x 162 mm 162 x 229 mm DL Env. 110 x 220 mm Custom 100 ~ 297 mm Custom 148 ~ 432 mm •...

  • Page 373: Utility Software

    7. Specifications • Windows NT 4.0 printer drivers are for the Intel x 86 platform. There is no Windows NT 4.0 printer driver for the PowerPC, Alpha, or MIPS platforms. • PS3 drivers are all genuine Adobe PostScript drivers, excluding Windows 2000 which uses Microsoft PS.

  • Page 374: System Configuration

    Printer System Configuration Item Machine Code Printer G147 LCIT RT45 B543 Paper Feed Unit PB 3020 G839 Finisher 3000 SR 3040 G838 Punch Unit Kit Type 1045 B377* Bridge Unit Type 2045* B538 HDD (option) G841 Memory Unit Type D, E B584 (128 MB), G818 (256 MB) *1: 2/3-hole, 2/4-hole, 4-hole *2: The Bridge Unit is required for the Finisher 3000.

  • Page 375: Installable Option Table

    7. Specifications Installable Option Table Option Comment Bridge Unit Type 2045 (B538) Required for Finisher 3000 (G838) Finisher 3000 SR 3040 (B838) Requires Bridge Unit (B538) LCIT RT45 (B543) Requires Paper Feed Unit G839 Paper Feed Unit PB 3020 (G839) Required for LCIT RT45 (B543) Please refer to the next section for more details about specifications for these options.

  • Page 376: Option Specifications

    Option Specifications Option Specifications Bridge Unit Type 2045 (B538) Paper Size Standard: A6 Lengthwise (SEF) to A3, HLT to DLT Width: 100 to 305 mm Non-Standard: Length: 148 to 432 mm Paper Weight: 52 g/m ~ 135 g/m (16 lb. ~ 42 lb.) Finisher 3000 SR3040 (G838) Upper Tray Lower Tray...

  • Page 377: Lcit Rt45 (B543)

    7. Specifications A4, LT SEF 15~20 30~100 2~14 A4, LT LEF, B5 15~20 15~50 2~14 Other Sizes 15~30 25~50 2~14 Staple Limit A4, LT, smaller 30 sheets 50 sheets Larger than A4, LT 30 sheets Staple Position 1 staple, 3 positions (front, rear, rear-oblique) Staple Supply 5000-staple cartridges Power Source...

  • Page 378: Paper Feed Unit Pb3020 (G839)

    Option Specifications Paper Feed Unit PB3020 (G839) Paper Size: A5 lengthwise (SEF) to A3 HLT lengthwise (SEF) to DLT Paper Weight: 64 g/m ~ 105 g/m (20 lb. ~ 28 lb.) Tray Capacity: 1100 sheets (550 x 2) (80 g/m , 20 lb.
  • Page 379 MEMO...
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