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U-P1
Service manual
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MB U-P1 Service manual

Model U-P1
(Machine Code: G071)
SERVICE MANUAL

!IMPORTANT SAFETY NOTICES

1. Before disassembling or assembling parts of the printer and peripherals, make sure that the printer power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components.
4. The printer drives some of its components when it completes the warm-up period. Be careful to keep hands aw ay from the mechani cal an d ele ctr i c al components as the printer starts operation.
5. The inside and the metal parts of the fusing unit become extremely hot while the printer is operating. Be careful to avoid touching those components with your bare hands.
HEALTH SAFETY CONDITIONS
Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The printer and its peripherals must be serviced by a customer service representative who has completed the training course on those models.
2. The NVRAM module (op tion) installed on the controller has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations.
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame.
2. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor in ac cordance with local regulations . (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations. When keepi ng used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.
4. When keeping used lith ium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.
!WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
!WARNING
WARNING: Turn off the main switch before attempting any of the
procedures in the Laser Optics Housing Unit section. Laser beams can seriously damage your eyes.
CAUTION MARKING:

Trademarks

Microsoft
®
, Windows®, and MS-DOS® are registered trademarks of Microsoft
Corporation in the United States and /or other countries. PostScript
®
PCL Ethernet PowerPC
®
is a registered trademark of Adobe Systems, Incorporated.
is a registered trademark of Hewlett-Packard Company.
®
is a registered trademark of Xerox Corporation.
®
is a registered trademark of International Business Machines
Corporation. Other product names used herein are for identification purposes only and may be
trademarks of their respective companies. We disclaim any and all rights involved with those marks.

Conventions in this Manual

This manual uses several symbols.
Symbol What it means
☛ Refer to section number
!
"
#
$% &%
See Core Tech Manual for details Screw Connector Clip ring E-ring
Lengthwise, SEF (Short Edge Feed)
Sideways, LEF (Long Edge Feed)

TABLE OF CONTENTS

1. INSTALLA TION...........................................................................1-1
1.1 INSTALLATION REQUIREMENTS...........................................................1-1
1.1.1 ENVIRONMENT .............................................................................. 1-1
1.1.2 MACHINE LEVEL............................................................................ 1-1
1.1.3 SPACE REQUIREMENTS............................................................... 1-2
1.1.4 POWER REQUIREMENTS.............................................................. 1-2
1.2 MACHINE INSTALLATION....................................................................... 1-3
1.3 OPTIONS.................................................................................................. 1-4
1.4 REMARKS FOR INSTALLATION............................................................. 1-5
2. PREVENTIVE MAINTENANCE...................................................2-1
2.1 OVERVIEW .............................................................................................. 2-1
Users Do the User PM Procedures...................................................... 2-1
All PM Done by Technicians................................................................ 2-1
Counters .............................................................................................. 2-1
2.2 USER MAINTENANCE............................................................................. 2-1
Main Unit.............................................................................................. 2-1
Optional Paper Tray Unit...................................................................... 2-2
2.3 SERVICE MAINTENANCE....................................................................... 2-2
Main Unit.............................................................................................. 2-2
Optional Units....................................................................................... 2-3
3. REPLACEMENT AND ADJUSTMENT........................................ 3-1
3.1 SPECIAL TOOLS................................................................................ 3-1
3.2 EXTERIOR COVERS............................................................................... 3-2
3.2.1 REAR COVER................................................................................. 3-2
3.2.2 LOWER LEFT COVER.................................................................... 3-3
3.2.3 UPPER COVER, OPERATION PANEL........................................... 3-3
3.3 ELECTRICAL COMPONENTS................................................................. 3-4
3.3.1 PRINTER CONTROLLER................................................................ 3-4
3.3.2 CONTROLLER BOX........................................................................ 3-4
3.3.3 BCU BOARD.................................................................................... 3-4
3.3.4 I/O BOARD...................................................................................... 3-5
3.3.5 PSU ................................................................................................. 3-5
3.3.6 HIGH VOLTAGE SUPPLY BOARD................................................. 3-6
3.4 DRIVE UNITS........................................................................................... 3-7
3.4.1 DEVELOPMENT CLUTCHES.......................................................... 3-7
K/Y Development Units........................................................................ 3-7
C/M Development Units....................................................................... 3-7
3.4.2 DEVELOPMENT MOTOR................................................................3-8
3.4.3 MAIN MOTOR.................................................................................. 3-8
3.4.4 PCU GEAR BOX AND OPC BELT CLEANING CLUTCH................ 3-9
3.4.5 FUSING UNIT MOTOR.................................................................... 3-9
3.4.6 PAPER FEED MOTOR.................................................................. 3-10
i
3.4.7 PAPER FEED CLUTCH................................................................. 3-10
3.4.8 REGISTRATION CLUTCH............................................................. 3-10
3.5 LASER OPTICS SECTION..................................................................... 3-11
3.5.1 CAUTION DECAL LOCATION....................................................... 3-11
3.5.2 LASER OPTICS HOUSING UNIT.................................................. 3-12
Adjusting for Image Skew .................................................................. 3-14
Laser Beam Pitch Adjustment............................................................ 3-15
3.5.3 POLYGONAL MIRROR MOTOR AND LSD...................................3-16
3.6 DEVELOPMENT UNIT........................................................................... 3-17
3.7 PHOTOCONDUCTOR UNIT (PCU)........................................................ 3-19
3.7.1 MAIN UNIT..................................................................................... 3-19
3.7.2 WASTE TONER BOTTLES........................................................... 3-20
3.7.3 CHARGE CORONA WIRE............................................................. 3-21
3.7.4 CHARGE CORONA WIRE CLEANER MOTOR............................ 3-22
3.7.5 OPC BELT CLEANING UNIT......................................................... 3-22
3.7.6 IMAGE TRANSFER BELT CLEANING UNIT................................. 3-22
3.8 PAPER TRANSFER UNIT...................................................................... 3-23
3.8.1 VERTICAL TRANSPORT UNIT..................................................... 3-23
3.8.2 TRANSFER ROLLER.................................................................... 3-23
Cleaning the Paper Dust Mylar .......................................................... 3-24
3.9 FUSING/PAPER EXIT............................................................................ 3-25
3.9.1 FUSING UNIT................................................................................ 3-25
3.9.2 OIL SUPPLY UNIT......................................................................... 3-25
3.9.3 LAMPS........................................................................................... 3-26
3.9.4 FUSING INNER UNIT.................................................................... 3-27
3.9.5 PRESSURE ROLLER THERMOFUSE.......................................... 3-27
3.9.6 FUSING BELT UNIT AND PRESSURE ROLLER UNIT................ 3-27
3.9.7 PRESSURE ROLLER THERMISTOR........................................... 3-28
3.9.8 HOT ROLLER STRIPPERS........................................................... 3-28
3.9.9 PRESSURE ROLLER .................................................................... 3-29
3.9.10 OIL ABSORBERS........................................................................ 3-30
3.9.11 PAPER EXIT UNIT AND PAPER EXIT/
OVERFLOW SENSOR................................................................ 3-31
3.10 PAPER FEED AND TRANSPORT........................................................3-32
3.10.1 FEED ROLLER AND FRICTION PAD......................................... 3-32
3.10.2 REGISTRATION SENSOR.......................................................... 3-33
3.10.3 PAPER FEED SENSOR.............................................................. 3-35
3.10.4 PAPER NEAR-END SENSOR..................................................... 3-35
3.10.5 PAPER END SENSOR................................................................ 3-35
3.11 BYPASS TRAY..................................................................................... 3-36
3.11.1 PICKUP/FEED ROLLER.............................................................. 3-36
3.11.2 PAPER FEED CLUTCH............................................................... 3-37
3.11.3 REVERSE ROLLER .................................................................... 3-37
4. TROUBLESHOOTING.................................................................4-1
4.1 SERVICE CALL........................................................................................ 4-1
4.1.1 SERVICE CALL CONDITIONS........................................................ 4-1
4.1.2 SC TABLE........................................................................................ 4-2
ii
4.2 CONTROLLER ERROR TABLE............................................................... 4-9
4.3 BLOWN FUSE CONDITIONS................................................................. 4-12
4.4 CHECK POINTS FOR IMAGE PROBLEMS AT REGULAR
INTERVALS............................................................................................ 4-12
5. SERVICE TABLES......................................................................5-1
5.1 SERVICE PROGRAM MODE................................................................... 5-1
5.1.1 OPERATION PANEL KEYS............................................................. 5-1
5.1.2 STARTING SERVICE PROGRAM MODE....................................... 5-2
Procedure 1.......................................................................................... 5-2
Procedure 2.......................................................................................... 5-2
5.1.3 MAIN MENU.................................................................................... 5-2
5.1.4 SPECIFYING A VALUE OR SETTING............................................ 5-3
5.1.5 LEAVING SERVICE MODE............................................................. 5-3
5.2 SP MODE TABLES................................................................................... 5-4
5.2.1 SERVICE (CONTROLLER SERVICE MODES)............................... 5-4
Bit Switch Settings ............................................................................... 5-6
Gamma Adjustment ............................................................................. 5-8
5.2.2 ENGINE SERVICE MODES.......................................................... 5-11
SP1-XXX: (Feed) ............................................................................... 5-11
SP2-XXX: (Drum)............................................................................... 5-15
SP3-XXX: (Process)........................................................................... 5-27
SP5-XXX: (Mode)............................................................................... 5-30
SP7-XXX: (Data Log)......................................................................... 5-38
Input Check Table.............................................................................. 5-46
Table 1: Tray 1 Paper Size ................................................................ 5-49
Table 2: 1st/2nd Bank Paper Size...................................................... 5-49
Table 3: 1st/2nd Bank Near End........................................................ 5-49
Output Check Table........................................................................... 5-50
5.3 CONTROLLER SELF-DIAGNOSTICS.................................................... 5-52
5.3.1 OVERVIEW.................................................................................... 5-52
5.3.2 DETAILED SELF-DIAGNOSTICS.................................................. 5-53
5.4 USER PROGRAM MODE....................................................................... 5-54
5.5 UPGRADING SOFTWARE..................................................................... 5-55
5.5.1 OVERVIEW.................................................................................... 5-55
5.5.2 UPGRADING................................................................................. 5-56
Procedure........................................................................................... 5-56
Error Recovery................................................................................... 5-57
5.6 DIP SWITCHES...................................................................................... 5-58
Controller Board................................................................................. 5-58
BCU Board......................................................................................... 5-58
5.7 PRINTING A TEST PATTERN ............................................................... 5-59
6. DETAILED SECTION DESCRIPTIONS.......................................6-1
6.1 OVERVIEW .............................................................................................. 6-1
6.1.1 MAJOR COMPONENTS.................................................................. 6-1
6.1.2 PAPER PATH.................................................................................. 6-2
6.1.3 DRIVE COMPONENTS................................................................... 6-3
iii
v
6.1.4 ELECTRICAL COMPONENTS........................................................ 6-4
Image Transfer..................................................................................... 6-4
Development Units............................................................................... 6-5
Paper Path........................................................................................... 6-6
Drive Components............................................................................... 6-7
Circuit Boards....................................................................................... 6-8
6.2 PRINTING PROCESS OVERVIEW.......................................................... 6-9
6.3 PROCESS CONTROL............................................................................ 6-11
6.3.1 OVERVIEW.................................................................................... 6-11
6.3.2 PROCESS CONTROL STEPS...................................................... 6-12
Six Steps............................................................................................ 6-12
When is Process Control Done?........................................................ 6-12
6.4 PHOTOCONDUCTOR UNIT (PCU)........................................................ 6-13
6.4.1 OVERVIEW.................................................................................... 6-13
6.4.2 NEW PHOTOCONDUCTOR UNIT DETECTION........................... 6-14
New PCU Sensor............................................................................... 6-14
Mechanism......................................................................................... 6-14
PCU Counter...................................................................................... 6-14
6.4.3 CHARGE CORONA UNIT.............................................................. 6-15
Power Supply..................................................................................... 6-15
Wire Cleaning..................................................................................... 6-15
Cleaning Interval................................................................................ 6-15
Quenching.......................................................................................... 6-16
6.4.4 OPC BELT DRIVE......................................................................... 6-16
6.4.5 OPC BELT CLEANING UNIT......................................................... 6-17
Toner Collection Augers..................................................................... 6-17
Counter Blade + Brush....................................................................... 6-17
Waste Toner Bottle Sensors.............................................................. 6-17
Drive................................................................................................... 6-18
6.4.6 IMAGE TRANSFER BELT UNIT.................................................... 6-19
Drive................................................................................................... 6-19
Belt Mark Sensor................................................................................ 6-19
Bias Roller.......................................................................................... 6-20
6.4.7 TRANSFER BELT CLEANING UNIT............................................. 6-21
Bias Brush.......................................................................................... 6-21
Bias Roller and Cleaning Blade.......................................................... 6-21
Collecting Coil.................................................................................... 6-21
Waste Toner Bottle Sensors.............................................................. 6-21
Contact Mechanism ........................................................................... 6-22
Power Supply..................................................................................... 6-23
Drive................................................................................................... 6-23
6.5 LASER EXPOSURE............................................................................... 6-24
6.5.1 OVERVIEW.................................................................................... 6-24
Dust Shield Glass Cleaning ............................................................... 6-25
LD Unit Adjustment............................................................................ 6-25
Polygonal Mirror................................................................................. 6-25
Laser Diode Power Control................................................................ 6-25
Maintenance Adjustment.................................................................... 6-25
6.5.2 LD SAFETY SWITCH.................................................................... 6-26
i
v
Operation Panel Message and Switch Mechanism............................ 6-27
6.6 DEVELOPMENT..................................................................................... 6-28
6.6.1 OVERVIEW.................................................................................... 6-28
6.6.2 DEVELOPMENT UNIT .................................................................. 6-29
Rollers and Agitators.......................................................................... 6-29
Replacing Units.................................................................................. 6-29
Memory Chip...................................................................................... 6-29
6.6.3 TONER SUPPLY MECHANISM.................................................... 6-30
Toner Cartridge Agitators................................................................... 6-30
Drive Power Path............................................................................... 6-30
Development Unit Agitator................................................................. 6-30
Toner Supply Roller and Doctor Roller............................................... 6-30
Shutter ............................................................................................... 6-30
6.6.4 TONER END DETECTION............................................................ 6-31
Mechanism......................................................................................... 6-31
Toner Near-End Detection................................................................. 6-31
Toner End Detection.......................................................................... 6-32
Toner End Recovery.......................................................................... 6-32
6.6.5 DEVELOPMENT UNIT CONTACT MECHANISM ......................... 6-33
Mechanism......................................................................................... 6-33
Reverse Rotation ............................................................................... 6-33
6.6.6 POWER SOURCE......................................................................... 6-34
Development, Toner Supply, and Doctor Rollers............................... 6-34
Doctor Roller...................................................................................... 6-34
6.7 PAPER FEED......................................................................................... 6-35
6.7.1 OVERVIEW.................................................................................... 6-35
Transport Speed................................................................................ 6-36
Friction Pad........................................................................................ 6-36
6.7.2 STANDARD TRAY DRIVE............................................................. 6-36
Feed and Vertical Transport Rollers................................................... 6-36
Registration Roller.............................................................................. 6-36
6.7.3 STANDARD TRAY – BOTTOM PLATE LIFT................................. 6-37
Lift Mechanism................................................................................... 6-37
Paper Near End Detection................................................................. 6-37
Paper End Detection.......................................................................... 6-37
6.7.4 STANDARD TRAY - PAPER SIZE DETECTION........................... 6-38
Mechanism......................................................................................... 6-38
Switch Pattern.................................................................................... 6-38
6.7.5 BYPASS TRAY.............................................................................. 6-39
Paper Feed Mechanism..................................................................... 6-39
Bypass Tray Drive Power Path .......................................................... 6-39
Pick-up Solenoid................................................................................ 6-39
Paper End Sensor.............................................................................. 6-39
6.8 PAPER TRANSFER AND SEPARATION............................................... 6-40
6.8.1 OVERVIEW.................................................................................... 6-40
Jammed Paper Release..................................................................... 6-40
Image Transfer and Paper Separati on............................................... 6-40
6.8.2 MECHANISM................................................................................. 6-41
Timing................................................................................................ 6-41
Mechanism......................................................................................... 6-41
6.8.3 POWER SUPPLY.......................................................................... 6-42
Electric Power Path............................................................................ 6-42
Transfer Roller Bias ........................................................................... 6-42
Discharge Plate.................................................................................. 6-42
Temperature/Humidity Control........................................................... 6-42
Roller Cleaning................................................................................... 6-43
6.9 FUSING UNIT AND OIL SUPPLY UNIT................................................. 6-44
6.9.1 OVERVIEW.................................................................................... 6-44
6.9.2 FUSING UNIT CONFIGURATION................................................. 6-45
Fusing Belt......................................................................................... 6-45
Oil Supply........................................................................................... 6-45
Heating Roller Lamp .......................................................................... 6-45
Pressure Roller Lamp ........................................................................ 6-45
Pressure Roller Pawls ........................................................................ 6-45
Fusing Bias........................................................................................ 6-46
Fusing Unit SCs................................................................................. 6-46
6.9.3 TEMPERATURE CONTROL......................................................... 6-47
6.9.4 OIL SUPPLY AND CLEANING...................................................... 6-48
Oil Supply........................................................................................... 6-48
Oil Path.............................................................................................. 6-48
Oil Recycling...................................................................................... 6-48
Belt Cleaning...................................................................................... 6-48
Oil End Detection............................................................................... 6-49
Fusing unit switch............................................................................... 6-49
6.9.5 DRIVE............................................................................................ 6-49
Drive Power Path (Fusing Unit and Oil Supply Roller)....................... 6-49
Drive Power Path (Pressure Roller)................................................... 6-49
6.9.6 ENERGY SAVER MODE............................................................... 6-50
Level 1 Energy Saver Mode (default: off)........................................... 6-50
Level 2 Energy Saver Mode............................................................... 6-50
Ready Mode....................................................................................... 6-50
6.9.7 PAPER EXIT.................................................................................. 6-51
Drive Power Path............................................................................... 6-51
Paper Jam Detection.......................................................................... 6-51
6.9.8 OVERFLOW DETECTION............................................................. 6-51
6.10 PRINTED CIRCUIT BOARDS .............................................................. 6-52
6.10.1 PRINTER CONTROLLER............................................................ 6-52
Function............................................................................................. 6-52
Memory.............................................................................................. 6-52
Interfaces........................................................................................... 6-52
Slots................................................................................................... 6-53
Options............................................................................................... 6-53
DIP Switch.......................................................................................... 6-53
LED Indicators.................................................................................... 6-53
6.10.2 BASE ENGINE CONTROL UNIT (BCU)...................................... 6-54
Function............................................................................................. 6-54
Upgrading........................................................................................... 6-54
Nonvolatile Random Access Memory (NVRAM)................................ 6-54
vi
DIP Switch.......................................................................................... 6-54
6.10.3 INPUT/OUTPUT (I/O) BOARD..................................................... 6-55
6.10.4 POWER SUPPLY UNIT (PSU).................................................... 6-55
6.10.5 HIGH VOLTAGE SUPPLY........................................................... 6-55
6.11 CONTROLLER..................................................................................... 6-56
6.11.1 OVERVIEW.................................................................................. 6-56
6.11.2 BOARD LAYOUT......................................................................... 6-58
6.11.3 PRINT DATA PROCESSING....................................................... 6-59
RPCS Driver....................................................................................... 6-59
PCL5c Driver...................................................................................... 6-59
PS3 Driver.......................................................................................... 6-60
CMS (Color Management System) .................................................... 6-60
Gray Correction.................................................................................. 6-60
BG/UCR (Black Generation/Under Color Removal)........................... 6-60
Gamma Correction............................................................................. 6-60
Toner Limitation................................................................................. 6-61
Dither Processing and ROP/RIP........................................................ 6-61
6.11.4 CONTROLLER FUNCTIONS....................................................... 6-62
Sample Print....................................................................................... 6-62
Locked Print....................................................................................... 6-62
Paper Source Selection ..................................................................... 6-63
Auto Continue.................................................................................... 6-64
Paper Output Tray.............................................................................. 6-65
Stapling.............................................................................................. 6-66
6.12 IEEE1394 INTERFACE........................................................................ 6-67
6.12.1 SPECIFICATIONS....................................................................... 6-67
Hardware Specification...................................................................... 6-67
System Requirements........................................................................ 6-67
6.12.2 IEEE1394..................................................................................... 6-67
6.12.3 BLOCK DIAGRAM....................................................................... 6-68
6.12.4 PIN ASSIGNMENT...................................................................... 6-68
6.12.5 REMARKS ABOUT THIS INTERFACE KIT................................. 6-69
6.12.6 TROUBLESHOOTING NOTES.................................................... 6-69
6.12.7 IP OVER IEEE 1394.................................................................... 6-70
6.13 IEEE 802.11B (WIRELESS LAN) ......................................................... 6-71
6.13.1 SPECIFICATIONS....................................................................... 6-71
6.13.2 BLOCK DIAGRAM....................................................................... 6-71
6.13.3 TRANSMISSION MODE.............................................................. 6-72
Ad hoc Mode...................................................................................... 6-72
Infrastructure Mode............................................................................ 6-72
6.13.4 SECURITY FEATURES............................................................... 6-73
Using the SSID in Ad hoc mode......................................................... 6-73
6.13.5 TROUBLESHOOTING NOTES.................................................... 6-74
Communication Status....................................................................... 6-74
Channel Settings................................................................................ 6-74
Troubleshooting Steps....................................................................... 6-75
6.14 USB ...................................................................................................... 6-76
6.14.1 SPECIFICATIONS....................................................................... 6-76
6.14.2 USB 1.1/2.0.................................................................................. 6-76
vii
6.14.3 USB CONNECTORS................................................................... 6-77
6.14.4 PIN ASSIGNMENT...................................................................... 6-77
6.14.5 REMARKS................................................................................... 6-78
Related SP Mode............................................................................... 6-78

PERIPHERALS

PAPER TRAY UNIT (G313)

1. REPLACEMENT A N D ADJUSTMENT................................. G313-1
1.1 REAR COVER....................................................................................G313-1
1.2 PAPER FEED CLUTCH......................................................................G313-1
1.3 LIFT MOTOR......................................................................................G313-2
1.4 PAPER FEED MOTOR.......................................................................G313-2
1.5 CONTROLLER BOARD......................................................................G313-2
1.6 PICK-UP/FEED/SEPARATION ROLLERS.........................................G313-3
2. DETAILED DESCRIPTIONS ................................................ G313-4
2.1 MECHANICAL COMPONENT LAYOUT.............................................G313-4
Feed and Reverse Roller (FRR).....................................................G313-4
Drive Path......................................................................................G313-4
Paper End Feeler Method..............................................................G313-4
2.2 ELECTRICAL COMPONENT LAYOUT..............................................G313-5
2.3 DRIVE LAYOUT .................................................................................G313-6
2.4 PAPER SIZE DETECTION.................................................................G313-7
2.5 PAPER LIFT.......................................................................................G313-8
2.6 PAPER HEIGHT AND END DETECTION..........................................G313-9
Paper Height Detection..................................................................G313-9
Paper End Detection......................................................................G313-9

INTERCHANGE UNIT (G305)

1. REPLACEMENT A N D ADJUSTMENT................................. G305-1
1.1 EXTERIOR COVER AND PAPER EXIT SENSOR.............................G305-1
1.2 CONTROL BOARD.............................................................................G305-1
2. DETAILED DESCRIPTIONS ................................................ G305-2
2.1 ELECTRICAL COMPONENTS...........................................................G305-2
2.2 DRIVE.................................................................................................G305-2
2.3 MECHANISM......................................................................................G305-3

DUPLEX UNIT (G303)

1. REPLACEMENT A N D ADJUSTMENT................................. G303-1
1.1 EXTERIOR COVER............................................................................G303-1
1.2 ENTRANCE/EXIT SENSORS.............................................................G303-1
viii
1.3 INVERTER MOTOR...........................................................................G303-2
1.4 CONTROLLER BOARD......................................................................G303-2
1.5 TRANSPORT MOTOR.......................................................................G303-2
2. DETAILED DESCRIPTIONS ................................................ G303-3
2.1 OVERVIEW ........................................................................................G303-3
2.2 ELECTRICAL COMPONENT LAYOUT..............................................G303-4
2.3 DRIVE LAYOUT .................................................................................G303-5
2.4 DUPLEX PAPER FEED ORDER........................................................G303-6
2.4.1 LONGER THAN A4/LT LEF .......................................................G303-6
2.4.2 UP TO A4/LT LEF......................................................................G303-7
2.5 REVERSE MECHANISM....................................................................G303-8

500-SHEET FINISHER (G314)

1. REPLACEMENT A N D ADJUSTMENT................................. G314-1
1.1 EXTERIOR COVERS.........................................................................G314-1
Front Cover....................................................................................G314-1
Rear Cover.....................................................................................G314-1
Lower Guide...................................................................................G314-2
Upper Cover...................................................................................G314-3
Right Cover....................................................................................G314-3
1.2 ENTRANCE UPPER GUIDE AND PAPER EXIT UNIT.......................G314-4
1.3 MOTORS............................................................................................G314-5
1.3.1 MAIN MOTOR............................................................................G314-5
1.3.2 JOGGER MOTOR .....................................................................G314-5
1.4 STAPLER ...........................................................................................G314-6
1.5 PADDLE ROLLER SOLENOID...........................................................G314-6
1.6 MAIN CONTROL PCB........................................................................G314-7
1.7 OUTPUT TRAY UNIT.........................................................................G314-8
2. DETAILED DESCRIPTIONS .............................................. G314-10
2.1 OVERALL MACHINE INFORMATION..............................................G314-10
2.1.1 COMPONENT LAYOUT..........................................................G314-10
2.1.2 DRIVE LAYOUT.......................................................................G314-11
2.1.3 ELECTRICAL COMPONENTS................................................G314-12
2.2 DETAILED SECTION DESCRIPTIONS............................................G314-14
2.2.1 OUTPUT TRAY........................................................................G314-14
Stack Height Detection.................................................................G314-14
Output Tray Up/Down Mechanism............................................... G314-15
2.2.2 PAPER FEED..........................................................................G314-16
Overview......................................................................................G314-16
Straight Feed-out Mode ...............................................................G314-16
Shift Sorting Mode........................................................................G314-17
Stapling Mode..............................................................................G314-19
2.2.3 JAM CONDITIONS..................................................................G314-20
2.2.4 ERROR DETECTION..............................................................G314-20
ix

FOUR-BIN MAILBOX (G312)

1. REPLACEMENT A N D ADJUSTMENT................................. G312-1
1.1 EXTERIOR COVER............................................................................G312-1
1.2 MAIN MOTOR AND CONTROLLER BOARD.....................................G312-1
1.3 VERTICAL TRANSPORT AND PAPER OVERFLOW SENSORS...... G312-2
2. DETAILED DESCRIPTIONS ................................................ G312-3
2.1 OVERVIEW ........................................................................................G312-3
2.2 DRIVE.................................................................................................G312-4
Drive Path......................................................................................G312-4
2.3 ELECTRICAL COMPONENT LAYOUT..............................................G312-5
2.4 PAPER DISTRIBUTION.....................................................................G312-6
Mechanism.....................................................................................G312-6
Paper Overflow Sensor..................................................................G312-6
2.5 BASIC OPERATION...........................................................................G312-7
2.6 PAPER MISFEED DETECTION TIMING.............................................G312-7

SPECIFICATIONS

SPECIFICATIONS......................................................................Spec-1

1. GENERAL SPECIFICATIONS.............................................................. Spec-1
1.1 MAIN UNIT....................................................................................Spec-1
2. SUPPORTED PAPER SIZES............................................................... Spec-4
2.1 MAIN TRAY, BYPASS TRAY, AND DUPLEX UNIT ..................... Spec-4
2.2 FINISHER, MAIL BOX, AND PAPER TRAY UNIT........................ Spec-5
3. SOFTWARE ACCESSORIES...............................................................Spec-6
3.1 PRINTER DRIVERS..................................................................... Spec-6
3.2 UTILITY SOFTWARE...................................................................Spec-6
4. MACHINE CONFIGURATION.............................................................. Spec-7
4.1 SYSTEM COMPONENTS.............................................................Spec-7
Exterior........................................................................................... Spec-7
Interior............................................................................................ Spec-8
Maintenance Kits............................................................................Spec-8
4.2 OPTIONAL EQUIPMENT ............................................................. Spec-9
Paper Tray Unit.............................................................................. Spec-9
Finisher.......................................................................................... Spec-9
Mail Box....................................................................................... Spec-10
Duplex Unit...................................................................................Spec-10
Interchange Unit........................................................................... Spec-10
x
21 August 2002 INSTALLATION REQUIREMENTS

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

1. Temperature Range:
2. Humidity Range: 20% to 80% RH
3. Ambient Illumination: Less than 2,000 lux (keep the machine out of direct
4. Ventilation: 3 times/hr/person or more
5. Avoid exposing the machine to sudden temperature changes, which include:
1) Direct cool air from an air conditioner
2) Direct heat from a heater
6. Avoid installing the machine in areas that may be exposed to corrosive gas.
7. Install the machine at a location lower than 2,500 m (8,200 ft.) above sea level.
8. Install the machine on a strong, level base. (☛ 1.1.2)
9. Avoid installing the machine in areas that may be subjected to strong vibration.
10°C to 32°C (50°F to 89°F)
sunlight.)
Installation

1.1.2 MACHINE LEVEL

Front to back: Within 5 mm (0.2") of level Right to left: Within 5 mm (0.2") of level
1-1
INSTALLATION REQUIREMENTS 21 August 2002
A

1.1.3 SPACE REQUIREMENTS

B
: Over 100 mm (4")
B: Over 100 mm (4")
A
C
C: Over 550 mm (22") D: Over 750 mm (30")
D
G070I001.WMF

1.1.4 POWER REQUIREMENTS

!CAUTION
1. Insert the plug firmly in the outlet.
2. Avoid using an outlet extension plug or cord.
3. Ground the machine.
1. Input voltage level: 120 V, 60 Hz, More than 11 A 220 to 240 V, 50/60 Hz, More than 7 A
2. Permissible voltage fluctuation: ±10%
3. Do not put or place anything on the power cord.
1-2
21 August 2002 MACHINE INSTALLATION

1.2 MACHINE INSTALLATION

Refer to the Operating Instructions for details. If the customer has a service contract, change the settings of the following SP
modes depending on the contract type.
Item SP No. Function Default
Meter charge SP5-930-1
(Meter_
Charge)
Counting method SP5-045-1
(Counter
Method)
A3/11" x 17" double counting
SP5-104-1
(Double
Count)
PM warning display 1
SP5-931-1
(PM_Display
– Charger)
PM warning display 2
SP5-931-2
(PM_Display
– PCU)
Specifies whether the meter charge mode is enabled or disabled. If the user is doing the user PM procedures, set meter charge to ‘O f f’. If the technician is doing a ll t he PM, set meter charge to ‘On’.
Meter charge mode enabled:
• The Counter menu appears immediately after the Menu key is pressed.
• The counter type selected by the counting method (SP5-045-1, Counter Method) can be displayed with the Counter menu.
• The counter values can also be printed with the Counter me nu.
• The selected counter starts fro m a negative number.
Meter charge mode disabled:
• The Counter menu is not displayed.
• The total counter starts from 0.
Specifies whether the counting method used in meter charge mode is based on developments or print s.
Important:
This SP can only be done bef ore the negative counters are res et w ith SP7­825-001 (Counter Reset)
Specifies whether the counter is doubled for A3/11" x 17" paper.
Specifies whether the PM warning for the charge corona unit is displayed when the replacement time arrives. 1: Displayed 0: Not displayed
Specifies whether the PM warning for the PCU is displayed. 1: Displayed 0: Not displayed
Off
Developments
No: Single counting
1
1
Installation
1-3
OPTIONS 21 August 2002
Item SP No. Function Default
PM warning display 3
Fax No. setting SP5-812-2
Counter reset SP7-825-1
SP5-931-3
(PM_Display
- Bank_ Feed)
(FAX TEL
No.)
(Counter
Reset)
Specifies whether the PM warning for the feed rollers in the optional paper feed unit is displayed. 1: Displayed 0: Not displayed
Programs the service station fa x number.
The number is printed on the cou nt er list when the meter charge mode is selected, so that the user can fax the counter data to the service station.
Resets the counters to 0. Important: Th is must be done at
installation after all the above settings have been finished. The n egat ive counters used in meter charge mode will be reset to zero.
0
NOTE: 1) The default setting for this machine is meter-charge mode off.
2) The meter-charge counter cannot be reset.

1.3 OPTIONS

Refer to the Option Setup Guide for details.
No. Optional Unit Alternative Requirements
500-sheet finisher
1 2 4-bin mailbox No. 1
3 Interchange unit
Duplex unit
4 5 Paper tray unit
6 Printer hard disk
DIMM memory (64, 128, or 256
7
MB modules available) IEEE1394 interface unit
8 9 User account enhance men t unit
10 IEEE802.11b (Wireless LAN)
No. 2
• No. 3
• Hard disk or memory (extra 64
MB or more) for sort mode
• No. 3
• No. 3
• Extra 64 MB (or more) optional
SDRAM module
NOTE: 1) You cannot install the finisher and mailbox on the same machine.
2) You can install either 1 or 2 paper tray units.
1-4
21 August 2002 REMARKS FOR INSTALLATION

1.4 REMARKS FOR INSTALLATION

In case you install this printer or you instruct customers to install, please note the following remark for development unit installation and replacement:
After installation or replacement of the development unit, print out the development unit check sheet by user mode (User Mode – Maintenance – Development Unit Check).
NOTE: For details please refer to the Quick Installation Guide.
Installation
1-5
21 August 2002 OVERVIEW

2. PREVENTIVE MAINTENANCE

2.1 OVERVIEW

Users Do the User PM Procedures

The user does PM for the items in section 2.2. The technician does PM for the items in section 2.3. Meter-charge mode must be set to “off” (SP5-930 [Meter_Charge], ☛ 5.2).

All PM Done by Technicians

The technician does PM for the items in sections 2.2 and 2.3. Meter-charge mode must be set to “on” (SP5-930, [Meter_Charge], ☛ 5.2).

Counters

When a maintenance counter for a unit has reached the limit, the corresponding message is displayed on the operation panel. After completing the maintenance procedure for that item, reset the counter (SP7-804, [PM_Clear ], ☛ 5.2).

2.2 USER MAINTENANCE

Abbreviations: C
lean, Inspect, Lubricate, Replace, KiloPrints, KiloDevelopments, WheneverNecessary
Preventive
Maintenance

Main Unit

Item
T/B waste toner bottle O/B waste toner bottle Oil supply unit
Fusing unit with paper feed roller
* : Replacement period calculat ed for a 50% color ratio (the actual wast e t oner bottle condition
is detected with the sensors)
** : Standard replacement period (the actual oil amount is detected with the sen sor)
KD KP
50 120 30 120
R*
R*
R**
R
Waste toner sensors
Waste toner sensors
Oil end sensor/Oil supply unit counter
Exit sheet counter
Detection Reset
Auto-reset (sensor)
Auto-reset (sensor)
Manual reset
Manual reset
Machine
stops
Yes Yes
Yes
Yes
2-1
SERVICE MAINTENANCE 21 August 2002
Item
Black development unit Color development unit PCU (includes charge
corona unit & dust filters)
*Displayed with SP7-906 (PMCounter-PREV)
60 120 240
KD
R
R
R
Item WN Detection Reset
Registration roller Dust shield glass
(LD unit) Bottom plate pad
C None None No C None None No C None None No

Optional Paper Tray Unit

Item 150KP Detection Reset
Feed, pick-up, and separation rollers
R None None No
Detection Reset
Dev. Bk counter*
Dev. color counter*
PCU counter* Auto-reset (new
Auto-reset (memory chip)
Auto-reset (memory chip)
PCU sensor) No
Machine
stops
Machine
stops
Remarks
➀ damp cloth and ➁ dry cloth
Built-in cleaning brush
➀ damp cloth and ➁ dry cloth
Remarks
➀ damp cloth and ➁ dry cloth
Machine
stops
Yes Yes

2.3 SERVICE MAINTENANCE

Abbreviations: C
lean, Inspect, Lubricate, Replace, KiloPrints, KiloDevelopments, WheneverNecessary

Main Unit

Bypass Tray
Item WN Remarks
Feed Roller Pick-up Roller Separation Roller
C C C
➀ damp cloth and ➁ dry cloth
➀ damp cloth and ➁ dry cloth
➀ damp cloth and ➁ dry cloth
2-2
21 August 2002 SERVICE MAINTENANCE

Optional Units

Paper Tray Unit
Item WN Remarks
Relay Roller Bottom Plate Pad
C C
➀ damp cloth and ➁ dry cloth
➀ damp cloth and ➁ dry cloth
Finisher
Item WN Remarks
Rollers
C
➀ damp cloth and ➁ dry cloth
Sensors C Blower blush or dry cloth Anti-Static Brush C Blower blush or dry cloth Bushings
Stapler
L
R
Launa oil when abnormal noise occurs
Every 200K staples (estimated replacement period)
Mail Box
Preventive
Maintenance
Item WN Remarks
Rollers
C
➀ damp cloth and ➁ dry cloth
Tray Paper Sensors C Blower blush or dry cloth
Duplex Unit
Item WN Remarks
Rollers
C
➀ damp cloth and ➁ dry cloth
Feed/exit sensors C Blower blush or dry cloth
Interchange Unit
Item WN Remarks
Paper Exit Sensor C Blower blush or dry cloth
2-3
21 August 2002 SPECIAL TOOLS

3. REPLACEMENT AND ADJUSTMENT

!CAUTION
Turn off the main power switch and unplug the machine before beginning any of the procedures in this section.
NOTE: This manual uses the following symbols.
☛ : See or Refer to ! : Screws " : Connector # : Clip ring $ : E-ring

3.1 SPECIAL TOOLS

Part Number Part Name
N8036701 Flash Memory Card - 4MB G0219350 Loop-back connector - Parallel
Adjustment
Replacement
3-1
EXTERIOR COVERS 21 August 2002

3.2 EXTERIOR COVERS

3.2.1 REAR COVER

1. Duct cover [A] (4 hooks)
2. Ozone filter [B]
3. Printer controller [C] (! x 2)
[C]
G070R702.WMF
[A]
[B]
4. Rear cover [D] (! x 2)
G070R703.WMF
[D]
3-2
21 August 2002 EXTERIOR COVERS

3.2.2 LOWER LEFT COVER

1. Lower left cover [A] (! x 3)
[A]

3.2.3 UPPER COVER, OPERATION PANEL

1. Open the right cover [A].
2. Upper right cover [B]
3. Paper exit cover [C] (! x 1)
4. Open the front cover [D].
[F]
[E]
G070R704.WMF
Adjustment
Replacement
[C]
[B]
5. Upper cover [E] (! x 4)
6. Operation panel [F] (4 hooks, " x 2, ! x 1)
NOTE: Insert a screwdriver between
the upper cover and the main unit and unhook the panel.
[D]
G070R701.WMF
[A]
3-3
ELECTRICAL COMPONENTS 21 August 2002

3.3 ELECTRICAL COMPONENTS

3.3.1 PRINTER CONTROLLER

☛ 3.2.1
NOTE: Remove the NVRAM from the old controller board, and install it on the new
one. If the controller NVRAM is defective, reset the total counter to 0 after changing the NVRAM, if meter charge mode is enabled.

3.3.2 CONTROLLER BOX

1. Rear cover (☛ 3.2.1)
2. Cooling fan [A] (! x 2) NOTE: When rea ssembling, install
the fan with the label facing the inside.
3. Controller box [B] (! x 11) NOTE: 1) Do not remove the
BCU board base with the controller box.
2) When putting back the controller box, take care not to pinch the cable from the I/O board.

3.3.3 BCU BOARD

1. Controller box (☛ 3.3.2)
2. All " (12)
3. 1 flat cable
4. BCU board base [A] (! x 5)
5. BCU board [B] (! x 5) NOTE: Remove the NVRAM from the old
BCU board, and install it on the new one.
[B]
[B]
[A]
G070R705.WMF
[A]
G070R706.WMF
3-4
21 August 2002 ELECTRICAL COMPONENTS

3.3.4 I/O BOARD

1. Controller box (☛ 3.3.2)
2. All " (33)
3. I/O board [A] (! x 4)

3.3.5 PSU

1. Controller box (☛ 3.3.2)
2. Flywheel (! x 3) (☛ 3.4.1)
[A]
G070R707.WMF
[B]
Adjustment
Replacement
[C]
3. Duct [A] (" x 1, ! x 1) NOTE: When removing and
reassembling the fan, install it with the label facing the outside.
4. PSU protector [B] (! x 1)
5. Unlink the main switch [C].
6. PSU base (" x 8, ! x 4) NOTE: 1) Remove the PSU [D]
with the PSU base.
2) When reas sem blin g, check that the main switch is linked to the PSU.
[A]
[D]
G070R717.WMF
3-5
ELECTRICAL COMPONENTS 21 August 2002

3.3.6 HIGH VOLTAGE SUPPLY BOARD

1. Photoconductor unit (☛ 3.7)
2. Right inner cover (☛ 3.10.2)
3. Photoconductor unit rail [A] (! x 2)
4. " [B] x 1
5. Bushing [C] x 1
[B]
[A]
G070R719.WMF
[C]
6. High voltage supply board [D] (" x 17, ! x 6)
[D]
G070R720.WMF
3-6
21 August 2002 DRIVE UNITS

3.4 DRIVE UNITS

3.4.1 DEVELOPMENT CLUTCHES

1. Controller box (☛ 3.3.2)
K/Y Development Units
1. Unhook the lock [A] and pull out the clutch [B] (" x 1).
C/M Development Units
1. Flywheel [A] (! x 3)
2. Unhook the lock [B] and pull out the clutch [C] (" x 1).
[A]
[B]
G070R708.WMF
Adjustment
Replacement
3-7
[C]
[A]
[B]
G070R709.WMF
DRIVE UNITS 21 August 2002

3.4.2 DEVELOPMENT MOTOR

1. Controller box (☛ 3.3.2)
2. Development motor [A] (" x 1, ! x 3)
[A]

3.4.3 MAIN MOTOR

1. Controller box (☛ 3.3.2)
2. Flywheel [A] (! x 3)
3. Main motor [B] (" x 1, ! x 3)
G070R710.WMF
[B]
[A]
3-8
G070R711.WMF
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