Ricoh CL4000DN Service Manual

G104

SERVICE MANUAL

002111MIU

RICOH GROUP COMPANIES

®

®

G104

MANUAL SERVICE

RICOH GROUP COMPANIES

G104

SERVICE MANUAL

002111MIU

It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies.

NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.

All product names, domain names or product illustrations, including desktop images, used in this document are trademarks, registered trademarks or the property of their respective companies.

They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies. No such use, or the use of any trade name, or web site is intended to convey endorsement or other affiliation with Ricoh products.

2004 RICOH Corporation. All rights reserved.

WARNING

The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.

Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection.

Ricoh Corporation

LEGEND

PRODUCT CODE		COMPANY
	GESTETNER	LANIER	RICOH	SAVIN
G104	P7425dn	LP126cn	Aficio CL4000DN	CLP26DN

DOCUMENTATION HISTORY

REV. NO.	DATE	COMMENTS
*	11/2004	Original Printing

G104

TABLE OF CONTENTS

INSTALLATION

1. INSTALLATION............................................................................		1-1
1.1	INSTALLATION REQUIREMENTS ...........................................................	1-1
	1.1.1 ENVIRONMENT ...............................................................................	1-1
	1.1.2 MACHINE LEVEL.............................................................................	1-1
	1.1.3 MACHINE SPACE REQUIREMENT.................................................	1-2
	1.1.4 POWER REQUIREMENTS ..............................................................	1-2
1.2	MACHINE INSTALLATION........................................................................	1-3
	1.2.1 UNPACKING ....................................................................................	1-3
	1.2.2 INSTALLING THE TONER BOTTLE ................................................	1-5
	1.2.3 LOADING PAPER ............................................................................	1-7
	1.2.4 CONNECTING THE POWER CORD ...............................................	1-9
	1.2.5 SELECTING THE PANEL DISPLAY LANGUAGE..........................	1-10
	1.2.6 PRINTING THE TEST PAGE .........................................................	1-10
1.3	OPTIONAL UNIT INSTALLATION...........................................................	1-11
1.4	METER CHARGE....................................................................................	1-12
1.5	TRAY HEATER .......................................................................................	1-13
PREVENTIVE MAINTENANCE

2. PREVENTIVE MAINTENANCE....................................................		2-1
2.1	USER REPLACEABLE ITEMS..................................................................	2-1
2.2	SERVICE MAINTENANCE........................................................................	2-2
	2.2.1 RECOMMENDED CLEANING PROCEDURE..................................	2-2
REPLACEMENT AND ADJUSTMENT

3. REPLACEMENT AND ADJUSTMENT ........................................		3-1
	3.1 SPECIAL TOOLS AND LUBRICANTS ................................................	3-1
	3.1.1 TOOLS .............................................................................................	3-1
3.2 ELECTRICAL COMPONENTS..................................................................		3-2
	3.2.1 ELECTRICAL BOARD UNIT ............................................................	3-2
	3.2.2 IOB (INPUT/OUTPUT BOARD)........................................................	3-4
	3.2.3 CONTROLLER BOARD ...................................................................	3-4
	3.2.4 PSU (POWER SUPPLY UNIT) BOARD ...........................................	3-5
	3.2.5 HIGH VOLTAGE POWER SUPPLY BOARD 1 ................................	3-5
	3.2.6 EGB (ENGINE BOARD) AND HIGH VOLTAGE POWER
	SUPPLY BOARD 2...........................................................................	3-6
	3.2.7 LCD PANEL......................................................................................	3-6
3.3 LASER OPTICS ........................................................................................		3-7
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3.3.1 CAUTION DECAL LOCATIONS.......................................................	3-7
3.3.2 LD UNIT............................................................................................	3-8
Color registration adjustment ................................................................	3-8
3.3.3 LDB.................................................................................................	3-10
3.3.4 POLYGON MIRROR MOTOR ........................................................	3-10
3.3.5 LASER SYNCHRONIZING DETECTOR BOARDS ........................	3-11
3.3.6 LDU SHUTTER MOTOR UNIT AND SENSOR ..............................	3-11
3.4 PAPER FEED..........................................................................................	3-12
3.4.1 PAPER FEED ROLLER..................................................................	3-12
3.4.2 PAPER FRICTION PAD .................................................................	3-13
3.4.3 BY-PASS PAPER SIZE SENSOR..................................................	3-13
3.4.4 BY-PASS FEED ROLLER, FRICTION PAD ...................................	3-14
3.4.5 REGISTRATION SENSOR.............................................................	3-15
3.4.6 0PAPER VOLUME SENSOR, END SENSOR AND PAPER
WIDTH SENSOR............................................................................	3-15
3.4.6 PAPER VOLUME SENSOR, END SENSOR AND PAPER
WIDTH SENSOR............................................................................	3-16
3.4.7 PAPER SIZE SENSOR AND TEMPERATURE/ HUMIDITY
SENSOR ........................................................................................	3-17
3.4.8 PAPER FEED MOTOR...................................................................	3-18
3.4.9 PAPER REGISTRATION CLUTCH, PAPER FEED CLUTCH
AND BY-PASS CLUTCH................................................................	3-19
3.5 DEVELOPMENT .....................................................................................	3-20
3.5.1 COLOR DEVELOPMENT MOTOR, COLOR OPC MOTOR
AND BLACK OPC/DEVELOPMENT MOTOR ................................	3-20
3.5.2 DEVELOPMENT CLUTCH .............................................................	3-20
3.5.3 TRANSFER BELT CONTACT MOTOR..........................................	3-21
3.5.4 TONER SUPPLY MOTOR..............................................................	3-21
3.5.5 TRANSFER ROLLER CONTACT MOTOR ....................................	3-22
3.5.6 ID SENSORS .................................................................................	3-23
3.6 DRIVE .....................................................................................................	3-23
3.6.1 DRIVE UNIT ...................................................................................	3-23
3.7 DUPLEX ..................................................................................................	3-24
3.7.1 DUPLEX JAM SENSOR .................................................................	3-24
3.7.2 INVERTER SENSOR .....................................................................	3-24
3.7.3 DUPLEX MOTOR AND INVERTER MOTOR .................................	3-25
3.8 FUSING...................................................................................................	3-26
3.8.1 FUSING UNIT.................................................................................	3-26
3.8.2 THERMISTOR AND THERMOSTAT..............................................	3-26
3.8.3 FUSING LAMP ...............................................................................	3-27
3.8.4 FUSING EXIT SENSOR AND PAPER EXIT SENSOR ..................	3-28
3.8.5 FUSING REGISTRATION SENSOR ..............................................	3-28
Fan Direction ......................................................................................	3-29
3.9 ADJUSTMENTS ......................................................................................	3-30
3.9.1 GAMMA ADJUSTMENT .................................................................	3-30

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TROUBLESHOOTING

4. TROUBLESHOOTING .................................................................	4-1
4.1 PROCESS CONTROL RESULT ...............................................................	4-1
4.2 SERVICE CALL CONDITIONS .................................................................	4-2
4.2.1 SUMMARY .......................................................................................	4-2
4.2.2 SC CODE DESCRIPTIONS .............................................................	4-3
Engine SC.............................................................................................	4-3
Controller Error ...................................................................................	4-14
4.3 TROUBLESHOOTING GUIDE ................................................................	4-21
4.3.1 BLANK PRINT ................................................................................	4-21
4.3.2 ALL-BLACK PRINT.........................................................................	4-21
4.3.3 MISSING CMY COLOR..................................................................	4-22
4.3.4 LIGHT PRINT .................................................................................	4-22
4.3.5 REPEATED SPOTS OR LINES ON PRINTS .................................	4-23
4.3.6 DARK VERTICAL LINE IN PRINT..................................................	4-23
4.3.7 WHITE HORIZONTAL LINES OR BANDS .....................................	4-24
4.3.8 MISSING PARTS OF IMAGES.......................................................	4-24
4.3.9 DIRTY BACKGROUND ..................................................................	4-24
4.3.10 PARTIAL CMY COLOR DOTS .....................................................	4-24
4.3.11 DARK IRREGULAR STREAKS ON PRINTS................................	4-24
4.3.12 CMY COLOR IRREGULAR STREAKS ........................................	4-25
4.3.13 GHOSTING ..................................................................................	4-25
4.3.14 UNFUSED OR PARTIALLY FUSED PRINTS ..............................	4-25
4.3.15 IMAGE SKEW ..............................................................................	4-25
4.3.16 BACKGROUND STAIN ................................................................	4-26
4.3.17 NO PRINTING ON PAPER EDGE................................................	4-26
4.3.18 IMAGE NOT CENTERED WHEN IT SHOULD BE .......................	4-26
4.4 ELECTRICAL COMPONENT DEFECTS ................................................	4-27
4.4.1 SENSORS ......................................................................................	4-27
4.5 BLOWN FUSE CONDITIONS .................................................................	4-29
Power supply unit ...............................................................................	4-29
IOB......................................................................................................	4-29
4.6 LEDS ........................................................................................................	4-29
SERVICE TABLES

5. SERVICE TABLES.......................................................................		5-1
5.1 SERVICE PROGRAM MODE....................................................................		5-1
	5.1.1 SERVICE MODE OPERATION ........................................................	5-1
	Entering the Service Mode....................................................................	5-1
	Accessing the Required Program .........................................................	5-2
	Inputting a Value or Setting for a Service Program...............................	5-2
	Exiting Service Mode ............................................................................	5-2
	5.1.2 REMARKS........................................................................................	5-3
	Display on the Control Panel Screen ....................................................	5-3
	Others ...................................................................................................	5-4
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5.2 SERVICE MODE TABLE...........................................................................	5-5
5.2.1 CONTROLLER SERVICE MODE.....................................................	5-5
5.2.2 BIT SWITCH PROGRAMMING ........................................................	5-9
5.2.3 ENGINE SERVICE MODE .............................................................	5-10
SP1-XXX (Feed) .................................................................................	5-10
SP2-XXX (Drum).................................................................................	5-21
SP3-XXX (Process) ............................................................................	5-47
SP5-XXX (Mode) ................................................................................	5-57
SP7-XXX (Data Log)...........................................................................	5-71
SP8-XXX (Data Log 2)........................................................................	5-82
SP9-XXX.............................................................................................	5-92
5.2.4 INPUT CHECK TABLE ...................................................................	5-96
5.2.5 OUTPUT CHECK TABLE ...............................................................	5-98
5.3 FIRMWARE UPDATE ...........................................................................	5-100
5.3.1 TYPE OF FIRMWARE..................................................................	5-100
5.3.2 PRECAUTIONS............................................................................	5-100
Handling SD Cards ...........................................................................	5-100
Upload or Download .........................................................................	5-100
Network Connection..........................................................................	5-100
5.3.3 FILE ARRANGEMENT .................................................................	5-101
How the Program Works...................................................................	5-101
Example............................................................................................	5-101
5.3.4 UPDATING ...................................................................................	5-102
Procedure .........................................................................................	5-102
Error Handling...................................................................................	5-103
Power Failure....................................................................................	5-103
5.3.5 NVRAM DATA UPLOAD/DOWNLOAD ........................................	5-104
Uploading NVRAM Data ...................................................................	5-104
Downloading NVRAM Data...............................................................	5-105
5.3.6 ERROR CODE TABLE .................................................................	5-106
5.4 SD CARD APPLI MOVE........................................................................	5-107
5.4.1 OVERVIEW ..................................................................................	5-107
5.4.2 MOVE EXEC ................................................................................	5-108
5.4.3 UNDO EXEC ................................................................................	5-109
Keeping the SD card.........................................................................	5-109
DETAILED SECTION DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS .......................................	6-1
6.1 OVERVIEW ...............................................................................................	6-1
6.1.1 COMPONENT LAYOUT ...................................................................	6-1
6.1.2 PAPER PATH...................................................................................	6-2
6.1.3 DRIVE LAYOUT ...............................................................................	6-3
6.1.4 BOARD STRUCTURE......................................................................	6-4
Descriptions ..........................................................................................	6-5
6.1.5 PRINTING PROCESS ......................................................................	6-6

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6.2 PROCESS CONTROL ..............................................................................		6-8
	6.2.1 OVERVIEW ......................................................................................	6-8
	6.2.2 POTENTIAL CONTROL ...................................................................	6-9
	Overview...............................................................................................	6-9
	Process Control Self-check...................................................................	6-9
	6.2.3 PROCESS CONTROL SELF-CHECK PROCEDURE ....................	6-11
	Step 1: VSG Adjustment .....................................................................	6-11
	Step 2: ID Sensor Solid Pattern Generation .......................................	6-11
	Step 3: Sensor Pattern Detection .......................................................	6-11
	Step 4: Toner Amount Calculation ......................................................	6-11
	Step 5: VD, VB, VL Selection and VREF Adjustment .........................	6-12
	6.2.4 TONER SUPPLY CONTROL .........................................................	6-12
	Toner Supply Control Modes ..............................................................	6-12
	Low Image Coverage..........................................................................	6-13
	6.2.5 TONER NEAR END/TONER END DETECTION............................	6-14
	Introduction .........................................................................................	6-14
	Toner Near End Detection ..................................................................	6-15
	Toner End Detection ...........................................................................	6-15
	Toner End Recovery ...........................................................................	6-15
	6.2.6 DEVELOPER INITIALIZATION ......................................................	6-16
6.3 PAPER FEED..........................................................................................		6-17
	6.3.1 OVERVIEW ....................................................................................	6-17
	6.3.2 PAPER FEED DRIVE .....................................................................	6-18
	6.3.3 PAPER TRAY.................................................................................	6-19
	Paper Lift ............................................................................................	6-19
	Paper Size Detection ..........................................................................	6-20
	Paper Size Detection ..........................................................................	6-20
	Paper Near End/End Detection...........................................................	6-21
	Near-end detection .............................................................................	6-21
	End detection......................................................................................	6-21
	Paper width sensor .............................................................................	6-21
	By-pass Tray Feed and Size Detection...............................................	6-22
	6.3.4 DUPLEX .........................................................................................	6-23
	Drive ...................................................................................................	6-24
	Interleaving .........................................................................................	6-25
6.4 LASER EXPOSURE................................................................................		6-26
	6.4.1 OVERVIEW ....................................................................................	6-26
	6.4.2 OPTICAL PATH..............................................................................	6-27
	6.4.3 LASER SYNCHRONIZING DETECTOR ........................................	6-28
	Overview.............................................................................................	6-28
	Main Scan Start Detection ..................................................................	6-28
	6.4.4 LD SAFETY SWITCH .....................................................................	6-29
	6.4.5 AUTOMATIC LINE POSITION ADJUSTMENT ..............................	6-30
	Overview.............................................................................................	6-30
	Summary of Each Adjustment ............................................................	6-31
	Main Scan Skew Adjustment ..............................................................	6-34
	LDU Shutter ........................................................................................	6-35
6.5 PHOTOCONDUCTOR UNIT ...................................................................		6-36
	6.5.1 OVERVIEW ....................................................................................	6-36
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	6.5.2 DRIVE AND DRIVE GEAR POSITION SENSOR...........................	6-37
	Mechanism .........................................................................................	6-37
	Initialization Process and SC Codes...................................................	6-38
	6.5.3 DRUM CHARGE AND QUENCHING .............................................	6-39
	6.5.4 DRUM CLEANING..........................................................................	6-40
	6.5.5 WASTE TONER COLLECTION .....................................................	6-41
	6.5.6 WASTE TONER BOTTLE FULL DETECTION AND SET
	DETECTION...................................................................................	6-42
	6.5.7 PCU DETECTION (DEVELOPMENT UNIT DETECTION) .............	6-43
	Unit Set Detection Pins .......................................................................	6-43
	New Unit Detection .............................................................................	6-43
	Error Message ....................................................................................	6-44
6.6 DEVELOPMENT .....................................................................................		6-45
	6.6.1 OVERVIEW ....................................................................................	6-45
	6.6.2 DRIVE.............................................................................................	6-46
	6.6.3 DEVELOPER MIXING ....................................................................	6-47
	6.6.4 DEVELOPMENT BIAS ...................................................................	6-48
	6.6.5 TONER SUPPLY MECHANISM .....................................................	6-49
	Overview.............................................................................................	6-49
	Toner Near End Detection ..................................................................	6-49
	6.6.6 TONER BOTTLE DETECTION ......................................................	6-49
6.7 IMAGE TRANSFER.................................................................................		6-50
	6.7.1 OVERVIEW ....................................................................................	6-50
	Transfer Unit Detection and New Unit Detection ................................	6-51
	Transfer belt unit detection .................................................................	6-51
	New transfer belt unit detection ..........................................................	6-51
	6.7.2 TRANSFER BELT DRIVE AND TRANSFER BELT ROLLER
	VOLTAGE.................................................................................................	6-52
	Transfer belt contact ...........................................................................	6-53
	Transfer belt cleaning .........................................................................	6-54
	6.7.3 TRANSFER ROLLER UNIT............................................................	6-55
	Transfer from the belt..........................................................................	6-55
	Image transfer.....................................................................................	6-55
	Discharge............................................................................................	6-56
	Transfer roller contact .........................................................................	6-57
6.8 FUSING...................................................................................................		6-58
	6.8.1 OVERVIEW ....................................................................................	6-58
	6.8.2 FUSING TEMPERATURE CONTROL............................................	6-59
	Machine ready temperature: [B]..........................................................	6-60
	Print ready temperature: [C]................................................................	6-60
	Target printing temperature: [D]..........................................................	6-60
	First print temperature: [G]..................................................................	6-60
	Corrections for Small Paper Sizes (less than A5) ...............................	6-61
	Overheat Protection............................................................................	6-61
	6.8.3 DRIVE.............................................................................................	6-62
6.9 CONTROLLER ........................................................................................		6-63
	6.9.1 OVERVIEW ....................................................................................	6-63
	6.9.2 BOARD LAYOUT ............................................................................	6-65
G104	vi	SM

SPECIFICATIONS

1.	GENERAL SPECIFICATIONS.....................................................................		7-1
2.	SUPPORTED PAPER SIZES......................................................................		7-3
3.	SOFTWARE ACCESSORIES .....................................................................		7-4
	3.1	PRINTER DRIVERS............................................................................	7-4
	3.2	UTILITY SOFTWARE ..........................................................................	7-4
4.	MACHINE CONFIGURATION .....................................................................		7-5
5.	OPTIONAL EQUIPMENT ...........................................................................		7-6

PAPER FEED UNIT TYPE 4000 (G392)

SEE SECTION G392 FOR DETAILED TABLE OF CONTENTS

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IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

1.Before disassembling or assembling parts of the printer and peripherals, make sure that the printer power cord is unplugged.

2.The wall outlet should be near the printer and easily accessible.

3.If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components.

4.The printer drives some of its components when it completes the warm-up period. Be careful to keep hands away from the mechanical and electrical 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. Immediately wash eyes with plenty of water. If unsuccessful, get medical attention.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

The printer and its peripherals must be serviced by a customer service representative who has completed the training course on those models.

LITHIUM BATTERIES

Incorrect replacement of lithium battery(s) on the EGB may pose risk of explosion. Replace only with the same type or with an equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer’s instructions.

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 accordance with local regulations. (These are non-toxic supplies.)

3.Dispose of replaced parts in accordance with local regulations.

4.When keeping 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.

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® is a registered trademark of Adobe Systems, Incorporated.

PCL® is a registered trademark of Hewlett-Packard Company. Ethernet® is a registered trademark of Xerox Corporation.

PowerPC® 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.

Symbols and Abbreviations

This manual uses the symbols and abbreviations shown below.

Symbol					Meaning
			Refer to section number
			Clip ring
			Screw
			Connector
			Clamp
	SEF		Short Edge Feed
	LEF		Long Edge Feed

Short Edge Feed (SEF)

Long Edge Feed (LEF)

INSTALLATION

PREVENTIVE MAINTENANCE

REPLACEMENT AND ADJUSTMENT

TROUBLESHOOTING

SERVICE TABLES

DETAILED DESCRIPTIONS

SPECIFICATIONS

G392 PAPER TRAY UNIT

TAB	POSITION 1
TAB	POSITION 2
TAB	POSITION 3
TAB	POSITION 4
TAB	POSITION 5
TAB	POSITION 6
TAB	POSITION 7
TAB	POSITION 8

INSTALLATION

INSTALLATION REQUIREMENTS

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

1.	Temperature Range: 10°C to 32°C (50°F to 89.6°F)
2.	Humidity Range:	15% to 80% RH
3.	Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight)
4.	Ventilation:	3 times/hr/person

5.Do not put the machine in areas that get sudden temperature changes. This includes:

1)Areas directly exposed to cool air from an air conditioner.

2)Areas directly exposed to heat from a heater.

6.Do not put the machine in areas that get exposed to corrosive gas.

7.Do not install the machine at locations over 2,500 m (8,125 ft.) above sea level.

8.Put the machine on a strong, level bottom. (Inclination on any side must be no more than 5 mm.)

9.Do not put the machine in areas with strong vibrations.

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

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INSTALLATION REQUIREMENTS

1.1.3 MACHINE SPACE REQUIREMENT

Put the machine near the power source with these clearances:

Left side:	Over 50 cm (19.7")
Rear:	Over 10 cm (4")
Right side:	Over 10 cm (4")
Front:	Over 70 cm (27.6")

1.1.4 POWER REQUIREMENTS

CAUTION

1.Make sure that the plug is tightly in the outlet.

2.Avoid multi-wiring.

3.Make sure that you ground the machine.

1.Input voltage level: 120 V, 60 Hz: More than 11 A (for North America)

220 V to 240 V, 50 Hz/60 Hz: More than 6 A (for Europe/

Asia)

2.Permitted voltage fluctuation: ±10%

3.Do not set anything on the power cord.

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