Ricoh ap204 Service Manual ap206e
POMELO-P3 (G063)
SERVICE MANUAL
!
IMPORTANT SAFETY NOTICES
PHYSICAL INJURY PREVENTION
1. Before disassembling or assembling parts of the printer and peripherals,
make sure that the power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. Note that some printer components are supplied with electrical voltage even
if the main switch is turned off.
4. If an adjustment or operation check must be made requiring the removal or
opening of the exterior covers while the main switch is on, keep hands away
from electrified or mechanically driven components.
5. The printer drives some of its components when it completes the warm-up
period. Keep hands away from mechanical and electrical components when
the printer starts operation.
6. The interior and metal parts for the fusing unit become extremely hot while
the printer is operating. Do NOT touch these components with bare hands.
HEALTH SAFETY CONDITIONS
1. Never operate the printer without ozone filters installed.
2. Always replace the ozone filters with the specified replacement at the
specified maintenance intervals.
3. Toner is non-toxic, but if it gets in your eyes by accident, it may cause
temporary eye discomfort. Remove it with eye drops or flush eyes with
water. If this is unsuccessful, get medical attention immediately.
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do NOT incinerate toner cartridges or used toner. Toner dust may ignite
suddenly when exposed to an open flame.
2. Dispose of used toner and belt cartridge in accordance with local
regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
Trademarks
Microsoft, Windows 98/95/3.1x, and Windows NT 4.0 are registered trademarks of
Microsoft Corporation.
Macintosh and AppleTalk are registered trademarks of Apple Computer, Inc.
NetWare is a registered trademark of Novell, Inc.
Ethernet is a registered trademark of Xerox Corporation.
General Notice:
Other product names used herein are for identification purposes only and may be
trademarks of their respective companies. We disclaim any and all rights in those
marks.
TABLE OF CONTENTS
1 INSTALLATION ........................................................................... 1-1
1.1 INSTALLATION ENVIRONMENT..............................................................1-1
During Operation ..................................................................................1-1
1.2 INSTALLATION NOTES............................................................................1-3
1.3 RELOCATION PROCEDURE...................................................................1-3
2 PREVENTIVE MAINTENANCE .................................................... 2-1
2.1 HANDLING PRECAUTIONS.....................................................................2-1
2.2 MAINTENANCE BASICS..........................................................................2-2
2.2.1 CLEANING.......................................................................................2-2
2.2.2 REPLACEMENT...............................................................................2-2
2.3 PERIODIC CLEANING..............................................................................2-3
2.3.1 OVERVIEW......................................................................................2-3
2.3.2 DAILY MAINTENANCE....................................................................2-4
2.3.3 PERIODIC MAINTENANCE.............................................................2-4
2.3.4 PROCEDURES................................................................................2-5
(1) Registration Roller Cleaning............................................................2-5
(2) Transfer Roller Cleaning..................................................................2-6
(3) Paper Discharger Cleaning (AC Corona Unit).................................2-7
(4) Belt Cartridge Cleaning ...................................................................2-8
(5) Optics Unit Dust Shield Glass Cleaning........................................2-10
(6) Printer Interior Cleaning.................................................................2-11
2.4 PERIODIC REPLACEMENT...................................................................2-12
2.4.1 OVERVIEW....................................................................................2-12
Fusing Unit Replacement....................................................................2-13
Transfer Roller Replacement..............................................................2-16
Paper Discharger Replacement..........................................................2-18
Drum Cleaning Unit Replacement ......................................................2-20
Paper Feed Roller and Separation Pad Check...................................2-22
Transfer Drum Replacement...............................................................2-23
3 REPLACEMENT AND ADJUSTMENT......................................... 3-1
3.1 COVERS...................................................................................................3-1
3.1.1 LEFT UPPER SIDE COVER ............................................................3-1
3.1.2 RIGHT SIDE COVER AND OZONE FILTER COVER......................3-2
3.1.3 LEFT SIDE COVER..........................................................................3-3
3.1.4 FRONT LEFT SIDE COVER ............................................................3-4
3.1.5 TOP COVER ....................................................................................3-5
3.1.6 PAPER EXIT FRONT COVER / PAPER EXIT COVER ASS’Y........3-6
3.1.7 LOWER REAR COVER (TRANSFER COVER) ...............................3-7
3.1.8 LOWER REAR COVER....................................................................3-8
3.1.9 UPPER REAR COVER.....................................................................3-9
3.1.10 RIGHT BASE COVER.................................................................. 3-10
3.1.11 LEFT BASE COVER.....................................................................3-11
3.1.12 CLEANER COVER.......................................................................3-12
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3.1.13 FRONT COVER............................................................................3-13
3.2 PCBS.......................................................................................................3-14
3.2.1 PCB LAYOUT.................................................................................3-14
3.2.2 MCTL..............................................................................................3-15
3.2.3 IOD 1..............................................................................................3-17
3.2.4 IOD2...............................................................................................3-18
3.2.5 PANEL BOARD (INCLUDING LCD)...............................................3-19
3.2.6 POWER SUPPLY UNIT..................................................................3-20
3.2.7 HIGH VOLTAGE UNIT...................................................................3-22
3.2.8 ERASE LAMP.................................................................................3-24
3.3 MOTORS.................................................................................................3-25
3.3.1 MOTOR LAYOUT...........................................................................3-25
3.3.2 MAIN MOTOR / GEAR ASS’Y .......................................................3-26
3.3.3 MAIN DRIVE UNIT.........................................................................3-27
3.3.4 DEVELOPMENT MOTOR..............................................................3-28
3.3.5 DEVELOPMENT DRIVE UNIT.......................................................3-29
3.3.6 OPTICAL UNIT (INCLUDING POLYGONAL MIRROR MOTOR)...3-30
3.3.7 CONTROLLER FAN.......................................................................3-31
3.3.8 FUSING UNIT FAN.........................................................................3-32
3.3.9 OZONE FAN...................................................................................3-33
3.4 CLUTCHES AND SOLENOIDS...............................................................3-34
3.4.1 CLUTCH AND SOLENOID LAYOUT..............................................3-34
3.4.2 FUSING / CLEANING / REGISTRATION CLUTCH........................3-35
3.4.3 PAPER FEED CLUTCH.................................................................3-36
3.4.4 DEVELOPMENT CLUTCHES........................................................3-37
3.4.5 DRUM CLEANER / TRANSFER CLUTCH.....................................3-38
3.5 SENSORS AND SWITCHES...................................................................3-39
3.5.1 SENSOR LAYOUT......................................................................... 3-39
3.5.2 FRONT COVER SWITCH ..............................................................3-40
3.5.3 EXIT COVER SWITCH...................................................................3-40
3.5.4 REAR COVER SWITCH.................................................................3-41
3.5.5 PAPER FEED SENSOR.................................................................3-42
3.5.6 PAPER EXIT SENSOR..................................................................3-43
3.5.7 PAPER SENSOR / OHP SENSOR.................................................3-44
3.5.8 PAPER SIZE SENSOR..................................................................3-45
3.5.9 DRUM PAPER JAM SENSOR .......................................................3-46
3.5.10 OIL SENSOR................................................................................3-47
3.5.11 DRUM ENCODER SENSOR........................................................3-48
3.5.12 BELT SENSOR ............................................................................3-49
3.5.13 WASTE TONER SENSOR...........................................................3-50
3.5.14 TONER SENSOR ASSEMBLY..................................................... 3-51
3.5.15 CLEANING ROLLER SENSOR ....................................................3-52
3.5.16 PAPER EXIT TRAY FULL SENSOR............................................3-53
3.5.17 TONER TYPE SENSOR...............................................................3-54
3.6 DRUM AND ROLLERS ...........................................................................3-55
3.6.1 TRANSFER UNIT...........................................................................3-55
3.6.2 REGISTRATION ROLLER .............................................................3-56
3.6.3 TRANSFER DRUM.........................................................................3-57
3.6.4 PAPER FEED ROLLER / SEPARATION PAD...............................3-58
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3.6.5 FRONT COVER UNIT....................................................................3-59
3.6.6 PAPER EXIT ROLLER...................................................................3-60
3.6.7 DISCHARGER BRUSH..................................................................3-61
3.6.8 FUSING UNIT CONNECTOR.........................................................3-62
3.6.9 LOWER WASTE TONER FEEDER................................................3-63
3.7 FUSING UNIT..........................................................................................3-64
3.7.1 INTRODUCTORY NOTES .............................................................3-64
3.7.2 FUSING LAMPS / OIL PAN UNIT ..................................................3-65
3.8 MCTL FIRMWARE DOWNLOAD............................................................ 3-66
4 TROUBLESHOOTING ................................................................. 4-1
4.1 OVERVIEW...............................................................................................4-1
4.2 OPERATOR CALLS..................................................................................4-2
4.2.1 OVERVIEW......................................................................................4-2
4.2.2 TROUBLESHOOTING TIPS.............................................................4-4
4.3 PAPER TRANSPORT ERRORS...............................................................4-7
4.4 PRINTER ERRORS .................................................................................. 4-9
4.4.1 OVERVIEW......................................................................................4-9
4.4.2 ERROR CODE TABLE...................................................................4-10
4.4.3 TROUBLESHOOTING TIPS...........................................................4-11
4.5 IMAGING FAILURE .................................................................................4-29
4.5.1 DEFECTS AT REGULAR INTERVALS ON THE IMAGE...............4-29
4.5.2 IMAGING FAILURE TROUBLESHOOTING...................................4-30
5 SERVICE TABLES....................................................................... 5-1
5.1 PANEL LAYOUT.......................................................................................5-1
5.2 SP MODE..................................................................................................5-2
5.2.1 OVERVIEW......................................................................................5-2
5.3 SERVICE MODE (ENGINE SP MODE) OVERVIEW................................5-2
5.4 SERVICE MODE (ENGINE SP MODE) ....................................................5-4
5.4.1 OVERVIEW......................................................................................5-4
5.4.2 PROCEDURES................................................................................5-6
5.5 ADJUSTMENT PROCEDURES..............................................................5-31
5.5.1 ADJUSTING THE LEADING EDGE AND LEFT SIDE
REGISTRATIONS..........................................................................5-31
5.5.2 NVRAM TUNE UP..........................................................................5-32
5.5.3 SETTING THE NEXT LIFE LIMIT VALUE......................................5-33
6 DETAILED DESCRIPTIONS........................................................ 6-1
6.1 OVERVIEW...............................................................................................6-1
6.1.1 MAIN UNITS.....................................................................................6-1
6.1.2 BASIC COLOR PRINTING MECHANISM........................................6-3
6.1.3 OPC BELT STRUCTURE.................................................................6-5
6.2 PRINT SYSTEM AND TRANSFER SYSTEM............................................6-6
6.2.1 INTRODUCTION.............................................................................. 6-6
6.2.2 PRINTER COMPONENTS...............................................................6-7
6.2.3 THE PRINTING SYSTEM.................................................................6-8
6.2.4 PROCESS DETAILS......................................................................6-10
Charge................................................................................................6-10
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Exposure.............................................................................................6-11
Development.......................................................................................6-12
Toner Cartridge Positioning Mechanism.............................................6-14
Toner End Sensor...............................................................................6-16
First Transfer (From Belt to Drum)......................................................6-17
The Transfer Drum .............................................................................6-17
First Transfer Process.........................................................................6-18
Belt Discharging (Quenching Lamp)...................................................6-19
Discharge Process..............................................................................6-19
Belt Cleaning ......................................................................................6-20
Second Transfer (From Drum to Paper).............................................6-21
Second Transfer Components............................................................6-21
Second Transfer Process...................................................................6-21
Paper Discharging..............................................................................6-22
Drum Cleaning ....................................................................................6-23
6.3 OPTICAL SYSTEM .................................................................................6-24
6.3.1 OUTLINE........................................................................................6-24
6.3.2 OPTICAL SYSTEM COMPONENTS..............................................6-24
6.3.3 SPECIFICATIONS..........................................................................6-25
6.4 PAPER TRANSPORTATION SYSTEM...................................................6-26
6.4.1 OUTLINE........................................................................................6-26
6.4.2 PAPER TRANSPORTATION SYSTEM COMPONENTS...............6-26
6.4.3 OHP SENSOR................................................................................6-27
6.5 FUSING UNIT..........................................................................................6-28
6.5.1 OVERVIEW....................................................................................6-28
6.5.2 COMPONENTS..............................................................................6-28
6.5.3 FUSING PROCESS........................................................................6-29
6.6 CONTROL SYSTEM...............................................................................6-30
6.6.1 COMPONENTS..............................................................................6-30
Sequence Control Components..........................................................6-30
PCBs...................................................................................................6-32
Motors and Interlock Switches............................................................6-33
Clutches and Solenoids......................................................................6-34
Sensors...............................................................................................6-35
6.6.2 CONTROL SYSTEM......................................................................6-37
Print Process Control..........................................................................6-37
Laser Drive Control Circuit..................................................................6-37
Operation............................................................................................6-37
Fusing Temperature Control...............................................................6-38
Temperature Control Circuit................................................................6-38
Temperature Control and Safety.........................................................6-40
Service Codes Generated by Temperature Control Signals...............6-40
Interface Control.................................................................................6-41
General...............................................................................................6-41
iv
CONTROLLER
1 INSTALLATION ........................................................................... 1-1
2 PERIODIC MAINTENANCE......................................................... 2-1
3 REPLACEMENT AND ADJUSTMENT......................................... 3-1
3.1 CONTROLLER BOARD REPLACEMENT ................................................3-1
3.2 REGISTRATION ADJUSTMENT...............................................................3-1
3.3 IMAGE ADJUSTMENT..............................................................................3-2
3.3.1 OVERVIEW......................................................................................3-2
3.3.2 SERVICE GAMMA ADJUSTMENT..................................................3-3
Adjustment Menu (Controller SP, S7. Gamma Calibration)..................3-3
Adjustment Overview............................................................................3-4
Adjustment Procedure ..........................................................................3-5
3.3.3 SOFTWARE UPGRADE PROCEDURE...........................................3-6
4 TROUBLESHOOTING ................................................................. 4-1
4.1 TYPES OF PROBLEMS............................................................................4-1
4.2 TROUBLESHOOTING PROCEDURE.......................................................4-2
4.2.1 HARDWARE TESTS........................................................................ 4-2
4.2.2 OPERATION-RELATED TESTS......................................................4-2
4.2.3 SOFTWARE-RELATED TESTS.......................................................4-3
4.3 ERROR MESSAGES ................................................................................4-4
4.3.1 OVERVIEW......................................................................................4-4
4.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS.............................4-5
4.3.3 CONTROLLER USER ERRORS......................................................4-6
4.3.4 INTERNAL ERRORS........................................................................4-7
4.3.5 ENGINE USER ERRORS (CAUTIONARY)......................................4-8
4.3.6 ENGINE USER ERRORS................................................................. 4-9
4.3.7 ENGINE SERVICE CODES ...........................................................4-10
5 SERVICE TABLES....................................................................... 5-1
5.1 SP MODES ...............................................................................................5-1
5.1.1 OVERVIEW......................................................................................5-1
5.1.2 ENGINE SP MODE..........................................................................5-1
5.1.3 CONTROLLER SP MODE................................................................5-1
Entering and Exiting Controller SP Mode..............................................5-1
SP Mode Menu Hierarchy.....................................................................5-2
5.1.4 SP MODE DETAILS.........................................................................5-3
S1. Maintenance Page..........................................................................5-3
Toner density setting.............................................................................5-4
S2. Color Chart.....................................................................................5-5
S3. Maintenance Clear.........................................................................5-5
S4. Transfer Bias..................................................................................5-5
S5. Registration....................................................................................5-5
S6. Clear All Memory............................................................................5-5
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S7. Gamma Calibration.........................................................................5-6
S8. Printer ID........................................................................................5-6
S9. Toner Limiter..................................................................................5-6
Sa Meter Click ......................................................................................5-7
5.2 DETAILED SELF-DIAGNOSTICS MODE .................................................5-8
Overview...............................................................................................5-8
Operating Procedure.............................................................................5-8
Operation Panel Behaviour during Detailed Self-diagnostics................5-9
Immediately after power is turned on....................................................5-9
During detailed self-diagnostics............................................................5-9
When the tests terminate normally........................................................5-9
When an error is detected.....................................................................5-9
Detailed Self-diagnostics Flow Chart..................................................5-10
Test Results Printout when No Fatal Errors Occur.............................5-11
5.3 BRAND SETTING ...................................................................................5-11
Operating Procedure...........................................................................5-11
6 DETAILED DESCRIPTIONS........................................................ 6-1
6.1 FUNCTIONAL OVERVIEW .......................................................................6-1
6.1.1 PRINT DATA PROCESSING ...........................................................6-1
CMS (Color Management System).......................................................6-2
Color Adjustment by the Driver.............................................................6-2
Color Conversion, Gamma Conversion, and Dithering by
the Controller.....................................................................................6-2
6.1.2 GAMMA CORRECTION...................................................................6-2
Controller gamma.................................................................................6-2
Service gamma..................................................................................... 6-2
6.2 FUNCTIONAL DESCRIPTION..................................................................6-3
6.2.1 CONTROLLER LAYOUT..................................................................6-3
6.2.2 FUNCTIONS OF COMPONENTS....................................................6-4
6.3 POWER-UP SELF-DIAGNOSTICS...........................................................6-5
6.3.1 OPERATION PANEL DISPLAY DURING POWER-UP
SELF-DIAGNOSTICS.......................................................................6-5
Immediately after turning the power on.................................................6-5
During power-up self-diagnostics..........................................................6-5
If the test terminates normally...............................................................6-5
If an error is detected............................................................................6-5
Non-fatal error (user error) detected.....................................................6-6
Fatal error detected ..............................................................................6-6
6.4 POWER-UP SELF-DIAGNOSTICS FLOW CHART .................................. 6-7
vi
PERIPHERALS
DUPLEX
1 REPLACEMENT AND ADJUSTMENT................................G657D-1
1.1 COVERS AND PAPER GUIDES..................................................... G657D-1
1.1.1 RIGHT SIDE COVER LOW .................................................... G657D-1
1.1.2 LEFT SIDE COVER LOW....................................................... G657D-1
1.1.3 RIGHT COVER TOP..............................................................G657D-2
1.1.4 LEFT COVER TOP................................................................. G657D-2
1.1.5 COVER TOP ASSY 1 (WITH 4 GUIDE ROLLERS)................ G657D-3
1.1.6 COVER TOP ASSY 2 (WITH 4 GUIDE ROLLERS)................ G657D-4
1.1.7 COVER LOW ASSY (INCLUDING 4 GUIDE ROLLERS,
HANDLE, AND LOCK LEVER)............................................... G657D-5
1.1.8 BOTTOM COVER ASS’Y....................................................... G657D-6
1.1.9 PAPER GUIDE RVS UNIT ..................................................... G657D-7
1.1.10 PAPER GUIDE RVS IN........................................................ G657D-8
1.1.11 PAPER GUIDE BOTTOM..................................................... G657D-9
1.2 PAPER TOP ASSY.......................................................................G657D-10
1.2.1 SEPARATION OF D TOP UNIT AND D LOWER UNIT........ G657D-10
1.2.2 PAPER GUIDE TOP ASSY.................................................. G657D-10
1.3 PCB............................................................................................... G657D-11
1.3.1 DUPLEX UNIT CONTROLLER BOARD............................... G657D-11
1.3.2 RELAY BOARD.................................................................... G657D-12
1.4 MOTORS....................................................................................... G657D-13
1.4.1 MOTOR (1) ........................................................................... G657D-13
1.4.2 MOTOR (2) ........................................................................... G657D-14
1.4.3 FAN MOTOR........................................................................ G657D-15
1.5 SOLENOID ASSEMBLIES............................................................ G657D-16
1.5.1 UPPER SOLENOID ASS’Y.................................................. G657D-16
1.5.2 LOWER SOLENOID ASS’Y................................................. G657D-16
1.6 SENSORS AND SWITCHES......................................................... G657D-17
1.6.1 INTERLOCK SWITCHES (D-SW1, D-SW2)......................... G657D-17
1.6.2 INTERLOCK SWITCH (D-SW3, D-SW4).............................. G657D-17
1.6.3 DUPLEX PAPER SENSOR (PT5)........................................ G657D-18
1.6.4 PAPER SENSOR LOW (PT4)..............................................G657D-18
2 DETAILED SECTION DESCRIPTIONS ............................ G657D-19
2.1 INTERNAL STRUCTURE.............................................................. G657D-19
2.2 PAPER FEED PATH FOR DUPLEX PRINTING...........................G657D-20
2.2.1 FEED PATH FOR PRINTING THE REAR SIDE (B FACE).. G657D-20
2.2.2 FEED PATH FOR PRINTING THE FRONT SIDE (A FACE) G657D-20
2.3 DUPLEX PRINT MODES.............................................................. G657D-21
2.3.1 DUP-1 MODE....................................................................... G657D-21
2.3.2 DUP-2 MODE....................................................................... G657D-22
2.3.3 DUP-3 MODE....................................................................... G657D-23
vii
PFU
1 REPLACEMENT AND ADJUSTMENT................................ G657P-1
1.1 COVER.............................................................................................G657P-1
1.1.1 RIGHT TOP COVER...............................................................G657P-1
1.1.2 LEFT TOP COVER..................................................................G657P-1
1.1.3 RIGHT BASE COVER.............................................................G657P-2
1.1.4 LEFT BASE COVER................................................................G657P-2
1.1.5 FRONT TOP COVER..............................................................G657P-2
1.2 PAPER SENSOR (PEL)...................................................................G657P-3
1.3 PAPER FEEDING ROLLER/SEPARATOR PAD (2) ........................G657P-3
1.4 PAPER FEEDING CLUTCH (PKCLL)/LF CLUTCH D (DPKCL).......G657P-4
1.5 PAPER SIZE SENSOR 2 (SL2-PS-A57 PWB ASSY)......................G657P-5
NIB
1 OVERVIEW......................................................................... G678N-1
1.1 BLOCK DIAGRAM........................................................................... G678N-1
1.2 COMPONENT LAYOUT.................................................................. G678N-2
1.2.1 NETWORK INTERFACE BOARD DIAGRAM......................... G678N-2
1.2.2 DEVICES................................................................................ G678N-2
1.3 DETAILED SECTION DESCRIPTIONS.......................................... G678N-3
1.3.1 OVERVIEW............................................................................ G678N-3
1.3.2 NVRAM RESET...................................................................... G678N-3
NVRAM Reset Procedure........................................................... G678N-3
viii
17 January, 2001 INSTALLATION ENVIRONMENT
1. INSTALLATION
1.1 INSTALLATION ENVIRONMENT
If the printer is set up in an inappropriate location, it may not function as expected.
Therefore, the following factors should be taken into consideration prior to deciding
where to install the printer.
Do NOT place the printer in a place where it is:
• Likely to encounter direct sunlight or strong light. (For example, by a window.)
• Likely to encounter wide ranges of temperature and humidity. (Normal operation
environment is within 10 ~ 32.5°C, 20 ~ 80%RH and without condensation.)
• Likely to encounter cold air from an air-conditioner, warm air from a heater, or
direct radiant heat.
• Likely to encounter a lot of dust or exposure to corrosive gases such as
ammonia.
During Operation
Installation
Ambient Humidity (%RH)
Ambient Temperature (°C)
Recommended
Conditions:
17.5 to 27°C
50 to 70%RH
G063I001.WMF
1-1
INSTALLATION ENVIRONMENT 17 January, 2001
Place the printer:
• Near good ventilation
• On a stable, strong, flat surface.
• With a maximum tilt of 1°.
Make sure to stand the printer on all of its legs. Otherwise, the frame will
warp and belt home position errors will occur.
10 cm (4")
40 cm (16")
Rear
70 cm (28")
Front
10 cm (4")
G063I000.WMF
1-2
17 January, 2001 INSTALLATION NOTES
1.2 INSTALLATION NOTES
• For installation procedures, see the Operating Instructions.
• When installing the toner cartridge, do not force it into the machine. Otherwise,
the development roller may be pushed into contact with the OPC belt.
• Make sure that the correct brand name is selected (Refer to 5 - 3 Brand Setting
in the controller manual). This ensures that the correct model name is displayed
on the configuration page and on the LCD.
1.3 RELOCATION PROCEDURE
CAUTION: Observe the following precautions when relocating this unit:
1. This unit requires two or more persons to carry it, because it weighs about
36kg.
2. Keep the unit level during transportation (do not put pressure on any single part
of the base).
3. Whenever possible, use the packing materials shipped with the unit.
4. Carry the unit AFTER removing the following supply parts:
• Fusing Unit Oil Bottle
• Toner Cartridge
• Photoconductor Unit
• Waste Toner Bottle
5. Be sure to protect the photoconductor unit surface with paper.
6. Be sure to remove the following items from various units:
• Silicone oil from the fusing unit oil sump (with a syringe).
• Paper from the cassette
• Optional paper feed unit (remove from the machine)
7. Clean the interior of the unit before re-packing.
8. Secure the front, rear, and top covers with tape so that they do not open and
cassettes can not fall out.
Installation
CAUTION: Since oil and toner will spill if they remain inside the unit if it is carried,
be sure to remove those items and clean the unit before relocating it.
If oil gets on the transfer belt, printouts may be faded.
1-3
17 January, 2001 HANDLING PRECAUTIONS
2. PREVENTIVE MAINTENANCE
2.1 HANDLING PRECAUTIONS
Since a high quality laser printer is a precision instrument, daily checks and
periodic maintenance are indispensable to maintain high performance.
The following is a list of important precautions for maintenance and periodic
replacement of parts:
1. Refrain from any operation, disassembly, or modification that is not specified in
this manual.
2. When assembling or disassembling the printer, turn the power supply off first
and be sure to unplug the power supply cord before starting any work.
3. After replacing parts, make sure that the replaced parts are in place before
starting the printer.
4. Carefully read all precautions and warning labels attached to any parts.
5. Unless otherwise specified, precisely follow the reverse order of the
disassembly procedures for re-assembly. Be careful not to confuse the type
and size of removed screws.
6. Do NOT use a solvent to clean any part of the printer.
7. It is strictly forbidden by law to dump or burn waste toner. Follow the
appropriate laws for proper disposal of waste toner in your area.
Preventive
Maintenance
2-1
MAINTENANCE BASICS 17 January, 2001
2.2 MAINTENANCE BASICS
2.2.1 CLEANING
Clean the following whenever you visit the customer. Details follow in the ‘Periodic
Cleaning’ section.
• Registration roller
• Transfer roller
• Paper discharger
• Belt cartridge, cleaning blade, charge corona wire
• Dust shield glass (optics unit)
• Inside the printer
2.2.2 REPLACEMENT
Replace the following parts at the stated interval. Details follow in a later section.
• Fusing unit (about 60 k prints, the exact interval depends on the average image
ratio during the life of the part)
• Transfer roller (120 k prints)
• Paper discharger (120 k prints)
• Drum cleaner (120 k prints)
• Paper feed roller and separation pad (120 k prints)
• Transfer drum (300 k images – the same as 120 k prints if the ratio of
monochrome printouts to color printouts is 1:1)
The following gives an outline of the maintenance procedure, and how to use both
the controller and engine SP modes dur i ng mai nte nance.
!
CAUTION
When turning off the unit to perform periodic maintenance, make sure that
no data has been sent to the printer.
1. Enter controller SP mode and print a configuration page (user menu),
maintenance page (S1), and a color chart (S2). The configuration page is
required to restore the settings if they are altered during maintenance. Refer to
the controller service manual for how to use controller SP modes.
2. Perform the periodic maintenance and cleaning procedures as instructed in the
Periodic Maintenance – Periodic Cleaning section of this manual.
3. Examine the color chart to check the densities of the solid images and the
grayscales in the images with gradations. If an anomaly is found, check the
engine (see ‘4.Troubleshooting – 4.5 Imaging’ in this manual).
4. If the “Change Fuser” and/or “Change 120K” message appears, replace the
fusing unit and/or the parts in the 120k maintenance kit.
Then, use either controller SP mode S3 (Maint. Clear) or engine SP mode 36
(Clear Care) to reset the counters for the fusing unit and 120k kit.
For details on the replacement items and procedures, refer to ‘2. Preventive
Maintenance – 2.4 Periodic Replacement’ in this manual).
2-2
17 January, 2001 PERIODIC CLEANING
2.3 PERIODIC CLEANING
2.3.1 OVERVIEW
!
WARNING
Before starting any cleaning, unplug the printer.
There is a risk of electric shock in working while the printer is energized.
Name of Part Cleaning Symptoms Prevented
Registration
Roller
Transfer Roller
Paper
Discharger
1. Open the transfer unit
2. Clean the roller and neighboring areas
with a dry cloth.
1. Open the transfer unit.
2. Clean the roller and neighboring areas
with a dry cloth.
1. Open the transfer unit.
2. Remove the paper discharge unit.
Defective print quality
Smeared paper
Defective print quality
Smeared paper
Defective print quality
Paper jam
Preventive
Maintenance
Belt Cartridge
Optical Unit
Dust Shield
Glass
Printer Interior
3. Clean the corona wire and case with a
cotton bud or dry cloth.
1. Remove the belt cartridge.
2. Clean off the toner around the belt
cartridge and cleaning blade.
3. Clean the charge corona wire with a
wire brush.
1. Remove the toner cartridge.
2. Remove the belt cartridge.
3. Remove the dust shield glass.
4. Using a dry cloth or cotton bud, clean
off any stains on the dust-proof glass.
1. Remove the toner and belt cartridges.
2. Clean the base of the printer with a
vacuum cleaner and wipe it with a dry
cloth.
Defective print quality
Defective print quality
Defective print quality
2-3
PERIODIC CLEANING 17 January, 2001
2.3.2 DAILY MAINTENANCE
There is no part in the standard or optional paper feed units that requires daily
maintenance, such as cleaning etc.
2.3.3 PERIODIC MAINTENANCE
There is no part in the standard or optional paper feed units that requires periodic
replacement. However, it is recommended for good paper feed performance to
replace the following parts in accordance with the periodic replacement cycle
based on the counter of the main engine.
Part Name Part Code Replacement Cycle
Paper Feed Roller 126142
Separator Pad (2) * 126528
*: ‘Separator Pad (2)’ is a part name. The ‘2’ does not indicate the quantity; there is
only one separator pad in the main engine paper feed section. There is another
pad, with the same name, in the optional paper feed unit.
Every 120k prints
2-4
17 January, 2001 PERIODIC CLEANING
2.3.4 PROCEDURES
(1) Registration Roller Cleaning
[A]
[B]
G063P011.WMF
Preventive
Maintenance
[A]
[B]
G063P008.WMF
Materials
1. Dry cotton cloth (2 ~ 3 pieces)
Cleaning Procedure
1. Turn off the power supply, and unplug the power cord.
2. Open the transfer unit [A].
3. Using the cotton cloth, clean the registration roller [B] in the transfer unit.
CAUTION: Do NOT use alcohol or a similar solvent to clean the registration roller.
2-5
PERIODIC CLEANING 17 January, 2001
(2) Transfer Roller Cleaning
[A]
[B]
G063P011.WMF
[B]
[A]
G063P009.WMF
Materials
1. Dry cotton cloth (2 ~ 3 pieces)
Cleaning Procedure
1. Turn off the power supply, and unplug the power cord.
2. Open the transfer unit [A].
3. Using a cotton cloth, clean the transfer roller [B].
CAUTION: Do not use alcohol or a similar solvent to clean the transfer roller.
2-6
17 January, 2001 PERIODIC CLEANING
(3) Paper Discharger Cleaning (AC Corona Unit)
Materials
1. Dry cotton cloth (2 to 3 pieces).
2. Cotton buds (2 to 3)
[C]
[D]
[E]
G063P010.WMF
[A]
[G]
[B]
[I]
[H]
Preventive
Maintenance
[F]
G063P002.WMF
Cleaning Procedure
1. Turn off the power, and unplug the machine.
2. Open the transfer unit [A].
3. Remove the paper discharger unit [B].
1) Slide the AC corona unit [C] in the direction of the arrow, and release it from
the locking claw [D].
2) Pull up the AC corona unit to remove it from the transfer unit holder [E].
4. Clean the case [F] with a cotton cloth [G].
5. Clean the corona wire [H] and inside the case with a cotton bud [I].
CAUTION: Do not break the corona wire when cleaning the paper discharger unit.
2-7
PERIODIC CLEANING 17 January, 2001
(4) Photoconductor Unit (Belt Cartridge) Cleaning
CAUTION: 1) Do NOT expose the OPC belt to more than 800 luxes of light (i.e.,
ordinary office light) for more than two minutes.
2) Do NOT touch the surface of the OPC belt.
NOTE: The photoconductor unit is sometimes referred to in the documentation as
the ‘belt cartridge’.
Materials
1. Clean cotton cloth (2 ~ 3 pieces)
[D]
[C]
[A]
G063R575.BMP
e
d
i
l
S
[B]
G063R031.WMF
2-8
17 January, 2001 PERIODIC CLEANING
Cleaning Procedure
1. Turn off the power supply switch.
2. Open the paper exit cover.
3. Open the front cover unit.
4. Release the lock mechanism for the belt cartri dg e.
5. Pull out the belt cartridge [A].
6. Clean the belt cartridge with a cotton cloth.
1) Clean the rear of the belt cartridge.
2) Holding the wire cleaner [B] attached to corona case, slide the wire cleaner
to left and right for several times along the corona case [C]. After completing
this operation, put the wire cleaner back to the original position.
3) Clean the belt cartridge case [D].
CAUTION: Take care NOT to break the corona wire when cleaning it.
Preventive
Maintenance
2-9
PERIODIC CLEANING 17 January, 2001
(5) Optics Unit Dust Shield Glass Cleaning
Materials
1. Dry cotton cloth (2 ~ 3 pieces)
2. Cotton buds (2 ~ 3)
[E]
[C]
Cleaning Procedure
1. Turn off the power supply switch.
2. Open the paper exit cover.
3. Open the front cover unit.
[A]
LASER2.TIF
[D]
[B]
G063P004.WMF
4. Remove the toner cartridges.
5. Remove the belt cartridge.
6. Holding the knobs [A] on the glass frame [B], carefully remove it from the
optical unit [C].
7. Clean the surface of the glass with a cotton bud or cloth.
Reinstallation
NOTE: Align the triangle mark on the glass [D] with the similar mark [E] on the
optical unit, then push the dust shield glass in until it is firmly locked.
CAUTION: Do NOT use alcohol or a similar solvent to clean the glass, or print
quality will deteriorate.
2-10
17 January, 2001 PERIODIC CLEANING
(6) Printer Interior Cleaning
[B]
[A]
G063P005.WMF
Materials
Preventive
Maintenance
1. Compact vacuum cleaner, specially designed for vacuuming toner [A]
2. Dry cotton cloth (2 to 3 pieces)
Cleaning Procedure
1. Open the paper exit cover.
2. Open the front cover.
3. Remove the toner cartridge.
4. Remove the belt cartridge.
5. Vacuum toner scattered on the bottom of the printer interior [B]
6. Clean the printer interior with a cotton cloth.
7. Put back the removed units.
2-11
PERIODIC REPLACEMENT 17 January, 2001
2.4 PERIODIC REPLACEMENT
2.4.1 OVERVIEW
Component Cycle
Fusing Unit 60k prints *1
Transfer Roller 120k prints
Paper Discharge Unit 120k prints
Drum Cleaner 120k prints
Paper Feed Roller/Separat ion Pad 120k prints
Transfer Drum 300k images. *2
*1: The machine calculates the fusing unit replacement cycle from the image
ratio. The greater the image ratio, the shorter the cycle.
Example: If the image ratio is 5% for each color, the total image ratio is 20%
for all four colours. The machine will ask the user to repla c e the fusing unit
after 50k copies (this value is 60k if the image ratio is less than 12.5%). See
section 5.5.3 for details on how the machine changes the replacement cycle
depending on image ratio.
*2: The image count is 1 for one monochrome print and 4 for a full color print. If
the user makes monochrome and full color prints at a ratio of 1:1 on average,
the image count per sheet (averaged out) is 2.5. In this condition, 300 k
images is the same as 120 k prints.
After replacing a part, reset the maintenance counters as explained in each
procedure.
2-12
17 January, 2001 PERI O DI C REPLACEMENT
Fusing Unit Replacement
(1) Replacement Criteria
Replace when this error message appears on
the operation panel LCD.
IPDL-C
Change Fuser
(2) Purpose of Replacement
To prevent print quality decline caused by fusing unit roller wear.
(3) Precaution
!
WARNING
The fusing unit and surrounding parts are very hot. Make sure, prior to
starting replacement, that the fusing unit and surrounding parts are cool,
otherwise, you may get burned.
HOT.BMP
(4) Necessary tools and replacement materials
1. Two or three pieces of cotton cloth.
2. New fusing unit
Preventive
Maintenance
2-13
PERIODIC REPLACEMENT 17 January, 2001
(5) Procedure
- Disassembly [B]
[C]
[A]
G063R034.WMF
1. After turning the power off, unplug the machine.
2. Open the paper exit unit [A].
3. Loosen the screws.
1) Place a sheet of paper over the transfer drum surface to protect it.
2) Loosen the screws [B] at both left and right sides.
4. Holding the handles [C] at both sides of the fusing unit, remove the fusing unit.
!
CAUTION
When removing the fusing unit, keep it level so that oil does not leak.
2-14
17 January, 2001 PERI O DI C REPLACEMENT
NOTE: Before installing a new fusing unit, restore the tension-release levers (left
and right side) in the arrow direction.
Preventive
Maintenance
G063R035.WMF
2-15
PERIODIC REPLACEMENT 17 January, 2001
Transfer Roller Replacement
(1) Replacement Criteria
When it is time to replace the transfer roller,
an error message appears on the operati on
panel LCD.
IPDL-C
Change 120K
(2) Replacement Purpose
Prevents transfer efficiency from declining due to transfer roller wear.
(3) Necessary tools and replacement materials
1. Two or three pieces of cotton cloth for cleaning.
2. New transfer roller
(4) Procedure
[A]
G063P021.WMF
- Disassembly -
1. After turning the power off, unplug the machine.
2. Open the lower rear cove r [A].
2-16
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