Ricoh ap2700 Service Manual ap2700
Russian Printer
Aficio AP2700
SERVICE MANUAL
October 1st, 1999
Subject to change
I
IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the printer power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. Note that some components of the printer and the paper tray unit are
supplied with electrical voltage even if the main power switch is turned off.
4. 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.
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
1. 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 installed and maintained by a
customer service representative who has completed the training course on
those models.
2. The NVRAM on the system control board 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, developer, and organic photoconductors 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 or der to dispos e 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
ø
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
WARNING
ø
WARNING: Turn off the main switch before attempting any of the
procedures in the Laser 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.
TABLE OF CONTENTS
1. OVERALL MACHINE INFORMAT ION........................................1-1
1.1 SPECIFICATIONS.................................................................................... 1-1
1.1.1 GENERAL SPECIFICATIONS......................................................... 1-1
1.1.2 SUPPORTED PAPER SIZES.......................................................... 1-3
1.2 SOFTWARE ACCESSORIES................................................................... 1-4
1.2.1 PRINTER DRIVERS........................................................................ 1-4
1.2.2 UTILITY SOFTWARE...................................................................... 1-4
1.2.3 SERVICE TOOLS............................................................................ 1-4
1.3 MACHINE CONFIGURATION.................................................................. 1-5
1.3.1 SYSTEM COMPONENTS ............................................................... 1-5
1.4 PAPER PATH........................................................................................... 1-7
1.5 MECHANICAL COMPONENT LAYOUT................................................... 1-8
1.6 ELECTRICAL COMPONENT DESCRIPTIONS........................................ 1-9
1.7 PRINTING PROCESS............................................................................ 1-11
1.8 BOARD STRUCTURE............................................................................ 1-13
1.8.1 OVERVIEW ................................................................................... 1-13
1.8.2 DESCRIPTIONS............................................................................ 1-14
2. DETAILED SECTION DESCRIPTIONS.......................................2-1
2.1 LASER EXPOSURE................................................................................. 2-1
2.1.1 OVERVIEW ..................................................................................... 2-1
2.1.2 AUTO POWER CONTROL (APC)................................................... 2-2
2.1.3 LD SAFETY SWITCH...................................................................... 2-3
2.2 PHOTOCONDUCTOR UNIT (PCU).......................................................... 2-4
2.2.1 OVERVIEW ..................................................................................... 2-4
2.2.2 DRIVE MECHANISM....................................................................... 2-5
2.2.3 NEW PCU DETECTION MECHANINSM......................................... 2-6
2.3 DRUM CHARGE....................................................................................... 2-7
2.3.1 OVERVIEW ..................................................................................... 2-7
2.3.2 CHARGE ROLLER VOLTAGE CORRECTION............................... 2-8
2.3.3 ID SENSOR PATTERN PRODUCTION TIMING............................. 2-9
2.3.4 DRUM CHARGE ROLLER CLEANING......................................... 2-10
2.4 DEVELOPMENT..................................................................................... 2-11
2.4.1 OVERVIEW ................................................................................... 2-11
2.4.2 DRIVE MECHANISM..................................................................... 2-12
2.4.3 DEVELOPER MIXING................................................................... 2-13
2.4.4 DEVELOPMENT BIAS................................................................... 2-14
2.4.5 TONER SUPPLY........................................................................... 2-15
2.4.6 TONER DENSITY CONTROL....................................................... 2-17
2.4.7 TONER NEAR END/END DETECTION AND RECOVERY........... 2-21
2.5 DRUM CLEANING AND TONER RECYCLING...................................... 2-22
2.5.1 DRUM CLEANING......................................................................... 2-22
2.5.2 TONER RECYCLING .................................................................... 2-23
i
2.6 PAPER FEED.........................................................................................2-24
2.6.1 OVERVIEW ................................................................................... 2-24
2.6.2 PAPER FEED DRIVE MECHANISM ............................................. 2-25
2.6.3 PAPER FEED AND SEPARATION MECHANISM......................... 2-26
2.6.4 PAPER LIFT MECHANISM............................................................ 2-27
2.6.5 PAPER END DETECTION............................................................. 2-28
2.6.6 PAPER HEIGHT DETECTION....................................................... 2-29
2.6.7 PAPER SIZE DETECTION............................................................ 2-30
2.6.8 SPECIAL PAPER SETTING.......................................................... 2-31
2.6.9 SIDE AND END FENCES.............................................................. 2-32
2.6.10 PAPER REGISTRATION............................................................. 2-33
2.7 IMAGE TRANSFER AND PAPER SEPARATION.................................. 2-34
2.7.1 OVERVIEW ................................................................................... 2-34
2.7.2 IMAGE TRANSFER MECHANISM................................................ 2-35
2.7.3 TRANSFER ROLLER CLEANING................................................. 2-36
2.7.4 PAPER SEPARATION MECHANISM............................................ 2-36
2.8 IMAGE FUSING AND PAPER EXIT....................................................... 2-37
2.8.1 OVERVIEW ................................................................................... 2-37
2.8.2 FUSING DRIVE AND RELEASE MECHANISM............................. 2-38
2.8.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM...................... 2-39
2.8.4 PRESSURE ROLLER.................................................................... 2-40
2.8.5 CLEANING MECHANISM.............................................................. 2-40
2.8.6 NEW FUSING UNIT DETECTION................................................. 2-41
2.8.7 FUSING TEMPERATURE CONTROL........................................... 2-42
2.8.8 OVERHEAT PROTECTION........................................................... 2-44
2.8.9 PAPER EXIT.................................................................................. 2-44
2.9 ENERGY SAVER MODES..................................................................... 2-45
2.10 CONTROLLER FUNCTIONS ............................................................... 2-46
2.10.1 PAPER SIZE/TYPE DETECTION AND SELECTION.................. 2-46
2.10.2 PAPER SOURCE SELECTION................................................... 2-46
2.10.3 OUTPUT TRAY SELECTION ......................................................2-48
2.10.4 COLLATION (SORT)................................................................... 2-49
2.10.5 DUPLEX PRINTING .................................................................... 2-50
2.10.6 STAPLING................................................................................... 2-50
2.10.7 PROOF PRINT ............................................................................ 2-51
2.10.8 RESET OPERATIONS ................................................................2-52
2.10.9 HDD (OPTIONAL)........................................................................ 2-52
3. INSTALLA T ION...........................................................................3-1
3.1 INSTALLING THE MACHINE................................................................... 3-1
3.2 INSTALLING OPTIONAL UNITS.............................................................. 3-2
3.2.1 BRIDGE UNIT.................................................................................. 3-2
3.2.2 1,000-SHEET FINISHER................................................................. 3-4
3.2.3 HARD DISK (HDD).......................................................................... 3-6
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4. SERVICE TABLES......................................................................4-1
4.1 GENERAL CAUTION................................................................................ 4-1
4.1.1 PCU................................................................................................. 4-1
4.1.2 TRANSFER ROLLER UNIT............................................................. 4-1
4.1.3 LASER UNIT.................................................................................... 4-1
4.1.4 FUSING UNIT.................................................................................. 4-2
4.1.5 PAPER FEED.................................................................................. 4-2
4.1.6 OTHERS.......................................................................................... 4-2
4.2 SERVICE PROGRAM MODE................................................................... 4-3
4.2.1 ENABLING AND DISABLING SERVICE PROGRAM MODE.......... 4-3
4.2.2 SERVICE PROGRAM MODE MENU TREE.................................... 4-4
4.3 PRINTER CONTROLLER SERVICE MODE............................................ 4-5
4.3.1 BIT SWITCH PROGRAMMING ....................................................... 4-5
4.3.2 NVRAM RESET............................................................................... 4-6
4.3.3 POWER-ON DIAGNOSTICS ERROR DISPLAY............................. 4-7
4.3.4 VENDER MAKER............................................................................ 4-7
4.3.5 SERVICE SUMMARY...................................................................... 4-7
4.4 PRINTER ENGINE SERVICE MODE....................................................... 4-9
4.4.1 SERVICE MODE MENU.................................................................. 4-9
4.4.2 SERVICE MODE TABLES............................................................. 4-10
4.4.3 INPUT CHECK TABLE.................................................................. 4-16
4.4.4 OUTPUT CHECK TABLE.............................................................. 4-20
4.4.5 ENGINE BOARD PROGRAM DOWNLOAD.................................. 4-22
4.5 SERVICE TOOLS................................................................................... 4-23
4.5.1 SERVICE TOOL MENU................................................................. 4-23
4.5.2 HDD TEST..................................................................................... 4-23
4.5.3 HDD FORMAT...............................................................................4-24
4.5.4 NIB NVRAM BACKUP AND RESTORE ........................................ 4-24
4.6 CONTROLLER FIRMWARE UPDATE................................................... 4-26
4.6.1 FIRMWARE DOWNLOAD............................................................. 4-26
4.6.2 ERROR RECOVERY..................................................................... 4-27
4.7 POWER-ON SELF TEST........................................................................ 4-28
4.7.1 PARALLEL LOOP-BACK TEST..................................................... 4-28
4.7.2 OTHER TESTS.............................................................................. 4-28
5. PREVENTIVE MAINTENANCE...................................................5-1
5.1 USER MAINTENANCE............................................................................. 5-1
5.2 SERVICE MAINTENANCE....................................................................... 5-2
5.2.1 PM TABLE....................................................................................... 5-2
6. REPLACEMENT AND ADJUSTMENT........................................ 6-1
6.1 LASER UNIT............................................................................................. 6-1
6.1.1 CAUTION DECAL LOCATIONS...................................................... 6-1
6.1.2 LASER UNIT.................................................................................... 6-2
6.1.3 POLYGONAL MIRROR MOTOR..................................................... 6-4
6.1.4 LASER DIODE (LD) UNIT ............................................................... 6-4
6.1.5 LASER SYNCHRONIZATION DETECTOR..................................... 6-5
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6.2 PHOTOCONDUCTOR UNIT (PCU)..........................................................6-6
6.2.1 PCU.................................................................................................6-6
6.3 TRANSFER UNIT.....................................................................................6-7
6.3.1 TRANSFER ROLLER UNIT.............................................................6-7
6.4 ID SENSOR..............................................................................................6-8
6.5 PAPER EXIT........................................................................................6-9
6.5.1 PAPER EXIT AND OVERFLOW SENSORS...................................6-9
6.6 PAPER FEED AND REGISTRATION.....................................................6-10
6.6.1 PAPER LIFT MOTORS..................................................................6-10
6.6.2 REGISTRATION CLUTCH.............................................................6-11
6.6.3 PAPER FEED CLUTCHES............................................................6-11
6.6.4 UPPER PAPER TRANSPORT CLUTCH.......................................6-12
6.6.5 LOWER PAPER TRANSPORT CLUTCH......................................6-12
6.6.6 REGISTRATION SENSOR............................................................6-13
6.6.7 UPPER RELAY SENSOR..............................................................6-14
6.6.8 LOWER RELAY SENSOR.............................................................6-15
6.6.9 UPPER PAPER SIZE SENSOR....................................................6-16
6.6.10 LOWER PAPER SIZE SENSOR/SPECIAL PAPER SENSOR....6-17
6.6.11 FEED ROLLERS..........................................................................6-18
6.6.12 PAPER END SENSOR (1ST AND 2ND PAPER FEED TRAYS).6-19
6.7 FUSING..................................................................................................6-20
6.7.1 FUSING UNIT................................................................................6-20
6.7.2 THERMISTOR...............................................................................6-20
6.7.3 THERMOFUSE..............................................................................6-21
6.7.4 HOT ROLLER AND FUSING LAMP..............................................6-22
6.7.5 PRESSURE ROLLER/CLEANING ROLLER.................................6-23
6.8 PCBS AND MOTORS.............................................................................6-24
6.8.1 PSU...............................................................................................6-24
6.8.2 ENGINE BOARD...........................................................................6-25
6.8.3 PRINTER CONTROLLER / NIB.....................................................6-26
6.8.4 HIGH VOLTAGE SUPPLY BOARD...............................................6-27
6.8.5 MAIN MOTOR................................................................................6-27
6.8.6 TONER BOTTLE MOTOR.............................................................6-28
7. TROUBLESHOOTING.................................................................7-1
7.1 SERVICE CALL CONDITIONS.................................................................7-1
7.1.1 PRINTER ENGINE SC CODES SUMMARY....................................7-1
7.1.2 PRINTER ENGINE SC CODES.......................................................7-2
7.2 PRINTER CONTROLLER ERROR.........................................................7-11
7.2.1 ERROR CODES............................................................................7-11
7.3 CONTROLLER LED DISPLAY...............................................................7-12
7.3.1 LOCATION.....................................................................................7-12
7.3.2 FATAL ERROR..............................................................................7-12
7.4 ELECTRICAL COMPONENT DEFECTS................................................7-15
7.4.1 SENSORS.....................................................................................7-15
7.4.2 SWITCHES....................................................................................7-17
7.5 BLOWN FUSE CONDITIONS.................................................................7-18
iv
OPTIONS
PAPER TRAY UNIT (A860)
1. OVERALL MACHINE INFORMATION..................................A860-1
1.1 SPECIFICATIONS..............................................................................A860-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A860-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A860-3
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A860-4
1.5 DRIVE LAYOUT.................................................................................A860-5
2. DETAILED DESCRIPTIONS.................................................A860-6
2.1 PAPER FEED AND SEPARATION MECHANISM..............................A860-6
2.2 PAPER LIFT MECHANISM................................................................A860-7
2.3 PAPER END DETECTION.................................................................A860-9
2.4 PAPER HEIGHT DETECTION.........................................................A860-10
2.5 PAPER SIZE DETECTION...............................................................A860-12
2.6 SIDE AND END FENCES.................................................................A860-13
Side Fences.................................................................................A860-13
End Fence....................................................................................A860-13
3. REPLACEMENT AND ADJUSTMENT................................A860-14
3.1 FEED ROLLER REPLACEMENT.....................................................A860-14
3.2 TRAY MAIN BOARD REPLACEMENT.............................................A860-15
3.3 TRAY MOTOR REPLACEMENT......................................................A860-15
3.4 RELAY CLUTCH REPLACEMENT...................................................A860-16
3.5 UPPER PAPER FEED CLUTCH REPLACEMENT..........................A860-17
3.6 LOWER PAPER FEED CLUTCH REPLACEMENT..........................A860-18
3.7 LIFT MOTOR REPLACEMENT........................................................A860-19
3.8 PAPER END SENSOR REPLACEMENT.........................................A860-20
3.9 VERTICAL TRANSPORT SENSOR REPLACEMENT.....................A860-20
3.10 PAPER SIZE SWITCH REPLACEMENT........................................A860-21
PAPER TRAY UNIT (A861)
1. OVERALL MACHINE INFORMATION...........................................1
1.1 SPECIFICATIONS........................................................................................1
1.2 MECHANICAL COMPONENT LAYOUT.......................................................2
1.3 ELECTRICAL COMPONENT LAYOUT........................................................3
1.4 ELECTRICAL COMPONENT DESCRIPTION..............................................4
1.5 DRIVE LAYOUT...........................................................................................5
2. DETAILED DESCRIPTIONS..........................................................6
2.1 PAPER FEED AND SEPARATION..............................................................6
2.2 PAPER LIFT MECHANISM..........................................................................7
2.3 PAPER END DETECTION...........................................................................9
v
2.4 PAPER HEIGHT DETECTION ...................................................................10
2.5 PAPER SIZE DETECTION.........................................................................12
2.6 SIDE AND END FENCES...........................................................................13
3. REPLACEMENT AND ADJUSTMENT......................................... 14
3.1 FEED ROLLER REPLACEMENT...............................................................14
3.2 TRAY MAIN BOARD REPLACEMENT....................................................... 15
3.3 TRAY MOTOR REPLACEMENT................................................................15
3.4 TRAY MOTOR REPLACEMENT................................................................16
3.5 LIFT MOTOR REPLACEMENT..................................................................17
3.6 PAPER END SENSOR REPLACEMENT...................................................18
3.7 PAPER SIZE SWITCH REPLACEMENT....................................................18
LCT (A862)
1. OVERALL MACH INE INFORMATION..................................A862-1
1.1 SPECIFICATIONS..............................................................................A862-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A862-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A862-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS..................................A862-4
2. DETAILED SECTION DESCRIPTIONS.................................A862-5
2.1 PAPER FEED.....................................................................................A862-5
2.2 REVERSE ROLLER AND PICK-UP ROLLER RELEASE...................A862-6
2.3 TRAY LIFT..........................................................................................A862-7
2.4 NEAR END/END DETECTION...........................................................A862-8
2.5 RIGHT TRAY SIDE FENCE................................................................A862-9
2.6 LEFT TRAY REAR FENCE................................................................A862-9
2.7 RIGHT TRAY PAPER END DETECTION.........................................A862-10
3. REPLACEMENT AND ADJUSTMENT ................................A862-11
3.1 DETACHING THE TRAY FROM THE MAINFRAME........................A862-11
3.2 REAR FENCE HP SENSOR.............................................................A862-11
3.3 CHANGING THE TRAY PAPER SIZE..............................................A862-12
3.4 LEFT TRAY PAPER END SENSOR.................................................A862-12
3.5 TRAY LIFT MOTOR..........................................................................A862-13
3.6 TRAY MOTOR..................................................................................A862-14
3.7 PAPER FEED CLUTCH AND RELAY CLUTCH...............................A862-15
3.8 PAPER FEED UNIT..........................................................................A862-16
3.9 UPPER LIMIT, RIGHT TRAY PAPER END, AND
RELAY SENSORS...........................................................................A862-17
3.10 REAR FENCE MOTOR..................................................................A862-18
3.11 PICK-UP/PAPER FEED/REVERSE ROLLERS..............................A862-19
vi
BY-PASS UNIT (A899)
1 OVERALL MACHINE INFORMATION...................................A899-1
1.1 SPECIFICATIONS..............................................................................A899-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A899-1
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A899-2
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A899-2
2 DETAILED DESCRIPTIONS..................................................A899-3
2.1 BASIC OPERATION...........................................................................A899-3
2.2 PAPER SIZE DETECTION.................................................................A899-4
3 REPLACEMENT AND ADJUSTMENT...................................A899-5
3.1 PAPER FEED ROLLER/FRICTION PAD/PAPER END SENSOR......A899-5
3.2 PAPER SIZE SENSOR BOARD.........................................................A899-6
3.3 PAPER FEED CLUTCH......................................................................A899-7
INTERCHANGE UNIT (G531)
1. OVERALL MACH INE INFORMATION................................. G531-1
1.1 SPECIFICATIONS..............................................................................G531-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................G531-2
1.3 DRIVE LAYOUT .................................................................................G531-3
2. DETAILED DESCRIPTION................................................... G531-4
2.1 JUNCTION GATE MECHANISM........................................................G531-4
To the Exit Tray or Bridge Unit (for the Upper Tray on top of
the Bridge Unit, or the Finisher).....................................................G531-4
To the 1-bin Tray............................................................................G531-4
To the Duplex Unit .........................................................................G531-4
3. REPLACEMENT AND ADJUSTMENT................................. G531-5
3.1 EXIT SENSOR REPLACEMENT........................................................G531-5
DUPLEX (G529)
1. OVERALL MACH INE INFORMATION................................. G529-1
1.1 SPECIFICATIONS..............................................................................G529-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................G529-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................G529-3
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................G529-4
1.5 DRIVE LAYOUT .................................................................................G529-5
vii
2. DETAILED DESCRIPTIONS ................................................ G529-6
2.1 BASIC OPERATION...........................................................................G529-6
Larger than A4 lengthwise/LT Lengthwise.....................................G529-6
Up to A4 Lengthwise/LT lengthwise...............................................G529-7
2.2 FEED IN AND EXIT MECHANISM.....................................................G529-8
When Paper is Fed Into Duplex Unit:.............................................G529-8
Inversion and Exit:..........................................................................G529-8
3. REPLACEMENT A N D ADJUSTMENT................................. G529-9
3.1 COVER REMOVAL ............................................................................G529-9
3.2 ENTRANCE SENSOR REPLACEMENT..........................................G529-10
3.3 EXIT SENSOR REPLACEMENT......................................................G529-11
BRIDGE UNIT (A897)
1. OVERALL MACH INE INFORMATION..................................A897-1
1.1 SPECIFICATIONS..............................................................................A897-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A897-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A897-3
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A897-4
1.5 DRIVE LAYOUT .................................................................................A897-5
2. DETAILED DESCRIPTION....................................................A897-6
2.1 JUNCTION GATE MECHANISM........................................................A897-6
3. REPLACEMENT AND ADJUSTMENT..................................A897-7
3.1 BRIDGE UNIT DRIVE MOTOR REPLACEMENT...............................A897-7
3.2 TRAY EXIT SENSOR REPLACEMENT .............................................A897-8
3.3 RELAY SENSOR REPLACEMENT....................................................A897-8
FINISHER (A681)
1. OVERALL MACH INE INFORMATION..................................A681-1
1.1 SPECIFICATIONS..............................................................................A681-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A681-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A681-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS..................................A681-4
1.5 DRIVE LAYOUT .................................................................................A681-6
viii
2. DETAILED DESCRIPTIONS .................................................A681-7
2.1 JUNCTION GATE MECHANISM........................................................A681-7
Staple Mode...................................................................................A681-7
No staple Mode..............................................................................A681-7
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM.......................A681-8
2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM............................A681-9
2.4 STAPLER .........................................................................................A681-10
2.5 FEED OUT MECHANISM.................................................................A681-11
2.6 SHIFT TRAY UP/DOWN MECHANISM............................................A681-12
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM.....................................A681-13
2.8 JAM CONDITIONS...........................................................................A681-14
2.9 TIMING CHARTS .............................................................................A681-15
2.9.1 NO STAPLE MODE (A4 SIDEWAYS, 3 SHEETS/2SETS)...... A681-15
2.9.2 STAPLE MODE (A4 SIDEWAYS, 2 SHEETS/2 SETS)...........A681-16
3. SERVICE TABLE................................................................A681-17
3.1 DIP SWITCH TABLE........................................................................A681-17
3.2 TEST POINTS..................................................................................A681-17
3.3 FUSES.............................................................................................. A681-17
4. REPLACEMENT AND ADJUSTMENT ................................A681-18
4.1 COVER REMOVAL ..........................................................................A681-18
Front Door....................................................................................A681-18
Front Cover..................................................................................A681-18
Rear Cover...................................................................................A681-18
Upper Cover.................................................................................A681-18
Lower Left Cover..........................................................................A681-19
Front Shift Tray Cover..................................................................A681-19
Rear Shift Tray Cover ..................................................................A681-19
Shift Tray......................................................................................A681-19
4.2 ENTRANCE SENSOR REPLACEMENT..........................................A681-20
4.3 EXIT SENSOR REPLACEMENT......................................................A681-21
4.4 STACK HEIGHT SENSOR REPLACEMENT...................................A681-22
4.5 POSITIONING ROLLER REPLACEMENT.......................................A681-23
4.6 STAPLER REPLACEMENT..............................................................A681-24
ix
MAILBOX (G518)
1. OVERALL MACH INE INFORMATION................................. G518-1
1.1 SPECIFICATIONS..............................................................................G518-1
1.2 COMPONENT LAYOUT.....................................................................G518-2
1.2.1 MECHANICAL COMPONENT LAYOUT ....................................G518-2
1.2.2 DRIVE LAYOUT.........................................................................G518-2
1.3 ELECTRICAL COMPONENT DESCRIPTIONS..................................G518-3
2. DETAILED DESCRIPTIONS ................................................ G518-5
2.1 BASIC OPERATION...........................................................................G518-5
2.2 PAPER OVERFLOW DETECTION ....................................................G518-6
2.2.1 OVERVIEW ...............................................................................G518-6
2.2.2 DETECTION TIMING.................................................................G518-6
2.3 PAPER MISFEED DETECTION TIMING............................................G518-7
3. REPLACEMENT AND ADJUSTMENT................................. G518-9
3.1 EXTERIOR COVER REMOVAL.........................................................G518-9
3.2 TRAY OVERFLOW AND VERTICAL TRANSPORT SENSOR
REPLACEMENT...............................................................................G518-10
3.3 MAIN MOTOR REPLACEMENT....................................................... G518-11
x
1 October, 1999 SPECIFICATIONS
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.1.1 GENERAL SPECIFICATIONS
Printing Speed: Maximum 27 pages per minute (A4/LT LEF)
(22 pages: duplex printing)
Printer Language: PCL6/PCL5e
PostScript Level 3
TIFF (rev 6.0 compatible)
Resolution: 600 dpi (PCL 6/PCL5e/PS3)
300 dpi (PCL 5e/PS3)
Resident Fonts: PCL:
35 Intellifonts
10 True Type fonts
1 Bitmap font
PS3:
136 fonts (24 Type 2 fonts, 112 Type 14 fonts)
Host Interface: Bi-directional IEEE1284 parallel x 1 (Standard)
Ethernet (100 Base-TX/10 Base-T for TCP/IP, IPX/SPX,
NetBEUI, Apple Talk)
Overall
Information
Printing Paper Size: Maximum: A3/11" x 17"
Minimum:
1st paper Tray: A5 SEF
2nd paper Tray: A6 SEF
By-pass: A6/ 90 x 148 mm SEF
(Refer to section 1.1.2, "Supported Paper Size".)
Printing Paper
Weight:
1st paper tray: 60 to 105 g/m
2nd paper tray: 60 to 157 g/m
By-pass Tray: 60 to 200 g/m
Print Paper
Capacity:
1st and 2nd paper tray: 500 sheets x 2
Optional paper tray unit:
500 sheets x 1/2
Optional LCT
1000 sheets x 2
Optional by-pass tray:
100 sheets
Output Paper
Capacity:
Standard output tray: 500 sheets
Optional finisher: 1,000 sheets
Optional 4-bin mailbox: 500 sheets total
2
(16 to 28 lb.)
2
(16 to 42 lb.)
2
(16 to 110 Index)
First Print Speed: 5 s or less (A4/LT LEF, 1st tray)
Warm-up Time Less than 45 seconds
1-1
SPECIFICATIONS 1 October, 1999
Memory:
Standard 16 MB, up to 80 MB with optional DIMM.
Power Source: 120 V, 60 Hz: More than 10 A (for North America)
220 V - 240 V, 50/60 Hz: More than 6.0 A (for Europe)
Power Consumption:
120V
Maximum 900W or less 900W or less
Printing 550W or less 550W or less
Energy Saver 25 W or less 25 W or less
230V
Noise Emission:
Mainframe Only Full System
Sound Power Level
Printing 51 dB or less 58 dB or less
Stand-by 23 dB or less 23 dB or less
NOTE:
The above measurements were made in accordance with ISO 9296 at
the operator position.
Dimensions (W x D x H): 550 x 520 x 516 mm
Weight: Less than 46 kg
1-2
1 October, 1999 SPECIFICATIONS
1.1.2 SUPPORTED PAPER SIZES
Paper Size (W x L)
Trays LCT Duplex
1st 2nd OP
By-pass/
Tray 2
Ledger 11 x 17” Y Y Y NYY
Legal 8.5 x 14“ Y Y Y NYY
Letter SEF 8.5 x 11” Y Y Y NYY
Letter LEF 11 x 8.5” Y Y Y Y Y Y
Half Letter
SEF
5.5 x 8.5”
#
Y
#
Y
#
Y
N N Y
Half Letter LEF 8.5 x 5.5” N N N N N N
Executive SEF 7.25 x 10.5” Y
Executive LEF 10.5 x 7.25” Y
#
#
#
Y
#
Y
#
Y
#
Y
NYY
N Y Y
A3 297 x 420 mm Y YY N Y Y
B4 257 x 364 mm Y
#
#
Y
#
Y
N Y Y
A4 SEF 210 x 297 mm Y Y Y NYY
A4 LEF 297 x 210 mm Y Y Y Y Y Y
B5 SEF 182 x 257 mm Y
B5 LEF 257 x 182 mm Y
A5 SEF 148 x 210 mm Y
#
#
#
#
Y
#
Y
#
Y
#
Y
#
Y
#
Y
NYY
NYY
NYY
A5 LEF 210 x 148 mm N N N N N Y
A6 SEF 105 x 148 mm N Y
Folio 8.25 x 13” Y
Foolscap 8.5 x 13” Y
F8 x 13”Y
#
#
#
Com10 Env. 4.125 x 9.5” N Y
Monarch Env. 3.875 x 7.5” N Y
C6 Env. 114 x 162 mm N Y
C5 Env. 162 x 229 mm N Y
DL Env. 110 x 220 mm N Y
8K 267 x 390 mm Y
16K SEF 195 x 267 mm Y
16K LEF 267 x 195 mm Y
#
#
#
#
N N N Y
#
Y
#
Y
#
Y
#
#
#
#
#
#
Y
#
Y
#
Y
#
Y
#
Y
#
Y
NYY
N Y Y
N Y Y
N N N Y
N N N Y
N N N Y
N N N Y
N N N Y
#
Y
#
Y
#
Y
N N Y
N N Y
N N Y
Custom [Minimum]
90 x 148 mm
[Maximum]
N N N N N Y
297 x 432 mm
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
C
Overall
Information
Remarks:
Y Supported. The paper size sensor detects the paper size.
#
Y
C
Y
N Not supported.
Supported. The user has to select the correct paper size for the tray.
Supported. The user has to enter the width and length of the paper.
1-3
SOFTWARE ACCESSORIES 1 October, 1999
1.2 SOFTWARE ACCESSORIES
The printer drivers and utility software are provided on one CD-ROM. An auto-run
installer allows you to select which components to install. The service tools are not
provided on the CD-ROM.
1.2.1 PRINTER DRIVERS
Printer Language Windows 3.1x Windows 95/98 Windows NT4.0 Macintosh
PCL 6 Yes Yes Yes No
PCL 5e Yes Yes Yes No
PS3 Yes Yes Yes Yes
NOTE:
1) The printer drivers for Windows NT 4.0 are only for the Intel x86
platform. There is no Windows NT 4.0 printer driver for PowerPC, Alpha,
or MIPS platforms.
2) The PS3 drivers are all genuine AdobePS drivers. A PPD file for each
operating system is provided with the driver.
3) The PS3 drivers for Macintosh support Mac OS 7.1 or later versions.
4) The PS3 drivers for Windows 3.1x and Windows NT4.0 do not support
the “Proof Print” function.
1.2.2 UTILITY SOFTWARE
Software Description
Agfa Font Manager
(Win3.1x, 95/98, NT4)
Aficio Manager for Admin
(Win 95/98, NT4)
Aficio Manager for Client
(Win95/98, NT4)
Multi-Direct Print
(Win95/98, NT4)
Port Navi
(Win95/98, NT4)
A font management utility with screen fonts for the printer.
A printer management utility for network administrators. NI B
setup utilities are also available.
A printer management utility for client users.
A utility for peer-to-peer printing over a NetBEUI or TCP/IP
network.
A peer to peer print utility over a TCP/IP network. This
provides parallel printing and recovery printing function.
1.2.3 SERVICE TOOLS
Software Description
NBTFTP NIB firmware update utility for use on a NetBEUI network.
This utility is not on the Driver and Utilities CD-ROM; it is
issued separately as a service tool
1-4
1 October, 1999 MACHINE CONFIGURATION
1.3 MACHINE CONFIGURATION
1.3.1 SYSTEM COMPONENTS
[A]
[J]
[I]
[B]
[C]
[H]
Overall
Information
[D]
[G]
[E]
G038V502.WMF
[F]
1-5
MACHINE CONFIGURATION 1 October, 1999
Item
Main Unit G038 I
Option
Paper Tray Unit - 1 tray A861
Paper Tray Unit - 2 trays A860
LCT A862
By-pass Tray A899
Interchange Unit G531 B
Duplex Unit G529 C (See note 2, 3)
4-bin Mailbox G518 A (See note 2)
Bridge Unit A897 I
1000-sheet Finisher A681 H Used in common with
Internal Option
HDD G690
Memory 32or 64 MB G688 Used in common with
Others
Maintenance Kit G719
Machine
Code
No. Remarks
User installable
Used in common with
G
F
E
D
Stinger-C (See note 1)
User installable
Used in common with
Stinger-C/Russian-C
(See note 1)
User installable
Used in common with
Russian-C (See note 1)
User installable
Used in common with
Russian-C
User installable
User installable
User installable
User installable
Used in common with
Russian-C
(See note 4)
Service installation
Russian-C/NAD
(See note 4)
Service installation
Used in common with
Stinger-C/Russian-C
Service installation
Stinger-C/Russian-C
User installable
NOTE:
1) Only one of these options can be installed on the machine.
2) Requires the Interchange unit to be installed.
3) Requires the memory option to be installed.
4) The Bridge unit must be installed together with the 1000 sheet Finisher.
Either the LCT or Paper Tray Unit (2 trays) must also be installed.
1-6
1 October, 1999 PAPER PATH
1.4 PAPER PATH
[F]
[A]
[B]
[E]
[C]
Overall
Information
[A]: Optional interchange unit
[B]: Optional duplex unit
[C]: Optional by-pass tray
[D]: Optional paper tray unit (2 trays)
[E]: Optional 1000-sheet finisher
[F]: Optional bridge unit
[D]
G038V101.WMF
1-7
MECHANICAL COMPONENT LAYOUT 1 October, 1999
1.5 MECHANICAL COMPONENT LAYOUT
17
16
15
18
1
2
3
4
5
6
7
8
9
10
11
12
1. Exit roller
2. Hot roller
3. Fusing pressure roller
4. Cleaning unit
5. Drum
6. Transfer roller
7. Development roller
8. ID sensor
9. Registration roller
13
G038V503.WMF
14
10. Friction pad
11. Paper feed roller
12. Paper size sensor
13. Special paper sensor
14. Bottom plate
15. Polygon mirror motor
16. Laser unit
17. Toner supply bottle holder
18. Charge roller
1-8
1 October, 1999 ELECTRICAL COMPONENT DESCRIPTIONS
1.6 ELECTRICAL COMPONENT DESCRIPTIONS
Refer to the electrical component layout on the reverse side of the point-to-point
diagram for the location of the components.
Symbol Name Function
Motors
M1 Polygonal Mirror Turns the polygonal mirror.
M2 Main Motor Drives the main unit components.
M3 Exhaust Fan Removes heat from around the fusing unit.
M4 Upper Paper Lift Raises the bottom plate in the 1st paper tray.
M5 Lower Paper Lift Raises t he bottom plate in the 2nd paper tray.
M6 Toner Supply
Magnetic Clutches
MC1 Upper Paper Feed Starts paper feed from the 1st paper tray.
MC2 Lower Paper Feed Starts paper feed from the 2nd paper tray.
MC3 Upper Paper Transport Drives the upper transport rollers.
MC4 Lower Paper Transport Drives the lower transport rollers.
MC5 Registration Drives the registration rollers.
Switches
SW1 M ain Switc h
SW2 Right Upper Cover Detects whether right upper cover is open or not.
SW3 Right Cover
SW4 Right Lower Cover Det ect s whether right lower cover is open or not.
SW5 Upper Paper Size
SW6 Lower Paper Size
SW7 Special Paper
SW8 New PCU Detect Det e ct s when a new PCU is installed.
SW9 Front Cover Safety
Sensors
S1 Toner Density (TD)
S2 1st Paper End
S3 1st Paper End
S4 Image Density (ID)
S5 Paper Overflow Detects paper overflow condition.
S6 Paper Exit Detects misfeeds.
S7 Upper Relay Detects misfeeds.
Rotates the toner bottle to supply toner to the
development unit.
Provides power to the machine. If this is off,
there is no power supplied to the machine.
Cuts the +5VLD and +24V dc power line and
detects whether the right cover is open or not.
Determines what size of paper is in the upper
paper tray.
Determines what size of paper is in the Lower
paper tray.
Determines the special paper is in the lower
paper tray.
Cuts the +5VLD and +24V dc power line and
detects whether the front cover is open or not.
Detects the amount of toner inside the
development unit.
Informs the CPU when the 1st paper tray runs
out of paper.
Informs the CPU when the 2nd paper tray runs
out of paper.
Detects the density of various patterns and the
reflectivity of the drum for process control.
Overall
Information
1-9
ELECTRICAL COMPONENT DESCRIPTIONS 1 October, 1999
Symbol Name Function
S8 Lower Relay Detects misfeeds.
S9 Registration
S10 1st Paper Lift
S11 2nd Paper Lift
S12 1st Paper Height - 1
S13 1st Paper Height - 2
S14 2nd Paper Height - 1
S150 2nd Paper Height - 2
Detects misfeeds and controls registration clutch
off-on timin g.
Detects when the paper in the 1st paper tray is at
the feed height.
Detects when the paper in the 2nd paper tray is
at the feed height.
Detects the amount of paper in the 1st paper
tray.
Detects the amount of paper in the 1st paper
tray.
Detects the amount of paper in the 2nd paper
tray.
Detects the amount of paper in the 2nd paper
tray.
PCBs
PCB1 Engine Board Controls all printer engine functions.
PCB2 Printer Controller Board Controls the printer functions
PCB3 Network Interface Board Net work interface board
PCB4 PSU (Power Supply Unit)
Provides dc power to the system and ac power to
the fusing lamp and heaters.
PCB5 LDD (Laser Diode Driver) Controls the laser diode.
PCB6 Operation Panel Controls the operation panel.
PCB7 High Voltage Supply
Supplies high voltage to the drum charge roller,
development roller, and transfer roller.
PCB8 Memory (Option) Expands memory capacity.
Lamps
L1 Fusing Lamp Heats the hot roller.
L2 Quenching Lamp
Neutralizes any charge remaining on the drum
surface after cleaning.
Others
TF1 Fusing Thermofu s e
Opens the fusing lamp circuit if the fusing unit
overheats.
TH1 Fusing Thermistor Det ects the temperature of the hot roller.
LSD 1
Laser Synchronization
Detector
Detects the laser beam at the start of the main
scan.
1-10
1 October, 1999 PRINTING PROCESS
1.7 PRINTING PROCESS
[6]
Overview
[7]
[8]
Overall
Information
[1]
[5]
[2]
[3]
G038V504.WMF
[4]
1. DRUM CHARGE
The charge roller gives a negative charge to the organic photoconductive
(OPC) drum. The charge remains on the surface of the drum because the OPC
layer has a high electrical resistance in the dark.
2. LASER EXPOSURE
Processed data from the computer/network is retrieved from the memory and
transferred to the drum by a laser beam, which forms an electrical latent image
on the drum surface. The amount of charge remaining as a latent image on the
drum depends on the laser beam intensity, which is controlled by the engine
board.
3. DEVELOPMENT
The magnetic developer brush on the developm e nt rol ler s comes in contact
with the latent image on the drum surface. Toner particles are electrostatically
attached to the areas of the drum surface where the laser reduced the negative
charge on the drum.
4. ID SENSOR
The laser forms a sensor pattern on the drum surface. The ID sensor measures
the reflectivity of the pattern. The output signal is one of the factors used for
toner supply control. Also, the ID sensor measures the reflectivity of the drum
surface. The output signal is used for charge roller voltage control.
1-11
PRINTING PROCESS 1 October, 1999
5. IMAGE TRANSFER
Paper is fed to the area between the drum surface and the transfer roller at the
proper time for aligning the print paper and the developed image on the drum
surface. Then, the transfer roller applies a high positive charge to the reverse
side of the paper. This positive charge pulls the toner particles from the drum
surface onto the paper. At the same time, the paper is electrostatically attracted
to the transfer roller.
6. PAPER SEPARATION
Paper separates from the drum as a result of the electrostatic attraction
between the paper and the transfer roller. The discharge plate helps separate
the paper from the drum.
7. CLEANING
The cleaning blade removes any toner remaining on the drum surface after the
image transfers to the paper.
8. QUENCHING
The light from the quenching lamp electrically neutralizes the charge on the
drum surface.
1-12
1 October, 1999 BOARD STRUCTURE
1.8 BOARD STRUCTURE
1.8.1 OVERVIEW
Standard
components
Operation
Panel
Overall
Information
Optional
components
Power
Pack
By-pass
Tray
Motors
Interchange
Unit
Polygon
Motor
Engine Board
Paper Tray
or
LCT
Laser
Synch.
LDDR
Bridge
Unit
Printer
Controller
Board
Clutches
Network
Interface
PS DIMM
DRAM DIMM
HDD
PSU
Fusing Lamp
Thermistor
Sensors
Duplex
Unit
4-bin
Mailbox
Finisher
G038V501.WMF
The engine control firmware controls the components connected to the engine
board. The printer control board controls the connected components.
1-13
BOARD STRUCTURE 1 October, 1999
1.8.2 DESCRIPTIONS
1. Engine Board
The engine board controls the following functions:
•
Engine sequence
•
Machine control, printer engine control
•
Timing control for peripherals
•
Video control
•
Drive control for the sensors, motors, solenoids, and high voltage supply
board
2. Printer Control Board
The printer control board handles the following functions:
•
Interface of the connected components to the engine board
•
Printer host interface
•
Edge smoothing and toner saving
•
Operation panel interface
•
Interface and control of NIB and the other additional options (HDD, PS
DIMM, and DRAM DIMM)
3. LD Drive Board
This is the laser diode drive circuit board.
4. Network Interface Board (NIB)
The network interface board allows the printer to be used on a network
5. HDD Unit (Option)
The HDD unit stores the data to perform the following functions.
•
Additional soft fonts
•
Collation
•
Proof-print
•
Downloading forms for form overlay
6. PS DIMM
This is to add the PostScript feature.
7. DRAM DIMM (Option)
This is used for an additional printer processing memory area and for soft fonts.
8. Control Panel Board
Controls the display panel, the LED, and the touch keypad.
1-14
1 October, 1999 LASER EXPOSURE
2. DETAILED SECTION DESCRIPTIONS
2.1 LASER EXPOSURE
2.1.1 OVERVIEW
[H]
[A]
[I]
[C]
[D]
[B]
[F]
[G]
The LD unit [A] outputs a laser beam to the polygon mirror [B] through the
cylindrical lens [C]. The shield glass [D] prevents dust from reaching the polygon
mirror.
[E]
G038D523.WMF
Detailed
Descriptions
Each surface of the polygon mirror reflects one full main scan line. The laser beam
goes to the F-theta mirror [E], mirror [F], and BTL (barrel toroidal lens) [G]. Then
the laser beam goes to the drum through the toner shield glass [H].
The laser synchronizing detector [I] determines the starting position for the main
scan.
The speed of the polygon mirror motor is 28,818.9 rpm for 600 dpi.
2-1
LASER EXPOSURE 1 October, 1999
2.1.2 AUTO POWER CONTROL (APC)
LD LEVEL
LD ON
LD OFF
LD OFF
VIDEO
LD
Controller
LD Drive Board
VIDEO
LD Driver
LD
VREF
Reference
Circuit
+5V
PD LD
Monitor
G038D510.WMF
The LD driver IC drives the laser diode. To prevent the intensity of the laser beam
from changing because of the temperature, the machine monitors the current
passing through the laser diode (LD). The machine adjusts the current to the laser
diode by comparing it with the reference level from the reference circuit.
This auto power control is done just after the machine is turned on and during
printing while the laser diode is active.
The laser diode power is adjusted on the production line.
NOTE:
Do not touch the variable resistors on the LD unit in the field.
2-2
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