Ricoh ap305 Service Manual ap306e

FRESA WIN+

(Machine Code: G047/G048)

SERVICE MANUAL

[Engine]



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, development toner magazine (DTM) or used toner. Toner dust may ignite suddenly when exposed to an open flame.

2. Dispose of used toner bottle and photoconductor unit (PCU) in accordance with local regulations. (These are non-toxic supplies.)

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

LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is only replaceable in the field by a qualified Customer Engineer. The laser chassis is not field repairable. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when the optical subsystem requires replacement.



WARNING Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.



WARNING WARNING: Turn off the main switch before attempting any of the

procedures in the Laser Unit section. Laser beams can seriously damage your eyes.

CAUTION MARKING:

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS

Configuration Desk top Print Process Dry electrostatic transfer system Resolution 600 dpi Paper Size Standard tray

Short edge feed (SEF):

A3, 11" x 17", 8 8

" x 13", 8

1/4

Long edge feed (LEF):

A4, 8 5

1/2

" x 8

" x 11", 7

")

1/2

By-pass feed tray*

Short edge feed:

A3, A6, B4 JIS, B6 JIS, 12" x 18",11" x 17",

8

" x 14", 8" x 13", 8

1/2

Long edge feed:

A4, A5, B5 JIS, 8 Custom size paper (Length: 148 to 457.2 mm, Width: 90 to 297 mm)

" x 14", Others* (B4 JIS, 8" x 13",

1/2

" x 13")

1/2

" x 10

1/4

1/2

" x 13", 8

1/4

" x 11", 5

", Others* (B5 JIS, A5,

" x 13"

1/2

" x 8

1/2

", 7

1/4

" x 10

1/2

Overall

Information

"

* Specify the paper size with the system menu (at the

operation panel by the user).

Paper Weight Standard and optional trays: 64 to 105 g/m2 (17 to 28 lbs.)

By-pass feed tray: 64 to 160 g/

Plain paper mode: 64 to 105 g/m

m2 (17 lbs to 43 lbs

2

)

Thick paper mode: 105 to 160 g/m2, adhesive labels OHP transparency mode: OHP transparencies

First Printout Time Color: Less than 26 seconds (A4 A4/8

Monochrome: Less than 13 seconds (A4 A4/8

" x 11" LEF)

1/2

" x 11"

LEF)

Print Speed Simplex prints

Color: 6 ppm (A4/8 Monochrome: 24 ppm (A4/8

" x 11" LEF)

1/2

" x 11" LEF)

1/2

Duplex prints

Warm-up Time

Color: 5.5 ppm (A4/8 Monochrome: 21.7 ppm (A4/8

Less than 380 seconds (at 23°C/73°F)

" x 11" LEF)

1/2

" x 11" LEF)

1/2

Paper Capacity Standard tray: 250 sheets (80 g/m2, 20 lbs.)

By-pass feed tray: 50 sheets (80 g/m2, 20 lbs.) Optional trays: 500 sheets (80 g/m2, 20 lbs.)

1-1

SPECIFICATIONS 30 June 2000

Paper Output Capacity

250 sheets (A4/8

" x 11" or less)

1/2

100 sheets (More than A4/8

" x 11")

1/2

Output Method Face down Power Supply 120 V, 60 Hz, 10 A

220 to 240 V, 50/60 Hz, 5.2 A

Power Consumption Maximum: Less than 1,200 W

Average during printing: Less than 750 W Stand-by mode: Less than 150 W Energy saver mode: Less than 45 W

Noise Emission (Sound Power Level)

Stand-by: Less than 43 dB Operating: Less than 65 dB

Dimensions Simplex model (G047)

660 x 575 x 475 mm (26” x 22.6” x 18.7”) (without paper tray)

Auto duplex model (G048)

660 x 652 x 610 mm (26” x 25.7” x 24”) (without paper tray)

Weight Simplex model (G047)Approximately 62 kg (136.7 lbs.)

(including consumables)

Auto-Duplex model (G048)

Approximately 82 kg (180.8 lbs.) (including consumables)

Option Paper Feed Unit Type 305 (Paper Tray Unit) – up to two of

these units can be installed

1-2

30 June 2000 MECHANICAL OVERVIEW

1.2 MECHANICAL OVERVIEW

Same as base model (G024) Refer to the Section 1-2 of base model manual.

1.3 MAIN UNIT LAYOUT

13

1

2

12

11

Overall

Information

10

9

8

1. Paper Transfer Unit

2. Photoconductor Unit (PCU)

3. Paper Tray/Paper Feed Mechanism

4. Development Unit (DTM)

5. Duplex Unit

6. Optical Housing Unit

7. Main Control Unit (MCU)

5

467

G048V101.WMF

8. Vertical Transport Unit

9. High Voltage Supply Unit

10. DC Supply Unit

11. Controller Board

12. Power Supply Unit

13. Fusing Unit

3

1-3

MAIN UNIT LAYOUT 30 June 2000

(1) Optical Housing Unit

• Optical system: 6-sided polygon mirror, F-theta mirror, BTL

• Resolution: 600 dpi

• Modulation method: PM+PWM

(2) MCU

• CPU: XC68334 GFC16

• Engine system control

• Process control

• Video interface

(3) Vertical Transport Unit (Auto-duplex Model Only)

• Paper feeding for duplex printing by rollers

(4) High Voltage Supply Unit

• Constant current: Paper transfer, charge corona wire

• Constant voltage: Charge corona grid, belt transfer, supply roller,

development blade

(5) DC Supply Unit (Auto-duplex Model Only)

• Outputs: +24 VDC supply for duplex unit

(6) Controller Board

• Host interface

• Video interface

• Image processing

• Operation panel control

(7) Power Supply Unit

• Outputs: +5 VDC, +24 VDC, 120/230 VAC

(8) Fusing Unit

• Fusing method: Hot roller method

• Oil application: Application roller method

• Cleaning: Cleaning roller method

• Temperature detection: Thermistor

• Safety precaution: Thermofuse

(9) Paper Transfer Unit

• Transfer: Transfer rol l er met hod

(10) PCU

A unit consisting of the OPC belt and the primary (belt) transfer section.

• OPC belt: 93-mm diameter

• Charging: Single scorotron charge corona wire

• Primary transfer: Transfer belt

• Cleaning: Counter blade

• Lubricant: Zinc stearate

1-4

30 June 2000 SYSTEM BLOCK

(11) Tray/Transport

• Standard tray: Universal tray, friction pad separation By-pass tray: FRR method

(12) Development Unit

• Development method: Monocomponent non-magnetic toner

• Development unit changeover: Revolver method

• Toner replenishment: DTM change

(13) Duplex Unit

• Stack-less

• Paper side edge jogging

1.4 SYSTEM BLOCK

1.4.1 BLOCK DIAGRAM

ADC

CPU

ROM

ID Sensor

Humidity

Sensor

High Voltage

Supply Board

D/A

PWM

Overall

Information

NVRAM DRAM

IC Card

Sensors

Vertical

Transport

Sensor

PSU

Fusing

Control

I/O

AMDG

MCU

Thermistor

Fusing Unit

: Additional components on deplex model (G048)

Solenoids

Clutches

Interchange

Solenoids

LD

Modulation

Control

DC Supply Unit

ASIC

Video I/FGAVD/PLLC

Printer

Controller

Pattern

Generation

FIFO

Selector

Operation

Panel

Sensor

Motor Solenoids

Motor

Control

Revolver Main Motor PCU Motor

Expander

DDB

G048V554.WMF

1-5

30 June 2000 DIFFERENT POINTS FROM BASE MODEL (G024)

2. DETAILED SECTION DESCRIPTIONS

2.1 DIFFERENT POINTS FROM BASE MODEL (G024)

2.1.1 OVERVIEW

The following points are different from the base model (G024).

1. Duplex printing The following units were added to the Auto-duplex model (G048)

Paper Exit Unit Switching the paper path to the exit or to the duplex unit after

fusing.

Vertical Transport Unit

Duplex Unit This unit is located at the bottom of the main-body. In this

Interleaf control is used for this model to increase the printing speed.

For duplex printing, feeding a sheet to duplex unit after fusing. This unit is located behind the main-body.

unit, a sheet is turned, jogged and then fed to the main-body again. Sheets are fed into this unit one-by-one.

Detailed

Descriptions

2. Printing Speed

Printing Speed G047/G048 Base Model (G024)

Black & White mode 24 ppm 17 ppm Color mode 6 ppm 5 ppm

First Print G047/G048 Base Model (G024)

Black & White mode 13 sec. 14 sec. Color mode 26 sec. 30 sec.

3. Image Quality Improvement Increasing the line frequency in photograph and text mode improves the quality of the image. A new laser optical unit is used to increase the line frequency.

Line Frequency G047/G048 Base Model (G024)

Photograph 180 lpi 106 lpi Graphics 106 lpi 106 lpi Text 268 lpi 211 lpi

2-1

DIFFERENT POINTS FROM BASE MODEL (G024) 30 June 2000

2.1.2 FUSING UNIT

The followings differ from the base model (G024) in the Fusing unit.

1. Pressure Roller For the duplex printing, The material used to make the pressure roller was changed from Teflon to Silicon rubber to improve duplex printing performance.

2. Heat Isolation To maintain the fusing roller temperature, heat isolation bushings are mounted between the fusing roller bushing and drive gear.

3. Connector All of the drawer connectors were replaced with harness connectors.

4. Exit Cover Switch (Auto-duplex model only) The location of paper exit cover switch was moved to the main-body of the machine from the fusing unit..

2.1.3 OPTICAL UNIT

The following optical unit ite ms differ from the previous model.

1. Polygonal Mirror Motor The speed of the polygonal mirror motor was increased to increase the printing speed.

G047/G048 Base Model (G024)

Paper feed speed 121.54 mm/sec 101.27 mm/sec. Mirror motor revolution

speed

28,706 rpm 23,922 rpm

2. LD Unit To improve the image quality, the diameter of the beam was decreased and the power of the beam was increased.

G047/G048 Base Model (G024)

Diameter of Beam LD Power 1.91 mW 1.58 mW

69 µm x 76 µm 76 µm x 76 µm

3. Dust Prevention To prevent the polygonal mirror and polygon mirror motor from collecting dust, two sponges were added to the optical housing. One is above the polygon mirror motor and the other is on the side of the housing unit.

2-2

30 June 2000 DIFFERENT POINTS FROM BASE MODEL (G024)

2.1.4 PAPER FEEDING AND REGISTRATION

1. Paper size detection of bypass tray Paper width detection mechanism on the bypass tray is not available.

2. Pick-up roller The material of pick-up roller is changed to Silicone rubber for duplex printing from the bypass tray.

2.1.5 PROCESS CONTROL

1. K-DTM Initialization The image density target level was lowered.

G047/G048 Base Model (G024)

ID on sheet 1.6 1.7 Volume of toner 0.56 mg/cm

2

0.60 mg/cm

2

Detailed

Descriptions

2. Color-DTMs Initialization The image density target level was changed.

G047/G048 Base Model (G024)

ID on sheet 1.4 1.5 Volume of toner (C) 0.56 mg/cm Volume of toner (Y) 0.54 mg/cm Volume of toner (M) 0.62 mg/cm

2

0.55 mg/cm

0.60 mg/cm

3. Charge Grid Bias Compensation Compensation control was changed because the number of lines in photo mode was changed from 106 to 180.

2.1.6 ELECTRICAL COMPONENTS

1. Main Motor The main motor was changed to increase the print speed. The PCU motor was not changed but the clock rate was changed.

2. MCU The MCU was changed to improve the efficiency of duplex printing by adding new electrical components.

2

3. PSU A different PCU was used to increase the current level. A DC supply unit was added for Auto-duplex models only.

2-3

DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY) 30 June 2000

2.2 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.1 OVERVIEW

Layout

10

9

8

7

1

2

1. Junction Gate

2. Relay Roller

3. Duplex Roller

4. Duplex Pick-up Roller

5. Jogger Fence

56

G048D101.WMF

6. Duplex Feed Roller

7. Duplex Unit

8. Vertical Transport Roller

9. Vertical Transport Unit

10. Exit Unit

34

2-4

30 June 2000 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

Electrical Components

13

15 14

17

16

18

12

11

10

1

8

9

G048D103.WMF

2

3

Detailed

Descriptions

4

5

6

7

1. Vertical Transport Entrance Sensor

2. Vertical Transport Cover Switch

3. Duplex DC Supply Unit

4. Vertical Transport Unit Switch

5. Vertical Transport Motor

6. Temp./Hum. Sensor

7. Duplex Driver Board

8. Relay Motor

9. Duplex Feed Sensor

10. Jogger HP Sensor

11. Jogger Motor

12. Reverse Solenoid

13. Reverse Sensor

14. Duplex Reverse Motor

15. Duplex Feed Motor

16. Vertical Transport Exit Sensor

17. Junction Gate Solenoid

18. Exit Cover Switch

Exit Unit

- A solenoid moves the junction gate.

- A micro-switch detects if the cover is open.

Vertical Transport Unit

- The vertical transport rollers driven by the vertical transport motor feed paper to the duplex unit.

- Two sensors detect paper fed in the entrance and out the exit of the unit.

- Two micro-switches detect whether the vertical transport unit and cover are open.

2-5

DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY) 30 June 2000

Duplex Unit

- The duplex, duplex transport and duplex pick-up rollers reverse the paper in the unit.

- The jogger fence prepares to feed paper into the main body after reversing it.

- The duplex, duplex pick-up, and relay rollers feed paper into the main body for reverse side printing.

- The duplex feed sensor and reverse sensor detect paper.

2-6

30 June 2000 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.2 EXIT UNIT

Driving Mechanism

[D]

[E]

Detailed

Descriptions

[A]

[B]

[C]

G048D002.WMF

The fusing unit [A] and drive gears [B], powered by the main motor [C], drive the feed and exit rollers [D and E].

Junction Gate

[A]

[B]

G048D001.WMF

The Junction gate [A] is located at the entrance of exit unit. Paper is fed to the exit tray or to the vertical transport unit by this gate. This gate is driven by solenoid [B]. When this solenoid activates, the paper is fed into the vertical transport unit.

2-7

DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY) 30 June 2000

Exit Cover Open Detection

[A]

G048D003.WMF

The exit unit cover switch [A] is on the right side of the unit to detect whether the cover is open. This switch interrupts the 24VDC line to the main control board (PCB2).

2-8

30 June 2000 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.3 VERTICAL TRANSPORT UNIT

Driving Mechanism

[B]

[D]

[A] [C]

G048D501.WMF

The vertical transport motor [A] drives the vertical transport rollers [B] using gears [C] and timing-belts [D].

Paper Feed Detection

[A]

Detailed

Descriptions

[B]

G048D010.WMF

Two sensors (photo interrupters) detect paper: One is the entrance sensor [A] and the other is the exit sensor [B].

2-9

DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY) 30 June 2000

Vertical Transport Unit Cover Open Detection

[A]

G048D008.WMF

G048D007.WMF

The interruption of the current for the vertical transport switches [A and B] determines whether the vertical transport unit or cover is open.

[B]

2-10

30 June 2000 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.4 DUPLEX UNIT

Driving Mechanism

[A]

[B]

G048D502.WMF

Detailed

Descriptions

The duplex feed motor [A] feeds paper from the vertical transport unit up to the reverse tray. Then the duplex reverse motor [B] feeds the paper from the reverse tray to the relay rollers.

Reverse Mechanism

[A]

First, paper is fed by the duplex feed rollers [A] and then by the duplex rollers [B]. When the reverse sensor [C] detects the leading edge of paper, the reverse solenoid [D] activates and paper is fed into the duplex tray [E]. When the reverse sensor detects the trailing edge of paper, the reverse solenoid deactivates.

[B]

[D]

[C]

2-11

[E]

G048D015.WMF

DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY) 30 June 2000

Jogging Mechanism

The standby position distance between jogger fences [A] is 10mm wider than the printed paper width while printing. After the duplex roller stops, the jogger motor [B] slides the jogger fences so that they are 1mm narrower than the printed paper width. After finishing all print job s , the fences return to the home position, until the home position sensor [C] activates.

Feed-out

After jogging the paper, the duplex roller turns counter-clock wise and the reverse solenoid activates. This fee ds paper to the relay roller [A], which is driven by the relay motor [B].

[A]

[B]

[C]

G048D006.WMF

Reverse Tray Detection

The tray is connected to the duplex driver board [A] through drawer connectors [B] when the tray is pushed into the machine. This connection is monitored by a loop back signal to make sure that the tray is positioned properly in the machine.

[B]

[A]

G048D009.WMF

[A]

[B]

2-12

G048D153.WMF

30 June 2000 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.5 INTERLEAF

An interleaf mechanism was added to increase duplex printing performance in black & white print mode. Also, this model only prints face down.

E

D/J

K

C/I

B/H

Detailed

Descriptions

A-1 G

F

A-2

G048D211.WMF

Paper Path for Duplex Printing

A: Paper feed for back-side print ( -1: Standard tray -2: Optional tray)

B: Secondary transfer for back-side print C: Fusing back-side print D: Junction

E: Vertical transport

F: Reverse G: Paper fee d for front-s ide print H: Secondary transfer for front-side print

I: Fusing for front-side print

J: Junction

K: Paper exit

2-13

DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY) 30 June 2000

Print Order for Duplex Black & White Printing

The following example shows what happens when printing 8 sheets of A4/LTR size in duplex black & white mode. 4 sheets of A4/LTR size paper can be kept inside the machine during this print mode.

2

➀➁➂➃

135

➀➄➁➅➂➆

10

4 6 8

12 14

➃➇

7

16

1513119

➇➆➅➄

G048D212.WMF

Print Order for Duplex Color Printing

The following example shows what happens when printing 8 sheets of A4/LTR size in duplex color mode.

2 sheets print 2 sheets print 2 sheets print

2 4 6 81357

➁➂➃➀➃➂➁➀

G048D214.WMF

2-14

30 June 2000 INSTALLATION PROCEDURE

3. INSTALLATION PROCEDURE

Refer to the following materials.

• For the printer: Quick Installation Guide

• For options: Operating Instructions

If the customer has a service contract with a meter click system, set up the counter with an SP mode as follows:

1. Enter Controller SP mode (se e 4.1.1 ENTERING AND EXITING CONTROLLER SP MODE in Service manual for controller).

2. Set “Meter Click” from the maintenance menu to the proper mode depending on the contract type (see 4.1.4 SP MODE DETAILS in Service manual for controller).

3. Exit SP mode, and then confirm that display of both “Color” and “Black” is 0 by executing “ Show Counter”

Installation

3-1

30 June 2000 OVERVIEW

4. SP MODE

4.1 OVERVIEW

This printer has two SP modes:

1) Engine SP mode

2) Controller SP mode

The controller SP modes are described in the service manual for the controller. These two modes contain different functions.

4.2 ENGINE SP MODE

4.2.1 OVERVIEW

To enter and exit engine SP mode

Same as the base model (G024)

Outline of the engine SP mode functions

The following table shows differences from the base model (G024)

Menu Item Difference from the base model (G024)

1: Margin Duplex printing menu and two adjustable items were added. 2: Parameter The secondary transfer bias can be adjusted individually for

printing on the front side and for the other side of paper. 3: Clear Memory Same as the base model (G024) 4: Sensor Check

5: Nip Width Same as the base model (G024) 6: Reset SC Same as the base model (G024) 7: Process Ctrl Same as the base model (G024) 8: Test Print Three menus were added for auto-duplex printing. 9: ID Sensor PWM Same as the base model (G024) 10: Image Adjust Same as the base model (G024) 11: Output Check 10 more components were added to the vertical transport and

12: Hi-light Same as the base model (G024) 13: Lub_Interval Same as the base model (G024) 14: BLT-TR BIAS Additional function to adjust the primary transfer bias.

Eight more sensors were added to the vertical transport and

duplex units.

Tables

Service

4-1

ENGINE SP MODE 30 June 2000

4.2.2 MENU OPERATION/DISPLAY

Same as the base model (G024)

4.2.3 MARGIN (REGISTRATION ADJUSTMENT)

NOTE: Items in bold are additional ones for this model.

Layer 1 Layer 2 Layer 3 Layer 4

Maintenance 1: Margin

Margin Pattern Print

Margin Adjust

Margin: Print Std. Paper

Margin: Print Thick Paper

Margin: Print Transparency

Marg in: Adjust Tray1: Left

Marg in: Adjust Tray1: Top: 1st

Marg in: Adjust Trans: Top : 1st (For OHPs)

Margin: Adjust Back: Left

Margin: Adjust Back: Top

Print: Std Tray 1 Tray 2 Tray 3

(D) Tray 1 (D) Tray 2 (D) Tray 3

By-pass Tray (D) shows duplex

printing. Print: Thick

By-pass Tray Print: Trans

By-pass Tray Tray1: Left

X.X Tray1: Top: 1st

X.X It can be adjusted

for tray 2, tray 3, and the by-pass tray in the same way as for tray1.

Trans: Top : 1st X.X

Back: Left X. X

Back: Top X. X

4-2

30 June 2000 ENGINE SP MODE

4.2.4 PARAMETER

NOTE: Items in bold are additional ones for this model.

Layer 1 Layer 2 Layer 3 Layer 4

Maintenance 2: Parameter

Parameter Std. Paper

Parameter Thick Paper

Parameter Transparency

Std. Paper Transfer Bias

Std. Paper (D) Transfer Bias

Std. Paper Fusing Temp.

Same as Std. Paper Same as Std. Paper Same as Std. Paper Same as Std. Paper

Bias XXX%

(D) Bias XXX%

Temp. Low

Temp. Normal

Temp. High

4.2.5 CLEAR MEMORY

Same as the base model (G024)

NOTE: Counter values used for meter click are not cleared.

Tables

Service

4-3

ENGINE SP MODE 30 June 2000

4.2.6 SENSOR CHECK

NOTE: Bolded items are additions to this model.

Sensor Name Sensor Status

Name Display 0 1

Paper End Sensor (Tray 1)

Paper End Sensor (By-pass Tray)

Paper End Sensor (Tray 2)

Paper End Sensor (Tray 3)

Registration Sensor Registration Paper not detected Paper detected Exit Sensor Exit Paper detected Paper not detected Paper Size Switch

(Tray 1) Paper Size Switch

(Tray 2) Paper Size Switch

(Tray 3) By-pass Paper Width

Detection Board PCU Set Switch PCU Set Detected Not detec te d DTM Set Sensor CTC Set Detected Not detected Toner End Sensor CTC Toner End Not end End Door Safety Switch Cvr Opn-F Closed Open Exit Cover Switch Cvr Opn-EX Closed Open Oil End Sensor Oil End End Not end (Fusing Unit) Fusing Set Detected Not detected Used Toner Sensor Used Toner Not full Full (Tray 2) Tray Set-2nd Not detected Detected (Tray 3) Tray Set-3rd Not detected Detected PCU Reset Sensor PCU Reset Old New Revolver H.P. Sensor Revolver H.P. Home position Not home position Transfer Roller

Position Sensor Pull-out Sensor

(Tray 2) Pull-out Sensor

(Tray 3) ID Sensor ID *3 *3

Sensor DTM Cover Switch Cvr Opn-S Open Closed

Pull-out Sensor (Main Body)

Charger Corona Set Switch

Vertical transport unit/cover switch

Reverse sensor Reverse Sensor Paper detected Paper not detected

P End-1st Paper detected Paper not detected

P End-By-pass Paper detected Paper not detected P End-2nd Paper detected Paper not detected P End-3rd Paper detected Paper not detected

P Size-1st *1 *1 P Size-2nd *1 *1 P Size-3rd *1 *1 P Size-By-pass

Tfr Position Release Touch P Feed-2nd Paper not detected Paper detected

P Feed-3rd Paper not detected Paper detected

Humidity *4 *4Temperature/Humidity Temp *5 *5

Pick-up Paper detected Paper not detected Main Charger Detected Not detected

Cvr Open-Duplex Open

*2 *2

Closed

*6

4-4

30 June 2000 ENGINE SP MODE

Sensor Name Sensor Status

Name Display 0 1 Duplex Feed sensor P Feed-Duplex Paper not detected Paper detected Jogger HP sensor Jogger H. P Home position Not home position Duplex unit

connection signal Duplex tray

connection signal Vertical transport

entrance sensor Vertival transport

exit sensor

Duplex-Unit Set Not detected

*7

Duplex Tray Set Not detected

*8

V feed P1 Paper detected Paper not detected

V Feed P2 Paper detected Paper not detected

Detected *7

Detected *8

*1: “Paper size detection” in Section 2 explains the status of the paper size

switches for paper size detection. (0: Pressed, 1: Not pressed)

*2: The indicated value is always “1f” as there is no paper size detection

mechanism on this model.

*3: The displayed value indicates the K sensor output when the LED in the ID

sensor is turned on. The specified output value (reference for normal operation) is 2.7 ± 0.8 V.

*4: The detection results are shown in the XXX YYY format. XXX indicates

absolute humidity, and YYY indicates relative humidity. (Reference for normal operation: YYY should be between 5 and 95.)

Tables

Service

*5: The displayed value indicates the detected temperature. (Reference for normal

operation: Between 8 and 42)

*6: If either the vertical transport unit or vertical transport cover is open, “0”

(open) is indicated.

*7: The connection signal in between the MCU and the duplex driver board is

checked. (10th pin of the CN254 on the MCU)

*8: Loop back signal for the duplex driver board is checked. (13th pin of the

CN896 on the Duplex driver board)

4.2.7 NIP WIDTH

Same as the base model (G024)

4.2.8 RESET SC

Same as the base model (G024)

4-5

ENGINE SP MODE 30 June 2000

4.2.9 PROCESS CTRL

Same as the base model (G024)

4.2.10 TEST PRINT

NOTE: Bolded items are additions to this model.

Layer 1 Layer 2 Layer 3 Layer 4

Maintenance 8: Test Print

Test Print Pattern 1

Test Print Pattern 2

Test Print Pattern 3

Test Print Pattern 1(D)

Test Print Pattern 2(D)

Test Print Pattern 3(D)

Pattern 1 Tray X

Same as Pattern 1 Same as Pattern 1 Same as Pattern 1 Same as Pattern 1

Same as Pattern 1 Same as Pattern 1

Printing Tray X

4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)

Same as the base model (G024)

4.2.12 IMAGE ADJUST

Same as the base model (G024)

4-6

30 June 2000 ENGINE SP MODE

4.2.13 OUTPUT CHECK

NOTE: Bolded items are additions to this model.

Name Display Operation

By-pass Feed Clutch Bypass Feed Cl. O perating for a certain time Pull-out Clutch Pick-up Cl. Operating until instructed to

turn OFF Paper Feed Clutch Feed Cl. Operating for a certain time Relay Roller Clutch Transport Cl. Operating until instructed to

turn OFF Registration Clutch Regist. Cl.

Transfer Roller Clutch Tr. Roller Cl. Oper ating f or a certain time Development Drive Solenoid Development Sol. Operating until instructed to

By-pass Feed Solenoid Bypass Sol. Operating for a certain time Transfer Belt Cleaning Solenoid Cleaning Sol. Operating until instructed to

Quenching Lamp Quenching LED Operating until instructed to PCU Motor

Main Mo tor

Polygon Mirror Motor Scanner Motor Revolver Motor Revolver Motor Operating until instructed to Tray Main Motor (for tray 2) OT1 Motor Operating until instructed to Paper Feed Clutch (for tray 2) OT1 Feed Clutch Operating for a certain time

Tray Main Motor (for tray 3) OT2 Motor Paper Feed Clutch (for tray 3) OT2 Feed Clutch Operating for a certain time

Vertical Transport Motor V Feed motor

Duplex Feed Motor Duplex Tray Mtr Operating until instructed

Duplex Reverse Motor ()

PCU Motor-slow PCU Motor-normal Operating unt il instructed to PCU Motor-fast Operating until instructed to PCU Motor-reverse Main Mtr-normal Operating until instructed to Main Mtr-slow Operating until instructed to

Rvrs Mtr Operating until instructed

Operating until instructed to

turn OFF

Operating until instructed to

turn OFF

Operating until instructed to

turn OFF

Operating until instructed to

turn OFF

Operating until instructed to

turn OFF

Operating until instructed

to turn OFF

Tables

Service

4-7

ENGINE SP MODE 30 June 2000

Name Display Operation

Duplex Reverse Motor ()

Reverse Solenoid Press Roller Sol Operating until instructed

Jogger (for H.P.)

Jogger (for

Relay Motor Pull Out Motor Operating until instructed

Junction Gate Solenoid Divergence Sol.

Rvrs Mtr-rvrs

Jogger HP Operating for a certain time

Jogger Operating for a certain time

Jogger reverse Operating for a certain time

Operating until instructed

to turn OFF

Operating until instructed

to turn OFF

4.2.14 HIGHLIGHT ADJUSTMENT

Same as the base model (G024)

4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT)

Same as the base model (G024)

4-8

30 June 2000 ENGINE SP MODE

4.2.16 PRIMARY BIAS ADJUSTMENT

Use this menu to adjust the primary bias (belt transfer bias). The adjustment can be done in 100V steps between 800 V and 1,500 V. The default value is 1,200 V.

Layer 1Layer 2Layer 3

Maintenance 14: BLT-TR BIAS

BLT-TR B IAS Cyan

BLT-TR B IAS Magenta

BLT-TR B IAS Yellow

BLT-TR B IAS Black

Cyan XXX

Magenta XXX

Yellow XXX

Black XXX

Tables

Service

4-9

30 June 2000 PM TASKSPM TASKSPM TASKS

5. PREVENTIVE MAINTENANCE

5.1 PM TASKS

5.1.1 REPLACEMENT

Replace the PM parts every 100 K printouts as shown in the PM table on the next page.

The fusing unit replacement interval is not determined in the same manner as the base machine. For details, see the note after the PM table.

• For the replacement procedures, refer to Chapter 6 “Replacement and

Adjustment” in this manual and Chapter 3, “Replacement and Adjustment” in the manual for the optional 500-sheet paper tray.



CAUTION When replacing components, be aware that the fusing unit may be hot. Handle it with care.

5.1.2 CLEANING

Clean the printer components when visiting the customer site.

• See the PM table for the correct way to wipe components.

NOTE: Make sure that the charge corona unit cleaner is in the home position.

5.1.3 INSPECTION

Inspect the printer components when visiting the customer’s site.

• Visually inspect the components, and replace them if there is any damage.



CAUTION A high voltage is applied to bias electrodes. To inspect a bias electrode, ensure that the power switch is turned off.

Preventive

Maintenance

5-1

PM TABLE 30 June 2000

5.2 PM TABLE

5.2.1 MAIN UNIT

C: Clean R: Replace I: Inspect

Item EM 60K 100K Note

Paper Feed Roller C R Alcohol or water Registration Roller C Alcohol or water Frict ion Pad C R Water Bottom Plate Pad C Water By-pass Feed Roller C Alcohol or water By-pass Pick up Roller C Alcohol or water By-pass Separation Roller C Alcohol or water Charge Corona Unit C* Quenching Lamp I Blower brush (if dirty) ID Sensor C Dry cloth Dust Shield Glass C* Fusing Unit R* Exit roller-Exit Unit C Auto-duplex model only Feed roller-Exit Unit C Auto-duplex model only Feed rollers-Duplex Unit C Auto-duplex model only Vertical Transport Rollers C Auto-duplex model only Duplex Rollers C Auto-duplex model only Relay Roller C Auto-duplex model only

1

2

Cleaner in the PCU

Cleaner brush (P/N: G0241533)

*1: This is a common item with user maintenance. *2: Regardless of the meter-click setting, the number of pages that the counter

counts depends on the paper size:

• A3 or larger: 2 counts

• Smaller than A3: 1 count

• When the fusing unit counter reaches 60 K a message is displayed on the

LCD only if “No meter-click mode” is selected. However, printing can still continue.

NOTE: The following indication will NOT be shown on the display when one of

the meter-click mode is selected even if the counter reaches the PM interval. “Change Fusing Unit” “Change PCU” “Need Charger Unit” The Charger unit and Fusing unit counter need to be manually cleared by “Maintenance” menu and controller SP mode (S4).

5.2.2 OPTIONAL PAPER FEED UNIT

See the manual for base model (G024)

5-2

30 June 2000 EXTERIOR

6. REPLACEMENT AND ADJUSTMENT (AUTO-DUPLEX MODEL)

6.1 EXTERIOR

6.1.1 TOP OVER

[D]

[B]

[A]

1. Open the front cover [A] and paper exit unit [B].

2. Open the vertical transport unit [C] (2 screws).

3. Remove the top cover [D] (2 screws).

G048R810.WMF

[C]

Adjustment

Replacement

6-1

PAPER EXIT UNIT 30 June 2000

6.2 PAPER EXIT UNIT

6.2.1 UPPER COVER

[A]

[B]

G048R829.WMF

1. Open the paper exit unit [A].

2. Remove upper cover [B] (2 screws)

6.2.2 LOWER COVER

[B]

[A]

G048R830.WMF

1. Remove the upper cover. (Refer to section 6.2.1.)

2. Open the vertical transport unit.

3. Remove the paper exit tray [A] (2 screws).

4. Remove the lower cover [B] (2 screws).

6-2

30 June 2000 PAPER EXIT UNIT

6.2.3 PAPER EXIT UNIT

[A]

[B]

[D]

[C]

G048R824.WMF

1. Remove the top cover. (Refer to section 6.1.1.)

2. Remove the stopper plate [A] (1 screw). NOTE: Removing the stopper plate will allow this unit to tip fully back, so be

careful.

3. Remove the lower cover. (Refer to section 6.2.2.)

4. Remove clips [B], springs [C] and the unit [D].

Adjustment

Replacement

6-3

PAPER EXIT UNIT 30 June 2000

6.2.4 JUNCTION GATE SOLENOID

[A]

[C]

G048R827.WMF

[E]

G048R825.WMF

1. Remove the fusing unit. (Refer to section 6.5.1.)

2. Remove the paper exit unit. (Refer to section 6.2.3.)

[D]

[B]

G048R840.WMF

3. Remove the guide plate [A] (4 screws).

4. Remove the clip [B] and the locking bar [C] while releasing the spring [D].

5. Remove the solenoid [E] together with the bracket.

6. Remove the solenoid from the bracket.

NOTE: Be sure to note the locations of the screws securing the solenoid to the

bracket.

6-4

30 June 2000 VERTICAL TRANSPORT UNIT

6.3 VERTICAL TRANSPORT UNIT

6.3.1 VERTICAL TRANSPORT UNIT COVER

[A]

[B]

G048R802.WMF

1. Open the vertical unit cover [A].

2. Remove a screw [B] at the joint arm and then remove the cover.

6.3.2 UPPER, LEFT AND RIGHT SIDE COVER

[A]

[C]

[B]

Adjustment

Replacement

G048R803.WMF

1. Open the vertical transport unit (2 screws).

2. Remove the upper cover [A] (3 screws).

3. If present, open the vertical transport unit cover.

4. Remove the left side cover [B] (2 screws) and right side cover [C] (2 screws).

6-5

VERTICAL TRANSPORT UNIT 30 June 2000

6.3.3 VERTICAL UNIT SENSORS

[B]

[A]

G048R801.WMF

1. Open the vertical transport unit

2. Remove the brackets [A] (1 screw each).

3. Remove the cables from the connectors, then remove the sensor [B].

6.3.4 VERTICAL TRANSPORT MOTOR

[A]

G048R804.WMF

1. Remove the vertical transport cover. (Refer to section 6.3.1.)

2. Remove the upper and left side cover. (Refer to section 6.3.2.)

3. Remove the motor [A] (2 screws and 1 connector).

6-6

30 June 2000 VERTICAL TRANSPORT UNIT

6.3.5 VERTICAL TRANSPORT UNIT

[C]

[B]

[A]

G048R823.WMF

1. Remove the vertical transport cover. (Refer to section 6.3.1.)

2. Remove the upper, left side, right side covers. (Refer to section 6.3.2.)

3. Remove connectors.

4. Remove the brackets on the left [A] and right side [B] (1 screw each). NOTE: The brackets on the left and right side differ from each other. The left

side bracket has a longer pin than the other.

5. Remove the clip [C] at the joint. NOTE: Be sure that the harness for the vertical transport motor is removed

beforehand so the harness is not damaged.

Adjustment

Replacement

6-7

DUPLEX UNIT 30 June 2000

6.4 DUPLEX UNIT

6.4.1 DUPLEX TRAY

[B]

[A]

G048R828.WMF

1. Pull the tray [A] out about halfway.

2. Loosen the screw that holds the stopper plate [B].

3. Move the stopper plate up and pull out the tray.

6-8

30 June 2000 DUPLEX UNIT

6.4.2 REVERSE ROLLER

[C]

[A]

G048R811.WMF

[F]

G048R819.WMF

[G]

[B]

[D]

[E]

G048R813.WMF

Adjustment

Replacement

1. Pull the duplex tray out. (Refer to section 6.4.1.)

2. Remove the left [A] and right side covers [B] (4 screws each).

3. Open the upper and lower guide plate [C].

4. Remove the upper reverse plate [D] (2 clips).

5. Remove the lower reverse plate [E] (2 screws). NOTE: Be sure not to damage the Myler sheet on the lower plate while

removing the plate.

6. Remove the reverse roller gears [F] and roller [G] (4 clips and 4 bushings).

6-9

DUPLEX UNIT 30 June 2000

6.4.3 DUPLEX FEED MOTOR/REVERSE MOTOR

[A]

[B]

G048R815.WMF

1. Remove the duplex tray. (Refer to section 6.4.1.)

2. Remove the left and right side covers. (Refer to section 6.4.2.)

3. Remove the duplex feed motor [A] and duplex reverse motor [B] together with the brackets (3 screws).

4. Remove motors from brackets (2 screws and 1 connector each).

6.4.4 DUPLEX FEED SENSOR

[A]

[B]

G048R817.WMF

1. Remove the duplex tray. (Refer to section 6.4.1.)

2. Remove the left and right side covers. (Refer to section 6.4.2.)

3. Remove the center plate [A] (2 screws).

4. Remove the duplex feed sensor [B] (1 connector). NOTE: Be sure not to damage the Myler sheet while removing the plate and

sensor.

6-10

30 June 2000 DUPLEX UNIT

6.4.5 JOGER HOME POSITION SENSOR

[B]

[C]

[E]

[A]

[F]

[D]

G048R812.WMF

1. Remove the duplex tray. (Refer to section 6.4.1.)

2. Remove the left and right side covers. (Refer to section 6.4.2.)

3. Remove the center plate and duplex feed sensor connector [A]. (Refer to section 6.4.4.)

4. Remove the feed [B] and reverse motor [C] connectors.

5. Open the upper and lower guide plates and slide the jogger fences [D] to the inside.

6. Remove the upper unit [E] (8 screws).

7. Remove the jogger H.P. sensor [F] (1 connector).

Adjustment

Replacement

6-11

DUPLEX UNIT 30 June 2000

6.4.6 JOGGER MOTOR/REVERSE SOLENOID

[A]

[B]

G048R814.WMF

[C]

G048R816.WMF

1. Remove the duplex tray. (Refer to section 6.4.1.)

2. Reverse the tray and remove the bottom cover [A] (6 screws).

3. Remove the jogger motor [B] together with bracket (3 screws).

4. Remove the motor from the bracket (2 screws and 1 connector).

5. Remove the reverse solenoid [C] (3 screws, 1 connector and 1 spring).

6-12

30 June 2000 DUPLEX UNIT

6.4.7 REVERSE SENSOR

[A]

G048R818.WMF

1. Remove the duplex tray. (Refer to section 6.4.1.)

2. Remove the bottom cover. (Refer to section 6.4.6.)

3. Remove the reverse sensor [A] together with bracket (1 screw).

4. Remove the sensor from the bracket (1 screw and 1 connector).

6.4.8 TEMPERATURE/HUMIDITY SENSOR

[A]

Adjustment

Replacement

G048R808.WMF

1. Open the vertical transport unit.

2. Remove the temperature/humidity sensor [A] (1 screw and 1 connector).

6-13

DUPLEX UNIT 30 June 2000

6.4.9 RELAY MOTOR/RELAY ROLLER

[C]

[E]

G048R836.WMF

[F]

[D]

[A]

[B]

G048R835.WMF

[G]

[J]

[H]

G048R834.WMF

[I]

G048R839.WMF

1. Remove the left and right side mainframe covers.

2. Remove the vertical transport unit. (Refer to section 6.3.5.)

3. Remove the connector [A] and the grounding plate [B].

4. Remove the 4 screws [C] that join the mainframe and the duplex unit, then separate them.

5. Remove the duplex tray. (Refer to section 6.4.1.)

6. Remove the temperature/humidity sensor. (Refer to section 6.4.8.)

7. Reverse the duplex unit and remove the unit frame [D] (8 screws).

8. Remove the gear [E] and motor bracket [F] (1 screw).

9. Remove the relay motor [G] (2 screws).

10. Remove the grounding plate [H] (1 screw).

11. Remove the relay roller drive gear [I] (1 clip)

12. Remove the relay roller [J] (2 clips and 2 bushings).

6-14

30 June 2000 FUSING SECTION

6.5 FUSING SECTION

6.5.1 FUSING UNIT



CAUTION

1. The fusing unit is hot. Handle it with care.

2. Be careful not to spill silicone oil.

3. In the event of a fusing-related SC, replace the applicable components and execute “6: Reset SC” from the engine SP menu to remove the SC.

4. When the fusing unit has been replaced, execute “S3 Maintenance Clear” from the controller SP menu to reset the fusing counter.

[C]

[A]

[E]

[B]

G048R831.WMF

1. Remove the top cover of mainframe. (Refer to section 6.1.1.)

2. Open the front cover and paper exit unit.

3. Open the oil bottle cover [A] and remove the bottle [B].

4. Remove the harness cover [C] and all connectors.

[D]

G048R832.WMF

Adjustment

Replacement

5. Remove the grounding wire [D] (1 screw).

6. Remove the fusing unit [E] (3 dial screws).

6-15

LASER SECTION 30 June 2000

6.6 LASER SECTION



WARNING Turn off the main switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes.

6.6.1 CAUTION DECAL LOCATIONS

Two caution decals are located in the laser section as shown below.

LASER_PS2.WMF

G048R504A.WMF

LASER_PS1.WMF

6-16

30 June 2000 LASER SECTION

6.6.2 OPTICAL HAUSING UNIT

[A]

G048R827.WMF

[C]

[D]

G048R826.WMF

The procedure for removing the screws on the front side is the same as the base model (G024). The following section explains how to remove the screws on the back side.

1. Remove the top cover. (Refer to section 6.1.1.)

2. Remove the paper exit unit. (Refer to section 6.2.3.)

[B]

Adjustment

Replacement

3. Remove the guide plate [A] (4 screws).

4. Remove the clip [B] and the locking bar [C] with releasing the spring.

5. Remove the duct [D] (1 screw).

6. Remove 2 screws fixing the unit at backside.

6-17

ELECTRICAL COMPONENTS 30 June 2000

6.7 ELECTRICAL COMPONENTS

6.7.1 CONTROLLER BOARD

NOTE: Before replacing the controller, print the list of settings whenever possible.

In the event of NV-RAM damage, it is necessary to configure all settings according to this list.

[A]

G048R805.WMF

[C]

[D] [B]

G048R806.WMF

1. Remove the top, left and right side covers.

2. Remove the vertical transport unit. (Refer to section 6.3.5.)

3. Remove the controller board cover [A] (14 screws).

4. Remove the RPS module [B] and RAM module [C].

5. Remove the controller board [D] (6 screws and 1 connector). NOTE: 1) If the customer has added optional expansion memory or a NIC, remove

it before replacing the controller. Remember to install the memory or NIC on the new controller board.

2) To replace the controller boards, remove the NVRAM chip (IC23) on the old board, install it on the new board, then install the new board. The NVRAM chip stores user settings and service records. These settings will be lost if the NVRAM chip is not transferred.

6-18

30 June 2000 ELECTRICAL COMPONENTS

6.7.2 DUPLEX DC SUPPLY UNIT



WARNING To avoid an electric shock, unplug the power cable before replacing the power supply unit.

[A]

[B]

G048R807.WMF

1. Remove the controller board cover. (Refer to section 6.7.1.)

2. Remove the duplex dc supply unit [A] together with the bracket [B] (2 screws and 2 connectors).

3. Remove the dc supply unit from the bracket (4 screws).

Adjustment

Replacement

6-19

ELECTRICAL COMPONENTS 30 June 2000

6.7.3 POWER SUPPLY UNIT



WARNING To avoid an electric shock, unplug the power cable before replacing the power supply unit.

[A]

[B]

G048R820.WMF

1. Remove the controller board. (Refer to section 6.7.1.)

2. Remove the duplex dc supply unit. (Refer to section 6.7.2.)

3. Remove the stay for the paper exit tray [A] (2 screws).

[C]

G048R821.WMF

4. Remove the 6 screws holding the electrical wiring box [B], unplug 4 connectors, and release 2 hooks. Lift the left side of the electrical wiring box [B] upwards

➀

to swing it out ➁.

5. Remove the power supply unit [C] (6 screws, 6 connectors and 2 hooks).

6-20

30 June 2000 ELECTRICAL COMPONENTS

6.7.4 HIGH VOLTAGE SUPPLY UNIT

[A]

[B]

G048R255.WMF

1. Swing the electrical wiring box [A] out. (Refer to section 6.7.3.)

2. Remove the high voltage supply unit [B] (4 screws, 8 connectors and 2 hooks).



WARNING

Carefully connect the high-voltage wires as shown in the diagram below.

Blue connector:

Supply roller

CN190

White connector:

Belt transfer bias roller

White connector:

Development roller

Yellow connector:

Charge corona unit wire

White connector:

Transfer roller

Adjustment

Replacement

Yellow connector:

Development blade

Blue connector:

Charge corona unit grid

G048R512.WMF

6-21

ELECTRICAL COMPONENTS 30 June 2000

6.7.5 MCU

[A]

G048R822.WMF

1. Swing the electrical wiring box out. (Refer to section 6.7.3.)

2. Remove the MCU [A] (2 screws and all connectors).

NOTE: When replacing an MCU, remove the NVRAM chip (IC106) from the old

board, install it on the new board, and then install the new board. In the event of NVRAM damage, install a new NVRAM chip, and contact your supervisor for additional steps. A forced process control will also be necessary (Engine SP mode 7: Process Control – Initialize).

6.7.6 DUPLEX DRIVE BOARD

[B]

[A]

G048R833.WMF

1. Remove the duplex backside cover [A] (4 screws).

2. Remove all connectors from the board.

3. Remove the duplex drive board [B] (6 screws, 1 ground wire).

6-22

30 June 2000 SC TABLES

7. TROUBLESHOOTING

7.1 SC TABLES

7.1.1 TYPES OF SERVICE CALL

For this printer engine, service calls and process control errors are classified into three types:

Service Call Type Results

TYPE 1: Safety warning and immediate shutdown (Fusing unit errors)

TYPE 2: Immediate shutdown

TYPE 3: Log only (Process control errors)

NOTE: In this section, additional or different codes from the base model (G024)

are marked with an asterisk

The printer stops immediately and the LCD displays an SC error message. The error is logged.

The printer does not stop. No SC error message is displayed. The error is only logged.

.

“*”

Fusing Unit SC Errors

Fusing unit SC errors (Type 1 errors) can be released by executing the Reset SC item in the engine SP mode menu. They cannot be released by turning the main power switch off and on.

Trouble-

shooting

7-1

SC TABLES 30 June 2000

7.1.2 SC ERROR LIST

NOTE: The errors marked with an asterisk “*” are additional or changed codes for

this model.

SC

No.

20

21

22

23

24

25

26

* 27

Type Name Occurre nce conditi ons Detection conditions Cause

Type 2 Optional tray

Type 1 Pressure

Type 1 High

Type 1 Low

Type 1 Hot roller

Type 1 High hot

Type 1

Type 2

unit error

roller thermistor error

pressure roller temperature

thermistor error

roller temperature

Low hot roller temperature

Zero-cross cycle detection error

The detection signal for the 500-sheet paper tray unit is abnormal.

The roller temperature has been at 0°C for five seconds.

The roller temperature has been at 190°C or higher for three seconds.

Reheating has been done and the motor is not running, or 60 seconds have passed after the main motor halted. Then, the roller temperature has been below 130°C for 60 seconds

The roller temperature has been 0°C for five seconds.

The roller temperature has been 190°C or higher for three seconds. Reheat has been done and the motor is not running, or 60 seconds have passed after main motor halt. Then, the roller temperature has been below 130°C for 60 seconds 50 Hz AC The number of zero-cross is detected less than 89 times or more than 111 times in one second for continuous 5 seconds. 60 Hz AC The number of zero-cross is detected less than 109 times or more than 131 times in one second for continuous 5 seconds.

Always monitored The optional tray

unit connector has a bad connection.

No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit

No detection in the event of SC or lack of fusing unit

No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit

No detection in the event of SC or fusing unit absence

No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or fusing unit absence

Pressure roller thermistor, MCU

Pressure roller thermistor, MCU, pressure roller lamp connector

Hot roller thermistor, MCU

Hot roller thermistor, MCU, hot roller lamp connector

Frequency of the commercial AC power

7-2

30 June 2000 SC TABLES

SC

No.

28

29

31

32

33

34

35

36

Type Name Occurre nce conditi ons Detection conditions Cause

Type 2

Type 2 Primary

Type 2 Supply bias

Type 2

Type 2 Charge

Type 2 Main motor

Type 2 PCU motor

Paper transfer positive bias release error

transfer bias open

error

Blade bias error

corona unit bias open

corona unit grid bias error

error

The PWM duty has been 50% or higher for 240 ms. Or, the paper transfer roller clutch does not operate.

The PWM duty has been 50% or higher for 240 ms.

The voltage has been higher than the appropriate control voltage for the target voltage for 240 ms. However, detection is disabled when the calculated control voltage is 5 V or higher.

The PWM duty has been 50% or higher for 240 ms.

The voltage has been higher than the appropriate control voltage for the target voltage for 240 ms. However, detection is disabled when the calculated control voltage is 5 V or higher.

Continuous unlock for two seconds

Detection starts 60 ms after control starts for this component.

There is a disconnection in the paper transfer bias supply circuit. (Deformation of terminals or springs, dirty bearings) When the contact/separation lever is normal: Bad transfer roller position sensor, harness, or MCU When the contact/separation lever is faulty: Bad transfer roller clutch or MCU

There is a disconnection in the primary transfer bias supply circuit. (Dirty or deformed electrodes)

There is a short circuit in the supply bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter)

There is a short circuit in the blade bias supply circuit.

There is disconnection in the charge corona unit bias supply circuit. (Dirty or deformed electrodes)

There is a short circuit in the charge corona unit grid bias supply circuit (due to deformed terminals or electrodes or conductive foreign matters).

Main motor, MCU

PCU motor, MCU

Trouble-

shooting

7-3

SC TABLES 30 June 2000

SC

No.

38

39

40

41

42

43

45

46

47

48

49

Type Name Occurre nce conditi ons Detection conditions Cause

Type 2

Type 2 Transfer belt

Type 2

Type 2 Charge bias

Type 2 Paper

Type 2

Type 1 Pressure

Revolver motor error

Polygon mirror motor error

ID sensor error

H.P. sensor error

Laser diode error

Synchronizat ion detection error

short

transfer positive current error

Paper transfer negative bias open

Paper transfer negative current error

roller reheat timeout

Movement to the home position took four or more seconds. For black, movement to the home position took one second or longer.

Continuous unlock for two seconds

The ID sensor output voltage is not between

0.1 V and 1.1 V while the ID sensor LED is off.

No mark has been detected for 500 ms during PCU motor operation.

LD error (abnormal laser power output)

Synchronization detection error of the optical unit

A/D converted voltage has been 4.8 V or more for 240 ms.

A/D converted voltage has been 0.2 V or less for 240 ms.

The PWM duty has been 50% or greater for 240 ms.

A/D converted voltage has been 4.8 V or more for 240 ms.

When reheating, the roller temperature does not reach the reheat start temperature (target temperature –20°C) within five minutes.

Revolver motor, MCU, or incorrect installation of color development unit

Polygon mirror motor, MCU

ID sensor calibration ID sensor

Transfer belt H.P. sensor, MCU

LD, LD control board

During polygon mirror motor revolution

Detection starts 60 ms after control starts for this component.

During re-heating Pressure roller

Synchronization detection board, LD control board

There is a short circuit in the charge bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter)

There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter)

There is disconnection in the paper transfer bias supply circuit. (Dirty or deformed electrodes)

There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter)

thermistor, pressure roller lamp connector, MCU

7-4

30 June 2000 SC TABLES

SC

No.

50

51

52

57

59

60

*61

*62

*63

Type Name Occurre nce conditi ons Detection conditions Cause

Type 1

Type 1 Pressure

Type 1 Hot roller

Type 2 Print

Type 2

Type 2 Humidity

Type 2 Paper

Type 2 Auto-Duplex

Type 2 Jogger

Hot roller reheat timeout

roller lamp full-power operation error

lamp fullpower operation error

command error

Temperature sensor error

sensor error

Transfer roller error

unit detection error.

movement error

When reheating, the roller temperature does not reach the reheat start temperature (target temperature –10°C) within five minutes.

When full-power operation occurs during reheating, the main motor is not running and the difference between the current temperature and that of 60 seconds ago is 18°C or less.

When an abnormal combination of print commands is received.

5 V (4.75 V) or more has continuously been detected for five seconds.

Paper transfer position sensor does not detect the movement of roller.

Auto-duplex unit is detected on the manualduplex model.

Jogger home position sensor does not turn on.

During reheating

No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or fusing unit absence.

When the power is on, or the AC development bias is off.

When the contact and separation of the roller need to be detected.

When the power is on MCU

During duplex printing Jogger motor

Hot roller thermistor, hot roller lamp connector, MCU

Pressure roller thermistor, pressure roller lamp connector, MCU

Hot roller thermistor, hot roller lamp connector, MCU

Temperature sensor

Humidity sensor

Transfer roller position sensor MCU Harness Transfer roller clutch

Jogger HP sensor MCU DDB

7-5

Trouble-

shooting

SC TABLES 30 June 2000

7.1.3 PROCESS CONTRL ERROR LIST

PE

No.

103 Type 3

104 Type 3

105 Type 3

110 Type 3

111 Type 3

112 Type 3

116 Type 3

Type Name Occurre nce conditi ons Detection conditions Cause

K ID sensor error

ID sensor output error (rough adjustment)

ID sensor output error (fine adjustment)

ID sensor pattern error (Cyan)

ID sensor pattern error (Magenta)

ID sensor pattern error (Yellow)

ID sensor pattern error (K)

While the LED is off, the ID sensor output does not meet the standard voltage (between 0.05 V and 1.5 V).

The difference in ID sensor outputs when the transfer belt is read and when the LED is off does not meet the standard voltage (Vbkcal ± 0.4 V).

The difference in ID sensor outputs when the transfer belt is read and when the LED is off does not meet the standard voltage (Vbkcal ± 0.1 V).

The slope γM of the line representing the relationship between the C development bias and attached toner amount is not between –0.01 and –

0.0005. The slope γM of the line

representing the relationship between the M development bias and attached toner amount is not between –0.01 and –

0.0005.

The slope γM of the line representing the relationship between the Y development bias and attached toner amount is not between –0.01 and –

0.0005. The slope γM of the line

representing the relationship between the K development bias and attached toner amount is not between –0.01 and –

0.001.

ID sensor (K) calibration

Color DTM initialization

When the output meets the standard voltage: MCU,

harness

When the output does not meet the standard:

sensor

K ID sensor, MCU, transfer belt error, transfer belt surface unevenness, incorrect ID sensor installation

K ID sensor, MCU, transfer belt error, transfer belt surface unevenness

Incorrect color DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization

Incorrect K DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization

K ID

7-6

30 June 2000 SC TABLES

PE

No.

118 Type 3

123 Type 3

Type Name Occurre nce conditi ons Detection conditions Cause

ID sensor pattern read error (K)

ID sensor pattern error (K)

The difference in ID sensor outputs when the ID sensor pattern is read and when the background surface of the transfer belt is read is

0.8 V or less.

The slope γM of the line representing the relationship between the DTM bias and attached toner amount is not between –0.01 and –

0.001.

K-DTM bias initialization

K-DTM bias control Incorrect DTM

Incorrect DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization

installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization

7-7

Trouble-

shooting

USER ERROR LIST 30 June 2000

7.2 USER ERROR LIST

This table only shows additional and different items from the base model (G024).

Error

Add Toner: xx Printing stops. The PCU counter is

Low on : x,x,x Printing can be

Change PCU Printing can be

Change Fusing Unit

Need Charger Printing can be

Vertical Transport Unit Cover Open

Operation after error

done.

Printing can be done.

done.

Printing is disabled. Always monitored Close the cover.

Detection

conditions

increased to 100 after toner near-end is detected.

Toner near-end detection is enabled two seconds after the development drive solenoid turns on until it turns off. The toner near-end message is displayed when toner end is detected five times.

The CPU counter reaches 72,000.

The fusing unit counter reaches 60,000.

Charger counter reaches 24 K.

Release method Remarks

Replace the DTM.

Replace the PCU to reset the counter.

Manually release the message using ‘Maintenance Clear’ in controller SP mode.

Replace charger unit and reset the charger counter.

This error is shown when “Stop” is selected in the Toner Empty menu.

When near-end is detected, closing the front cover initiates recovery. If the toner near-end status is cleared, it is not detected during recovery. In singlecolor (black-and-white) continuous output, toner near-end is detected during process control.

Counting (upon exit) A3/DLT or smaller

K single-color: Plus 1 Full color: Plus 4

For sizes larger than A3/DLT, counting doubles. This is not shown if meter-click mode is selected.

A3 or larger: Number of sheets that have passed x 2

Smaller than A3: Number of sheets that have passed

This is not shown if meter-click mode is selected.

7-8

30 June 2000 USER ERROR LIST

Error

Duplex-tray Jam

Vertical Transport Unit Jam

Duplex Unit Exit Jam

Operation after error

Printing is disabled.

Printing is disabled. The vertical

Printing is disabled.

Detection

conditions

<Case 1> The duplex feed sensor does not detect paper 3.2 seconds after the vertical transport exit sensor detects paper.

<Case 2> The reverse sensor does not detect paper 3.2 seconds after the duplex feed sensor detects paper.

<Case 3> The reverse sensor does not detect paper 0.5 seconds after the duplex reverse motor turns on.

transport entrance sensor does not detect paper 3.2 seconds after the paper exit sensor in fusing unit detects paper.

Or The vertical

transport exit sensor does not detect paper 2.8 seconds after the vertical entrance sensor detects paper.

The pull-out sensor for the main frame does not detect paper 0.9 seconds after the relay motor turns on.

Release method Remarks

Remove the jammed paper.

Remove the jammed paper by opening the vertical transport unit.

7-9

Trouble-

shooting

12345678

A

B

C

D

Paper Feed Clutch

E

Registration Clutch

Development Drive

Transfer Roller Clutch

F

Used Toner Sensor

PCU Reset Sensor

G

H

I

Registration Sensor

J

Power Cord

LINE

NUTRAL

Door Safety Switch

Exit Cover Switch

By-pass Feed Clutch

Relay Roller Clutch

Transfer Belt Cleaning Solenoid

Solenoid

Pull-out Sensor

ID Sensor

Temperature Humidity Sensor

By-pass Paper

End Sensor

Transfer Roller Position Sensor

Revolver H.P.

SOL3

Charge Corona Set Switch

Paper End Sensor

Paper Size Switch

S10

Toner End Sensor

S13

Sensor

Transfer Belt H.P. Sensor

S15

( )

CN802-1

CN805-1

DTM Cover Switch

CL2

CL4

Pull-out Clutch

CL6

PCU Set Switch

3 2

S2

1

CN813

3 2

S4

1

CN827

3 2

S6

1

CN823

5 4 3

S8

2

CN820

1

3 2 1

CN817

3 2 1

CN874

3 2 1

CN831

Oil End Sensor

AC DC

,P

Pulse Signal Direction Active High Active Low Voltage

T108

Inlet

T109

Ground

CN801-2

CN802-2

CN803-2

CN805-2

CN804-1

High Voltage

C

Supply Board

G TB TP

PCB3

BL BSPDevelopment

CL1

CL3

SOL2

CL5

S1

S3

S5

S7

S9

S11

S12

S14

S17

T101

T102

122

CN815

CN822

3 2 1

CN818

4 3 2 1

CN824

6 5 4 3

CN814CN826

1

3 2 1

CN821

3 2 1

CN830

3 2 1

CN828

CN801-1

CN803-1

CN804-2

A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B10 B9

CN190

B8 B7 B6 B5 B4 B3 B2 B1

122

1

122

1

122

1

CN841 CN839 CN837

122

1

CN844

1 2

3 4 5

6 7

1 2 3

4 5 6

1 2 3 4 5

FU1

250V

15A

CN105-6

CN105-3

T115

T113

1

CN840 CN838 CN836

1

CN843

7 6

5 4 3

CN870

2 1

6 5 4

3

CN872

2 1

5 4 3 2

CN871

1

Main Switch

T116

T112

CN105-1

CN105-4

1 2

A1 A2 A3 A4 A5 A6 A7 A8 A9

A10

B1 B2 B3 B4 B5 B6 B7 B8 B9

B10

A1 A2

A4 A5

A7 A8

A10 A11

B1 B2

B4 B5

B7 B8

B10 B11

1 2

3 4 5

6 7

9 10 11

A2 A3 A4

A5 A6 A7

A9 A10 A11 A12

B1

B2

B3

B4

B5

B7

B8

B9 B10

B12

1 2 3

4 5 6

8 9

10 11

12 13

A1

A2

A3

A4

A5

A6

A7

A8

B1

Power Supply Unit

PCB1

DC Voltage Generator

5V 5V INT

24V 24V INTR

CN204

24V INR 24V INTS

24V DB 24V DBSW

CN250

GND (COM3) 24V INT 5V GND (COM4) FB VBL (

W

5

W

FB VSP (

5 → 0 to 5)

W

FB ITP (

5 → 0 to 5)

W

5 → 0 to 5)

FB VTB (

W

FB VG (

5 → 0 to 5)

FB IC (

W

5 → 0 to 5)

V

PWM C (

CN205

CN212

CN207

CN209

CN209 CN208

CN210

123456789

TXD

V

PWM G ( PWM TB ( PWM TP+ ( PWM SP ( PWM BL ( PWM TP– (

W

TRG G ( TRG AC (

W

TRG B (

24V XBPFEDCL (

24V XPAPEOCL (

24V XTRNROCL (

24V XREGICL (

24V XTRCBESL (

24V XDEVSLC (

24V XPIUPCL (

24V XTRCROCL (

GND (COM2) XTNBTS (

GND (COM2) XTNFULS ( 5V

GND (COM2) XINPUT (

W

GND (COM2) XPCUNOS ( 5V

GND (COM2) XPAPEND ( 5V

GND (COM2) XPICKS (

W

5V

V

XNOB0 (

V

XNOB1 ( GND (COM2)

V

XNOB2 (

W

LEDIN (

W5 →

VOUT1 (

W

VOUT2 ( GND (COM2) 5V

XTHREMO ( GND (COM4) GND (COM4) XHUMIDS ( N.C. 5V

GND (COM2) XBPFEDS ( 5V

GND (COM2) XTRCRLS ( 5V

GND (COM2) XCOLEND ( 5V

GND (COM2) XDTMS (

W

5V GND (COM2)

MARKSEN ( 5V

GND (COM2) XREGIST ( 5V

GND (COM2) XOILEND ( 5V

5V5V5V

XOFGATE

GND (COM2)

5 → 0/5) 5 → 0/5)

V

V V5 → V

5 → 0/5)

V

5)

W

5)

W

5)

W

5)

W

5)

5 → 0 to 4)

5 → 0 to 5)

W

5)

W

T105

T106

T107

T108

TF1

2

CN832CN834

L3

2

FM2

2

CN875

FM3

2

CN878

CN849

CN846CN850

CN851

CN855

CN863

P1SPS0 P2 P3 P4 P5 P6 P7 P8

P9 P10 P11

D(6)

OPR_W

GND (COM2)

L1

L2

Pressure Roller Lamp

Fusing Unit

Quenching Lamp

Laser Diode (LD) Unit

Operation Panel

CN863

CN860-2

CN852

P22 P21 P20 P19 P18 P17 P16 P15 P14 P13 P12

D(4)

LED4ON

LED3ON

GND (COM2)

3 2 1

CN809

DTM Set Sensor

211

5 4 3 2 1

CN85222CN860

CN860

CN852

860-2

P11

J11

P10

J10

P9

J9

P8

J8

P7

J7

P6

J6

P5

J5

P4

J4

P3

J3

P2

J2

P1

J1

XVDATA2

XVDATA0

GND (COM2)

TF1

Hot Roller Thermofuse

TF2

Pressure Roller Thermofuse

S19

Exit Sensor

211

2

CN877

211

2

CN835

211

2

CN876

211

2

CN833

211

10

9 8 7 6 5 4 3 2 1

1

5

2

4

3

4

2

CN847

5

1

7 6 5 4 3 2 1

26

24

(Option)

Paper Fedd Unit

SPS1

SPS2 SPEND SPSEN

XSPST0 XSPST1

SPSEL

XSNDFD0 XSNDCL0

XSNDCK0

5V5V5V

ENABLE

GND (COM2)

CN102-1

Power Relay

Heater Control

Circuit

Vcc (5.1V)

CN101-1

CN101-2

CN101-3

1234567

→→→→

0 to 5)

5 → 0/5)

0/5)

5 → 0/5)

W

24)

W

24)

W

24)

24 → 0/24)

W

24 → 0/24)

W

24)

5)

0 to 5)

5 → 0 to 5)

5)

1011121314151617181920212223242526272829303132333435363738394041424344454647484950515253545556575859606162636465666768697071727374757677787980

5V

XILSYNC

GND (COM2)

GND (COM1) (Vcc)

Vaa (24V)

CN101-4

CN101-5

CN101-6

CN101-7

CN201

ICLOCK

XVDATA7

GND (COM2)

GND (COM3) (Vaa)

CN101-8

12345

8

CN202 CN203

XFIXRAI (W24)

XFIXRA2 (W24)

XPWRRL (W24)

CN217

1 3 5 7

9 11 13 15 17 19 21 23

CN221

1

3

5

7

9 11 13 15 17 19 21 23 1

CN218

A1 A2 A3 A4 A5 A6 A7 A8 A9

A10 A11

N.C.

XVDATA5

XVDATA3

XVDATA1

GND (COM2)

123456789

6

24 V INT

GND (COM2)

GND (COM4)

ZCROSS (W5 → 0/5)

Main Control Board

5VINT

GND (COM2)

5VINT GND (COM2) GND (COM2)

LDOFF

XLDERR

LDCLK

GND (COM2)

SPEND

SPSEN XSPST0 XSPST1

SPSEL SNDFD0 SNDCL0 SNDCK0

XS

GND (COM2)

PCB2

XLD7 XLD5 XLD3 XLD1

LED2 LED4 SW2 SW4 SW6 SW8

5V

E DB4 DB6

SPS0 SPS1 SPS2

N.C.

RSEL

GND (COM2)

XFTFRM2 (W5 → 0 to 5)

(V5)

W

5)

(

W

(

5)

W

5)

( (

W

5)

W

5)

( (

W

(

5)

W

5)

(

W

(

5)

W

5)

( (

W

5)

W

(

5)

(

W

5)

V

(

5)

V

(

5)

V

(

5)

(W5)

W

(

5)

W

5)

(

W

(

5)

W

(

5)

W

5)

(

W

5)

(

V

5)

(

V

5)

(

V

(

5)

V

(

5)

D(7)

GND (COM2)

GND (COM4)

GND (COM2)

XFTHRM1 (W5 → 0 to 5)

CN851

25 23 21 19 17 15 13

P

11

P

9

P

7

P

5

P

3 125

CN855

23 21 19 17 15 13 11

9 7 5 3

CN852

P11 P10

P9 P8 P7 P6 P5 P4 P3 P2

P

P1

D(5)

LED1ON

GND (COM2)

CN102-2 CN102-3 CN102-4

10

5V

REVMOBB (

REVMOAB (

5VINT

GND (COM2)

5VINT

GND (COM2)

LDMODE

LEVEL

XLDON

GND (COM2)

OPRXW

GND (COM2)

SDDFD1

SNDCL1

SNDK1

GND (COM3) GND (COM3) GND (COM3)

CN223

CN1

SW4ON

SW7ON

SW8ON

PCB8

XBPFEDSL (

XRRMLED (

XFMSTAT2 (

XFMSTAT1 (

XFMSTAT3 (

XFMSTAT4 (

XFMSTAT5 (

REVMOB (

REVMOA (

XBMLOCK (

BMOCLK(

BMSPEED (

XBMSTART (

XPMSTART (

PMCLK (

XMMLOCK ( MMSTART ( MMSPEED (

LDS XLD6 XLD4 XLD2 XLD0

LED1 LED3 SW1 SW3 SW5 SW7

5V

RS DB5 DB7

5V

24V

RXD

XOLSYNC

GND (COM2)

5V

XFSET (W5)

GND (COM1)

XPAPOUT (W5)

CN217 CN851

2 4 6

8 10 12 14 16 18 20 22 24 26

CN221 CN855

2

4

6

8 10 12 14 16 18 8 20 6 22 4 24 2

CN218 CN852 B1 B2 B3 B4 B5 B6 B7 B8

B9 P14 B10 P13 B11 P12

5V

SW3ON

LED2ON

Controller Board WIN

W

24 → 0/24)

W

24 → 0/24)

W

24 → 0/24)

W

24 → 0/24)

GND (COM3) GND (COM2)

W

24 → 0/24)

BMFF ( BMFR (

XDPINI (

GND (COM2)

GND (COM3)

XSCRDY (

W

24 → 0/24)

GND (COM3) GND (COM3)

W

5)

( (V5)

W

(

5)

V

5)

(

W

5)

(

W

(

5)

W

(

5)

W

(

5)

W

5)

(

W

(

5)

W

5)

( (

W

5)

W

(

5)

(

W

5)

W

5)

(

V

(

5)

V

(

5)

V

(

5)

V

5)

(

V

(

5)

(

V

5)

OCLOCK

GND (COM2)

CN1

CN2-2

CN3

CN4-2

211

3 2 1

24V

W

24)

24V

W

24)

24V

W

24)

24V

W

24)

24V

W

24)

24V

W

24)

24V

W

24)

24V INT

5V

W

24)

W

24)

W

24)

W

24)

W

24)

W

5)

5V

24V

W

24)

W

24)

24V INT 24V INT

W

24)

W

24)

W

24)

26 24 22 20 18 16 14 12

P

10

P

8

P

6

P

4 2

24 22 20 18 16 14 12 10

P22 P21 P20 P19

P

P18 P17 P16 P15

5V5V5V

XIFGATE

GND (COM2)

2

CN807

2 1

1 2 3

CN811 CN888

CN808

S16

CN211CN214CN213

CN215CN216

CN217

CN221

CN218

5V

XVDATA6

1 2

3 4

5 6

7 8

9 10

11 12

13 14

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10

1 2 3

4 5 6 7 8

1 2 3 4 5 6 7

XVDATA4

GND (COM2)

Hot Roller Lamp

Pressure Roller Thermisotr

TF2

SOL1

FM1

Exhaust Fan

FM5

Transport Fan

FM4

M1

M2

3 2

PCB4

1

CN845

M3

M4

PCB5

PCB7

(Option)

Paper Feed Unit

CN860

860-2

J11 J10

GND (COM2)

J9

XSNDFD1

J8

XSNDCL1

J7

XSNDCK1

J6

24V

J5

24V

J4

24V

J3

GND (COM3)

J2

GND (COM3)

J1

GND (COM3)

NC

SW1ON

SW2ON

SW5ON

SW6ON

Hot Roller Thermistor

By-pass Feed Solenoid

Transport Fan

Charge Inlet Fan

Inlet Fan

Revolver Motor

PCU Motor

Laser Synchronization Detector Board

Polygon Mirror Motor

Main Motor

CN863

5V

P22 P21 P20 P19 P18 P17 P16 P15 P14 P13 P12

A

B

C

D

E

F

G

CN863-2

H

I

J

Option Board

K

Point to Point Diagram (G047/G048)

12345678

(Option)

Network Interface Board

(Option)

IEEE 1284 Parallel

Interface

(Option)

16 MB/32 MB Memory

(Option)

16 MB/32 MB Memory

(Option)

Ricoh-script 2

K

ELECTRICAL COMPONENT LAYOUT

SENSORS

14

1

2

13

12

11

10

9

8

7

Index No. Description Symbol P-to-P

1 Exit Sensor S19 B7 2 Oil End Sensor S17 J1 3 Transfer Belt H.P. Sensor S14 I2 4 Transfer Roller Position Sensor S11 H2 5 Used Toner Sensor S2 F1 6 PCU Reset Sensor S4 F1 7 Paper End Sensor S5 G2 8 ID Sensor S8 G1

9 Pull-out Sensor S6 G1 10 By-pass Paper End Sensor S10 H1 11 Registration Sensor S15 I1 12 Toner End Sensor S12 I2 13 Revolver H.P. Sensor S13 I1 14 DTM Set Sensor S16 B6

G048V551A.WMF

1

SWITCHES

7

6

3

4

5

6

4

G048V551.WMF

Index No. Description Symbol P-to-P

1 Main Switch SW1 B3 2Exit Cover Switch SW2 C2 3 Door Safety Switches SW3 B2 4 Paper Size Switch S7 G2 5 PCU Set Switch S1 F2 6 Charge Corona Unit Set Switch S3 F2 7DTM Cover Switch SW4 C2

2

3

PCBS AND PSU

1

9

2

MOTORS, CLUTCHES, AND SOLENOIDS

17

16

15

14

13

12

11

10

9

Index No. Description Symbol P-to-P

1 Exhaust Fan FM2 C8

2 PCU Motor M2 D8

3 Transfer Belt Cleaning Solenoid SOL2 E2

4 Main Motor M4 F8

5 Revolver Motor M1 D8

6 Polygon Mirror Motor M3 E8

7 Development Drive Solenoid SOL3 E1

8 Pull-out Clutch CL5 F2

9 Paper Feed Clutch CL2 E1 10 Relay Roller Clutch CL3 E2 11 By-pass Feed Clutch CL1 E2 12 Registration Clutch CL4 E1 13 Transfer Roller Clutch CL6 F1 14 By-pass Feed Solenoid SOL1 B8 15 Charge Inlet Fan FM5 C8 16 Inlet Fan FM4 C8 17 Transport Fans FM1, FM3 C7

8

G048V552.WMF

8

3

4

5

7

1

6 2 3

4 5

6

7

Index No. Description Symbol P-to-P

1 Power Supply Unit (PSU) PCB1 A3-A5 2 Controller Board PCB8 J3-J7 3 High Voltage Supply Board PCB3 D2 4 Temperature/Humidity Sensor S9 H2 5 Main Control Unit (MCU) PCB2 C3-I6 6 Laser Synchronization Detector Board PCB4 E8 7 Quenching Lamp L3 C7 8 Laser Diode (LD) Unit PCB5 F7 9 Operation Panel PCB7 G7

G048V111.WMF

THERMISTORS, HEATERS, AND FUSES

1

2

6

5

4

3

G048V111.WMF

Index No. Description Symbol P-to-P

1 Pressure Roller Thermistor TH1 B7 2 Pressure Roller Lamp L2 A7 3 Hot Roller Thermofuse TF1 A7 4 Hot Roller Thermistor TH2 B8 5 Hot Roller Lamp L1 A7 6 Pressure Roller Thermofuse TF2 A7

12345678

A

B

C

D

E

F

G

H

I

J

MCU

PCB2

DIV_SL (

REVMOA (

FEDMTCLK (

XFEDMTON (

PLMTCLK (

XPLMTON (

PLTFMTCLK (

XTFMTON (

TRVMTCLK (

XTRVMTON (

TRVMTINV (

JGMTCLK (

JGMTON (

JGMTINV (

XTRVSOL (

XTRVPAP1 ( XTRVPAP2 (

XTRVJGHP (

XUNITSET (

XPULLSET (

XTRVPAPR (

SNDCD0 ( SNDCL0 ( SNDCK0 (

SNDCD1 ( SNDCL1 ( SNDCK1 (

24V DBSW

W

GND (COM2)

PAPS_L (

GND (COM2)

PAPS_V (

W

24 → 0/24)

W

5 → 0/5)

W

5 → 0/5)

W

5 → 0/5)

W

5 → 0/5)

W

5 → 0/5)

+24V DBSW +24V DBSW

GND (COM3) GND (COM3)

GND (COM2)

SPS0 (W5) SPS1 (

SPS2 ( SPEND ( SPSEN (

XPST0 ( XPST1 ( SPSEL (

GND (COM1)

GND (COM3) GND (COM3) GND (COM3)

24V DB

24V

24)

W

5)

5V

W

5)

5V

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

5V

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

W

5)

V

5)

V

5)

V

5)

V

5)

5V

V

5)

V

5)

V

5) 24V 24V 24V

1 2 3 4

CN255

1

2

CN250CN251

12211

4

1 235

6 34

4

CN252

5 621

12

1

11

2

10

3

9

4

8

5

7

6

7

5

8

CN253

4

9

3

10

2

11

1

12

13

1 2

12

3

11

4

10

5

9

6

8 7

7

6

8

CN254

5

9

4

10

3

11

2

12

1

13

11

A1

10

A2

9

A3

8

A4

7

A5

6

A6

5

A7

4

A8

3

A9

2

A10

1

A11

11

B1

CN218

10

B2

9

B3

8

B4

7

B5

6

B6

5

B7

4

B8

3

B9

2

B10

1

B11

Vertical Transport Cover Switch

122

CN812CN810

2

2 3

CN816

5 6

1 2 3 4 5 6 7 8

CN854CN886CN887 CN856

9 10 11 12

Relay Motor

1 2 3 4 5 6 7 8 9 10 11

CN806-1

31 2 1

M6

P11 P10

P9 P8 P7 P6 P5 P4 P3 P2 P1

P22 P21 P20 P19 P18 P17 P16 P15 P14 P13 P12

CN806-2

Junction Gate Solenoid

S20

CN825

1 2 3 4 5 6

CN886

CN889-2

SOL4

Vertical Transport Entrance Sensor

Vertical Transport

Exit Sensor 3 2 1

CN829

12 11 10

9 8 7 6 5 4 3 2 1

13 12 11 10

9 8 7 6 5 4 3 2 1

1

6

2

5

3

4 3

4

2

5

CN859

1

6

4 3 2 1

CN897

CN889-1

Vertical Transport Unit Switch

Vertical Transport Unit

Vertical Transport Motor

S21

65432

CN857

231

65432

CN891CN892

CN857

CN893

24V DBSW

FED-B (W24 → 0/24)

FED-XB (W24 → 0/24)

PL-A (W24 → 0/24) 24V DBSW PL-XA (

W

24 → 0/24)

W

24 → 0/24)

PL-B ( 24V DBSW

W

24 → 0/24)

PL-XB (

Duplex Driver Board

PCB9

GND (COM3) GND (COM3) Vaa (24V DB) Vaa (24V DB)

M5

1

564

1

24V DBSW

FED-XA (W24 → 0/24)

TRV-XB (

TRV-XA (

FED-A (W24 → 0/24)

CN105-6

W

24 → 0/24)

TF-XB (

24V DBSW

TF-B (

W

24 → 0/24)

W

24 → 0/24)

TF-XA (

24V DBSW

W

24 → 0/24)

TF-A (

W

24 → 0/24)

24V DBSW

TRV-B (

W

24 → 0/24)

W

24 → 0/24)

24V DBSW

W

24 → 0/24)

TRV-A (

XTRVPAP1 (

GND (COM2)

XTRVPAP2 (

GND (COM2)

XTRVPAPR (

GND (COM2)

XPULLSET (

GND (COM2)

24V DBSW

JG-B (W24 → 0/24)

W

JG-XB (

24 → 0/24)

W

24 → 0/24)

JG-XA (

W

24 → 0/24)

JG-A (

24V DBSW

XTRVSOL (

XTRVJGHP (W5)

GND (COM2)

DC Supply Unit

PCB10

Factory Check

CN105-3

Main switch

T115

T116

T113

T114

2 3 4 5 6 7

CN895

10 11 12 13 14

A1

5V

A2

W

5) A3

A4

5V

A5

W

5) A6

A7

5V

A8

W

5) A9

A10

W

5) A11

B1 B2 B3

CN896

B4 B5 B6

B7

24V

W

B8

24)

B9

5V

B10 B11

CN105-1

CN105-4

J13 J12 J11 J10

J22 J21 J20

J19 J18 J17 J16 J15 J14 J13 J12

J11 J10

J9 J8

J69 J5 J4 J3 J2 J1

J9 J8 J7 J6

J5 J4

J3 J2 J1

PSU

PCB1

CN898

CN864

CN866

CN865

CN867

P13

1

P12

2

P11

3

P10

4

P9

5

P8

6

P6

1

P5

2

P4

3

P3

4

P2

5

P1

6

P22

1

P21

2

P20

3

P19 P18 P17 P16 P15 P14 P13 P12

P11

1

P10

2

P9

3

P8

4

P7

5

P6

6

P5

12

P4

2

P3 P2 P1

Duplex Unit

6 5 4 3 2

CN868

1

6 5 4 3 2

CN869

1

CN873

6 5 4 3 2

CN869CN885

1

GND

24V

S22

( )

2 1

CN890

,P

2 1

CN2

Duplex Feed Motor

M7

Duplex Reverse Motor

M8

Duplex Feed Sensor

1 2

S23

3

CN884

Reverse Sensor

Jogger Motor

M9

Reverse Solenoid

SOL5

1 2

S24

3

CN848

Jogger H.P. Sensor

AC DC Pulse

Signal Direction Active High Active Low Voltage

A

B

C

D

E

F

G

H

I

J

K

Point to Point Diagram (G048)

K

ELECTRICAL COMPONENT LAYOUT

Duplex

13

15 14

17

16

18

12

1

2

3

4

5

6

7

8

9

10

11

G048D103.WMF

Index No. Description Symbol P-to-P

1 Vertical Transport Entrance Sensor S20 D3 2 Vertical Transport Cover Switch SW5 C3 3 Duplex DC Supply Unit PCB10 B4-B7 4 Vertical Transport Unit Switch SW6 C4 5 Vertical Transport Motor M5 D4 6 Duplex Driver Board PCB9 E4-H6 7 Relay Motor M6 G3 8 Duplex Feed Sensor S22 F7

9 Jogger H.P. Sensor S24 H8 10 Jogger Motor M9 G7 11 Reverse Solenoid SOL5 G7 12 Reverse Sensor S23 F8 13 Duplex Reverse Motor M8 E7 14 Duplex Feed Motor M7 E7 15 Vertical Transport Exit Sensor S21 D4 16 Junction Gate Solenoid SOL4 C3

Ricoh ap305 Service Manual ap306e

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORTANT SAFETY NOTICES

LASER SAFETY

TABLE OF CONTENTS

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS

1.2 MECHANICAL OVERVIEW

1.3 MAIN UNIT LAYOUT

1.4 SYSTEM BLOCK

1.4.1 BLOCK DIAGRAM

2. DETAILED SECTION DESCRIPTIONS

2.1 DIFFERENT POINTS FROM BASE MODEL (G024)

2.1.1 OVERVIEW

2.1.2 FUSING UNIT

2.1.3 OPTICAL UNIT

2.1.4 PAPER FEEDING AND REGISTRATION

2.1.5 PROCESS CONTROL

2.1.6 ELECTRICAL COMPONENTS

2.2 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.1 OVERVIEW

Layout

Electrical Components

2.2.2 EXIT UNIT

Driving Mechanism

Junction Gate

Exit Cover Open Detection

2.2.3 VERTICAL TRANSPORT UNIT

Driving Mechanism

Paper Feed Detection

Vertical Transport Unit Cover Open Detection

2.2.4 DUPLEX UNIT

Driving Mechanism

Reverse Mechanism

Jogging Mechanism

Feed-out

Reverse Tray Detection

2.2.5 INTERLEAF

Paper Path for Duplex Printing

Print Order for Duplex Black & White Printing

Print Order for Duplex Color Printing

3. INSTALLATION PROCEDURE

4. SP MODE

4.1 OVERVIEW

4.2 ENGINE SP MODE

4.2.1 OVERVIEW

To enter and exit engine SP mode

Outline of the engine SP mode functions

4.2.2 MENU OPERATION/DISPLAY

4.2.3 MARGIN (REGISTRATION ADJUSTMENT)

4.2.4 PARAMETER

4.2.5 CLEAR MEMORY

4.2.6 SENSOR CHECK

4.2.7 NIP WIDTH

4.2.8 RESET SC

4.2.9 PROCESS CTRL

4.2.10 TEST PRINT

4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)

4.2.12 IMAGE ADJUST

4.2.13 OUTPUT CHECK

4.2.14 HIGHLIGHT ADJUSTMENT

4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT)

4.2.16 PRIMARY BIAS ADJUSTMENT

5. PREVENTIVE MAINTENANCE

5.1 PM TASKS

5.1.1 REPLACEMENT

5.1.2 CLEANING

5.1.3 INSPECTION

5.2 PM TABLE

5.2.1 MAIN UNIT

5.2.2 OPTIONAL PAPER FEED UNIT

6. REPLACEMENT AND ADJUSTMENT (AUTO-DUPLEX MODEL)

6.1 EXTERIOR

6.1.1 TOP OVER

6.2 PAPER EXIT UNIT

6.2.1 UPPER COVER

6.2.2 LOWER COVER

6.2.3 PAPER EXIT UNIT