Ricoh ap3600 schematic

Model-U

(Machine Code: G071)

SERVICE MANUAL

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

4. The printer drives some of its components when it completes the warm-up period. Be careful to keep hands away from the mechanical and electrical components as the printer starts operation.

5. The inside and the metal parts of the fusing unit become extremely hot while the printer is operating. Be careful to avoid touching those components with your bare hands.

HEALTH SAFETY CONDITIONS

Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

2. The NVRAM module (option) installed on the controller has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame.

2. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor in accordance with local regulations. (These are non-toxic supplies.)

3. Dispose of replaced parts in accordance with local regulations. When keepi ng used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

4. When keeping used lithiu m batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

LASER SAFETY

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

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

WARNING WARNING: Turn off the main switch before atte mpting any of the

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

CAUTION MARKING:

Trademarks

Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the United States and /or other countries.

PostScript® is a registered trademark of Adobe Systems, Incorporated. PCL® is a registered trademark of Hewlett-Packard Company. Ethernet® is a registered trademark of Xerox Corporation. PowerPC® is a registered trademark of International Business Machines

Corporation. Other product names used herein are for identification purposes only and may be

trademarks of their respective companies. We disclaim any and all rights involved with those marks.

Conventions in this Manual

This manual uses several symbols.

Symbol What it means

☛

$ %

Refer to section number See Core Tech Manual for details

Screw Connector Clip ring E-ring

Lengthwise, SEF (Short Edge Feed)

Sideways, LEF (Long Edge Feed)

1 INSTALLATION ........................................................................... 1-1

1.1 INSTALLATION REQUIREMENTS...........................................................1-1

1.1.1 ENVIRONMENT...............................................................................1-1

1.1.2 MACHINE LEVEL.............................................................................1-1

1.1.3 SPACE REQUIREMENTS................................................................1-2

1.1.4 POWER REQUIREMENTS..............................................................1-2

1.2 MACHINE INSTALLATION .......................................................................1-3

1.3 OPTIONS..................................................................................................1-4

2 PREVENTIVE MAINTENANCE.................................................... 2-1

2.1 OVERVIEW...............................................................................................2-1

Users Do the User PM Procedures.......................................................2-1

All PM Done by Technicians.................................................................2-1

Counters...............................................................................................2-1

2.2 USER MAINTENANCE .............................................................................2-1

Main Unit...............................................................................................2-1

Optional Paper Tray Unit......................................................................2-2

2.3 SERVICE MAINTENANCE........................................................................2-2

Main Unit...............................................................................................2-2

Bypass Tray..........................................................................................2-2

Optional Units.......................................................................................2-3

Paper Tray Unit.....................................................................................2-3

Finisher.................................................................................................2-3

Mail Box................................................................................................2-3

Duplex Unit...........................................................................................2-3

Interchange Unit ...................................................................................2-3

3 REPLACEMENT AND ADJUSTMENT......................................... 3-1

3.1 SPECIAL TOOLS......................................................................................3-1

3.2 EXTERIOR COVERS................................................................................3-2

3.2.1 REAR COVER..................................................................................3-2

3.2.2 LOWER LEFT COVER.....................................................................3-3

3.2.3 UPPER COVER, OPERATION PANEL............................................3-3

3.3 ELECTRICAL COMPONENTS..................................................................3-4

3.3.1 PRINTER CONTROLLER ................................................................3-4

3.3.2 CONTROLLER BOX.........................................................................3-4

3.3.3 BCU BOARD....................................................................................3-4

3.3.4 I/O BOARD.......................................................................................3-5

3.3.5 PSU..................................................................................................3-5

3.3.6 HIGH VOLTAGE SUPPLY BOARD..................................................3-6

3.4 DRIVE UNITS............................................................................................3-7

3.4.1 DEVELOPMENT CLUTCHES..........................................................3-7

K/Y Development Units.........................................................................3-7

C/M Development Units........................................................................3-7

3.4.2 DEVELOPMENT MOTOR................................................................3-8

3.4.3 MAIN MOTOR..................................................................................3-8

3.4.4 PCU GEAR BOX AND OPC BELT CLEANING CLUTCH ................3-9

3.4.5 FUSING UNIT MOTOR ....................................................................3-9

3.4.6 PAPER FEED MOTOR...................................................................3-10

3.4.7 PAPER FEED CLUTCH.................................................................3-10

3.4.8 REGISTRATION CLUTCH.............................................................3-10

3.5 LASER OPTICS SECTION .....................................................................3-11

3.5.1 CAUTION DECAL LOCATION.......................................................3-11

3.5.2 LASER OPTICS HOUSING UNIT ..................................................3-12

Adjusting for Image Skew...................................................................3-14

3.5.3 LD UNIT..........................................................................................3-14

3.5.4 POLYGONAL MIRROR MOTOR AND SYNC. DETECTION

BOARD...........................................................................................3-15

3.6 DEVELOPMENT UNIT............................................................................3-16

3.7 PHOTOCONDUCTOR UNIT (PCU)........................................................3-17

3.7.1 MAIN UNIT.....................................................................................3-17

3.7.2 WASTE TONER BOTTLES............................................................3-18

3.7.3 CHARGE CORONA WIRE.............................................................3-19

3.7.4 CHARGE CORONA WIRE CLEANER MOTOR.............................3-20

3.7.5 OPC BELT CLEANING UNIT.........................................................3-20

3.7.6 OPC BELT UNIT ............................................................................ 3-21

3.7.7 IMAGE TRANSFER BELT CLEANING UNIT .................................3-21

3.7.8 IMAGE TRANSFER BELT UNIT ....................................................3-22

Reassembling.....................................................................................3-22

3.8 PAPER TRANSFER UNIT.......................................................................3-23

3.8.1 VERTICAL TRANSPORT UNIT......................................................3-23

3.8.2 TRANSFER ROLLER.....................................................................3-23

3.9 FUSING/PAPER EXIT............................................................................. 3-24

3.9.1 FUSING UNIT.................................................................................3-24

3.9.2 OIL SUPPLY UNIT.........................................................................3-24

3.9.3 LAMPS ...........................................................................................3-25

3.9.4 FUSING INNER UNIT..................................................................... 3-26

3.9.5 PRESSURE ROLLER THERMOFUSE...........................................3-26

3.9.6 FUSING BELT UNIT AND PRESSURE ROLLER UNIT.................3-26

3.9.7 PRESSURE ROLLER THERMISTOR............................................3-27

3.9.8 PAPER EXIT UNIT AND PAPER EXIT/OVERFLOW SENSOR.....3-27

3.10 PAPER FEED AND TRANSPORT........................................................3-28

3.10.1 FEED ROLLER AND FRICTION PAD..........................................3-28

3.10.2 REGISTRATION SENSOR...........................................................3-29

3.10.3 PAPER FEED SENSOR...............................................................3-30

3.10.4 PAPER NEAR-END SENSOR......................................................3-30

3.10.5 PAPER END SENSOR.................................................................3-30

3.11 BYPASS TRAY......................................................................................3-31

3.11.1 PICKUP/FEED ROLLER..............................................................3-31

3.11.2 PAPER FEED CLUTCH...............................................................3-32

3.11.3 REVERSE ROLLER.....................................................................3-32

4 TROUBLESHOOTING ................................................................. 4-1

4.1 SERVICE CALL.........................................................................................4-1

4.1.1 SERVICE CALL CONDITIONS ........................................................4-1

4.1.2 SC TABLE........................................................................................4-2

4.2 CONTROLLER ERROR TABLE................................................................4-9

4.3 BLOWN FUSE CONDITIONS.................................................................4-12

4.4 CHECK POINTS FOR IMAGE PROBLEMS AT REGULAR

INTERVALS ............................................................................................4-12

5 SERVICE TABLES....................................................................... 5-1

5.1 SERVICE PROGRAM MODE....................................................................5-1

5.1.1 OPERATION PANEL KEYS.............................................................5-1

5.1.2 STARTING SERVICE PROGRAM MODE........................................5-2

Procedure 1..........................................................................................5-2

Procedure 2..........................................................................................5-2

5.1.3 MAIN MENU.....................................................................................5-2

5.1.4 SPECIFYING A VALUE OR SETTING.............................................5-3

5.1.5 LEAVING SERVICE MODE..............................................................5-3

5.2 SP MODE TABLES...................................................................................5-4

5.2.1 SERVICE (CONTROLLER SERVICE MODES) ...............................5-4

Bit Switch Settings................................................................................5-6

How to Change Bit Switch Settings ......................................................5-6

Bit Switch 1...........................................................................................5-7

Bit Switch 2...........................................................................................5-7

Bit Switch 3...........................................................................................5-7

Bit Switch 4...........................................................................................5-7

Gamma Adjustment..............................................................................5-8

Summary ..............................................................................................5-8

Adjustment Procedure ..........................................................................5-9

5.2.2 ENGINE SERVICE MODES...........................................................5-11

SP1-XXX: (Feed)................................................................................5-11

SP2-XXX: (Drum)................................................................................5-15

SP3-XXX: (Process) ...........................................................................5 -24

SP5-XXX: (Mode) ...............................................................................5-27

SP7-XXX: (Data Log)..........................................................................5-33

Input Check Table...............................................................................5-39

Table 1: Tray 1 Paper Size.................................................................5-42

Table 2: 1st/2nd Bank Paper Size ......................................................5-42

Table 3: 1st/2nd Bank Near End.........................................................5-42

Output Check Table............................................................................5-43

5.3 CONTROLLER SELF-DIAGNOSTICS....................................................5-45

5.3.1 OVERVIEW....................................................................................5-45

5.3.2 DETAILED SELF-DIAGNOSTICS..................................................5-46

5.4 USER PROGRAM MODE.......................................................................5-47

5.5 UPGRADING SOFTWARE .....................................................................5-48

5.5.1 OVERVIEW....................................................................................5-48

5.5.2 UPGRADING..................................................................................5-49

Procedure...........................................................................................5-49

iii

Error Recovery....................................................................................5-50

Installation Error..................................................................................5-50

Power Failure......................................................................................5-50

5.6 DIP SWITCHES.......................................................................................5-51

Controller Board..................................................................................5-51

BCU Board..........................................................................................5-51

6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1

6.1 OVERVIEW...............................................................................................6-1

6.1.1 MAJOR COMPONENTS ..................................................................6-1

6.1.2 PAPER PATH...................................................................................6-2

6.1.3 DRIVE COMPONENTS....................................................................6-3

6.1.4 ELECTRICAL COMPONENTS.........................................................6-4

Image Transfer .....................................................................................6-4

Development Units ...............................................................................6-5

Paper Path............................................................................................6-6

Drive Components................................................................................6-7

Circuit Boards.......................................................................................6-8

6.2 PRINTING PROCESS OVERVIEW...........................................................6-9

6.3 PROCESS CONTROL ............................................................................6-11

6.3.1 OVERVIEW....................................................................................6-11

6.3.2 PROCESS CONTROL STEPS....................................................... 6-12

Six Steps.............................................................................................6-12

When is Process Control Done?.........................................................6-12

6.4 PHOTOCONDUCTOR UNIT (PCU)........................................................6-13

6.4.1 OVERVIEW....................................................................................6-13

6.4.2 NEW PHOTOCONDUCTOR UNIT DETECTION...........................6-14

New PCU Sensor................................................................................6-14

Mechanism .........................................................................................6-14

PCU Counter ......................................................................................6-14

6.4.3 CHARGE CORONA UNIT..............................................................6-15

Power Supply......................................................................................6-15

Wire Cleaning.....................................................................................6-15

Cleaning Interval .................................................................................6-15

Quenching ..........................................................................................6-16

6.4.4 OPC BELT DRIVE..........................................................................6-16

6.4.5 OPC BELT CLEANING UNIT.........................................................6-17

Toner Collection Augurs.....................................................................6-17

Counter Blade + Brush.......................................................................6-17

Waste Toner Bottle Sensors...............................................................6-17

Drive ...................................................................................................6-18

6.4.6 IMAGE TRANSFER BELT UNIT ....................................................6-19

Drive ...................................................................................................6-19

Belt Mark Sensor................................................................................6-19

Bias Roller ..........................................................................................6-20

6.4.7 TRANSFER BELT CLEANING UNIT..............................................6-21

Bias Brush ..........................................................................................6-21

Bias Roller and Cleaning Blade..........................................................6-21

Collecting Coil.....................................................................................6-21

Waste Toner Bottle Sensors...............................................................6-21

Contact Mechanism............................................................................6-22

Power Supply......................................................................................6-23

Drive ...................................................................................................6-23

6.5 LASER EXPOSURE................................................................................6-24

6.5.1 OVERVIEW....................................................................................6-24

Dust Shield Glass Cleaning................................................................6-25

LD Unit Adjustment.............................................................................6-25

Polygonal Mirror..................................................................................6-25

Laser Diode Power Control.................................................................6-25

Maintenance Adjustment....................................................................6-25

6.5.2 LD SAFETY SWITCH.....................................................................6-26

Operation Panel Message and Switch Mechanism.............................6-27

“Close Front Cover”........................................................................6-27

“Close Right Cover”........................................................................6-27

“Close Left Cover” ..........................................................................6-27

6.6 DEVELOPMENT.....................................................................................6-28

6.6.1 OVERVIEW....................................................................................6-28

6.6.2 DEVELOPMENT UNIT...................................................................6-29

Rollers and Agitators...........................................................................6-29

Replacing Units...................................................................................6-29

Memory Chip ......................................................................................6-29

6.6.3 TONER SUPPLY MECHANISM.....................................................6-30

Toner Cartridge Agitators....................................................................6-30

Drive Power Path................................................................................6-30

Development Unit Agitator..................................................................6-30

Toner Supply Roller and Doctor Roller...............................................6-30

Shutter................................................................................................6-30

6.6.4 TONER END DETECTION .............................................................6-31

Mechanism .........................................................................................6-31

Toner Near-end Detection ..................................................................6-31

Toner End Detection...........................................................................6-31

Toner End Recovery...........................................................................6-31

6.6.5 DEVELOPMENT UNIT CONTACT MECHANISM..........................6-32

Mechanism .........................................................................................6-32

Reverse Rotation................................................................................6-32

6.6.6 POWER SOURCE..........................................................................6-33

Development, Toner Supply, and Doctor Rollers................................6-33

Doctor Roller.......................................................................................6-33

6.7 PAPER FEED..........................................................................................6-34

6.7.1 OVERVIEW....................................................................................6-34

Transport Speed.................................................................................6-35

Friction Pad.........................................................................................6-35

6.7.2 STANDARD TRAY DRIVE .............................................................6-35

Feed and Vertical Transport Rollers...................................................6-35

Registration Roller..............................................................................6-35

6.7.3 STANDARD TRAY – BOTTOM PLATE LIFT .................................6-36

Lift Mechanism....................................................................................6-36

Paper Near End Detection..................................................................6-36

Paper End Detection...........................................................................6-36

6.7.4 STANDARD TRAY - PAPER SIZE DETECTION ...........................6-37

Mechanism .........................................................................................6-37

Switch Pattern.....................................................................................6-37

6.7.5 BYPASS TRAY...............................................................................6-38

Paper Feed Mechanism......................................................................6-38

Bypass Tray Drive Power Path...........................................................6-38

Pick-up Solenoid.................................................................................6-38

Paper End Sensor ..............................................................................6-38

6.8 PAPER TRANSFER AND SEPARATION ...............................................6-39

6.8.1 OVERVIEW....................................................................................6-39

Jammed Paper Release.....................................................................6-39

Image Transfer and Paper Separati on................................................6-39

6.8.2 MECHANISM..................................................................................6-40

Contact/Separation.............................................................................6-40

Drive Power Path................................................................................6-40

6.8.3 POWER SUPPLY...........................................................................6-42

Electric Power Path ............................................................................ 6-42

Transfer Roller Bias............................................................................6-42

Discharge Plate .................................................................................. 6-42

Temperature/Humidity Control............................................................6-42

Roller Cleaning...................................................................................6-43

6.9 FUSING UNIT AND OIL SUPPLY UNIT..................................................6-44

6.9.1 OVERVIEW....................................................................................6-44

6.9.2 FUSING UNIT CONFIGURATION..................................................6-45

Fusing Belt..........................................................................................6-45

Oil Supply ...........................................................................................6-45

Heating Roller Lamp...........................................................................6-45

Pressure Roller Lamp......................................................................... 6-45

Pressure Roller Pawls.........................................................................6-45

Fusing Bias.........................................................................................6-46

Fusing Unit SCs..................................................................................6-46

6.9.3 TEMPERATURE CONTROL..........................................................6-47

6.9.4 OIL SUPPLY AND CLEANING.......................................................6-48

Oil Supply ...........................................................................................6-48

Oil Path...............................................................................................6-48

Oil Recycling.......................................................................................6-48

Belt Cleaning ......................................................................................6-48

Oil End Detection................................................................................6-49

Fusing unit switch...............................................................................6-49

6.9.5 DRIVE.............................................................................................6-49

Drive Power Path (Fusing Unit and Oil Supply Roller)........................6-49

Drive Power Path (Pressure Roller)....................................................6-49

6.9.6 ENERGY SAVER MODE................................................................6-50

Level 1 Energy Saver Mode (default: on)............................................6-50

Level 2 Energy Saver Mode................................................................6-50

Ready Mode .......................................................................................6-50

6.9.7 PAPER EXIT ..................................................................................6-51

Drive Power Path................................................................................6-51

Paper Jam Detection..........................................................................6-51

6.9.8 OVERFLOW DETECTION.............................................................6-51

6.10 PRINTED CIRCUIT BOARDS...............................................................6-52

6.10.1 PRINTER CONTROLLER ............................................................6-52

Function..............................................................................................6-52

Memory............................................................................................... 6-52

Interfaces............................................................................................6-52

Slots....................................................................................................6-53

Options ...............................................................................................6-53

DIP Switch..........................................................................................6-53

LED Indicators....................................................................................6-53

6.10.2 BASE ENGINE CONTROL UNIT (BCU).......................................6-54

Function..............................................................................................6-54

Upgrading...........................................................................................6-54

Nonvolatile Random Access Memory (NVRAM).................................6-54

DIP Switch..........................................................................................6-54

6.10.3 INPUT/OUTPUT (I/O) BOARD.....................................................6-55

6.10.4 POWER SUPPLY UNIT (PSU) .....................................................6-55

6.10.5 HIGH VOLTAGE SUPPLY............................................................6-55

6.11 CONTROLLER......................................................................................6-56

6.11.1 OVERVIEW..................................................................................6-56

6.11.2 BOARD LAYOUT..........................................................................6-58

6.11.3 PRINT DATA PROCESSING .......................................................6-59

RPCS Driver.......................................................................................6-59

PCL5c Driver ......................................................................................6-59

PS3 Driver ..........................................................................................6-60

CMS (Color Management System)..................................................... 6-60

Gray Correction ..................................................................................6-60

BG/UCR (Black Generation/Under Color Removal)............................6-60

Gamma Correction .............................................................................6-60

Toner Limitation..................................................................................6-61

Dither Processing and ROP/RIP.........................................................6-61

6.11.4 CONTROLLER FUNCTIONS.......................................................6-62

Sample Print.......................................................................................6-62

Locked Print........................................................................................6-62

Paper Source Selection......................................................................6-63

Tray Priority (Auto Tray Select)...........................................................6-63

Tray Lock............................................................................................6-63

Manual Tray Select.............................................................................6-63

Auto Continue.....................................................................................6-64

Overview.............................................................................................6-64

Auto Tray Select.................................................................................6-64

Manual Tray Select.............................................................................6-64

Paper Output Tray..............................................................................6-65

Output Tray Selected..........................................................................6-65

Sequential Stacking............................................................................6-65

Stapling...............................................................................................6-66

6.12 IEEE1394 INTERFACE.........................................................................6-67

6.12.1 SPECIFICATIONS........................................................................6-67

vii

Hardware Specification.......................................................................6-67

System Requirements.........................................................................6-67

6.12.2 IEEE1394 .....................................................................................6-67

6.12.3 BLOCK DIAGRAM........................................................................6-68

6.12.4 PIN ASSIGNMENT.......................................................................6-68

6.12.5 REMARKS ABOUT THIS INTERFACE KIT..................................6-69

6.12.6 TROUBLESHOOTING NOTES....................................................6-69

PERIPHERALS

PAPER TRAY UNIT (Machine Code: G313)

1 REPLACEMENT AND ADJUSTMENT...................................G313-1

1.1 REAR COVER....................................................................................G313-1

1.2 PAPER FEED CLUTCH.....................................................................G313-1

1.3 LIFT MOTOR......................................................................................G313-2

1.4 PAPER FEED MOTOR ......................................................................G313-2

1.5 CONTROLLER BOARD.....................................................................G313-2

1.6 PICK-UP/FEED/SEPARATION ROLLERS.........................................G313-3

2 DETAILED DESCRIPTIONS..................................................G313-4

2.1 MECHANICAL COMPONENT LAYOUT ............................................G313-4

Feed and Reverse Roller (FRR)....................................................G313-4

Drive Path......................................................................................G313-4

Paper End Feeler Method..............................................................G313-4

2.2 ELECTRICAL COMPONENT LAYOUT..............................................G313-5

2.3 DRIVE LAYOUT.................................................................................G313-6

2.4 PAPER SIZE DETECTION.................................................................G313-7

2.5 PAPER LIFT.......................................................................................G313-8

2.6 PAPER HEIGHT AND END DETECTION..........................................G313-9

Paper Height Detection..................................................................G313-9

Paper End Detection......................................................................G313-9

INTERCHANGE UNIT (Machine Code: G305)

1. REPLACEMENT AND ADJUSTMENT..................................G305-1

1.1 EXTERIOR COVER AND PAPER EXIT SENSOR.............................G305-1

1.2 CONTROL BOARD............................................................................G305-1

2. DETAILED DESCRIPTIONS.................................................G305-2

2.1 ELECTRICAL COMPONENTS...........................................................G305-2

2.2 DRIVE ................................................................................................G305-2

2.3 MECHANISM......................................................................................G305-3

viii

DUPLEX UNIT (Machine Code: G303)

1 REPLACEMENT AND ADJUSTMENT...................................G303-1

1.1 EXTERIOR COVER...........................................................................G303-1

1.2 ENTRANCE/EXIT SENSORS............................................................G303-1

Entrance Sensor............................................................................G303-1

Exit Sensor ....................................................................................G303-1

1.3 INVERTER MOTOR...........................................................................G303-2

1.4 CONTROLLER BOARD.....................................................................G303-2

1.5 TRANSPORT MOTOR.......................................................................G303-2

2 DETAILED DESCRIPTIONS..................................................G303-3

2.1 OVERVIEW........................................................................................G303-3

2.2 ELECTRICAL COMPONENT LAYOUT..............................................G303-4

2.3 DRIVE LAYOUT.................................................................................G303-5

2.4 DUPLEX PAPER FEED ORDER........................................................G303-6

2.4.1 LONGER THAN A4/LT LEF.......................................................G303-6

2.4.2 UP TO A4/LT LEF......................................................................G303-7

2.5 REVERSE MECHANISM ...................................................................G303-8

500-SHEET FINISHER (Machine Code: G314)

1 REPLACEMENT AND ADJUSTMENT...................................G314-1

1.1 EXTERIOR COVERS.........................................................................G314-1

Front Cover....................................................................................G314-1

Rear Cover ....................................................................................G314-1

Lower Guide ..................................................................................G314-2

Reassembly...................................................................................G314-2

Upper Cover ..................................................................................G314-3

Right Cover....................................................................................G314-3

1.2 ENTRANCE UPPER GUIDE AND PAPER EXIT UNIT......................G314-4

1.3 MOTORS............................................................................................G314-5

1.3.1 MAIN MOTOR...........................................................................G314-5

1.3.2 JOGGER MOTOR.....................................................................G314-5

1.4 STAPLER...........................................................................................G314-6

1.5 PADDLE ROLLER SOLENOID ..........................................................G314-6

1.6 MAIN CONTROL PCB........................................................................G314-7

1.7 OUTPUT TRAY UNIT.........................................................................G314-8

2 DETAILED DESCRIPTIONS................................................G314-10

2.1 OVERALL MACHINE INFORMATION .............................................G314-10

2.1.1 COMPONENT LAYOUT..........................................................G314-10

2.1.2 DRIVE LAYOUT......................................................................G314-11

2.1.3 ELECTRICAL COMPONENTS................................................G314-12

2.2 DETAILED SECTION DESCRIPTIONS...........................................G314-14

2.2.1 OUTPUT TRAY.......................................................................G314-14

Stack Height Detection................................................................G314-14

Output Tray Up/Down Mechanism...............................................G314-15

Overview......................................................................................G314-15

Output Tray Downward Movement..............................................G314-15

Output Tray Upward Movement...................................................G314-15

2.2.2 PAPER FEED..........................................................................G314-16

Overview......................................................................................G314-16

Straight Feed-out Mode...............................................................G314-16

Shift Sorting Mode.......................................................................G314-17

Stapling Mode..............................................................................G314-19

2.2.3 JAM CONDITIONS..................................................................G314-20

2.2.4 ERROR DETECTION..............................................................G314-20

FOUR-BIN MAILBOX (Machine Code: G312)

1. REPLACEMENT AND ADJUSTMENT..................................G312-1

1.1 EXTERIOR COVER...........................................................................G312-1

1.2 MAIN MOTOR AND CONTROLLER BOARD.....................................G312-1

1.3 VERTICAL TRANSPORT AND PAPER OVERFLOW SENSORS.....G312-2

2. DETAILED DESCRIPTIONS.................................................G312-3

2.1 OVERVIEW........................................................................................G312-3

2.2 DRIVE ................................................................................................G312-4

Drive Path......................................................................................G312-4

2.3 ELECTRICAL COMPONENT LAYOUT..............................................G312-5

2.4 PAPER DISTRIBUTION.....................................................................G312-6

Mechanism ....................................................................................G312-6

Paper Overflow Sensor..................................................................G312-6

2.5 BASIC OPERATION...........................................................................G312-7

2.6 PAPER MISFEED DETECTION TIMING...........................................G312-7

SPECIFICATIONS.....................................................................SPEC-1

1 GENERAL SPECIFICATIONS..............................................................SPEC-1

1.1 MAIN UNIT..................................................................................SPEC-1

1.2 SUPPORTED PAPER SIZES......................................................SPEC-4

1.2.1 MAIN TRAY, BYPASS TRAY, AND DUPLEX UNIT ...........SPEC-4

1.2.2 FINISHER, MAIL BOX, AND PAPER TRAY UNIT..............SPEC-5

2 SOFTWARE ACCESSORIES..............................................................SPEC-6

2.1 PRINTER DRIVERS....................................................................SPEC-6

2.2 UTILITY SOFTWARE..................................................................SPEC-6

3 MACHINE CONFIGURATION

3.1 SYSTEM COMPONENTS...........................................................SPEC-7

EXTERIOR ...................................................................................SPEC-7

INTERIOR.....................................................................................SPEC-8

MAINTENANCE KITS...................................................................SPEC-8

3.2 OPTIONAL EQUIPMENT............................................................SPEC-9

PAPER TRAY UNIT......................................................................SPEC-9

FINISHER.....................................................................................SPEC-9

MAIL BOX...................................................................................SPEC-10

DUPLEX UNIT............................................................................SPEC-10

INTERCHANGE UNIT ................................................................SPEC-10

17 September, 2001 INSTALLATION REQUIREMENTS

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

1. Temperature Range:

2. Humidity Range: 20% to 80% RH

3. Ambient Illumination: Less than 2,000 lux (keep the machine out of direct

4. Ventilation: 3 times/hr/person or more

5. Avoid exposing the machine to sudden temperature changes, which include:

1) Direct cool air from an air conditioner

2) Direct heat from a heater

6. Avoid installing the machin e in areas that may be exposed to corrosive gas.

7. Install the machine at a location lower than 2,500 m (8,200 ft.) above sea level.

8. Install the machine on a strong, level base. (☛ 1.1.2)

9. Avoid installing the machine in areas that may be subjected to strong vibration.

10°C to 32°C (50°F to 89°F)

sunlight.)

Installation

1.1.2 MACHINE LEVEL

Front to back: Within 5 mm (0.2") of level Right to left: Within 5 mm (0.2") of level

1-1

INSTALLATION REQUIREMENTS 17 September, 2001

1.1.3 SPACE REQUIREMENTS

A: Over 100 mm (4") B: Over 100 mm (4")

C:Over 550 mm (22") D:Over 750 mm (30")

G070I001.WMF

1.1.4 POWER REQUIREMENTS

CAUTION

1. Insert the plug firmly in the outlet.

2. Avoid using an outlet extension plug or cord.

3. Ground the machine.

1. Input voltage level: 120 V, 60 Hz, More than 11 A 220 to 240 V, 50/60 Hz, More than 7 A

2. Permissible voltage fluctuation: ±10%

3. Do not put or place anything on the power cord.

1-2

17 September, 2001 MACHINE INSTALLATION

1.2 MACHINE INSTALLATION

Refer to the Operating Instructions for details. If the customer has a service contract, change the settings of the following SP

modes depending on the contract type.

Item SP No. Function Default

Meter charge SP5-930-1 Specifies whether the meter charge

mode is enabled or disabled. If the user is doing the user PM procedures, set meter charge to ‘Off’. If the technician is doing all the PM, set meter charge to ‘On’.

Meter charge mode enabl ed:

• The Counter menu appears immediately after the Menu key is pressed.

• The counter type selected by the counting method (SP5-045-1) can be displayed with the Co unt er menu.

• The counter values can also be printed with the Counter menu.

• The selected counter starts from a negative number.

Meter charge mode disabled:

• The Counter menu is not displayed.

• The t otal counter starts from 0.

Counting method SP5-045-1 Specifies whether the counting

method used in meter charge mode is based on developments or prints.

Off

Developments

Installation

A3/11" x 17" double counting

PM warning display 1

PM warning display 2

PM warning display 3

Important:

This SP can only be done before t he negative counters are reset with S P7825-001

SP5-104-1 Specifies whether the counter is

doubled for A3/11" x 17" paper.

SP5-931-1

SP5-931-2 Specifies whether the PM warning f or

SP5-931-3 Specifies whether the PM warning f or

Specifies whether the PM warning f or the charge corona unit is displayed when the replacement time arriv es. 1: Displayed 0: Not displayed

the PCU is displayed. 1: Displayed 0: Not displayed

the feed rollers in the optional paper feed unit is displayed. 1: Displayed 0: Not displayed

1-3

No: Single counting

OPTIONS 17 September, 2001

Item SP No. Function Default

Fax No. setting SP5-812-2 Programs the service station fax

number. The number is printed on the counter list when the meter charge mode is selected, so that the user can fax t he counter data to the service station.

Counter reset SP7-825-1 Resets the counters to 0.

Important: This must be done at installation after all the a bove settings have been finished. The ne gat ive counters used in meter charge mode will be reset to zero.

NOTE: 1) The def ault setting for this machine is meter-c harge mode off.

2) The meter-charge counter cannot be reset.

1.3 OPTIONS

Refer to the Option Setup Guide for details.

No. Optional Unit Alternative Requirements

500-sheet finisher

1 2 4-bin mailbox No. 1

3 Interchange unit

Duplex unit

4 5 Paper tray unit

6 Printer hard disk

DIMM memory (64, 128, or 256

MB modules available) IEEE1394 interface unit

8 9 User account enhancement unit

No. 2

NOTE: 1) You cannot install the finisher and mailbox on the same machine.

2) You can install either 1 or 2 paper tray units.

• No. 3

• Hard disk or memory (extra 64

MB or more) for sort mode

• No. 3

• Extra 64 MB (or more) optional

SDRAM module

1-4

17 September, 2001 OVERVIEW

2. PREVENTIVE MAINTENANCE

2.1 OVERVIEW

Users Do the User PM Procedures

The user does PM for the items in section 2.2. The technician does PM for the items in section 2.3 . Meter-charge mode mu st be set to “off” (SP5-9 30, ☛ 5.2).

All PM Done by Technicians

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

Counters

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

Preventive

Maintenance

2.2 USER MAINTENANCE

Abbreviations: C

lean

Main Unit

O/B and T/B waste toner bottles

Oil supply unit Fusing unit with paper

feed roller

* : Replacement period calculated for a 50% color rat io (the actual waste toner bottle conditi on **: Standard replacement period (the actual oil amount is detected w it h t he sensor)

nspect

, I

Item

is detected with the sensors)

, L

ubricate

eplace

, R

30 120

R**

, K

iloPrints

iloDevelopments

, K

Detection Reset

Waste toner sensors

Oil end sensor Exit sheet

counter

, W

heneverNecessary

Auto-reset (sensor)

Manual reset

Machine

stops

Yes Yes Yes

2-1

SERVICE MAINTENANCE 17 September, 2001

Item

Black development unit Color development unit Charge corona unit &

dust filters PCU

*Displayed with SP7-906

Item WN Detection Reset

Registration roller Dust shield glas s

(LD unit) Bottom plate pad

120 240

R R R

Detection Reset

Dev. Bk counter*

Dev. color counter*

Charge corona counter*

PCU counter* Auto-reset (new

Machine

stops

C None None No C None None No C None None No

Auto-reset (memory chip)

Manual reset

PCU sensor)

➀ damp cloth and ➁ dry cloth

Built-in cleaning brush

➀ damp cloth and ➁ dry cloth

Machine

stops

Yes Yes

No No

Remarks

Optional Paper Tray Unit

Item 150KP Detection Reset

Feed, pick-up, and separation rollers

R None None No

2.3 SERVICE MAINTENANCE

Abbreviations:

lean

Main Unit

Bypass Tray

Feed Roller Pick-up Roller Separation Roller

, I

nspect

, L

ubricate

, R

eplace

, K

iloPrints

, K

Item WN Remarks

C C C

Machine

iloDevelopments

➀ damp cloth and ➁ dry cloth

stops

heneverNecessary

, W

Remarks

➀ damp cloth and ➁ dry cloth

2-2

17 September, 2001 SERVICE MAINTENANCE

Optional Units

Paper Tray Unit

Item WN Remarks

Relay Roller Bottom Plate Pad

C C

➀ damp cloth and ➁ dry cloth

Finisher

Item WN Remarks

Rollers Sensors C Blower blush or dry cloth

Anti-Static Brush C Blower blush or dry cloth Bushings

Stapler

➀ damp cloth and ➁ dry cloth

Launa oil when abnormal noise occurs

Every 200K staples (estimated replacement period)

Preventive

Maintenance

Mail Box

Item WN Remarks

Rollers Tray Paper Sensors C Blower blush or dry cloth

➀ damp cloth and ➁ dry cloth

Duplex Unit

Item WN Remarks

Rollers Feed/exit sensors C Blower blush or dry cloth

➀ damp cloth and ➁ dry cloth

Interchange Unit

Item WN Remarks

Paper Exit Sensor C Blower blush or dry cloth

2-3

17 September, 2001 SPECIAL TOOLS

3. REPLACEMENT AND ADJUSTMENT

CAUTION Turn off the main power switch and unplug the machine before beginning any of the procedures in this section.

NOTE: This manual uses the following symbols.

☛ : See or Refer to ! : Screws " : Connector # : Clip ring $ : E-ring

3.1 SPECIAL TOOLS

Part Number Part Name

N8036701 Flash Memory Card - 4MB G0219350 Loop-back connector - Parallel

Adjustment

Replacement

3-1

EXTERIOR COVERS 17 September, 2001

3.2 EXTERIOR COVERS

3.2.1 REAR COVER

1. Duct cover [A] (4 hooks)

2. Ozone filter [B]

3. Printer controller [C] (! x 2) [A]

4. Rear cover [D] (! x 2)

[C]

[B]

G070R702.WMF

[D]

G070R703.WMF

3-2

17 September, 2001 EXTERIOR COVERS

3.2.2 LOWER LEFT COVER

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

[A]

3.2.3 UPPER COVER, OPERATION PANEL

1. Open the right cover [A].

2. Upper right cover [B]

3. Paper exit cover [C] (! x 1)

4. Open the front cover [D].

5. Upper cover [E] (! x 4)

6. Operation panel [F] (4 hooks,

" x 2, ! x 1)

NOTE: Insert a screwdriver between

the upper cover and the main unit and unhook the panel.

[F]

[D]

[E]

G070R704.WMF

G070R701.WMF

[C]

[B]

[A]

Adjustment

Replacement

3-3

ELECTRICAL COMPONENTS 17 September, 2001

3.3 ELECTRICAL COMPONENTS

3.3.1 PRINTER CONTROLLER

☛ 3.2.1

NOTE: Remove the NVRAM from the old controller board, and install it on the new

one. If the controller NVRAM is defective, reset the total counter to 0 after changing the NVRAM, if meter charge mode is enabled.

3.3.2 CONTROLLER BOX

1. Rear cover (☛ 3.2.1)

2. Cooling fan [A] (! x 2)

NOTE: When reassembling, inst all

the fan with the label facing the inside.

3. Controller box [B] (! x 11)

NOTE: Do not remove the BCU

board base with the controller box.

NOTE: When pu tting back the

controller box, take care not to pinch the cable from the I/O board.

3.3.3 BCU BOARD

1. Controller box (☛ 3.3.2)

2. All " (12)

3. 1 flat cable

4. BCU board base [A] (! x 5)

5. BCU board [B] (! x 5)

NOTE: Remove the NVRAM f rom the old

BCU board, and install it on the new one.

[B]

[A]

G070R705.WMF

[A]

3-4

[B]

G070R706.WMF

17 September, 2001 ELECTRICAL COMPONENTS

3.3.4 I/O BOARD

1. Controller box (☛ 3.3.2)

2. All " (33)

3. I/O board [A] (! x 4)

3.3.5 PSU

1. Controller box (☛ 3.3.2)

2. Flywheel (! x 3) (☛ 3.4.1)

[A]

G070R707.WMF

[B]

[C]

Adjustment

Replacement

3. Duct [A] (" x 1, ! x 1)

NOTE: When removing and

reassembling t he fan, install it with the label facing the outside.

4. PSU protector [B] (! x 1)

5. Unlink the main switch [C].

6. PSU base (" x 8, ! x 4)

NOTE: 1) Remove the PSU [D]

with the PSU base.

2) When reas semb lin g, check that the main switch is linked to the PSU.

[A]

[D]

G070R717.WMF

3-5

ELECTRICAL COMPONENTS 17 September, 2001

3.3.6 HIGH VOLTAGE SUPPLY BOARD

1. Photoconductor unit (☛ 3.7)

2. Right inner cover (☛ 3.10.2)

3. Photoconductor unit rail [A] (! x 2)

4. " [B] x 1

5. Bushing [C] x 1

[A]

G070R719.WMF

[C]

[B]

6. High voltage supply board [D] (" x 17, ! x 6)

[D]

G070R720.WMF

3-6

17 September, 2001 DRIVE UNITS

3.4 DRIVE UNITS

3.4.1 DEVELOPMENT CLUTCHES

1. Controller box (☛ 3.3.2)

K/Y Development Units

1. Unhook the lock [A] and pull out the clutch [B] (" x 1).

[B]

Adjustment

Replacement

C/M Development Units

1. Flywheel [A] (! x 3)

2. Unhook the lock [B] and pull out the clutch [C] (" x 1).

[C]

[A]

G070R708.WMF

[B]

G070R709.WMF

3-7

+ 167 hidden pages

Ricoh ap3600 schematic

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORTANT SAFETY NOTICES

LASER SAFETY

Trademarks

Conventions in this Manual

TABLE OF CONTENTS

PERIPHERALS

PAPER TRAY UNIT (Machine Code: G313)

INTERCHANGE UNIT (Machine Code: G305)

DUPLEX UNIT (Machine Code: G303)

500-SHEET FINISHER (Machine Code: G314)

FOUR-BIN MAILBOX (Machine Code: G312)

SPECIFICATIONS.....................................................................SPEC-1

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

1.1.2 MACHINE LEVEL

1.1.3 SPACE REQUIREMENTS

1.1.4 POWER REQUIREMENTS

1.2 MACHINE INSTALLATION

1.3 OPTIONS

2. PREVENTIVE MAINTENANCE

2.1 OVERVIEW

Users Do the User PM Procedures

All PM Done by Technicians

Counters

2.2 USER MAINTENANCE

Main Unit

Optional Paper Tray Unit

2.3 SERVICE MAINTENANCE

Main Unit

Optional Units

3. REPLACEMENT AND ADJUSTMENT

3.1 SPECIAL TOOLS

3.2 EXTERIOR COVERS

3.2.1 REAR COVER

3.2.2 LOWER LEFT COVER

3.2.3 UPPER COVER, OPERATION PANEL

3.3 ELECTRICAL COMPONENTS

3.3.1 PRINTER CONTROLLER

3.3.2 CONTROLLER BOX

3.3.3 BCU BOARD

3.3.4 I/O BOARD

3.3.5 PSU

3.3.6 HIGH VOLTAGE SUPPLY BOARD

3.4 DRIVE UNITS

3.4.1 DEVELOPMENT CLUTCHES

K/Y Development Units

C/M Development Units