Ricoh AP4500 Service Manual
G035
SERVICE MANUAL
RICOH GROUP COMPANIES
000872MIU
®
®
SERVICE MANUAL
G035
RICOH GROUP COMPANIES
G035
SERVICE MANUAL
MIU000872
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2000 RICOH Corporation. All rights reserved.
WARNING
The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Corporation. Users of this
manual should be either service trained or certified
by successfully completing a Ricoh Technical
Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Corporation
LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
G035 P7045 AP4500 SLP45
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 10/99 Original Printing
1 08/2000 A683, G909/G912, A688, A681,
A697 Addition
TABLE OF CONTENTS
OVERALL INFORMATION
1. OVERALL MACHINE INFORMATION ........................................1-1
1.1 SPECIFICATIONS .................................................................................... 1-1
1.1.1 PRINTER.......................................................................................... 1-1
1.1.2 NETWORK INTERFACE BOARD .................................................... 1-4
1.2 PAPER EXIT TRAY SELECTION .............................................................1-5
1.3 MACHINE CONFIGURATION................................................................... 1-6
1.3.1 SYSTEM COMPONENTS................................................................ 1-6
1.3.2 INSTALLABLE OPTION TABLE.......................................................1-7
1.4 MECHANICAL COMPONENT LAYOUT ...................................................1-8
1.5 PAPER PATH............................................................................................1-9
1.6 ELECTRICAL COMPONENT DESCRIPTIONS ...................................... 1-10
1.7 DRIVE LAYOUT...................................................................................... 1-13
1.8 PRINT PROCESS................................................................................... 1-15
1.8.1 OVERVIEW....................................................................................1-15
1.9 BOARD STRUCTURE ............................................................................1-17
1.9.1 BLOCK DIAGRAM..........................................................................1-17
1.9.2 DESCRIPTIONS ............................................................................1-18
DETAILED DESCRIPTIONS
2. DETAILED SECTION DESCRIPTIONS....................................... 2-1
2.1 PRINTER CONTROLLER ......................................................................... 2-1
2.1.1 HARDWARE OVERVIEW ................................................................2-1
2.1.2 IMAGE PRINTING............................................................................ 2-3
2.1.3 IMAGE DATA PROCESSING .......................................................... 2-4
2.1.4 FEATURES ......................................................................................2-5
2.1.5 HARD DISK...................................................................................... 2-8
2.1.6 PAPER OVERFLOW DETECTION .................................................. 2-9
2.2 LASER EXPOSURE................................................................................2-10
2.2.1 OVERVIEW....................................................................................2-10
2.2.2 OPTICAL PATH .............................................................................2-11
2.2.3 AUTO POWER CONTROL (APC).................................................. 2-12
2.2.4 DUAL BEAM WRITING .................................................................. 2-13
2.2.5 LASER BEAM PITCH CHANGE MECHANISM..............................2-14
2.2.6 LD SAFETY SWITCHES................................................................ 2-15
2.3 PHOTOCONDUCTOR UNIT (PCU) ........................................................ 2-16
2.3.1 OVERVIEW....................................................................................2-16
2.3.2 DRIVE MECHANISM......................................................................2-17
2.4 DRUM CHARGE .....................................................................................2-18
2.4.1 OVERVIEW....................................................................................2-18
2.4.2 CHARGE ROLLER VOLTAGE CORRECTION.............................. 2-19
2.4.3 ID SENSOR PATTERN PRODUCTION TIMING ...........................2-21
2.4.4 DRUM CHARGE ROLLER CLEANING.......................................... 2-21
SM i G035
2.5 DEVELOPMENT ..................................................................................... 2-22
2.5.1 OVERVIEW....................................................................................2-22
2.5.2 DRIVE MECHANISM......................................................................2-23
2.5.3 DEVELOPER MIXING.................................................................... 2-24
2.5.4 DEVELOPMENT BIAS ................................................................... 2-25
2.5.5 TONER SUPPLY............................................................................ 2-26
2.5.6 TONER DENSITY CONTROL........................................................ 2-28
2.5.7 TONER NEAR END/END DETECTION ......................................... 2-31
2.5.8 TONER END RECOVERY ............................................................. 2-33
2.5.9 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS...........2-34
2.6 DRUM CLEANING AND TONER RECYCLING ......................................2-35
2.6.1 DRUM CLEANING .........................................................................2-35
2.6.2 TONER RECYCLING..................................................................... 2-36
2.7 PAPER FEED..........................................................................................2-37
2.7.1 OVERVIEW....................................................................................2-37
2.7.2 PAPER FEED DRIVE MECHANISM.............................................. 2-38
2.7.3 PICK-UP AND SEPARATION ROLLER RELEASE
MECHANISM .................................................................................2-39
2.7.4 PAPER LIFT MECHANISM............................................................ 2-40
2.7.5 PAPER END DETECTION............................................................. 2-42
2.7.6 PAPER HEIGHT DETECTION ....................................................... 2-43
2.7.7 PAPER REGISTRATION ...............................................................2-44
2.7.8 PAPER SIZE DETECTION.............................................................2-45
2.7.9 PAPER FEED AND JAM TIMING .................................................. 2-46
2.8 BY-PASS FEED ...................................................................................... 2-47
2.8.1 BASIC OPERATION.......................................................................2-47
2.9 IMAGE TRANSFER AND PAPER SEPARATION................................... 2-48
2.9.1 OVERVIEW....................................................................................2-48
2.9.2 BELT DRIVE MECHANISM............................................................2-49
2.9.3 IMAGE TRANSFER AND PAPER SEPARATION
MECHANISM .................................................................................2-49
2.9.4 TRANSFER BELT UNIT CONTACT MECHANISM........................ 2-51
2.9.5 TRANSFER BELT CHARGE.......................................................... 2-52
2.9.6 TRANSFER BELT CLEANING MECHANISM................................ 2-53
2.10 IMAGE FUSING AND PAPER EXIT......................................................2-54
2.10.1 OVERVIEW..................................................................................2-54
2.10.2 FUSING DRIVE AND RELEASE MECHANISM........................... 2-55
2.10.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM..................... 2-56
2.10.4 PRESSURE ROLLER ..................................................................2-57
2.10.5 CLEANING MECHANISM ............................................................ 2-57
2.10.6 FUSING TEMPERATURE CONTROL .........................................2-58
2.10.7 OVERHEAT PROTECTION ......................................................... 2-59
2.11 DUPLEX................................................................................................ 2-60
2.11.1 BASIC OPERATION.....................................................................2-60
2.11.2 FEED IN AND EXIT MECHANISM............................................... 2-62
2.12 ENERGY SAVER MODE ......................................................................2-63
2.13 NEW UNIT DETECTION MECHANISM ................................................ 2-64
G035 ii SM
Rev. 08/2000
INSTALLATION
3. INSTALLATION PROCEDURE ................................................... 3-1
3.1 INSTALLATION REQUIREMENTS........................................................... 3-1
3.1.1 ENVIRONMENT............................................................................... 3-1
3.1.2 MACHINE LEVEL............................................................................. 3-1
3.1.3 MINIMUM SPACE REQUIREMENTS ..............................................3-2
3.1.4 POWER REQUIREMENTS..............................................................3-3
3.2 PRINTER INSTALLATION ........................................................................ 3-4
3.2.1 CONNECTING THE INTERFACE CABLES..................................... 3-4
3.2.2 CHECKING THE CONNECTION .....................................................3-4
3.2.3 HARD DISK DRIVE INSTALLATION (A853).................................... 3-7
3.3 NETWORK INTERFACE BOARD (NIB) INSTALLATION ......................... 3-8
3.3.1 SERIAL NUMBER AND MAC ADDRESS ........................................3-8
3.3.2 STATUS SHEET ..............................................................................3-8
3.3.3 PROGRAMMING NETWORK/PROTOCOL PARAMETERS............3-9
3.3.4 SETUP FOR VARIOUS NETWORK TYPES.................................. 3-12
3.4 BRIDGE UNIT INSTALLATION (A688)................................................... 3-14
3.4.1 ACCESSORY CHECK ...................................................................3-14
3.4.2 INSTALLATION PROCEDURE ...................................................... 3-15
3.5 LCT INSTALLATION (A683) ................................................................... 3-18
3.5.1 ACCESSORY CHECK ...................................................................3-18
3.5.2 INSTALLATION PROCEDURE ...................................................... 3-19
3.6 1,000-SHEET FINISHER INSTALLATION (A681) .................................. 3-21
3.6.1 ACCESSORY CHEK...................................................................... 3-21
3.6.2 INSTALLATION PROCEDURE ...................................................... 3-22
3.7 3,000-SHEET FINISHER INSTALLATION (A697) ..................................3-25
3.7.1 ACCESSORY CHECK ...................................................................3-25
3.7.2 INSTALLATION PROCEDURE ...................................................... 3-26
3.8 MAILBOX INSTALLATION (G909).......................................................... 3-30
3.8.1 ACCESSORY CHECK ...................................................................3-30
3.8.2 REQUIREMENT OPTIONS FOR MAIN MACHINE........................ 3-30
3.8.3 INSTALLATION PROCEDURE ...................................................... 3-31
3.9 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912) ......................... 3-34
3.9.1 ACCESSORY CHECK ...................................................................3-34
3.9.2 INSTALLATION PROCEDURE ...................................................... 3-35
3.10 PUNCH UNIT INSTALLATION.............................................................. 3-40
3.10.1 ACCESSORY CHECK .................................................................3-40
3.10.2 INSTALLATION PROCEDURE .................................................... 3-41
3.11 DRAM SIMM ......................................................................................... 3-44
3.11.1 .......................................................................................................3-44
3.11.2 .......................................................................................................3-44
SERVICE TABLES
4. SERVICE TABLES ...................................................................... 4-1
4.1 GENERAL CAUTIONS.............................................................................. 4-1
4.1.1 DRUM............................................................................................... 4-1
4.1.2 TRANSFER BELT UNIT................................................................... 4-2
SM iii G035
4.1.3 LASER UNIT ....................................................................................4-2
4.1.4 CHARGE ROLLER........................................................................... 4-2
4.1.5 DEVELOPMENT ..............................................................................4-2
4.1.6 FUSING UNIT ..................................................................................4-3
4.1.7 PAPER FEED................................................................................... 4-3
4.1.8 USED TONER.................................................................................. 4-3
4.2 SERVICE PROGRAM MODE ...................................................................4-4
4.2.1 SERVICE PROGRAM MODE OPERATION ....................................4-4
4.2.2 SERVICE PROGRAM MODE TABLES............................................ 4-6
4.2.3 TEST PATTERN PRINTING (SP2-12) ........................................... 4-14
4.2.4 INPUT CHECK ............................................................................... 4-15
4.2.5 OUTPUT CHECK ........................................................................... 4-18
4.2.6 SYSTEM PARAMETER AND DATA LISTS (SMC LISTS) ............. 4-19
4.2.7 MEMORY ALL CLEAR (SP2-18)....................................................4-19
4.2.8 SOFTWARE RESET ...................................................................... 4-20
4.2.9 PRINTER RESTART AND MENU RESET (USER MENU) ............ 4-20
4.3 DOWNLOADING NEW FIRMWARE....................................................... 4-21
4.3.1 FIRMWARE UPDATE USING A FLASH MEMORY CARD
(SP1-1-2 AND 1-2-2)...................................................................... 4-21
4.3.2 FIRMWARE UPDATE FROM PARALLEL PORT
(SP1-1-1 AND 1-2-1)...................................................................... 4-22
4.3.3 FORMATING THE HARD DISK (SP1-4)........................................ 4-22
4.3.4 PARALLEL LOOP BACK TEST (SP1-9) ........................................ 4-23
4.4 DOWNLOADING NEW SOFTWARE ...................................................... 4-24
4.5 NETWORK INTERFACE BOARD........................................................... 4-25
4.5.1 FACTORY RESET (NVRAM CLEAR) ............................................ 4-25
4.5.2 FLASH ROM UPDATE................................................................... 4-26
4.6 USER MENU........................................................................................... 4-33
4.6.1 HOW TO ENTER AND EXIT USER MENU....................................4-33
4.6.2 USER MENU TABLE......................................................................4-33
4.7 TEST POINTS/DIP SWITCHES/LEDS....................................................4-35
4.7.1 DIP SWITCHES .............................................................................4-35
4.7.2 JUMPER PINS ...............................................................................4-36
4.7.3 TEST POINTS................................................................................ 4-36
4.7.4 LEDS.............................................................................................. 4-37
4.8 SPECIAL TOOLS AND LUBRICANTS.................................................... 4-37
4.8.1 SPECIAL TOOLS ........................................................................... 4-37
4.8.2 LUBRICANTS................................................................................. 4-37
PREVENTIVE MAINTENANCE
5. PREVENTIVE MAINTENANCE SCHEDULE...............................5-1
5.1 PM TABLE ................................................................................................5-1
REPLACEMENT AND ADJUSTMENT
6. REPLACEMENT AND ADJUSTMENT ........................................ 6-1
6.1 LASER UNIT ............................................................................................. 6-1
6.1.1 CAUTION DECAL LOCATIONS....................................................... 6-1
G035 iv SM
6.1.2 LASER UNIT ....................................................................................6-2
6.1.3 POLYGON MIRROR MOTOR.......................................................... 6-3
6.1.4 LASER SYNCHRONIZATION DETECTOR .....................................6-4
6.1.5 LD UNIT ...........................................................................................6-4
6.2 PHOTOCONDUCTOR UNIT (PCU) AND DEVELOPMENT UNIT ............6-6
6.3 PHOTOCONDUCTOR UNIT (PCU) .......................................................... 6-6
6.3.1 PCU.................................................................................................. 6-6
6.3.2 DRUM............................................................................................... 6-7
6.3.3 PICK-OFF PAWLS ........................................................................... 6-8
6.3.4 CHARGE ROLLER/CHARGE ROLLER CLEANING PAD................6-9
6.3.5 DRUM CLEANING BLADE............................................................. 6-10
6.3.6 ID SENSOR.................................................................................... 6-10
6.4 DEVELOPMENT ..................................................................................... 6-11
6.4.1 DEVELOPMENT UNIT................................................................... 6-11
6.4.2 DEVELOPMENT FILTER............................................................... 6-12
6.4.3 DEVELOPMENT ROLLER............................................................. 6-13
6.4.4 DEVELOPER .................................................................................6-14
6.4.5 TD SENSOR ..................................................................................6-15
6.5 DUPLEX.................................................................................................. 6-16
6.5.1 DUPLEX UNIT................................................................................ 6-16
6.5.2 DUPLEX UNIT COVER.................................................................. 6-17
6.5.3 ENTRANCE SENSOR....................................................................6-17
6.5.4 EXIT SENSOR ............................................................................... 6-18
6.6 TRANSFER UNIT.................................................................................... 6-19
6.6.1 TRANSFER BELT UNIT................................................................. 6-19
6.6.2 TRANSFER BELT .......................................................................... 6-20
6.6.3 TRANSFER BELT CLEANING BLADE/TONER OVERFLOW
SENSOR ........................................................................................ 6-21
6.6.4 RIGHT COVER ..............................................................................6-22
6.7 BY-PASS FEED ...................................................................................... 6-23
6.7.1 BY-PASS FEED UNIT.................................................................... 6-23
6.7.2 BY-PASS FEED UNIT COVERS.................................................... 6-24
6.7.3 PAPER FEED AND PICK-UP ROLLER .........................................6-25
6.7.4 SEPARETION ROLLER................................................................. 6-26
6.7.5 PAPER END SENSOR AND PICK-UP SELENOID .......................6-27
6.7.6 PAPER SIZE SENSOR BOARD ....................................................6-28
6.7.7 BY-PASS TABLE ........................................................................... 6-29
6.7.8 PAPER FEED CLUTCH ................................................................. 6-30
6.8 PAPER FEED..........................................................................................6-31
6.8.1 PICK-UP, SEPARATION, AND FEED ROLLERS.......................... 6-31
6.8.2 LOWER RIGHT COVER/LOWER REAR COVER..........................6-32
6.8.3 RELAY/UPPER PAPER FEED/LOWER PAPER FEED
CLUTCHES .................................................................................... 6-33
6.8.4 UPPER PAPER FEED UNIT.......................................................... 6-34
6.8.5 LOWER PAPER FEED UNIT ......................................................... 6-35
6.8.6 PAPER END/PAPER HEIGHT/RELAY SENSORS........................ 6-36
6.8.7 REGISTRATION SENSOR ............................................................6-37
6.9 FUSING................................................................................................... 6-39
6.9.1 FUSING UNIT ................................................................................6-39
SM v G035
Rev. 03/2000
6.9.2 HOT ROLLER STRIPPERS AND FUSING LAMP ......................... 6-40
6.9.3 THERMISTOR AND THERMOFUSE ............................................. 6-41
6.9.4 CLEANING ROLLER...................................................................... 6-42
6.9.5 HOT ROLLER AND PRESSURE ROLLER.................................... 6-43
6.10 DRIVE AREA.........................................................................................6-44
6.10.1 REGISTRATION CLUTCH AND TRANSFER BELT CLUTCH..... 6-44
6.10.2 MAIN MOTOR .............................................................................. 6-45
6.10.3 TONER BOTTLE MOTOR............................................................6-46
6.11 COVERS ............................................................................................... 6-47
6.12 PCBs ..................................................................................................... 6-49
6.12.1 POWER PACK ............................................................................. 6-49
6.12.2 PSU.............................................................................................. 6-49
6.12.3 PRINTER CONTROL BOARD AND NIB...................................... 6-50
6.12.4 HARD DISK.................................................................................. 6-51
6.12.5 I/O BOARD................................................................................... 6-52
6.12.6 BICU BOARD ............................................................................... 6-53
6.13 PRINT IMAGE ADJUSTMENTS............................................................6-54
TROUBLESHOOTING
7. TROUBLESHOOTING................................................................. 7-1
7.1 SERVICE CALL CONDITIONS ................................................................. 7-1
7.1.1 SUMMARY ....................................................................................... 7-1
7.1.2 SC CODE DESCRIPTIONS ............................................................. 7-1
7.1.3 PRINTER CONTROLLER .............................................................. 7-20
7.1.4 NETWORK INTERFACE BOARD .................................................. 7-22
7.2 ELECTRICAL COMPONENT DEFECTS ................................................ 7-24
7.2.1 SENSORS...................................................................................... 7-24
7.2.2 SWITCHES ....................................................................................7-25
7.3 BLOWN FUSE CONDITIONS ................................................................. 7-25
7.4 ROM HISTORY....................................................................................... 7-26
PAPER TRAY UNIT G520
1. OVERALL MACHINE INFORMATION ........................................8-1
1.1 SPECIFICATIONS .................................................................................... 8-1
1.2 MECHANICAL COMPONENT LAYOUT ...................................................8-2
1.3 ELECTRICAL COMPONENT LAYOUT.....................................................8-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ..........................................8-4
1.5 DRIVE LAYOUT........................................................................................ 8-5
2. DETAILED DESCRIPTIONS........................................................8-6
2.1 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM............ 8-6
2.2 PAPER LIFT MECHANISM....................................................................... 8-7
2.3 PAPER END DETECTION........................................................................ 8-9
2.4 PAPER HEIGHT DETECTION................................................................ 8-10
2.5 PAPER SIZE DETECTION .....................................................................8-11
G035 vi SM
3. SERVICE TABLES .................................................................... 8-12
3.1 DIP SWITCHES ...................................................................................... 8-12
3.2 TEST POINTS......................................................................................... 8-12
3.3 SWITCHES .............................................................................................8-12
3.4 FUSES ....................................................................................................8-12
4. REPLACEMENT AND ADJUSTMENT ...................................... 8-13
4.1 COVER REPLACEMENT........................................................................ 8-13
4.2 ROLLER REPLACEMENT ...................................................................... 8-14
4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ............. 8-14
4.3 TRAY MOTOR REPLACEMENT.............................................................8-15
4.4 PAPER FEED AND RELAY CLUTCH REPLACEMENT......................... 8-16
4.5 PAPER FEED UNIT REPLACEMENT ....................................................8-17
4.6 PAPER END, TRAY LIFT, AND RELAY SENSOR
REPLACEMENT .....................................................................................8-19
SWAPBOX AND SWAPFTL INSTALLATION MANUAL
1. INTRODUCTION ......................................................................... 9-1
1.1 PRECAUTIONS ......................................................................................... 9-1
1.1.1 SWAPBOX AND SOFTWARE .........................................................9-1
1.1.2 SOFTWARE LICENSE AGREEMENT ............................................. 9-1
1.2 SYSTEM REQUIREMENTS ...................................................................... 9-1
1.3 ITEMS TO PREPARE BEFORE INSTALLATION ..................................... 9-1
1.4 WINDOWS 95 VERSION CONFIRMATION .............................................9-2
2. SWAPBOX INSTALLATION ........................................................ 9-4
2.2 DRIVER INSTALLATION ..........................................................................9-4
3. SOFTWARE (SWAPFTL) INSTALLATION .................................9-5
3.1 SWAPFTL SOFTWARE INSTALLATION .................................................. 9-5
3.2 VERIFICATION ......................................................................................... 9-5
3.2.1 SOFTWARE VERSION .................................................................... 9-5
3.2.2 FLASH MEMORY CARD AUTOMATIC DETECTION ...................... 9-6
4. TROUBLESHOOTING..................................................................9-7
4.1 SWAPBOX RESOURCE CONFLICT ........................................................ 9-7
4.11 IRQ AND I/O ADDRESS ...................................................................9-7
4.1.2 MEMORY ADDRESS........................................................................ 9-7
4.2 FAILED TO OPEN PCCARD ERRORS ..................................................... 9-8
4.2.1 TIMELAG TO LOADING DRIVER ..................................................... 9-8
4.2.3 RESOURCE CONFLICT ................................................................... 9-8
4.3 INVALID DYNAMIC LINK CALL FROM SWAPENUM ERROR.................9-9
4.4 SWAPFTL PROBLEM WITH NOTEBOOK COMPUTERS.........................9-9
4.4.1 WINDOWS AND PC CARD DRIVER VERSION ............................... 9-9
4.4.2 SYSTEM SUMMERY ........................................................................9-9
4.5 COMPLETE UNINSTALL......................................................................... 9-10
SM vii G035
Rev. 08/2000
SWAPFTL BINARY UTILITY OPERATION MANUAL
1. OVERVIEW................................................................................. 10-1
2. OPERATION............................................................................... 10-2
2.1 PROGRAMMING A FLASH MEMORY CARD .........................................10-2
2.1.1 GETTING A SOURCE FILE ............................................................ 10-2
2.1.2 PROGRAMMING A CARD WITH THE SOURCE ...........................10-2
2.2 DOWNLOADING TO A MACHINE........................................................... 10-4
2.3 SAVING DATA TO A FILE ....................................................................... 10-4
3. FUNCTIONS ...............................................................................10-5
3.1 FILE MENU .............................................................................................. 10-5
3.1.1 FILE – OPEN................................................................................... 10-5
3.1.2 FILE – CLOSE................................................................................. 10-5
3.1.3 FILE – SAVE ................................................................................... 10-5
LARGE CAPACITY TRAY (A683)
1. OVERALL MACHINE INFORMATION ......................................11-1
1.1 SPECIFICATIONS .................................................................................. 11-1
1.2 MECHANICAL COMPONENT LAYOUT .................................................11-2
1.3 ELECTRICAL COMPONENT LAYOUT...................................................11-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................11-4
1.5 DRIVE LAYOUT...................................................................................... 11-5
2. DETAILED DESCRIPTIONS...................................................... 11-6
2.1 PAPER FEED MECHANISM................................................................... 11-6
2.2 TRAY LIFT AND PAPER HEIGHT DETECTION MECHANISM.............. 11-7
Tray lifting conditions.......................................................................... 11-7
Tray lowering conditions..................................................................... 11-7
2.3 TRAY UNIT SLIDE MECHANISM ........................................................... 11-8
3. SERVICE TABLES .................................................................... 11-9
3.1 DIP SWITCHES ...................................................................................... 11-9
3.2 TEST POINTS......................................................................................... 11-9
3.3 SWITCHES .............................................................................................11-9
3.4 FUSES ....................................................................................................11-9
4. REPLACEMENT AND ADJUSTMENT .................................... 11-10
4.1 COVER REPLACEMENT...................................................................... 11-10
Tray Cover........................................................................................ 11-10
Front Cover....................................................................................... 11-10
Rear Cover .......................................................................................11-10
Right Lower Cover............................................................................ 11-10
Upper Cover .....................................................................................11-10
4.2 ROLLER REPLACEMENT .................................................................... 11-11
G035 viii SM
Rev. 08/2000
4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ........... 11-11
Pick-up Roller ...................................................................................11-11
Paper Feed Roller ............................................................................11-11
Separation Roller.............................................................................. 11-11
4.3 TRAY LIFT AND PAPER END SENSOR REPLACEMENT ..................11-12
Tray Lift Sensor ................................................................................ 11-12
Paper End Sensor ............................................................................ 11-12
4.4 RELAY SENSOR REPLACEMENT.......................................................11-13
4.5 SIDE FENCE POSITION CHANGE ......................................................11-14
NINE-TRAY MAILBOX AND BRIDGE UNIT G909/G912
1. OVERALL MACHINE INFORMATION ......................................12-1
1.1 SPECIFICATIONS .................................................................................. 12-1
1.2 COMPONENT LAYOUT.......................................................................... 12-2
1.2.1 MECHANICAL COMPONENT LAYOUT ........................................12-2
1.2.2 DRIVE LAYOUT ............................................................................. 12-3
1.3 ELECTRICAL COMPONENT DESCRIPTIONS ...................................... 12-4
2. DETAILED DESCRIPTIONS...................................................... 12-6
2.1 BASIC OPERATION ...............................................................................12-6
Proof Tray........................................................................................... 12-6
Bridge Unit.......................................................................................... 12-6
Trays................................................................................................... 12-6
2.2 PROOF TRAY SENSORS ......................................................................12-7
2.2.1 PAPER SENSOR ........................................................................... 12-7
2.2.2 PAPER OVERFLOW SENSOR...................................................... 12-7
2.3 TRAY SENSORS .................................................................................... 12-8
2.3.1 PAPER SENSOR ........................................................................... 12-8
2.3.2 PAPER OVERFLOW SENSOR...................................................... 12-8
2.3.3 TRAY EXIT SENSOR..................................................................... 12-8
2.4 TIMING CHART AND MISFEED DETECTION .......................................12-9
3. INSTALLATION PROCEDURE ............................................... 12-11
3.1 MAILBOX (G909) .................................................................................. 12-11
3.1.1 ACCESSORY CHECK .................................................................12-11
3.1.2 REQUIREMENT OPTIONS FOR MAIN MACHINE...................... 12-11
3.1.3 INSTALLATION PROCEDURE .................................................... 12-12
1.2 BRIDGE UNIT FOR MAILBOX (G912)..................................................12-15
1.2.1 ACCESSORY CHECK .................................................................12-15
1.2.2 INSTALLATION PROCEDURE .................................................... 12-16
4. REPLACEMENT AND ADJUSTMENT .................................... 12-21
4.1 PROOF TRAY UNIT.............................................................................. 12-21
4.1.1 PROOF TRAY SENSOR AND PAPER
OVERFLOW SENSORS ............................................................... 12-21
4.1.2 PROOF TRANSPORT UNIT ........................................................ 12-21
SM ix G035
Rev. 08/2000
4.2 TRAY UNIT ...........................................................................................12-22
4.2.1 TRAYS ......................................................................................... 12-22
4.2.2 PAPER SENSOR, PAPER OVERFLOW SENSOR,
AND TRAY EXIT SENSOR .......................................................... 12-23
Paper Overflow Sensor.....................................................................12-23
Paper Sensor....................................................................................12-23
Tray Exit Sensor (above the 1st tray, and in the 3rd, 6th,
and 9th trays).................................................................................... 12-23
4.2.3 MAIN CONTROL BOARD ............................................................ 12-24
4.2.4 TRAY EXIT SENSOR ADJUSTMENT.......................................... 12-25
5. SERVICE TABLES .................................................................. 12-27
5.1 DIP SWITCHES/VRIABLE RESISTORS/LEDS .................................... 12-27
5.1.1 DIP SWITCHES ...........................................................................12-27
5.1.2 VARIABLE RESISTORS .............................................................. 12-28
5.1.3 LEDS............................................................................................ 12-28
BRIDGE UNIT A688
1. OVERALL MACHINE INFORMATION ......................................13-1
1.1 SPECIFICATIONS .................................................................................. 13-1
1.2 MECHANICAL COMPONENT LAYOUT .................................................13-2
1.3 ELECTRICAL COMPONENT LAYOUT...................................................13-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................13-3
1.5 DRIVE LAYOUT...................................................................................... 13-4
2. DETAILED DESCRIPTION........................................................ 13-5
2.1 JUNCTION GATE MECHANISM.............................................................13-5
3. REPLACEMENT AND ADJUSTMENT ...................................... 13-6
3.1 EXIT SENSOR REPLACEMENT ............................................................13-6
1,000-SHEET FINISHER A681
1. OVERALL MACHINE INFORMATION ......................................14-1
1.1 SPECIFICATIONS .................................................................................. 14-1
1.2 MECHANICAL COMPONENT LAYOUT .................................................14-2
1.3 ELECTRICAL COMPONENT LAYOUT...................................................14-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS ...................................... 14-4
1.5 DRIVE LAYOUT...................................................................................... 14-6
2. DETAILED DESCRIPTIONS...................................................... 14-7
2.1 JUNCTION GATE MECHANISM.............................................................14-7
Staple mode .......................................................................................14-7
No staple mode ..................................................................................14-7
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM ...........................14-8
G035 x SM
Rev. 08/2000
2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM.................................14-9
2.4 STAPLER.............................................................................................. 14-10
2.5 FEED OUT MECHANISM .....................................................................14-11
2.6 SHIFT TRAY UP/DOWN MECHANISM ................................................ 14-12
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM ......................................... 14-13
2.8 JAM CONDITIONS................................................................................ 14-14
2.9 TIMING CHARTS..................................................................................14-15
2.9.1 NO STAPLE MODE (A4 SIDEWAYS, 3 SHEETS/2SETS) .......... 14-15
2.9.2 STAPLE MODE (A4 SIDEWAYS, 2 SHEETS/2 SETS)................ 14-16
3. SERVICE TABLE..................................................................... 14-17
3.1 DIP SWITCH TABLE............................................................................. 14-17
3.2 TEST POINTS....................................................................................... 14-17
3.3 FUSES ..................................................................................................14-17
4. REPLACEMENT AND ADJUSTMENT .................................... 14-18
4.1 COVER REMOVAL............................................................................... 14-18
Front Door ........................................................................................14-18
Front Cover....................................................................................... 14-18
Rear Cover .......................................................................................14-18
Upper Cover .....................................................................................14-18
Lower Left Cover ..............................................................................14-19
Front Shift Tray Cover ......................................................................14-19
Rear Shift Tray Cover....................................................................... 14-19
Shift Tray .......................................................................................... 14-19
4.2 ENTRANCE SENSOR REPLACEMENT............................................... 14-20
4.3 EXIT SENSOR REPLACEMENT ..........................................................14-21
4.4 STACK HEIGHT SENSOR REPLACEMENT........................................ 14-22
4.5 POSITIONING ROLLER REPLACEMENT............................................ 14-23
4.6 STAPLER REPLACEMENT .................................................................. 14-24
4.7 ROM HISTORY..................................................................................... 14-25
3,000-SHEET FINISHER A697
1. OVERALL MACHINE INFORMATION ......................................15-1
1.1 SPECIFICATIONS .................................................................................. 15-1
1.2 MECHANICAL COMPONENT LAYOUT .................................................15-3
1.3 ELECTRICAL COMPONENT LAYOUT...................................................15-4
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................15-5
1.5 DRIVE LAYOUT...................................................................................... 15-7
2. DETAILED DESCRIPTIONS...................................................... 15-8
2.1 TRAY AND STAPLER JUNCTION GATE MECHANISM ........................ 15-8
Normal mode ...................................................................................... 15-8
Sort/stack mode.................................................................................. 15-8
Staple mode .......................................................................................15-8
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM ...........................15-9
SM xi G035
Rev. 08/2000
Vertical Paper Alignment .................................................................... 15-9
Horizontal Paper Alignment................................................................ 15-9
2.3 STAPLER UNIT MOVEMENT MECHANISM ........................................ 15-10
Side-to-side: .....................................................................................15-10
Rotation: ........................................................................................... 15-10
2.4 STAPLER.............................................................................................. 15-11
2.5 FEED-OUT MECHANISM ..................................................................... 15-12
2.6 SHIFT TRAY UP/DOWN MECHANISM ................................................ 15-13
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM ......................................... 15-14
2.8 PUNCH UNIT DRIVE MECHANISM .....................................................15-15
2.9 PUNCH WASTE COLLECTION MECHNISM........................................15-16
2.10 JAM CONDITIONS.............................................................................. 15-17
2.11 TIMING CHARTS................................................................................ 15-18
2.11.1 A4 SIDEWAYS (2 SHEETS): NORMAL AND
PUNCH MODE ...........................................................................15-18
2.11.2 A4 SIDEWAYS (2 SHEETS): SORT/STACK AND
PUNCH MODE ...........................................................................15-19
2.11.3 A4 SIDEWAYS (2 SHEETS): STAPLE AND
PUNCH MODE ...........................................................................15-20
3. SERVICE TABLES .................................................................. 15-21
3.1 DIP SWITCHES .................................................................................... 15-21
3.2 TEST POINTS....................................................................................... 15-21
3.3 LED .......................................................................................................15-21
3.4 VARIABLE RESISTORS....................................................................... 15-21
3.5 FUSES ..................................................................................................15-21
4. REPLACEMENT AND ADJUSTMENT .................................... 15-22
4.1 COVER REPLACEMENT...................................................................... 15-22
Rear Cover .......................................................................................15-22
Upper Left Cover ..............................................................................15-22
Upper Cover .....................................................................................15-22
Front Door ........................................................................................15-22
Left Front Cover................................................................................ 15-22
Shift Tray .......................................................................................... 15-23
Lower Left Cover ..............................................................................15-23
Right Cover....................................................................................... 15-23
Front Shift Tray Cover ......................................................................15-23
Rear Shift Tray Cover....................................................................... 15-23
4.2 POSITIONING ROLLER REPLACEMENT............................................ 15-24
4.3 ALIGNMENT BRUSH ROLLER REPLACEMENT................................. 15-25
4.4 SENSOR REPLACEMNT...................................................................... 15-26
4.4.1 STACK HEIGHT SENSOR 1 AND 2 ............................................15-26
4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR...................... 15-27
Upper Tray Paper Limit Sensor ........................................................15-27
Upper Tray Exit Sensor ....................................................................15-27
4.4.3 SHIFT TRAY EXIT SENSOR .......................................................15-28
4.4.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSOR.........15-29
Entrance Sensor............................................................................... 15-29
G035 xii SM
Rev. 08/2000
Stapler Tray Entrance Sensor ..........................................................15-29
4.4.5 STAPLER ROTATION HP SENSOR............................................15-30
4.5 STAPLER REMOVAL ...........................................................................15-31
4.6 PUNCH POSITION ADJUSTMENT ......................................................15-32
Right to left .......................................................................................15-32
Front to rear...................................................................................... 15-32
4.7 STACK FEED-OUT MOTOR SPEED ADJUSTMENT........................... 15-33
4.8 ROM HISTORY..................................................................................... 15-34
APPENDIX
APPENDIX 1.....................................................................APPENDIX-1
1.1 JAM HISTORY .......................................................................... APPENDIX-1
1.1.1 JAM CONDITION TABLE................................................. APPENDIX-1
SM xiii G035
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. If the print job process starts before the printer completes the warm-up
period, keep hands away from the mechanical and the electrical components
because the printer starts printing sheets as soon as the warm-up period is
complete.
5. The inside and the metal parts of the fusing unit become extremely hot while
the printer is operating. Be careful to avoid touching those components with
your bare hands.
HEALTH SAFETY CONDITIONS
1. Toner and developer are non-toxic, but if you get either of them in your eyes
by accident, it may cause temporary eye discomfort. Try to remove with eye
drops or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The printer’s peripherals (except for paper tray unit) must be installed and
maintained by a customer service representative who has completed the
training course on those models.
2. The NVRAM on the controller board has a lithium battery which can explode
if replaced incorrectly. Replace the NVRAM only with an identical one. The
manufacturer recommends replacing the entire NVRAM. Do not recharge or
burn this battery. Used NVRAM must be handled in accordance with local
regulations.
SAFETY AND ECOLOGICAL
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly
when exposed to an open flame.
2. Dispose of used toner, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in 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.
NOTES
FOR DISPOSAL
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of
laser-based optical units in the field. The optical housing unit can only be repaired
in a factory or at a location with the requisite equipment. The laser subsystem is
replaceable in the field by a qualified Customer Engineer. The laser chassis is not
repairable in the field. Customer engineers are therefore directed to return all
chassis and laser subsystems to the factory or service depot when replacement of
the optical subsystem is required.
WARNING
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
WARNING
WARNING: Turn off the main switch before attempting any of the
procedures in the Laser Unit section. Laser beams can
seriously damage your eyes.
CAUTION MARKING:
OVERALL MACHINE INFORMATION G035
SWAPBOX
TM
AND SWAPFTL
TM
MANUAL
DETAILED SECTION DESCRIPTIONS G035
SWAPFTL
TM
BINARY UTILITY OPERATION MANUAL
INSTALLATION PROCEDURE G035
LARGE CAPACITY TRAY (A683)
SERVICE TABLES G035
NINE-TRAY MAILBOX AND BRIDGE UNIT (G909/G912)
INSTALLATION
TAB
POSITION 1
TAB
POSITION 2
TAB
POSITION 3
TAB
POSITION 4
PREVENTIVE MAINTENANCE G035
BRIDGE UNIT (A688)
REPLACEMENT AND ADJUSTMENT G035
1000 SHEET FINISHER (A681)
TROUBLESHOOTING G035
3000 SHEET FINISHER (A697)
PAPER TRAY UNIT G520
APPENDIX
TAB
POSITION 5
TAB
POSITION 6
TAB
POSITION 7
TAB
POSITION 8
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