Ricoh CL4000DN Service Manual
RICOH GROUP COMPANIES
G104
SERVICE MANUAL
002111MIU
SERVICE MANUAL
®
®
G104
RICOH GROUP COMPANIES
G104
SERVICE MANUAL
002111MIU
A
f
r
It is the reader's responsibility when discussing the information contained
within this document to maintain a level of confidentiality that is in the best
interest of Ricoh Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
FASHION AND DISTRIBUTED WITHOUT THE PRIOR
PERMISSION OF RICOH CORPORATION.
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desktop images, used in this document are trademarks, registered
trademarks or the property of their respective companies.
They are used throughout this book in an informational or editorial fashion
only and for the benefit of such companies. No such use, or the use o
any trade name, or web site is intended to convey endorsement or othe
affiliation with Ricoh products.
2004 RICOH Corporation. All rights reserved.
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WARNING
The Service Manual contains information
regarding service techniques, procedures,
rocesses and spare parts of office equipmen
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
information contained in this service manual to
repair or modify Ricoh equipment risk persona
injury, damage to property or loss of warrant
rotection.
Ricoh Corporation
LEGEND
PRODUCT CODE COMPANY
G104 P7425dn LP126cn Aficio CL4000DN CLP26DN
GESTETNER LANIER RICOH SAVIN
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*
11/2004 Original Printing
G104
TABLE OF CONTENTS
INSTALLATION
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 MACHINE SPACE REQUIREMENT.................................................1-2
1.1.4 POWER REQUIREMENTS .............................................................. 1-2
1.2 MACHINE INSTALLATION........................................................................1-3
1.2.1 UNPACKING ....................................................................................1-3
1.2.2 INSTALLING THE TONER BOTTLE ................................................1-5
1.2.3 LOADING PAPER ............................................................................1-7
1.2.4 CONNECTING THE POWER CORD ...............................................1-9
1.2.5 SELECTING THE PANEL DISPLAY LANGUAGE..........................1-10
1.2.6 PRINTING THE TEST PAGE ......................................................... 1-10
1.3 OPTIONAL UNIT INSTALLATION...........................................................1-11
1.4 METER CHARGE....................................................................................1-12
1.5 TRAY HEATER .......................................................................................1-13
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE.................................................... 2-1
2.1 USER REPLACEABLE ITEMS..................................................................2-1
2.2 SERVICE MAINTENANCE........................................................................2-2
2.2.1 RECOMMENDED CLEANING PROCEDURE..................................2-2
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1
3.1 SPECIAL TOOLS AND LUBRICANTS ................................................3-1
3.1.1 TOOLS .............................................................................................3-1
3.2 ELECTRICAL COMPONENTS..................................................................3-2
3.2.1 ELECTRICAL BOARD UNIT ............................................................3-2
3.2.2 IOB (INPUT/OUTPUT BOARD)........................................................3-4
3.2.3 CONTROLLER BOARD ...................................................................3-4
3.2.4 PSU (POWER SUPPLY UNIT) BOARD ...........................................3-5
3.2.5 HIGH VOLTAGE POWER SUPPLY BOARD 1 ................................3-5
3.2.6 EGB (ENGINE BOARD) AND HIGH VOLTAGE POWER
SUPPLY BOARD 2...........................................................................3-6
3.2.7 LCD PANEL......................................................................................3-6
3.3 LASER OPTICS ........................................................................................3-7
SM i G104
3.3.1 CAUTION DECAL LOCATIONS.......................................................3-7
3.3.2 LD UNIT............................................................................................3-8
Color registration adjustment ................................................................3-8
3.3.3 LDB.................................................................................................3-10
3.3.4 POLYGON MIRROR MOTOR ........................................................3-10
3.3.5 LASER SYNCHRONIZING DETECTOR BOARDS ........................3-11
3.3.6 LDU SHUTTER MOTOR UNIT AND SENSOR .............................. 3-11
3.4 PAPER FEED..........................................................................................3-12
3.4.1 PAPER FEED ROLLER..................................................................3-12
3.4.2 PAPER FRICTION PAD .................................................................3-13
3.4.3 BY-PASS PAPER SIZE SENSOR.................................................. 3-13
3.4.4 BY-PASS FEED ROLLER, FRICTION PAD ...................................3-14
3.4.5 REGISTRATION SENSOR.............................................................3-15
3.4.6 0PAPER VOLUME SENSOR, END SENSOR AND PAPER
WIDTH SENSOR............................................................................3-15
3.4.6 PAPER VOLUME SENSOR, END SENSOR AND PAPER
WIDTH SENSOR............................................................................3-16
3.4.7 PAPER SIZE SENSOR AND TEMPERATURE/ HUMIDITY
SENSOR ........................................................................................3-17
3.4.8 PAPER FEED MOTOR...................................................................3-18
3.4.9 PAPER REGISTRATION CLUTCH, PAPER FEED CLUTCH
AND BY-PASS CLUTCH................................................................3-19
3.5 DEVELOPMENT .....................................................................................3-20
3.5.1 COLOR DEVELOPMENT MOTOR, COLOR OPC MOTOR
AND BLACK OPC/DEVELOPMENT MOTOR ................................3-20
3.5.2 DEVELOPMENT CLUTCH .............................................................3-20
3.5.3 TRANSFER BELT CONTACT MOTOR..........................................3-21
3.5.4 TONER SUPPLY MOTOR..............................................................3-21
3.5.5 TRANSFER ROLLER CONTACT MOTOR ....................................3-22
3.5.6 ID SENSORS .................................................................................3-23
3.6 DRIVE .....................................................................................................3-23
3.6.1 DRIVE UNIT ...................................................................................3-23
3.7 DUPLEX ..................................................................................................3-24
3.7.1 DUPLEX JAM SENSOR .................................................................3-24
3.7.2 INVERTER SENSOR .....................................................................3-24
3.7.3 DUPLEX MOTOR AND INVERTER MOTOR .................................3-25
3.8 FUSING................................................................................................... 3-26
3.8.1 FUSING UNIT................................................................................. 3-26
3.8.2 THERMISTOR AND THERMOSTAT..............................................3-26
3.8.3 FUSING LAMP ...............................................................................3-27
3.8.4 FUSING EXIT SENSOR AND PAPER EXIT SENSOR ..................3-28
3.8.5 FUSING REGISTRATION SENSOR ..............................................3-28
Fan Direction ......................................................................................3-29
3.9 ADJUSTMENTS ......................................................................................3-30
3.9.1 GAMMA ADJUSTMENT .................................................................3-30
G104 ii SM
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 PROCESS CONTROL RESULT ...............................................................4-1
4.2 SERVICE CALL CONDITIONS .................................................................4-2
4.2.1 SUMMARY ....................................................................................... 4-2
4.2.2 SC CODE DESCRIPTIONS .............................................................4-3
Engine SC.............................................................................................4-3
Controller Error ...................................................................................4-14
4.3 TROUBLESHOOTING GUIDE ................................................................4-21
4.3.1 BLANK PRINT ................................................................................4-21
4.3.2 ALL-BLACK PRINT.........................................................................4-21
4.3.3 MISSING CMY COLOR..................................................................4-22
4.3.4 LIGHT PRINT .................................................................................4-22
4.3.5 REPEATED SPOTS OR LINES ON PRINTS .................................4-23
4.3.6 DARK VERTICAL LINE IN PRINT.................................................. 4-23
4.3.7 WHITE HORIZONTAL LINES OR BANDS .....................................4-24
4.3.8 MISSING PARTS OF IMAGES.......................................................4-24
4.3.9 DIRTY BACKGROUND ..................................................................4-24
4.3.10 PARTIAL CMY COLOR DOTS .....................................................4-24
4.3.11 DARK IRREGULAR STREAKS ON PRINTS................................4-24
4.3.12 CMY COLOR IRREGULAR STREAKS ........................................4-25
4.3.13 GHOSTING ..................................................................................4-25
4.3.14 UNFUSED OR PARTIALLY FUSED PRINTS ..............................4-25
4.3.15 IMAGE SKEW ..............................................................................4-25
4.3.16 BACKGROUND STAIN ................................................................4-26
4.3.17 NO PRINTING ON PAPER EDGE................................................4-26
4.3.18 IMAGE NOT CENTERED WHEN IT SHOULD BE .......................4-26
4.4 ELECTRICAL COMPONENT DEFECTS ................................................4-27
4.4.1 SENSORS ......................................................................................4-27
4.5 BLOWN FUSE CONDITIONS .................................................................4-29
Power supply unit ...............................................................................4-29
IOB......................................................................................................4-29
4.6 LEDS ........................................................................................................4-29
SERVICE TABLES
5. SERVICE TABLES....................................................................... 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 SERVICE MODE OPERATION ........................................................5-1
Entering the Service Mode....................................................................5-1
Accessing the Required Program .........................................................5-2
Inputting a Value or Setting for a Service Program...............................5-2
Exiting Service Mode ............................................................................5-2
5.1.2 REMARKS........................................................................................5-3
Display on the Control Panel Screen ....................................................5-3
Others ...................................................................................................5-4
SM iii G104
5.2 SERVICE MODE TABLE........................................................................... 5-5
5.2.1 CONTROLLER SERVICE MODE.....................................................5-5
5.2.2 BIT SWITCH PROGRAMMING ........................................................5-9
5.2.3 ENGINE SERVICE MODE .............................................................5-10
SP1-XXX (Feed) .................................................................................5-10
SP2-XXX (Drum).................................................................................5-21
SP3-XXX (Process) ............................................................................5-47
SP5-XXX (Mode) ................................................................................5-57
SP7-XXX (Data Log)...........................................................................5-71
SP8-XXX (Data Log 2)........................................................................5-82
SP9-XXX.............................................................................................5-92
5.2.4 INPUT CHECK TABLE ...................................................................5-96
5.2.5 OUTPUT CHECK TABLE ...............................................................5-98
5.3 FIRMWARE UPDATE ...........................................................................5-100
5.3.1 TYPE OF FIRMWARE..................................................................5-100
5.3.2 PRECAUTIONS............................................................................ 5-100
Handling SD Cards ...........................................................................5-100
Upload or Download .........................................................................5-100
Network Connection..........................................................................5-100
5.3.3 FILE ARRANGEMENT ................................................................. 5-101
How the Program Works...................................................................5-101
Example............................................................................................5-101
5.3.4 UPDATING ...................................................................................5-102
Procedure ......................................................................................... 5-102
Error Handling................................................................................... 5-103
Power Failure....................................................................................5-103
5.3.5 NVRAM DATA UPLOAD/DOWNLOAD ........................................5-104
Uploading NVRAM Data ...................................................................5-104
Downloading NVRAM Data...............................................................5-105
5.3.6 ERROR CODE TABLE .................................................................5-106
5.4 SD CARD APPLI MOVE........................................................................ 5-107
5.4.1 OVERVIEW ..................................................................................5-107
5.4.2 MOVE EXEC ................................................................................ 5-108
5.4.3 UNDO EXEC ................................................................................5-109
Keeping the SD card.........................................................................5-109
DETAILED SECTION DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ...............................................................................................6-1
6.1.1 COMPONENT LAYOUT ...................................................................6-1
6.1.2 PAPER PATH...................................................................................6-2
6.1.3 DRIVE LAYOUT ...............................................................................6-3
6.1.4 BOARD STRUCTURE......................................................................6-4
Descriptions ..........................................................................................6-5
6.1.5 PRINTING PROCESS ......................................................................6-6
G104 iv SM
6.2 PROCESS CONTROL ..............................................................................6-8
6.2.1 OVERVIEW ...................................................................................... 6-8
6.2.2 POTENTIAL CONTROL ...................................................................6-9
Overview...............................................................................................6-9
Process Control Self-check...................................................................6-9
6.2.3 PROCESS CONTROL SELF-CHECK PROCEDURE ....................6-11
Step 1: VSG Adjustment .....................................................................6-11
Step 2: ID Sensor Solid Pattern Generation .......................................6-11
Step 3: Sensor Pattern Detection .......................................................6-11
Step 4: Toner Amount Calculation ......................................................6-11
Step 5: VD, VB, VL Selection and VREF Adjustment .........................6-12
6.2.4 TONER SUPPLY CONTROL .........................................................6-12
Toner Supply Control Modes ..............................................................6-12
Low Image Coverage..........................................................................6-13
6.2.5 TONER NEAR END/TONER END DETECTION............................6-14
Introduction .........................................................................................6-14
Toner Near End Detection .................................................................. 6-15
Toner End Detection........................................................................... 6-15
Toner End Recovery ...........................................................................6-15
6.2.6 DEVELOPER INITIALIZATION ......................................................6-16
6.3 PAPER FEED..........................................................................................6-17
6.3.1 OVERVIEW .................................................................................... 6-17
6.3.2 PAPER FEED DRIVE .....................................................................6-18
6.3.3 PAPER TRAY.................................................................................6-19
Paper Lift ............................................................................................6-19
Paper Size Detection ..........................................................................6-20
Paper Size Detection ..........................................................................6-20
Paper Near End/End Detection........................................................... 6-21
Near-end detection .............................................................................6-21
End detection......................................................................................6-21
Paper width sensor .............................................................................6-21
By-pass Tray Feed and Size Detection...............................................6-22
6.3.4 DUPLEX ......................................................................................... 6-23
Drive ...................................................................................................6-24
Interleaving ......................................................................................... 6-25
6.4 LASER EXPOSURE................................................................................6-26
6.4.1 OVERVIEW .................................................................................... 6-26
6.4.2 OPTICAL PATH..............................................................................6-27
6.4.3 LASER SYNCHRONIZING DETECTOR ........................................6-28
Overview.............................................................................................6-28
Main Scan Start Detection ..................................................................6-28
6.4.4 LD SAFETY SWITCH .....................................................................6-29
6.4.5 AUTOMATIC LINE POSITION ADJUSTMENT ..............................6-30
Overview.............................................................................................6-30
Summary of Each Adjustment ............................................................6-31
Main Scan Skew Adjustment .............................................................. 6-34
LDU Shutter ........................................................................................6-35
6.5 PHOTOCONDUCTOR UNIT ...................................................................6-36
6.5.1 OVERVIEW .................................................................................... 6-36
SM v G104
6.5.2 DRIVE AND DRIVE GEAR POSITION SENSOR...........................6-37
Mechanism .........................................................................................6-37
Initialization Process and SC Codes ...................................................6-38
6.5.3 DRUM CHARGE AND QUENCHING .............................................6-39
6.5.4 DRUM CLEANING..........................................................................6-40
6.5.5 WASTE TONER COLLECTION .....................................................6-41
6.5.6 WASTE TONER BOTTLE FULL DETECTION AND SET
DETECTION...................................................................................6-42
6.5.7 PCU DETECTION (DEVELOPMENT UNIT DETECTION) .............6-43
Unit Set Detection Pins .......................................................................6-43
New Unit Detection .............................................................................6-43
Error Message .................................................................................... 6-44
6.6 DEVELOPMENT .....................................................................................6-45
6.6.1 OVERVIEW .................................................................................... 6-45
6.6.2 DRIVE.............................................................................................6-46
6.6.3 DEVELOPER MIXING ....................................................................6-47
6.6.4 DEVELOPMENT BIAS ...................................................................6-48
6.6.5 TONER SUPPLY MECHANISM .....................................................6-49
Overview.............................................................................................6-49
Toner Near End Detection .................................................................. 6-49
6.6.6 TONER BOTTLE DETECTION ......................................................6-49
6.7 IMAGE TRANSFER.................................................................................6-50
6.7.1 OVERVIEW .................................................................................... 6-50
Transfer Unit Detection and New Unit Detection ................................6-51
Transfer belt unit detection .................................................................6-51
New transfer belt unit detection ..........................................................6-51
6.7.2 TRANSFER BELT DRIVE AND TRANSFER BELT ROLLER
VOLTAGE.................................................................................................6-52
Transfer belt contact ...........................................................................6-53
Transfer belt cleaning .........................................................................6-54
6.7.3 TRANSFER ROLLER UNIT............................................................6-55
Transfer from the belt..........................................................................6-55
Image transfer.....................................................................................6-55
Discharge............................................................................................6-56
Transfer roller contact......................................................................... 6-57
6.8 FUSING................................................................................................... 6-58
6.8.1 OVERVIEW .................................................................................... 6-58
6.8.2 FUSING TEMPERATURE CONTROL............................................6-59
Machine ready temperature: [B]..........................................................6-60
Print ready temperature: [C]................................................................6-60
Target printing temperature: [D]..........................................................6-60
First print temperature: [G]..................................................................6-60
Corrections for Small Paper Sizes (less than A5) ...............................6-61
Overheat Protection............................................................................6-61
6.8.3 DRIVE.............................................................................................6-62
6.9 CONTROLLER ........................................................................................6-63
6.9.1 OVERVIEW .................................................................................... 6-63
6.9.2 BOARD LAYOUT ............................................................................6-65
G104 vi SM
SPECIFICATIONS
1. GENERAL SPECIFICATIONS.....................................................................7-1
2. SUPPORTED PAPER SIZES...................................................................... 7-3
3. SOFTWARE ACCESSORIES .....................................................................7-4
3.1 PRINTER DRIVERS............................................................................ 7-4
3.2 UTILITY SOFTWARE ..........................................................................7-4
4. MACHINE CONFIGURATION..................................................................... 7-5
5. OPTIONAL EQUIPMENT ...........................................................................7-6
PAPER FEED UNIT TYPE 4000 (G392)
SEE SECTION G392 FOR DETAILED TABLE OF CONTENTS
SM vii G104
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. Immediately wash eyes with
plenty of water. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
The printer and its peripherals must be serviced by a customer service
representative who has completed the training course on those models.
LITHIUM BATTERIES
Incorrect replacement of lithium battery(s) on the EGB may pose risk of
explosion. Replace only with the same type or with an equivalent type
recommended by the manufacturer. Discard used batteries in accordance with
the manufacturer’s instructions.
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.
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.
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 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.
Symbols and Abbreviations
This manual uses the symbols and abbreviations shown below.
Symbol Meaning
SEF Short Edge Feed
LEF Long Edge Feed
Refer to section number
Clip ring
Screw
Connector
Clamp
Long Edge Feed (LEF)Short Edge Feed (SEF)
INSTALLATION
PREVENTIVE MAINTENANCE
REPLACEMENT AND ADJUSTMENT
TROUBLESHOOTING
TAB
POSITION 1
TAB
POSITION 2
TAB
POSITION 3
TAB
POSITION 4
SERVICE TABLES
DETAILED DESCRIPTIONS
SPECIFICATIONS
G392 PAPER TRAY UNIT
TAB
POSITION 5
TAB
POSITION 6
TAB
POSITION 7
TAB
POSITION 8
INSTALLATION
INSTALLATION REQUIREMENTS
1. INSTALLATION
1.1 INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT
1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)
2. Humidity Range: 15% to 80% RH
3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight)
4. Ventilation: 3 times/hr/person
5. Do not put the machine in areas that get sudden temperature changes. This
includes:
1) Areas directly exposed to cool air from an air conditioner.
2) Areas directly exposed to heat from a heater.
6. Do not put the machine in areas that get exposed to corrosive gas.
7. Do not install the machine at locations over 2,500 m (8,125 ft.) above sea level.
8. Put the machine on a strong, level bottom. (Inclination on any side must be no
more than 5 mm.)
9. Do not put the machine in areas with strong vibrations.
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
SM 1-1 G104
INSTALLATION REQUIREMENTS
1.1.3 MACHINE SPACE REQUIREMENT
Put the machine near the power source with these clearances:
Left side: Over 50 cm (19.7")
Rear: Over 10 cm (4")
Right side: Over 10 cm (4")
Front: Over 70 cm (27.6")
1.1.4 POWER REQUIREMENTS
CAUTION
1. Make sure that the plug is tightly in the outlet.
2. Avoid multi-wiring.
3. Make sure that you ground the machine.
1. Input voltage level: 120 V, 60 Hz: More than 11 A (for North America)
220 V to 240 V, 50 Hz/60 Hz: More than 6 A (for Europe/
Asia)
2. Permitted voltage fluctuation: ±10%
3. Do not set anything on the power cord.
G104 1-2 SM