Ricoh CL4000DN Service Manual

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RICOH GROUP COMPANIES

G104

SERVICE MANUAL

002111MIU

SERVICE MANUAL

G104

RICOH GROUP COMPANIES

G104

SERVICE MANUAL

002111MIU

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.

ll product names, domain names or product illustrations, including 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.

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

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 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

MACHINE INSTALLATION

1.2 MACHINE INSTALLATION

1.2.1 UNPACKING

1. Open the left cover [A] of the printer.

2. Turn the green levers

counterclockwise . Then slowly open the drum positioning plate .

[A]

G105I903.WMF

Installation

3. Remove the end of the tape from the printer.

4. Slowly pull out the eight pieces of tape protruding from PCU in a horizontal direction.

5. Close the drum positioning plate. Push the green lever

 to lock the drum

positioning plate. Then turn it clockwise

.

6. Close the left cover.

G105I901.WMF

G105I902.WMF

SM 1-3 G104

MACHINE INSTALLATION

7. Open the top cover by grasping the handles on the left and right sides.

8. Remove the clip that prevents damage to the mouth of the toner hopper (one clip for each of the four toner hoppers).

9. Close the top cover.

10. Put labels “1” on the front of the paper tray.

G105I900.WMF

G105I906.WMF

G105I908.WMF

11. Attach the supplied sticker (stating you cannot use paper for an ink-jet printer with this printer) at the front of the machine.

G104 1-4 SM

G105I907.WMF

MACHINE INSTALLATION

1.2.2 INSTALLING THE TONER BOTTLE

1. Open the top cover [A].

Installation

2. Remove the toner bottles from the box.

3. Shake the toner bottle up and down seven or eight times.

G105I900.WMF

G105I914.WMF

SM 1-5 G104

G105I915.WMF

MACHINE INSTALLATION

4. Remove the tape from the toner bottle.

5. Install the yellow toner bottle first. Hold the toner bottle in the horizontal position  with the locking lever on the top side. Install the toner bottle bottom first. Then move the locking lever to the triangular mark position .

6. Turn the fixing lever to adjust it to the position of the circular mark. Continue to press the fixing lever toward the printer until it rotates smoothly into its position. NOTE: Do not insert and remove toner

bottles again and again. This causes toner leakage.

G105I916.WMF

G105I917.WMF

7. Do the same procedures again to insert the other three bottles: cyan (C),

G105I918.WMF

magenta (M), and black (K).

8. Close the top cover. NOTE: Do not turn off the power

switch at the time “Loading Toner…” shows on the display. This prevents malfunction.

G104 1-6 SM

MACHINE INSTALLATION

1.2.3 LOADING PAPER

CAUTION: Be careful not to pull the paper tray with too much force when you

remove it from the machine. This can let the tray fall and cause personal injury.

1. Pull the paper tray [A] out of the printer until it stops. Then tilt slightly, and pull it out. Put it on a flat surface. NOTE: You cannot pull tray 1 out if

the by-pass tray is open.

Installation

2. Adjust the green clips of the side guide and the end guide to the paper size you want.

3. Move the green switch on the front of the tray to match the type of paper you want to load. Move the switch to the left when you load thick paper of 75 g/m2 or more.

[A]

G105I909.WMF

G105I910.WMF

G105I911.WMF

SM 1-7 G104

MACHINE INSTALLATION

4. Arrange and load a stack of new paper into the tray with the print side up. Make sure that there is no gap between the paper and the paper guides. Adjust the paper guides to close gaps if necessary.

G105I912.WMF

5. Lift the front of the paper tray. Then slowly move the paper tray to the rear until it stops. Set the tray firmly in place to avoid paper jams.

G105I913.WMF

G104 1-8 SM

MACHINE INSTALLATION

1.2.4 CONNECTING THE POWER CORD

CAUTION

1. Do not touch the plug with wet hands. This causes electrical shock.

2. When you pull the plug out of the socket, grip the plug, not the cord, to avoid damaging the cord and causing a fire or an electric shock.

Installation

NOTE:

1) Make sure to firmly connect the power plug to the socket outlet.

2) The printer must be off when you connect or disconnect the power cord.

1. Make sure that the power switch is turned off.

2. Plug in the power cord.

3. Turn the power switch on.

NOTE: It can take a few minutes after the

main power comes on before you can use the machine.

G105I904.WMF

G105I905.WMF

SM 1-9 G104

MACHINE INSTALLATION

1.2.5 SELECTING THE PANEL DISPLAY LANGUAGE

NOTE:

1. Turn on the printer.

2. Press the Menu key.

3. Press the “V” or “W” key to show “Language.”

4. Press the Enter key. “Language: >English” shows on the panel display.

5. Press the “V” or “W” key to get the language you want.

6. Press the Enter key. “Menu” shows on the panel display.

7. Press the On Line key. “Ready” shows on the panel display.

1) You can select one of these languages (the default is English): English, German, French, Italian, Dutch, Swedish, Norwegian, Danish, Spanish, Finnish, Portuguese, Czech, Polish or Hungarian.

2) You do not have to do this procedure if you use English. Do this procedure if you want to use a different language.

NOTE: “Ready” shows on the panel display after the machine warms up.

NOTE: “Menu” shows on the panel display.

1.2.6 PRINTING A TEST PAGE

NOTE: You can check if the printer works correctly by printing a test page such as

the configuration page. However, you cannot check the connection between the printer and the computer by printing the test page.

1. Turn on the printer. NOTE: “Ready” shows on the panel display after the machine warms up.

2. Press the Menu key.

3. Press the “V” or “W” key to get “List/Test Print.”

4. Press the Enter key. “List/Test Print Config. Page” shows on the panel display.

5. Make sure that “Config. Page” is on the display. Then press the Enter key.

6. The test printing starts shortly after.

7. Press the “On Line” key. “Ready” shows on the panel display.

8. Turn off the printer's power switch.

G104 1-10 SM

OPTIONAL UNIT INSTALLATION

1.3 OPTIONAL UNIT INSTALLATION

These options are available for this machine. Refer to the Operating Instructions for how to install these options:

• Paper Tray Unit (G392).

• Hard disk for G104 (G395)

• IEEE802.11b interface (Wireless LAN: G813)

• IEEE1394 interface (B581)

• IEEE 1284 interface (B679)

• Bluetooth interface (B736)

• 128 MB DIMM (B584)

• 256 MB DIMM (G818)

• NVRAM (User account enhancement: G395)

Installation

SM 1-11 G104

METER CHARGE

1.4 METER CHARGE

Change these SP modes settings if the customer has a service contract. The settings depend on the contract type.

Item SP No. Function Default

Meter charge SP 5930 1

Counting method SP 5045 1

Fax No. Setting SP 5812 2

Specifies whether the meter charge mode is enabled or disabled.

Meter charge mode enabled:

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

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

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

• The PM warning is not shown when the replacement time arrives.

Meter charge mode disabled:

• The Counter menu is not shown.

Specifies whether the counting method used in meter charge mode is based on developments or prints.

Programs the service station fax number.

The number is printed on the counter list when the meter charge mode is selected. This lets the user fax the counter data to the service station.

Off

Prints

NOTE:

1) The default setting for this machine is meter-charge mode off.

2) You cannot reset the meter-charge counter.

G104 1-12 SM

TRAY HEATER

1.5 TRAY HEATER

1. Electrical boards unit [A]

2. Rear cover [B]

3. Rear cover piece [C] for the power supply connector

4. Decal [D]

5. Decal [E]

6. Harness [F] ( x 2,  x 3)

7. Tray heater switch [G]

8. Tray heater [H] ( x 2,  x 1)

NOTE: You can adjust the tray

heater switch setting as the below table shows with SP5953-001.

[A]

[F]

[D]

G105I101.WMF

[B]

Installation

[E]

[C]

[G]

SP5953-001

[H]

Tray heater

switch

On No power supply Power supply 0: Off Off No power supply No power supply On Power supply Power supply 1: On Off No power supply No power supply

When the Main Power

turns on

When the printer is in

energy saver mode

G105I102.WMF

SM 1-13 G104

PREVENTIVE MAINTENANCE

USER REPLACEABLE ITEMS

2. PREVENTIVE MAINTENANCE

2.1 USER REPLACEABLE ITEMS

The user replaces these items if the service contract requires that the user does some of the PM.

Item Remarks

PCU 50 K (YMC, BK) Transfer Belt Unit 100 K Waste Toner Bottle 50 K Maintenance Kit

- Fusing Unit

- Transfer Roller

- Paper Feed Roller x 3

- Friction Pad x 3

- Dust Filter x 2

100 K

Preventive

Maintenance

Chart: Letter, 5% Mode: Continuously Printing Environment: Recommended temperature and humidity Yield changes depend on circumstances and print conditions

An error message shows when a maintenance counter reaches the value in the PM table when the machine’s default settings are used.

It is not necessary to reset counters for each part if the technician does the PM. The machine detects new components automatically and resets the necessary counters.

SM 2-1 G104

SERVICE MAINTENANCE

2.2 SERVICE MAINTENANCE

2.2.1 RECOMMENDED CLEANING PROCEDURE

1. Turn off the main switch.

2. Remove the waste toner bottle.

3. Remove the PCUs.

4. Remove the transfer belt unit. Do not touch the transfer belt surface.

5. Remove the fusing unit.

6. Remove the standard paper tray.

7. Clean the paper path.

8. Clean all printer rollers with dry cloth only. Do not clean the transfer roller.

9. Use a blower brush to clean the laser unit windows.

10. Vacuum the interior of the printer.

11. Carefully clean the area around the transfer roller.

G104 2-2 SM

REPLACEMENT AND ADJUSTMENT

SPECIAL TOOLS AND LUBRICANTS

3. REPLACEMENT AND ADJUSTMENT

CAUTION

Turn off the main power switch and unplug the machine before you do the procedures in this section.

Important: Remove these before you do the procedures in this section:

• 4 toner bottles (cyan, magenta, yellow, and black)

• Waste toner bottle

• Standard paper tray

3.1 SPECIAL TOOLS AND LUBRICANTS

3.1.1 TOOLS

Item Part Number Description Q’ty

1 G0219350 Loop Back Connector: Parallel: Bi-direct 1 2 A0299387 Digital Multimeter –FLUKE87 1 3 B6455010 SD Card 1 4 B6456700 PCMCIA Card Adapter 1 5 B6456800 USB Reader/ Writer 1 6 C4019503 20X Magnification Scope 1

Adjustment

Replacement

SM 3-1 G104

ELECTRICAL COMPONENTS

3.2 ELECTRICAL COMPONENTS

3.2.1 ELECTRICAL BOARD UNIT

1. Front door

2. Top cover

3. Right cover [A] ( x 1)

[A]

Ｇ105R101.WMF

4. Color development motor unit [B] ( x 3,  x 1)

5. Side bar [C] ( x 4) and 3 wire clamps

6. IOB (Input/Output Board) [D] ( x 2,  x 3)

7.  [E] x 1

CN220 (IOB)

[B]

[D]

Ｇ105R102.WMF

(EGB)

[C]

G105R103.WMF

[E]

G104 3-2 SM

ELECTRICAL COMPONENTS

8. Left cover [A]

9. Drum positioning plate [B]

10. Drum positioning plate belt [C] ( x 1)

11.  [D] x 3,  [E] x 1

[D]

[A]

12. Electrical board unit [D] ( x 4,  x 2)

[C]

[B]

G105R104.WMF

[E]

Adjustment

Replacement

G105R105.WMF

[D]

SM 3-3 G104

ELECTRICAL COMPONENTS

3.2.2 IOB (INPUT/OUTPUT BOARD)

1. Front door

2. Top cover

3. Right cover ( 3.2.1)

4. Side bar ( 3.2.1)

5. IOB [A] ( x 2,  x all)

[A]

3.2.3 CONTROLLER BOARD

1. Controller unit [A] ( x 3)

2. Controller unit cover [B] ( x 4)

3. Controller board [C] ( x 7) NOTE: Remove the NVRAM from the

old board. Then install it on the new board.

[A]

G105R133.WMF

G105R111.WMF

[B]

G104 3-4 SM

[C]

G105R135.WMF

ELECTRICAL COMPONENTS

3.2.4 PSU (POWER SUPPLY UNIT) BOARD

1. Electrical boards unit ( 3.2.1)

2. PSU board [A] ( x 6,  x 5)

[A]

3.2.5 HIGH VOLTAGE POWER SUPPLY BOARD 1

1. Electrical boards unit ( 3.2.1)

2. PSU board ( 3.2.4)

3. Electrical board unit flame [A] ( x 4)

4. High voltage terminal plate [B] ( x 1)

5. High voltage power supply board 1 [C] ( x 4,  x 4, stand offs x 2) NOTE: Make sure that each high

voltage terminal is connected securely after you replace this board.

[A]

[B]

G105R136.WMF

[C]

G105R137.WMF

Adjustment

Replacement

SM 3-5 G104

ELECTRICAL COMPONENTS

3.2.6 EGB (ENGINE BOARD) AND HIGH VOLTAGE POWER

SUPPLY BOARD 2

1. Electrical board unit ( 3.2.1)

[A]

2. EGB shield [A] ( x 3,  x 1)

3. EGB [B] ( x 4,  x 4) NOTE: Make sure that each high

voltage terminal is connected securely after you replace this board.

[D]

4. High voltage terminal plate [C] ( x 1)

5. High voltage power supply board 2 [D] ( x 3,  x 2) NOTE: Make sure that each high

voltage terminal is

[C]

connected securely after you replace this board.

NOTE: Remove the NVRAM from the old board. Then install it on the new

board.

3.2.7 LCD PANEL

[B]

G105R138.WMF

1. LCD panel [A] ( x 1)

[A]

G105R115.WMF

G104 3-6 SM

LASER OPTICS

3.3 LASER OPTICS



WARNING

Turn off the main power switch and unplug the printer before you do the procedures in this section. Laser beams can cause serious eye injury.

3.3.1 CAUTION DECAL LOCATIONS

Caution decal is attached as shown below

Adjustment

Replacement

G105R927.WMF

G105R901.WMF

 WARNING

Make sure to turn off the main power switch and disconnect the power plug from the power outlet before you do any disassembly or adjustment of the laser unit. This printer uses a class 3B laser beam with a wavelength of 655 nm and an output of 7 mW. The laser can cause serious eye injury.

SM 3-7 G104

LASER OPTICS

3.3.2 LD UNIT

1. Electrical boards unit (3.2.1)

2. LDU [A] NOTE: Print the SMC report with

SP 5990-002 before you replace the LDU.

[A]

G105R106.WMF

Color registration adjustment

NOTE: You must manually perform the color registration adjustment after you

install a new LDU.

Perform these steps: NOTE: When the polygon mirror motor or Laser Diode Board (LDB) unit is

defective, only replace the defective parts. At this time, it is not necessary to do this adjustment procedure.

1. Print the SMC report with SP 5990 2 before you replace the LDU. (5.1.1) Find the values for SP 2181 1, SP 2181 11, 2181 21, and 2181 31, and make a note of them.

2. Execute SP 2111 2 (Pro. Position Adj > Execute) to roughly adjust the line position after you install the new LDU. “Result = OK” shows on the LCD if this is done correctly. If not, do it again until you get “OK”.

3. Execute SP2111 3 (Skew Adjust. > Execute) to measure the skew values for each color. “Result = OK” shows on the LCD if this is done correctly. If not, do it again until you get “OK”.

4. Check the skew values with SP 2181 and write down the values. (You can also check these values if you print the SMC report again with SP 5990 2. The values will probably be different from the values on the report that you printed in step 1.)

• SP 2181 1 for black skew

• SP 2181 11 for magenta skew

• SP 2181 21 for cyan skew

• SP 2181 31 for yellow skew

NOTE: The new skew values for magenta, cyan, yellow and black must all be the

same as the original skew value for magenta that was recorded in step 1. The magenta color is used as a reference point.

G104 3-8 SM

LASER OPTICS

5. Open the left cover

6. Adjust the skew adjustment cam [A]

for each color with a screwdriver. You must adjust the skew values for each color until they are all the same as the original value for magenta that you found in step 1, before you replaced

[A]

the LDU. Example, if the new value for K (after step 4) is –300 and the old value for magenta (in step 1) is –250, you must adjust the skew for K until it is –250.

Adjustment Procedure:

G105R902.WMF

Turn the cam as shown in the “Cam Rotation Direction” (table below) to increase the skew value. Turn in the opposite direction to decrease the skew value. “Adjustment value” shows the change when you turn the cam “one click”.

Color

Yellow CW 14 µm

Cyan CW 8 µm

Magenta CCW 7 µm

Black CCW 10 µm

Cam Rotation

Direction

Adjustment

value

NOTE: The adjustment values in the table are not exact values. These are

approximate values. CW: Clockwise, CCW: Counter-clockwise

The diagram to the right shows the effect on line skew [B] when you turn the cam in a counter clockwise direction.

7. Close the left cover. Then measure the skew values again with SP 2111 3. (To do this, repeat step 3.) If these are close to the value for magenta that you found in step 1 (within one click in the above table), go to the next step. If

Y C

M K

[B]

not, do SP 2111 3 again until you get a good result.

8. Do SP 2111 1 to finely adjust the line

G105R903.WMF

position for each color. Try SP 2111 2 if “Result = OK” does not show.

Adjustment

Replacement

9. When you get “Result = OK”, this adjustment is completed.

SM 3-9 G104

LASER OPTICS

3.3.3 LDB

1. LDU ( 3.3.2)

2. LDB [A] ( x 2) NOTE: Make sure that the

spring plate [B] holds the LDB unit.

3.3.4 POLYGON MIRROR MOTOR

1. LDU ( 3.3.2)

2. Top cover [A] ( x 5, tabs x 4) NOTE: Do not touch the mirrors.

Clean with an optics cloth if you touch the mirrors.

[A]

[B]

G105R107.WMF

3. Polygon motor cover [B] ( x 3), shading plate [C], sponge [D]

4. Polygon mirror motor [E] ( x 4), drive board [F] ( x 2,  x 1, 1 flat cable)

[F]

[D]

[E]

[B] [C]

G105R108.WMF

G105R109.WMF

G104 3-10 SM

LASER OPTICS

3.3.5 LASER SYNCHRONIZING DETECTOR BOARDS

1. LDU ( 3.3.2)

2. Top cover

3. Synchronizing detector board unit [A] ( x 1)

4. Synchronizing detector board [B] ( x 1,  x 1) NOTE: Do not touch the mirrors.

Clean with an optics cloth if you touch the mirrors.

3.3.6 LDU SHUTTER MOTOR UNIT AND SENSOR

1. Electrical boards unit (3.2.1)

2. LDU ( 3.3.2)

3. LDU shutter motor unit [A] ( x 2, 

x 2,  x 1)

4. Remove the gear [B] ( x1).

NOTE: To do this, turn the projection [E]

of the gear to the position as shown in the diagram below. The worm gear [F] must turn to adjust the position of the projection.

5. LDU shutter sensor [C]

6. LDU shutter motor [D] ( x 2,  x 1)

[A]

G105R110.WMF

[D]

[B]

G105R155.WMFF

[B]

Adjustment

Replacement

[C]

[F]

[E]

G105R929.WMF

SM 3-11 G104

PAPER FEED

3.4 PAPER FEED

3.4.1 PAPER FEED ROLLER

1. Standard tray [A]

2. Slide the side roller holder [B] to the

right.

3. Paper feed roller [C]

[A]

G105R904.WMF

[B]

[C]

G105R149.WMF

G104 3-12 SM

PAPER FEED

3.4.2 PAPER FRICTION PAD

1. Standard tray (3.4.1)

2. Paper friction pad [A]

NOTE: Make sure that the paper friction

pad stick is put through the spring when you reassemble it.

[A]

3.4.3 BY-PASS PAPER SIZE SENSOR

1. By-pass tray cover [A]

2. By-pass paper size sensor [B] ( x

[A]

[B]

G105R150.WMFF

G105R112.WMF

Adjustment

Replacement

SM 3-13 G104

PAPER FEED

3.4.4 BY-PASS FEED ROLLER, FRICTION PAD

1. By-pass tray cover [A]

2. By-pass tray [B] ( x 2,  x 1) and the harness cover [C]

3. By-pass feed shaft cover [D]

4. Move the holding roller left [E]

[B]

[A]

[C]

G105R113.WMF

[D]

5. By-pass feed roller [F]

6. By-pass friction pad [G]

1) Pull up the edge of the by-pass

friction pad ().

2) Pull the by-pass friction pad

forward. When you do this, hold down the edge where its shaft is located ().

Reassembling the by-pass friction pad

1. Place the spring [H] on the projection

[I] of the by-pass tray.

[J]

[I]

[E]

[F]

G105R114.WMF

[G]

[H]

G105R156.WMF

2. Hold down the by-pass friction pad

after you put the spring on the projection of pad’s reverse side ().

3. Release the by-pass tray friction pad when it passes through the bushing [J].

4. Pull up the shaft of the by-pass friction pad to the busing until it clicks.

G104 3-14 SM

PAPER FEED

3.4.5 REGISTRATION SENSOR

1. Front Door

2. Fusing unit ( 3.8.1)

3. Registration guide [A]

4. Registration sensor [B] ( x 1)

[A]

[B]

G105R139.WMF

Adjustment

Replacement

SM 3-15 G104

PAPER FEED

3.4.6 PAPER VOLUME SENSOR, END SENSOR

AND PAPER WIDTH SENSOR

1. Standard tray ( 3.4.1)

2. Front door

3. Fusing unit ( 3.8.1)

4. Harness cover [A] ( x 1)

5. Front door cover [B] ( x 1,  x 2)

[A]

6. Registration guide ( 3.4.5)

7. Paper dust case holder [C]

8. Tray paper sensor box [D] ( x 2)

[B]

[C]

G105R121.WMF

G105R140.WMF

G104 3-16 SM

[D]

G105R141.WMF

PAPER FEED

9. Tray paper sensor box cover [A] ( x 1,)

10. Paper height sensor [B] ( x 1)

11. Paper height sensor [C] ( x 1)

12. Paper end sensor [D] ( x 1)

13. Paper width sensor [E] ( x 1) NOTE: Each sensor and each cable

have a number written on them. Make sure to connect the correct cables to each sensor.

3.4.7 PAPER SIZE SENSOR AND

TEMPERATURE/ HUMIDITY SENSOR

[C]

[B]

[A]

[E]

G105R142.WMF

[D]

Adjustment

Replacement

1. Standard tray ( 3.4.1)

2. Rear cover [A]

3. Paper size sensor [B] ( x 1)

4. Temperature/Humidity sensor [C] ( x

1, x 1)

[C]

[A]

G105R147.WMFF

[B]

SM 3-17 G104

PAPER FEED

3.4.8 PAPER FEED MOTOR

[A]

1. Front door cover ( 3.4.6)

2. Right cover ( x 1)

3. Side bar ( 3.2.1)

4. Harness guide [A] ( x 1,  x 3)

5. Front support unit [B] ( x 3)

[B]

6. Paper feed motor [C] ( x 4,  x 1)

G105R128.WMF

G105R131.WMF

[C]

G104 3-18 SM

PAPER FEED

3.4.9 PAPER REGISTRATION CLUTCH,

PAPER FEED CLUTCH AND BY-PASS CLUTCH

1. Front door

2. Front door cover ( 3.2.1)

3. Right cover ( 3.2.1)

4. Side bar ( 3.2.1)

5. Harness cover ( 3.7.3)

6. Paper registration clutch [A] ( x 1,  x1)

7. By-pass clutch [B] ( x 1,  x 1)

8. Front support unit ( 3.4.8)

9. Paper feed clutch support [C] ( x

10. Paper feed clutch [D] ( x 1)

[D]

[A]

[C]

[B]

G105R129.WMF

Adjustment

Replacement

SM 3-19 G104

DEVELOPMENT

3.5 DEVELOPMENT

3.5.1 COLOR DEVELOPMENT MOTOR, COLOR OPC MOTOR

AND BLACK OPC/DEVELOPMENT MOTOR

1. Front door

2. Right cover ( 3.2.1)

3. Color development motor [A] ( x 4,  x 1)

4. Color OPC motor [B] ( x 4,  x 1)

5. Black OPC/development motor [C] ( x 4,  x 1)

[C]

[B]

3.5.2 DEVELOPMENT CLUTCH

1. Front door

2. Top cover

3. Right cover ( 3.2.1)

4. Development clutch plate [A] ( x 2)

5. Development clutch [B] (metal pin x 1,  x 1)

G105R134.WMF

[A]

[B]

[A]

G105R130.WMF

G104 3-20 SM

DEVELOPMENT

3.5.3 TRANSFER BELT CONTACT MOTOR

1. Front door

2. Top cover

3. Right cover ( 3.2.1)

4. Transfer belt contact motor unit [A] ( x 2,  x 1)

3.5.4 TONER SUPPLY MOTOR

1. Front cover

2. Top cover

3. Right cover ( 3.2.1)

4. Toner supply motor unit [A] ( x 2,  x 1)

5. Toner supply motor [B] ( x 2)

[A]

[B]

G105R127.WMF

G105R132.WMF

Adjustment

Replacement

SM 3-21 G104

DEVELOPMENT

3.5.5 TRANSFER ROLLER CONTACT MOTOR

1. Front door

2. Left cover

3. Front door support unit [A] ( x 2,  x 1)

4. Inner cover [B] ( x 2)

[B]

[A]

G105R143.WMF

5. Transfer roller contact motor unit [C]

( x 2,  x 1)

6. Transfer roller contact motor [D] ( x 2)

[D]

G105R144.WMF

[C]

G105R145.WMF

G104 3-22 SM

DRIVE

3.5.6 ID SENSORS

1. Front door

2. Fusing unit ( 3.8.1)

3. ID sensor cover [A] ( x 1)

4. ID sensor bracket [B] ( x 3,  x 1) NOTE: Do SP 2111 4 to adjust the ID

sensors after you replace the ID sensor.

3.6 DRIVE

3.6.1 DRIVE UNIT

1. Top cover

2. Front door

3. Left cover

4. Transfer belt unit

[A]

[B]

[A]

G105R146.WMF

Adjustment

Replacement

5. PCU x 4

6. Toner bottle x 4

7. Toner supply motor unit x 4 (3.5.4) NOTE: Clean the toner hopper and

toner transport path before you remove the toner supply motor unit. If not, toner scattering can occur.

8. Right cover ( 3.2.1)

9. Top frame [A] ( x 5)

[C]

10. Fusing unit fan [B] ( x 1)

11. Harness guide [C] ( x 2)

12. Drive unit [D] ( x 6,  x 16)

[B]

G105R152.WMF

G105R151.WMFF

[D]

SM 3-23 G104

DUPLEX

3.7 DUPLEX

3.7.1 DUPLEX JAM SENSOR

1. Front door cover ( 3.4.6)

2. Duplex jam sensor 1 [A] ( x 1)

3. Duplex jam sensor 2 [B] ( x 1)

3.7.2 INVERTER SENSOR

1. Front door

[B]

[C]

[A]

G105R117.WMF

2. Duplex paper guide plate [A] ( x

3. Inverter sensor board [B]

4. Inverter sensor [C] ( x 1)

[B]

G105R119.WMF

[A]

G104 3-24 SM

DUPLEX

3.7.3 DUPLEX MOTOR AND INVERTER MOTOR

1. Front door

2. Front door cover (3.4.6)

3. Duplex paper guide plate [A] ( x 6)

4. Harness cover [B] ( x 2)

5. Inverter motor [C] ( x 2,  x 1)

6. Harness [D]

7. Harness cover [E]

8. Duplex roller unit [F] ( x 4)

9. Duplex motor [G] ( x 2,  x 1)

[C]

[G]

[A]

G105R153.WMF

[B]

[D]

[E]

Adjustment

Replacement

[F]

G105R154.WMF

SM 3-25 G104

FUSING

3.8 FUSING

CAUTION

1. Make sure that the fusing unit is cool before you touch it. The fusing unit can be very hot.

2. Make sure to restore the insulators, shields, etc after you service the fusing unit.

3.8.1 FUSING UNIT

1. Front door

2. Fusing unit [A]

[A]

3.8.2 THERMISTOR AND THERMOSTAT

1. Front door

2. Fusing unit ( 3.8.1)

3. Fusing unit upper cover [A] ( x 4)

4. Fusing unit lower cover [B] ( x 6)

G105R122.WMF

[A]

[B]

G104 3-26 SM

G105R126.WMF

FUSING

5. Fusing supporter right [A] ( x 2) and left plate [B] ( x 2)

6. Thermistor [C] ( x 1,  x 1)

7. Thermostat [D] x 2 ( x 3) NOTE: Do not recycle a thermostat

that is already opened. Safety is not guaranteed if you do this.

[B]

[A]

[D]

G105R124.WMF

[C]

Adjustment

Replacement

3.8.3 FUSING LAMP

1. Fusing unit

2. Fusing unit upper and lower cover ( 3.8.2)

3. Fusing supporter right and left plate ( 3.8.2)

4. Fusing lamp supporter right [A] ( x 1) and left plate [B] ( x 1)

5. Fusing lamp [C] ( x 2)

[B]

G105R125.WMF

[C]

[A]

G105R123.WMF

SM 3-27 G104

FUSING

3.8.4 FUSING EXIT SENSOR AND PAPER EXIT SENSOR

1. Front door

2. Paper exit unit ( x 3)

3. Sensor board [A] ( x 1,  x 2)

4. Fusing exit senor [B]

5. Paper exit sensor [C]

[C]

[A]

3.8.5 FUSING REGISTRATION SENSOR

1. Front door

2. Paper guide [A] ( x 2,  x 1)

3. Fusing registration sensor [B]

[B]

[A]

G105R116.WMF

G105R118.WMF

[B]

G104 3-28 SM

FUSING

Fan Direction

Adjustment

Replacement

G105V204.WMF

NOTE: You must reinstall the cooling fans in the original orientations. Do not

reinstall the cooling fans opposite to the original orientations, or the air will blow in the wrong directions.

SM 3-29 G104

ADJUSTMENTS

3.9 ADJUSTMENTS

3.9.1 GAMMA ADJUSTMENT

NOTE: Clean and/or replace related parts first to solve any color quality problems.

Summary

To adjust the printer gamma:

Example:

Perform these procedures if adjustments are necessary:

• Select the print mode you want to calibrate

• Print a color calibration test sheet

• Make the gradation scales on the printout smooth from the lowest to the

highest density. Adjust the CMY gradation scale at the top of the chart by balancing the density of the C, M, and Y gradation scales – the CMY gray scale should change smoothly from minimum to maximum. There should be no coloration.

[C]

[B]

[A]

G105R913.JPG

G104 3-30 SM

ADJUSTMENTS

You can adjust 15 points for each color: (example [A]) between 0 (lowest density) [B] and 255 (highest density) [C]. For each point, you can adjust the density within 0 and 255.

The gradation scales marked ‘Default’ are printed according to the default gamma settings in the flash ROM in the controller. The gamma adjustment changes the densities at the adjustable points in the gradation scale. The gradation scale marked “Current” shows the current settings.

Compare the “Current” gradation scale with the ‘Default’ at the time you perform the adjustment procedure. Select the density for each of the 15 adjustable points, excluding points 0 and 255, from the ‘Default’ gradation scale.

The NVRAM holds three sets of controller gamma settings:

• Those saved this time: Controller SP 1101 ToneCtlSet - Tone (Current)

• Those saved in the previous adjustment: Controller SP 1101 ToneCtlSet -

Tone (Prev)

• The factory settings: Controller SP 1101 ToneCtlSet - Tone (Factory).

Adjustment Procedure

Adjustment

Replacement

1. Enter the controller service mode. (5.1.1)

2. Use the down arrow key to select Controller SP 1102 “ToneCtlSet”. Then press the Enter key.

3. Use the up/down key to select the mode you want to calibrate, Then press the Escape key until you get back to the controller service mode menu.

4. Use the down arrow key to select Controller SP 1103 “PrnColorSheet”. Then press the Enter key.

5. Use the up/down key to select Controller SP 1103 001 “ToneCtlSheet” (normally this is displayed by default). Then press the Enter key.

6. Press the Enter key to print out the “color calibration test sheet”. When “Execute?” shows.

7. Press the Escape key 2 times to exit from the menu. (You return to Controller SP 1103 “PrnColorSheet” in the controller service menu.)

8. Use the down arrow key to select Controller SP 1104 “ToneCtlValue”. Then press the enter key.

SM 3-31 G104

ADJUSTMENTS

9. Use the up/down arrow key to select the setting you want to adjust. Then press the enter key. The three digits in the display (example ‘016’) indicate a position on the color calibration test sheet.

Operation Panel

Display

Set Black 1 Default Value 16 Set Black 2 Default Value 32 Set Black 3 Default Value 48

: :

: : Set Black 13 Default Value 208 Set Black 14 Default Value 224 Set Black 15 Default Value 240

Set Cyan 1 ~ 15 See Set Black 1 ~ 15

Set Magenta 1 ~ 15 See Set Black 1 ~ 15

Set Yellow 1 ~ 15 See Set Black 1 ~ 15

Color Calibration

Test Sheet

Adjust the color density at each of the 15 points for each of the four colors.

NOTE:

1) Execute these to decide what density value to input:

2) Look at the color adjustment sheet.

3) Look at the gradation scale entitled ‘Default’ for the color you want to adjust.

4) Go along the scale until you reach the density you want to input.

5) Read off the value on the scale and store it in the machine. a) Use the up/down key to move the cursor along the three-digit

display. Then press the Enter key.

b) Use the up/down key to change the digit at the cursor. Then

press the Enter key.

c) Press the Escape key to exit from the menu.

6) Execute the same for all 15 points.

10. When the density setting is complete for all colors, print out a color adjustment sheet again and make sure that the gradation scale for each printed color is smooth and that the CMY gradation scale is gray. Do the adjustment again if there is an anomaly (normally, repeat this procedure 3 to 5 times).

11. Execute these when the adjustment results are satisfactory:

1) Use Controller SP 1105 “ToneCtlSave” in the controller service menu, to

store the new settings in the controller.

2) Reset the controller (press the [Reset] key when the machine is off line”) to

use the new settings.

NOTE: You must reset the controller to keep the new settings in the controller

NVRAM.

G104 3-32 SM

TROUBLESHOOTING

PROCESS CONTROL RESULT

4. TROUBLESHOOTING

4.1 PROCESS CONTROL RESULT

The table below lists the process control results shown in SP 3821.

Number Result Notes

10 Success No error 21 ID sensor correction error SC 400 22 ID sensor: LED adjustment error SC 418 31 Charge bias correction error SC 300 to 307 51 High Vmin (Bk), High K2 (Color) error SP3145 NOTE 52 Low K2 (Color) error SP3146 NOTE 53 High K5 error SP3147 NOTE 54 Low K5 error SP3147 NOTE 55 High development gamma 56 Low development gamma 57 Development bias adjustment error Vk >150V NOTE 58 Development bias adjustment error Vk < -150V NOTE 90 No process control 99 Not successful

Interrupt during the process

NOTE: This error code does not usually occur. Although an error code may be

displayed, if no problem is observed with image density and/or development gamma, nothing needs to be done. If an image problem such as low image density is observed, check the following points: Transfer belt / PCU / ID sensor / Toner Bottle

The 8 numbers on the LCD in SP 3821 indicate the process control result for each color.

γ > 5.0, NOTE γ < 0.5, NOTE

control (e.g. Door open)

Trouble-

shooting

There are two numbers for each color. The numbers are shown from left to right on the display as follows: Black, Magenta, Cyan, Yellow. For example, if process control for each color is successful: 10101010 10 (Black), 10 (Magenta), 10 (Cyan), 10 (Yellow)

If a problem is detected during process control: 10515110 10 (Black), 51 (Magenta), 51 (Cyan), 10 (Yellow)

SM 4-1 G104

SERVICE CALL CONDITIONS

4.2 SERVICE CALL CONDITIONS

4.2.1 SUMMARY

1. All SCs are logged.

2. If a PCB is suspected to be the cause of a problem, first disconnect, then reconnect the connectors before you replace them.

3. If a motor is suspected to be the cause of a problem, first check the mechanical load before you replace motors or sensors due to a motor lock.

There are 4 levels of service call conditions.

Level Definition Reset Procedure

To prevent damage to the machine, the main machine cannot be operated until a service representative has reset the SC.

SCs that disable only the features that use the defective item. Although these SCs are not shown to the user under normal conditions, they are displayed on the operation panel only when the defective feature is selected.

The SC history is updated. The machine can be operated as usual.

Turning the main switch off then on resets SCs displayed on the operation panel. These are redisplayed if the error occurs again.

Execute SP 5810, and then turn the main power switch off and on.

Turn the operation switch or main switch off and on.

The SC will not be displayed. Only the SC history is updated.

Turn the operation switch off and on.

G104 4-2 SM

SERVICE CALL CONDITIONS

4.2.2 SC CODE DESCRIPTIONS

NOTE: If the EGB or controller board is replaced, remove the NVRAM from the old

board and install it on the new one.

• The SC level is indicated under SC number in the table below.

• The symbol “●” that is in the “Possible Cause/Required Action” column indicates

the possible cause.

• The figure “1,etc.” that is in the “Possible Cause/Required Action” column

indicates the required action.

Engine SC

[Level]

195

[D]

Symptom Possible Cause/Required Action

Incorrect serial number When checking the

registered product number, it does not match the printer’s product number.

Polygon motor error: Time out with the polygon motor activated 202 After the polygon motor turns on or changes the speed, the SCRDY_N is not active within 10 seconds.

Polygon motor error: Time out with the polygon motor inactivated 203 After the polygon motor turns off or changes the speed, the SCRDY_N is not inactive within 10 seconds.

Polygon motor error: XSCRDY signal error 204 PMRDY_N signal consecutively detects that the polygon motor is an inactive state while LDB unit scans.

Polygon motor error: XSCRDY signal not stable 205 PMRDY_N signal consecutively detects that the polygon motor is an inactive state while the polygon motor turns on or changes the speed.

Item

• Registered product number does not match the printer’s product number.

1. Try again to input the correct product number with

SP5811-001.

• Disconnected cable from the polygon motor drive

board or defective connection

• Defective polygon motor or drive board

• Disconnected cable from the polygon motor drive

board or defective connection

• Defective polygon motor or drive board

• Disconnected cable from the polygon motor drive

board or defective connection

• Defective polygon motor or drive board

1. Check the connectors.

2. Replace the polygon motor.

3. Replace the polygon motor drive board.

• Disconnected cable from the polygon motor drive board or defective connection

• Defective polygon motor or drive board.

1. Check the connectors.

2. Replace the polygon motor.

3. Replace the polygon motor drive board.

Trouble-

shooting

SM 4-3 G104

SERVICE CALL CONDITIONS

[Level]

210

[C]

Symptom Possible Cause/Required Action

Trailing edge laser detection error: [K] The laser synchronizing

• Disconnected cable from the laser synchronizing

detection signal for LDB [K] of the trailing edge is not detected for one second after the LDB unit turned on when detecting the main scan magnification.

• Defective laser synchronizing detector

• Defective LDB

• Defective EGB

1. Check the connectors.

2. Replace the laser-synchronizing detector.

Item

detection unit or defective connection

3. Replace the LDB.

4. Replace the EGB.

211

[C]

Trailing edge laser detection error: [Y] The laser synchronizing

Same as SC 210 detection signal for LDB [Y] of the trailing edge is not detected for one second after the LDB unit turned on when detecting the main scan magnification.

212

[C]

Trailing edge laser detection error: [M] The laser synchronizing

Same as SC 210 detection signal for LDB [M] of the trailing edge is not detected for one second after the LDB unit turned on when detecting the main scan magnification.

213

[C]

Trailing edge laser detection error: [C] The laser synchronizing

Same as SC 210 detection signal for LDB [C] of the trailing edge is not detected for one second after the LDB unit turned on when detecting the main scan magnification.

220

[D]

Laser Synchronizing Detection Error: LDB of the leading edge [K] The laser synchronizing

detection signal for LDB [K] of the leading edge is not output for two seconds after LDB unit turns on while the polygon motor is rotating normally.

• Disconnected cable from the laser synchronizing detection unit or defective connection

• Defective laser synchronizing detector

• Defective LDB

• Defective EGB

1. Check the connectors.

2. Replace the laser-synchronizing detector.

3. Replace the LDB.

4. Replace the EGB.

G104 4-4 SM

SERVICE CALL CONDITIONS

[Level]

222

[D]

[C]

Symptom Possible Cause/Required Action

Leading edge laser detection error: [Y] The laser synchronizing

Same as SC 221 detection signal for LDB [Y] of the leading edge is not output for two seconds after LDB unit turns on while the polygon motor is rotating normally.

Leading edge laser detection error: [M] 224 The laser synchronizing

Same as SC 221 detection signal for LDB [M] of the leading edge is not output for two seconds after LDB unit turns on while the polygon motor is rotating normally.

Leading edge laser detection error: [C] 226 The laser synchronizing

Same as SC 221 detection signal for LDB [C] of the leading edge is not output for two seconds after LDB unit turns on while the polygon motor is rotating normally.

FGATE: On error [K] 230 The PFGATE ON signal

does not assert within 5 seconds after processing the image in normal job or MUSIC for [K] starts.

• Defective connection between the controller board and EGB

• Defective cable between the EGB and LDB

1. Check the connectors.

2. Replace the LDB.

3. Replace the EGB.

FGATE: Off error [K] 231

1. The PFGATE ON signal still asserts within 5 seconds after processing the image in normal job or MUSIC for [K] ends.

2. The PFGATE ON signal

• Defective connection between the controller board and EGB

• Defective cable between the EGB and LDB

1. Check the connectors.

2. Replace the LDB.

3. Replace the EGB.

still asserts when the

next job starts. FGATE: On error [Y] 232 The PFGATE register of

Same as SC 230 GAVD does not assert within 5 seconds after processing the image in normal job or MUSIC for [Y] started.

Item

Trouble-

shooting

SM 4-5 G104

SERVICE CALL CONDITIONS

[Level]

[C]

[D]

Symptom Possible Cause/Required Action

FGATE: Off error [Y] 233

1. The PFGATE ON signal

still asserts within 5 seconds after processing the image in normal job or MUSIC for [K] ends.

2. The PFGATE ON signal

still asserts when the

next job starts. FGATE: On error [M] 234 The PFGATE register of

GAVD does not assert within 5 seconds after processing the image in normal job or MUSIC for [M] started.

FGATE: Off error [M] 235

1. The PFGATE ON signal

still asserts within 5

seconds after

processing the image in

normal job or MUSIC

for [M] ends.

2. The PFGATE ON signal

still asserts when the

next job starts. FGATE: On error [C] 236 The PFGATE register of

GAVD does not assert within 5 seconds after processing the image in normal job or MUSIC for [C] started.

FGATE: Off error [C] 237

1. The PFGATE ON signal

still asserts within 5

seconds after

processing the image in

normal job or MUSIC

for [C] ends.

2. The PFGATE ON signal

still asserts when the

next job starts. LDB error [K] 240 The EGB detects LDB error

a few times consecutively when LDB unit turns on after LDB initialisation.

Item

Same as SC 231

Same as SC 230

Same as SC 231

Same as SC 230

Same as SC 231

• Defective LDB

1. Replace the LDB.

G104 4-6 SM

SERVICE CALL CONDITIONS

[Level]

[D]

Symptom Possible Cause/Required Action

LDB error [Y] 241 The EGB detects LDB error

a few times consecutively when LDB unit turns on after LDB initialisation.

LDB error [M] 242 The EGB detects LDB error

a few times consecutively when LDB unit turns on after LDB initialisation.

LDB error [C] 243 The EGB detects LDB error

a few times consecutively when LDB unit turns on after LDB initialisation.

LDU shutter error 270 Sensor output does not

change even if 1 second passes after the LDU shutter motor is on.

High voltage power board: Charge voltage output error [K] 300 The measured voltage is

not proper when EGB measures the charge output for each color.

High voltage power board: Charge voltage output error [M] 301 The measured voltage is

not proper when EGB measures the charge output for each color.

High voltage power board: Charge voltage output error [C] 302 The measured voltage is

not proper when EGB measures the charge output for each color.

Item

Same as SC240

• Sensor defective or LDU shutter motor defective

1. Replace the LDU shutter sensor or shutter motor.

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for black.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for magenta.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for cyan.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

Trouble-

shooting

SM 4-7 G104

SERVICE CALL CONDITIONS

[Level]

[D]

Symptom Possible Cause/Required Action

High voltage power board: Charge voltage output error [Y] 303 The measured voltage is

not proper when EGB measures the charge output for each color.

Charge AC bias error [K] 304 The charge current less

than 200 µA is detected.

Charge AC bias error [M] 305 The charge current less

than 200 µA is detected.

Charge AC bias error [C] 306 The charge current less

than 200 µA is detected.

Charge AC bias error [Y] 307 The charge current less

than 200 µA is detected.

Item

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for yellow.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for black.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for magenta.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for cyan.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

• Defective charge roller

• Defective connectors

• Disconnected harness

• Defective high voltage power 1

1. Check the connectors.

2. Replace the PCU for yellow.

3. Replace the drum positioning plate.

4. Replace the high voltage power 1.

G104 4-8 SM

SERVICE CALL CONDITIONS

[Level]

[D]

Symptom Possible Cause/Required Action

Color development motor error 325

1. LOCK signal is not

detected for more than two seconds while the motor START signal is on.

2. LOCK signal is not

cancelled within two seconds after the motor

is off. TD sensor: Output maximum error [K] 360 Vt is more than the

maximum value (4.5) for three times consecutively.

TD sensor: Output maximum error [M] 361 Same as SC 360 TD sensor: Output maximum error [C] 362 Same as SC 360 TD sensor: Output maximum error [Y] 363 Same as SC 360 TD sensor: Output minimum error [K] 364 Vt is less than the minimum

value (0.5) for three times consecutively.

TD sensor Output minimum error [M] 365 Same as SC 364 TD sensor: Output minimum error [C] 366 Same as SC 364 TD sensor: Output minimum error [Y] 367 Same as SC 364 TD sensor: Initial control voltage error [K] 368

1. Vt is less than 1 V even

though the control power voltage is adjusted to the maximum.

2. Vt is more than 1 V even

though the control power voltage is adjusted to the

minimum. TD sensor: Initial control voltage error [M] 369 Same as SC 368 TD sensor: Initial control voltage error [C] 370 Same as SC 368 TD sensor: Initial control voltage error [Y] 371 Same as SC 368

Item

• Color development motor slip due to the increase of the load torque

1. Adjust the load torque properly by replacing or

cleaning the development unit.

2. Replace or repair the development motor if the

load torque is normal.

• Defective connector connection

• Increasing toner density

1. Replace the PCU.

• Defective connector connection

• Decreasing toner density

1. Replace the PCU.

• Defective connector connection

• Defective TD sensor

• The toner density in the developer is different

from the initial condition.

1. Replace the PCU.

Trouble-

shooting

SM 4-9 G104

SERVICE CALL CONDITIONS

[Level]

[D]

[C]

[D]

Symptom Possible Cause/Required Action

TD sensor: Initial adjustment error [K] 372 Vt is not (A ± 0.2) when

initial setting for TD sensor is executed.

A = SP3011-001 for [K]

TD sensor: Initial adjustment error [M] 373 Vt is not (A ± 0.2) when

initial setting for TD sensor is executed.

A = SP3011-002 for [M] TD sensor: Initial adjustment error [C]: same as 372 374 Vt is not (A ± 0.2) when

initial setting for TD sensor is executed.

A = SP3011-003 for [C] TD sensor: Initial adjustment error [Y]: same as 372 375 Vt is not (A ± 0.2) when

initial setting for TD sensor is executed.

A = SP3011-004 for [Y] Drum gear position sensor error 380 When receiving the input

signal of drum gear position sensor is not correctly done, SC380 is logged.

Drum motor error [K] 396 The LOCK signal is not

detected for 2 seconds more while the start signal of the drum motor for black PCU is output.

Drum motor error [CMY] 397 The LOCK signal is not

detected for 2 seconds more while the start signal of the drum motor for color PCU is output.

ID sensor correction error 400 Regular Vsp is not (4 ± 0.5

V) when ID sensor correction is executed.

ID sensor: LED adjustment error 418 LED PWM adjustment is

not [A] for three times consecutively.

[A] = 50 < [A] < 400

Item

• Defective connector connection

• Defective TD sensor

• The toner density in the developer is different

from the initial condition.

1. Replace the PCU.

Same as 372

• Unclean or defective drum gear position sensor

1 Clean the drum gear position sensor. 2 Replace the drive unit.

• OPC motor slip due to the excessive load

1. Clean the PCU.

2. Check the cable from the Black OPC/ Development motor. Replace it if necessary.

3. Replace the EGB.

4. Replace the Black OPC/ Development motor.

Same as SC 396

• Defective ID sensors

• Dirty ID sensors or transfer belt

• ID sensor life is over.

1. Replace the ID sensors.

• Defective ID sensors

• Dirty ID sensors or transfer belt

• ID sensor life is over.

1. Replace the ID sensors.

G104 4-10 SM

SERVICE CALL CONDITIONS

[Level]

[D]

Symptom Possible Cause/Required Action

Transfer belt contact error 442 The transfer belt contact

sensor does not detect the movement of actuator at the sensor while the polygon motor rotates.

Transfer roller contact error 452 The transfer roller contact

sensor does not detect the movement of actuator at the sensor while the polygon motor rotates.

High Voltage Power 1: High voltage output error 490 Error signal is detected for

10 times consecutively.

High Voltage Power 2: High voltage output error 491 Error signal is detected for

10 times consecutively.

Paper feed / Fusing motor error 531

1. LOCK signal is not detected for more than two seconds while the motor START signal is on.

2. LOCK signal is not cancelled within two seconds after the motor is off.

Item

• Dirty transfer belt contact sensor

• Defective transfer belt contact motor

• Disconnected connector of transfer belt contact

sensor or motor

• Disconnected cable

1. Replace the transfer belt contact sensor.

2. Replace the transfer belt contact motor.

• Defective transfer roller contact sensor

• Defective transfer roller contact motor

• Defective IOB

1. Replace the transfer roller contact sensor.

2. Replace the transfer roller contact motor.

3. Replace the IOB.

• One of the DC bias outputs for each PCU is shorted or one of the transfer belt bias outputs for [Y], [M] and [C].

• Power leaking

• Defective connection

• Disconnected cable

• Defective PCU

• Defective High Voltage Power 1

1. Replace the High Voltage Power 1.

2. Reset the cables and components.

3. Replace the PCU.

• One of the separation bias output, development

bias output and transfer belt cleaning bias output is shorted or one of the transfer belt bias output for [K] and transfer roller bias output is shorted.

• Power leaking

• Defective connection

• Defective PCU

• Defective High Voltage Power 2

1. Replace the High Voltage Power 2.

2. Reset the cables and components.

3. Replace the PCU.

• Defective paper feed/ fusing motor

1. Replace the paper feed/ fusing motor.

Trouble-

shooting

SM 4-11 G104

SERVICE CALL CONDITIONS

[Level]

[D]

[A]

Symptom Possible Cause/Required Action

Fan motor error 532 The fan motor “On” signal is

not detected for the components below after the drum motor for black is set to “On”.

• PSU fan

• Fusing unit fan

• Polygon motor fan

• Drive unit fan

• Exit paper fan

Thermistor error 541 The thermistor output is

less than 0°C for six seconds.

Print ready temperature error 542

1. The heating roller temperature increase that is less than 67 degrees for 9 seconds is detected five times consecutively.

2. The fusing temperature does not reach the print ready temperature within 15 seconds after the fusing lamp was controlled.

High temperature detection: Software 543 The thermistor detects

230°C for 0.2 seconds.

High temperature detection: Hard 544 The thermistor detects

250°C.

Heating lamp error 545 The fusing lamp is full-

powered for 8 seconds after the heating roller reaches the print ready temperature.

Item

• Defective fan motor

1. If the error occurs again, one of the fans is defective. Remove the covers, find the defective fan and replace it.

• Disconnected thermistor

• Defective connector connection

• Defective thermistor

• Thermistor coming off

• Incorrect power supply input at the main power

socket

• Defective fusing lamp

• Defective thermistor

• Defective I/O board

• Defective EGB

• Defective thermistor

• Defective I/O board

• Defective EGB

• Defective fusing unit, PSU, or EGB

1. Replace the fusing unit.

2. Replace the PSU.

• Deformed thermistor

• Thermistor coming off

• Defective fusing lamp

G104 4-12 SM

SERVICE CALL CONDITIONS

[Level]

[D]

[C]

[D]

Symptom Possible Cause/Required Action

Zero cross error 547

1. The zero cross signal is detected three times even though the heater relay is off when turning on the main power.

2. The zero cross signal is not detected for three seconds even though the heater relay is on after turning on the main power or closing the front door.

3. The detection error occurs twice or more in the ten zero cross signal detections. This error is defined when the detected zero cross signal is less than 17 for 200 ms.

Zero cross frequency error 557 The detection error occurs

ten times in a row in ten zero cross signal detections. This error is defined when the detected zero cross signal is more than 28 for 200 ms.

This SC is only logged. In this case, the power frequency is defined as 60 Hz. Engine start-up error 670

The ready signal from the engine board is not detected.

Controller board command error 687 A command from the

controller board is not received.

EGB data error 690 The data transfer in the

EGB is interrupted by some incident (e.g. cover open etc.) during the data transfer.

Item

• Defective fusing lamp relay

• Defective fusing lamp relay circuit

• Unstable power supply

1. Check the power supply source.

2. Replace the PSU.

• Noise (High frequency)

1. Check the power supply source.

• Defective engine board.

1. Replace the engine board.

• Loose connection

• Defective controller board

• Defective EGB

1. Check the connection of the controller board.

2. Replace the controller board.

3. Replace the EGB

• Defective EGB

1. Replace the EGB.

Trouble-

shooting

SM 4-13 G104

SERVICE CALL CONDITIONS

Controller Error

The following table shows the controller error codes. These codes show at the following times if an error occurs:

• Power-on

• After the power-on self diagnostic test

Important: Always try turning the main switch off and on to check if the problem

persists.

[D]

819

[D]

Symptom Possible Cause/Required Action

[00FF] Watch-dog error 818 While the system program

is running, other processes do not operate at all.

[0696e] Kernel stop: Process error

System completely down

[0766d] Kernel stop: VM full error Unexpected system

memory size

[4361] Kernel stop: Cache error Cache error in the CPU

[----] Kernel stop: The others Error in OS

• Defective controller

1. Replace the controller if it occurs frequently.

• Defective RAM DIMM

• Defective SD card in slot 1

• Defective controller

• Software error

1. Check and/or replace the RAM DIMM.

2. Check and/or replace the SD card in slot 1.

3. Replace the controller.

4. See NOTE at the end of the SC table.

• Defective RAM DIMM

• Defective SD card in slot 1

• Defective controller

• Software error

1. Check and/or replace the RAM DIMM.

2. Check and/or replace the SD card in slot 1.

3. Replace the controller.

4. See “NOTE” at the end of the SC table.

• Defective CPU

1. Replace the controller board.

• Defective memory

• Defective flash memory

• Defective CPU

1. Replace the controller board.

Item

G104 4-14 SM

SERVICE CALL CONDITIONS

820

[D]

Item

Symptom Possible Cause/Required Action

[0001-0015] [000A-000D] Self-diagnostic error– CPU: Detailed error code During the boot monitor

program and selfdiagnostic, any exception or cut-in are not supposed to happen. If these happen, it is defined as SC.

• Defective CPU device

• Defective boot monitor program or self-diagnostic

program

1. Replace the controller board.

2. Reinstall the system firmware.

[00FF] Self-diagnostic error– CPU: Detailed error code Cache access error in the

CPU

• Defective CPU

• Defective local bus

1. Turn the main switch off and on.

2. Reinstall the system program.

3. Replace the controller board.

[0601, 0602, 0605, 0606, 0607, 0609] Self-diagnostic error– CPU: Detailed error code

Exceptional command does not operate even though it

• Defective CPU devices

1. Replace the controller board

is executed on purpose. [060A-060E] Self-diagnostic error– CPU: Detailed error code Cut-in command does not

operate when it is executed.

• Defective CPU devices

• Defective ASIC devices

1. Replace the controller board [0610] Self-diagnostic error– CPU: Detailed error code Timer cut-in does not

operate even though it is

• Defective CPU devices

1. Replace the controller board set.

[0612] Self-diagnostic error– CPU: Detailed error code Cut-in in ASIC occurs.

• Defective ASIC

• Defective devices in which ASIC detects cut-in.

1. Replace the controller board. [06FF] Self-diagnostic error– CPU: Detailed error code The pipeline clock

frequency rate is different from the prescribed value.

• Defective CPU devices

• Mode bit data error, which is used for initialising

CPU

1. Replace the controller board [0702] Self-diagnostic error– CPU: Detailed error code The result when the

program is executed in the command cache is different from desirable value.

• Insufficient CPU cache

• Insufficient memory process speed

1. Replace the controller board.

2. Replace the RAM DIMM. [0709, 070A] Self-diagnostic error– CPU: Detailed error code Even you write the data in

the only cache of memory, the data is actually written in another area of memory.

• Defective CPU devices

• Incorrect SPD

• Boot mode setting error

1. Replace the controller board.

2. Replace the RAM DIMM.

Trouble-

shooting

SM 4-15 G104

SERVICE CALL CONDITIONS

821

[D]

822

[B]

823

[B]

Item

Symptom Possible Cause/Required Action

[0801, 0804, 0807, 0808, 0809, 80A] Self-diagnostic error– CPU: Detailed error code

An error occurs when checking the TLB.

• Defective CPU devices

1. Replace the controller board. [4002-4005] Self-diagnostic error– CPU: Detailed error code The calculation error in the

CPU occurs.

• Defective CPU

1. Replace the CPU. [0B00] Self-diagnostic error - ASIC ASIC and CPU timer error

detected during self-

• Defective controller

1. Replace the controller if the error is frequent. diagnostic.

[0D05] Self-diagnostic error– ASIC The CPU checks if the

ASIC timer works properly compared with the CPU timer. If the ASIC timer does not function in the specified range, this SC code is displayed.

• System firmware problem

• Defective RAM-DIMM

• Defective controller

1. Reinstall the controller system firmware.

2. Replace the RAM-DIMM.

3. Replace the controller board.

[3003] Self-diagnostic error– HDD: Time out error When the main switch is

turned on or starting the self-diagnostic, the HDD stays busy for the specified time or more.

• Loose connection

• Defective HDD

• Defective controller

1. Check that the HDD is properly connected to the

controller.

2. Replace the HDD.

3. Replace the controller. [3004] Self-diagnostic error– HDD: Command error When the main switch is

turned on or starting the

• Defective HDD

1. Replace the HDD. self-diagnostic, the

diagnostic error from HDD occurs.

[6101] Self-diagnostic error – NIC: MAC address check sum error The result of the MAC

address check sum does

• Defective controller

1. Replace the controller. not match the check sum

stored in ROM. [6104] Self-diagnostic error – NIC: PHY IC error The PHY IC on the

Same as [6101] controller cannot be properly recognized.

[6105] Self-diagnostic error – NIC: PHY IC loop back error An error occurred during

the loop-back test for the PHY IC on the controller.

Same as [6101]

G104 4-16 SM

SERVICE CALL CONDITIONS

[D]

828

[D]

829

[B]

Item

Symptom Possible Cause/Required Action

[1401] Self-diagnostic error – NVRAM 824 The controller cannot

recognize the standard NVRAM installed or detects that the NVRAM is defective.

• Loose connection

• Defective standard NVRAM

• Defective controller

1. Check the standard NVRAM is firmly inserted into the socket.

2. Replace the NVRAM.

3. Replace the controller.

[0201] Self-diagnostic error – RAM: Verification error 827 Error detected during a

write/verify check for the standard RAM (SRAM DIMM).

• Loose connection

• Defective RAM DIMM

• Defective controller

1. Replace the RAM DIMM.

2. Replace the controller.

[0101] Self-diagnostic error – ROM: Check sum error 1 The boot monitor and OS

program stored in the ROM DIMM is checked. If the check sum of the program is incorrect, this SC code is

• Defective SD card in slot 1

• Defective controller

1. Replace the SD card in slot 1.

2. Replace the controller.

displayed. [0104] Self-diagnostic error – ROM: Check sum error 2 All areas of the ROM DIMM

Same as [0101] are checked. If the check sum of all programs stored in the ROM DIMM is incorrect, this SC code is displayed.

[0302] Self-diagnostic error – RAM: Composition error (Slot 0) The result of checking the

composition data of the RAM in Slot 0 (CN5) on the controller is incorrect.

• Not specified RAM DIMM installed

• Defective RAM DIMM

1. Replace the RAM DIMM.

2. Replace the controller board. [0401] Self-diagnostic error – RAM: Verification error (Slot 1) The data stored in the RAM

Same as SC 829 [0302] in Slot 1 does not match the data when reading.

[0402] Self-diagnostic error – RAM: Composition error (Slot 1) The result of checking the

Same as SC 829 [0302] composition data of the RAM in Slot 1 (CN6) on the controller is incorrect.

Network interface error 850 The network is unusable.

• Defective controller

1. Replace the controller.

Trouble-

shooting

SM 4-17 G104

SERVICE CALL CONDITIONS

[B]

[D]

Symptom Possible Cause/Required Action

IEEE1394 interface error 851 The 1394 interface is

unusable.

Wireless LAN card not detected 853 The wireless LAN card is

not detected before communication is established, though the wireless LAN board is detected.

Wireless LAN card not detected 854 The wireless LAN card is

not detected after communication is established, though the wireless LAN board is detected.

Wireless LAN card error 855 An error is detected in the

wireless LAN card.

Wireless LAN card error 856 An error is detected in the

wireless LAN board.

USB interface error 857 The USB interface cannot

be used due to a driver error.

HDD: Initialization error 860 The controller detects that

the hard disk fails.

HDD: Reboot error 861 The HDD does not become

ready within 30 seconds after the power is supplied to the HDD.

Item

• Defective IEEE1394

• Defective controller.

1. Replace the IEEE1394 interface board.

2. Replace the controller.

• Loose connection

1. Check the connection.

• Loose connection

1. Check the connection.

• Loose connection

• Defective wireless LAN card

1. Check the connection.

2. Replace the wireless LAN card.

• Defective wireless LAN board

• Loose connection

1. Check the connection.

2. Replace the wireless LAN board.

• Defective USB driver

• Loose connection

1. Check the connection.

2. Replace the controller.

• HDD not initialized

• Defective HDD

1. Reformat the HDD. (SP5832)

2. Replace the HDD.

• Loose connection

• Defective cables

• Defective HDD

• Defective controller

1. Check the connection between the HDD and controller.

2. Check and replace the cables.

3. Replace the HDD.

4. Replace the controller.

G104 4-18 SM

Ricoh CL4000DN Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

INSTALLATION

INSTALLATION REQUIREMENTS

Installation

MACHINE INSTALLATION

OPTIONAL UNIT INSTALLATION

METER CHARGE

Tray heater

PREVENTIVE MAINTENANCE

USER REPLACEABLE ITEMS

SERVICE MAINTENANCE

REPLACEMENT AND ADJUSTMENT

SPECIAL TOOLS AND LUBRICANTS

3. REPLACEMENT AND ADJUSTMENT

ELECTRICAL COMPONENTS

LASER OPTICS

PAPER FEED

DEVELOPMENT

DRIVE

DUPLEX

FUSING

ADJUSTMENTS

TROUBLESHOOTING

PROCESS CONTROL RESULT

SERVICE CALL CONDITIONS