Ricoh CL5000 Service Manual

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RICOH GROUP COMPANIES

G071

SERVICE MANUAL

001479MIU

SERVICE MANUAL

G071

RICOH GROUP COMPANIES

G071

SERVICE MANUAL

001479MIU

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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

G071 C7010 LP 036c Aficio CL5000 CLP1036

GESTETNER LANIER RICOH SAVIN

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

* 12/2002 Original Printing

G071

TABLE OF CONTENTS

INSTALLATION

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

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

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

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

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

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

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

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

1.4 REMARKS FOR INSTALLATION..............................................................1-5

PREVENTIVE MAINTENANCE

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

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

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

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

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

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

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

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

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

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

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

REPLACEMENT AND ADJUSTMENT

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

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

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

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

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

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

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

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

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

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

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

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

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

SM i G071

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Laser Beam Pitch Adjustment.............................................................3-15

3.5.3 POLYGONAL MIRROR MOTOR AND LSD ................................... 3-16

3.6 DEVELOPMENT UNIT ............................................................................3-17

3.7 PHOTOCONDUCTOR UNIT (PCU) ........................................................ 3-19

3.7.1 MAIN UNIT ..................................................................................... 3-19

3.7.2 WASTE TONER BOTTLES ............................................................3-20

3.7.3 CHARGE CORONA WIRE .............................................................3-21

3.7.4 CHARGE CORONA WIRE CLEANER MOTOR .............................3-22

3.7.5 OPC BELT CLEANING UNIT ......................................................... 3-22

3.7.6 IMAGE TRANSFER BELT CLEANING UNIT ................................. 3-22

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

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

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

Cleaning the Paper Dust Mylar ...........................................................3-24

3.9 FUSING/PAPER EXIT.............................................................................3-25

3.9.1 FUSING UNIT................................................................................. 3-25

3.9.2 OIL SUPPLY UNIT .........................................................................3-25

3.9.3 LAMPS ...........................................................................................3-26

3.9.4 FUSING INNER UNIT.....................................................................3-27

3.9.5 PRESSURE ROLLER THERMOFUSE...........................................3-27

3.9.6 FUSING BELT UNIT AND PRESSURE ROLLER UNIT .................3-27

3.9.7 PRESSURE ROLLER THERMISTOR ............................................3-28

3.9.8 HOT ROLLER STRIPPERS ...........................................................3-28

3.9.9 PRESSURE ROLLER.....................................................................3-29

3.9.10 OIL ABSORBERS.........................................................................3-30

3.9.11 PAPER EXIT UNIT AND PAPER EXIT/

OVERFLOW SENSOR .................................................................3-31

3.10 PAPER FEED AND TRANSPORT ........................................................ 3-32

3.10.1 FEED ROLLER AND FRICTION PAD ..........................................3-32

3.10.2 REGISTRATION SENSOR...........................................................3-33

3.10.3 PAPER FEED SENSOR...............................................................3-35

3.10.4 PAPER NEAR-END SENSOR......................................................3-35

3.10.5 PAPER END SENSOR.................................................................3-35

3.11 BYPASS TRAY......................................................................................3-36

G071 ii SM

3.11.1 PICKUP/FEED ROLLER ..............................................................3-36

3.11.2 PAPER FEED CLUTCH ...............................................................3-37

3.11.3 REVERSE ROLLER .....................................................................3-37

Rev. 04/2003

TROUBLESHOOTING

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

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

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

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

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

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

4.4 CHECK POINTS FOR IMAGE PROBLEMS AT REGULAR

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

SERVICE TABLES

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SP3-XXX: (Process) ...........................................................................5-29

SP5-XXX: (Mode) ...............................................................................5-32

SP7-XXX: (Data Log)..........................................................................5-39

Input Check Table............................................................................... 5-47

Table 1: Tray 1 Paper Size ................................................................. 5-50

Table 2: 1st/2nd Bank Paper Size ......................................................5-50

Table 3: 1st/2nd Bank Near End.........................................................5-50

Output Check Table............................................................................5-51

5.3 CONTROLLER SELF-DIAGNOSTICS ....................................................5-53

5.3.1 OVERVIEW .................................................................................... 5-53

5.3.2 DETAILED SELF-DIAGNOSTICS ..................................................5-54

5.4 USER PROGRAM MODE .......................................................................5-55

5.5 UPGRADING SOFTWARE......................................................................5-56

5.5.1 OVERVIEW .................................................................................... 5-56

SM iii G071

5.5.2 UPGRADING..................................................................................5-57

Procedure ........................................................................................... 5-57

Error Recovery....................................................................................5-58

5.6 DIP SWITCHES.......................................................................................5-59

Controller Board.................................................................................. 5-59

BCU Board..........................................................................................5-59

5.7 PRINTING A TEST PATTERN ................................................................5-60

Rev. 04/2003

DETAILED SECTION DESCRIPTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Toner Collection Augers .....................................................................6-17

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

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

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

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

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

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

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

G071 iv SM

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Toner End Detection........................................................................... 6-32

Toner End Recovery ...........................................................................6-32

6.6.5 DEVELOPMENT UNIT CONTACT MECHANISM ..........................6-33

Mechanism .........................................................................................6-33

Reverse Rotation ................................................................................6-33

6.6.6 POWER SOURCE..........................................................................6-34

Development, Toner Supply, and Doctor Rollers................................6-34

Doctor Roller.......................................................................................6-34

6.7 PAPER FEED..........................................................................................6-35

6.7.1 OVERVIEW .................................................................................... 6-35

Transport Speed .................................................................................6-36

Friction Pad.........................................................................................6-36

6.7.2 STANDARD TRAY DRIVE .............................................................6-36

Feed and Vertical Transport Rollers ...................................................6-36

Registration Roller ..............................................................................6-36

6.7.3 STANDARD TRAY – BOTTOM PLATE LIFT .................................6-37

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

SM v G071

Paper Near End Detection ..................................................................6-37

Paper End Detection...........................................................................6-37

6.7.4 STANDARD TRAY - PAPER SIZE DETECTION ...........................6-38

Mechanism .........................................................................................6-38

Switch Pattern.....................................................................................6-38

6.7.5 BYPASS TRAY............................................................................... 6-39

Paper Feed Mechanism......................................................................6-39

Bypass Tray Drive Power Path ...........................................................6-39

Pick-up Solenoid................................................................................. 6-39

Paper End Sensor ..............................................................................6-39

6.8 PAPER TRANSFER AND SEPARATION ...............................................6-40

6.8.1 OVERVIEW .................................................................................... 6-40

Jammed Paper Release .....................................................................6-40

Image Transfer and Paper Separation................................................6-40

6.8.2 MECHANISM..................................................................................6-41

Timing .................................................................................................6-41

Mechanism .........................................................................................6-41

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

G071 vi SM

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SM vii G071

6.12.7 IP OVER IEEE 1394 .....................................................................6-70

6.13 IEEE 802.11B (WIRELESS LAN) .......................................................... 6-71

6.13.1 SPECIFICATIONS........................................................................6-71

6.13.2 BLOCK DIAGRAM........................................................................6-71

6.13.3 TRANSMISSION MODE...............................................................6-72

Ad hoc Mode.......................................................................................6-72

Infrastructure Mode............................................................................. 6-72

6.13.4 SECURITY FEATURES ...............................................................6-73

Using the SSID in Ad hoc mode .........................................................6-73

6.13.5 TROUBLESHOOTING NOTES ....................................................6-74

Communication Status........................................................................6-74

Channel Settings ................................................................................6-74

Troubleshooting Steps ........................................................................6-75

6.14 USB .......................................................................................................6-76

6.14.1 SPECIFICATIONS........................................................................6-76

6.14.2 USB 1.1/2.0 .................................................................................. 6-76

6.14.3 USB CONNECTORS....................................................................6-77

6.14.4 PIN ASSIGNMENT .......................................................................6-77

6.14.5 REMARKS....................................................................................6-78

Related SP Mode................................................................................ 6-78

SPECIFICATIONS

SPECIFICATIONS............................................................................. 7-1

1. GENERAL SPECIFICATIONS.....................................................................7-1

1.1 MAIN UNIT ..........................................................................................7-1

2. SUPPORTED PAPER SIZES...................................................................... 7-4

2.1 MAIN TRAY, BYPASS TRAY, AND DUPLEX UNIT ............................7-4

2.2 FINISHER, MAIL BOX, AND PAPER TRAY UNIT...............................7-5

3. SOFTWARE ACCESSORIES .....................................................................7-6

3.1 PRINTER DRIVERS............................................................................ 7-6

3.2 UTILITY SOFTWARE ..........................................................................7-6

4. MACHINE CONFIGURATION..................................................................... 7-7

4.1 SYSTEM COMPONENTS ...................................................................7-7

Exterior .................................................................................................7-7

Interior...................................................................................................7-8

Maintenance Kits ..................................................................................7-8

4.2 OPTIONAL EQUIPMENT ..............................................................7-9

Finisher .................................................................................................7-9

Mail Box ..............................................................................................7-10

Duplex Unit ......................................................................................... 7-10

Interchange Unit .................................................................................7-10

G071 viii SM

PAPER TRAY UNIT (G313)

SEE SECTION G313 FOR DETAILED TABLE OF CONTENTS

INTERCHANGE UNIT (G305)

SEE SECTION G305 FOR DETAILED TABLE OF CONTENTS

DUPLEX UNIT (G303)

SEE SECTION G303 FOR DETAILED TABLE OF CONTENTS

500-SHEET FINISHER (G314)

SEE SECTION G314 FOR DETAILED TABLE OF CONTENTS

FOUR-BIN MAILBOX (G312)

SEE SECTION G312 FOR DETAILED TABLE OF CONTENTS

SM ix G071

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

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

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

HEALTH SAFETY CONDITIONS

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

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

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

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

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

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

PCL

Ethernet

PowerPC

is a registered trademark of Adobe Systems, Incorporated.

is a registered trademark of Hewlett-Packard Company.

is a registered trademark of Xerox Corporation.

is a registered trademark of International Business Machines

Corporation.

Other product names used herein are for identification purposes only and may be trademarks of their respective companies. We disclaim any and all rights involved with those marks.

Conventions in this Manual

This manual uses several symbols.

Symbol What it means







 

Refer to section number See Core Tech Manual for details

Screw Connector Clip ring E-ring

Lengthwise, SEF (Short Edge Feed)

Sideways, LEF (Long Edge Feed)

INSTALLATION

TAB

POSITION 1

PREVENTIVE MAINTENANCE

TAB

POSITION 2

REPLACEMENT AND ADJUSTMENT

TAB

POSITION 3

TROUBLESHOOTING

500-SHEET FINISHER G314

FOUR-BIN MAILBOX G312

TAB

POSITION 4

SERVICE TABLES

INTERCHANGE UNIT G305

DUPLEX UNIT G303

DETAILED DESCRIPTIONS

SPECIFICATIONS

PAPER TRAY UNIT G313

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:

2. Humidity Range: 20% to 80% RH

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

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

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

1) Direct cool air from an air conditioner

2) Direct heat from a heater

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

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

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

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

10°C to 32°C (50°F to 89°F)

sunlight.)

Installation

1.1.2 MACHINE LEVEL

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

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

SM 1-1 G071

INSTALLATION REQUIREMENTS

1.1.3 SPACE REQUIREMENTS

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

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

G070I001.WMF

1.1.4 POWER REQUIREMENTS

CAUTION

1. Insert the plug firmly in the outlet.

2. Avoid using an outlet extension plug or cord.

3. Ground the machine.

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

2. Permissible voltage fluctuation: ±10%

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

G071 1-2 SM

MACHINE INSTALLATION

1.2 MACHINE INSTALLATION

Refer to the Operating Instructions for details.

If the customer has a service contract, change the settings of the following SP modes depending on the contract type.

Item SP No. Function Default

Meter charge

Counting method

A3/11" x 17" double counting

PM warning display 1

PM warning display 2

SP5-930-1

(Meter_

Charge)

SP5-045-1

(Counter

Method)

SP5-104-1

(Double

Count)

SP5-931-1

(PM_Display

– Charger)

SP5-931-2

(PM_Display

– PCU)

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

If the technician is doing all the PM, set meter charge to ‘On’.

Meter charge mode enabled:

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

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

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

• The selected counter starts from a negative number.

Meter charge mode disabled:

• The Counter menu is not displayed.

• The total counter starts from 0.

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

Important:

This SP can only be done before the negative counters are reset with SP7825-001 (Counter Reset)

Specifies whether the counter is doubled for A3/11" x 17" paper.

Specifies whether the PM warning for the charge corona unit is displayed when the replacement time arrives. 1: Displayed 0: Not displayed

Specifies whether the PM warning for the PCU is displayed. 1: Displayed 0: Not displayed

Off

Developments

No: Single counting

Installation

SM 1-3 G071

OPTIONS

Item SP No. Function Default

PM warning display 3

Fax No. setting

Counter reset

SP5-931-3

(PM_Display

- Bank_ Feed)

SP5-812-2

(FAX TEL

No.)

SP7-825-1

(Counter

Reset)

Specifies whether the PM warning for the feed rollers in the optional paper feed unit is displayed. 1: Displayed 0: Not displayed

Programs the service station fax number.

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

Resets the counters to 0.

Important: This must be done at installation after all the above settings have been finished. The negative counters used in meter charge mode will be reset to zero.

NOTE:

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

2) The meter-charge counter cannot be reset.

1.3 OPTIONS

Refer to the Option Setup Guide for details.

No. Optional Unit Alternative Requirements

500-sheet finisher

2 4-bin mailbox No. 1 3 Interchange unit

Duplex unit

5 Paper tray unit 6 Printer hard disk

DIMM memory (64, 128, or 256

MB modules available) IEEE1394 interface unit

9 User account enhancement unit

10 IEEE802.11b (Wireless LAN)

No. 2

• No. 3

• Hard disk or memory (extra 64

MB or more) for sort mode

• No. 3

• Extra 64 MB (or more) optional

SDRAM module

NOTE:

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

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

G071 1-4 SM

REMARKS FOR INSTALLATION

1.4 REMARKS FOR INSTALLATION

In case you install this printer or you instruct customers to install, please note the following remark for development unit installation and replacement:

After installation or replacement of the development unit, print out the development unit check sheet by user mode (User Mode – Maintenance – Development Unit Check).

NOTE: For details please refer to the Quick Installation Guide.

Installation

SM 1-5 G071

PREVENTIVE MAINTENANCE

OVERVIEW

2. PREVENTIVE MAINTENANCE

2.1 OVERVIEW

Users Do the User PM Procedures

The user does PM for the items in section 2.2. The technician does PM for the items in section 2.3. Meter-charge mode must be set to “off” (SP5-930 [Meter_Charge], ! 5.2).

All PM Done by Technicians

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

Counters

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

2.2 USER MAINTENANCE

Abbreviations:

lean, Inspect, Lubricate, Replace, KiloPrints, KiloDevelopments, WheneverNecessary

Preventive

Maintenance

Main Unit

Item

T/B waste toner bottle

O/B waste toner bottle

Oil supply unit

Fusing unit with paper feed roller

* : Replacement period calculated for a 50% color ratio (the actual waste toner bottle condition

is detected with the sensors)

** : Standard replacement period (the actual oil amount is detected with the sensor)

KD KP

50 120 30 120

R**

Detection Reset

Waste toner sensors

Oil end sensor/Oil supply unit counter

Exit sheet counter

Auto-reset (sensor)

Manual reset

Machine

stops

Yes

SM 2-1 G071

SERVICE MAINTENANCE

Item

Black development unit

Color development unit

PCU (includes charge corona unit & dust filters)

*Displayed with SP7-906 (PMCounter-PREV)

60 120 240

Item WN Detection Reset

Registration roller

Dust shield glass (LD unit)

Bottom plate pad

C None None No

Optional Paper Tray Unit

Item 150KP Detection Reset

Feed, pick-up, and separation rollers

R None None No

Detection Reset

Dev. Bk counter*

Dev. color counter*

PCU counter*

Auto-reset (memory chip)

Auto-reset (new PCU sensor) No

Machine

stops

" damp cloth and # dry cloth

Built-in cleaning brush

" damp cloth and # dry cloth

Machine

stops

" damp cloth and # dry cloth

Machine

stops

Yes

Remarks

2.3 SERVICE MAINTENANCE

Abbreviations:

lean, Inspect, Lubricate, Replace, KiloPrints, KiloDevelopments, WheneverNecessary

Main Unit

Bypass Tray

Item WN Remarks

Feed Roller

Pick-up Roller

Separation Roller

" damp cloth and # dry cloth

G071 2-2 SM

SERVICE MAINTENANCE

Optional Units

Paper Tray Unit

Item WN Remarks

Relay Roller

Bottom Plate Pad

" damp cloth and # dry cloth

Finisher

Item WN Remarks

Rollers

" damp cloth and # dry cloth

Sensors C Blower blush or dry cloth Anti-Static Brush C Blower blush or dry cloth Bushings

Stapler

Launa oil when abnormal noise occurs

Every 200K staples (estimated replacement period)

Mail Box

Item WN Remarks

Rollers

" damp cloth and # dry cloth

Tray Paper Sensors C Blower blush or dry cloth

Duplex Unit

Item WN Remarks

Rollers

" damp cloth and # dry cloth

Feed/exit sensors C Blower blush or dry cloth

Interchange Unit

Preventive

Maintenance

Item WN Remarks

Paper Exit Sensor C Blower blush or dry cloth

SM 2-3 G071

REPLACEMENT AND ADJUSTMENT

SPECIAL TOOLS

3. REPLACEMENT AND ADJUSTMENT

CAUTION

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

NOTE: This manual uses the following symbols.

! : See or Refer to  : Screws  : Connector  : Clip ring  : E-ring

3.1 SPECIAL TOOLS

Part Number Part Name

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

Adjustment

Replacement

SM 3-1 G071

EXTERIOR COVERS

3.2 EXTERIOR COVERS

3.2.1 REAR COVER

1. Duct cover [A] (4 hooks)

2. Ozone filter [B]

3. Printer controller [C] ( x 2)

[A]

4. Rear cover [D] ( x 2)

[C]

G070R702.WMF

G070R703.WMF

[B]

Adjustment

Replacement

[D]

G071 3-2 SM

EXTERIOR COVERS

3.2.2 LOWER LEFT COVER

1. Lower left cover [A] ( x 3)

[A]

3.2.3 UPPER COVER, OPERATION PANEL

1. Open the right cover [A].

2. Upper right cover [B]

3. Paper exit cover [C] ( x 1)

4. Open the front cover [D].

[F]

[E]

G070R704.WMF

Adjustment

Replacement

[C]

[B]

5. Upper cover [E] ( x 4)

6. Operation panel [F] (4 hooks,

 x 2,  x 1)

NOTE: Insert a screwdriver between

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

[D]

G070R701.WMF

[A]

SM 3-3 G071

ELECTRICAL COMPONENTS

3.3 ELECTRICAL COMPONENTS

3.3.1 PRINTER CONTROLLER

! 3.2.1

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

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

3.3.2 CONTROLLER BOX

1. Rear cover (! 3.2.1)

2. Cooling fan [A] ( x 2)

NOTE: When reassembling,

install the fan with the label facing the inside.

3. Controller box [B] ( x 11)

NOTE:

1) Do not remove the BCU board base with the controller box.

2) When putting back the controller box, take care not to pinch the cable from the I/O board.

3.3.3 BCU BOARD

[B]

[A]

G070R705.WMF

Adjustment

Replacement

1. Controller box (! 3.3.2) [A]

2. All  (12)

3. 1 flat cable

4. BCU board base [A] ( x 5)

5. BCU board [B] ( x 5)

NOTE: Remove the NVRAM from the old

BCU board, and install it on the new one.

[B]

G071 3-4 SM

G070R706.WMF

ELECTRICAL COMPONENTS

3.3.4 I/O BOARD

1. Controller box (! 3.3.2)

2. All  (33)

3. I/O board [A] ( x 4)

3.3.5 PSU

1. Controller box (! 3.3.2)

2. Flywheel ( x 3) (! 3.4.1)

[A]

G070R707.WMF

[B]

Adjustment

Replacement

[C]

3. Duct [A] ( x 1,  x 1)

NOTE: When removing and

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

4. PSU protector [B] ( x 1)

5. Unlink the main switch [C].

6. PSU base ( x 8,  x 4)

NOTE:

1) Remove the PSU [D] with the PSU base.

2) When reassembling, check that the main switch is linked to the PSU.

[A]

[D]

G070R717.WMF

SM 3-5 G071

ELECTRICAL COMPONENTS

3.3.6 HIGH VOLTAGE SUPPLY BOARD

1. Photoconductor unit (! 3.7)

2. Right inner cover (! 3.10.2)

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

4.  [B] x 1

5. Bushing [C] x 1

[B]

[A]

G070R719.WMF

[C]

Adjustment

Replacement

6. High voltage supply board [D] ( x 17,  x 6)

[D]

G070R720.WMF

G071 3-6 SM

DRIVE UNITS

3.4 DRIVE UNITS

3.4.1 DEVELOPMENT CLUTCHES

1. Controller box (! 3.3.2)

K/Y Development Units

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

C/M Development Units

1. Flywheel [A] ( x 3)

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

[A]

[B]

G070R708.WMF

Adjustment

Replacement

[C]

[A]

SM 3-7 G071

G070R709.WMF

[B]

DRIVE UNITS

3.4.2 DEVELOPMENT MOTOR

1. Controller box (! 3.3.2)

2. Development motor [A] ( x 1,  x 3)

[A]

3.4.3 MAIN MOTOR

1. Controller box (! 3.3.2)

2. Flywheel [A] ( x 3)

3. Main motor [B] ( x 1,  x 3)

G070R710.WMF

Adjustment

Replacement

[B]

[A]

G070R711.WMF

G071 3-8 SM

DRIVE UNITS

3.4.4 PCU GEAR BOX AND OPC BELT CLEANING CLUTCH

1. I/O board (!3.3.4 )

2. Main motor (! 3.4.3)

3. C/M development unit clutch (! 3.4.1)

4. Bracket [A] ( x 2)

5. Tension spring [B]

6.  x 1 [C]

7. Gear box and clutch assembly [D] ( x 5)

[A]

3.4.5 FUSING UNIT MOTOR

[C]

[B]

G070R712.WMF

[D]

Adjustment

Replacement

1. Rear cover (! 3.2.1)

2. Fusing unit motor ( x 1,  x 3) [A]

G070R713.WMF

[A]

SM 3-9 G071

DRIVE UNITS

3.4.6 PAPER FEED MOTOR

1. Rear cover (! 3.2.1)

2. Pull out the handle [A].

3. Paper feed motor [B] ( x 1,  x 3)

[A]

3.4.7 PAPER FEED CLUTCH

1. Rear cover (! 3.2.1)

2. Pull out the handle [A].

3. Connector bracket [B] ( x 6,  x 2)

[A]

4. Paper feed clutch [C] ( x 1,  x 2)

3.4.8 REGISTRATION CLUTCH

[B]

G070R714.WMF

G070R716.WMF

[B]

[C]

Adjustment

Replacement

1. Rear cover (! 3.2.1)

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

[B]

[A]

G070R715.WMF

G071 3-10 SM

LASER OPTICS SECTION

3.5 LASER OPTICS SECTION

WARNING

Turn off the main switch and unplug the machine before beginning any of the procedures in this section. Laser beams can cause serious eye injury.

3.5.1 CAUTION DECAL LOCATION

LD_CAUTION.TIF

G070R208.WMF

DANGER

Turn off the main switch and disconnect the power plug from the power outlet before beginning any disassembly or adjustment of the laser unit. This printer uses a class-1 laser beam with a wavelength of 650 nm and an output of 7 mW. The laser can cause serious eye injury.

Adjustment

Replacement

SM 3-11 G071

LASER OPTICS SECTION

3.5.2 LASER OPTICS HOUSING UNIT

1. Open the left cover [A].

2. ID chip connectors [B] ( x 4)

3. Development units [C] x 4

4. Rear cover (

! 3.2.1)

5. Left cover [D]

6. Lower left cover [E] ( x 3)

[B]

[E]

[C]

[A]

G070R301.WMF

Adjustment

Replacement

7. Controller box (

! 3.3.2)

8. Flat cable [F] NOTE: When reassembling,

connect the flat cable with the blue side up.

9.  x 4 [G]

10. Harness clamps [H]

[G]

[D]

G070R201.WMF

[F]

[H]

G070R202.WMF

3-12 SM

G071

LASER OPTICS SECTION

11. Open the front cover.

12. Remove the dust shield glass cleaner lever [A] from the dust shield glass cleaner. NOTE: The dust shield glass

cleaner lever is the blue lever at the right side of the main switch.

13. LD cover [B] ( x 2)

14. Laser optics housing unit [C] ( x 4)

[A]

[B]

G070R209.WMF

Adjustment

Replacement

[C]

G070R203.WMF

SM 3-13 G071

LASER OPTICS SECTION

Adjusting for Image Skew

1. Positioning pin [A] ( x 1)

2. Loosen  (x 4) [B].

3. Adjust the position of the laser optics housing unit [! NOTE].

4. Fasten  (x 4) [B]. NOTE: After changing the position

of the laser optics housing unit, do not reinstall the positioning pin. Keep the pin in a safe place.

NOTE: When the image skews as

shown, move the unit 1 mm in the direction of the black arrow as shown in the upper diagram.

1mm

[B]

[A]

G070R207.WMF

[! NOTE]

Adjustment

Replacement

Paper feed

(A3 SEF)

G070R001.WMF

G071 3-14 SM

LASER OPTICS SECTION

Laser Beam Pitch Adjustment

1. Select test pattern 15 with SP5-955-1 (Test Pattern – Pattern).

2. Check if vertical black stripes can be seen.

a) If stripes cannot be seen

(Figure 2), laser beam pitch adjustment is not required.

b) If stripes can be seen

(Figure 1), laser beam pitch adjustment is required. Go on to the next step.

3. To adjust the laser beam pitch, tighten or loosen the screw [A] on the LD unit holder.

Feed direction

Figure 1 Figure 2

G070R952.WMF

[A]

Adjustment

Replacement

4. Set SP 2-917 (Test Pattern) to ‘On’. Then send a one-page job to the printer, or print an SMC list (SP 5-990-6, SP Print mode – Non default).

5. Repeat steps 2 through 4 until the black stripes disappear (Figure 2).

G070R820.WMF

SM 3-15 G071

LASER OPTICS SECTION

3.5.3 POLYGONAL MIRROR MOTOR AND LSD

WARNING

Do not touch any edges of the polygon mirror, spring, or bracket. These edges can cause serious injury.

1. Development units, LD cover (! 3.5.2)

2. Cover [A] ( x 1) NOTE: Before removing the cover, clean

the cover to prevent toner from entering into the unit.

3. Polygonal mirror motor [B] ( x 1,  x 4) NOTE: Do not touch the surface.

of the polygonal motor.

4. Synch. detection board (LSD) [C] ( x 1,  x 1)

[C]

[B]

[A]

G070R204.WMF

Adjustment

Replacement

G070R205.WMF

G071 3-16 SM

DEVELOPMENT UNIT

3.6 DEVELOPMENT UNIT

CAUTION

Do not touch the development unit sleeves or ID chip terminals.

1. Open the left cover [A].

2. ID chip connector [B]

3. Lift up the development unit [C] slightly, and pull it out of the machine.

NOTE: Remove the units in the

order K, Y, C, M. For example, before removing the M unit, remove the K, Y, and C units first.

[B]

[C]

[A]

G070R301.WMF

Adjustment

Replacement

4. Peel off the toner cartridge seal [D].

5. Reinstall the toner cartridge in the development unit.

6. Keep the development unit level and shake the development unit about 10 times from side to side.

NOTE:

1) Do not touch the development roller or the development roller gear.

2) Use caution not to drop the cartridge or to damage it.

3) If the cartridge has not been shaken well, the machine takes a longer time to initialize the development unit, or an error message or SC350 is displayed. When either of them is displayed, turn the main switch off and on.

[D]

G070R901.WMF

G070R902.WMF

SM 3-17 G071

DEVELOPMENT UNIT

7. Install the development unit in the machine.

8. After installing the development unit, print out the "development unit check" sheet to confirm the correct installation of the development unit (Menu — Maintenance — Devp.UnitCheck). NOTE: A white line or band may

appear on one end of the paper if a development is incorrectly installed. To correct this, pull out the development unit partially (about 30 mm) [E] and slowly reinstall it.

[E]

G070R457.WMF

Adjustment

Replacement

G071 3-18 SM

PHOTOCONDUCTOR UNIT (PCU)

3.7 PHOTOCONDUCTOR UNIT (PCU)

3.7.1 MAIN UNIT

NOTE:

1) Before replacing any of the parts or consumables in this section, cover the floor with cloth or some sheets of paper.

2) Never tilt the unit. The toner may come out of the unit.

3) When handling the unit, grasp the brown (front) and green (top) grips. Never touch the OPC (left) or transfer (right) belts.

4) After removing the photoconductor unit, cover it with a light-proof sheet. Keep it in a dark place.

[C]

Adjustment

Replacement

1. Open the front cover [A].

2. Open the right cover [B].

3.  x 4

4. Pull the OPC unit [C] out of the machine.

5. Grasp the brown and green grips.

6. Lift the unit and remove it.

[B]

[A]

G070R308.WMF

SM 3-19 G071

PHOTOCONDUCTOR UNIT (PCU)

3.7.2 WASTE TONER BOTTLES

1. O/B waste toner bottle [A]

2. T/B waste toner bottle [B]

[A]

[B]

G070R302.WMF

G070R303.WMF

Adjustment

Replacement

G071 3-20 SM

PHOTOCONDUCTOR UNIT (PCU)

3.7.3 CHARGE CORONA WIRE

1. Modular cable [A]

2. Loosen  (x 1) [B]

3. Charge corona unit [C]

4. Front bracket ( x 1) [D]

5. Grid [E]

6. Rear bracket [F]

[B]

[D]

[A]

[E]

[C]

G070R304.WMF

Adjustment

Replacement

[F]

[H]

G070R305.WMF

7. Front wire cover [G]

8. Rear wire cover [H]

9. Wire cleaner [I]

[G]

[J]

10. Unhook the corona wire [J].

G070R259.WMF

SM 3-21 G071

[I]

PHOTOCONDUCTOR UNIT (PCU)

3.7.4 CHARGE CORONA WIRE CLEANER MOTOR

1. Charge corona unit (! 3.7.3)

2. Front motor cover [A] ( x 3)

3. Motor [B]

[A]

3.7.5 OPC BELT CLEANING UNIT

1. Photoconductor unit (! 3.7.1)

2. Charge corona unit (! 3.7.3)

3. Drive gear [A] ( x 1)

4. Rear brace [B] ( x 1)

5. Front brace [C] ( x 1)

6. OPC belt cleaning unit [D]

( x 2) NOTE: Hold up the

photoconductor unit while removing the OPC belt cleaning unit.

[A]

[B]

G070R306.WMF

[C]

G070R315.WMF

Adjustment

Replacement

3.7.6 IMAGE TRANSFER BELT CLEANING UNIT

1. Photoconductor unit (! 3.7.1)

2. Bracket [A] ( x 2)

3. Image transfer belt cleaning unit [B]

G071 3-22 SM

[B]

G070R309.WMF

[A]

PAPER TRANSFER UNIT

Rev. 03/2003

3.8 PAPER TRANSFER UNIT

3.8.1 VERTICAL TRANSPORT UNIT

1. Open the right lower cover [A].

2. Right cover [B] ( x 1)

[B]

3.8.2 TRANSFER ROLLER

⇒

1. Brace [A] ( x 1)

2. Guide [B] NOTE: To remove the screws,

turn the roller unit on its pivot.

3. Transfer roller [C] ( x 2, Bushing x 2, Bearing x 2)

[A]

[C]

G070R451.WMF

[B]

Adjustment

Replacement

[A]

SM 3-23 G071

G070R453.WMF

PAPER TRANSFER UNIT

Cleaning the Paper Dust Mylar

–Quick Method–

1. Cover [A]

2. Sweep away paper dust with a blower brush [B].

–When the paper dust has to be removed completely–

[D]

1. Bracket [C] ( x 2)

[E]

[C]

[B]

[A]

G070R562.WMF

Adjustment

Replacement

2. Plate spring [D]

3. Metal roller [E]

[G]

4. Bearing [F][G]

5. Spring [H][I]

6. Clean the mylar [J] with a dry cloth.

[I]

[F]

[H]

[J]

G070R561.WMF

G071 3-24 SM

FUSING/PAPER EXIT

3.9 FUSING/PAPER EXIT

CAUTION

Turn off the main switch and wait until the fusing unit cools down before beginning any of the procedures in this section. The fusing unit can cause serious burns.

3.9.1 FUSING UNIT

[C]

1. Loosen the knob screw [A].

2. Pull the unit out of the machine.

3. Unhook the bottom stopper [B].

4. Grasp the rear end (marked with a green label) [C].

5. Release the unit [D] from the base plate [E].

[A]

[D]

Adjustment

Replacement

3.9.2 OIL SUPPLY UNIT

NOTE: When removing either of the

lamps (! 3.9.3), remove the knob screw (! 3.9.1) before removing the oil supply unit.

1. Fusing unit (! 3.9.1)

2. Put the fusing unit on a level place.

3. Oil supply unit [A]

NOTE:

1) Do not touch the oiling felt.

2) When reassembling, push the top of the oil supply unit so that the front and rear hinges are correctly set.

[B]

[A]

[E]

G070R501.WMF

G070R502.WMF

SM 3-25 G071

FUSING/PAPER EXIT

3.9.3 LAMPS

1. Oil supply unit (! 0)

2. Gear bracket [A] ( x 2)

3. Upper cover [B] ( x 2, shoulder

screw x 1)

4. Terminals [C], [D] ( x 5)

NOTE:

[C]: Pressure roller lamp

terminals

[D]: Heating roller lamp

terminals

[D]

[B]

[C]

G070R503.WMF

[A]

[D]

Adjustment

Replacement

5. Pull out the lamp (350 W) [E].

6. Pull out the lamp (770 W) [F].

NOTE: “350 W” and “770 W” are etched

on the respective terminals.

[H]

[F]

350W

G070R504.WMF

[E]

770W

G070R510.WMF

G071 3-26 SM

FUSING/PAPER EXIT

3.9.4 FUSING INNER UNIT

1. Lamps (! 3.9.3)

2. Drive gear [A]

3. Knob screw [B] ( x 1)

4. Heating roller lamp harness terminal

[C] ( x 1)

5. Fusing inner unit [D] ( x 2,  x 3)

[B]

3.9.5 PRESSURE ROLLER THERMOFUSE

1. Fusing inner unit (! 3.9.4)

2. Pressure roller thermofuse [A] ( x 2)

[D]

[A]

G070R506.WMF

[C]

[A]

Adjustment

Replacement

G070R508.WMF

3.9.6 FUSING BELT UNIT AND PRESSURE ROLLER UNIT

1. Fusing inner unit (! 3.9.4)

2. Springs [A] [B]

3. Separate the fusing belt unit [C] and pressure roller unit [D].

[A]

[C]

[D]

G070R507.WMF

[B]

SM 3-27 G071

FUSING/PAPER EXIT

3.9.7 PRESSURE ROLLER THERMISTOR

1. Pressure roller unit (! 3.9.6)

2. Pressure roller lower stay [A] ( x 2)

3. Pressure roller thermistor holder [B] ( x 1)

4. Pressure roller thermistor [C]

[C]

[B]

3.9.8 HOT ROLLER STRIPPERS

1. Oil supply unit (! 3.9.2)

2. Fusing lamps (! 3.9.3)

3. Fusing inner unit (! 3.9.4)

4. Gear [A] NOTE: Remove the gear before

removing the stripper pawl assembly; otherwise, the gear may be damaged.

5. Hot roller stripper pawl assembly [B] (Spring x 1,  x 2)

[F]

[D]

[E]

G070R509.WMF

[C] [B]

[A]

Adjustment

Replacement

6. Hot roller stripper pawl [C]

G070R552.WMF

Reassembling

1. Put the spring [D] on the pawl.

2. Put the left end of the pawl in the square opening [E].

3. Put the front and rear ends of the pawl in the holder [F].

4. Confirm that the pawl moves correctly.

G071 3-28 SM

FUSING/PAPER EXIT

3.9.9 PRESSURE ROLLER

[B]

[C]

[D]

1. Pressure roller unit (! 3.9.6)

2. Gear [A]

[E]

G070R900.WMF

[A]

Adjustment

Replacement

3. Hot roller stripper assembly [B] ( x 2)

4. Front bracket [C] ( x 1)

5. Bearing [D]

6. Pressure roller [E]

SM 3-29 G071

FUSING/PAPER EXIT

3.9.10 OIL ABSORBERS

[A]

[C]

G070R516.WMF

[G]

[L]

[K]

[J]

[I]

1. Fusing inner unit (! 3.9.4)

2. Absorber 1 [A]

3. Pressure roller unit (! 3.9.6)

4. Absorber holder [B] ( x 1)

[H]

[F]

[D]

[B]

Adjustment

Replacement

[E]

G070R825.WMF

5. Absorber 2 [C]

6. Spring [D]

7. Absorber holder [E] ( x 1)

8. Absorber 3 [F]

9. Spring [G]

10. Base bracket [H] ( x 2)

11. Absorber holder [I] ( x 1)

12. Absorber 4 [J]

13. Absorber 5 [K]

14. Absorber 6 [L]

G071 3-30 SM

FUSING/PAPER EXIT

3.9.11 PAPER EXIT UNIT AND PAPER EXIT/OVERFLOW SENSOR

CAUTION

Turn off the main switch and wait until the paper exit unit cools down before beginning any of the procedures in this section. The paper exit unit can cause serious burns.

1. Paper exit cover (! 3.2.3)

2. Paper exit unit [A] ( x 3,  x 1) NOTE: Remove 2 connectors

before removing the unit. To remove the last connector, remove the unit and turn it. The connector is on the bottom side.

3. Paper exit sensor [B]

4. Paper overflow sensor [C]

[C]

[B]

[A]

G070R601.WMF

Adjustment

Replacement

SM 3-31 G071

PAPER FEED AND TRANSPORT

3.10 PAPER FEED AND TRANSPORT

3.10.1 FEED ROLLER AND FRICTION PAD

1. Paper tray [A]

[A]

2.  x 1 [B]

3. Slide the shaft [C].

4. Feed roller [D] (1 hook)

5. Friction pad [E]

[B]

[D]

[E]

G070R101.WMF

Adjustment

Replacement

[C]

G070R102.WMF

G071 3-32 SM

PAPER FEED AND TRANSPORT

3.10.2 REGISTRATION SENSOR

1. Front cover [A] (L-shaped-pin x 2)

2. Rear cover (! 3.2.1)

3. Upper cover (! 3.2.3)

4. Lower left cover (! 3.5.2)

5. Dust shield glass cleaning lever [B] (! 3.5.2)

6. Charge corona unit (! 3.7.3)

7. Right cover (! 3.8.1)

8. Left inner cover door [C]

9. Left inner cover [D] ( x 2)

10. Right inner cover [E] ( x 3)

[C]

[B]

[D]

[A]

[E]

G070R103.WMF

G070R653.WMF

Adjustment

Replacement

SM 3-33 G071

PAPER FEED AND TRANSPORT

11. Terminal [A] ( x 1)

NOTE: You have to remove the

terminal to lift the transport stay (! step

14).

12. Transport guide [B] ( x 1)

[B]

G070R104.WMF

[A]

13. Drive gear [C] (1 hook)

14. Lift the transport stay [D] ( x 2) and release the wire [E]. NOTE: You can see the wire clip

from the rear of the machine.

15. Registration sensor [F] ( x 1,  x 1)

[E]

[D]

[F]

G070R105.WMF

Adjustment

Replacement

[C]

G071 3-34 SM

PAPER FEED AND TRANSPORT

3.10.3 PAPER FEED SENSOR

1. Lift the transport stay [A] (! 3.10.2)

2. Paper feed sensor [B] ( x 1) NOTE: Unhook the rear two pawls

first, move the feeler, and unhook the front pawl.

3.10.4 PAPER NEAR-END SENSOR

1. Lift the transport stay [A] (! 3.10.2)

2. Feeler [B]

3. Sensor bracket [C] ( x 1)

4. Paper near-end sensor [D] ( x 1)

3.10.5 PAPER END SENSOR

[A]

[B]

[A]

[C]

G070R106.WMF

[D]

G070R107.WMF

[B]

Adjustment

Replacement

1. Lift the transport stay [A] (! 3.10.2)

2. Feeler [B]

3. Sensor bracket [C] ( x 2)

4. Paper end sensor [D] ( x 1)

[A]

[D]

[C]

SM 3-35 G071

[B]

G070R108.WMF

BYPASS TRAY

3.11 BYPASS TRAY

3.11.1 PICKUP/FEED ROLLER

1. Bypass tray ( x 3)

2. Upper cover [A] ( x 3)

[A]

3. Lift the paper end sensor feeler [B].

4. Pick-up roller [C] (1 hook)

5. Paper feed roller [D] ( x 1)

[D]

[B]

G070R151.WMF

[C]

G070R152.WMF

Adjustment

Replacement

G071 3-36 SM

BYPASS TRAY

3.11.2 PAPER FEED CLUTCH

1. Upper cover (! 3.11.1)

2. Rear cover [A] ( x 1)

3. Gear holder [B] ( x 3)

4. Gears [C][D]

5. Clutch [E] ( x 1)

[A]

[C]

G070R153.WMF

[E]

[D]

[B]

Adjustment

Replacement

3.11.3 REVERSE ROLLER

1. Bypass tray (! 3.11.1)

2. Turn the unit upside down.

3. Bottom cover [A] ( x 3)

4. Reverse roller [B] ( x 1)

Bottom of unit

Top of unit

[A]

G070R154.WMF

[B]

G070R155.WMF

SM 3-37 G071

TROUBLESHOOTING

SERVICE CALL

4. TROUBLESHOOTING

4.1 SERVICE CALL

4.1.1 SERVICE CALL CONDITIONS

Level Definition Reset Procedure

NOTE:

Fusing unit SCs displayed on the operation panel. The machine is disabled. The user cannot 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.

SCs that are not shown on the operation panel. They are internally logged.

Turning the operation switch or main power switch off then on resets the SC. The SC is displayed on the operation panel. It is redisplayed if it occurs after the main power switch is turned on again.

1) All SCs are logged.

2) When an electrical circuit board has a problem, check the connections before replacing the PCBs.

3) When a motor has a problem, check the mechanical load before replacing the motor or sensor.

Turn the main switch off then on before entering SP mode. Reset the SC (set SP5-810 [SC_Reset] to 1), then turn the main switch off then on again.

Turn the main power switch off and on.

Logging only

Turn the main power switch off and on.

Trouble-

shooting

SM 4-1 G071

SERVICE CALL

4.1.2 SC TABLE

No.

Definition

Symptom Possible Cause

Polygon motor error 201 D

• The polygon motor starts operating. → The lock signal is not detected within 20 seconds.

• The polygon motor starts operating. → The lock signal is detected within 20 seconds. → After a 3-second waiting time, no lock signal is detected within 20 seconds.

• The polygon motor strops operating. → The lock signal is not detected within 20 seconds.

• The polygon motor is operating. → The lock signal remains undetected for 0.5 seconds.

1st beam synchronization error 220 D A polygon motor lock is detected; the LD door is closed; the LD remains on. → The LD error (1st beam

synchronization error) continues for 0.5 seconds.

2nd beam synchronization error 221 D A polygon motor lock is detected; the LD door is closed; the LD remains on. → The LD error (2nd beam

synchronization error) continues for 0.5 seconds.

FGATE on error 230 D A transfer belt mark is detected. → No FGATE on signal

is detected within 175+50 milliseconds. FGATE off error 231 D A FGATE assert signal is detected. → The FGATE

negate signal is not detected within 30 seconds. LD error 241 D An LD error continues for 0.5 seconds. (After an LD

error is detected, an LD error release is written to the GAVD chip during monitoring.)

Image transfer belt mark detection error 280 D

• An imaging process starts. → No belt mark is detected in 1 revolution.

• A color imaging process starts. → A mono color image is transferred. → FGATE becomes active. → No belt mark is detected in 1 revolution.

• Thick paper or OHP film is used. → The belt slows down. → No belt mark is detected in 1 revolution.

GAPCI communication error 281 D Data is transferred. → The CPU does not detect the

communication ACK signal from GAPCI. GAVD communication error 282 D Data is transferred. → The CPU does not detect the

communication ACK signal from GAVD.

• Defective polygon motor

• Defective harness

• Disconnected

synchronization detector board

• Defective LD unit

• Defective BCU

• Disconnected

synchronization detector board

• Defective LD unit

• Defective BCU

• Defective LD unit

• Defective BCU

• Poor electrical

connection

• Noise

• Defective BCU

G071 4-2 SM

SERVICE CALL

No.

Definition

Symptom Possible Cause

Charge corona unit electrical leak 300 D The charge corona unit keeps outputting; the unit is operating at the minimum PWM duty value. → 4.5 Volt

(or more) is returning for 60 milliseconds.

Charge corona unit disconnection 301 D The charge corona unit keeps outputting. → The unit is

operating at the maximum PWM duty value for 60 milliseconds.

Charge grid electrical leak 302 D The charge grid keeps outputting. → The returning

voltage exceeds the target by 0.5 Volt or more for 120 milliseconds.

Charge corona unit cleaner error 305 D

• Cleaning starts. → The lock signal is not detected within 30 seconds.

• Cleaning starts. → The cleaner turns. → The lock signal is detected within 6 seconds.

• The lock signal is detected while the unit is moving away from the HP. → The next lock signal is detected within 6 seconds after the unit has turned toward the HP.

Development error 1 (K/Y) 350 D A development process starts. → The returning voltage

exceeds the target by 0.5 Volt or more for 60 milliseconds.

Development error 2 (C/M) 351 D A development process starts. → The returning voltage

exceeds the target by 0.5 Volt or more for 60 milliseconds.

Development motor error 352 D

• The development motor starts or changes speed. → The motor does not detect a 1-second lock signal within 3 seconds.

• The development motor starts. → The lock signal is detected during normal operation. → The lock signal is interrupted for 1 second or more.

• Short circuit in the charge corona unit

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Defective PCU installation

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Short circuit in the charge grid

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Defective cleaner

• Short circuit in the

development unit

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Short circuit in the development unit

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Defective development motor

Trouble-

shooting

SM 4-3 G071

SERVICE CALL

No.

Definition

Symptom Possible Cause

1st transfer (image transfer) electric leakage (+) 400 D Image transfer starts. → The process operates at the

minimum PWM duty value. The returned current exceeds 1.8 V for 180 milliseconds.

1st transfer (image transfer) electric leakage (–) 401 D Image transfer starts. → The negative (–) output is at the

maximum PWM duty value for 60 milliseconds.

2nd transfer (paper transfer) electric leakage (+) 410 D Paper transfer starts. → The positive (+) output is at the

minimum PWM duty value. → The returning voltage stays at 2.7 V or more for 60 milliseconds.

2nd transfer (paper transfer) electric leakage (–) 411 D Paper transfer starts. → The negative (–) output is at the

minimum PWM duty value. → The returning voltage stays at 4.5 V or more for 60 milliseconds.

2nd transfer (paper transfer) disconnection (+) 412 D Paper transfer starts. → The positive (+) output is at the

maximum PWM duty value for 60 milliseconds.

2nd transfer (paper transfer) disconnection (–) 413 D Paper transfer starts. → The negative (–) output is at the

maximum PWM duty value for 60 milliseconds.

• Short circuit in the

image transfer unit

• Defective image

transfer belt

• Defective high

voltage supply board

• Defective harness

(BCU - high voltage supply board)

• Short circuit in the

image transfer belt

• Defective high

voltage supply board

• Defective harness

(BCU - high voltage supply board)

• Short circuit in the paper transfer unit

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Short circuit in the paper transfer unit

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Right cover not closed

• Defective transfer roller contact mechanism

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Right cover not closed

• Defective transfer roller contact mechanism

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

G071 4-4 SM

SERVICE CALL

No.

Definition

Symptom Possible Cause

Discharge error (fusing bias) 420 D The discharge circuit is operating at the maximum PWM

duty value for 60 milliseconds.

Discharge plate error 421 D During discharging, the leakage detection signal is low

for 60 milliseconds.

Transfer belt cleaning error 430 D Cleaning is operating at the maximum PWM duty value

for 60 milliseconds.

Main motor error 440 D

• The main motor starts or changes speed. → The lock signal does not continue for 1 second within 3 seconds.

• The main motor starts. → The lock signal is detected and operation proceeds normally. → The lock signal is interrupted for 1 second.

Temperature sensor error 460 D The output is 4.5 V (or higher) or 0.3 V (or lower) for 12

seconds.

Humidity sensor error 461 D The output is 4.5 V (or higher) or 0.3 V (or lower) for 12

seconds.

ID sensor error 480 D The ID sensor is being calibrated (process control, step

1) → While the LED is off, the output voltage is 0.5 V or

lower. Transfer belt mark detection error 481 D The main motor is operating; and the lock signal is detected. → The belt mark sensor signal does not

change for 120 milliseconds.

2nd tray error 502 B

• The tray lift motor turns on. → The top of the paper stack is not detected for 13 seconds.

• The tray is set. → The top of the paper stack is detected. → The bottom plate is lowered. → The stack detection is not cleared within 5 seconds. → These steps are repeated 4 times.

• Discharge pin short circuit

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Scratched fusing belt

• Short circuit in the

discharge plate

• Defective high

voltage supply board

• Defective harness

(BCU - high voltage supply board)

• Short circuit in the transfer belt cleaning unit

• Defective high voltage supply board

• Defective harness (BCU - high voltage supply board)

• Defective main motor

• Short circuit in the

temperature sensor

• Defective circuit

• Defective connector

• Short circuit in the

humidity sensor

• Defective circuit

• Defective connector

• Defective ID sensor

• Defective connector

• Defective main motor

• Image transfer belt

out of position

• Belt mark blurred or absent

• Defective paper height sensor

• Defective tray lift motor

Trouble-

shooting

SM 4-5 G071

SERVICE CALL

No.

Definition

Symptom Possible Cause

3rd tray error 503 B

• The tray lift motor turns on. → The top of the paper stack is not detected for 13 seconds.

• The tray is set. → The top of the paper stack is detected. → The bottom plate is lowered. → The stack detection is not cleared within 5 seconds. → These steps are repeated 4 times.

Duplex unit communication error 515 D

• A connection error occurs.

• The signal is sent from the printer to the duplex unit

every 3 seconds while paper is not transported by the unit. However, the duplex unit does not respond within 5 seconds.

Paper feed motor error 520 D

• The motor starts or changes speed. → The lock signal does not continue for 1 second within a 3-second interval.

• The motor starts. → The lock signal is detected and operation proceeds normally. → The lock signal is interrupted for 1 second.

Thermistor disconnection (heating roller) 541 A The fusing unit starts warm up to the print ready temperature. → The temperature does not reach 7°C for

10 seconds. Fusing warm-up timeout (heating roller) 542 A The main switch is turned on or a cover is closed. →

The heating roller does not reach the warm-up temperature within 50 seconds.

Overheat error (heating roller) 543 A The heating roller thermistor detects 220°C for 5

seconds. Low temperature error (heating roller) 544 A During standby or operation, the heating roller

thermistor detects 100 °C or less for 5 seconds.

Full power error (heating roller) 545 A Fusing unit warm-up is complete. → The heating roller

stops turning. → The heating roller lamp keeps outputting the maximum power for 30 seconds.

• Defective paper height sensor

• Defective tray lift motor

• Defective duplex unit board

• Defective BCU

• Defective IOB

• Defective connection

(Main unit - Duplex unit)

• Defective paper feed motor

• Defective thermistor

• Thermistor loose

connection

• Defective connector

• Defective lamp

(loose connection, thermostat failure, PSU, thermostat)

• Incorrect detection (loose thermistor connection, fusing drawer loose connection)

• Short circuit

• Defective BCU board

• Defective PSU

• Defective lamp

(loose connection, thermostat failure, PSU, thermostat)

• Incorrect detection (loose thermistor connection, fusing drawer loose connection)

• Thermistor loose connection

• Fusing - drawer loose connection

G071 4-6 SM

SERVICE CALL

No.

Definition

Unstable temperature (heating roller) 546 A

• The heating roller thermistor detects unstable temperature increases or decreases within 60 seconds.

Thermistor disconnection (pressure roller) 551 A The pressure roller thermistor detects7°C or lower for 30

seconds.

Warm-up time over (pressure roller) 552 A The main switch is turned on or a cover is closed. →

The fusing pressure roller does not reach the ready temperature within 200 seconds.

Overheat error (pressure roller) 553 A The pressure roller thermistor detects 220°C for 5

seconds. Low temperature error (pressure roller) 554 A During standby or operation, the pressure roller

thermistor detects 80°C or less for 5 seconds.

Full power error (pressure roller) 555 A Fusing unit warm-up is complete.→ The fusing pressure

roller stops turning. → The pressure roller lamp keeps outputting the maximum power for 200 seconds.

Unstable temperature (pressure roller) 556 A

• The pressure roller thermistor detects unstable temperature increases or decreases within 60 seconds.

Zero cross error 560 D The main switch is turned on; the fusing relay turns on. → 50 Hz or 60 Hz is not detected within 5 seconds.

670 D No response from BCU at power on

EEPROM error 680 D The main switch is turned on.→ EEPROM is not

connected.

Symptom Possible Cause

• Thermistor loose connection

• Fusing - drawer loose connection

• Thermistor loose connection

• Defective harness

• Defective connector

• Defective lamp

(loose connection, thermostat failure, PSU, thermostat)

• Incorrect detection (thermistor loose connection, fusing drawer loose connection)

• Loose connection

• Defective BCU board

• Defective PSU

• Defective lamp

(loose connection, thermostat failure, PSU, thermostat)

• Incorrect detection (thermistor loose connection, fusing drawer loose connection)

• Thermistor loose connection

• Fusing - drawer loose connection

• Thermistor loose connection

• Fusing - drawer loose connection

• Defective relay circuit

• Defective PSU

• Incorrect power

supply

• Loose connection

• Defective controller

• Defective BCU

• Incorrect EEPROM

connection

Trouble-

shooting

SM 4-7 G071

SERVICE CALL

No.

Definition

Symptom Possible Cause

PER command error 687 D

• Some image data is transferred. → The controller does not report the necessary memory address.

• The PES command is issued. → The controller does not issue the necessary memory report (PER) command within 6 seconds..

Four-bin mail box communication error 730 D

• A connection error occurs.

• The UART reports a communication error.

• In other cases than paper transport, after an every-3-

second command is sent, the mail box does not respond within 5 seconds.

Finisher communication error 740 D

• A connection error occurs.

• The UART reports a communication error.

• In other cases than paper transport, after an every-3-

second command is sent, the finisher does not respond within 5 seconds.

Finisher jogger motor error 741 D The jogger home position sensor (on/off) is not detected

in a given time.

Finisher stapler unit error 742 D

• The stapler does not return to home position within 1 second.

Finisher output tray motor error 743 D The stack height and lever sensors do not detect paper. Finisher output tray motor lock 744 D The tray is locked for 10 seconds. Finisher paper detection error 745 D The stack height and lever sensors do not correctly

detect paper. 1st paper tray unit communication error 750 D

• A connection error occurs.

• The UART reports a communication error.

• In other cases than paper transport, after an every-3-

second command is sent, the paper tray unit does not respond within 5 seconds.

2nd paper tray unit communication error 751 D

• After the 1st paper tray has recognized the 2nd paper tray, the trays cannot communicate with each other.

• After the 1st paper tray has recognized the 2nd paper tray, an ATM (CPU reset) is sent from the 2nd paper tray.

• Poor connection between BCU and controller

• Defective BCU

• Defective controller

• Defective mail box

control board

• Defective BCU

• Defective IOB

• Incorrect installation

• Defective finisher

control board

• Defective board

• Defective BCU

• Defective IOB

• Incorrect installation

• Defective jogger

motor

• Defective jogger home position sensor

• Defective stapler unit

• Defective motor

• Defective paper tray

unit control board

• Defective BCU

• Defective IOB

• Defective connection

(Paper tray - main unit)

• Defective paper tray unit control board

• Defective connection (1st - 2nd paper tray

G071 4-8 SM

CONTROLLER ERROR TABLE

4.2 CONTROLLER ERROR TABLE

The table lists the controller error codes. If an error occurs, the code is displayed when the main switch is turned on or after the startup self-diagnostics.

NOTE: For the startup self-diagnostics, see section 5.3.

Code Description Required Action

640 BCU – Controller

communication error (no response)

641 BCU – Controller

communication error (no response)

800 Video output error (K) 801 Video output error (Y) 802 Video output error (M) 803 Video output error (C) 818 Watchdog error Turn the main switch off and on.

819 Fatal error Turn the main switch off and on.

820 Self-diagnostics error:

CPU [XXXX]: Detailed error code

821 Self-diagnostics error:

ASIC

822 Self-diagnostics error:

HDD (Hard Disk Drive) [XXXX]: Detailed error code

823 Self-diagnostics error: NIB

[XXXX]: Detailed error code

824 Self-diagnostics error:

Standard NVRAM

827 Self-diagnostics error:

Standard SRAM DIMM [XXXX]: Detailed error code

Turn the main switch off and on. Replace the controller. Replace the BCU. Turn the main switch off and on. Check the connection between BCU and controller. Replace the controller. Replace the BCU. Data transfer starts to the BCU, but the transfer

completion command does not return to the controller within the required time. Defective controller board

Replace the controller. See NOTE at the end of this table

Check and/or replace the RAM DIMM. Check and/or replace the ROM DIMM. Replace the controller. See NOTE at the end of this table Turn the main switch off and on. Reinstall the controller system firmware. Replace the controller. Turn the main switch off and on. Reinstall the controller system firmware. Replace the RAM DIMM. Replace the controller board. Turn the main switch off and on. Check that the HDD is properly connected to the

controller. Replace the HDD. Replace the controller. Turn the main switch off and on. Replace the controller.

Turn the main switch off and on. Check that the standard NVRAM is firmly inserted into the socket. Replace the NVRAM. Replace the controller. Turn the main switch off and on. Replace the SRAM DIMM. Replace the controller.

Trouble-

shooting

SM 4-9 G071

CONTROLLER ERROR TABLE

Code Description Required Action

828 Self-diagnostics error :

ROM [XXXX]: Detailed error code

829 Self-diagnostics error:

optional RAM [XXXX]: Detailed error code

835 Self-diagnostics error:

Centronics interface [XXXX]: Detailed error code

836 Self-diagnostics error:

Font ROM (standard)

838 Self-diagnostics error:

Font ROM (clock generator)

850 Network interface error Turn the main switch off and on.

851 IEEE1394 interface error Turn the main switch off and on.

853 IEEE802.11b error - card

not detected (power-on)

854 IEEE802.11b error - card

not detected (during operation)

855 IEEE802.11b error Check the wireless LAN card connection.

856 IEEE802.11b interface

board error

857 USB interface error

detected.

860 HDD: Error detected at

power up (partition error, unformatted disk, incorrect disk type)

861 HDD: Reboot error Turn the main switch off and on.

862 Defective sector

management maximum

863 HDD: Read error Turn the main switch off and on.

864 HDD: CRC error Turn the main switch off and on.

865 HDD: Access error Turn the main switch off and on.

Turn the main switch on and off. Replace the ROM DIMM Replace the controller. Turn the main switch off and on. Replace the RAM DIMM. Replace the controller board. Turn the main switch off and on. Check the connection between the Centronics connector

and loop-back connector. Reconnect the loop-back connector. Replace the controller. Turn the main switch off and on. Replace the standard ROM-DIMM. Replace the controller.

Replace the controller.

Replace the IEEE1394 interface board. Replace the controller. Check the wireless LAN card connection. Replace the wireless LAN card. Check the wireless LAN card connection. Replace the wireless LAN card.

Replace the wireless LAN card. Check the wireless LAN interface board connection. Replace the interface board. Check the USB connections, make sure that they are

securely connected. Replace the controller board. Turn the main switch off and on. Reformat the HDD (SP 5-832-1 [HDD Init]). Replace the HDD.

Check the connection between HDD and controller. Check and replace the cables. Replace the HDD. Replace the controller. Replace the HDD.

Replace the HDD. Replace the controller.

Replace the HDD.

G071 4-10 SM

CONTROLLER ERROR TABLE

Code Description Required Action

900 Electrical counter error Turn the main switch off and on.

Check the connection between NVRAM and controller. Replace the NVRAM. Replace the controller.

990 Software performance

error

991 Unexpected software

error

998 Application start error Turn the main switch off and on.

999 Program installation error Controller DIP SW1 setting incorrect.

Turn the main switch off and on. Reinstall the controller and/or engine main firmware. See NOTE at the end of this table. The machine does not stop and the SC code is not

displayed. The machine automatically recovers. However, the SC code is logged in the engine summary sheet (SMC).

Check that the RAM DIMM and ROM DIMM are properly connected.

Reinstall the controller system firmware. Replace the controller.

Defective software on IC card. Controller software download error. Replace the controller.

NOTE: If a problem always occurs in a specific situation (for example, same printer

driver settings, same image file), the problem may be caused by a software error. In this case, send the following data and information to your product specialist.

Trouble-

shooting

• Symptom/Possible causes/Action taken

• Summary sheet (SP mode ‘1 Service’, [Print Summary])

• SMC All (SP5-990-2, SP print mode - All)

• Logged data (SP5-990-4, SP print mode - Logging)

• Printer driver settings used when the problem occurs

• All data displayed on the screen (SC code, error code, and program

address where the problem is logged.)

• Image file which causes the problem, if possible

SM 4-11 G071

BLOWN FUSE CONDITIONS

is displayed. The interchange unit (and

4.3 BLOWN FUSE CONDITIONS

Fuse

Power Supply Board

FU1 (N.A.)/

CB1 (Eur./Asia)

FU2 6.3A/250V 3.15A/250V No response FU3 4A/125V 4A/125V

FU4 4A/125V 4A/125V

*1: Vaa (+24V) for the optional tray is cut. *2: Vaa (+24V) for the interchange unit is cut.

15A/125V 8A/250V No response

Rating

115V 220 ~ 240V

Symptom when turning on the main switch

“Tray 2 Hardware Problem ” is displayed. The optional tray does not operate.*1

“Ready” the finisher and/or the 4-bin mail box and/or duplex) does not operate.*2

4.4 CHECK POINTS FOR IMAGE PROBLEMS AT REGULAR INTERVALS

Symptoms for image problems at regular intervals depend on the circumference of certain components. The following diagram shows the possible symptoms (black or white dots at regular intervals) .

Paper feed

Pitched images

G070T801.WMF

Color spots at 2.1 inches (54-mm) intervals: Development roller in the development unit Abnormal image at 2.7 inches (68-mm) intervals: Transfer roller Abnormal image at 7.4 inches (188-mm) intervals: Fusing belt in the fusing unit Abnormal image at 5 inches (125-mm) intervals: Pressure roller in the fusing unit

G071 4-12 SM

SERVICE TABLES

SERVI CE PROGRAM MODE

5. SERVICE TABLES

5.1 SERVICE PROGRAM MODE

CAUTION



Before starting a service program, check that no data is coming into the printer. If data is coming in, wait until the data is completely processed.

5.1.1 OPERATION PANEL KEYS

[B]

[C]

[A]

[H]

On Line Menu

Job Reset

Form Feed

[G]

[A]: Online [B]: Menu [C]: Escape [D]: Up arrow

Power

Error

Data In

[E]: Down arrow [F]: Enter [G]: Form feed [H]: Reset

Escape

Enter

[F]

G070S001.WMF

[D]

[E]

Service

Tables

SM 5-1 G071

SERVICE PROGRAM MODE

5.1.2 STARTING SERVICE PROGRAM MODE

You can enter service mode with either of the following procedures.

Procedure 1

1. Turn the main switch off.

2. Press the online key and the escape key at the same time, and hold them.

3. Turn the main switch on.

4. Wait until “SYSTEM ver V.x.xx. 1. Service” is displayed.

NOTE: “ver V.x.xx.” indicates the machine’s firmware version.

Procedure 2

1. Press the up arrow key and the down arrow key at the same time, and hold

them for about 5 seconds. NOTE: At this moment, the display does not change.

2. Press the enter key. “SYSTEM ver V.x.xx. 1. Service” is displayed.

NOTE: “ver V.x.xx.” indicates the machine’s firmware version.

5.1.3 MAIN MENU

1. The main menu has three sub menus (see below). Press the up arrow key or

the down arrow key to scroll through these sub menus.

1) Service: Goes to the controller service modes

2) Engine: Goes to the engine service modes

3) End: Exits from the main menu

2. Press the enter key.

3. Press the up arrow key or the down arrow key to scroll through the items in the

selected sub menu.

4. To exit from the sub menu, press the escape key.

G071 5-2 SM

Ricoh CL5000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INSTALLATION

INSTALLATION REQUIREMENTS

Installation

MACHINE INSTALLATION

OPTIONS

REMARKS FOR INSTALLATION

PREVENTIVE MAINTENANCE

OVERVIEW

SERVICE MAINTENANCE

REPLACEMENT AND ADJUSTMENT

SPECIAL TOOLS

3. REPLACEMENT AND ADJUSTMENT

EXTERIOR COVERS

ELECTRICAL COMPONENTS

DRIVE UNITS

LASER OPTICS SECTION

DEVELOPMENT UNIT

PHOTOCONDUCTOR UNIT (PCU)

PAPER TRANSFER UNIT

FUSING/PAPER EXIT

PAPER FEED AND TRANSPORT

BYPASS TRAY

TROUBLESHOOTING

SERVICE CALL

CONTROLLER ERROR TABLE

BLOWN FUSE CONDITIONS

SERVICE TABLES

SERVI CE PROGRAM MODE