Ricoh cl7000 Service Manual

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Model J-P2

(Machine Code: G080)

SERVICE MANUAL

!IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

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

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

HEALTH SAFETY CONDITIONS

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

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

3. The optional fax and memory expansion units contain lithium batteries, which can explode if replaced incorrectly. Replace only with the same or an equivalent type recommended by the manufacturer. Do not recharge or burn the batteries. Used batteries 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.

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.

5. Dispose of used fusing oil in accordance with local regulations.

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.

Symbols and Abbreviations

This manual uses the symbols and abbreviations shown below.

Symbol Meaning

☛

SEF Short Edge Feed LEF Long Edge Feed

"See," "Refer to" Clip ring Screw Connector

Long Edge Feed (LEF)Short Edge Feed (SEF)

TABLE OF CONTENTS

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

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

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

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

1.1.3 MACHINE SPACE REQUIREMENT................................................ 1-2

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

Main Unit and Finisher ......................................................................... 1-2

CF Expander with Rack ....................................................................... 1-3

CF Expander without Rack .................................................................. 1-3

1.1.4 POWER REQUIREMENTS.............................................................. 1-4

1.2 OPTIONAL UNIT COMBINATIONS.......................................................... 1-5

1.3 INSTALLATION FLOW CHART................................................................ 1-6

Without Optional CF Expander............................................................. 1-6

With Optional CF Expander.................................................................. 1-7

1.4 MACHINE INSTALLATION....................................................................... 1-8

1.5 NOTES FOR TRANSPORTING THE MACHINE.................................... 1-10

1.5.1 MACHINE STANDS....................................................................... 1-10

1.5.2 MACHINE BODY ........................................................................... 1-11

1.6 OPTIONAL UNIT INSTALLATION.......................................................... 1-13

1.6.1 LIST OF OPTIONS ........................................................................ 1-13

1.6.2 PUNCH UNIT INSTALLATION ...................................................... 1-14

Accessory Check ............................................................................... 1-14

Installation Procedure ........................................................................ 1-15

1.6.3 CF EXPANDER RACK .................................................................. 1-18

Accessories Check List ...................................................................... 1-19

Assembling the Rack ......................................................................... 1-20

Docking the Rack and Printer Mainframe........................................... 1-22

1.6.4 CF EXPANDER ............................................................................. 1-24

Accessories Check List ...................................................................... 1-24

CF Expander Installation.................................................................... 1-24

1.6.5 INSTALLING THE HANDSET........................................................ 1-31

1.6.6 40GB HDD..................................................................................... 1-32

Accessories Check List ...................................................................... 1-32

40 GB HDD Installation ...................................................................... 1-32

1.6.7 ARDF ............................................................................................. 1-34

Accessories Check List ...................................................................... 1-34

ARDF Installation ............................................................................... 1-34

1.6.8 MULTI-BIN OUTPUT TRAY........................................................... 1-37

Accessories Check List ...................................................................... 1-37

Installing the Multi-Bin Output Tray .................................................... 1-37

1.6.9 ANTI-CONDENSATION HEATER ................................................. 1-39

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

2.1 USER MAINTENANCE............................................................................. 2-1

2.2 SERVICE MAINTENANCE....................................................................... 2-3

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

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

3.2 IMAGE ADJUSTMENT ............................................................................. 3-2

3.2.1 REGISTRATION.............................................................................. 3-2

Image Area........................................................................................... 3-2

Leading Edge....................................................................................... 3-2

Side to Side.......................................................................................... 3-2

Adjustment Standard............................................................................ 3-2

Paper Registration Standard................................................................ 3-2

Adjustment Procedure.......................................................................... 3-3

3.2.2 COLOR REGISTRATION ................................................................ 3-3

Line Position Adjustment...................................................................... 3-3

Adjustment of Line Speed for Thick Paper........................................... 3-3

3.2.3 PRINTER GAMMA........................................................................... 3-4

Adjustment Overview ........................................................................... 3-4

Adjustment Procedure.......................................................................... 3-4

3.3 EXTERIOR COVERS ............................................................................... 3-5

3.3.1 REAR COVER AND UPPER REAR COVER................................... 3-5

3.3.2 PAPER EXIT TRAY ......................................................................... 3-5

3.3.3 UPPER RIGHT COVER................................................................... 3-5

3.3.4 FRONT COVER............................................................................... 3-6

3.3.5 LEFT COVER AND REAR LEFT COVER........................................ 3-6

3.3.6 UPPER LEFT COVER AND OPERATION PANEL.......................... 3-7

3.4 LASER OPTICS........................................................................................ 3-8

3.4.1 CAUTION DECAL LOCATIONS ...................................................... 3-8

3.4.2 LASER OPTICS HOUSING UNIT.................................................... 3-9

Adjustments after Replacing the Laser Optics Housing Unit.............. 3-12

3.4.3 POLYGON MIRROR MOTOR ....................................................... 3-13

3.4.4 LASER SYNCHRONIZING DETECTOR BOARDS ....................... 3-13

3.5 PCU AND DEVELOPMENT UNIT .......................................................... 3-14

3.6 PAPER FEED......................................................................................... 3-15

3.6.1 PICK-UP, FEED, AND SEPARATION ROLLERS.......................... 3-15

Tray 1 and Tray 2............................................................................... 3-15

By-pass Tray...................................................................................... 3-15

3.6.2 PAPER WIDTH DETECTION BOARD........................................... 3-16

3.6.3 VERTICAL TRANSPORT SENSOR .............................................. 3-17

3.6.4 RIGHT DOOR UNIT....................................................................... 3-17

3.6.5 REGISTRATION SENSOR AND RELAY SENSORS .................... 3-18

3.6.6 PAPER FEED CLUTCHES............................................................ 3-18

3.6.7 BY-PASS FEED CLUTCH ............................................................. 3-19

3.6.8 TRAY LIFT MOTOR....................................................................... 3-19

3.6.9 PAPER FEED MOTOR.................................................................. 3-20

3.7 TRANSFER AND PAPER TRANSPORT UNIT ...................................... 3-21

3.7.1 TRANSFER UNIT .......................................................................... 3-21

3.7.2 TRANSFER BELT CLEANING UNIT............................................. 3-22

3.7.3 CLEANING BLADE AND CLEANING ROLLER............................. 3-23

3.7.4 TRANSFER BELT.......................................................................... 3-25

3.7.5 TRANSFER UNIT DRIVE MOTOR................................................ 3-27

3.8 ID SENSORS.......................................................................................... 3-28

3.9 FUSING .................................................................................................. 3-29

3.9.1 FUSING UNIT................................................................................ 3-29

3.9.2 OIL SUPPLY UNIT AND UPPER COVER..................................... 3-30

3.9.3 CLEANING UNIT ........................................................................... 3-31

3.9.4 HEATING ROLLER LAMP............................................................. 3-32

3.9.5 FUSING BELT UNIT...................................................................... 3-33

3.9.6 HOT ROLLER................................................................................ 3-34

3.9.7 HEATING ROLLER........................................................................ 3-34

3.9.8 PAPER GUIDE PLATES AND STRIPPER PAWLS....................... 3-35

3.9.9 THERMISTOR AND FUSE ............................................................ 3-36

3.9.10 PRESSURE ROLLER FUSING LAMP......................................... 3-37

3.9.11 PRESSURE ROLLER.................................................................. 3-38

3.9.12 FUSING UNIT FAN...................................................................... 3-40

3.9.13 WASTE OIL BOTTLE .................................................................. 3-41

3.9.14 PAPER EXIT................................................................................ 3-42

3.10 ELECTRICAL COMPONENTS............................................................. 3-43

3.10.1 MOVING THE CONTROLLER BOX OUT OF THE WAY............. 3-43

3.10.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT - C, B OUT OF THE

WAY 3-43

3.10.3 CONTROLLER AND BCU ........................................................... 3-44

3.10.4 NVRAM REPLACEMENT PROCEDURE .................................... 3-46

NVRAM for BCU ................................................................................ 3-46

NVRAM for Controller ........................................................................ 3-46

NVRAMs for both BCU and Controller ............................................... 3-47

3.10.5 REMOVING THE HIGH VOLTAGE SUPPLY BOARD - C, B....... 3-48

3.10.6 PSU ............................................................................................. 3-48

3.10.7 DRIVER BOARD.......................................................................... 3-49

3.11 DRIVE UNIT ......................................................................................... 3-50

3.11.1 REGISTRATION CLUTCH........................................................... 3-50

3.11.2 DEVELOPMENT CLUTCHES...................................................... 3-50

3.11.3 DEVELOPMENT MOTOR - CMY ................................................ 3-51

3.11.4 DRUM DRIVE MOTOR - CMY AND DRUM DRIVE MOTOR - K . 3-54

3.11.5 DEVELOPMENT DRIVE MOTOR - K.......................................... 3-55

3.12 TONER SUPPLY UNIT......................................................................... 3-57

M Toner Supply Unit .......................................................................... 3-57

C and Y Toner Supply Units............................................................... 3-61

K Toner Supply Unit........................................................................... 3-62

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

4.1 PROCESS CONTROL ERROR CONDITIONS ........................................ 4-1

4.1.1 DEVELOPER INITIALIZATION RESULT......................................... 4-1

4.1.2 PROCESS CONTROL SELF-CHECK RESULT .............................. 4-3

4.1.3 LINE POSITION ADJUSTMENT RESULT....................................... 4-4

4.2 SERVICE CALL CONDITIONS................................................................. 4-7

4.2.1 SUMMARY....................................................................................... 4-7

SC Classification .................................................................................. 4-7

4.3 SC TABLE ................................................................................................ 4-9

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4.4 TROUBLESHOOTING GUIDE ............................................................... 4-43

4.4.1 IMAGE QUALITY........................................................................... 4-43

Work-flow ........................................................................................... 4-43

Detailed Explanation .......................................................................... 4-45

4.4.2 COLOR SHIFT............................................................................... 4-50

Adjustment Standard: Max. 180 mm................................................. 4-52

Preparation......................................................................................... 4-52

How to measure the gap between color lines..................................... 4-58

4.4.3 COLOR SHIFT AFTER TRANSFER UNIT REPLACEMENT......... 4-60

Check the color shift level .................................................................. 4-60

Fusing/ Registration Roller Speed Adjustment................................... 4-60

4.4.4 BLACK OVER PRINT .................................................................... 4-63

Black Over Print Disabled .................................................................. 4-63

Black Over Print Enabled................................................................... 4-63

4.5 ELECTRICAL COMPONENT DEFECTS................................................ 4-64

4.5.1 SENSORS ..................................................................................... 4-64

4.6 BLOWN FUSE CONDITIONS................................................................. 4-66

4.7 LEDS (BCU) ........................................................................................... 4-66

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

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

5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE .......... 5-1

Entering the Service Program Mode .................................................... 5-1

Accessing the Required Program......................................................... 5-2

Inputting a Value or Setting for a Service Program .............................. 5-2

Exiting Service Program Mode............................................................. 5-2

5.1.2 REMARKS ....................................................................................... 5-3

Display on the Control Panel Screen ................................................... 5-3

Others .................................................................................................. 5-4

5.2 SERVICE PROGRAM MODE – CF CONFIGURATION ........................... 5-5

5.2.1 ENABLING AND DISABLING SERVICE PROGRAM MODE .......... 5-5

Entering SP Mode................................................................................ 5-5

Exiting SP Mode................................................................................... 5-5

5.2.2 TYPES OF SP MODES ................................................................... 5-5

SP Mode Button Summary................................................................... 5-6

Switching Between SP Mode and Copy Mode for Test Printing........... 5-7

Selecting the Program Number............................................................ 5-7

Exiting Service Mode ........................................................................... 5-8

5.2.3 REMARKS ....................................................................................... 5-8

Display on the Control Panel Screen ................................................... 5-8

Others .................................................................................................. 5-8

5.3 PRINTER CONTROLLER SERVICE MODE ............................................ 5-9

5.3.1 SERVICE MODE MENU.................................................................. 5-9

5.3.2 BIT SWITCH PROGRAMMING ..................................................... 5-11

5.4 PRINTER ENGINE SERVICE MODE..................................................... 5-12

5.4.1 SERVICE MODE TABLE............................................................... 5-12

SP1-XXX (Feed) ................................................................................ 5-12

SP2-XXX (Drum)................................................................................ 5-21

SP3-XXX (Process)............................................................................ 5-32

SP4-XXX (Scanner) ........................................................................... 5-40

SP5-XXX (Mode)................................................................................ 5-45

SP6-XXX (Peripherals) ...................................................................... 5-60

SP7-XXX (Data Log) .......................................................................... 5-62

5.4.2 INPUT CHECK TABLE .................................................................. 5-76

ARDF Input Check: SP6-007 ............................................................. 5-78

Table 1: Paper Height Sensor............................................................ 5-78

Table 2: Paper Size Switch (Tray 2)................................................... 5-79

Table 3: Paper Size (By-pass Table) ................................................. 5-79

Table 4: Original Size Detection......................................................... 5-79

5.4.3 OUTPUT CHECK TABLE .............................................................. 5-80

5.4.4 TEST PATTERN (SP5-997)........................................................... 5-84

5.5 SCANNER SP ........................................................................................ 5-85

5.5.1 SP MODES.................................................................................... 5-85

SP1-xxx (System and Others)............................................................ 5-85

SP2-XXX (Scanning-image quality) ................................................... 5-86

SP8-XXX (Delivery)............................................................................ 5-93

SP9-XXX (Delivery)............................................................................ 5-94

5.6 REBOOT / SYSTEM SETTING RESET.................................................. 5-95

5.6.1 SOFTWARE RESET...................................................................... 5-95

5.6.2 SYSTEM SETTINGS AND COPY SETTING RESET .................... 5-95

System Setting Reset......................................................................... 5-95

Copier Setting Reset.......................................................................... 5-96

5.7 FIRMWARE UPDATE............................................................................. 5-97

5.7.1 TYPE OF FIRMWARE................................................................... 5-97

5.7.2 ERROR RECOVERY..................................................................... 5-97

Engine Firmware/Controller NIB Firmware......................................... 5-97

Controller System Firmware............................................................... 5-97

5.7.3 CONTROLLER/ENGINE FIRMWARE UPGRADE......................... 5-98

5.8 FIRMWARE UPDATE – CF CONFIGURATION..................................... 5-99

5.8.1 TYPE OF FIRMWARE................................................................... 5-99

5.8.2 ERROR RECOVERY..................................................................... 5-99

5.8.3 FIRMWARE UPGRADE............................................................... 5-100

5.9 NVRAM DATA DOWNLOAD ................................................................ 5-102

NVRAM Data Upload (SP5-824)...................................................... 5-102

NVRAM Data Download (SP5-825) ................................................. 5-102

5.10 CONTROLLER SELF-DIAGNOSTICS................................................ 5-103

5.10.1 OVERVIEW................................................................................ 5-103

5.10.2 DETAILED SELF-DIAGNOSTICS.............................................. 5-104

Without Optional CF Expander......................................................... 5-104

With Optional CF Expander.............................................................. 5-104

5.11 USER PROGRAM MODE................................................................... 5-105

5.11.1 WITHOUT OPTIONAL CF EXPANDER..................................... 5-105

5.11.2 WITH OPTIONAL CF EXPANDER ............................................ 5-106

UP Mode Initial Screen: User Tools/Counter Display....................... 5-106

System Settings ............................................................................... 5-106

Copier/Document Server Features................................................... 5-107

Printer, Facsimile, Scanner Settings ................................................ 5-107

Counter ............................................................................................ 5-108

Maintenance..................................................................................... 5-108

5.12 DIP SWITCHES.................................................................................. 5-109

Controller Board............................................................................... 5-109

BCU Board....................................................................................... 5-109

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

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

6.1.1 COMPONENT LAYOUT .................................................................. 6-1

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

6.1.3 DRIVE LAYOUT............................................................................... 6-3

6.1.4 BOARD STRUCTURE ..................................................................... 6-4

Overview .............................................................................................. 6-4

Descriptions ......................................................................................... 6-5

6.1.5 PRINTING PROCESS ..................................................................... 6-7

6.2 PROCESS CONTROL.............................................................................. 6-9

6.2.1 OVERVIEW...................................................................................... 6-9

6.2.2 POTENTIAL CONTROL .................................................................. 6-9

Overview .............................................................................................. 6-9

Process Control Self Check ............................................................... 6-10

6.2.3 PROCESS CONTROL SELF CHECK PROCEDURE.................... 6-11

Step 1: VSG Adjustment .................................................................... 6-11

Step 2: ID Sensor Solid Pattern Generation....................................... 6-12

Step 3: Sensor Pattern Detection....................................................... 6-12

Step 4: Toner Amount Calculation ..................................................... 6-12

Step 5: VD, VB, VL Selection and VREF Adjustment......................... 6-13

Step 6: ID Sensor Highlight Pattern Generation................................. 6-14

Step 7: Sensor Pattern Density Detection.......................................... 6-14

Step 8: VL (LD Power) Selection........................................................ 6-14

6.2.4 VREF COMPENSATION DURING A PRINT JOB ......................... 6-15

Highlight Pattern................................................................................. 6-15

Adjustment Process ........................................................................... 6-15

6.2.5 TONER SUPPLY CONTROL......................................................... 6-16

Overview ............................................................................................ 6-16

Toner Supply Control Modes.............................................................. 6-16

6.2.6 TONER NEAR END/TONER END DETECTION ........................... 6-17

Introduction ........................................................................................ 6-17

Toner Near End Detection 1............................................................... 6-18

Toner Near End Detection 2............................................................... 6-18

Toner End Detection .......................................................................... 6-19

Toner End Recovery .......................................................................... 6-19

6.2.7 DEVELOPER INITIALIZATION...................................................... 6-20

6.3 LASER EXPOSURE ............................................................................... 6-21

6.3.1 OVERVIEW.................................................................................... 6-21

6.3.2 OPTICAL PATH............................................................................. 6-22

6.3.3 LASER SYNCHRONIZING DETECTOR ....................................... 6-23

Overview ............................................................................................ 6-23

Main Scan Start Detection.................................................................. 6-23

Clock Frequency Adjustment ............................................................. 6-23

6.3.4 DUAL BEAM WRITING.................................................................. 6-24

Dual Beam Mechanism ...................................................................... 6-24

Laser Beam Pitch Change Mechanism .............................................. 6-24

Printing Mode and Black LD Unit Position.......................................... 6-25

6.3.5 LD SAFETY SWITCH .................................................................... 6-26

Error Messages.................................................................................. 6-27

6.3.6 AUTOMATIC LINE POSITION ADJUSTMENT.............................. 6-28

Overview ............................................................................................ 6-28

Summary of Each Adjustment............................................................ 6-29

Adjustment Conditions ....................................................................... 6-30

Main Scan Skew Adjustment.............................................................. 6-31

6.4 PHOTOCONDUCTOR UNIT .................................................................. 6-32

6.4.1 OVERVIEW.................................................................................... 6-32

6.4.2 DRIVE............................................................................................ 6-33

6.4.3 DRUM GEAR POSITION SENSORS ............................................ 6-34

Mechanism......................................................................................... 6-34

Initialization Process and SC Codes .................................................. 6-35

6.4.4 DRUM CHARGE AND QUENCHING ............................................ 6-36

6.4.5 DRUM CLEANING......................................................................... 6-37

6.4.6 WASTE TONER COLLECTION..................................................... 6-38

6.4.7 WASTE TONER BOTTLE FULL DETECTION .............................. 6-39

6.4.8 PCU DETECTION (DEVELOPMENT UNIT DETECTION) ............ 6-40

Detection Pins.................................................................................... 6-40

Detection Process.............................................................................. 6-40

Error Message.................................................................................... 6-41

6.5 DEVELOPMENT..................................................................................... 6-42

6.5.1 OVERVIEW.................................................................................... 6-42

6.5.2 DRIVE............................................................................................ 6-43

6.5.3 DEVELOPER AGITATION............................................................. 6-44

6.5.4 DEVELOPMENT BIAS................................................................... 6-45

6.5.5 DEVELOPMENT UNIT DETECTION............................................. 6-45

6.5.6 TONER SUPPLY MECHANISM .................................................... 6-46

Overview ............................................................................................ 6-46

Toner Agitation and Attraction............................................................ 6-46

Air Flow and Toner Flow .................................................................... 6-47

Toner Near End Detection.................................................................. 6-47

Toner Transport ................................................................................. 6-48

6.5.7 TONER CARTRIDGE DETECTION............................................... 6-49

6.6 PAPER FEED......................................................................................... 6-50

6.6.1 OVERVIEW.................................................................................... 6-50

6.6.2 DRIVE – TRAY 1, TRAY 2, AND BY-PASS TRAY ........................ 6-51

6.6.3 PAPER LIFT – TRAYS 1 & 2......................................................... 6-52

6.6.4 PAPER SIZE DETECTION – TRAYS 1 & 2................................... 6-53

6.6.5 PAPER HEIGHT DETECTION – TRAYS 1 & 2 ............................. 6-54

6.6.6 PAPER END DETECTION – TRAYS 1 & 2 ................................... 6-54

6.6.7 REGISTRATION............................................................................ 6-55

6.6.8 PAPER FEED LINE SPEED.......................................................... 6-56

6.6.9 GRIP ROLLER RELEASE MECHANISM....................................... 6-57

vii

6.7 IMAGE TRANSFER AND PAPER SEPARATION .................................. 6-58

6.7.1 OVERVIEW.................................................................................... 6-58

6.7.2 TRANSFER BELT DRIVE.............................................................. 6-59

6.7.3 TRANSFER CURRENT ................................................................. 6-60

6.7.4 TRANSFER BELT CLEANING ...................................................... 6-61

6.7.5 TRANSFER BELT CONTACT ....................................................... 6-62

Mechanism......................................................................................... 6-62

Transfer Belt Sensor .......................................................................... 6-63

ACS (Auto Color Sensing) Mode........................................................ 6-64

6.8 FUSING .................................................................................................. 6-65

6.8.1 OVERVIEW.................................................................................... 6-65

6.8.2 FUSING UNIT DRIVE .................................................................... 6-66

Belt and Rollers.................................................................................. 6-66

Fusing Clutch ..................................................................................... 6-66

6.8.3 FUSING TEMPERATURE CONTROL........................................... 6-67

Fusing Temperatures......................................................................... 6-67

Temperature Corrections ................................................................... 6-68

Overheat Protection ........................................................................... 6-68

6.8.4 OIL SUPPLY AND CLEANING ...................................................... 6-69

Oil Supply Pad and Roller .................................................................. 6-69

Oil Supply Mechanism ....................................................................... 6-70

6.8.5 WASTE OIL ................................................................................... 6-71

Bottle Set Sensor ............................................................................... 6-71

Waste Oil Sensor ............................................................................... 6-72

6.8.6 NEW FUSING OIL SUPPLY UNIT DETECTION ........................... 6-73

6.8.7 NEW FUSING UNIT DETECTION................................................. 6-74

6.8.8 ENERGY SAVER MODE............................................................... 6-75

Level 1 Energy Saver Mode............................................................... 6-75

Level 2 Energy Saver Mode............................................................... 6-75

6.9 PAPER EXIT........................................................................................... 6-76

6.9.1 OVERVIEW.................................................................................... 6-76

6.9.2 PAPER OVERFLOW DETECTION................................................ 6-77

6.10 CONTROLLER ..................................................................................... 6-78

6.10.1 OVERVIEW.................................................................................. 6-78

6.10.2 BOARD LAYOUT......................................................................... 6-80

6.10.3 PRINT DATA PROCESSING....................................................... 6-81

RPCS Driver....................................................................................... 6-81

PCL5c Driver...................................................................................... 6-81

PS3 Driver.......................................................................................... 6-82

CMS (Color Management System) .................................................... 6-82

Gray Correction.................................................................................. 6-82

BG/UCR (Black Generation/Under Color Removal) ........................... 6-82

Gamma Correction............................................................................. 6-82

Toner Limitation ................................................................................. 6-83

Dither Processing and ROP/RIP ........................................................ 6-83

6.10.4 CONTROLLER FUNCTIONS....................................................... 6-84

Sample Print....................................................................................... 6-84

Locked Print ....................................................................................... 6-84

Paper Source Selection ..................................................................... 6-85

viii

Auto Continue .................................................................................... 6-86

Paper Output Tray.............................................................................. 6-87

Stapling .............................................................................................. 6-88

Punching ............................................................................................ 6-88

6.11 HARD DISK .......................................................................................... 6-89

6.12 IEEE1394 INTERFACE ........................................................................ 6-90

6.12.1 SPECIFICATIONS....................................................................... 6-90

Hardware Specification ...................................................................... 6-90

System Requirements........................................................................ 6-90

6.12.2 IEEE1394 SCSI PRINT................................................................ 6-90

6.12.3 BLOCK DIAGRAM....................................................................... 6-91

6.12.4 PIN ASSIGNMENT ...................................................................... 6-91

6.12.5 REMARKS ................................................................................... 6-92

6.12.6 TROUBLESHOOTING NOTES.................................................... 6-92

6.12.7 IP OVER 1394 ............................................................................. 6-93

6.13 IEEE802.11B (WIRELESS LAN) .......................................................... 6-94

6.13.1 SPECIFICATIONS....................................................................... 6-94

6.13.2 BLOCK DIAGRAM....................................................................... 6-95

6.13.3 TRANSMISSION MODE.............................................................. 6-96

Ad Hoc Mode ..................................................................................... 6-96

Infrastructure Mode............................................................................ 6-96

6.13.4 SECURITY FEATURES............................................................... 6-97

SSID (Service Set ID) ........................................................................ 6-97

Using the SSID in Ad hoc mode......................................................... 6-97

WEP (Wired Equivalent Privacy)........................................................ 6-97

MAC Address..................................................................................... 6-97

6.13.5 TROUBLESHOOTING NOTES.................................................... 6-98

Communication Status....................................................................... 6-98

Channel Settings................................................................................ 6-98

Troubleshooting steps........................................................................ 6-99

6.14 BLUETOOTH (WIRELESS)................................................................ 6-100

6.14.1 SPECIFICATIONS..................................................................... 6-100

6.14.2 BLOCK DIAGRAM..................................................................... 6-100

6.14.3 COMMUNICATION USING BLUETOOTH................................. 6-101

Piconet ............................................................................................. 6-101

Frequency Hopping Spread Spectrum (FHSS) ................................ 6-101

Profiles ............................................................................................. 6-102

6.14.4 SECURITY FEATURES............................................................. 6-102

Public and Private Mode .................................................................. 6-102

PIN Code (Personal Identification Number) ..................................... 6-102

6.15 USB .................................................................................................... 6-103

6.15.1 SPECIFICATIONS..................................................................... 6-103

6.15.2 USB 1.1/2.0................................................................................ 6-103

6.15.3 USB CONNECTORS ................................................................. 6-103

6.15.4 PIN ASSIGNMENT .................................................................... 6-104

6.15.5 REMARKS ................................................................................. 6-104

Related SP Mode............................................................................. 6-104

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

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

2. SUPPORTED PAPER SIZES..............................................................SPEC-3

2.1 PAPER FEED ..............................................................................SPEC-3

2.2 PAPER EXIT................................................................................SPEC-4

3. SOFTWARE ACCESSORIES..............................................................SPEC-5

3.1 PRINTER DRIVERS ....................................................................SPEC-5

3.2 UTILITY SOFTWARE ..................................................................SPEC-5

4. MACHINE CONFIGURATION .............................................................SPEC-6

5. OPTIONAL EQUIPMENT ....................................................................SPEC-8

5.1 500-SHEET TRAY .......................................................................SPEC-8

5.2 1000-SHEET TRAY .....................................................................SPEC-8

5.3 2000-SHEET LARGE CAPACITY TRAY .....................................SPEC-8

5.4 TWO-TRAY FINISHER & PUNCH UNIT......................................SPEC-9

5.5 FOUR-BIN MAILBOX.................................................................SPEC-10

5.6 PRINTER WITH CF EXPANDER...............................................SPEC-11

GENERAL SPECIFICATIONS (COPY MODE)...........................SPEC-11

GENERAL SPECIFICATIONS (SCANNER MODE)....................SPEC-15

SOFTWARE ACCESSORIES.....................................................SPEC-17

OPTIONAL EQUIPMENT FOR CF EXPANDER.........................SPEC-17

PERIPHERALS

DUPLEX UNIT (G348)

1. REPLACEMENT AND ADJUSTMENT................................. G348-1

1.1 DUPLEX INVERTER UNIT.................................................................G348-1

1.1.1 TOP COVER..............................................................................G348-1

1.1.2 DUPLEX CONTROL BOARD ....................................................G348-1

1.1.3 DUPLEX INVERTER MOTOR 1 ................................................G348-2

1.1.4 DUPLEX INVERTER MOTOR 2 AND SWITCH.........................G348-2

1.1.5 EXIT SENSOR 3 AND DUPLEX INVERTER SENSOR.............G348-3

1.1.6 EXIT SENSOR 1 AND 2 ............................................................G348-3

1.2 DUPLEX FEED UNIT..........................................................................G348-4

1.2.1 DUPLEX DRIVE BOARD...........................................................G348-4

1.2.2 DUPLEX FEED MOTOR............................................................G348-4

1.2.3 DUPLEX FEED SENSOR..........................................................G348-5

2. DETAILED DESCRIPTIONS ................................................ G348-6

2.1 OVERVIEW ........................................................................................G348-6

2.2 DUPLEX OPERATION .......................................................................G348-7

2.2.1 UP TO A4/LT (81/2" X 11") LEF.................................................G348-7

2.2.2 LARGER THAN A4/LT (81/2" X 11") LEF ..................................G348-7

2.3 DUPLEX INVERTER UNIT.................................................................G348-8

2.3.1 DRIVE........................................................................................G348-8

2.3.2 FEED TO EXTERNAL EXIT TRAY (NON-DUPLEX MODE)......G348-9

2.3.3 FEED TO DUPLEX FEED UNIT ..............................................G348-10

2.3.4 FEED TO TWO-TRAY FINISHER............................................G348-11

With Optional One-Tray Paper Feed Unit ....................................G348-11

With Optional LCT or Two-Tray Paper Feed Unit.........................G348-11

2.4 DUPLEX FEED UNIT........................................................................G348-12

2.4.1 DRIVE......................................................................................G348-12

2.4.2 FEED-IN AND FEED-OUT.......................................................G348-12

CF EXPANDER (G367)

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

1.1 SPECIAL TOOLS................................................................................ 1-1

1.2 LUBRICANTS ........................................................................................... 1-1

1.3 IMAGE ADJUSTEMNT ............................................................................. 1-2

1.3.1 PRINTING........................................................................................ 1-2

Leading edge registration..................................................................... 1-2

Side-to-side registration ....................................................................... 1-2

1.3.2 SCANNING...................................................................................... 1-2

Scanner sub-scan magnification .......................................................... 1-2

Scanner leading edge and side-to-side registration ............................. 1-2

Main scan dot position correction......................................................... 1-3

1.3.3 ARDF ............................................................................................... 1-4

ARDF side-to-side and leading edge registration................................. 1-4

1.3.4 PRINTER GAMMA CORRECTION.................................................. 1-5

Printer Mode......................................................................................... 1-5

Copy Mode........................................................................................... 1-7

1.4 REPLACEMENT..................................................................................... 1-10

1.4.1 EXPOSURE GLASS...................................................................... 1-10

1.4.2 ORIGINAL LENGTH/WIDTH SENSOR ......................................... 1-10

1.4.3 SENSOR BOARD UNIT (SBU)...................................................... 1-11

1.4.4 EXPOSURE LAMP STABILIZER................................................... 1-12

1.4.5 XENON LAMP ............................................................................... 1-12

1.4.6 SCANNER POWER SUPPLY UNIT (PSU).................................... 1-14

1.4.7 SCANNER MOTOR ....................................................................... 1-14

1.4.8 FRONT SCANNER WIRE.............................................................. 1-15

1.4.9 REAR SCANNER WIRE ................................................................ 1-18

1.4.10 NVRAM REPLACEMENT PROCEDURE .................................... 1-20

NVRAM on the Controller (IC9).......................................................... 1-20

NVRAM Expansion Board on the Controller (CN13).......................... 1-20

NVRAM on the BCU (IC20)................................................................ 1-21

1.4.11 REQUIRED ACTIONS WHEN REPLACING ITEMS.................... 1-22

1.5 OTHERS................................................................................................. 1-23

1.5.1 TOUCH PANEL POSITION ADJUSTMENT .................................. 1-23

2. TROUBLESHOOTING................................................................. 2-1

2.1 SCANNER TEST MODE .......................................................................... 2-1

2.1.1 VPU TEST MODE............................................................................ 2-1

SP4-907-1 VPU Test Pattern: R.......................................................... 2-1

SP4-907-2 VPU Test Pattern: G ......................................................... 2-1

SP4-907-3 VPU Test Pattern: B.......................................................... 2-1

2.1.2 IPU TEST MODE............................................................................. 2-2

SP4-904-1 Register Write/Read Check Result.................................... 2-2

SP4-904-2 Image Path Check Result .................................................. 2-2

3. DETALED DESCRIPTIONS ........................................................ 3-1

3.1 SCANNING............................................................................................... 3-1

3.1.1 OVERVIEW...................................................................................... 3-1

3.1.2 SCANNER DRIVE ........................................................................... 3-2

3.1.3 ORIGINAL SIZE DETECTION ......................................................... 3-3

3.1.4 OTHERS.......................................................................................... 3-5

DC Power Supply................................................................................. 3-5

Anti-Condensation Heater.................................................................... 3-5

3.2 IMAGE PROCESSING ............................................................................. 3-6

3.2.1 OVERVIEW...................................................................................... 3-6

3.2.2 SBU BLOCK DIAGRAM................................................................... 3-7

Signal Processing ................................................................................ 3-7

A/D Conversion.................................................................................... 3-7

White Level Correction:........................................................................ 3-7

Others .................................................................................................. 3-7

Black Level Correction ......................................................................... 3-8

Adjustments ......................................................................................... 3-8

VPU Test Mode.................................................................................... 3-8

3.2.3 IPU BLOCK DIAGRAM.................................................................... 3-9

Shading Correction .............................................................................. 3-9

Picture Element (Dot Position) Correction.......................................... 3-10

Scan Line Correction.......................................................................... 3-10

Image Separation............................................................................... 3-10

Scanner Gamma Correction (RGB Gamma Correction) .................... 3-11

Filtering .............................................................................................. 3-12

ADS (Auto Image Density Selection) ................................................. 3-12

Color Conversion ............................................................................... 3-13

Main Scan Magnification.................................................................... 3-14

Printer Gamma Correction ................................................................. 3-15

Error Diffusion .................................................................................... 3-17

IPU Board Test................................................................................... 3-17

3.3 PRINTER ENGINE ................................................................................. 3-18

3.3.1 DIFFERENCES IN THE PRINTER MAINFRAME.......................... 3-18

3.3.2 PAPER FEED LINE SPEED.......................................................... 3-18

3.3.3 ENERGY SAVER MODES............................................................. 3-19

Overview ............................................................................................ 3-19

Panel Off Mode .................................................................................. 3-20

Auto Off Mode.................................................................................... 3-21

xii

3.4 SCANNER FUNCTIONS ........................................................................ 3-22

3.4.1 IMAGE PROCESSING FOR SCANNER MODE............................ 3-22

Image Data Path ................................................................................ 3-22

3.5 HARD DISK DRIVES.............................................................................. 3-23

3.6 IMAGE DATA PATH ............................................................................... 3-24

Copier Application.............................................................................. 3-24

Printer Application.............................................................................. 3-24

Scanner Application (1 bit/8 bits)........................................................ 3-24

Fax Application (Transmission/Reception)......................................... 3-24

xiii

17 January, 2003 INSTALLATION REQUIREMENTS

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)

2. Humidity Range: 15% to 80% RH

3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight)

4. Ventilation: 3 times/hr/person 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 might 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. (Inclination on any side must be no more than 5 mm.)

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

1.1.2 MACHINE LEVEL

Installation

Front to back: Within 5 mm (0.2")

Right to left: Within 5 mm (0.2")

1-1

INSTALLATION REQUIREMENTS 17 January, 2003

1.1.3 MACHINE SPACE REQUIREMENT

Place the machine near the power source, providing clearance as shown.

Main Unit

575mm

G080I901.WMF

Main Unit and Finisher

1450mm

678mm

B: Over 100 mm (4") C: Over 550 mm (22") D: Over 700 mm (28")

: Over 460 mm (18")

678mm

G080I902.WMF

A: Over 460 mm (18") B: Over 100 mm (4")

C: Over 550 mm (22") D: Over 700 mm (28")

1-2

17 January, 2003 INSTALLATION REQUIREMENTS

CF Expander with Rack

: Over 460 mm (18.1")

from the printer mainframe

B: Over 100 mm (3.9")

from the printer mainframe

C: Over 550 mm (21.7")

from the printer mainframe

D: Over 700 mm (27.6")

from the printer mainframe

G367I901.WMF

Installation

CF Expander without Rack

A: Over 460 mm (18") B: Over 100 mm (4") C: Over 100 mm (4") D: Over 100 mm (4")

G367I902.WMF

E: Over 100 mm (4") F: Over 700 mm (28") G: Over 450 mm (17.7")

1-3

INSTALLATION REQUIREMENTS 17 January, 2003

1.1.4 POWER REQUIREMENTS

!CAUTION

1. Insert firmly the plug 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 10 A 220 V ~ 240 V, 50 Hz/60 Hz: More than 6 A

2. Permissible voltage fluctuation: ±10 %

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

1-4

17 January, 2003 OPTIONAL UNIT COMBINATIONS

1.2 OPTIONAL UNIT COMBINATIONS

Item

No.

1 PFU (1 Tray) Items 2, 3 2 PFU (2 Trays) Items 1, 3 3 LCT Items 1, 2 4

5 3 types of punch

6 Four-bin mailbox Items 4, 5, 15, 20 7 Duplex unit 8 3 types of memory

9 20 GB HDD

10 IEEE 1394 Items 11, 12, 13 11 IEEE 802.11b Items 10, 12, 13 12 USB Items 10, 11, 13 13 Bluetooth Items 10, 11, 12 14 NVRAM

15 CF expander Item 6 Item 18 or 19

16 40GB HDD Option for item 15 17 Rack Item 1, 2, or 3 Option for item 15 18 ARDF Item 19 Option for item 15 19 Platen cover Item 18 Option for item 15 20 Multi-bin output

21 Fax unit Option for item 15 22 G3 additional unit Item 23 Option for item 21 23 G4 unit Item 22 Option for item 21 24 JBIG Option for item 21

25 Handset

Options Alternative Required Remarks

Item 16 and item 17 are recommended. See note 2.

Option for item 15

Option for item 21 (U.S. model only)

Two-tray finisher

kit

DIMMs

tray

• Item 7

• Item 8 (Total 128

MB needed), 9,

Item 6, 20

Item 4, 5, 6 Item 7

or 16

• Item 1, 2, or 3

Item 4

Installation

NOTE: 1) Two memory DIMMs (up to 384 MB) can be installed.

2) If the 40GB HDD is not installed, some copier functions such as duplex copying and sorting, and document server functions cannot be used.

1-5

INSTALLATION FLOW CHART 17 January, 2003

1.3 INSTALLATION FLOW CHART

The following flow chart shows how to install the optional units more efficiently.

Without Optional CF Expander

Unpack the printer.

Will the paper feed unit or LCT be installed?

Yes No

Place the printer on the paper feed unit or LCT.

Install the paper feed unit or LCT.

Install the controller options (if required).

Will the duplex unit be installed?

Yes No

Install the duplex unit.

Will the two-tray finisher be installed?

NoYes

Install the punch unit

(if required).

Install the two-tray finisher.

Install the printer.

Install the four-bin mailbox

(if required).

G080I903.WMF

Two-tray Finisher: Needs the duplex unit, HDD or at least 128 MB of memory,

and a paper tray unit or LCT.

Punch Unit: Needs the finisher.

1-6

17 January, 2003 INSTALLATION FLOW CHART

With Optional CF Expander

Unpack the printer.

Will the paper feed unit (PFU) or LCT be

installed?

1. Place the printer on the PFU or LCT.

2. Install the PFU or LCT.

Install the controller options (if required).

Install the duplex unit (if required).

Will the rack be installed?

Yes

1. Install the printer.

2. Assemble the rack during printer initialaization

Will the two-tray finisher be installed?

Yes

Install the punch unit (if required).

Install the multi-bin

output tray (if required).

Install the two-tray finisher.

Select the language.

Installation

Install the printer

Set the date and time.

Dock the printer and rack.

Clear the memory of IPU/Net file/

Scanner. (SP5-801-10, 12)

Install the CF expander.

Perform ACC.

Install the platen cover or ARDF.

Check magnification and registration.

Adjust the operation panel display if

Set the meter charge mode depending

necessary.

on the service contract.

G080I906.WMF

NOTE: Install the fax unit after making sure that the CF expander works properly.

(☛ “1. Installation” in the service manual for the fax option)

1-7

MACHINE INSTALLATION 17 January, 2003

1.4 MACHINE INSTALLATION

Refer to the Operating Instructions. If the customer has made a service contract, change the settings of the following SP mode menus in accordance with it.

NOTE: 1) The meter charge mode must be enabled for any meter click counter

contract (☛ SP5-930-1).

2) One of the counter methods (developments/prints) must be selected in accordance with the contract (☛ SP5-045-1).

3) The default of the meter-charge mode is "off."

4) The meter-charge counter cannot be reset.

Item SP No. Function Default

Meter charge

Counting method

A3/11" x 17" double counting

SP5-930-1 Specifies whether the meter charge mode is

enabled or disabled.

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) 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.

• When the ACS mode is on, a monochrome

page is counted as such even if it follows a color page.

Meter charge mode disabled:

• The Counter menu is not displayed.

• The total counter starts from 0.

• When the ACS mode is on, a monochrome

page is counted as a color page if it follows a color page.

NOTE: The menu items, "Show Counter" and

"Print," appear in the UP mode after the meter charge mode (SP5-930-1) is enabled or the optional CF expander is installed. (These menu items always appear after the CF expander is installed.)

SP5-045-1 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 SP7-825-001.

SP5-104-1 Specifies whether the counter is doubled for

A3/11" x 17" paper.

"OFF"

"0": Developments

"No": Single counting

1-8

17 January, 2003 MACHINE INSTALLATION

Item SP No. Function Default

PM warning display 1

SP5-930-3 Specifies whether the PM warning for the

PCUs, development units, and fusing unit is

"Click 1"

displayed when the replacement time arrives. Click 1: Displayed Click 2: Not displayed

PM warning display 2

Fax No. setting

SP5-930-4

SP5-930-5

Specifies whether the PM warnings for the paper feed roller, transfer unit, and transfer cleaning unit are displayed.

SP5-812-2 Programs the service station fax number.

The number is printed on the counter list when

"No Alert": Not displayed

the meter charge mode is selected, so that the user can fax the counter data to the service station.

Counter reset

SP7-825-1 Resets the counters to "0."

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

Installation

1-9

NOTES FOR TRANSPORTING THE MACHINE 17 January, 2003

1.5 NOTES FOR TRANSPORTING THE MACHINE

1.5.1 MACHINE STANDS

If it is difficult to slide the machine across the floor after installing the optional paper feed unit or LCT, remove the two stands with the following procedure.

[A]

G080I910.WMF

[B]

G080I911.WMF

1. Remove all trays in the optional paper feed unit or LCT.

2. Remove the front stand [A] (! x 2).

3. Remove the rear stand [B] (! x 2, 2 brackets).

CAUTION: Reinstall the two stands in their original positions, or the machine might

tip over when drawing out the paper trays and so on.

1-10

17 January, 2003 NOTES FOR TRANSPORTING THE MACHINE

1.5.2 MACHINE BODY

!CAUTION

Fix the transfer belt in its position before moving the machine, otherwise the transfer belt and the black PCU may be damaged.

Before transporting the machine for both short and long hauls, return it to its original condition.

1. Remove the toner cartridges to prevent toner from flowing into the toner supply tube due to vibrations experienced during transport. This may cause the tube to be clogged with toner.

2. Put air packing into the toner cartridge holder to shield the toner supply entrance. This prevents toner from flowing out to the toner cartridge holder.

3. Set the lock pin (which comes with the machine) in the transfer belt unit.

NOTE: The lower end of the transfer belt moves. The surfaces of the belt and

PCU may be damaged by the friction between them if you transport the machine without locking the belt.

Installation

4. Make sure there is no paper left in the paper trays and fix down the bottom plates with a sheet of paper and tape.

5. Empty out the waste toner bottle and attach securing tape to prevent the bottle from coming out.

6. Empty out the waste oil bottle and attach securing tape to prevent the bottle from coming out.

[A]

G080I904.WMF

7. Turn the release lever [A] counterclockwise to its lowermost position. (The lever does not stay in this position if you do not hold it.) Stick the lever in this position with tape. NOTE: The release lever lifts the transfer belt up and presses it against the

black PCU. The surfaces of the belt and PCU may be damaged by the friction between them if you transport the machine with the two units in this position.

1-11

NOTES FOR TRANSPORTING THE MACHINE 17 January, 2003

8. Attach shipping tape to the covers and doors, or shrink-wrap the machine tightly.

NOTE: 1) If pre-installing machines for some test prints at a service depot, use a

jig oil supply unit, and not the oil supply unit enclosed as an accessory.

This is because the toner supply system uses a touch-and-release mechanism, which can cause the unit to move freely up and down during transport if shipping the mainframe with the oil supply unit installed. This in turn may cause damage to the white holder on the fusing unit. However if simply moving the machine from floor to floor, the oil supply unit can be left installed.

2) If shipping a used machine to a new location, dispose of the used oil supply unit and install a new one because of the reason explained above. This is not necessary when simply moving the machine from floor to floor.

3) Whenever having moved the machine to a new location, be sure to perform Auto Adjust (User Program mode) or forced Line Position Adjustment (SP5-993-002) to optimize color line alignment.

4) Make sure that the side fences in the trays are properly positioned to prevent color shifting.

1-12

17 January, 2003 OPTIONAL UNIT INSTALLATION

1.6 OPTIONAL UNIT INSTALLATION

1.6.1 LIST OF OPTIONS

The available printer options are listed below. Installation is explained in the Operating Instructions. This list does not include the CF expander and its options.

• Paper Feed Unit (500 sheets x 1)

• Paper Feed Unit (500 sheets x 2)

• Large Capacity Tray

• Two-tray Finisher

• Four-bin Mailbox

• DIMM Memory (64/128/256 MB)

• IEEE1394

• IEEE 802.11b

• USB

• Bluetooth

• 20GB HDD

• NVRAM

Installation

1-13

OPTIONAL UNIT INSTALLATION 17 January, 2003

1.6.2 PUNCH UNIT INSTALLATION

Accessory Check

Check the quantity and condition of the accessories in the box against the following list:

Description Q’ty

1. Punch unit ............................................................................. 1

2. Sensor arm ........................................................................... 1

3. Hopper .................................................................................. 1

4. Step screw ............................................................................ 1

5. Spring.................................................................................... 1

6. Spacer (2 mm) ...................................................................... 1

7. Spacer (1 mm) ...................................................................... 1

8. Tapping screw....................................................................... 1

9. Tapping screw....................................................................... 2

1-14

17 January, 2003 OPTIONAL UNIT INSTALLATION

Installation Procedure

[A]

Installation

B377I102.WMF

[C]

B377I103.WMF

!CAUTION

Switch off the main machine and unplug its power cord. If the two-tray finisher has been installed, disconnect it and pull it away from the machine.

1. Unpack the punch unit and remove all tapes and shipping retainers.

2. Open the front door and remove the rear cover [A] (! x 4).

3. Remove the bracket [B] (! x 2) and paper guide [C] (stepped ! x 1).

[B]

1-15

OPTIONAL UNIT INSTALLATION 17 January, 2003

[B]

[A]

[C]

B377I101.WMF

[E]

4. Remove the hopper cover [A] (! x 2).

5. Install the sensor bracket [B] (stepped ! x 1).

6. Install the spring [C].

7. Install the 2 mm spacer [D].

8. Install the punch unit [E] (! x 2, stepped ! x 1).

1-16

B377I104.WMF

[D]

17 January, 2003 OPTIONAL UNIT INSTALLATION

[A]

B377I200.WMF

Installation

[B]

B377I106.WMF

9. Connect the harnesses [A] and clamp them as shown.

10. Slide in the hopper [B].

11. Fasten the two 1-mm spacers [C] to the rear frame for future adjustment. NOTE: The spacers are used to adjust the horizontal positioning of the punch

holes.

12. Reassemble the finisher and check the punch operation.

[C]

1-17

OPTIONAL UNIT INSTALLATION 17 January, 2003

1.6.3 CF EXPANDER RACK

NOTE: 1) Section 1.6.4 shows the procedure for installing the Copier Feature

Expander in a machine equipped with the optional rack. Before installing the CF expander, you must install the rack.

2) For the printer mainframe and printer option installation procedures, please refer to the Operating Instructions "Set-up Guide."

3) To avoid a possible build-up of ozone, make sure to install the machine in a room that is well ventilated.

!CAUTION

Rating Voltage:

G367I914.WMF

Rating voltage of output connector;

For the ARDF

Maximum DC 24V

G367I208.WMF

Rating voltage of I/F harness connector;

Scanner I/F Harness

Maximum DC 24V

1-18

17 January, 2003 OPTIONAL UNIT INSTALLATION

Accessories Check List

Description Q'ty

1. Left Side Stand ..................................................................... 1

2. Right Side Stand ................................................................... 1

3. Table Board .......................................................................... 1

4. Backboard............................................................................. 1

5. Left Arm ................................................................................ 1

6. Right Arm .............................................................................. 1

7. Left Securing Bracket............................................................ 1

8. Right Securing Bracket ......................................................... 1

9. Grounding Wire..................................................................... 2

10. Grounding Bracket................................................................ 1

11. Large Thumb Screw.............................................................. 4

12. Small Thumb Screw.............................................................. 4

13. Spacer................................................................................... 2

14. Screw (M6 x 10).................................................................... 14

15. Screw (M4 x 6)...................................................................... 4

16. Washer.................................................................................. 4

17. Spring Washer ...................................................................... 4

18. Clamp.................................................................................... 1

Installation

1-19

OPTIONAL UNIT INSTALLATION 17 January, 2003

Assembling the Rack

1. Insert a screw [A] about half way into the center holes of both the left [B]

[B]

and right [C] side stands.

2. Hook the center part of the backboard onto the 2 screws.

[C]

3. Making sure that the two side stands are parallel, insert the remaining screws, then tighten all 6 screws.

4. With the 2 square holes [D] in the table board in front of you as shown, attach the left [E] and right [F] arms. When attaching the right arm, secure the ground wires [G] with screws [H] as shown. NOTE: Please make sure to orient the

table with the square holes toward you.

[A]

[D]

[H]

G367I101.WMF

[E]

[F]

[G]

G367I102.WMF

1-20

17 January, 2003 OPTIONAL UNIT INSTALLATION

[E]

[A]

[B]

[C]

[D]

[F]

[H] [I]

[G]

G367I103.WMF

5. Set the table board [A] on the stand as shown.

NOTE: 1) Make sure that the screw holes for the scanner unit are positioned

at the right rear [C] and left front [B] of the table board.

2) Recommended attachment positions for the table board:

• Machine with Two-tray Paper Supply Unit & LCT: 2nd hole from

the top

• Machine with One-tray Paper Supply Unit: 6th hole from the top

3) When attaching the table board at a position lower than the recommended one, make sure the upper right cover can be opened and the toner cartridges (especially black) can be replaced. When attaching the table board below the recommended position, it is necessary to shift the printer mainframe 10 cm (3.9") toward the front so that the upper right cover can be opened for toner replenishment.

G367I903.WMF

Installation

6. Align the cushion [D] (enclosed as accessories for the optional CF Expander) as follows and attach it to the backboard [E]:

• Align the top side with the bottom end of the lowermost slot of the right side

stand [F].

• Align the right side with the left side of the right side stand [G].

NOTE: The cushion prevents the right side stand [I] from damaging the

scanner cable [H]. The cushion can be ineffective if attached to an incorrect position.

1-21

OPTIONAL UNIT INSTALLATION 17 January, 2003

7. Secure the two grounding wires [A] (! x 2 each). There is a wire at the left side and one at the right side.

8. Attach the securing brackets [B] to the left and right arms as shown (1 thumb screw [C] for each).

Docking the Rack and Printer Mainframe

NOTE: If the Finisher is going to be

installed, the mounting bracket of the rail should be attached after docking the mainframe with the rack. In addition, the Finisher should be attached after docking is complete.

[B]

[A]

[C]

G367I104.WMF

1. Remove the paper tray and front stand [A] from the paper feed unit as shown (! x 2).

[A]

G367I201.WMF

2. Remove the brackets [B] and rear stand [C] (! x 1 for each).

3. Reinsert the paper tray. NOTE: Since the front and rear

[B]

stands will no longer be necessary, dispose of them according to local regulations.

4. Place the assembled rack down in the area where the mainframe is to be installed.

[B]

[C]

G367I202.WMF

5. Adjust the height of the side stand legs for stabilization if necessary.

CAUTION: The stand is designed to support objects placed on the table only after

the rack and mainframe have been docked. Therefore, use caution in handling the assembled stand before docking, as it is relatively unstable.

1-22

17 January, 2003 OPTIONAL UNIT INSTALLATION

[B]

[G]

[H]

Installation

[J]

[I]

[A]

[F]

[C]

G367I206.WMF

[D]

[E]

6. Attach the right bridging bracket [A] to the rack’s right stand (2 screws [B]).

7. Attach the left bridging bracket [C] to the lower left corner of the paper feed unit (2 stepped screws [D], 2 spring washers [E] and 2 washers [F]).

8. Insert the printer in between the racks as shown and set it to the desired position.

9. Secure the right bridging bracket [A] to the paper feed unit (2 stepped screws [G], 2 spring washers [H] and 2 washers [I]).

10. Secure the left bridging bracket [C] to the rack’s left stand (! x 2 [J]).

[M]

[L]

[K]

11. Remove the mailbox upper cover [K]. With a pair of pliers, remove the small square cutout [L] in the corner of the cover with a pair of pliers.

Then, set the grounding bracket [M] in the machine as shown and reattach the upper cover.

G367I217.WMF

1-23

OPTIONAL UNIT INSTALLATION 17 January, 2003

1.6.4 CF EXPANDER

NOTE: This section shows the procedure for installing the Copier Feature

Expander in a machine equipped with the optional rack. For the procedure

Accessories Check List

Description Q'ty

for installing the rack, see section 1.6.3.

1. Scanner Unit ......................................................................... 1

2. Main Switch Cover ................................................................ 1

3. Screw (M3 x 6)...................................................................... 3

4. Screw (M3 x 6)...................................................................... 2

5. IPU Board ............................................................................. 1

6. NVRAM Board ...................................................................... 1

7. DIMM #1 (SYSTEM) ............................................................. 1

8. DIMM #2 (PRT/SCN) ............................................................ 1

9. 128 MB DIMM (for 230V only)............................................... 1

10. Pad........................................................................................ 1

11. Power Strip (for 230V only)................................................... 1

12. Cushion................................................................................. 1

CF Expander Installation

[A]

G367I203.WMF

1. Remove the controller board (! x 2) [A].

1-24

17 January, 2003 OPTIONAL UNIT INSTALLATION

[C]

[A]

[B]

[D]

[E]

Installation

[C]

[B]

G367I205.WMF

G367I701.WMF

2. Replace the printer module [A] in the upper slot with DIMM #1 (SYSTEM) [B].

3. Insert DIMM #2 (PRT/SCN) [C] into the center slot.

4. Insert the 128MB memory [D]. NOTE: 1) It is not necessary to install the additional memory if the present

memory is 192MB or more.

2) Make sure that the modules are firmly set in their slots. If they are not, this will cause SC997.

5. Attach the NVRAM board [E] (! x 1).

NOTE: 1) It is not necessary to install this NVRAM board in machines that

already contain the optional User Account Enhancement Unit Type C.

2) If replacing the Unit Type C with the NVRAM board, be sure to back up and re-enter the User Code data using SmartNetMonitor for Admin.

1-25

OPTIONAL UNIT INSTALLATION 17 January, 2003

[B]

[A]

G367I204.WMF

6. Remove the scanner connector cover [A].

7. Install the IPU board [B] (! x 2).

8. Reinsert the controller into the printer using the 2 screws (M3 x 6) enclosed as accessories instead of the original screws. NOTE: Make sure that the IPU board is firmly connected to the controller

board. If it is not, this will cause SC990.

1-26

17 January, 2003 OPTIONAL UNIT INSTALLATION

[B]

Installation

[A]

[C]

[I] [H]

[D]

G367I905.WMF

9. Align the cushion [A] as follows and attach it to the backboard [B]:

• Align the top side with the bottom end of the lowermost slot of the right side

stand [C].

• Align the right side with the left side of the right side stand [D].

NOTE: The cushion prevents the right side stand [H] from damaging the

scanner cable [I]. The cushion can be ineffective if attached to an incorrect position.

G367I903.WMF

1-27

OPTIONAL UNIT INSTALLATION 17 January, 2003

[C]

[D]

[A]

[E]

[B]

[G]

[F]

G367I105.WMF

[H]

G367I208.WMF

10. Place the pad [A] on the table board [B].

11. Place the scanner unit [C] on the table board so that the scanner unit legs [D] line up with the indents [E] in the table as shown.

12. Secure the scanner unit in place (! x 2 [F] and spacers [G] enclosed as accessories for the optional rack).

13. Remove the shipping tape from the scanner cables.

14. Lead the scanner cable [H] along the inside of the rack as shown, then connect it to the IPU board on the controller frame.

1-28

17 January, 2003 OPTIONAL UNIT INSTALLATION

For 120V machines

[A]

Installation

[B]

For 230V machines

G367I602.WMF

[C]

[E]

[D]

G367I601.WMF

15. For 120V machines: Connect the printer power cord [A] to the output port on the scanner, then plug the scanner power cord [B] into the power outlet.

For 230V machines: Connect the power cords [C] from both the printer and scanner to the power strip [D] enclosed as an accessory. Then, plug the power cord [E] into the power outlet.

16. Attach the printer main switch cover.

NOTE: Make sure that the wall outlet is near the machine and freely accessible, so

that in the event of an emergency the cord can be easily unplugged.

For 230V machines: In addition, make sure that the power strip is also freely accessible, so that in the event of an emergency the power cords from the machines can be easily unplugged.

1-29

OPTIONAL UNIT INSTALLATION 17 January, 2003

17. Select the language in the UP mode.

18. Set the date and time.

19. Enter SP Mode.

20. Clear the scanner application settings by using SP5-801-9.

21. Clear the IPU settings by using SP5-801-12.

22. Exit SP mode and turn the main power off/on.

23. Perform Auto Color Calibration (ACC).

24. Make some test copies in the following modes using a C4 Test Chart.

• Full color in Text Mode

• B&W in Text Mode

25. Check the test copies to make sure each of the following is within standard values, making any necessary adjustments. (☛ 3.3 Image Adjustment)

• Leading edge registration

• Side-to-side registration

• Scanner sub-scan magnification

• Scanner leading edge registration

• Scanner side-to-side registration

• ARDF side-to-side registration

• ARDF sheet through registration

26. If necessary, perform the touch panel position adjustment. (☛ 3.6 Others )

27. If the customer has a service contract, change the meter charge SP mode settings accordingly.

1-30

17 January, 2003 OPTIONAL UNIT INSTALLATION

1.6.5 INSTALLING THE HANDSET

[D]

[F]

Installation

[C]

[A]

[E]

[B]

G307I114.WMF

NOTE: The optional handset is for the U.S. model only.

1. Remove the thumb screw [A] on the left spacer.

2. Install the handset bracket [B] on the left arm (! x 2, 1 thumb screw).

3. Install the handset holder [C] on the bracket ((! x 2).

4. Place the handset [D] with the handset cord resting on the cord holder [E] of the bracket.

5. Attach the cord holder [F] (enclosed as accessories for the optional fax unit) to the uppermost end of the front side of the left side stand.

NOTE: Attached to this position, the cord holder prevents the duplex unit and

the upper left cover from catching the handset cord when they are closed. The holder can be ineffective if attached to a lower position.

6. Connect the handset cord to the jack.

1-31

OPTIONAL UNIT INSTALLATION 17 January, 2003

1.6.6 40GB HDD

Accessories Check List

Description Q'ty

1. 40GB HDD ............................................................................ 1

2. Power Cable ......................................................................... 1

3. Harness................................................................................. 1

4. Screw (M3 x 6)...................................................................... 2

5. Key Top (Document Server) ................................................. 1

40 GB HDD Installation

1. Remove the controller board [A] ((! x 2).

2. Mount the 40GB HDD [B] on the controller (" x 2, ! x 2). NOTE: If the CF expander has

already been installed, remove the IPU board first, then install the HDD.

3. Reinsert the controller in the printer using the 2 screws (M3 x

6) enclosed in the CF expander, instead of the original screws. NOTE: When installing the HDD

and CF expander simultaneously, be sure to install both before performing the next step.

4. Make sure that the power cords are properly plugged in, then turn on the main switch. Format the HDD according to the instructions displayed on the touch panel. Print the configuration page and confirm that the HDD has been properly installed.

[B]

[A]

G367I203.WMF

G367I215.WMF

1-32

17 January, 2003 OPTIONAL UNIT INSTALLATION

5. Remove the cover key top [A] and replace it with the document box key top [B].

[A]

[B]

Installation

G367I218.WMF

1-33

OPTIONAL UNIT INSTALLATION 17 January, 2003

1.6.7 ARDF

Accessories Check List

Description Q'ty

1. Stepped Screw ..................................................................... 2

2. Screw (M4 x 10) ................................................................... 2

3. Knob Screw .......................................................................... 4

4. Attention Decal – Scanner.................................................... 1

5. Attention Decal – Top Cover................................................. 1

6. Installation Procedure........................................................... 1

[B]

[C]

[A]

G564I151.WMF

ARDF Installation

1. Attach and tighten [A] (! x 2 stud).

2. Mount the ARDF by aligning the screw keyholes [B] in the ARDF support plate

over the stud screws, and slide the ARDF toward the front of the machine.

NOTE: To avoid damaging the ARDF, hold it as shown in the illustration.

3. Secure the ARDF (! x 2 [C]).

1-34

17 January, 2003 OPTIONAL UNIT INSTALLATION

[D]

[A]

[C]

G564I104.WMF

[B]

Installation

[E]

G564I102.WMF

4. Attach the left [A] and right [B] stopper brackets with knob screws [C] (! x 4).

5. Connect the I/F cable [D] (" x 1) to the main machine.

6. Peel off the platen sheet [E] and place it on the exposure glass.

1-35

OPTIONAL UNIT INSTALLATION 17 January, 2003

[A]

G564I103.WMF

[D]

[B]

G564I105.WMF

G564I106.WMF

7. Line up the rear left corner of the platen sheet flush against corner [A] on the

exposure glass.

8. Close the ARDF.

9. Attach the decal [B] to the top cover as shown, choosing the language most

suitable for the machine installed.

[C]

10. Attach the decal [C] to the cover so that the arrow on the decal lines up with the

groove [D] of the left scale as shown. As with step 9, choose the language most suitable for the machine installed.

11. Check the ARDF operation and copy quality. Be sure to check and adjust the

registration for the ARDF with the SP modes.

1-36

17 January, 2003 OPTIONAL UNIT INSTALLATION

1.6.8 MULTI-BIN OUTPUT TRAY

Accessories Check List

Description Q'ty

1. Front Tray Holder .................................................................. 1

2. Rear Tray Holder ................................................................... 1

3. Tray ....................................................................................... 2

4. Screw (3 x 1 4) ...................................................................... 4

5. Discharge Brush .................................................................... 2

6. Ground Plate for Left Cover................................................... 1

7. Ground Plate for Upper Exit................................................... 1

8. Ground Plate for Lower Exit................................................... 1

Installing the Multi-Bin Output Tray

NOTE: Before installing the multi-bin output tray, install the duplex unit.

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

[E]

[D]

unit.

2. Install the ground plate [B] behind the magnet.

3. Install the ground plate [C] on the rear of the left cover.

4. Attach the ground plate to the top cover, aligning the bottom edges of the plate [D] and cover [E].

[C]

[B]

Installation

[A]

G306I101.WMF

5. Attach the discharge brushes [F][G] to the upper edges of the paper exits, so that the ends of the brushes [H][I] touch the ground plates [C][D] respectively. NOTE: Make sure the brushes do not

obstruct paper coming from the exits.

1-37

[H]

[I]

[F]

[G]

G306I102.WMF

OPTIONAL UNIT INSTALLATION 17 January, 2003

6. Install the front [A] and rear [B] tray holders on the top cover (! x 2 for each).

7. Install the upper [C] and lower [D] trays.

8. Turn the main switch on; select the SP mode menu, SP6–901–1; and change the multi-bin output tray setting.

NOTE: The multi-bin output tray is not

automatically recognized by the printer mainframe. The multi-bin output tray cannot be used until you have changed this SP mode setting.

[A]

[C]

[B]

G306I103.WMF

[D]

1-38

17 January, 2003 OPTIONAL UNIT INSTALLATION

1.6.9 ANTI-CONDENSATION HEATER

1. Remove the rear scale [A] (! x 3).

2. Remove the exposure glass [B] with the left scale [C] (! x 2).

NOTE: You do not have to remove the

ADF exposure glass. If the glass is removed, position the glass marker [D] at the rear-left corner when reattaching.

3. Remove the rear cover [E] (! x 3).

4. Remove the right cover [F] (! x 3).

5. Remove the left cover [G] (! x 3).

6. Remove the rear frame [H] (! x 12, " x 2).

[C]

[F]

[D]

[B]

[H]

[A]

G367I106.WMF

Installation

7. Install the anti-condensation heater [I] in the rear-left corner of the scanner unit (! x 2).

8. Pass the cable through the opening [J] in the rear rail and connect it to the connector [K] at the front-left corner of the power supply unit.

9. Reassemble the scanner unit.

[E]

[K]

[J]

[G]

G367I107.WMF

[I]

G367I219.WMF

1-39

17 January, 2003 USER MAINTENANCE

2. PREVENTIVE MAINTENANCE

2.1 USER MAINTENANCE

The following maintenance kits are available for the customer to do PM.

Type A Color (C/M/Y) PCU 50KP Type B Color (C/M/Y) Development Unit 100KP Type C Fusing Unit 100KP Type D Black Development Unit / Dust Filter 100KP Type E Waste Toner Bottle 50KP Type F Black PCU 50KP Type G Oil Supply Unit 30KP Type H Paper Feed Rollers 150KP

Chart: A4 (LT)/5% Mode: 5 prints/job Environment: Normal temperature and humidity Yield may change depending on circumstances and print conditions.

When the machine’s default settings are used, an error message is displayed when a maintenance counter reaches the value in the PM table below, except for the items in maintenance kit H.

NOTE: To have the machine display the message for maintenance kit H also, set

SP5-930-4 to 1.

After the user replaces the items in a maintenance kit, the machine automatically resets the counter for this maintenance kit, except for the items in kit H.

NOTE: Except for the items in kit H, the machine can automatically detect when

new items have been installed.

The machine stops when the counters for parts in maintenance kits E and G reach the replacement value in the following table.

NOTE: To have the machine display the alert only for maintenance kits E and G,

set SP5-930-3 to 0.

Preventive

Maintenance

2-1

USER MAINTENANCE 17 January, 2003

Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect

Main Unit

Item 30K 50K 100K 150K EM Remarks

Black PCU

Color (Y/M/C) PCU

Black Development Unit

Color (C/M/Y) Development Unit

Fusing Unit

Oil Supply Unit

Waste Toner Bottle

Dust Filter

Pick-up Roller

Feed Roller

Separation Roller

Included in maintenance kit F

Included in maintenance kit A

Included in maintenance kit D

Included in maintenance kit B

Included in maintenance kit C

Included in maintenance kit G

Included in maintenance kit E

Included in maintenance kit D

Included in maintenance kit H

Punch Kit

Item 10K EM Remarks

Chads I Discard chads.

2-2

17 January, 2003 SERVICE MAINTENANCE

2.2 SERVICE MAINTENANCE

NOTE: After replacing the transfer unit and the transfer cleaning unit, make sure to

reset the maintenance counter using SP7-804-16 and SP7-804-17 respectively. After replacing paper feed rollers, reset the maintenance counters for these also: By-pass tray (7-804-10), Tray 1 (7-804-11), Tray 2 (7-804-12), Tray 3/LCT (7-804-13), Tray 4 (7-804-14)

Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect

Main unit

Item 100K 150K 500K 1,000K 3,000K EM Remarks

Transfer Unit R Transfer Cleaning Unit R By-pass Feed Roller R By-pass Pick-up Roller R By-pass Separation Roller R Waste Oil Bottle R

One-tray Paper Feed Unit (500 sheets x 1)

Item 100K 150K 500K 1,000K 3,000K EM Remarks

Relay Roller C Damp cloth Bottom Plate Pad C Damp cloth

Two-tray Paper Feed Unit (500 sheets x 2)

Item 100K 150K 500K 1,000K 3,000K EM Remarks

Relay Roller C Damp cloth Bottom Plate Pad C Damp cloth

Preventive

Maintenance

LCT (2000 sheets)

Item 100K 150K 500K 1,000K 3,000K EM Remarks

Relay Roller C Damp cloth Bottom Plate Pad C Damp cloth

Two-tray Finisher

Items 100K 150K 500K 1,000K 3,000K EM Remarks

Rollers C Damp cloth Discharge Brush C Dry cloth Sensors C Blower brush Jogger Fences I Replace if required.

2-3

SERVICE MAINTENANCE 17 January, 2003

Four-bin Mailbox

Item 100K 150K 500K 1,000K 3,000K EM Remarks

Rollers C Damp cloth Tray Paper Sensors

Blower blush or dry cloth

CF Expander

1st Mirror C Optics cloth 2nd Mirror C Optics cloth 3rd Mirror C Optics cloth APS Sensor C Dry cloth Xenon Exposure Lamp C Dry cloth Exposure Glass (Sheet

through)

Item 20k 50k 100k

1000k

EM Remarks

Dry cloth or alcohol

ARDF

Item 400k EM Remarks

Pick-up Roller R C

Feed Belt R C

Separation Roller R C

Sensors C C Blower brush

Platen Sheet Cover C

White Plate C Dry or damp cloth Drive Gear L Grease, G501

Damp cloth or alcohol

Damp cloth or alcohol. Replace platen sheet if required.

NOTE: 400k copies (= 80k originals x 5 copies/original)

2-4

17 January, 2003 SPECIAL TOOLS

3. REPLACEMENT AND ADJUSTMENT

!CAUTION

Turn off the main 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 ! : Screw " : Connector # : Clip ring $ : E ring

3.1 SPECIAL TOOLS

Part Number Part Name Q’ty

N8036701 Flash Memory Card - 4MB 1 G0219350 Loop-back connector - Parallel 1 C4019503 20X Magnification Scope 1

Adjustment

Replacement

3-1

IMAGE ADJUSTMENT 17 January, 2003

3.2 IMAGE ADJUSTMENT

3.2.1 REGISTRATION

Image Area

The image area shown in the

illustration must be guaranteed. So make sure that the registration is

Feed direction

adjusted within the adjustment standard range as described below.

Image Area

= B = C = 4.2mm (1.6”)

G080R902.WMF

Leading Edge

Adjusts the leading edge registration for each paper type and process line speed.

Side to Side

Adjusts the side to side registration for each paper feed station. NOTE: The side to side registration for the optional paper feed unit, LCT, and

duplex unit can be adjusted with SP mode or with the user tools (Maintenance menu).

Adjustment Standard

• Leading edge (sub-scan direction): 3 ± 0 mm

• Side to side (main-scan direction): 2 ± 0 mm

Paper Registration Standard

The registration in both main- and sub-scan directions may fluctuate within the following tolerance.

1st side

• Sub-scan direction: 0 ± 1.5 mm

• Main-scan direction: 0 ± 2 mm

2nd side in duplex

• Sub-scan direction: 0 ± 3 mm

• Main-scan direction: 0 ± 4 mm

3-2

17 January, 2003 IMAGE ADJUSTMENT

Adjustment Procedure

1. Enter SP mode and access SP5-997.

2. Print out the pattern (14: 1-dot trimming pattern) with SP5-997. NOTE: Registration may change slightly print by print as shown above.

Therefore print a few pages of the trimming pattern for step 3 and 4, and average the leading edge and side-to-side registration values and adjust each SP mode.

3. Perform the leading edge registration adjustment.

1) Check the leading edge registration and adjust it with SP1-001.

2) Select the adjustment conditions (paper type and process line speed).

3) Input the value then press the [Escape] key.

4) Check the leading edge adjustment by generating the trim pattern.

4. Perform the side to side registration adjustment.

1) Check the side to side registration and adjust it with SP1-002.

2) Select the adjustment conditions (paper feed station).

3) Input the value then press the [Escape] key.

4) Check the side to side adjustment by generating the trim pattern.

Adjustment

Replacement

3.2.2 COLOR REGISTRATION

Line Position Adjustment

Normally, the automatic line position adjustment is executed under a specified condition to optimize the color prints. If color registration shifts, execute “Auto Adjust” with the user tools (Maintenance menu – Color registration) or SP5-993-2 to do the forced line position adjustment. In addition, it is recommended to perform the line position adjustment under the following conditions:

• After transporting or moving the printer (If printers are pre-installed at the

workshop and transported to the user location, forced line position adjustment should be done after printer installation is completed at the user location.)

• When opening the drum positioning plate

• When removing or replacing the motors, clutches, and/or gears related to the

drum/development/transfer sections

• When removing or replacing the transfer belt or laser optical housing unit

Adjustment of Line Speed for Thick Paper

You must adjust the line speed of the fusing unit (the speed of development motorK) under the following conditions:

• The color registration shifts more on the trailing edge than on the leading

edge.

• This problem has not been solved by the line position adjustment.

Use the following user tool for this adjustment:

• Menu/Maintenance/Color Regist./Fuser Adjust/Thick paper

3-3

IMAGE ADJUSTMENT 17 January, 2003

3.2.3 PRINTER GAMMA

NOTE: Normally, the printer gamma is enough to adjust the color balance to

achieve the optimum print output. The gamma correction is only required

Adjustment Overview

Make the gradation scales on the printout smooth from the highlight to the shadow density. Adjust the CMY gradation scale at the top of the chart by balancing the density of the C, M, and Y gradation scales – the CMY gray scale should change smoothly from minimum to maximum, and there should be no coloration.

For each color, you can adjust 15 points between 0 (lowest density) and 255 (highest density).

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

During the adjustment procedure, compare the “Current Value” gradation scale with the “Default Value” Select the density for each of the 15 adjustable points, excluding points 0 and 255, from the “Default Value” gradation scale.

for fine-tuning to meet the user requirements.

The NVRAM holds three printer gamma settings, those saved this time (Current), those saved in the preceding adjustment (Previous), and the factory settings (Factory).

Adjustment Procedure

1. Enter SP mode.

2. Select “1. Service”

3. Select “Data Recall” and load the settings that will serve as the base for the adjustment.

4. Select “Mode Selection”, and select the print mode that you are going to adjust.

5. To review the image quality for these settings, choose “Test Page” to print out a color calibration test sheet.

6. Select “Gamma Adj.”

7. Adjust the color density at each of the 15 points for a color (CMY and K).

8. When the density setting is complete for all colors, print out a color calibration test sheet again and make sure that the gradation scale for each printed color is smooth and that the CMY gradation scale is gray. Repeat the adjustment if there is an anomaly.

9. If the adjustment results prove satisfactory, execute “Data Save.”

3-4

17 January, 2003 EXTERIOR COVERS

3.3 EXTERIOR COVERS

3.3.1 REAR COVER AND UPPER REAR COVER

1. Rear cover [A] (! x 4, 2 hooks)

2. Remove the optional mailbox if it is installed.

3. Upper exit cover [B] (1 hook) if the optional mailbox is not installed.

4. Open the upper right cover [C].

5. Upper rear cover [D] (! x 4)

3.3.2 PAPER EXIT TRAY

1. Paper exit tray [A] (! x 2)

[C]

[B]

[D]

[A]

G080R903.WMF

Adjustment

Replacement

3.3.3 UPPER RIGHT COVER

1. Right cover [A] (! x 2) NOTE: To remove the right cover,

open the upper right cover.

2. Upper right cover [B]

[A]

G080R904.WMF

[B]

3-5

[A]

G080R905.WMF

EXTERIOR COVERS 17 January, 2003

3.3.4 FRONT COVER

1. Front cover [A] (2 pins)

[A]

G080R906.WMF

3.3.5 LEFT COVER AND REAR LEFT COVER

1. Remove the optional finisher from the printer if it is installed.

2. Remove the optional duplex inverter unit if it is installed.

3. Connector cover [A] if the optional duplex unit is not installed

4. Left cover [B] (! x 6)

[A]

5. Open the left door [C].

6. Rear left cover [D] (! x 3)

3-6

[D]

[B]

G080R907.WMFFF

[C]

G080R908.WMF

17 January, 2003 EXTERIOR COVERS

3.3.6 UPPER LEFT COVER AND OPERATION PANEL

[D]

[C]

[A]

1. Open the front cover [A].

2. Open the upper right cover [B].

3. Operation panel [C] (! x 2, " x 3, 2 hooks)

4. Upper left cover [D] (! x 1, Shoulder-screw x 1, 2 hooks)

G080R909.WMF

[B]

Adjustment

Replacement

3-7

LASER OPTICS 17 January, 2003

3.4 LASER OPTICS

!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.

3.4.1 CAUTION DECAL LOCATIONS

Caution decals are placed as shown below.

LASER CAUTION 1.TIF

G080R910.WMF

LASER CAUTION 2.TIF

! WARNING

Be sure to 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 IIIb laser beam with a wavelength of 655 nm and an output of 7 mW. The laser can cause serious eye injury.

3-8

17 January, 2003 LASER OPTICS

3.4.2 LASER OPTICS HOUSING UNIT

CAUTION: Before installing a new laser optics housing unit, remove the sponge

Steps 1 through 4 refer to the procedure for a newly supplied unit that replaces the old one.

padding and the tag from the new unit.

[A]

1. Top cover of the laser optics housing unit [A] (! x 4)

2. Sponge padding [B]

3. Tag [C]

4. Reinstall the top cover.

5. Rear cover (☛ 3.3)

6. Upper rear cover (☛ 3.3)

7. Paper exit tray (☛ 3.3)

8. Right cover (☛ 3.3)

[C]

[B]

G080R757.WMF

[D]

Replacement

Adjustment

9. Securing screws for the toner supply unit [D] (! x 4)

10. Securing screws for the laser optics housing unit [E]

[D]

3-9

[E]

G080R911.WMF

LASER OPTICS 17 January, 2003

11. Hold the toner supply unit [C] up

➀. Then, lower the unit ➁.

NOTE: The pin [D] for the front

and rear shafts holds the toner supply unit.

12. Connector cover [E] (! x 1)

13. Four flat cables [F]

14. Connector [G]

[D]

[F]

[C]

G080R912.WMF

3-10

[G]

[E]

G080R913.WMF

17 January, 2003 LASER OPTICS

15. Flat cable bracket [G] (! x 1)

16. Cable (clamps [H])

17. Duct [I]

18. Laser optics housing unit (! x 2) NOTE: Hold the unit with both hands

and slowly lift up.

19. After reinstalling the laser optics housing unit, do some adjustments (☛ the procedures on the following page).

NOTE: When pulling the laser optics

housing unit up, make sure that the flat cables from the laser diode board are not caught by the brackets. If you roughly remove the unit without paying attention to this point, the cables will be caught by the bracket and the laser diode board may be damaged. To ensure that the unit is removed carefully, remove the unit by placing a sheet of paper between the laser optic housing unit and the machine rear frame, in order to prevent the cables from being caught by the brackets.

[H]

[G]

[I]

G080R914.WMF

G080R209.WMF

Replacement

Adjustment

After installing the laser optics housing unit, do forced line position adjustment (SP5-993-002 or “Maintenance – Color Registration - Auto Adjust” in User Program mode).

3-11

LASER OPTICS 17 January, 2003

Adjustments after Replacing the Laser Optics Housing Unit

1. Enter SP mode.

2. Input the values printed on three decals on the new laser optics housing unit into the following SPs. Each decal contains two values.

Value on the left Value on the right Function

Decal 1 SP2-109-3 SP2-109-2 Laser beam pitch

Decal 2 Not used Not used

Decal 3 Not used Not used

Main-scan registration correction for black and cyan

Main-scan registration correction for magenta and yellow

Decal 1

Jp:xxxxx P:46,41

1200dpi600dpi

G080R917.WMF

Decal 2

Jp:xxxxx KC:-2,-2

G080R915.WMF

Decal 3

Jp:xxxxx MY:-2,-2

G080R916.WMF

NOTE: The values on decals 2 and 3 do not need to be input, as the machine

performs the main scan registration correction for each color during automatic line position adjustment.

3. Print out the following test pattern (17: cross-stitch main-scan) with SP5-997.

4. Check these test patterns. If the laser beam pitch is not correct, vertical black strips seem to appear.

• Cross-stitch pattern: The thin lines should be of uniform thickness (no

striping effect should appear on the printout).

5. Adjust the laser beam pitch values in SP2-109-2 and -3 until the printout is correct, as shown below.

Feed direction

Adjustment not completed Adjustment completed

G080R918.WMF

6. Execute SP5-993-2 or “Auto Adjust” with the Maintenance menu in the user tools.

3-12

17 January, 2003 LASER OPTICS

3.4.3 POLYGON MIRROR MOTOR

[A]

[B]

Adjustment

Replacement

G080R919.WMF

1. Laser optics housing unit (☛ 3.4.2)

2. Cover [A] (! x 4)

3. Polygon mirror motor [B] (! x 4, " x 1)

3.4.4 LASER SYNCHRONIZING DETECTOR BOARDS

[A]

1. Laser optics housing unit (☛ 3.4.2)

2. Synchronizing detector boards [A] (! x 1, " x 1)

3-13

G080R920.WMF

PCU AND DEVELOPMENT UNIT 17 January, 2003

3.5 PCU AND DEVELOPMENT UNIT

NOTE: Do not touch the PCU development drum. Do not let any metal object

touch the PCU development sleeve.

1. Open the front cover [A].

2. To raise the drum positioning plate [B], loosen the 2 screws.

3. Turn the release lever [C] counterclockwise.

4. Pull the required development unit [D] out.

5. Install a new development unit.

6. Check that the development units are installed in the proper color order (black → yellow → cyan → magenta moving from left to right). NOTE: When the main switch is turned

on, the newly installed development units are automatically initialized.

[C]

[A]

[D]

[B]

G080R921.WMF

G080R922.WMF

7. Release the lever and pull the PCU [E] out until the handle appears.

8. Grasp the handle [F] and pull the PCU out of the machine.

3-14

[E]

[F]

G080R923.WMF

17 January, 2003 PAPER FEED

3.6 PAPER FEED

3.6.1 PICK-UP, FEED, AND SEPARATION ROLLERS

Tray 1 and Tray 2

1. Tray 1 and Tray 2

2. Pick-up roller [A] (1 hook)

3. Feed roller [B] (# x 1)

4. Separation roller [C] (# x 1)

By-pass Tray

1. Open the right door.

2. By-pass tray cover [A] (1 hook, ! x 1)

3. Raise the paper end sensor actuator.

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

[A]

[C]

G080R924.WMF

[B]

Adjustment

Replacement

5. Feed roller [C] (# x 1)

6. Vertical transport cover [D] (! x 4) NOTE: Remove the right rear

cover (☛ 3.6.4) if you want to have easier access to the four screws.

7. Separation roller [E] (# x 1)

[C]

G080R926.WMF

3-15

G080R925.WMF

[D]

[E]

PAPER FEED 17 January, 2003

3.6.2 PAPER WIDTH DETECTION BOARD

[A]

1. Open the by-pass tray.

[D]

[B]

[C]

G080R753.WMF

2. Center the side fences [A].

3. By-pass tray cover [B] (! x 2, 2 hooks) NOTE: There is a square opening [C] on each side of the tray. Insert a

screwdriver into each of the openings.

4. Paper width detection board [D] (" x 1) NOTE: To remove the connector,

open the bottom cover [E].

[E]

G080R755.WMF

3-16

17 January, 2003 PAPER FEED

3.6.3 VERTICAL TRANSPORT SENSOR

[B]

[A]

G080R752.WMF

1. Open the right door.

2. Vertical transport cover [A] (! x 4) NOTE: Remove the right rear cover (☛ 3.6.4) if you want to have easier

access to the four screws.

Adjustment

Replacement

3. Vertical transport sensor [B] (" x 1)

3.6.4 RIGHT DOOR UNIT

G080R927.WMF

[A]

[B]

G080R928.WMF

1. Rear cover (☛ 3.3)

2. Upper rear cover (☛ 3.3)

3. Upper right cover (☛ 3.3)

4. Right rear cover [A] (! x 4)

5. Open the right door.

6. Lift the vertical transport unit [B] to remove it from its hinges (" x 3, # x 1).

3-17

PAPER FEED 17 January, 2003

3.6.5 REGISTRATION SENSOR AND RELAY SENSORS

[B]

[C]

[A]

G080R751.WMF

1. Right door unit (☛ 3.6.4)

2. Registration guide [A] (! x 2)

3. Registration sensor [B] (! x 2, " x 1)

4. Relay sensor [C] (" x 1)

3.6.6 PAPER FEED CLUTCHES

1. Paper trays

2. Rear cover (☛3.3)

3. Swing out the high voltage supply unit (☛3.10.2).

4. Clutch holder [A] (! x 2, 1 bearing)

G080R929.WMF

[B]

5. Paper feed clutch for tray 1 [B] (" x 1)

6. Clutch holder [C] (! x 2, 1 bearing)

7. Paper feed clutch for tray 2 [D] (" x 1)

3-18

[D]

[C]

G080R930.WMF

[A]

17 January, 2003 PAPER FEED

3.6.7 BY-PASS FEED CLUTCH

1. Right door unit (☛ 3.6.4)

2. By-pass tray cover [A] (! x 1, 1 hook)

[A]

3. Loosen the screw on the right door latch.

4. Turn the latch in the opposite

[C]

direction.

5. Upper guide plate [B] (! x 4)

6. Support plate [C] ($ x 2)

7. Relay gear [D] (1 hook)

8. By-pass feed clutch [E] (" x 1)

3.6.8 TRAY LIFT MOTOR

[E]

[D]

[B]

G080R931.WMF

Replacement

Adjustment

[B]

G080R932.WMF

1. Rear cover (☛ 3.3)

2. Swing out the high voltage supply unit. (☛ 3.10.2)

3. Tray lift motors (tray 1 [A], tray 2 [B]) (! x 2, " x 1)

3-19

[A]

PAPER FEED 17 January, 2003

3.6.9 PAPER FEED MOTOR

[B]

[A]

1. Rear cover (☛ 3.3)

2. Swing out the high voltage supply unit. (☛ 3.10.2)

3. Paper feed motor [A] (! x 3, " x 1) NOTE: The connector is CN604 on the driver board [B].

G080R750.WMF

3-20

17 January, 2003 TRANSFER AND PAPER TRANSPORT UNIT

3.7 TRANSFER AND PAPER TRANSPORT UNIT

3.7.1 TRANSFER UNIT

NOTE: 1) When removing or installing the transfer unit, grasp the central areas of

the front and rear frame. Do not touch the transfer belt [A]. Do not damage the entrance mylar [B].

2) Remove the duplex feed unit (if it is installed) before replacing the transfer unit.

3) After replacing the transfer unit, reset the maintenance counter, SP7804-16, and conduct the output check, SP5-804-74.

[A]

Adjustment

Replacement

[C]

G080R737.WMF

[B]

1. Turn the release lever counterclockwise. (☛ 3.5)

2. Pull out the transfer unit [C] until the entire unit is visible (! x 2).

3. Grasp the transfer unit grips as shown above. Lift the unit to remove it.

NOTE: Grasp the front grip. Use caution not to damage the actuator on the rear.

After replacing the transfer unit:

• Perform forced line position adjustment (SP5-993-002 or “Maintenance menu –

Color Registration - Auto Adjust” in User Program mode).

• Print the 1-dot grid pattern on A3/11" x 17" paper and check the color shift level

(☛ 4.4.3).

3-21

TRANSFER AND PAPER TRANSPORT UNIT 17 January, 2003

3.7.2 TRANSFER BELT CLEANING UNIT

NOTE: After replacing the transfer belt cleaning unit, reset the maintenance

counter, SP7-804-17.

[A]

[B]

G080R739.WMF

While pushing the lever, pull out the transfer belt cleaning unit [A] (! x 1).

NOTE: 1) The blade [B] may damage the belt if you do not keep pushing the lever.

2) When reassembling, check that the transfer unit release lever is put back to the original position (☛ 3.5).

After replacing the transfer belt cleaning unit, perform forced line position adjustment (SP5-993-002 or “Maintenance menu – Color registration - Auto Adjust” in User Program mode).

3-22

17 January, 2003 TRANSFER AND PAPER TRANSPORT UNIT

3.7.3 CLEANING BLADE AND CLEANING ROLLER

[A]

[B]

G080R740.WMF

1. Transfer belt cleaning unit (☛ 3.7.2)

Adjustment

Replacement

2. Cleaning blade [A] (! x 2)

3. Tension spring [B]

[D]

[C]

4. Lever [C] (! x 1)

[E]

G080R741.WMF

5. 3 gears [D] ($ x 1)

6. Gear box [E] (! x 1)

3-23

TRANSFER AND PAPER TRANSPORT UNIT 17 January, 2003

[A]

[B]

[C]

G080R742.WMF

7. Roller cover [A] (! x 2)

8. Cleaning brush gear [B] ($ x 1)

9. Cleaning brush [C] (Bushing x 1)

After replacing the cleaning blade, perform forced line position adjustment (SP5993-002 or “Maintenance menu – Color registration - Auto Adjust” in User Program mode).

3-24

17 January, 2003 TRANSFER AND PAPER TRANSPORT UNIT

3.7.4 TRANSFER BELT

NOTE: Do not touch the transfer belt during handling. When replacing the belt,

hold the belt at its end.

[A]

[B]

Adjustment

Replacement

1. Transfer unit (☛ 3.7.1)

2. Transfer belt cleaning unit (☛ 3.7.2)

3. Transfer entrance guide [A] (! x 3)

4. Right bracket [B] (! x 2)

[C]

G080R744.WMF

[D]

5. Left bracket [C] (! x 2)

6. Tension roller [D] (! x 2)

G080R745.WMF

3-25

TRANSFER AND PAPER TRANSPORT UNIT 17 January, 2003

[A]

G080R933.WMF

7. Lay the transfer unit on its side. Grasp the upper end of the transfer belt and pull the transfer belt [A] up and out.

NOTE: 1) If the transfer charge brushes are dirty, clean them with a vacuum

cleaner.

2) If the drive rollers are dirty, clean them with a damp cloth.

After replacing the transfer belt, perform forced line position adjustment (SP5-993002 or “Maintenance menu – Color registration - Auto Adjust” in User Program mode).

3-26

17 January, 2003 TRANSFER AND PAPER TRANSPORT UNIT

3.7.5 TRANSFER UNIT DRIVE MOTOR

[B]

[A]

Adjustment

Replacement

1. Pull out the transfer unit (☛ 3.7.1).

2. Transfer belt cleaning unit (☛ 3.7.2)

3. Release lever [A] (! x 1)

4. Front cover [B] (! x 3)

[C]

[D]

G080R738.WMF

5. Front plate [C] (! x 5, Timing belt x 1)

6. Transfer unit drive motor [D] (! x 2, " x 1)

3-27

G080R743.WMF

ID SENSORS 17 January, 2003

3.8 ID SENSORS

[A]

G080R756.WMF

CAUTION: Use caution not to damage the black PCU when removing and

installing the ID sensor bracket.

1. Pull out the transfer unit until the entire unit is visible (☛ 3.7.1).

2. Fusing unit (☛ 3.9.1)

3. ID sensor bracket [A] (! x 2, " x 1)

3-28

17 January, 2003 FUSING

3.9 FUSING

!CAUTION

1. Be careful when handling the fusing unit. It is very hot.

2. Take care not to spill silicone oil.

3.9.1 FUSING UNIT

[C]

[B]

[D]

[A]

G080R508.WMF

CAUTION: Do not tilt the fusing unit [A] while handling it. The oil supply unit [B] can

fall off the fusing unit after the grip [C] is released from the oil supply unit.

Adjustment

Replacement

1. Detach the finisher from the printer if it is installed.

2. Open the duplex inverter unit if it is installed.

3. Push the heat insulator [D]. The grip [C] is released from the oil supply unit.

4. Fusing unit [A]

After replacing the fusing unit, if the customer uses thick paper, make some test prints on a sample of the paper used by the customer. If there are any color registration problems, adjust the line speed for thick paper with the following user tool:

• Menu/Maintenance/Color Regist./Fuser Adjust/Thick paper

Refer to Maintenance Guide of the Operating Instructions for how to adjust this (section 2. Cleaning and Adjusting the Printer - Adjusting the Color Registration).

3-29

FUSING 17 January, 2003

3.9.2 OIL SUPPLY UNIT AND UPPER COVER

[B]

[A]

1. Detach the finisher from the printer if it is installed.

2. Open the duplex inverter unit if it is installed.

3. Fusing unit (☛ 3.9.1)

4. Oil supply unit [A]

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

G080R701.WMF

3-30

17 January, 2003 FUSING

3.9.3 CLEANING UNIT

[A]

[B]

[C]

G080R702.WMF

Adjustment

Replacement

1. Upper cover (☛ 3.9.2)

2. 2 handle guides [A][B] (! x 2 for each)

3. Handle [C] (Spring x 1)

[D]

G080R706.WMF

4. Cleaning unit [D] (! x 2)

3-31

FUSING 17 January, 2003

3.9.4 HEATING ROLLER LAMP

[C]

[A]

[B]

G080R705.WMF

1. Upper cover (☛ 3.9.2)

2. Heating roller lamp [A] (! x 2)

NOTE: When reinstalling, make sure the front [B] and rear [C] ends of the lamp are

on the correct terminals.

3-32

17 January, 2003 FUSING

3.9.5 FUSING BELT UNIT

[A]

[E]

[B]

Adjustment

Replacement

G080R707.WMF

[C]

[D]

1. Cleaning unit (☛ 3.9.3)

2. Heating roller lamp (☛ 3.9.4)

3. Upper paper guide plate (☛ 3.9.8)

4. Pressure roller gear [A] (C ring x 1)

5. 2 pressure brackets [B][C] (Spring x 1 for each)

6. Knob [D] (! x 1)

7. Fusing belt unit [E] (! x 1, " x 1)

3-33

FUSING 17 January, 2003

3.9.6 HOT ROLLER

[A]

G080R708.WMF

1. Fusing belt unit (☛ 3.9.5)

2. Hot roller [A] (Bushing x 2)

3.9.7 HEATING ROLLER

[A]

G080R709.WMF

1. Pressure roller (☛ 3.9.6)

2. Heating roller [A]

3-34

17 January, 2003 FUSING

3.9.8 PAPER GUIDE PLATES AND STRIPPER PAWLS

[A]

Adjustment

Replacement

1. Upper cover (☛ 3.9.2)

2. Lower paper guide plate [A] (! x 2)

[B]

[C]

G080R703.WMF

G080R704.WMF

3. Upper paper guide plate [B] (! x 2)

4. 5 stripper pawls [C]

3-35

FUSING 17 January, 2003

3.9.9 THERMISTOR AND FUSE

[A]

G080R713.WMF

1. Lower right cover [A] (! x 2)

2. Thermistor [B] (! x 1, " x 1)

[B]

G080R714.WMF

3-36

17 January, 2003 FUSING

[A]

3. Fuse [A] (! x 3)

3.9.10 PRESSURE ROLLER FUSING LAMP

[A]

G080R715.WMF

Adjustment

Replacement

1. Fusing belt unit (☛ 3.9.5)

2. Pressure roller fusing lamp [A] (! x 2)

3-37

G080R710.WMF

FUSING 17 January, 2003

3.9.11 PRESSURE ROLLER

[C]

[A]

G080R711.W MF

1. Pressure roller fusing lamp (☛ 3.9.10)

2. Lower paper guide plate (☛ 3.9.8)

3. Drive gear holder [A] (! x 1)

4. Drive gear [B] ($ x 1)

5. Lower right cover (☛ 3.9.9)

6. Pressure roller unit [C] (! x 5, " x 2)

[B]

3-38

17 January, 2003 FUSING

[C]

[A]

Adjustment

Replacement

G080R712.WMF

7. Pressure roller gear [A] (C ring x 1, Bushing x 1)

8. Pressure roller holder [B] (! x 1)

9. Pressure roller [C] (C ring x 1)

[B]

3-39

FUSING 17 January, 2003

3.9.12 FUSING UNIT FAN

!CAUTION

When reinstalling, make sure the fan faces to the correct direction. The arrow on the fan [A] and the arrow on the duct [B] must face to the same direction.

[A] [B]

1. Rear cover (☛ 3.3)

2. Upper rear cover (☛ 3.3)

3. Left cover (☛ 3.3)

4. Rear left cover (☛ 3.3)

5. Connector cover (on the top of the controller box) (☛3.10.1)

6. Fusing fan duct [C] (! x 2, " x 1)

7. Fusing fan [D] (! x 2, " x 1)

[D] [C]

G080R901.WMF

3-40

Ricoh cl7000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

1.1.2 MACHINE LEVEL

1.1.3 MACHINE SPACE REQUIREMENT

Main Unit

Main Unit and Finisher

CF Expander with Rack

CF Expander without Rack

1.1.4 POWER REQUIREMENTS

1.2 OPTIONAL UNIT COMBINATIONS

1.3 INSTALLATION FLOW CHART

Without Optional CF Expander

With Optional CF Expander

1.4 MACHINE INSTALLATION

1.5 NOTES FOR TRANSPORTING THE MACHINE

1.5.1 MACHINE STANDS

1.5.2 MACHINE BODY

1.6 OPTIONAL UNIT INSTALLATION

1.6.1 LIST OF OPTIONS

1.6.2 PUNCH UNIT INSTALLATION

Accessory Check

Installation Procedure

1.6.3 CF EXPANDER RACK

Accessories Check List

Assembling the Rack

Docking the Rack and Printer Mainframe

1.6.4 CF EXPANDER

Accessories Check List

CF Expander Installation

1.6.5 INSTALLING THE HANDSET

1.6.6 40GB HDD

Accessories Check List

40 GB HDD Installation

1.6.7 ARDF

Accessories Check List

ARDF Installation

1.6.8 MULTI-BIN OUTPUT TRAY

Accessories Check List

Installing the Multi-Bin Output Tray

1.6.9 ANTI-CONDENSATION HEATER

2. PREVENTIVE MAINTENANCE

2.1 USER MAINTENANCE

2.2 SERVICE MAINTENANCE

3. REPLACEMENT AND ADJUSTMENT

3.1 SPECIAL TOOLS

3.2 IMAGE ADJUSTMENT

3.2.1 REGISTRATION

Image Area

Leading Edge

Side to Side

Adjustment Standard

Paper Registration Standard

Adjustment Procedure

3.2.2 COLOR REGISTRATION

Line Position Adjustment

Adjustment of Line Speed for Thick Paper

3.2.3 PRINTER GAMMA

Adjustment Overview

Adjustment Procedure

3.3 EXTERIOR COVERS

3.3.1 REAR COVER AND UPPER REAR COVER

3.3.2 PAPER EXIT TRAY

3.3.3 UPPER RIGHT COVER

3.3.4 FRONT COVER

3.3.5 LEFT COVER AND REAR LEFT COVER

3.3.6 UPPER LEFT COVER AND OPERATION PANEL

3.4 LASER OPTICS

3.4.1 CAUTION DECAL LOCATIONS

3.4.2 LASER OPTICS HOUSING UNIT

Adjustments after Replacing the Laser Optics Housing Unit

3.4.3 POLYGON MIRROR MOTOR

3.4.4 LASER SYNCHRONIZING DETECTOR BOARDS

3.5 PCU AND DEVELOPMENT UNIT

3.6 PAPER FEED

3.6.1 PICK-UP, FEED, AND SEPARATION ROLLERS