Ricoh Kr-P2 Field Service Manual
Model Kr-P2
Machine Code: M047
Field Service Manual
15 December,2009
Safety Notices
Important Safety Notices
Prevention of Physical Injury
1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine
power cord is unplugged.
2. The wall outlet should be near the machine 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 machine 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 machine starts operation.
5. The inside and the metal parts of the fusing unit become extremely hot while the machine is operating.
Be careful to avoid touching those components with your bare hands.
Health Safety Conditions
Toner is 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
The machine and its peripherals must be serviced by a customer service representative who has completed
the training course on those models.
• The Controller board on this machine contains a lithium battery. The danger of explosion exists if a
battery of this type is incorrectly replaced. Replace only with the same or an equivalent type
recommended by the manufacturer. Discard batteries in accordance with the manufacturer's
instructions and 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
in accordance with local regulations. (These are non-toxic supplies.)
of used toner, the maintenance unit which includes developer or the organic photoconductor
1
3. Dispose of replaced parts in accordance with local regulations.
prevent a fire or explosion, keep the machine away from flammable liquids, gases, and aerosols.
• To
A fire or an explosion might occur.
Handling Toner
• Work carefully when removing paper jams or replacing toner bottles or cartridges to avoid spilling
toner on clothing or the hands.
toner is inhaled, immediately gargle with large amounts of cold water and move to a well ventilated
• If
location. If there are signs of irritation or other problems, seek medical attention.
• If toner gets on the skin, wash immediately with soap and cold running water.
• If toner gets into the eyes, flush the eyes with cold running water or eye wash. If there are signs of
irritation or other problems, seek medical attention.
• If toner is swallowed, drink a large amount of cold water to dilute the ingested toner. If there are signs
of any problem, seek medical attention.
• If toner spills on clothing, wash the affected area immediately with soap and cold water. Never use
hot water! Hot water can cause toner to set and permanently stain fabric.
• Always store toner and developer supplies such as toner and developer packages, cartridges, and
bottles (including used toner and empty bottles and cartridges) out of the reach of children.
• Always store fresh toner supplies or empty bottles or cartridges in a cool, dry location that is not
exposed to direct sunlight.
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.
• Use
of controls, or adjustment, or performance of procedures other than those specified in this manual
may result in hazardous radiation exposure.
WARNING
2
WARNING:
Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams
can seriously damage your eyes.
CAUTION MARKING:
Conventions and Trademarks
Conventions
Symbol What it means
Refer to section number
Screw
Connector
E-ring
C-ring
The following notations are used in text to describe the direction of paper feed: lengthwise and sideways.
The annotations "SEF" and "LEF" denote "Short Edge Feed" and "Long Edge Feed". (The arrows indicate
the direction of paper feed.)
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Trademarks
Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the United
States and /or other countries.
PostScript® is a registered trademark of Adobe Systems, Incorporated.
PCL® is a registered trademark of Hewlett-Packard Company.
Ethernet® is a registered trademark of Xerox Corporation.
PowerPC® is a registered trademark of International Business Machines Corporation.
Other product names used herein are for identification purposes only and may be trademarks of their
respective companies. We disclaim any and all rights involved with those marks.
This manual uses several symbols and some simple abbreviations.
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TABLE OF CONTENTS
Safety Notices.....................................................................................................................................................1
Important Safety Notices...............................................................................................................................1
Laser Safety.....................................................................................................................................................
Conventions and Trademarks........................................................................................................................3
1. Product Information
Specifications......................................................................................................................................................9
Overview..........................................................................................................................................................10
Mechanical Component Layout ................................................................................................................10
Paper Path....................................................................................................................................................11
Machine Configuration....................................................................................................................................
Model M047...............................................................................................................................................13
13
2. Installation
Installation Requirements.................................................................................................................................15
Environment..................................................................................................................................................15
Machine Level..............................................................................................................................................15
Machine Space Requirement ....................................................................................................................16
Power Supply...............................................................................................................................................16
Machine Installation.........................................................................................................................................
Main Unit and Option Unit.........................................................................................................................17
17
2
Printer Option...............................................................................................................................................17
SD Card Appli Move...................................................................................................................................17
3. Preventive Maintenance
User Maintenance............................................................................................................................................21
Service Maintenance.......................................................................................................................................22
Main..............................................................................................................................................................
Paper Feed Unit (Option)............................................................................................................................23
22
4. Replacement and Adjustment
General.............................................................................................................................................................25
Precautions on Disassembly........................................................................................................................25
Releasing Plastic Latches.............................................................................................................................26
After Servicing the Machine........................................................................................................................
Special Tools....................................................................................................................................................28
Exterior Covers.................................................................................................................................................29
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5
Operation Panel...........................................................................................................................................29
Rear Cover...................................................................................................................................................30
Upper Cover................................................................................................................................................30
By-pass Tray.................................................................................................................................................30
Left Cover......................................................................................................................................................32
Front Door.....................................................................................................................................................32
Right Cover ..................................................................................................................................................33
Laser Unit..........................................................................................................................................................35
Caution Decal Location ..............................................................................................................................35
Polygon Mirror Motor ................................................................................................................................36
Laser Unit......................................................................................................................................................36
Laser Diode Unit ..........................................................................................................................................38
Laser Beam Pitch Adjustment ......................................................................................................................39
Image Transfer..................................................................................................................................................41
Transfer Roller .............................................................................................................................................41
Toner End Sensor.........................................................................................................................................41
Fusing................................................................................................................................................................43
Fusing Unit....................................................................................................................................................43
Hot Roller and Fusing Lamp........................................................................................................................43
Pressure Roller..............................................................................................................................................47
Thermistor and Thermostat..........................................................................................................................49
Hot Roller Strippers......................................................................................................................................51
Paper Feed........................................................................................................................................................53
Paper Feed Roller .......................................................................................................................................53
Friction Pad ..................................................................................................................................................53
Paper End Sensor.........................................................................................................................................54
Remaining Paper Sensors............................................................................................................................55
By-pass Feed ...................................................................................................................................................56
By-pass Feed Unit........................................................................................................................................56
By-pass Feed Roller.....................................................................................................................................56
By-pass Friction Pad....................................................................................................................................57
By-pass Paper Set Sensor...........................................................................................................................59
Paper Exit .........................................................................................................................................................61
6
Paper Exit Sensor.........................................................................................................................................61
Overflow Sensor..........................................................................................................................................61
Paper Exit Unit .............................................................................................................................................61
Fusing Exit Sensor........................................................................................................................................62
Electrical Components.....................................................................................................................................64
Printer Controller Board...............................................................................................................................64
Engine Board................................................................................................................................................64
Main Motor..................................................................................................................................................65
Relay Clutch.................................................................................................................................................66
Paper Feed Clutch.......................................................................................................................................66
Registration Clutch.......................................................................................................................................68
Registration Sensor......................................................................................................................................68
Power Supply Board and High Voltage Supply Board............................................................................69
Fusing Pressure Sensor................................................................................................................................71
Fusing Fan.....................................................................................................................................................72
PSU Fan........................................................................................................................................................72
Image Adjustment.............................................................................................................................................74
Registration Adjustment ..............................................................................................................................74
Parallelogram Image Adjustment...............................................................................................................74
5. System Maintenance Reference
Service Program Mode....................................................................................................................................77
SP Tables......................................................................................................................................................77
Inputting a Value or Setting for a Service Program...................................................................................77
Exiting Service Mode..................................................................................................................................78
Updating the Firmware....................................................................................................................................79
Type of Firmware.........................................................................................................................................79
Precautions...................................................................................................................................................79
Machine Firmware Update.........................................................................................................................80
Error Recovery..............................................................................................................................................81
Power-On Self Tests ........................................................................................................................................83
Dip Switches.....................................................................................................................................................84
Controller Board..........................................................................................................................................84
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6. Troubleshooting
Service Call Conditions...................................................................................................................................85
Electrical Component Defects.........................................................................................................................86
Sensors..........................................................................................................................................................86
Switches........................................................................................................................................................87
Blown Fuse Conditions................................................................................................................................88
LEDs...............................................................................................................................................................88
7. Energy Saving
Energy Save......................................................................................................................................................89
Energy Saver Modes...................................................................................................................................89
Paper Save.......................................................................................................................................................91
Effectiveness of Duplex/Combine Function...............................................................................................91
INDEX.............................................................................................................................................................95
8
1. Product Information
1
Specifications
See "Appendices" for the "General Specifications".
9
1. Product Information
1
Overview
Mechanical Component Layout
1: Laser unit
9: Registration roller
2: Charge roller
10: Transfer roller
3: Development roller
11: Drum
4: Cartridge (AIO-type)
12: Pressure roller
5: By-pass feed tray
13: Hot roller
6: By-pass feed roller
14: Paper exit roller
7: Paper feed roller
15: Quenching lamp
8: Friction pad
10
Paper Path
1
Printer
Overview
[A]: Paper path from the paper tray (main)
[B]: Paper path from the by-pass tray (main)
• If both optional paper tray units are installed, the envelope feeder must go in the top tray.
11
1. Product Information
1
Printer with optional units
[A]: Paper path from the paper tray (main)
[B]: Paper path from the by-pass tray (main)
[C]: Paper path from the paper tray 2 (option)
[D]: Paper path from the paper tray 3 (option)
[E]: Paper path from the duplex unit (option)
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Machine Configuration
1
Model M047
Machine Configuration
Item Machine Code No. Remarks
Main Unit M047 A NIB is standard.
Optional Units
Duplex Unit G806 B
Paper Tray Unit M374 C, D Up to two tray units can be installed.
If both optional paper trays are
Envelope Feeder G807 C
installed, the envelope feeder must go
in the top tray.
13
1. Product Information
1
14
2. Installation
2
Installation Requirements
Environment
• This machine, which uses high voltage power sources, can generate ozone gas. High ozone density
is harmful to human health. Therefore, the machine must be installed in a well-ventilated room.
1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)
2. Humidity Range: 15 % to 89 % RH
3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight).
4. Ventilation: 3 times/hr/person
5. Avoid areas that are exposed to sudden temperature changes. This includes:
• Areas directly exposed to cool air from an air conditioner.
• Areas directly exposed to heat from a heater.
6. Do not install this machine in an area where it will be exposed to corrosive gases.
7. Do not install the machine at locations over 2,000 m (6,562 ft.) above sea level.
8. Put the machine on a strong and level base. Inclination on any side should not exceed 5 mm.
9. Do not put the machine where it may be subjected to strong vibrations.
Machine Level
Front to back: Within 5 mm. (0.2 inches) of level.
Right to left: Within 5 mm. (0.2 inches) of level.
15
2. Installation
2
Machine Space Requirement
Place the machine near the power source, providing the clearance as shown below:
A: Over 10 cm (4 inches)
B: Over 10 cm (4 inches)
C: Over 10 cm (4 inches)
D: Over 10 cm (4 inches)
Power Supply
• Make sure the plug is firmly inserted in the outlet.
Avoid multi-wiring.
•
• Be sure to ground the machine.
120 volts, 60 Hz: More than 10 A
Input voltage level
220-240 volts, 50 Hz/60Hz: More than 6 A
Permissible voltage Fluctuation: ±10 %
Do not set anything on the power cord
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Machine Installation
2
Machine Installation
Main Unit and Option Unit
Refer to the "Hardware Guide" for M041 model about the machines installation.
Printer Option
Refer to the "Hardware Guide" for M041 model about the machines installation. If more than two optional
applications are supposed to be installed, do "SD Card Appli Move" described below.
• IPDS option requires an optional memory (128 MB or 256 MB). Install an optional memory first
before installing the IPDS option. Otherwise, the machine may stall when large print job data is sent
to the machine.
SD Card Appli Move
Overview
The service program "SD Card Appli Move" (SP5-873) lets you to copy application programs from one
SD card to another SD card.
Slot 1 and Slot 2 are used to store application programs. However, more than two optional applications
are supplied for this machine. In that case, you can move application programs from Slot 2 to Slot 1 with
the following procedure.
Obey these precautions during the SD Card Appli move procedure:
authentication data is moved with the application program from an SD card to the other SD card.
• The
Authentication fails if you try to use the SD card after you move the application program from this card
to another SD card.
• Do not use an SD card if it has been used for some other work, for example, on a computer. Normal
operation is not guaranteed when such SD card is used.
• Store the original SD card in a safe location after the procedure. The original SD card cannot be used
but it must be saved because (1) the original card is the only proof that the user is licensed to use the
application program, and (2) you may need to check the SD card and its data to solve a problem in
the future.
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2. Installation
2
Move Exec
"Move Exec" (SP5873 1) moves application programs from the original SD card to another SD card. The
application programs are moved from Slot 2 to Slot 1.
1. Turn off the main power switch.
2. Remove the SD card slot cover [A] ( x 1).
3.
Insert the original SD card with the application in Slot 2 [B] (lower slot).
4. Insert the SD card to receive the application in Slot 1 [C] (upper slot).
5. Turn on the main power switch.
6. Enter the SP mode and do SP5873 1 "Move Exec."
7. Follow the messages on the operation panel to complete the procedure.
8. Exit the SP mode.
9. Turn off the main power switch.
10. Remove the original SD card from Slot 2.
11. Leave the other SD card in Slot 1.
12. Turn on the main power switch.
13. Confirm that the application program runs normally.
14. Tell the customer to store the original SD card in a safe place.
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Machine Installation
2
Undo Exec
"Undo Exec" (SP5873 2) restores an application to its original SD card. The application is moved from
Slot 1 to Slot 2.
1. Turn off the main power switch.
2. Remove the SD card slot cover [A] ( x 1).
3.
Insert the SD card that currently holds the application in Slot 1 [B].
4. Insert the original SD card to receive the restored application in Slot 2 [C].
5. Turn on the main power switch.
6. Enter the SP mode and do SP5873 "Undo Exec."
7. Follow the messages on the operation panel to complete the procedure.
8. Exit the SP mode.
9. Turn off the main power switch.
10. Remove both SD cards.
11. Insert the SD card with the restored application in Slot 1.
12. Turn on the main power switch.
13. Confirm that the application operates normally.
19
2. Installation
2
20
3. Preventive Maintenance
3
User Maintenance
The customer can do all PM items with the Maintenance Kit.
Meter-charge mode must be set to "disabled" (engine SP mode 5930).
Cross-reference: "Engine service mode" in the Appendices.
The Operation panel shows "Replace Maintenance Kit" when the PM counter gets to 90K. After the user
replaces the fusing unit in the maintenance kit, the machine automatically resets the PM counter.
Item Quantity Remarks
Fusing unit 1
Transfer roller 1
Paper feed roller 3 For standard and optional tray(s)
Friction pad 3 For standard and optional tray(s)
PSU Fan Filter 1
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3. Preventive Maintenance
3
Service Maintenance
To enable the machine for maintenance by the service technician, the meter-charge mode must be set to
"1: Yes" with SP5930-001.
The table below shows the PM items serviced by the service technician.
After completing a PM procedure, reset the PM counter for the replaced part with SP7-804.
•
7-804-2: Transfer roller
• 7-804-3: Paper feed roller
• 7-804-4: Fusing unit.
Main
Symbol keys: C: Clean/ R: Replace/ L: Lubricate/ I: Inspect
Item 90K EM Quantity Remarks
Paper Feed
Paper Feed Roller R C 1 Clean with water
Friction Pad R C 1 Clean with water
Registration Roller C C 1 Clean with water
Bottom Plate Pad C C 1 Clean with water
Around the Drum
Transfer Roller R 1
Fusing Unit and Paper Exit
Hot Roller R 1
Pressure Roller R 1
Hot Roller Strippers R 5
Fusing Thermistor R C 1
Bushings - Hot Roller R 2
Clean with alcohol if
necessary.
Bushings - Pressure Roller R 2
22
Service Maintenance
3
Item 90K EM Quantity Remarks
Fusing Entrance and Exit Guide
Plates
Fusing Unit R 1
Other
PSU Fan Filter R 1
C 1 each
Clean with water or
alcohol
Paper Feed Unit (Option)
Symbol keys: C: Clean/ R: Replace/ L: Lubricate/ I: Inspect
Item 90K EM Quantity Remarks
Paper Feed
Paper Feed Roller R C 1 Clean with water
Friction Pad R C 1 Clean with water
Bottom Plate Pad C C 1 Clean with water
23
3. Preventive Maintenance
3
24
4. Replacement and Adjustment
4
General
• Turn off the main power switch and unplug the machine before attempting any of the procedures in
this section.
Precautions on Disassembly
Use extreme caution when removing and replacing components. The cables in the machine are located
very close to moving parts; proper routing is a must.
After components have been removed, any cables that have been displaced during the procedure must
be restored as close as possible to their original positions. Before removing any component from the
machine, note any cable routings that may be affected.
Before servicing the machine:
1. Verify that documents are not stored in memory.
2. Remove the toner cartridge before you remove parts.
3. Unplug the power cord.
4. Work on a flat and clean surface.
5. Replace with authorized components only.
6. Do not force plastic material components.
Make sure all components are returned to their original positions.
Laser unit
1. Do not loosen or adjust the screws securing the LD drive board on the LD unit. Doing so will throw the
LD unit out of adjustment.
2. Do not adjust the variable resistors on the LD unit, as these are permanently adjusted at the factory.
If replacement of the LD drive board is necessary, replace the entire LD unit.
3. Keep the polygon mirror and toroidal lens free of dust. Laser performance is very sensitive to dust on
these components.
4. Do not touch the shield glass or the surface of the polygon mirror with bare hands.
5. Do not adjust the Laser Synchronization detector on the LD unit, as these are permanently adjusted
at the factory. If the position of the Laser Synchronization detector has changed from the factory set
position, SC 322 will be shown.
25
4. Replacement and Adjustment
4
Transfer Roller
1. Never touch the surface of the transfer roller with bare hands.
2. Be careful not to scratch the transfer roller, as the surface is easily damaged.
Fusing
1. After installing the fusing thermistor, make sure that it is in contact with the hot roller and that the roller
can rotate freely.
2. Be careful to avoid damage to the hot roller stripper pawls and their tension springs.
3. Do not touch the fusing lamp and rollers with bare hands.
4. Make sure that the fusing lamp is positioned correctly and that it does not touch the inner surface of
the hot roller.
Paper Feed
1. Do not touch the surface of paper feed rollers.
2. To avoid misfeeds, the side and end fences in each paper tray must be positioned correctly so as to
align with loaded paper size.
Releasing Plastic Latches
Many of the parts are held in place with plastic latches. The latches break easily, so release them carefully.
To remove such parts, press the hook end of the latch away from the part to which it is latched.
26
After Servicing the Machine
4
1. Make sure all parts that require grounding are properly grounded.
2. Make sure the interlock switch is functioning.
3. Do not leave unused solder or parts inside the machine.
4. Do not leave any tools inside the machine.
5. Make sure all wires are properly connected and routed.
6. Make sure wires are not jammed between parts of the machine.
General
27
4. Replacement and Adjustment
4
Special Tools
Part Number Description Q’ty Remarks
B6455010 SD Card 1 Used in common with other printers.
B6456705 SD Card Adapter 1 Used in common with other printers.
B6456830 USB Reader/Writer 1 Used in common with other printers.
A0069104
Scanner Positioning Pin
(4 pieces/set)
Used for LD Unit positioning. Used in
1
common with the model K-P series and
other models.
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