Ricoh Z-P2 Field Service Manual
Model Z-P2
Machine Codes: M257
Field Service Manual
April, 2015
Important Safety Notices
Responsibilities of the Customer Engineer
Customer Engineer
Maintenance shall be done only by trained customer engineers who have completed service training for
the machine and all optional devices designed for use with the machine.
Reference Material for Maintenance
• Maintenance shall be done using the special tools and procedures prescribed for maintenance of
the machine described in the reference materials (service manuals, technical bulletins, operating
instructions, and safety guidelines for customer engineers).
• In regard to other safety issues not described in this document, all customer engineers shall strictly
obey procedures and recommendations described the "CE Safety Guide".
• Use only consumable supplies and replacement parts designed for use of the machine.
Before Installation, Maintenance
Shipping and Moving the Machine
• Work carefully when lifting or moving the machine. If the machine is heavy, two or more customer
engineers may be required to prevent injuries (muscle strains, spinal injuries, etc.) or damage to the
machine if it is dropped or tipped over.
• Personnel moving or working around the machine should always wear proper clothing and
footwear. Never wear loose fitting clothing or accessories (neckties, loose sweaters, bracelets,
etc.) or casual footwear (slippers, sandals, etc.) when lifting or moving the machine.
• Always unplug the power cord from the power source before you move the product. Before you
move the product, arrange the power cord so it will not fall under the product.
Power
• Always disconnect the power plug before doing any maintenance procedure. After switching off
the machine, power is still supplied to the main machine and other devices. To prevent electrical
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shock, switch the machine off, wait for a few seconds, then unplug the machine from the power
source.
• Before you do any checks or adjustments after turning the machine off, work carefully to avoid
injury. After removing covers or opening the machine to do checks or adjustments, never touch
electrical components or moving parts (gears, timing belts, etc.).
• After turning the machine on with any cover removed, keep your hands away from electrical
components and moving parts. Never touch the cover of the fusing unit, gears, timing belts, etc.
Installation, Disassembly, and Adjustments
• After installation, maintenance, or adjustment, always check the operation of the machine to make
sure that it is operating normally. This ensures that all shipping materials, protective materials, wires
and tags, metal brackets, etc., removed for installation, have been removed and that no tools
remain inside the machine. This also ensures that all release interlock switches have been restored
to normal operation.
• Never use your fingers to check moving parts causing spurious noise. Never use your fingers to
lubricate moving parts while the machine is operating.
Special Tools
• Use only standard tools approved for machine maintenance.
• For special adjustments, use only the special tools and lubricants described in the service manual.
Using tools incorrectly, or using tools that could damage parts, could damage the machine or
cause injuries.
During Maintenance
General
• Before you begin a maintenance procedure:
1) Switch the machine off,
2) Disconnect the power plug from the power source,
3) Allow the machine to cool for at least 10 minutes.
• Avoid touching the components inside the machine that are labeled as hot surfaces.
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Safety Devices
• Never remove any safety device unless it requires replacement. Always replace safety devices
immediately.
• Never do any procedure that defeats the function of any safety device. Modification or removal of
a safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the
operation of the machine to ensure that it is operating normally and safely after removal and
replacement of any safety device.
• For replacements use only the correct fuses or circuit breakers rated for use with the machine. Using
replacement devices not designed for use with the machine could lead to a fire and personal
injuries.
Organic Cleaners
• During preventive maintenance, never use any organic cleaners (alcohol, etc.) other than those
described in the service manual.
• Make sure the room is well ventilated before using any organic cleaner. Use organic solvents in
small amounts to avoid breathing the fumes and becoming nauseous.
• Switch the machine off, unplug it, and allow it to cool before doing preventive maintenance. To
avoid fire or explosion, never use an organic cleaner near any part that generates heat.
• Wash your hands thoroughly after cleaning parts with an organic cleaner to contamination of
food, drinks, etc. which could cause illness.
• Clean the floor completely after accidental spillage of silicone oil or other materials to prevent
slippery surfaces that could cause accidents leading to hand or leg injuries. Use "My Ace" Silicone
Oil Remover (or dry rags) to soak up spills. For more details, please refer to Technical Bulletin
"Silicone Oil Removal" (A024-50).
Lithium Batteries
• Always replace a lithium battery on a PCB with the same type of battery prescribed for use on that
board. Replacing a lithium battery with any type other than the one prescribed for use on the board
could lead to an explosion or damage to the PCB.
• Never discard used batteries by mixing them with other trash. Remove them from the work site and
dispose of them in accordance with local laws and regulations regarding the disposal of such
items.
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Power Plug and Power Cord
• Before serving the machine (especially when responding to a service call), always make sure that
the power plug has been inserted completely into the power source. A partially inserted plug could
lead to heat generation (due to a power surge caused by high resistance) and cause a fire or other
problems.
• Always check the power plug and make sure that it is free of dust and lint. Clean it if necessary. A
dirty plug can generate heat which could cause a fire.
• Inspect the length of the power cord for cuts or other damage. Replace the power cord if
necessary. A frayed or otherwise damaged power cord can cause a short circuit which could lead
to a fire or personal injury from electrical shock.
• Check the length of the power cord between the machine and power supply. Make sure the power
cord is not coiled or wrapped around any object such as a table leg. Coiling the power cord can
cause excessive heat to build up and could cause a fire.
• Make sure that the area around the power source is free of obstacles so the power cord can be
removed quickly in case of an emergency.
• Make sure that the power cord is grounded (earthed) at the power source with the ground wire on
the plug.
• Connect the power cord directly into the power source. Never use an extension cord.
• When you disconnect the power plug from the power source, always pull on the plug, not the
cable.
After Installation, Servicing
Disposal of Used Items
• Never incinerate used toner or toner cartridges.
• Toner or toner cartridges thrown into a fire can ignite or explode and cause serious injury. At the
work site always carefully wrap used toner and toner cartridges with plastic bags to avoid spillage
before disposal or removal.
• Always dispose of used items (developer, toner, toner cartridges, OPC drums, etc.) in accordance
with the local laws and regulations regarding the disposal of such items.
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• To protect the environment, never dispose of this product or any kind of waste from consumables at
a household waste collection point. Dispose of these items at one of our dealers or at an
authorized collection site.
• Return used selenium drums to the service center for handling in accordance with company policy
regarding the recycling or disposal of such items.
Points to Confirm with Operators
At the end of installation or a service call, instruct the user about use of the machine. Emphasize the
following points.
• Show operators how to remove jammed paper and troubleshoot other minor problems by
following the procedures described in the operating instructions.
• Point out the parts inside the machine that they should never touch or attempt to remove.
• Confirm that operators know how to store and dispose of consumables.
• Make sure that all operators have access to an operating instruction manual for the machine.
• Confirm that operators have read and understand all the safety instructions described in the
operating instructions.
• Demonstrate how to turn off the power and disconnect the power plug (by pulling the plug, not the
cord) if any of the following events occur: 1) something has spilled into the product, 2) service or
repair of the product is necessary, 3) the product cover has been damaged.
• Caution operators about removing paper fasteners around the machine. They should never allow
paper clips, staples, or any other small metallic objects to fall into the machine.
Special Safety Instructions for Toner
Accidental Physical Exposure
• Work carefully when removing paper jams or replacing toner bottles or cartridges to avoid spilling
toner on clothing or the hands.
• If toner is inhaled, immediately gargle with large amounts of cold water and move to a well
ventilated 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.
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• 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.
Handling and Storing Toner
• Toner, used toner, and developer are extremely flammable.
• Never store toner, developer, toner cartridges, or toner bottles (including empty toner bottles or
cartridges) in a location where they will be exposed to high temperature or an open flame.
• 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.
Toner Disposal
• Never attempt to incinerate toner, used toner, or empty toner containers (bottles or cartridges).
Burning toner can explode and scatter, causing serious burns.
• Always wrap used toner and empty toner bottles and cartridges in plastic bags to avoid spillage.
Follow the local laws and regulations regarding the disposal of such items.
• Dispose of used toner and toner cartridges at one of our dealers or at an authorized collection site.
Always dispose of used toner cartridges and toner bottles in accordance with the local laws and
regulations regarding the disposal of such items.
Safety Instructions for this Machine
Prevention of Physical Injury
1. Before disassembling or assembling parts of the machine and peripherals, make sure that the
machine and peripheral power cords are unplugged.
2. The plug should be near the machine and easily accessible.
3. Note that some components of the machine and the paper tray unit are supplied with electrical
voltage even if the main power switch is turned off.
4. 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.
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5. If the [Start] key is pressed before the machine completes the warm-up period (the [Start] key starts
blinking red and green ), keep hands away from the mechanical and the electrical components as
the machine starts making copies as soon as the warm-up period is completed.
6. 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.
7. To prevent a fire or explosion, keep the machine away from flammable liquids, gases, and
aerosols.
Health Safety Conditions
1. Always replace the ozone filters with the specified types at the proper intervals.
2. 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 machine and its peripherals must be installed and maintained by a customer service
representative who has completed the training course on those models.
2. The NVRAM on the system control board has a lithium battery which can explode if replaced
incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends
replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled
in accordance with local regulations.
Safety and Ecological Notes for Disposal
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an
open flame.
2. Dispose of used toner, developer, and organic photoconductors 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.
• 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 used
batteries in accordance with the manufacturer's instructions.
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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: 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:
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Symbols, Abbreviations and Trademarks
This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations
are as follows:
See or Refer to
Clip ring
Screw
Connector
Clamp
E-ring
SEF Short Edge Feed
LEF Long Edge Feed
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.
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TABLE OF CONTENTS
Important Safety Notices................................................................................................................................... 1
Responsibilities of the Customer Engineer.................................................................................................... 1
Customer Engineer................................................................................................................................ 1
Reference Material for Maintenance...................................................................................................1
Before Installation, Maintenance..................................................................................................................1
Shipping and Moving the Machine..................................................................................................... 1
Power......................................................................................................................................................1
Installation, Disassembly, and Adjustments.........................................................................................2
Special Tools..........................................................................................................................................2
During Maintenance...................................................................................................................................... 2
General.................................................................................................................................................. 2
Safety Devices........................................................................................................................................3
Organic Cleaners..................................................................................................................................3
Lithium Batteries......................................................................................................................................3
Power Plug and Power Cord................................................................................................................ 4
After Installation, Servicing............................................................................................................................4
Disposal of Used Items..........................................................................................................................4
Points to Confirm with Operators......................................................................................................... 5
Special Safety Instructions for Toner.............................................................................................................5
Accidental Physical Exposure...............................................................................................................5
Handling and Storing Toner................................................................................................................. 6
Toner Disposal....................................................................................................................................... 6
Safety Instructions for this Machine...............................................................................................................6
Prevention of Physical Injury................................................................................................................. 6
Health Safety Conditions...................................................................................................................... 7
Observance of Electrical Safety Standards.........................................................................................7
Safety and Ecological Notes for Disposal...........................................................................................7
Laser Safety.....................................................................................................................................................8
Symbols, Abbreviations and Trademarks.........................................................................................................9
Trademarks..................................................................................................................................................... 9
1. Product Information
Specifications....................................................................................................................................................21
Machine Configuration....................................................................................................................................22
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Machine Configuration............................................................................................................................... 22
Guidance for Those Familiar with Predecessor Products.............................................................................. 23
Different Points from Previous Products...................................................................................................... 23
Overview.......................................................................................................................................................... 24
Mechanical Component Layout................................................................................................................. 24
Paper Path.................................................................................................................................................... 25
Drive Layout..................................................................................................................................................26
2. Installation
Installation Requirements................................................................................................................................. 29
Environment..................................................................................................................................................29
Machine Level..............................................................................................................................................30
Machine Space Requirements....................................................................................................................30
Power Requirements.................................................................................................................................... 31
Optional Unit Combinations............................................................................................................................32
Machine Options.........................................................................................................................................32
Controller Options....................................................................................................................................... 32
Printer Installation............................................................................................................................................. 33
Installation Procedure..................................................................................................................................33
Unpacking........................................................................................................................................... 33
Installing the toner............................................................................................................................... 37
Loading Paper..................................................................................................................................... 38
Turning Power On............................................................................................................................... 40
Selecting the Panel Display Language.............................................................................................. 41
Printing the Test Page.......................................................................................................................... 42
Settings Relevant to the Service Contract..........................................................................................42
Meter Click Charge..................................................................................................................................... 42
Moving the Machine................................................................................................................................... 45
Transporting the Machine........................................................................................................................... 45
Paper Feed Unit (M384).................................................................................................................................46
Caster Table (M393).......................................................................................................................................48
Accessory Check..........................................................................................................................................48
Installation Procedure..................................................................................................................................49
For Installing the Caster Table (M393) Only................................................................................... 49
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For Installing with the Paper Feed Unit (M384)............................................................................... 53
Tray Heater.......................................................................................................................................................57
Component Check.......................................................................................................................................57
Tray Heater (Mainframe)............................................................................................................................ 58
Tray Heater (Optional Unit)........................................................................................................................62
Component Check.............................................................................................................................. 62
For Installing the Tray Heater in M384.............................................................................................63
For Installing the Securing Bracket.....................................................................................................69
Controller Options............................................................................................................................................72
Overview...................................................................................................................................................... 72
I/F Card Slots......................................................................................................................................72
SD Card Slots...................................................................................................................................... 73
Installation Procedure for USB Device Server Option Type M12........................................................... 73
Component Check.............................................................................................................................. 73
Interface Board Surface......................................................................................................................74
Installation Procedure......................................................................................................................... 74
What Do the LED Indications Mean?................................................................................................ 78
IP Address Setting................................................................................................................................79
SD Card Appli Move...................................................................................................................................80
Overview............................................................................................................................................. 80
Outline of SD Card Appli Move........................................................................................................ 80
Move Exec...........................................................................................................................................81
Undo Exec........................................................................................................................................... 82
3. Preventive Maintenance
Maintenance Tables........................................................................................................................................ 83
4. Replacement and Adjustment
Notes on the Main Power Switch................................................................................................................... 85
Push Switch...................................................................................................................................................85
Characteristics of the Push Switch (DC Switch).................................................................................85
Shutdown Method...............................................................................................................................86
Forced Shutdown................................................................................................................................ 86
Before You Start............................................................................................................................................... 87
Special Tools.................................................................................................................................................... 88
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Tools..............................................................................................................................................................88
Exterior Covers................................................................................................................................................. 89
Left Cover......................................................................................................................................................89
Right Cover...................................................................................................................................................90
Rear Cover................................................................................................................................................... 91
When Reinstalling the Rear Cover.....................................................................................................91
Top Cover.....................................................................................................................................................92
When Reinstalling the Top Cover...................................................................................................... 93
Operation Panel...........................................................................................................................................93
Inner Left Upper Cover................................................................................................................................ 94
Inner Left Front Cover.................................................................................................................................. 95
Inner Left Rear Cover................................................................................................................................... 96
Inner Left Lower Cover.................................................................................................................................96
Inner Right Front Cover................................................................................................................................97
Inner Right Rear Cover................................................................................................................................ 99
Laser Optics....................................................................................................................................................100
Caution Decal Locations...........................................................................................................................100
Laser Unit....................................................................................................................................................100
Before removing the old laser unit...................................................................................................100
Recovery procedure for no replacement preparation of laser unit.............................................. 101
Removing the laser unit.................................................................................................................... 101
After installing a new laser unit........................................................................................................102
Laser Unit Fan............................................................................................................................................ 104
When installing the laser unit fan.................................................................................................... 104
LDU Shutter Motor.....................................................................................................................................105
Image Creation..............................................................................................................................................106
PCDU (Photo Conductor and Development Unit)...................................................................................106
When installing a new PCDU.......................................................................................................... 107
Waste Toner Bottle....................................................................................................................................110
Toner Supply Tube.................................................................................................................................... 111
Toner Supply Motor.................................................................................................................................. 117
Toner Collection Motor.............................................................................................................................118
Waste Toner Bottle Full Sensor.................................................................................................................120
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Waste Toner Bottle Set Sensor.................................................................................................................120
RFID CPU Board........................................................................................................................................121
RFID Board.................................................................................................................................................122
Development Fan...................................................................................................................................... 123
When installing the development fan..............................................................................................124
Image Transfer............................................................................................................................................... 125
ITB (Image Transfer Belt) Unit...................................................................................................................125
Image Transfer Belt....................................................................................................................................127
When Installing the Image Transfer Belt......................................................................................... 132
ITB Contact Motor.....................................................................................................................................133
ITB Contact Sensor....................................................................................................................................134
ID Sensor Board........................................................................................................................................ 136
After installing a new ID sensor board............................................................................................138
Paper Transfer................................................................................................................................................140
PTR (Paper Transfer Roller) Unit............................................................................................................... 140
When Installing the PTR Unit............................................................................................................140
PTR Contact Motor.................................................................................................................................... 141
PTR Contact Sensor................................................................................................................................... 142
Temperature/Humidity Sensor.................................................................................................................143
Drive Unit........................................................................................................................................................145
Gear Unit................................................................................................................................................... 145
When installing the gear unit........................................................................................................... 151
Toner Supply Fan...................................................................................................................................... 151
When installing the toner supply fan...............................................................................................152
Toner Supply Fan Base.................................................................................................................... 152
Drum Motor: CMY.................................................................................................................................... 152
Development Motor: CMY....................................................................................................................... 153
ITB Unit/ Drum-K/ Development-K Motor............................................................................................. 154
Development Clutch: K............................................................................................................................. 154
Fusing/Paper Exit Motor.......................................................................................................................... 155
Front Door Sensor..................................................................................................................................... 155
Motors with Bracket.................................................................................................................................. 156
Registration Motor.....................................................................................................................................158
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Paper Feed Motor..................................................................................................................................... 159
Vertical Transport Motor...........................................................................................................................160
Drum Phase Sensor: CMY........................................................................................................................ 161
Drum Phase Sensor: K...............................................................................................................................161
Drive Unit Fan............................................................................................................................................ 162
When installing the drive unit fan.................................................................................................... 163
Fusing..............................................................................................................................................................164
Fusing Unit..................................................................................................................................................164
When installing the fusing unit......................................................................................................... 164
Cleaning Unit.............................................................................................................................................164
Pressure Roller Fusing Lamp......................................................................................................................165
Pressure Roller............................................................................................................................................168
When Reinstalling the Pressure Roller.............................................................................................170
Heating Roller Fusing Lamp......................................................................................................................170
Fusing Belt.................................................................................................................................................. 175
Fusing, Heating and Tension Roller......................................................................................................... 177
When Reinstalling the Fusing Roller................................................................................................ 177
Heating Roller Thermostat.........................................................................................................................178
Heating Roller Thermistor..........................................................................................................................179
Pressure Roller Thermistor......................................................................................................................... 180
Pressure Roller Thermostat........................................................................................................................ 181
Thermopile................................................................................................................................................. 181
Paper Feed..................................................................................................................................................... 183
Separation Roller.......................................................................................................................................183
Pick-up and Paper Feed Rollers............................................................................................................... 183
Paper Feed Unit.........................................................................................................................................184
Registration Sensor....................................................................................................................................186
Vertical Transport Sensor..........................................................................................................................187
Paper Height Sensor 1..............................................................................................................................188
Paper Height Sensor 2..............................................................................................................................189
Paper Lift Sensor........................................................................................................................................ 190
Paper End Sensor...................................................................................................................................... 191
Paper Feed Sensor.................................................................................................................................... 192
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Tray Lift Motor............................................................................................................................................194
Tray 1 Set Sensor...................................................................................................................................... 195
Paper Size Sensor Board..........................................................................................................................197
Cleaning the Paper Dust Container......................................................................................................... 197
Paper Exit........................................................................................................................................................198
Paper Exit Unit........................................................................................................................................... 198
Paper Exit Sensor.......................................................................................................................................200
Inverter Sensor...........................................................................................................................................203
Paper Overflow Sensor.............................................................................................................................204
Fusing Exit Sensor......................................................................................................................................205
Inverter Motor............................................................................................................................................206
Fusing Cooling Fan....................................................................................................................................206
When installing the fusing cooling fan............................................................................................207
Upper Cover Sensor................................................................................................................................. 207
Duplex Unit.....................................................................................................................................................208
Duplex Unit................................................................................................................................................ 208
By-pass Tray Unit.......................................................................................................................................210
Duplex Entrance Sensor............................................................................................................................212
Duplex Exit Sensor.................................................................................................................................... 214
Fusing Entrance Sensor.............................................................................................................................215
Duplex/By-pass Motor.............................................................................................................................216
By-pass Paper End Sensor........................................................................................................................220
By-pass Feed Roller, Friction Pad.............................................................................................................221
HVPS: D......................................................................................................................................................224
Fusing Fan.................................................................................................................................................. 225
When installing the fusing fan..........................................................................................................226
Electrical Components...................................................................................................................................227
Boards........................................................................................................................................................ 227
HDD (Option)............................................................................................................................................ 229
Disposal of HDD Units......................................................................................................................230
Reinstallation..................................................................................................................................... 231
Controller Board........................................................................................................................................231
When installing the new controller board...................................................................................... 232
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Bridge Board............................................................................................................................................. 233
PSU............................................................................................................................................................. 234
Controller Box............................................................................................................................................235
BCU............................................................................................................................................................ 238
When installing the new BCU..........................................................................................................239
Removing the BCU with bracket......................................................................................................240
HVPS: T1T2 Board.................................................................................................................................... 241
HVPS: CB Board........................................................................................................................................242
DC Switch Board.......................................................................................................................................244
NVRAM Replacement Procedure............................................................................................................ 245
NVRAM on the BCU........................................................................................................................ 245
NVRAM on the Controller................................................................................................................246
Adjustments.................................................................................................................................................... 248
Gamma Adjustment...................................................................................................................................248
Summary............................................................................................................................................248
Adjustment Procedure.......................................................................................................................250
5. System Maintenance Reference
Service Program Mode.................................................................................................................................253
Service Mode Operation......................................................................................................................... 253
Accessing the Required Program.................................................................................................... 253
Inputting a Value or Setting for a Service Program....................................................................... 253
Exiting Service Mode....................................................................................................................... 253
Remarks......................................................................................................................................................254
Display on the Control Panel Screen.............................................................................................. 254
Bit Switch Programming............................................................................................................................ 256
Service SP Mode Tables............................................................................................................................... 258
SP1-XXX (Service Mode)..........................................................................................................................258
Engine SP Mode Tables: SP1000................................................................................................................271
SP1-XXX (Feed)......................................................................................................................................... 271
Engine SP Mode Tables - SP2000...............................................................................................................297
SP2-XXX (Drum).........................................................................................................................................297
Engine SP Mode Tables - SP3000...............................................................................................................397
SP3-XXX (Process)..................................................................................................................................... 397
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Engine SP Mode Tables - SP4000...............................................................................................................419
Engine SP Mode Tables - SP5000...............................................................................................................420
SP5-XXX (Mode)....................................................................................................................................... 420
Engine SP Mode Tables - SP6000...............................................................................................................472
Engine SP Mode Tables - SP7000...............................................................................................................473
SP7-XXX (Data Log).................................................................................................................................. 473
Engine SP Mode Tables - SP8000...............................................................................................................504
SP8-xxx: Data Log2.................................................................................................................................. 504
Input Check/ Output Check......................................................................................................................... 531
Input Check Table..................................................................................................................................... 531
Printer.................................................................................................................................................531
Table 1: Paper Size Switch (Tray 1)............................................................................................... 534
Table 2: Paper Height Sensor..........................................................................................................535
Output Check Table.................................................................................................................................. 535
Printer.................................................................................................................................................535
Test Pattern Printing........................................................................................................................................542
Test Pattern Printing....................................................................................................................................542
Firmware Update...........................................................................................................................................544
Type of Firmware.......................................................................................................................................544
SD Card Firmware Updating....................................................................................................................544
Before You Begin..............................................................................................................................544
File Arrangement.............................................................................................................................. 545
Update Procedure............................................................................................................................ 546
Error Handling.................................................................................................................................. 547
Power Failure.................................................................................................................................... 548
Handling Firmware Update Errors...........................................................................................................548
Error Message Table........................................................................................................................548
NVRAM Data Upload/Download.............................................................................................................. 550
Uploading NVRAM Data......................................................................................................................... 550
Downloading NVRAM Data.................................................................................................................... 551
Address Book Upload/Download.............................................................................................................. 552
Information List...........................................................................................................................................552
Download.................................................................................................................................................. 552
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Upload....................................................................................................................................................... 553
Capturing the Debug Logs............................................................................................................................ 554
Overview....................................................................................................................................................554
Types of debug logs that can be saved..........................................................................................554
Operation Log Security.................................................................................................................... 555
Storing the Debug Logs with SD Card.....................................................................................................556
Retrieving Debug Logs.............................................................................................................................. 556
Procedure for Retrieving the Debug Log.........................................................................................556
SP Text Mode (Saving SMC List to SD Card)..............................................................................................558
Overview....................................................................................................................................................558
SP Text Mode....................................................................................................................................558
Procedure...................................................................................................................................................558
File Names of the Saved SMC Lists......................................................................................................... 559
Error Messages..........................................................................................................................................560
DIP Switches...................................................................................................................................................561
Controller Board........................................................................................................................................561
6. Troubleshooting
SC Tables....................................................................................................................................................... 563
Service Call Conditions.............................................................................................................................563
Summary............................................................................................................................................563
SC1xx: Scanning.......................................................................................................................................564
SC 2xx: Exposure......................................................................................................................................564
SC3xx: Image Processing – 1..................................................................................................................571
SC4xx: Image Processing - 2...................................................................................................................576
SC5xx: Paper Feed and Fusing................................................................................................................581
SC6xx: Device Communication............................................................................................................... 595
SC8xx: Overall System.............................................................................................................................599
SC9xx: Miscellaneous.............................................................................................................................. 609
Process Control Results..................................................................................................................................612
Developer Initialization Result.................................................................................................................. 612
Process Control Self-Check Result............................................................................................................613
Vsg Adjustment Result.......................................................................................................................615
Line Position Adjustment Result................................................................................................................. 615
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Troubleshooting Guide..................................................................................................................................617
Blank Print...................................................................................................................................................617
All-black Print.............................................................................................................................................617
Missing CMY Color...................................................................................................................................618
Light Print.................................................................................................................................................... 618
Repeated Spots or Lines on Prints............................................................................................................ 618
Dark Vertical Line on Prints....................................................................................................................... 620
White Horizontal Lines or Bands..............................................................................................................620
Missing Parts of Images............................................................................................................................ 621
Dirty Background.......................................................................................................................................621
Partial CMY Color Dots............................................................................................................................ 621
Dark Irregular Streaks on Prints................................................................................................................621
CMY Color Irregular Streaks....................................................................................................................622
Ghosting.....................................................................................................................................................622
Unfused or Partially Fused Prints.............................................................................................................. 622
Image Skew............................................................................................................................................... 623
Background Stain......................................................................................................................................623
No Printing on Paper Edge.......................................................................................................................624
Image not centered when it should be.................................................................................................... 624
Jam Detection.................................................................................................................................................625
Paper Jam Display.....................................................................................................................................625
Jam Codes and Display Codes................................................................................................................625
Paper Size Code...............................................................................................................................627
Electrical Component Defects.......................................................................................................................628
Sensors....................................................................................................................................................... 628
Optional Paper Feed Unit................................................................................................................632
Blown Fuse Conditions..............................................................................................................................633
Power Supply Unit............................................................................................................................ 633
LEDs............................................................................................................................................................ 634
INDEX...........................................................................................................................................................635
20
1. Product Information
Specifications
See "Appendices" for the following information:
• "General Specifications"
• "Supported Paper Sizes"
• "Software Accessories"
• "Optional Equipment"
21
1. Product Information
Machine Configuration
Machine Configuration
Item Machine Code Remarks
SP C440DN M257
Paper Feed Unit PB1020 M384
Caster Table Type C M393 Common with Z-P1 (M065/ M066)
Hard Disk Drive Option Type P7 M479-00
IEEE802.11 Interface unit Type
O
IEEE1284 Interface Board Type
A
USB Device Server Option Type
M12
Camera Direct Print Card Type
P7
VM CARD Type P7 M479-08
IPDS Unit Type P7 M479-01, -02, -03
Direct Print Option Type P7 M479-05, -06, -07
M417
B679-17
D3A7
M479-04
Up to three tray units can be installed.
Common with Z-P1 (M065/ M066)
Common with Z-P1 (M065/ M066)
22
SD CARD SET FOR FONT TYPE
D FOR MFP
D641-54
Guidance for Those Familiar with Predecessor Products
Guidance for Those Familiar with Predecessor
Products
The Z-P2b (M257) is similar to the Z-P1a (M065) and P1b (M066) models.
If you have experience with those products, the following information will be of help when you read this
manual.
Different Points from Previous Products
New Predecessor Models
M257 M065 M066
PPM
Controller Type GW+ GW
Power Switch DC Switch AC Switch
Light Detection Sensor Available Not available
HDD Option Option Standard
Additional network
interface port
ELP-NX Option Option Standard
Data Overwrite
Security Unit and HDD
Encryption Unit
Log-storing function Available Not available
LT: 42 ppm,
A4: 40 ppm
Option Not available
On board SD card SD card
LT: 37 ppm,
A4: 35 ppm
LT: 42 ppm,
A4: 40 ppm
23
1. Product Information
Overview
Mechanical Component Layout
24
1. Toner Bottle [Y]
2. Toner Bottle [M]
3. Toner Bottle [C]
4. Toner Bottle [K]
5. ITB (Image Transfer Belt) Unit
6. Fusing Unit
7. Duplex Unit
8. ID Sensor
9. PTR (Paper Transfer Roller)
10. By-pass Tray
11. PCDU (Photo Conductor Development Unit)
12. Standard Paper Feed Tray (Tray 1)
13. PSU (Power Supply Unit)
14. Polygon Mirror Motor
15. LDU
16. ITB (Image Transfer Belt) Cleaning Unit
Paper Path
Overview
[A]: Duplex Unit
[B]: By-pass Tray
[C]: Optional Paper Feed Trays (Trays 2, 3, and 4)
[D]: Standard Paper Feed Tray (Tray 1)
[E]: Standard Paper Exit Tray
25
1. Product Information
Drive Layout
26
1. ITB Unit/ Drum-K/ Development-K Motor:
This controls the OPC for black, development unit for black, and ITB unit.
2. Drum Motor: CMY:
This controls the OPCs for cyan, magenta, and yellow.
3. Development Motor: CMY:
This controls the color development units (cyan/ magenta/ yellow).
4. Development Clutch: K:
This controls the drive power to the development unit for black.
5. Paper Feed Motor:
This controls the paper feed mechanisms (tray 1).
6. Vertical Transport Motor:
This controls the vertical transport roller.
7. Registration Motor:
This controls the registration rollers.
8. Duplex/By-pass Motor:
This controls the duplex entrance, relay, exit, and by-pass feed rollers.
9. Fusing/ Paper Exit Motor:
This controls the fusing unit and paper exit rollers.
10. Inverter Motor:
This controls the inverter roller.
Overview
27
1. Product Information
28
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