Ricoh AP3800 Full Service Manual

8/11/2019 Ricoh AP3800 Full Service Manual

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G060/G570

/G082

SERVICEMANUAL

RICOH GROUP COMPANIES


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G570

SERVICE MANUAL



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G570

SERVICEMANUAL



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G060/G570/G082SERVICE MANUAL

001159MIU


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It is the reader's responsibility when discussing the information containedwithin this document to maintain a level of confidentiality that is in the bestinterest of Ricoh Corporation and its member companies.

NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANYFASHION AND DISTRIBUTED WITHOUT THE PRIOR

PERMISSION OF RICOH CORPORATION.

All product names, domain names or product illustrations, includingdesktop images, used in this document are trademarks, registeredtrademarks or the property of their respective companies.They are used throughout this book in an informational or editorial fashiononly and for the benefit of such companies. No such use, or the use of

any trade name, or web site is intended to convey endorsement or otheraffiliation with Ricoh products.

!!!!2001 RICOH Corporation. All rights reserved.


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The Service Manual contains informationregarding service techniques, procedures,

processes and spare parts of office equipmendistributed by Ricoh Corporation. Users of this

manual should be either service trained ocertified by successfully completing a RicohTechnical Training Program.

Untrained and uncertified users utilizinginformation contained in this service manual torepair or modify Ricoh equipment risk personainjury, damage to property or loss of warrant

protection.

Ricoh Corporation

WARNING


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LEGEND

PRODUCT CODE COMPANY

GESTETNER LANIER RICOH SAVIN

G060 DSc38 2138 AH AP3800C SLP38c

G570 DSc38S 2138CMF AP3800CMF SLP38cS

G082 DSc38F 2138E AP3850C SLP38c DE

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

* 9/2001 Original Printing

1 2/2002 G570 Addition

2 6/2002 G082 Addition


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3.3 EXTERIOR COVERS ............................................................................... 3-53.3.1 REAR COVER AND UPPER REAR COVER................................... 3-53.3.2 PAPER EXIT TRAY ......................................................................... 3-53.3.3 UPPER RIGHT COVER................................................................... 3-5

3.3.4 FRONT COVER............................................................................... 3-63.3.5 LEFT COVER AND REAR LEFT COVER ....................................... 3-63.3.6 UPPER LEFT COVER AND OPERATION PANEL.......................... 3-7

3.4 LASER OPTICS........................................................................................ 3-83.4.1 CAUTION DECAL LOCATIONS ...................................................... 3-83.4.2 LASER OPTICS HOUSING UNIT.................................................... 3-9

Adjustments after Replacing the Laser Optics Housing Unit .............. 3-113.4.3 POLYGON MIRROR MOTOR ....................................................... 3-123.4.4 LASER SYNCHRONIZING DETECTOR BOARDS ....................... 3-12

3.5 PCU AND DEVELOPMENT UNIT .......................................................... 3-133.6 PAPER FEED......................................................................................... 3-14

3.6.1 PICK-UP, FEED, AND SEPARATION ROLLERS.......................... 3-14Tray 1 and Tray 2............................................................................... 3-14By-pass Tray...................................................................................... 3-14

3.6.2 PAPER WIDTH DETECTION BOARD........................................... 3-153.6.3 VERTICAL TRANSPORT SENSOR .............................................. 3-153.6.4 RIGHT DOOR UNIT....................................................................... 3-163.6.5 REGISTRATION SENSOR AND RELAY SENSOR....................... 3-173.6.6 PAPER FEED CLUTCHES............................................................ 3-173.6.7 BY-PASS FEED CLUTCH ............................................................. 3-183.6.8 TRAY LIFT MOTOR....................................................................... 3-18

3.7 TRANSFER AND PAPER TRANSPORT UNIT ...................................... 3-19

3.7.1 TRANSFER UNIT .......................................................................... 3-193.7.2 TRANSFER BELT CLEANING UNIT ............................................. 3-213.7.3 CLEANING BLADE AND CLEANING ROLLER............................. 3-223.7.4 TRANSFER BELT.......................................................................... 3-233.7.5 OTHERS........................................................................................ 3-27

Front Plate ......................................................................................... 3-27Grounding Spring ............................................................................... 3-27Drive Gear and Left Drive Roller ........................................................ 3-27

3.8 FUSING .................................................................................................. 3-283.8.1 FUSING UNIT................................................................................ 3-283.8.2 OIL SUPPLY UNIT......................................................................... 3-293.8.3 UPPER COVER............................................................................. 3-293.8.4 FUSING BELT UNIT...................................................................... 3-303.8.5 PRESSURE ROLLER.................................................................... 3-333.8.6 PAPER EXIT.................................................................................. 3-35

3.9 ELECTRICAL COMPONENTS............................................................... 3-363.9.1 MOVING THE CONTROLLER BOX OUT OF THE WAY .............. 3-363.9.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT - C, B OUT OF THE WAY................................................................ 3-363.9.3 CONTROLLER AND BCU ............................................................. 3-373.9.4 NVRAM REPLACEMENT PROCEDURE ...................................... 3-38

NVRAM for BCU ................................................................................ 3-38NVRAM for Controller ........................................................................ 3-38


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PCL5c Driver...................................................................................... 6-66PS3 Driver.......................................................................................... 6-67CMS (Color Management System) .................................................... 6-67Gray Correction.................................................................................. 6-67

BG/UCR (Black Generation/Under Color Removal) ........................... 6-67Gamma Correction............................................................................. 6-67Toner Limitation ................................................................................. 6-68Dither Processing and ROP/RIP ........................................................ 6-68

6.10.4 CONTROLLER FUNCTIONS....................................................... 6-69Sample Print ...................................................................................... 6-69Locked Print ....................................................................................... 6-69Paper Source Selection ..................................................................... 6-70Tray Priority (Auto Tray Select).......................................................... 6-70Tray Lock ........................................................................................... 6-70Manual Tray Select ............................................................................ 6-70

Auto Continue .................................................................................... 6-71Overview............................................................................................ 6-71Auto Tray Select................................................................................. 6-71Manual Tray Select ............................................................................ 6-71Paper Output Tray.............................................................................. 6-72Output Tray Selected ......................................................................... 6-72Sequential Stacking ........................................................................... 6-72Stapling .............................................................................................. 6-73Punching ............................................................................................ 6-73

6.11 IEEE1394 INTERFACE ........................................................................ 6-746.11.1 SPECIFICATIONS....................................................................... 6-74

Hardware Specification ...................................................................... 6-74System Requirements........................................................................ 6-74

6.11.2 IEEE1394..................................................................................... 6-746.11.3 BLOCK DIAGRAM....................................................................... 6-756.11.4 PIN ASSIGNMENT ...................................................................... 6-756.11.5 REMARKS ABOUT THIS INTERFACE KIT................................. 6-766.11.6 TROUBLESHOOTING NOTES.................................................... 6-76

DUPLEX UNIT G571

1 REPLACEMENT AND ADJUSTMENT......................................... 7-11.1 DUPLEX INVERTER UNIT....................................................................... 7-1

1.1.1 TOP COVER.................................................................................... 7-11.1.2 DUPLEX CONTROL BOARD .......................................................... 7-11.1.3 DUPLEX INVERTER MOTOR 1 ...................................................... 7-21.1.4 DUPLEX INVERTER MOTOR 2 AND SWITCH............................... 7-21.1.5 EXIT SENSOR 3 AND DUPLEX INVERTER SENSOR................... 7-31.1.6 EXIT SENSOR 1 AND 2 .................................................................. 7-3

1.2 DUPLEX FEED UNIT................................................................................ 7-41.2.1 DUPLEX DRIVE BOARD................................................................. 7-41.2.2 DUPLEX FEED MOTOR.................................................................. 7-4

1.2.3 DUPLEX FEED SENSOR................................................................ 7-5


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2.1.1 MECHANICAL COMPONENT LAYOUT.......................................... 9-62.1.2 ELECTRICAL COMPONENT LAYOUT ........................................... 9-72.1.3 DRIVE LAYOUT............................................................................... 9-8

LARGE CAPACITY TRAY G569

1 REPLACEMENT AND ADJUSTMENT....................................... 10-171.1 DETACHING THE TRAY FROM THE MAINFRAME............................ 10-11.2 REAR FENCE HP SENSOR................................................................... 10-11.3 CHANGING THE TRAY PAPER SIZE.................................................... 10-21.4 LEFT TRAY PAPER END SENSOR....................................................... 10-31.5 TRAY LIFT MOTOR................................................................................ 10-41.6 TRAY MOTOR AND STACK TRANSPORT CLUTCH............................ 10-51.7 PAPER FEED CLUTCH.......................................................................... 10-6

1.8 PAPER FEED UNIT................................................................................ 10-71.9 UPPER LIMIT, RIGHT TRAY PAPER END, AND RELAY SENSORS......................................................................... 10-81.10 PICK-UP/PAPER FEED/SEPARATION ROLLER ................................ 10-9

2 DETAILED SECTION DESCRIPTIONS.................................... 10-102.1 OVERVIEW .......................................................................................... 10-10

2.1.1 MECHANICAL COMPONENT LAYOUT...................................... 10-102.1.2 ELECTRICAL COMPONENT LAYOUT ....................................... 10-11

2.2 PAPER FEED....................................................................................... 10-122.3 SEPARATION ROLLER AND PICK-UP ROLLER RELEASE............... 10-13

2.4 TRAY LIFT............................................................................................ 10-142.5 NEAR END/END DETECTION............................................................. 10-152.6 PAPER STACK TRANSPORT MECHANISM....................................... 10-162.7 RIGHT TRAY PAPER END DETECTION............................................. 10-17

TWO-TRAY FINISHER G565

1 REPLACEMENT AND ADJUSTMENT....................................... 11-11.1 COVERS................................................................................................. 11-1

1.1.1 EXTERNAL COVERS.................................................................... 11-11.1.2 INNER COVER.............................................................................. 11-11.2 POSITIONING ROLLER......................................................................... 11-21.3 TRAY 1 EXIT SENSOR.......................................................................... 11-21.4 ENTRANCE SENSOR/STAPLER TRAY ENTRANCE SENSOR ........... 11-31.5 STAPLER TRAY..................................................................................... 11-31.6 UPPER STACK HEIGHT SENSORS/ TRAY 1 UPPER LIMIT SWITCH ............................................................ 11-41.7 EXIT GUIDE PLATE MOTOR................................................................. 11-51.8 LIFT MOTORS........................................................................................ 11-51.9 LOWER EXIT SENSOR.......................................................................... 11-7

1.10 LOWER STACK HEIGHT SENSORS................................................... 11-8


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1.11 TRAY 2 SHUNT POSITION SENSOR.................................................. 11-81.12 STAPLER UNIT.................................................................................... 11-91.13 STAPLER ROTATION HP SENSOR.................................................... 11-91.14 TRAY 1 INTERIOR............................................................................. 11-10

1.14.1 TRAY 1 COVERS ...................................................................... 11-10tray Shift Sensors and tray release sensor ...................................... 11-111.14.3 TRAY 1 SHIFT MOTOR............................................................. 11-111.14.4 BACK FENCE LOCK CLUTCH.................................................. 11-11

1.15 FINISHER MAIN BOARD ................................................................... 11-121.16 PUNCH HOLE POSITION ADJUSTMENT......................................... 11-12

2 TROUBLESHOOTING.............................................................. 11-132.1 JAM DETECTION................................................................................. 11-13

3 SERVICE TABLES................................................................... 11-14

3.1 DIP SWITCH SETTINGS...................................................................... 11-143.2 TEST POINTS ...................................................................................... 11-143.3 FUSES.................................................................................................. 11-14

4 DETAILED DESCRIPTIONS .................................................... 11-154.1 GENERAL LAYOUT ............................................................................. 11-154.2 DRIVE LAYOUT ................................................................................... 11-164.3 JUNCTION GATES .............................................................................. 11-174.4 TRAY SHIFTING .................................................................................. 11-18

4.4.1 TRAY SHIFT MECHANISMS....................................................... 11-18Tray 1 (Upper Tray).......................................................................... 11-18

Tray 2 (Lower Tray).......................................................................... 11-194.5 TRAY UP/DOWN MECHANISMS......................................................... 11-20

4.5.1 TRAY 1 ........................................................................................ 11-20Introduction ...................................................................................... 11-20Normal and sort/stack modes .......................................................... 11-20Staple Mode..................................................................................... 11-21Tray 1 release mechanism............................................................... 11-22

4.5.2 TRAY 2 ........................................................................................ 11-234.5.3 PRE-STACK MECHANISM.......................................................... 11-24

4.6 JOGGER UNIT PAPER POSITIONING MECHANISM......................... 11-25Vertical Paper Alignment.................................................................. 11-25Horizontal Paper Alignment ............................................................. 11-25

4.7 STAPLER MECHANISM....................................................................... 11-264.7.1 STAPLER MOVEMENT............................................................... 11-26

Stapler Rotation ............................................................................... 11-26Side-to-Side Movement.................................................................... 11-26

4.7.2 STAPLER .................................................................................... 11-274.7.3 FEED OUT AND TRANSPORT ................................................... 11-28

4.8 PUNCH UNIT (OPTIONAL) .................................................................. 11-294.8.1 PUNCH DRIVE MECHANISM ..................................................... 11-294.8.2 PUNCH WASTE COLLECTION................................................... 11-30


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FOUR-BIN MAILBOX G566

1 REPLACEMENT AND ADJUSTMENT ....................................... 12-1

1.1 EXTERIOR COVER REMOVAL.............................................................. 12-1

1.2 TRAY PAPER/OVERFLOW/VERTICAL TRANSPORT SENSORS ........12-2

1.3 MAIN MOTOR REPLACEMENT .............................................................12-3

2 DETAILED DESCRIPTIONS....................................................... 12-4

2.1 COMPONENT LAYOUT..........................................................................12-4

2.1.1 MECHANICAL COMPONENT LAYOUT.........................................12-4

2.1.2 DRIVE LAYOUT .............................................................................12-4

2.2 ELECTRICAL COMPONENT DESCRIPTIONS ...................................... 12-5

2.3 BASIC OPERATION................................................................................12-6

2.4 PAPER OVERFLOW DETECTION .........................................................12-7

SPECIFICATIONS

SPECIFICATIONS........................................................................... 13-1

1 GENERAL SPECIFICATIONS.................................................................... 13-1

1.1 SUPPORTED PAPER SIZES............................................................13-3

1.1.1 PAPER FEED.................................................................................13-3

1.1.2 PAPER EXIT ..................................................................................13-4

2 SOFTWARE ACCESSORIES ....................................................................13-5

2.1 PRINTER DRIVERS..........................................................................13-5

2.2 UTILITY SOFTWARE........................................................................13-5

3 MACHINE CONFIGURATION....................................................................13-6

4 OPTIONAL EQUIPMENT...........................................................................13-8

4.1 500-SHEET TRAY.............................................................................13-8

4.2 1000-SHEET TRAY...........................................................................13-8

4.3 2000-SHEET LARGE CAPACITY TRAY...........................................13-8

4.4 TWO-TRAY FINISHER & PUNCH UNIT ...........................................13-9

4.5 FOUR-BIN MAILBOX ......................................................................13-10

FIRMWARE HISTORY

FIRMWARE HISTORY .................................................................... 14-11 MAIN ENGINE FIRMWARE MODIFICATION HISTORY ........................... 14-1

2 MUSIC ENGINE FIRMWARE MODIFICATION HISTORY......................... 14-5

3 CONTROLLER FIRMWARE MODIFICATION HISTORY...........................14-6

4 NIB FIRMWARE MODIFICATION HISTORY .............................................14-9

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COPIER FEATURE EXPANDER G570TABLE OF CONTENTS

1. INSTALLATION........................................................................... 1-11.1 INSTALLATION REQUIREMENTS .......................................................... 1-1

1.1.1 ENVIRONMENT .............................................................................. 1-11.1.2 MACHINE LEVEL ............................................................................ 1-11.1.3 MACHINE SPACE REQUIREMENTS ............................................. 1-2

CF Expander with Rack ....................................................................... 1-2CF Expander without Rack .................................................................. 1-3

1.1.4 POWER REQUIREMENTS.............................................................. 1-41.2 OPTIONAL UNIT COMBINATIONS.......................................................... 1-4

1.3 INSTALLATION WORK FLOW................................................................. 1-51.4 MACHINE INSTALLATION....................................................................... 1-61.5 MACHINE INSTALLATION....................................................................... 1-8

1.5.1 RACK............................................................................................... 1-9Accessories Check List ........................................................................ 1-9Assembling the Rack ........................................................................... 1-9Docking the Rack and Printer Mainframe........................................... 1-11

1.5.2 CF EXPANDER ............................................................................. 1-13Accessories Check List ...................................................................... 1-13CF Expander Installation.................................................................... 1-13

1.5.3 40GB HDD..................................................................................... 1-19

Accessories Check List ...................................................................... 1-1940 GB HDD Installation...................................................................... 1-19

1.5.4 ARDF............................................................................................. 1-21Accessories Check List ...................................................................... 1-21ARDF Installation ............................................................................... 1-21

1.5.5 MULTI-BIN OUTPUT TRAY........................................................... 1-24Accessories Check List ...................................................................... 1-24Installing the Multi-Bin Output Tray .................................................... 1-24

1.5.6 ANTI-CONDENSATION HEATER ................................................. 1-26

2. PREVENTIVE MAINTENANCE ................................................... 2-12.1 USER MAINTENANCE............................................................................. 2-12.2 SERVICE MAINTENANCE....................................................................... 2-3

3. REPLACEMENT AND ADJUSTMENT........................................ 3-13.1 SPECIAL TOOLS ..................................................................................... 3-13.2 LUBRICANTS........................................................................................... 3-13.3 IMAGE ADJUSTMENT............................................................................. 3-2

3.3.1 PRINTING........................................................................................ 3-2

Leading edge registration..................................................................... 3-2Side-to-side registration ....................................................................... 3-2


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3.3.2 SCANNING...................................................................................... 3-2Scanner sub-scan magnification .......................................................... 3-2Scanner leading edge and side-to-side registration ............................. 3-2Main scan dot position correction......................................................... 3-3

3.3.3 ARDF............................................................................................... 3-4ARDF side-to-side and leading edge registration................................. 3-43.3.4 PRINTER GAMMA CORRECTION.................................................. 3-5

Printer Mode ........................................................................................ 3-5Copy Mode........................................................................................... 3-7

3.4 REPLACEMENT..................................................................................... 3-103.4.1 EXPOSURE GLASS...................................................................... 3-103.4.2 ORIGINAL LENGTH/WIDTH SENSOR ......................................... 3-103.4.3 SENSOR BOARD UNIT (SBU)...................................................... 3-113.4.4 EXPOSURE LAMP STABILIZER................................................... 3-123.4.5 XENON LAMP ............................................................................... 3-12

3.4.6 SCANNER POWER SUPPLY UNIT (PSU).................................... 3-143.4.7 SCANNER MOTOR....................................................................... 3-143.4.8 FRONT SCANNER WIRE.............................................................. 3-153.4.9 REAR SCANNER WIRE................................................................ 3-183.4.10 NVRAM REPLACEMENT PROCEDURE .................................... 3-20

NVRAM on the Controller (IC9).......................................................... 3-20NVRAM Expansion Board on the Controller (CN13).......................... 3-20NVRAM on the BCU (IC20)................................................................ 3-21

3.4.11 REQUIRED ACTIONS WHEN REPLACING ITEMS.................... 3-223.5 PRINTER ENGINE ................................................................................. 3-23

3.5.1 TONER SUPPLY UNIT.................................................................. 3-23

Preparation ........................................................................................ 3-23M Toner Supply Unit .......................................................................... 3-23K, C, and Y Toner Supply Units ......................................................... 3-27

3.5.2 BCU ............................................................................................... 3-28DIP switch settings............................................................................. 3-29

3.6 OTHERS................................................................................................. 3-303.6.1 TOUCH PANEL POSITION ADJUSTMENT .................................. 3-30

4. TROUBLESHOOTING................................................................. 4-14.1 PROCESS CONTROL ERROR CONDITIONS ........................................ 4-1

4.1.1 DEVELOPER INITIALIZATION RESULT......................................... 4-14.1.2 PROCESS CONTROL SELF-CHECK RESULT .............................. 4-34.1.3 LINE POSITION ADJUSTMENT RESULT....................................... 4-4

4.2 SCANNER TEST MODE .......................................................................... 4-74.2.1 VPU TEST MODE............................................................................ 4-7

SP4-907-1 VPU Test Pattern: R.......................................................... 4-7SP4-907-2 VPU Test Pattern: G ......................................................... 4-7SP4-907-3 VPU Test Pattern: B.......................................................... 4-7

4.2.2 IPU TEST MODE............................................................................. 4-8SP4-904-1 Register Write/Read Check Result ................................... 4-8

SP4-904-2 Image Path Check Result .................................................. 4-84.3 SERVICE CALL CONDITIONS................................................................. 4-9


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4.3.1 SUMMARY....................................................................................... 4-9SC Classification.................................................................................. 4-9

4.4 SC TABLE .............................................................................................. 4-114.5 TROUBLESHOOTING GUIDE ............................................................... 4-45

4.5.1 IMAGE QUALITY........................................................................... 4-454.5.2 COLOR SHIFT............................................................................... 4-49

Adjustment Standard: Max. 200 m................................................... 4-51Preparation ........................................................................................ 4-51

5. SERVICE TABLES...................................................................... 5-15.1 SERVICE PROGRAM MODE CF CONFIGURATION ........................... 5-1

5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE .......... 5-15.1.2 TYPES OF SP MODES ................................................................... 5-1

SP Mode Button Summary................................................................... 5-2

Switching Between SP Mode and Copy Mode for Test Printing........... 5-3Selecting the Program Number............................................................ 5-3Exiting Service Mode ........................................................................... 5-4

5.2 SERVICE MODE ...................................................................................... 5-55.2.1 REMARKS ....................................................................................... 5-5

Display on the Touch Panel Screen..................................................... 5-5Others .................................................................................................. 5-6

5.3 PRINTER SP MODE ................................................................................ 5-75.3.1 SP MODES...................................................................................... 5-75.3.2 BIT SWITCH PROGRAMMING ....................................................... 5-8

5.4 COPY SP MODE...................................................................................... 5-9

5.4.1 SP MODES...................................................................................... 5-9SP1-XXX (Feed) .................................................................................. 5-9SP2-XXX (Drum)................................................................................ 5-16SP3-XXX (Process)............................................................................ 5-27SP4-XXX (Scanner) ........................................................................... 5-34SP5-XXX (Mode)................................................................................ 5-39SP6-XXX (Peripherals) ...................................................................... 5-51SP7-XXX (Data Log).......................................................................... 5-53

5.4.2 INPUT CHECK TABLE .................................................................. 5-65Main Frame Input Check: SP5-803.................................................... 5-65ARDF Input Check: SP6-007 ............................................................. 5-67Table 1: Paper Height Sensor............................................................ 5-67Table 2: Paper Size Switch (Tray 2)................................................... 5-68Table 3: Paper Size (By-pass Table) ................................................. 5-68Table 4: Original Size Detection......................................................... 5-68

5.4.3 OUTPUT CHECK TABLE .............................................................. 5-695.4.4 TEST PATTERN (SP5-997)........................................................... 5-73

5.5 SCANNER SP ........................................................................................ 5-745.5.1 SP MODES.................................................................................... 5-74

SP1-xxx (System and Others)............................................................ 5-74SP2-XXX (Scanning-image quality) ................................................... 5-75

SP8-XXX (Delivery)............................................................................ 5-825.6 REBOOT / SYSTEM SETTING RESET.................................................. 5-84


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5.6.1 SOFTWARE RESET...................................................................... 5-845.6.2 SYSTEM SETTINGS AND COPY SETTING RESET .................... 5-84

System Setting Reset......................................................................... 5-84Copier Setting Reset.......................................................................... 5-85

5.7 FIRMWARE UPDATE PROCEDURE..................................................... 5-865.7.1 TYPE OF FIRMWARE................................................................... 5-865.7.2 ERROR RECOVERY..................................................................... 5-865.7.3 FIRMWARE UPGRADE................................................................. 5-87

5.8 CONTROLLER SELF-DIAGNOSTICS.................................................... 5-895.8.1 OVERVIEW ................................................................................... 5-895.8.2 DETAILED SELF-DIAGNOSTICS.................................................. 5-90

Executing Detailed Self-Diagnosis ..................................................... 5-905.9 USER PROGRAM MODE....................................................................... 5-91

5.9.1 HOW TO USE UP MODE.............................................................. 5-91UP Mode Initial Screen: User Tools/Counter Display......................... 5-91

System Settings ................................................................................. 5-91Copier/Document Server Features..................................................... 5-92Printer, Facsimile, Scanner Settings .................................................. 5-92Counter .............................................................................................. 5-93Maintenance ...................................................................................... 5-93

5.10 DIP SWITCHES.................................................................................... 5-94Controller Board................................................................................. 5-94BCU Board......................................................................................... 5-94

6. DETAILED DESCRIPTIONS ....................................................... 6-16.1 SCANNING............................................................................................... 6-1

6.1.1 OVERVIEW ..................................................................................... 6-16.1.2 SCANNER DRIVE ........................................................................... 6-26.1.3 ORIGINAL SIZE DETECTION ......................................................... 6-36.1.4 OTHERS.......................................................................................... 6-5

DC Power Supply................................................................................. 6-5Anti-Condensation Heater.................................................................... 6-5

6.2 IMAGE PROCESSING ............................................................................. 6-66.2.1 OVERVIEW ..................................................................................... 6-66.2.2 SBU BLOCK DIAGRAM................................................................... 6-7

Signal Processing ................................................................................ 6-7A/D Conversion.................................................................................... 6-7White Level Correction:........................................................................ 6-7Others .................................................................................................. 6-7Black Level Correction ......................................................................... 6-8Adjustments ......................................................................................... 6-8VPU Test Mode.................................................................................... 6-8

6.2.3 IPU BLOCK DIAGRAM.................................................................... 6-9Shading Correction .............................................................................. 6-9Picture Element (Dot Position) Correction.......................................... 6-10Scan Line Correction.......................................................................... 6-10

Image Separation............................................................................... 6-10Scanner Gamma Correction (RGB Gamma Correction) .................... 6-11


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Filtering .............................................................................................. 6-12ADS (Auto Image Density Selection) ................................................. 6-12Color Conversion ............................................................................... 6-13Main Scan Magnification .................................................................... 6-14

Printer Gamma Correction ................................................................. 6-15Error Diffusion .................................................................................... 6-17IPU BOARD TEST ............................................................................. 6-17

6.3 PRINTER ENGINE ................................................................................. 6-186.3.1 DIFFERENCES IN THE PRINTER MAINFRAME.......................... 6-186.3.2 PAPER FEED LINE SPEED .......................................................... 6-18

6.4 SCANNER FUNCTIONS ........................................................................ 6-196.4.1 IMAGE PROCESSING FOR SCANNER MODE............................ 6-19

Image Data Path ................................................................................ 6-196.5 HARD DISK DRIVES.............................................................................. 6-206.6 IMAGE DATA PATH ............................................................................... 6-21

Copier Application.............................................................................. 6-21Printer Application.............................................................................. 6-21Scanner Application (1 bit/8 bits)........................................................ 6-21Fax Application (Transmission/Reception)......................................... 6-21

SPECIFICATIONS............................................................................ 7-11. GENERAL SPECIFICATIONS (COPY MODE)........................................... 7-12. GENERAL SPECIFICATIONS (SCANNER MODE) ................................... 7-53. SUPPORTED PAPER SIZES..................................................................... 7-63.1 PLATEN/ARDF ORIGINAL SIZE DETECTION ........................................ 7-6

3.2 PAPER FEED........................................................................................... 7-73.3 PAPER EXIT............................................................................................. 7-84. SOFTWARE ACCESSORIES..................................................................... 7-94.1 SCANNER ................................................................................................ 7-9

Scanner Drivers ................................................................................... 7-9Scanner Utilities ................................................................................... 7-9

5. MACHINE CONFIGURATION .................................................................. 7-106. OPTIONAL EQUIPMENT ......................................................................... 7-12

ARDF (G564)

1. REPLACEMENT AND ADJUSTMENT........................................ 8-11.1 COVERS................................................................................................... 8-11.2 ORIGINAL FEED UNIT............................................................................. 8-21.3 ORIGINAL PICK-UP ROLLER.................................................................. 8-21.4 ORIGINAL FEED BELT............................................................................ 8-31.5 SKEW CORRECTION/INTERVAL/ REGISTRATION/ORIGINAL WIDTH SENSORS ................................................................................... 8-41.6 ORIGINAL LENGTH SENSORS............................................................... 8-51.7 SEPARATION ROLLER ........................................................................... 8-51.8 INVERTER /ORIGINAL SET SENSORS.................................................. 8-6


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1.9 PICK-UP MOTOR/ORIGINAL STOPPER HP SENSOR/PICK-UP HP SENSOR ............................................................................................ 8-61.10 TRANSPORT MOTOR AND INVERTER MOTOR ................................. 8-71.11 FEED MOTOR, SKEW CORRECTION ROLLER CLUTCH.................... 8-8

1.12 EXIT SENSOR........................................................................................ 8-91.13 STAMP SOLENOID................................................................................ 8-91.14 CONTROLLER BOARD.......................................................................... 8-9

2. TROUBLESHOOTING............................................................... 8-102.1 TIMING CHARTS ................................................................................... 8-10

2.1.1 A4(S)/LT(S) SINGLE-SIDED ORIGINAL MODE............................ 8-102.1.2 A4(S)/LT(S) DOUBLE-SIDED ORIGINAL MODE.......................... 8-11

2.2 JAM DETECTION................................................................................... 8-12

3. SERVICE TABLES.................................................................... 8-13

3.1 DIP SWITCHES...................................................................................... 8-133.2 TEST POINTS ........................................................................................ 8-133.3 FUSES.................................................................................................... 8-13

4. DETAILED DESCRIPTIONS ..................................................... 8-144.1 MAIN COMPONENTS............................................................................ 8-14

DRIVE LAYOUT................................................................................. 8-154.3 ORIGINAL SIZE DETECTION................................................................ 8-16

4.3.1 BASIC MECHANISM ..................................................................... 8-164.3.2 MIXED ORIGINAL SIZE MODE..................................................... 8-18

4.4 ORIGINAL FEED-IN MECHANISM ........................................................ 8-19

4.4.1 PICK-UP AND SEPARATION........................................................ 8-194.4.2 ORIGINAL SKEW CORRECTION ................................................. 8-204.4.3 REDUCING THE INTERVAL BETWEEN PAGES ......................... 8-20

4.5 ORIGINAL TRANSPORT AND EXIT ...................................................... 8-214.5.1 SINGLE-SIDED ORIGINALS......................................................... 8-214.5.2 DOUBLE-SIDED ORIGINALS........................................................ 8-22

4.6 STAMP ................................................................................................... 8-23


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FAX UNIT G307TABLE OF CONTENTS

1. INSTALLATION............................................................................ 1-11.1 FAX UNIT ................................................................................................. 1-1

1.1.1 CAUTIONS ...................................................................................... 1-11.1.2 FAX OPTION INSTALLATION......................................................... 1-21.1.3 INSTALLING THE HANDSET.......................................................... 1-4

1.2 FAX UNIT OPTIONS ................................................................................ 1-51.2.1 G3 INTERFACE UNIT INSTALLATION ........................................... 1-51.2.2 ISDN OPTION INSTALLATION ....................................................... 1-71.2.3 FAX FUNCTION UPGRADE UNIT INSTALLATION........................ 1-91.2.4 EXPANSION MEMORY INSTALLATION ...................................... 1-10

2. TROUBLESHOOTING................................................................. 2-12.1 ERROR CODES....................................................................................... 2-12.2 ERROR CODES FOR THE ISDN OPTION .............................................. 2-9

2.2.1 D-CHANNEL LAYER MANAGEMENT........................................... 2-102.2.2 D-CHANNEL, LAYER 1 ................................................................. 2-102.2.3 D-CHANNEL LINK LAYER ............................................................ 2-102.2.4 D-CHANNEL NETWORK LAYER.................................................. 2-112.2.5 B-CHANNEL LINK LAYER............................................................. 2-112.2.6 B-CHANNEL NETWORK LAYER .................................................. 2-122.2.7 TRANSPORT LAYER.................................................................... 2-12

2.2.8 SESSION LAYER .......................................................................... 2-132.2.9 DOCUMENT LAYER ..................................................................... 2-142.2.10 PRESENTATION LAYER ............................................................ 2-14

2.3 FAX SC CODES..................................................................................... 2-152.3.1 OVERVIEW ................................................................................... 2-152.3.2 SC1201.......................................................................................... 2-152.3.3 SC1207.......................................................................................... 2-152.3.4 FAX SC CODE TABLE .................................................................. 2-16

2.4 ISDN TEST FUNCTION.......................................................................... 2-172.4.1 LEDS ............................................................................................. 2-17

2.4.2 BACK-TO-BACK TEST.................................................................. 2-18

3. SERVICE TABLES...................................................................... 3-13.1 SERVICE PROGRAM MODE................................................................... 3-1

3.1.1 SERVICE PROGRAM MODE OPERATION.................................... 3-1Entering and Exiting SP mode ............................................................. 3-1SP Mode Button Summary................................................................... 3-2Switching Between SP Mode and Copy Mode for Test Printing........... 3-3Selecting the Program Number............................................................ 3-3

3.1.2 SERVICE PROGRAM MODE TABLES ........................................... 3-43.2 BIT SWITCHES ........................................................................................ 3-9

3.2.1 SYSTEM SWITCHES ...................................................................... 3-9


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3.2.2 SCANNER SWITCHES ................................................................. 3-223.2.3 PRINTER SWITCHES ................................................................... 3-263.2.4 COMMUNICATION SWITCHES.................................................... 3-313.2.5 G3 SWITCHES.............................................................................. 3-40

3.2.6 G3-2 SWITCHES........................................................................... 3-473.2.7 G4 INTERNAL SWITCHES............................................................ 3-533.2.8 G4 PARAMETER SWITCHES....................................................... 3-60

3.3 NCU PARAMETERS .............................................................................. 3-633.4 DEDICATED TRANSMISSION PARAMETERS ..................................... 3-74

3.4.1 PROGRAMMING PROCEDURE ................................................... 3-743.4.2 PARAMETERS.............................................................................. 3-75

3.5 SERVICE RAM ADDRESSES................................................................ 3-79

4. DETAILED SECTION DESCRIPTIONS....................................... 4-14.1 OVERVIEW .............................................................................................. 4-1

4.2 BOARDS................................................................................................... 4-24.2.1 FCU ................................................................................................. 4-24.2.2 MBU................................................................................................. 4-34.2.3 NCU (US)......................................................................................... 4-44.2.4 NCU (EUROPE/ASIA) ..................................................................... 4-54.2.5 SG3 BOARD.................................................................................... 4-64.2.6 SIG4 BOARD................................................................................... 4-7

4.3 VIDEO DATA PATH ................................................................................. 4-84.3.1 TRANSMISSION.............................................................................. 4-8

Memory Transmission and Parallel Memory Transmission.................. 4-9Immediate Transmission ...................................................................... 4-9

JBIG Transmission............................................................................... 4-9I-G3 (ISDN G3) Transmission .............................................................. 4-9Adjustments ......................................................................................... 4-9

4.3.2 RECEPTION.................................................................................. 4-104.4 FAX COMMUNICATION FEATURES..................................................... 4-12

4.4.1 PERSONAL/INFORMATION/TRANSFER BOXES........................ 4-12Personal Box (Confidential Box) ........................................................ 4-12Transfer Box....................................................................................... 4-13Information Box (Polling Tx)............................................................... 4-14

4.4.2 MULTI-PORT COMMUNICATION................................................. 4-15

4.4.3 DOCUMENT SERVER .................................................................. 4-164.4.4 LAN FAX DRIVER ......................................................................... 4-17Regular transmission ......................................................................... 4-18Print and transmission........................................................................ 4-18Using Document Server ..................................................................... 4-18

SPECIFICATIONS............................................................................ 5-11. GENERAL SPECIFICATIONS.................................................................... 5-12. CAPABILITIES OF PROGRAMMABLE ITEMS .......................................... 5-33. MACHINE CONFIGURATION .................................................................... 5-4


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Rev. 06/2002

G082TABLE OF CONTENTS

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

1.1 INSTALLATION REQUIREMENTS...................................................................1-11.1.1 ENVIRONMENT.........................................................................................1-1

1.1.2 MACHINE LEVEL ......................................................................................1-11.1.3 MACHINE SPACE REQUIREMENT.......................................................1-21.1.4 POWER REQUIREMENTS ......................................................................1-2

1.2 OPTIONAL UNIT COMBINATIONS ..................................................................1-31.3 INSTALLATION FLOW CHART.........................................................................1-4

1.4 MACHINE INSTALLATION.................................................................................1-5

1.5 OPTIONAL UNIT INSTALLATION ....................................................................1-71.5.1 LIST OF OPTIONS ....................................................................................1-7

Note for Transporting the Machine...............................................................1-71.5.2 DIMM MEMORY INSTALLATION ...........................................................1-8

1.5.3 PUNCH UNIT INSTALLATION ................................................................1-9

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

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

3.1 CONTROLLER.....................................................................................................3-13.2 CONTROLLER PSU............................................................................................3-2

3.3 PRINTER ENGINE ..............................................................................................3-2

4. TROUBLE SHOOTING....................................................................4-1

4.1 CONTROLLER SELF-DIAGNOSTICS ERRORS ...........................................4-14.2 INTERNAL ERROR.............................................................................................4-24.3 SERVICE CALL CONDITIONS..........................................................................4-2

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

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

5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE.............5-1Entering the Service Mode ............................................................................5-1Accessing the Required Program.................................................................5-2Inputting a Value or Setting for a Service Program...................................5-2Exiting Service Mode......................................................................................5-2

5.2 PRINTER CONTROLLER SERVICE MODE...................................................5-35.2.1 SERVICE MODE MENU ("1. SERVICE") ..............................................5-35.2.2 BIT SWITCH PROGRAMMING ...............................................................5-3

5.3 PRINTER ENGINE SERVICE MODE...............................................................5-45.4 FIRMWARE UPDATE PROCEDURE...............................................................5-5

5.4.1 TYPE OF FIRMWARE...............................................................................5-55.4.2 FIRMWARE UPGRADE OVERVIEW .....................................................5-55.4.3 SUPPORTED OS AND TOOLS...............................................................5-5

5.4.4 FIRMWARE UPGRADE............................................................................5-6


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Upgrading Printer Firmware ..........................................................................5-6

5.4.5 ERROR RECOVERY.................................................................................5-95.4.6 HARD DISK FAILURE ...............................................................................5-9

5.5 CONTROLLER SELF-DIAGNOSTICS...........................................................5-11

5.5.1 OVERVIEW ...............................................................................................5-115.6 USER PROGRAM MODE ................................................................................5-12

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

6.1 CONTROLLER.....................................................................................................6-1

6.1.1 BLOCK DIAGRAM AND FUNCTIONS ...................................................6-1Components.....................................................................................................6-1Networking .......................................................................................................6-2

IX ASIC .............................................................................................................6-2Engine Video Interface...................................................................................6-2

Hard Disk Drive ...............................................................................................6-2

Memory.............................................................................................................6-3Options..............................................................................................................6-4

6.1.2 BOARD LAYOUT .......................................................................................6-56.1.3 PRINT DATA PROCESSING...................................................................6-6

6.1.4 BUILT-IN COLOR MANAGEMENT.........................................................6-76.1.5 POINT-TO-POINT DIAGRAM ..................................................................6-7

6.2 PRINTER ENGINE ..............................................................................................6-8

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

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

1.1 SUPPORTED PAPER SIZES......................................................................7-3

1.1.1 PAPER FEED.............................................................................................7-31.1.2 PAPER EXIT...............................................................................................7-4

2. SOFTWARE ACCESSORIES..............................................................................7-52.1 PRINTER DRIVERS......................................................................................7-52.2 UTILITY SOFTWARE ...................................................................................7-5

3. MACHINE CONFIGURATION..............................................................................7-64. OPTIONAL EQUIPMENT......................................................................................7-7

4.1 500-SHEET TRAY.........................................................................................7-74.2 1000-SHEET TRAY.......................................................................................7-74.3 2000-SHEET LARGE CAPACITY TRAY...................................................7-74.4 TWO-TRAY FINISHER & PUNCH UNIT ...................................................7-84.5 FOUR-BIN MAILBOX ....................................................................................7-9


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IMPORTANT SAFETY NOTICESPREVENTION OF PHYSICAL INJURY

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

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

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

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

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

HEALTH SAFETY CONDITIONS

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

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

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

the batteries. Used batteries must be handled in accordance with localregulations.


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SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

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

3. Dispose of replaced parts in accordance with local regulations.When keeping used lithium batteries in order to dispose of them later, do notput more than 100 batteries per sealed box. Storing larger numbers or notsealing them apart may lead to chemical reactions and heat build-up.

4. When keeping used lithium batteries in order to dispose of them later, do notput more than 100 batteries per sealed box. Storing larger numbers or not

sealing them apart may lead to chemical reactions and heat build-up.

LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair oflaser-based optical units in the field. The optical housing unit can only be repairedin a factory or at a location with the requisite equipment. The laser subsystem isreplaceable in the field by a qualified Customer Engineer. The laser chassis is notrepairable in the field. Customer engineers are therefore directed to return all

chassis and laser subsystems to the factory or service depot when replacement ofthe optical subsystem is required.

WARNINGUse of controls, or adjustment, or performance of procedures other thanthose specified in this manual may result in hazardous radiation exposure.

WARNINGWARNING: Turn off the main switch before attempting any of the

procedures in the Laser Optics Housing Unit section. Laserbeams can seriously damage your eyes.

CAUTION MARKING:


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Trademarks

Microsoft, Windows, and MS-DOSare registered trademarks of MicrosoftCorporation in the United States and /or other countries.

PostScriptis a registered trademark of Adobe Systems, Incorporated.

PCLis a registered trademark of Hewlett-Packard Company.

Ethernetis a registered trademark of Xerox Corporation.

PowerPCis a registered trademark of International Business MachinesCorporation.

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


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INSTALLATION


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INSTALLATION REQUIREMENTS

Installation1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

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

2. Humidity Range: 15% to 80% RH

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

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

5. Avoid exposing the machine to sudden temperature changes, which include:1) Direct cool air from an air conditioner2) Direct heat from a heater

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

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

8. Install the machine on a strong, level base. (Inclination on any side must be nomore than 5 mm.)

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

1.1.2 MACHINE LEVEL

Front to back: Within 5 mm (0.2")Right to left: Within 5 mm (0.2")

Rev. 7/2001


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INSTALLATION REQUIREMENTS

1.1.3 MACHINE SPACE REQUIREMENT

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

1.1.4 POWER REQUIREMENTS

CAUTION

1. Insert firmly the plug in the outlet.

2. Avoid using an outlet extension plug or cord.

3. Ground the machine.

1. Input voltage level: 120 V, 60 Hz: More than 10 A

2. Permissible voltage fluctuation: 10 %

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

B

D

CA

575mm (23")

678mm(27")

B

D

CA

1450mm (57")

678mm

(27")

Rev. 7/2001

A: Over 460 mm (18")

B: Over 100 mm (4")

C: Over 550 mm (22")

D: Over 700 mm (28")


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INSTALLATION FLOW CHART

1.3 INSTALLATION FLOW CHART

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

Two-tray Finisher: Needs the duplex unit, HDD or at least 128 MB of memory,and a paper tray unit or LCT.

Punch Unit: Needs the finisher.IEEE1394 Board: Needs the memory DIMM.

Unpack the pr inter.

Wil l the paper feed unit or LCT be instal led?

Place the pr inter on the paper feed unit or LCT.Instal l the paper feed unit or LCT.

Install the controller options (if required).

Yes No

Wil l the duplex unit be instal led?

Install the duplex unit.

Insta l l the four-bin mailbox

(if required).

Install the two-tray f inisher.

Install the printer.

Yes No

NoYes

Instal l the punch unit

(if required).

Wil l the Two-tray f in isher be instal led?

G060I002.WMF


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MACHINE INSTALLATION

Installation

1.4 MACHINE INSTALLATION

Refer to the Operating Instructions for details.

If the customer has a service contract, change the settings of the following SP

modes depending on the contract type.

Item SP No. Function Default

Meter charge SP5-930-1 Specifies whether the meter chargemode is enabled or disabled.

Meter charge mode enabled:

The Counter menu appearsimmediately after the Menu key ispressed.

The counter type selected by thecounting method (SP5-045-1) can be

displayed with the Counter menu.The counter values can also be

printed with the Counter menu.

The selected counter starts from anegative number.

Meter charge mode disabled:

The Counter menu is not displayed.

The total counter starts from 0.

Off

Counting method SP5-045-1 Specifies whether the countingmethod used in meter charge mode isbased on developments or prints.

Important:

This SP can only be done before thenegative counters are reset with SP7-825-001

Developments

A3/11" x 17"double counting

SP5-104-1 Specifies whether the counter isdoubled for A3/11" x 17" paper.

No: Singlecounting

PM warningdisplay 1

SP5-930-3 Specifies whether the PM warning forPCUs and development units isdisplayed when the replacement timearrives.Type 1: DisplayedType 2: Not displayed

Type 1

PM warning

display 2

SP5-930-4

toSP5-930-5

Specifies whether the PM warning for

the paper feed roller and transfer unitis displayed.

Off:

Fax No. setting SP5-812-2 Programs the service station faxnumber.

The number is printed on the counterlist when the meter charge mode isselected, so that the user can fax thecounter data to the service station.


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MACHINE INSTALLATION

Item SP No. Function Default

Counter reset SP7-825-1 Resets the counters to 0.

Important: This must be done atinstallation after all the above settingshave been finished. The negativecounters used in meter charge modewill be reset to zero.

NOTE: 1) The default setting for this machine is meter-charge mode off.2) The meter-charge counter cannot be reset.


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OPTIONAL UNIT INSTALLATION

Installation

1.5 OPTIONAL UNIT INSTALLATION

1.5.1 LIST OF OPTIONS

The available options are listed below. The installation procedure for all the options(except the punch unit) can be found in the Set Up Guide. The installationprocedure for the punch kit is on the following page

Paper Feed Unit (500 sheets x 1)

Paper Feed Unit (500 sheets x 2)

Large Capacity Tray

Two-tray Finisher

Punch Unit

Four-bin Mailbox

DIMM Memory (64/128/256 MB)

IEEE1394 BoardHDD

NVRAM

Note for Transporting the Machine

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

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

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

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

CAUTION: Reinstall the two stands in their original positions, or the machine mighttip over when pulling out the paper trays and so on.

G571R112.WMF

G568I901.WMF[A]

[B]

Rev. 6/2001


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1.5.2 PUNCH UNIT INSTALLATION

Accessory Check

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

list:

Description Qty

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

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

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

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

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

6. Spacer (2 mm) .......................................................................... 17. Spacer (1 mm) .......................................................................... 1

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

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


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Installation

Installation Procedure

CAUTIONSwitch off the main machine and unplug its power cord. If the two-trayfinisher is installed, disconnect it and pull it away from the machine.

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

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

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

B377I102.WMF

B377I103.WMF

[A]

[B]

[C]

Rev. 6/2001


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

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

6. Install the spring [C].

7. Install the 2 mm spacer [D].

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

B377I101.WMF

B377I104.WMF

[A]

[B]

[C]

[D]

[E]


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Installation

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

10. Slide in the hopper [B].

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

holes.

12. Reassemble the finisher and check the punch operation.

B377I200.WMF

B377I106.WMF

[A]

[B]

[C]


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USER MAINTENANCE

Preventive

Maintenance

2. PREVENTIVE MAINTENANCE

2.1 USER MAINTENANCE

The following maintenance kits are available for the customer to do PM.

Type A Color (C/M/Y) PCU 50KPType B Color (C/M/Y) Development Unit 100KPType C Fusing Unit 100KPType D Black Development Unit / Dust Filter 100KPType E Waste Toner Bottle 50KPType F Black PCU 50KPType G Oil Supply Unit 20KPType H Paper Feed Rollers 150KP

Chart: A4(LT)/5%Mode: 5 prints/jobEnvironment: Normal temperature and humidityYield may change depending on circumstances and print conditions.

When the machines default settings are used, an error message is displayed whena maintenance counter reaches the value in the PM table below, except for theitems in maintenance kit H.

NOTE: To have the machine display the message for maintenance kit H also, setSP5-930-4 to 1.

After the user replaces the items in a maintenance kit, the machine automaticallyresets the counter for this maintenance kit, except for the items in kit H.

NOTE: Except for the items in kit H, the machine can automatically detect whennew items have been installed.

The machine stops when the counters for parts in maintenance kits C, E and Greach the replacement value in the following table.

NOTE: To have the machine display the alert only for maintenance kits C, E, andG, set SP5-930-3 to 0.


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USER MAINTENANCE

Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect

Main Unit

Item 20K 50K 100K 150K EM Remarks

Black PCU R Included in maintenancekit F

Color (Y/M/C) PCUR

Included in maintenancekit A

Black Development UnitR

Included in maintenancekit D

Color (C/M/Y) Development UnitR

Included in maintenancekit B

Fusing UnitR

Included in maintenancekit C

Oil Supply UnitR

Included in maintenancekit G

Waste Toner Bottle

R

Included in maintenance

kit EDust Filter

RIncluded in maintenancekit D

Pick-up RollerR

Included in maintenancekit H

Feed RollerR


Separation RollerR


Punch Kit

Item 10K EM RemarksChads I Discard chads.


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SERVICE MAINTENANCE

Preventive

Maintenance

2.2 SERVICE MAINTENANCE

NOTE: After replacing the transfer unit, make sure to reset the maintenancecounter using SP7-804-16 and 7-804-27.

After replacing paper feed rollers, reset the maintenance counters for thesealso: By-pass tray (7-804-10), Tray 1 (7-804-11), Tray 2 (7-804-12), Tray3/LCT (7-804-13), Tray 4 (7-804-14)

Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect

Main unit

Item 20K 50K 100K 150K 1,000K EM Remarks

Transfer Unit R

By-pass Feed Roller R

By-pass Pick-up Roller R

By-pass Separation Roller R

One-tray Paper Feed Unit (500 sheets x 1)


Relay Roller C Damp cloth

Bottom Plate Pad C Damp cloth

Two-tray Paper Feed Unit (500 sheets x 2)




LCT (2000 sheets)




Two-tray Finisher

Items 20K 50K 100K 150K 1,000K EM Remarks

Rollers C Damp clothDischarge Brush C Dry cloth

Sensors C Blower brush

Jogger Fences I Replace if required.

Four-bin Mailbox


Rollers C Damp cloth

Tray Paper SensorsC

Blower blush or drycloth


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REPLACEMENT AND ADJUSTMENT


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SPECIAL TOOLS

Replac

ement

an

d

A d j

3. REPLACEMENT AND ADJUSTMENT

CAUTION

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

NOTE: This manual uses the following symbols.

: See or refer to : Screw : Connector: Clip ring : E ring

3.1 SPECIAL TOOLS

Part Number Part Name Qty

A2309352 Flash Memory Card - 4MB 1

G0219350 Loop-back connector - Parallel 1


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IMAGE ADJUSTMENT

3.2 IMAGE ADJUSTMENT

3.2.1 REGISTRATION

Image AreaThe image area shown in theillustration must be accurate. So makesure that the registration is within theadjustment standard range asdescribed below.

Leading Edge

Adjusts the leading edge registration for each paper type and process line speed.

Side to Side

Adjusts the side to side registration for each paper feed station.NOTE: The side to side registration for the optional paper feed unit, LCT, and

duplex unit can be adjusted with SP mode or with the user tools(Maintenance menu).

Adjustment Standard

Leading edge (sub-scan direction): 3 0 mm

Side to side (main-scan direction): 2 0 mm

Paper Registration Standard

The registration in both main and sub-scan direction may fluctuate within thefollowing tolerance.

1st side

Sub-scan direction: 0 1.5 mm

Main-scan direction: 0 2 mm

2nd side in duplex

Sub-scan direction: 0 3 mm

Main-scan direction: 0 4 mm

A

B

C

G060R007.WMF

Feed direction

A = B = C = 4.2mm (1.6")

Image Area


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IMAGE ADJUSTMENT

Replac

ement

an

d

Adjustment Procedure

1. Enter SP mode and access SP5-997.

2. Print out the pattern (14: 1-dot trimming pattern) with SP5-997.

NOTE: Registration may change slightly print by print as shown above.Therefore print a few pages of the trimming pattern for step 3 and 4.Average the leading edge and side-to-side registration values andadjust each SP mode accordingly.

3. Perform the leading edge registration adjustment.1) Check the leading edge registration and adjust it with SP1-001.2) Select the adjustment conditions (paper type and process line speed).3) Input the value then press the [Escape] key.4) Check the leading edge adjustment by generating the trim pattern.

4. Perform the side to side registration adjustment.

1) Check the side to side registration and adjust it with SP1-002.2) Select the adjustment conditions (paper feed station).3) Input the value then press the [Escape] key.4) Check the side to side adjustment by generating the trim pattern.

3.2.2 COLOR REGISTRATION

Line Position Adjustment

Normally, the automatic line position adjustment is executed under a specifiedcondition to optimize the color prints. If a color registration shifts, execute "AutoAdjust" with the user tools (Maintenance menu - Color registration) or SP5-993-2to do the forced line position adjustment. In addition, it is recommended to performthe line position adjustment under the following conditions:

After transporting or moving the printer (if printers are pre-installed at theworkshop and transported to the user location, forced line position adjustmentshould be done after printer installation is completed at the user location.)

When opening the drum positioning plate

When removing or replacing the motors, clutches, and/or gears related to the

drum/development/transfer sections When removing or replacing the transfer belt or laser optical housing unit

Adjustment for Line Speed of Fusing Unit

Optimize the line speed for the fusing unit when the color registration shifts moreon the trailing edge compared with that on the leading edge, even after lineposition adjustment is executed. Adjust the speed of development motor-K with thefollowing user tool in the Maintenance menu.Menu/Maintenance/Color Regist./Fuser Adjust/Custom Adjust

Refer to Maintenance Guide 1 of the Operating Instructions for how to adjust this.


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IMAGE ADJUSTMENT

3.2.3 PRINTER GAMMA

NOTE: Normally, the printer gamma is enough to adjust the color balance toarchive the optimum print output. The gamma correction is only requiredfor fine-tuning to meet the user requirements.

Adjustment Overview

Make the gradation scales on the printout smooth from the highlight to the shadowdensity. Adjust the CMY gradation scale at the top of the chart by balancing thedensity of the C, M, and Y gradation scales the CMY gray scale should changesmoothly from minimum to maximum, and there should be no coloration.

For each color, you can adjust 15 points between 0 (lowest density) and 255(highest density).

The gradation scales marked Default Value are printed according to the default

gamma settings. The gamma adjustment changes the densities at the adjustablepoints in the gradation scale. The gradation scale marked Current Value showsthe current settings.

During the adjustment procedure, compare the Current Value gradation scalewith the Default Value. Select the density for each of the 15 adjustable points,excluding points 0 and 255, from the Default Value gradation scale.

The NVRAM holds three printer gamma settings, those saved this time (Current),those saved in the preceding adjustment (Previous), and the

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Ricoh AP3800 Full Service Manual