Ricoh Aficio AP2700 Service Manual Download Page 151

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SERVICE CALL CONDITIONS

1 October, 1999

7-6

SC541: Fusing temperature warm-up error

Definition: [A]

The fusing temperature detected by the thermistor was below 13

C for 10

seconds

Possible causes:

•

Fusing thermistor defective or out of position

•

Fusing lamp open

•

Fusing thermofuse open

•

Power supply board defective

•

Poor connection of the fusing unit

SC542: Fusing temperature warm-up error

Definition: [A]

The fusing temperature does not reach the fusing standby temperature within 40
seconds after the main switch is turned on.

Possible causes:

•

Fusing thermistor defective or out of position

•

Fusing lamp open

•

Fusing thermofuse open

•

Power supply board defective

•

Poor connection of the fusing unit

SC543: Fusing overheat error

Definition: [A]

A fusing temperature of over 230

C is detected for 1 second by the fusing

thermistor.

Possible causes:

•

Fusing thermistor defective

•

Power supply board defective

SC544: Fusing low temperature error

Definition: [A]

A fusing temperature of lower 100

C is detected for 1 second by the fusing

thermistor.

Possible causes:

•

Fusing thermistor defective

•

Power supply board defective

•

Poor connection of the fusing unit

Summary of Contents for Aficio AP2700

Page 1: ...Russian Printer Aficio AP2700 SERVICE MANUAL October 1st 1999 Subject to change...

Page 2: ...while the printer is operating Be careful to avoid touching those components with your bare hands HEALTH SAFETY CONDITIONS 1 Toner and developer are non toxic but if you get either of them in your eye...

Page 3: ...ological 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 s...

Page 4: ...s 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 Cor...

Page 5: ...TIONS 2 1 2 1 LASER EXPOSURE 2 1 2 1 1 OVERVIEW 2 1 2 1 2 AUTO POWER CONTROL APC 2 2 2 1 3 LD SAFETY SWITCH 2 3 2 2 PHOTOCONDUCTOR UNIT PCU 2 4 2 2 1 OVERVIEW 2 4 2 2 2 DRIVE MECHANISM 2 5 2 2 3 NEW P...

Page 6: ...2 37 2 8 2 FUSING DRIVE AND RELEASE MECHANISM 2 38 2 8 3 FUSING ENTRANCE GUIDE SHIFT MECHANISM 2 39 2 8 4 PRESSURE ROLLER 2 40 2 8 5 CLEANING MECHANISM 2 40 2 8 6 NEW FUSING UNIT DETECTION 2 41 2 8 7...

Page 7: ...4 2 SERVICE MODE TABLES 4 10 4 4 3 INPUT CHECK TABLE 4 16 4 4 4 OUTPUT CHECK TABLE 4 20 4 4 5 ENGINE BOARD PROGRAM DOWNLOAD 4 22 4 5 SERVICE TOOLS 4 23 4 5 1 SERVICE TOOL MENU 4 23 4 5 2 HDD TEST 4 2...

Page 8: ...ERS 6 18 6 6 12 PAPER END SENSOR 1ST AND 2ND PAPER FEED TRAYS 6 19 6 7 FUSING 6 20 6 7 1 FUSING UNIT 6 20 6 7 2 THERMISTOR 6 20 6 7 3 THERMOFUSE 6 21 6 7 4 HOT ROLLER AND FUSING LAMP 6 22 6 7 5 PRESSU...

Page 9: ...USTMENT A860 14 3 1 FEED ROLLER REPLACEMENT A860 14 3 2 TRAY MAIN BOARD REPLACEMENT A860 15 3 3 TRAY MOTOR REPLACEMENT A860 15 3 4 RELAY CLUTCH REPLACEMENT A860 16 3 5 UPPER PAPER FEED CLUTCH REPLACEM...

Page 10: ...2 DETAILED SECTION DESCRIPTIONS A862 5 2 1 PAPER FEED A862 5 2 2 REVERSE ROLLER AND PICK UP ROLLER RELEASE A862 6 2 3 TRAY LIFT A862 7 2 4 NEAR END END DETECTION A862 8 2 5 RIGHT TRAY SIDE FENCE A862...

Page 11: ...INTERCHANGE UNIT G531 1 OVERALL MACHINE INFORMATION G531 1 1 1 SPECIFICATIONS G531 1 1 2 MECHANICAL COMPONENT LAYOUT G531 2 1 3 DRIVE LAYOUT G531 3 2 DETAILED DESCRIPTION G531 4 2 1 JUNCTION GATE MECH...

Page 12: ...MATION A897 1 1 1 SPECIFICATIONS A897 1 1 2 MECHANICAL COMPONENT LAYOUT A897 2 1 3 ELECTRICAL COMPONENT LAYOUT A897 3 1 4 ELECTRICAL COMPONENT DESCRIPTION A897 4 1 5 DRIVE LAYOUT A897 5 2 DETAILED DES...

Page 13: ...4 SIDEWAYS 3 SHEETS 2SETS A681 15 2 9 2 STAPLE MODE A4 SIDEWAYS 2 SHEETS 2 SETS A681 16 3 SERVICE TABLE A681 17 3 1 DIP SWITCH TABLE A681 17 3 2 TEST POINTS A681 17 3 3 FUSES A681 17 4 REPLACEMENT AND...

Page 14: ...OMPONENT DESCRIPTIONS G518 3 2 DETAILED DESCRIPTIONS G518 5 2 1 BASIC OPERATION G518 5 2 2 PAPER OVERFLOW DETECTION G518 6 2 2 1 OVERVIEW G518 6 2 2 2 DETECTION TIMING G518 6 2 3 PAPER MISFEED DETECTI...

Page 15: ...10 Base T for TCP IP IPX SPX NetBEUI Apple Talk Printing Paper Size Maximum A3 11 x 17 Minimum 1st paper Tray A5 SEF 2nd paper Tray A6 SEF By pass A6 90 x 148 mm SEF Refer to section 1 1 2 Supported...

Page 16: ...on 120V 230V Maximum 900W or less 900W or less Printing 550W or less 550W or less Energy Saver 25 W or less 25 W or less Noise Emission Mainframe Only Full System Sound Power Level Printing 51 dB or l...

Page 17: ...Y N Y Y B5 LEF 257 x 182 mm Y Y Y N Y Y A5 SEF 148 x 210 mm Y Y Y N Y Y A5 LEF 210 x 148 mm N N N N N Y A6 SEF 105 x 148 mm N Y N N N Y Folio 8 25 x 13 Y Y Y N Y Y Foolscap 8 5 x 13 Y Y Y N Y Y F 8 x...

Page 18: ...Mac OS 7 1 or later versions 4 The PS3 drivers for Windows 3 1x and Windows NT4 0 do not support the Proof Print function 1 2 2 UTILITY SOFTWARE Software Description Agfa Font Manager Win3 1x 95 98 NT...

Page 19: ...1 October 1999 MACHINE CONFIGURATION 1 5 Overall Information 1 3 MACHINE CONFIGURATION 1 3 1 SYSTEM COMPONENTS G038V502 WMF A B C D E F G H I J...

Page 20: ...able 4 bin Mailbox G518 A See note 2 User installable Bridge Unit A897 I Used in common with Russian C See note 4 Service installation 1000 sheet Finisher A681 H Used in common with Russian C NAD See...

Page 21: ...7 Overall Information 1 4 PAPER PATH A Optional interchange unit B Optional duplex unit C Optional by pass tray D Optional paper tray unit 2 trays E Optional 1000 sheet finisher F Optional bridge uni...

Page 22: ...leaning unit 5 Drum 6 Transfer roller 7 Development roller 8 ID sensor 9 Registration roller 10 Friction pad 11 Paper feed roller 12 Paper size sensor 13 Special paper sensor 14 Bottom plate 15 Polygo...

Page 23: ...ower to the machine If this is off there is no power supplied to the machine SW2 Right Upper Cover Detects whether right upper cover is open or not SW3 Right Cover Cuts the 5VLD and 24V dc power line...

Page 24: ...rols all printer engine functions PCB2 Printer Controller Board Controls the printer functions PCB3 Network Interface Board Network interface board PCB4 PSU Power Supply Unit Provides dc power to the...

Page 25: ...as a latent image on the drum depends on the laser beam intensity which is controlled by the engine board 3 DEVELOPMENT The magnetic developer brush on the development rollers comes in contact with t...

Page 26: ...er particles from the drum surface onto the paper At the same time the paper is electrostatically attracted to the transfer roller 6 PAPER SEPARATION Paper separates from the drum as a result of the e...

Page 27: ...control board controls the connected components Engine Board By pass Tray Interchange Unit Paper Tray or LCT Bridge Unit Clutches PSU Fusing Lamp 4 bin Mailbox Duplex Unit Finisher Thermistor Power P...

Page 28: ...d toner saving Operation panel interface Interface and control of NIB and the other additional options HDD PS DIMM and DRAM DIMM 3 LD Drive Board This is the laser diode drive circuit board 4 Network...

Page 29: ...ust from reaching the polygon mirror Each surface of the polygon mirror reflects one full main scan line The laser beam goes to the F theta mirror E mirror F and BTL barrel toroidal lens G Then the la...

Page 30: ...current to the laser diode by comparing it with the reference level from the reference circuit This auto power control is done just after the machine is turned on and during printing while the laser...

Page 31: ...y switches are located at the front cover and right cover The switches are installed on the 5VLD line coming from the power supply unit through the Engine control board When the front cover or the rig...

Page 32: ...ck off Pawl 4 OPC Drum 5 ID Sensor see note 6 Development Roller 7 Development Unit 8 Charge Roller 9 Charge Roller Cleaning Pad 10 Quenching Lamp see note 11 Transfer Roller see note NOTE These parts...

Page 33: ...a timing belt C and the drum drive shaft D The main motor assembly includes a drive controller which outputs a motor lock signal when the rotation speed is out of the specified range The fly wheel E o...

Page 34: ...ecause the actuator of the new PCU comes in contact with the new PCU detect switch Then the machine automatically resets the PCU counter After the front cover and right cover are closed the machine th...

Page 35: ...uses a drum charge roller to charge the drum The drum charge roller A always contacts the surface of the drum B to give it a negative charge of 900V The high voltage supply board gives a negative dc...

Page 36: ...o the drum This measurement is made immediately after the ID sensor pattern for toner density control Immediately after making ID sensor pattern A the charge roller voltage stays on but the developmen...

Page 37: ...sor output reaches a certain point the drum charge voltage will be reduced To determine whether to change the drum charge roller voltage the machine compares Vsdp with Vsg Vsdp Vsg 0 95 Reduce the mag...

Page 38: ...it gets dirty easily So the cleaning pad B also contacts the drum charge roller all the time to clean the surface of the drum charge roller The pin C at the rear of the cleaning pad holder touches the...

Page 39: ...parts 1 Development roller 2 Mixing auger 2 3 TD sensor 4 Mixing auger 1 5 Doctor blade This machine uses a single roller development system Two mixing augers mix the developer The toner density TD s...

Page 40: ...augers C through a train of gears and the development drive shaft D When the PCU is pushed in the development drive shaft engages the development roller gear The development drive gears except for th...

Page 41: ...er evenly mixed Mixing auger 2 A transports excess developer scraped off the development roller C by the doctor blade D towards the front of the machine Mixing auger 1 B returns the excess developer a...

Page 42: ...arge about 900 V To attract negatively charged toner to the black areas of the latent image on the drum the high voltage supply board applies a bias of 600 volts to the development rollers throughout...

Page 43: ...position the cap F on the toner bottle is pulled away and kept in place by the chuck G The toner supply mechanism transports toner from the bottle to the development unit The toner bottle has a spiral...

Page 44: ...the toner falls down into the toner bottle holder The toner supply mylar blades transfer the toner to the slit D When the PCU is installed in the machine the shutter E above the PCU is opened by the...

Page 45: ...ory setting is P T control mode Basically toner density is controlled using the standard TD sensor voltage Vts toner supply reference voltage Vref actual TD sensor output voltage Vt and ID sensor outp...

Page 46: ...y amount Varies Toner end detection Performed Mode Fixed Quantity 1 Designer s use only do not use in the field Toner supply decision Compare Vt with a reference voltage Vts Toner control process This...

Page 47: ...en checking the ID sensor pattern In this way the reflectivity of both the drum surface and the pattern on the drum are checked This compensates for any variations in the reflectivity of the pattern o...

Page 48: ...sensitivity coefficient S value is 0 4 There are seven levels for toner supply motor on time as shown below Level Decision Motor On Time seconds 1 Vref Vt S 16 0 6 2 Vref Vt S 8 1 2 3 Vref Vt S 4 2 4...

Page 49: ...when in one of the following situations the machine leaves the toner near end condition While in the toner recovery cycle supplying toner on and off for 30 s see the previous page after the machine h...

Page 50: ...o the paper This model uses a counter blade system The cleaning blade scrapes off toner remaining on the drum When toner builds up in the cleaning unit toner at the top of the pile is removed by the t...

Page 51: ...G Toner picked up by the toner collection coil A is transported to the opening B at the side of the PCU Then this toner falls into the development unit with new toner coming from the toner bottle and...

Page 52: ...sensors are used for paper jam detection The components of the paper feed station are as follows 1 Paper Lift Sensor 2 Paper Height 1 Sensor 3 Paper Height 2 Sensor 4 Paper End Sensor 5 Paper Feed Ro...

Page 53: ...mechanism of both the first and second paper trays The paper feed clutches B transfer drive from this motor to the paper feed rollers C When the paper feed clutch turns on the feed rollers start to f...

Page 54: ...ISM The paper feed roller A drives the top sheet of paper from the paper tray The friction pad B allows only one sheet to feed at a time The friction pad applies pressure to the feed roller with a spr...

Page 55: ...that the lift motor can lift the bottom plate pressure lever The lift motor turns on and turns clockwise as viewed on the diagram The main pressure spring K pulls the bottom plate pressure lever and t...

Page 56: ...plate drops To make it easier to push the tray in the lift motor rotates backwards 1 7 seconds to return the bottom plate pressure lever coupling D to the original position 2 6 5 PAPER END DETECTION...

Page 57: ...bination of sensor signals is sent Amount of Paper Paper Height Sensor 1 Paper Height Sensor 2 Near End OFF ON 30 ON ON 70 ON OFF 100 OFF OFF When the tray contains paper of a small width the paper fe...

Page 58: ...ed from a tray if the paper size cannot be detected If the paper size actuator is broken or if there is no tray installed the Add Paper indicator will light When the paper size actuator is at the mark...

Page 59: ...it stays off and the machine detects that there is special paper in the 2nd paper tray When the machine detects the special paper signal the fusing temperature and the transfer roller current will be...

Page 60: ...this each side fence has a stopper A attached to it Each side fence can be secured with a screw B for customers who do not want to change the paper size End Fence As the amount of paper in the tray de...

Page 61: ...nd for detecting paper misfeeds The cleaning pad D contacts the registration roller It removes paper dust from the registration roller so that this dust will not transfer into the development unit thr...

Page 62: ...paper The current depends on the paper width paper type and paper feed tray The curvature of the drum and the antistatic plate C help the paper to separate from the drum The high voltage supply board...

Page 63: ...nsfer the toner to the paper 3 After the trailing edge of the paper has passed through the roller transfer current turns off In multiple printing the transfer current shifts again to the low transfer...

Page 64: ...positive cleaning current 10 A is applied to the transfer roller to push back to the drum any positively charged toner on the transfer roller The machine goes through the cleaning mode in the followin...

Page 65: ...VIEW The fusing unit and paper exit area consist of the following parts 1 Paper exit roller 2 Fusing exit sensor 3 Hot roller strippers 4 Pressure spring 5 Cleaning roller 6 Pressure roller 7 Fusing l...

Page 66: ...ugh a gear train and drives the paper exit rollers B through a timing belt C The fusing unit release mechanism automatically disengages the fusing unit drive gear D when the right cover E is opened Th...

Page 67: ...ble for paper thickness to prevent creasing The left screw holes B on each side are used as the default setting If creasing occurs frequently in the fusing unit adjust the entrance guide to the right...

Page 68: ...of the pressure springs The spring is positioned at the top D as the default setting The user moves the lever E when using thicker copy paper or envelopes to reduce the pressure between the hot and pr...

Page 69: ...ecomes opened Once the detector hook is released it will not re engage with the shaft for the duration of the fusing unit s life Then the machine clears the PM fusing counter Please note that this det...

Page 70: ...for the first job or for the first 11 consecutive pages of printing After that the machine maintains the fusing temperature at 170 C To prevent each end of the hot roller temperature from becoming to...

Page 71: ...from 1 second to 3 seconds Fusing soft start Fusing times In addition whenever the fusing lamp power switches on full power is applied to the fusing lamp gradually not all at once This prevents the p...

Page 72: ...se in series with the common ground line of the fusing lamp If the temperature of the thermofuse reaches 169 C the thermofuse opens removing power from the fusing lamp At the same time SC 542 is gener...

Page 73: ...el 2 The machine turns off the fusing lamp Entering Energy Saver Mode Energy saver mode starts after the machine has been idle for a certain time This period is specified by the user Energy saver mode...

Page 74: ...pecified in the PCL or PS commands for printing 2 10 2 PAPER SOURCE SELECTION Auto Tray Select The controller searches for the specified paper size and paper type starting from Tray 1 and uses the fir...

Page 75: ...in the tray search process If a tray has for example colored A4 size paper enable tray lock for that tray so that the controller does not select the tray for printing If the printer driver selects a...

Page 76: ...by pressing the Form Feed key The controller will print the job if the specified paper size and paper type are detected in a tray or if the user presses the Enter key after selecting a tray 2 10 3 OUT...

Page 77: ...s Note 1 With HDD Possible 1500 pages Note 2 NOTE 1 The number of pages is calculated using a sample MS Word document that contains 5 000 characters of plain text The sample document takes 409 6kB of...

Page 78: ...ontroller The ASIC Rocky R corrects the image printing order for duplexing as follows Larger than A4 lengthwise LT lengthwise example 8 pages 2nd page 1st page 4th page 3rd page 6th page 5th page 8th...

Page 79: ...the above diagram After all sets have been printed the controller deletes the file automatically If the proof print result is not OK the user must delete the file manually If there is no available spa...

Page 80: ...e RAM The menu settings NIB settings system log data and error codes remain unchanged NOTE Do not use this when the controller is receiving a print job Menu Reset This resets all the menu settings to...

Page 81: ...e Setup Guide for information about the installation environment and instructions on how to install and set up the machine Installation procedures for the following equipment are described Paper Tray...

Page 82: ...ry Check Check the quantity and condition of the accessories with the following list No Description Q ty 1 Bridge Unit 1 2 Securing Plate 1 3 Shoulder Screw 1 4 Knob Screw 1 Installation Procedure 1 R...

Page 83: ...n 7 Attach the securing plate E as shown NOTE Do not attach it with a screw this is done when securing the front stand for the optional finisher 8 Install the optional finisher A681 refer to the 1000...

Page 84: ...Bridge Unit A897 Paper Tray Unit A860 A861 or LCT A862 Installation Procedure 1 Unpack the finisher and remove the tapes 2 Install screw A loosely 3 Hang the front stand B on the screw that was insta...

Page 85: ...ush the stapler unit into the finisher 10 Secure the finisher 1 screw 11 Adjust the securing knobs F under the front and rear stand until the finisher is perpendicular to the floor 12 Install the shif...

Page 86: ...controller cover A 6 screws and the rear cover B 5 screws 2 Remove the cover bracket C 2 screws 3 Install the hard disk unit D to the upper socket of the printer controller 4 Reinstall the rear cover...

Page 87: ...solves the drum surface 3 Store the PCU in a cool dry place away from heat 4 Never expose the drum to corrosive gases such as ammonia gas 5 Never shake the used PCU Doing so may cause toner and or dev...

Page 88: ...that it does not touch the inner surface of the hot roller 4 1 5 PAPER FEED 1 Do not touch the surfaces of the pick up feed and separation rollers 2 The side fences and end fences of the paper tray m...

Page 89: ...ng the Required Program Use the Up Down arrow keys to scroll through the menu listing To select an item press the Enter key Then the sub menu will appear Scroll through the sub menu items using the Up...

Page 90: ...M Scan Reg Dplx Tray1 Other Trays Duplex D Fusing Times E Fusing Period F Fusing heat G LD Power H Developer bias I Developer data J Transfer set Tray Bypass Tray Duplex K Developer init L Separate vo...

Page 91: ...ear 3 Initializes the NVRAM on the NIB H Counter Clear Initializes all counters to zero I Diag Error Displays diagnostics error codes on the LCD J Vender Maker Selects the vender name K Service Print...

Page 92: ...inted the service summary report then press Enter 4 Press Enter to execute Or press Escape to exit CONTROLLER NVRAM RESET This initializes all the data in the controller NVRAM except the NIB settings...

Page 93: ...st 8 error codes that were found during the power on self test Refer to chapter 7 Troubleshooting for details of the error codes 1 Enter the SP mode and select 1 Service Menu 2 Select I Diag Error the...

Page 94: ...version Bit Switch List the current bit switch settings NOTE Currently the bit switches are not being used Counter List all the counters in the controller NOTE The total counter data is not stored in...

Page 95: ...2 801 L Separate volt Separation voltage adjustment 2 901 M Tailing cntrl Tailing correction shift value 2 906 1 N Tailing papers Tailing correction interval 2 906 2 O Toner supply Toner supply mode...

Page 96: ...CU counter Motor counter Engine settings Main sub scan registration for each trays density setting ID Sensor Error Remaining amount of paper Engine error logging last 10 error S Scan Reg Tray Leading...

Page 97: ...uplex unit Adjusts the printing side to side registration from the duplex unit using the test pattern 9 0 to 9 0 0 1 mm step 0 0 mm Tray1 Paper Feed Timing Tray 1 Other Trays Paper Feed Timing 2nd 3rd...

Page 98: ...fer Current Trays Adjusts the current applied to the transfer roller during printing from paper trays Bypass Tray Transfer Current Bypass Tray Adjusts the current applied to the transfer roller during...

Page 99: ...0 mm N Tailing papers Tailing Correction Interval Changes the interval for the image shift specified by the previous SP mode M Tailing cntrl 1 to 10 1 page step 1 page O Toner supply Toner Supply Mode...

Page 100: ...mmediately after the Enter key is pressed S Input check Input Check Displays signals received from sensors and switches See the Input Check section for details T Output check Output Check Turns on ele...

Page 101: ...y 1 Disp Eng ver Engine version display Displays the engine version 2 A3 11x17 Count A3 DLT Double Count Specifies whether the counter is doubled for A3 11 x 17 paper If Yes is selected the total coun...

Page 102: ...Paper not detected Paper detected 20 Paper exit sensor Paper not detected Paper detected 21 Exit sensor Optional interchange unit Paper not detected Paper detected 22 Duplex entrance sensor Optional...

Page 103: ...return position At return position 47 Side fence closed sensor Optional LCT Not detected Detected 48 Side fence open sensor Optional LCT Not detected Detected 49 Left tray paper end sensor Optional L...

Page 104: ...A4 SEF 0 1 0 1 0AH 11 x 17 0 1 1 1 0EH 11 x 81 2 1 0 0 0 01H 81 2 x 11 1 0 1 0 05H Asterisk 1 1 0 0 03H 81 2 x 14 33 34 39 40 1 1 1 1 0FH A3 1 Pushed Table 2 By pass Paper Size Sensor Paper Size Numbe...

Page 105: ...1 October 1999 PRINTER ENGINE SERVICE MODE 4 19 Service Tables Table 4 Paper Tray Unit Set Sensor Number SP Value Unit Installed 00H None 10H LCT 55 20H Paper tray unit 2 trays...

Page 106: ...paper tray unit 21 Upper relay clutch 22 Lower relay clutch 23 Relay clutch Optional paper tray unit 24 25 Not used 26 Upper paper feed clutch Optional paper tray unit 27 Lower paper feed clutch Opti...

Page 107: ...48 50 Not used 51 Polygonal mirror motor 52 Polygonal mirror motor and laser diode 53 Laser diode Do not use this mode 54 79 Not used 80 Duplex unit free run without paper 81 Duplex unit free run wit...

Page 108: ...cket slot NOTE Insert the flash memory card so that the surface printed A faces the back side of the machine as shown 4 Turn on the main switch to enter the SP mode then select 2 Service Menu 2 5 Scro...

Page 109: ...3 Specify the number of tests then press Enter If 000 is specified the test will continue until it is manually cancelled Increment decrement the digit at the cursor Escape Exit without executing the...

Page 110: ...nsupported HDD is detected 4 5 4 NIB NVRAM BACKUP AND RESTORE This backs up the NIB NVRAM to the controller and restores the data to the NIB NVRAM Use this procedure when replacing a NIB The following...

Page 111: ...ess Enter 10 Select the data copy direction CTL NIB then press Enter Select the data copy direction Escape Exit Enter Copy the NIB NVRAM to the controller NOTE Once data copying has started it cannot...

Page 112: ...IC card that contains the required firmware 2 Turn off the machine and remove the cover A 1 screw 3 Install the card B in the IC card slot on the controller NOTE Insert the flash memory card so that...

Page 113: ...Put back the controller and install the card in the IC card slot on the controller NOTE When you see the machine from the back the A side of the card must face the right side 5 Turn on the machine 6 W...

Page 114: ...test result the controller starts up as normal 3 Enter the SP mode and check the Diag Error for the error codes 1101 or 1102 Refer to the section 4 3 3 Printer Controller Service Mode for how to check...

Page 115: ...reaches 120K Replace Maintenance Kit is displayed After replacing the parts in the maintenance kit the machine automatically resets the PM fusing count Item Quantity Remarks Paper Feed Rollers 4 2 rol...

Page 116: ...ith water Relay Rollers C C Clean with water Registration Roller Mylar C C Clean with water Around the Drum Transfer Separation Unit R Fusing Unit and Paper Exit Hot Roller R Pressure Roller R Hot Rol...

Page 117: ...lay Clutch I Replace if necessary Paper Feed Clutch I Replace if necessary 120K EM NOTE Finisher Rollers C Clean with water or alcohol Brush Roller I I Replace if necessary Discharge Brush C C Clean w...

Page 118: ...ASER UNIT WARNING Turn off the main power switch and unplug the machine before attempting any of the procedures in this section Laser beams can seriously damage your eyes 6 1 1 CAUTION DECAL LOCATIONS...

Page 119: ...ion Laser beams can seriously damage your eyes 1 Remove the optional finisher and or bridge unit if these units have been installed 2 Remove the front cover A 2 pins 3 Remove the right front cover B 1...

Page 120: ...1 October 1999 LASER UNIT 6 3 Replacement Adjustment 6 Release the lock lever A and slide out the toner bottle B 7 Remove the laser unit C 2 screws 2 connectors G038R503 WMF A B C...

Page 121: ...with bear fingers 1 Remove the laser unit See Laser Unit Replacement 2 Remove the heat sink A 4 screws 3 Replace the polygonal mirror motor B 4 screws 1 connector 6 1 4 LASER DIODE LD UNIT 1 Remove th...

Page 122: ...ZATION DETECTOR 1 Remove the laser unit See Laser Unit Replacement 2 Remove the heat sink A 4 screws 3 Remove the laser upper cover B 3 screws 4 Remove the holding bracket C 1 screw 5 Remove the laser...

Page 123: ...ber 1999 6 6 6 2 PHOTOCONDUCTOR UNIT PCU 6 2 1 PCU 1 Open the right cover A and front cover B 2 Pull the PCU C out slightly while pushing the release lever D NOTE Do not touch the drum surface with ba...

Page 124: ...RANSFER UNIT 6 7 Replacement Adjustment 6 3 TRANSFER UNIT 6 3 1 TRANSFER ROLLER UNIT 1 Open the right cover A 2 Remove the transfer roller unit B 1 hook NOTE Do not touch the transfer roller surface G...

Page 125: ...e right cover A 3 Lift up the right cover band B and slide it to the left 4 Remove the connector of the ID sensor C while opening the right cover to a horizontal position 5 Remove the right cover A 6...

Page 126: ...W SENSORS 1 Remove the optional 4 bin mailbox unit if it has been installed 2 Open the right cover A 3 Open the paper exit guide cover B and remove the upper cover C 1 screw 4 Remove the right front c...

Page 127: ...6 6 1 PAPER LIFT MOTORS 1 Disconnect the interface harness of the optional paper tray unit of LCT 2 Remove the controller cover A 6 screws 3 Remove the rear cover B 5 screws 4 Remove the upper and low...

Page 128: ...t Motors 2 Remove the fly wheels A 1 screw 3 Remove the registration clutch B 1 connector 1 E ring 6 6 3 PAPER FEED CLUTCHES 1 Remove the rear cover See Paper Lift Motors 2 Remove the bracket A Then r...

Page 129: ...o hold the registration clutch B in place When attaching the bracket make sure to position it so that the bracket can perform both functions 3 Remove the upper paper transport clutch C 1 connector 6 6...

Page 130: ...STRATION SENSOR 1 Remove the right cover See Image Density Sensor 2 Remove the registration guide plate A 2 screws 3 Remove the paper support roller B 2 snap rings 2 bushings 4 Remove the sensor brack...

Page 131: ...unit have been installed 2 Remove the right cover See ID Sensor 3 Remove the right lower cover A 2 screws 4 Remove the guide plate B 5 Remove the bracket C 1 screw 6 Remove the guide plate D 2 screws...

Page 132: ...djustment 6 6 8 LOWER RELAY SENSOR 1 Open the paper transport cover A 1 clip 2 Remove the guide plate B 3 Remove the transport stay C 2 screws 4 Remove the sensor bracket D 1 screw 5 Remove the second...

Page 133: ...PER SIZE SENSOR 1 Pull out the paper tray 2 Remove the optional duplex unit and by pass tray unit if these units have been installed 3 Remove the right lower cover A 4 Remove the sensor bracket B 1 sc...

Page 134: ...acement Adjustment 6 6 10 LOWER PAPER SIZE SENSOR SPECIAL PAPER SENSOR 1 Pull out the paper tray 2 Remove the sensor bracket A 1 screw 3 Remove the lower paper size sensor B 1 connector 4 Remove the s...

Page 135: ...ober 1999 6 18 6 6 11 FEED ROLLERS 1 Remove the paper tray A 2 Pull the lever B 3 Replace the feed roller C NOTE Do not touch the roller surface with bare hands After reinstalling the feed roller retu...

Page 136: ...AND REGISTRATION 6 19 Replacement Adjustment 6 6 12 PAPER END SENSOR 1ST AND 2ND PAPER FEED TRAYS 1 Remove the paper tray A 2 Remove the sensor bracket B 1 screw 1 connector 3 Remove the paper end se...

Page 137: ...cool before doing the following procedure 1 Release the duplex unit if it has been installed and open the right cover 2 Remove the fusing unit A 2 screws 6 7 2 THERMISTOR 1 Remove the fusing unit See...

Page 138: ...3 THERMOFUSE 1 Remove the fusing unit See Fusing Unit 2 Remove the fusing upper cover A 4 screws 3 Remove the pressure springs B 4 Remove the hot roller stripper bracket C 3 screws 5 Replace the ther...

Page 139: ...2 screws and hot roller assembly A NOTE Do not touch the surface of the fusing lamp with bare hands 6 Replace the hot roller B 2 C rings 1 gear 2 bushings NOTE 1 Before installing the new hot roller...

Page 140: ...URE ROLLER CLEANING ROLLER 1 Remove the fusing lamp and hot roller assembly See Hot Roller and Fusing Lamp 2 Replace the pressure roller A 1 E ring 2 bushings 1 spring 3 Replace the cleaning roller B...

Page 141: ...4 6 8 PCBS AND MOTORS 6 8 1 PSU 1 Remove the left cover A 6 screws 2 Remove the bracket B 3 screws 3 230 V machine only Remove the coil C 1 screw 1 connector 4 Remove the PSU D All connectors 6 screws...

Page 142: ...ray unit or LCT 2 Remove the controller cover A 6 screws 3 Remove the rear cover B 5 screws 4 Remove the controller bracket C 1 connector 10 screws 5 Disconnect all harnesses and remove the engine boa...

Page 143: ...l the new controller 6 Turn on the machine and print the Printer Configuration Page 7 Ensure that all the controller settings are restored NIB 1 Back up the NIB NVRAM to the controller using the Servi...

Page 144: ...ove the high voltage supply board B 5 connectors 2 screws 2 locking supports 6 8 5 MAIN MOTOR 1 Remove the rear cover See Engine Board 2 Remove the fly wheels See High Voltage Supply Board 3 Remove th...

Page 145: ...sher and or bridge unit if these units have been installed 2 Remove the front cover A 2 pins 3 Swing up the toner bottle lever Then remove the inner cover B 5 screws 4 Remove the paper exit tray C 1 h...

Page 146: ...turning the main switch off and on if the SC was caused by a sensor error C The printer can be operated as usual except for the unit related to the service call NOTE 1 If the problem concerns electri...

Page 147: ...Poor connection between the polygon mirror motor driver and the engine board Engine board defective SC321 No laser writing signal F GATE error Definition B The laser writing signal F GATE is still no...

Page 148: ...ecutively during printing Possible causes TD sensor abnormal Poor connection of the PCU SC391 Development bias leak Definition B A development bias leak signal is detected Possible causes Poor connect...

Page 149: ...k Definition B A main motor lock signal is not detected for more than 500 ms after the main motor starts to rotate or the lock signal is not detected for more than 500 ms during rotation after the las...

Page 150: ...sor defective Too much load on the drive mechanism SC508 Rear fence drive error optional LCT Definition C The return position sensor is not activated after the rear fence drive motor has been on to lo...

Page 151: ...within 40 seconds after the main switch is turned on Possible causes Fusing thermistor defective or out of position Fusing lamp open Fusing thermofuse open Power supply board defective Poor connectio...

Page 152: ...ower supply unit defective SC547 Zero cross signal malfunction Definition A Zero cross signals are not detected within a certain period Possible causes Power supply board defective Engine board defect...

Page 153: ...e causes Poor connection of the interface cable for the finisher Finisher main board defective Engine board defective SC722 Finisher jogger motor error Definition B 1 The finisher jogger H P sensor re...

Page 154: ...s not activated within a certain period after the stapler motor turned on Possible causes Stapler motor defective Stapler H P sensor defective Poor stapler motor connection SC733 Finisher stack feed o...

Page 155: ...en the engine board and the interchange unit SC 751 Bridge unit connection error Definition B The engine board cannot communicate with the bridge unit properly when the finisher is installed Possible...

Page 156: ...m error or the battery has run out 1403 NVRAM write error 1404 NVRAM read error Replace the NVRAM if this error is frequent 1501 RTC error Replace the controller board if this error is frequent 1601 F...

Page 157: ...self test it uses two LEDs to notify the cause of the error If one of the following fatal errors happens the LED status changes as shown read from the left of the diagram to the right Flash ROM Error...

Page 158: ...ler ASIC Error Turn off the machine and turn it back on If the controller detects the same error replace the controller Other Diagnostic Error Turn off the machine check the connection to the optional...

Page 159: ...r 1999 7 14 APIP Error Turn off the machine check the connection to the engine board then turn on the machine If the controller detects the same error replace the controller or engine board LED2 Upper...

Page 160: ...he paper overflow message is not displayed when the paper overfull condition exist Paper Over Flow 324 5 Shorted The paper overflow message is displayed Open The Paper Jam indicator will light wheneve...

Page 161: ...ed The CPU cannot determine the paper near end condition properly Open 2nd Paper Height 1 308 8 Shorted The CPU cannot determine the paper near end condition properly Open 2nd Paper Height 2 308 11 Sh...

Page 162: ...s lit even if the right lower cover is closed Open Upper Paper Size 305 1 2 4 5 Shorted The CPU cannot detect the proper paper size and misfeeds may occur when a print is made Open Lower Paper Size 30...

Page 163: ...en turning on the main switch Power Supply Board FU1 15 A 250 V No response FU2 8 A 125 V 3 15 A 250 V No response FU3 3 15 A 125 V 3 15 A 250V Normal operation FU4 4 A 125 V 4 A 250V No response FU5...

Page 164: ...described in the LCT A862 point to point diagram CN234 CN504 CN134 1 2 CN221 1 2 3 4 CN203 2 1 CN130 1 2 3 CN205 1 2 3 4 CN1 1 2 3 4 S10 1st Paper Lift Sensor Upper Relay Sensor 2nd Paper Height 2 Se...

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