Aficio AP3800C User manual

Model J P1c
(Machine Code: G082)
SERVICE MANUAL
April, 2002
Subject to change

!IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the printer and peripherals,
make sure that the printer power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. If any adjustment or operation check has to be made with exterior covers off
or open while the main switch is turned on, keep hands away from electrified
or mechanically driven components.
4. The printer drives some of its components when it completes the warm-up
period. Be careful to keep hands away from the mechanical and electrical
components as the printer starts operation.
5. The inside and the metal parts of the fusing unit become extremely hot while
the printer is operating. Be careful to avoid touching those components with
your bare hands.
HEALTH SAFETY CONDITIONS
Toner and developer are non-toxic, but if you get either of them in your eyes by
accident, it may cause temporary eye discomfort. Try to remove with eye drops
or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The printer and its peripherals must be serviced by a customer service
representative who has completed the training course on those models.
2. The controller has a lithium battery which can explode if replaced incorrectly.
Replace the battery only with an identical one. Do not recharge or burn this
battery. Used battery must be handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly
when exposed to an open flame.
2. Dispose of used toner, the maintenance unit which includes developer or the
organic photoconductor in accordance with local regulations. (These are
non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
When keeping used lithium batteries in order to dispose of them later, do not
put more than 100 batteries per sealed box. Storing larger numbers or not
sealing them apart may lead to chemical reactions and heat build-up.
4. When keeping used lithium batteries in order to dispose of them later, do not
put more than 100 batteries per sealed box. Storing larger numbers or not
sealing them apart may lead to chemical reactions and heat build-up.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of
laser-based optical units in the field. The optical housing unit can only be repaired
in a factory or at a location with the requisite equipment. The laser subsystem is
replaceable in the field by a qualified Customer Engineer. The laser chassis is not
repairable in the field. Customer engineers are therefore directed to return all
chassis and laser subsystems to the factory or service depot when replacement of
the optical subsystem is required.
!WARNING
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
!WARNING
WARNING: Turn off the main switch before attempting any of the
procedures in the Laser Optics Housing Unit section. Laser
beams can seriously damage your eyes.
CAUTION MARKING:

Trademarks
Fiery® is a registered trademark of Electronics for Imaging, Inc.
Microsoft®, Windows®, and MS-DOS®are registered trademarks of Microsoft
Corporation in the United States and /or other countries.
PostScript®is a registered trademark of Adobe Systems, Incorporated.
PCL®is a registered trademark of Hewlett-Packard Company.
Ethernet®is a registered trademark of Xerox Corporation.
PowerPC®is a registered trademark of International Business Machines
Corporation.
Other product names used herein are for identification purposes only and may be
trademarks of their respective companies. We disclaim any and all rights involved
with those marks.
Symbols and Abbreviations
This manual uses the symbols and abbreviations shown below.
Symbol Meaning
☛"See," "Refer to"
!Clip ring
"Screw
#Connector
SEF Short Edge Feed
LEF Long Edge Feed

i
TABLE OF CONTENTS
1. INSTALLATION .......................................................................... 1-1
1.1 INSTALLATION REQUIREMENTS...........................................................1-1
1.1.1 ENVIRONMENT...............................................................................1-1
1.1.2 MACHINE LEVEL.............................................................................1-1
1.1.3 MACHINE SPACE REQUIREMENT.................................................1-2
1.1.4 POWER REQUIREMENTS..............................................................1-2
1.2 OPTIONAL UNIT COMBINATIONS ..........................................................1-3
1.3 INSTALLATION FLOW CHART ................................................................1-4
1.4 MACHINE INSTALLATION .......................................................................1-5
1.5 OPTIONAL UNIT INSTALLATION.............................................................1-7
1.5.1 LIST OF OPTIONS...........................................................................1-7
Note for Transporting the Machine .......................................................1-7
1.5.2 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..........................................................................................3-1
3.2 CONTROLLER PSU..................................................................................3-2
3.3 PRINTER ENGINE....................................................................................3-2
4. TROUBLE SHOOTING ............................................................... 4-1
4.1 CONTROLLER SELF-DIAGNOSTICS ERRORS......................................4-1
4.2 INTERNAL ERROR...................................................................................4-2
4.3 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...........5-1
Entering the Service Mode....................................................................5-1
Accessing the Required Program.........................................................5-2
Inputting a Value or Setting for a Service Program...............................5-2
Exiting Service Mode............................................................................5-2
5.2 PRINTER CONTROLLER SERVICE MODE.............................................5-3
5.2.1 SERVICE MODE MENU ("1. SERVICE").........................................5-3
5.2.2 BIT SWITCH PROGRAMMING........................................................5-3
5.3 PRINTER ENGINE SERVICE MODE........................................................5-4
5.4 FIRMWARE UPDATE PROCEDURE........................................................5-5
5.4.1 TYPE OF FIRMWARE......................................................................5-5
5.4.2 FIRMWARE UPGRADE OVERVIEW...............................................5-5
5.4.3 SUPPORTED OS AND TOOLS .......................................................5-5
5.4.4 FIRMWARE UPGRADE ...................................................................5-6
Upgrading Printer Firmware..................................................................5-6

ii
5.4.5 ERROR RECOVERY........................................................................5-9
5.5 CONTROLLER SELF-DIAGNOSTICS....................................................5-10
5.5.1 OVERVIEW ....................................................................................5-10
5.6 USER PROGRAM MODE .......................................................................5-11
6. DETAILED SECTION DESCRIPTIONS ...................................... 6-1
6.1 CONTROLLER..........................................................................................6-1
6.1.1 BLOCK DIAGRAM AND FUNCTIONS .............................................6-1
Components .........................................................................................6-1
Networking............................................................................................6-2
IX ASIC.................................................................................................6-2
Engine Video Interface..........................................................................6-2
Hard Disk Drive.....................................................................................6-2
Memory.................................................................................................6-3
Options .................................................................................................6-4
6.1.2 BOARD LAYOUT .............................................................................6-5
6.1.3 PRINT DATA PROCESSING ...........................................................6-6
6.1.4 BUILT-IN COLOR MANAGEMENT ..................................................6-7
6.1.5 POINT-TO-POINT DIAGRAM...........................................................6-7
6.2 PRINTER ENGINE....................................................................................6-8
SPECIFICATIONS.....................................................................SPEC-1
1. GENERAL SPECIFICATIONS.............................................................SPEC-1
1.1 SUPPORTED PAPER SIZES......................................................SPEC-3
1.1.1 PAPER FEED...........................................................................SPEC-3
1.1.2 PAPER EXIT ............................................................................SPEC-4
2. SOFTWARE ACCESSORIES .............................................................SPEC-5
2.1 PRINTER DRIVERS....................................................................SPEC-5
2.2 UTILITY SOFTWARE..................................................................SPEC-5
3. MACHINE CONFIGURATION.............................................................SPEC-6
4. OPTIONAL EQUIPMENT....................................................................SPEC-7
4.1 500-SHEET TRAY.......................................................................SPEC-7
4.2 1000-SHEET TRAY.....................................................................SPEC-7
4.3 2000-SHEET LARGE CAPACITY TRAY.....................................SPEC-7
4.4 TWO-TRAY FINISHER & PUNCH UNIT .....................................SPEC-8
4.5 FOUR-BIN MAILBOX ..................................................................SPEC-9

26 April, 2002 INSTALLATION
1-1
Installation
1. INSTALLATION
1.1 INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT
1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)
2. Humidity Range: 15% to 80% RH
3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight)
4. Ventilation: 3 times/hr/person or more
5. Avoid exposing the machine to sudden temperature changes, which include:
1) Direct cool air from an air conditioner
2) Direct heat from a heater
6. Avoid installing the machine in areas that might be exposed to corrosive gas.
7. Install the machine at a location lower than 2,500 m (8,200 ft.) above sea level.
8. Install the machine on a strong, level base. (Inclination on any side must be no
more than 5 mm.)
9. Avoid installing the machine in areas that may be subjected to strong vibration.
1.1.2 MACHINE LEVEL
Front to back: Within 5 mm (0.2")
Right to left: Within 5 mm (0.2")

INSTALLATION REQUIREMENTS 26 April, 2002
1-2
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: 11 A
220 V ~ 240 V, 50 Hz/60 Hz: 6.6 A
2. Permissible voltage fluctuation: ±10 %
3. Do not put or place anything on the power cord.
B
D
C
A
575mm (23")
678mm (27")
G082I801.WMF
B
D
C
A
1450mm (57")
678mm
(27")
G082I802.WMF
A: Over 460 mm (18")
B: Over 100 mm (4")
C:Over 550 mm (22")
D:Over 700 mm (28")

26 April, 2002 INSTALLATION
1-3
Installation
1.2 OPTIONAL UNIT COMBINATIONS
Item
No. Options Alternative Required
1 PFU (1 Tray) Items 2, 3
2 PFU (2 Trays) Items 1, 3
3 LCT Items 1, 2
4 Two-tray finisher •Item 7
•Item 1, 2 or 3
5 3 types of punch kit
Item 6
Item 4
6 Four-bin mailbox Items 4, 5
7 Duplex unit
8 2 types of memory DIMM
NOTE: Two memory DIMMs (up to 256 MB) can be installed.

INSTALLATION FLOW CHART 26 April, 2002
1-4
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 and a paper tray unit or LCT.
Punch Unit: Needs the finisher.
Unpack the printer.
Will the paper feed unit or LCT be installed?
Place the printer on the paper feed unit or LCT.
Install the paper feed unit or LCT.
Install the controller options (if required).
Yes No
Will the duplex unit be installed?
Install the duplex unit.
Install the four-bin mailbox
(if required).
Install the two-tray finisher.
Install the printer.
Yes No
NoYes
Install the punch unit
(if required).
Will the Two-tray finisher be installed?
G082I002.WMF