Ricoh Aficio 480W Dolphin-C2 User manual

Dolphin-C2
(Machine Code: B188)
SERVICE MANUAL
Subject to change
Ricoh Technical Service
28 April 2005

Conventions Used in this Manual
This manual uses several symbols.
Symbol What it means
☛Refer to section number
!See Core Tech Manual for
details
"Screw
#Connector
$E-ring
%Clip ring
&' Clamp
*
SEF (Short Edge
Feed) (Lengthwise)
LEF (Long Edge
Feed) (Sideways)

1. SAFETY INSTRUCTIONS
For your safety, please read this manual carefully before you use this product.
Keep this manual handy for future reference.
Safety Information
Always obey the following safety precautions when using this product.
Safety During Operation
In this manual, the following important symbols and notations are used.
The following headings provide special information:
!WARNING
FAILURE TO OBEY WARNING INFORMATION COULD RESULT IN SERIOUS INJURY OR
DEATH.
!CAUTION
Obey these guidelines to ensure safe operation and prevent minor injuries.
Important
• Obey these guidelines to avoid problems such as misfeeds, damage to originals,
loss of valuable data and to prevent damage to the machine.
NOTE: This information provides tips and advice about how to best service the
machine.
Switches and Symbols
Where symbols are used on or near switches on machines for Europe and other
areas, the meaning of each symbol conforms with IEC60417.
SAFE-SYM.WMF
ON
OFF
Push ON/Push OFF
STANDBY

1.1 RESPONSIBILITIES OF THE SERVICE TECHNICIAN
1.1.1 SERVICE TECHNICIAN
Maintenance shall be done only by trained Service Technicians who have
completed service training for the machine and all optional devices designed for
use with the machine.
1.1.2 REFERENCE MATERIAL FOR MAINTENANCE
Maintenance shall be done using the special tools and procedures prescribed for
maintenance of the machine described in the reference materials (service manuals,
technical bulletins, operating instructions, and safety guidelines for Service
Technicians).
Use only consumable supplies and replacement parts designed for use of the
machine.

1.2 BEFORE INSTALLATION, MAINTENANCE
1.2.1 SHIPPING AND MOVING THE MACHINE
!CAUTION
1. Work carefully when lifting or moving the machine. If the machine is heavy,
two or more Service Technicians may be required to prevent injuries (muscle
strains, spinal injuries, etc.) or damage to the machine if it is dropped or
tipped over.
2. Personnel moving or working around the machine should always wear proper
clothing and footwear. Never wear loose fitting clothing or accessories
(neckties, loose sweaters, bracelets, etc. ) or casual footwear (slippers,
sandals, etc.) when lifting or moving the machine.
3. Always unplug the power cord from the power source before you move the
product. Before you move the product, arrange the power cord so it will not
fall under the product.
4. The wall outlet should be near the copier and easily accessible.
1.2.2 POWER
!Warning
1. Always disconnect the power plug before doing any maintenance procedure.
After switching off the machine, power is still supplied to the main machine
and other devices. To prevent electrical shock, switch the machine off, wait
for a few seconds, then unplug the machine from the power source.
2. Before you do any checks or adjustments after turning the machine off, work
carefully to avoid injury. After removing covers or opening the machine to do
checks or adjustments, never touch electrical components or moving parts
(gears, timing belts, etc.).
3. After turning the machine on with any cover removed, keep your hands away
from electrical components and moving parts. Never touch the cover of the
fusing unit, gears, timing belts, etc.

1.2.3 INSTALLATION, DISASSEMBLY, AND ADJUSTMENTS
!CAUTION
1. After installation, maintenance, or adjustment, always check the operation of
the machine to make sure that it is operating normally. This ensures that all
shipping materials, protective materials, wires and tags, metal brackets, etc.,
removed for installation, have been removed and that no tools remain inside
the machine. This also ensures that all release interlock switches have been
restored to normal operation.
2. Never use your fingers to check moving parts causing spurious noise. Never
use your fingers to lubricate moving parts while the machine is operating.
1.2.4 SPECIAL TOOLS
!CAUTION
1. Use only standard tools approved for machine maintenance.
2. For special adjustments, use only the special tools and lubricants described
in the service manual. Using tools incorrectly, or using tools that could
damage parts, could damage the machine or cause injuries.

1.3 DURING MAINTENANCE
1.3.1 GENERAL
!CAUTION
1. Before you begin a maintenance procedure:
• Switch the machine off.
• Disconnect the power plug from the power source.
• Allow the machine to cool for at least 10 minutes.
2. Avoid touching the components inside the machine that are labeled as hot
surfaces.
3. The wall outlet should be near the copier and easily accessible.
1.3.2 SAFETY DEVICES
!WARNING
1. Never remove any safety device unless it requires replacement. Always
replace safety devices immediately.
2. Never do any procedure that defeats the function of any safety device.
Modification or removal of a safety device (fuse, switch, etc.) could lead to a
fire and personal injury. Always test the operation of the machine to ensure
that it is operating normally and safely after removal and replacement of any
safety device.
3. For replacements use only the correct fuses or circuit breakers rated for use
with the machine. Using replacement devices not designed for use with the
machine could lead to a fire and personal injuries.
!CAUTION: DOUBLE POLE/NEUTRAL FUSING
The machine power cord must be disconnected from the power source
before replacement of FU002.

1.3.3 ORGANIC CLEANERS
!CAUTION
1. During preventive maintenance, never use any organic cleaners (alcohol,
etc.) other than those described in the service manual.
2. Make sure the room is well ventilated before using any organic cleaner. Use
organic solvents in small amounts to avoid breathing the fumes and
becoming nauseous.
3. Switch the machine off, unplug it, and allow it to cool before doing preventive
maintenance. To avoid fire or explosion, never use an organic cleaner near
any part that generates heat.
4. Wash your hands thoroughly after cleaning parts with an organic cleaner to
contamination of food, drinks, etc. which could cause illness.
5. Clean the floor completely after accidental spillage of silicone oil or other
materials to prevent slippery surfaces that could cause accidents leading to
hand or leg injuries. Use “My Ace” Silicone Oil Remover (or dry rags) to soak
up spills. For more details, please refer to Technical Bulletin “Silicone Oil
Removal” (A024-50).
1.3.4 LITHIUM BATTERIES
!WARNING
1. Always replace a lithium battery on a PCB with the same type of battery
prescribed for use on that board. Replacing a lithium battery with any type
other than the one prescribed for use on the board could lead to an explosion
or damage to the PCB.
2. Never discard used batteries by mixing them with other trash. Remove them
from the work site and dispose of them in accordance with local laws and
regulations regarding the disposal of such items.
1.3.5 OZONE FILTERS
!CAUTION
1. Always replace ozone filters as soon as their service life expires (as
described in the service manual). An excessive amount of ozone can build up
around machines that use ozone filters if they are not replaced at the
prescribed time. Excessive ozone could cause personnel working around the
machine to feel unwell.
2. Never operate the copier without the ozone filters installed.

1.3.6 POWER PLUG AND POWER CORD
!WARNING
1. Before serving the machine (especially when responding to a service call),
always make sure that the power plug has been inserted completely into the
power source. A partially inserted plug could lead to heat generation (due to
a power surge caused by high resistance) and cause a fire or other problems.
2. Always check the power plug and make sure that it is free of dust and lint.
Clean it if necessary. A dirty plug can generate heat which could cause a fire.
3. Inspect the length of the power cord for cuts or other damage. Replace the
power cord if necessary. A frayed or otherwise damaged power cord can
cause a short circuit which could lead to a fire or personal injury from
electrical shock.
4. Check the length of the power cord between the machine and power supply.
Make sure the power cord is not coiled or wrapped around any object such
as a table leg. Coiling the power cord can cause excessive heat to build up
and could cause a fire.
5. Make sure that the area around the power source is free of obstacles so the
power cord can be removed quickly in case of an emergency.
6. Make sure that the power cord is grounded (earthed) at the power source
with the ground wire on the plug.
7. Connect the power cord directly into the power source. Never use an
extension cord.
8. When you disconnect the power plug from the power source, always pull on
the plug, not the cable.

1.4 AFTER INSTALLATION, SERVICING
1.4.1 DISPOSAL OF USED ITEMS
!WARNING
Never incinerate used toner or toner cartridges. Toner or toner cartridges thrown
into a fire can ignite or explode and cause serious injury. At the work site always
carefully wrap used toner and toner cartridges with plastic bags to avoid spillage
before disposal or removal.
!CAUTION
1. Always dispose of used items (developer, toner, toner cartridges, OPC
drums, etc.) in accordance with the local laws and regulations regarding the
disposal of such items.
2. To protect the environment, never dispose of this product or any kind of
waste from consumables at a household waste collection point. Dispose of
these items at one of our dealers or at an authorized collection site.
3. Return used selenium drums to the service center for handling in accordance
with company policy regarding the recycling or disposal of such items.