Ricoh Neptune-P1 User manual

Neptune-P1
Machine Code: G180
SERVICE MANUAL
June 2007
Subject to change

Safety, Conventions, Trademarks
Safety
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine
and peripheral power cords are unplugged.
2. The plug should be near the machine and easily accessible.
3. Note that some components of the machine and the paper tray unit are supplied with electrical voltage
even if the main power switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers off or open while the main
switch is turned on, keep hands away from electrified or mechanically driven components.
5. If the [Start] key is pressed before the machine completes the warm-up period (the [Start] key starts
blinking red and green ), keep hands away from the mechanical and the electrical components as
the machine starts making prints as soon as the warm-up period is completed.
6. The inside and the metal parts of the fusing unit become extremely hot while the machine is operating.
Be careful to avoid touching those components with your bare hands.
7. To prevent a fire or explosion, keep the machine away from flammable liquids, gases, and aerosols.
HEALTH SAFETY CONDITIONS
1. Never operate the machine without the ozone filters installed.
2. Always replace the ozone filters with the specified types at the proper intervals.
3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause
temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful,
get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The machine and its peripherals must be installed and maintained by a customer service representative
who has completed the training course on those models.
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.
1

2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations.
(These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100
batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical
reactions and heat build-up.
• The danger of explosion exists if a battery of this type is incorrectly replaced. Replace only with the
same or an equivalent type recommended by the manufacturer. Discard used batteries in accordance
with the manufacturer’s instructions.
Conventions and Trademarks
Conventions
Symbol What it means
Core Tech Manual
Screw
Connector
E-ring
C-ring
Harness clamp
FFC Flexible Flat Cable (ribbon connectors)
2

The notations "SEF" and "LEF" describe the direction of paper feed. The arrows indicate the direction of
paper feed.
In this manual "Horizontal" means the "Main Scan Direction" and "Vertical" means the "Sub Scan Direction"
relative to the paper feed direction.
Warnings, Cautions, Notes
In this manual, the following important symbols and notations are used.
• A Warning indicates a potentially hazardous situation. Failure to obey a Warning could result in
death or serious injury.
• A Caution indicates a potentially hazardous situation. Failure to obey a Caution could result in minor
or moderate injury or damage to the machine or other property.
• Obey these guidelines to avoid problems such as misfeeds, damage to originals, loss of valuable
data and to prevent damage to the machine
• This information provides tips and advice about how to best service the machine.
3

Trademarks
• Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the
United States and /or other countries.
• PostScript® is a registered trademark of Adobe Systems, Incorporated.
• PCL® is a registered trademark of Hewlett-Packard Company.
• Ethernet® is a registered trademark of Xerox Corporation.
• PowerPC® is a registered trademark of International Business Machines Corporation.
• Other product names used herein are for identification purposes only and may be trademarks of their
respective companies. We disclaim any and all rights involved with those marks.
4

TABLE OF CONTENTS
Safety, Conventions, Trademarks......................................................................................................................1
Safety..............................................................................................................................................................1
Conventions and Trademarks........................................................................................................................2
Warnings, Cautions, Notes...........................................................................................................................3
1. Installation
Preparation.......................................................................................................................................................13
Environment..................................................................................................................................................13
Minimum Space Requirements...................................................................................................................14
Machine Level..............................................................................................................................................14
Power Source...............................................................................................................................................15
Installation Overview...................................................................................................................................15
Operation Panel...........................................................................................................................................18
Main Machine Installation (G180)................................................................................................................21
Accessory Check..........................................................................................................................................21
Machine Installation Procedure..................................................................................................................22
Main Machine Final Installation.................................................................................................................37
Moving the Machine...................................................................................................................................42
Roll Feeder (B852)..........................................................................................................................................43
Accessory Check..........................................................................................................................................43
Roll Feeder Installation Procedure..............................................................................................................44
Paper Cassette (B853)....................................................................................................................................61
Accessory Check..........................................................................................................................................61
Paper Cassette Installation Procedure........................................................................................................61
Folder Unit (B889)...........................................................................................................................................64
Before You Begin.........................................................................................................................................64
Accessories...................................................................................................................................................65
Folder Unit Installation.................................................................................................................................66
Power On.....................................................................................................................................................80
Rear Stacker (D312)........................................................................................................................................81
Accessories...................................................................................................................................................81
Installation....................................................................................................................................................82
Manual Feeder (D333)...................................................................................................................................83
Before You Begin.........................................................................................................................................83
5

Accessories...................................................................................................................................................83
Manual Feeder Installation.........................................................................................................................84
Power On.....................................................................................................................................................89
Installation of MFP Options.............................................................................................................................91
Overview......................................................................................................................................................91
Using SD Cards............................................................................................................................................92
IEEE802.11b Interface Unit Type H (G813-45)/Type I (G874-39)....................................................95
Gigabit Ethernet Board Type A (G874-01)..............................................................................................97
Data Overwrite Security Unit Type D (B735-18).....................................................................................99
2. Preventive Maintenance
PM Table........................................................................................................................................................103
Main Machine (G180).............................................................................................................................103
Roll Feeder (B852)....................................................................................................................................106
Paper Cassette (B853).............................................................................................................................106
Folder FD/Manual Feeder (D889).........................................................................................................106
Manual Feeder (D333)............................................................................................................................107
Cleaning the Entrance Spurs.........................................................................................................................108
Lubrication Points...........................................................................................................................................109
Development Section................................................................................................................................109
Fusing Gears..............................................................................................................................................110
3. Replacement and Adjustment
Common Procedures.....................................................................................................................................111
Before Working On the Main Machine..................................................................................................111
Side Covers................................................................................................................................................112
Rear Cover.................................................................................................................................................113
Paper Exit Unit...........................................................................................................................................113
Front Panel and Opening the Top............................................................................................................114
Toner Hopper Cover.................................................................................................................................115
Idle Registration Roller Panel....................................................................................................................116
Drawer Front Cover..................................................................................................................................117
Removing the VDB, CGB..............................................................................................................................118
VDB.............................................................................................................................................................118
CGB Power Pack.......................................................................................................................................119
6

Around the Drum............................................................................................................................................120
Charge Corona Wire, Grid Wire, Wire Cleaner...................................................................................120
Quenching Lamps.....................................................................................................................................121
LPH (LED Print Head).................................................................................................................................123
Transfer Corona, Separation Corona Wires..........................................................................................124
Development .................................................................................................................................................126
Development Unit......................................................................................................................................126
Developer..................................................................................................................................................127
Paper Set Sensor, Registration Sensor.....................................................................................................129
Toner Supply Clutch..................................................................................................................................130
Development Filter.....................................................................................................................................130
Used Toner Collection Bottle, Toner Overflow Sensor...........................................................................131
Drum...............................................................................................................................................................132
Drum Unit...................................................................................................................................................132
Cleaning Blade..........................................................................................................................................134
ID Sensor, Pick-Off Pawls, Pick-Off Pawl Solenoid................................................................................135
Paper Feed.....................................................................................................................................................136
Registration Clutch, Registration Roller....................................................................................................136
Roll 1 Paper Feed Clutch, Feed Roller.....................................................................................................139
Roll 2 Paper Clutch, Feed Roller..............................................................................................................140
RF Exit Sensor.............................................................................................................................................141
Roll Feed Motor.........................................................................................................................................142
Cutter Motor, HP Sensors.........................................................................................................................143
Roll Paper End Sensors.............................................................................................................................144
Cassette Feed Roller..................................................................................................................................145
Cassette Relay Sensor, Cassette End Sensor..........................................................................................146
Cassette Feed Motor, Cassette Open Sensor.........................................................................................148
Cassette Feed Clutch.................................................................................................................................149
Fusing..............................................................................................................................................................150
Pressure Spring Adjustment......................................................................................................................150
Hot Roller Strippers...................................................................................................................................151
Fusing Exit Sensor......................................................................................................................................151
Pressure Roller Thermistors........................................................................................................................152
7

Pressure Roller Strippers...........................................................................................................................153
Exit Unit Switch..........................................................................................................................................154
Fusing Unit..................................................................................................................................................154
Fusing Cleaning Roller..............................................................................................................................156
Fusing Lamp...............................................................................................................................................157
Hot Roller...................................................................................................................................................158
Pressure Roller............................................................................................................................................158
Hot Roller Thermistor, Thermostats...........................................................................................................159
Motors............................................................................................................................................................160
Drum Motor...............................................................................................................................................160
Fusing Motor, Main Motor.......................................................................................................................161
Used Toner Bottle Motor...........................................................................................................................163
Boards............................................................................................................................................................164
MCU/IPU/MB..........................................................................................................................................164
PSU/Circuit Breaker.................................................................................................................................168
Controller Board........................................................................................................................................169
NVRAM......................................................................................................................................................172
T&S Power Pack........................................................................................................................................173
RFDB (Roll Feeder Drive Board)...............................................................................................................174
SFDB (Sheet Feed Drive Board)...............................................................................................................175
Others.............................................................................................................................................................177
HDD............................................................................................................................................................177
Cooling Fan, Ozone Filter........................................................................................................................178
SP Adjustments...............................................................................................................................................180
Image Adjustment with SP Codes............................................................................................................180
LPH Adjustment with SP Codes.................................................................................................................186
LPH Density Adjustment with SP Codes...................................................................................................189
4. Troubleshooting
Service Call Conditions.................................................................................................................................191
SC Code Descriptions...................................................................................................................................192
SC1XXX......................................................................................................................................................192
SC2XXX......................................................................................................................................................192
SC3XXX......................................................................................................................................................192
8

SC4XXX......................................................................................................................................................193
SC5XXX......................................................................................................................................................194
SC6XXX......................................................................................................................................................198
SC7XXX......................................................................................................................................................200
SC8XXX......................................................................................................................................................201
SC9XXX......................................................................................................................................................208
Jam Code Tables...........................................................................................................................................212
Overview....................................................................................................................................................212
Printer Jams................................................................................................................................................213
Folder Unit Jams........................................................................................................................................214
Cover Open...................................................................................................................................................217
Fuses...............................................................................................................................................................218
Image Problem Troubleshooting...................................................................................................................219
Printing........................................................................................................................................................219
Other Problems..........................................................................................................................................221
Board LEDS....................................................................................................................................................222
PSU, MCU, IPU.........................................................................................................................................222
VDB.............................................................................................................................................................224
5. Service Tables
Using the SP Mode........................................................................................................................................227
How to Use SP Mode...............................................................................................................................227
Firmware Update...........................................................................................................................................231
Overview....................................................................................................................................................231
Updating Firmware...................................................................................................................................231
Menus.............................................................................................................................................................235
Input Check....................................................................................................................................................240
Output Check.................................................................................................................................................244
SP Table Key..................................................................................................................................................246
SP1-xxx Feed.................................................................................................................................................247
Paper Thickness Default Selection............................................................................................................261
SP2-xxx Drum................................................................................................................................................278
SP3-xxx Process Control...............................................................................................................................292
SP5-xxx Mode...............................................................................................................................................293
9

SP6-xxx Peripherals.......................................................................................................................................334
SP7-xxx Data Log..........................................................................................................................................354
SP8-xxx Data Log 2......................................................................................................................................361
6. Details
Overview........................................................................................................................................................377
Machine General Layout..........................................................................................................................377
Mechanical Component Layout...............................................................................................................379
Drive Layout...............................................................................................................................................380
Paper Paths................................................................................................................................................381
Around the Drum............................................................................................................................................382
Overview....................................................................................................................................................382
Drum Drive.................................................................................................................................................383
Charge Corona Unit.................................................................................................................................384
Corona Wire Cleaning.............................................................................................................................385
Drum Cleaning...........................................................................................................................................386
Collecting Used Toner...............................................................................................................................387
Quenching.................................................................................................................................................388
Drum Anti-Condensation Heaters............................................................................................................389
Image Writing................................................................................................................................................390
Development..................................................................................................................................................391
Overview....................................................................................................................................................391
Development Drive Mechanism...............................................................................................................392
Toner Supply Mechanism.........................................................................................................................393
Developer Cross-Mixing...........................................................................................................................393
Development Bias......................................................................................................................................394
ID Sensor....................................................................................................................................................395
Warm-up Control (Vsg Correction).........................................................................................................395
Toner Density Control................................................................................................................................396
Toner End/Near-End Detection...............................................................................................................399
Paper Feed and Registration.........................................................................................................................402
Overview....................................................................................................................................................402
Manual Feed Mechanism.........................................................................................................................405
Roll Feed Mechanism................................................................................................................................406
10

Roll Feeder Paper Holders........................................................................................................................409
Roll Paper Cutting Mechanism.................................................................................................................410
Roll End Detection.....................................................................................................................................411
Paper Cassette Mechanism......................................................................................................................413
Paper Cassette Feed.................................................................................................................................414
Paper Cassette Paper End Detection.......................................................................................................416
Condensation Prevention..........................................................................................................................417
Paper Registration.....................................................................................................................................418
Image Transfer and Separation....................................................................................................................419
Overview....................................................................................................................................................419
Pick-Off Pawl Operation...........................................................................................................................420
Fusing Unit......................................................................................................................................................421
Overview....................................................................................................................................................421
Paper Feed Through the Fusing Unit........................................................................................................422
Fusing Pressure Control Mechanism........................................................................................................423
Hot Roller Thermistors and Thermostats...................................................................................................424
Temperature Control.................................................................................................................................424
Hot Roller Cleaning...................................................................................................................................433
Fusing Unit Drive Mechanism...................................................................................................................433
Wrinkle Prevention....................................................................................................................................434
Paper Exit........................................................................................................................................................435
Overview....................................................................................................................................................435
Electrical Components...................................................................................................................................437
Overview....................................................................................................................................................437
MCU, IPU...................................................................................................................................................444
PSU.............................................................................................................................................................445
VDB, CGB PP.............................................................................................................................................445
RFDB, SFDB................................................................................................................................................446
GW Controller Board...............................................................................................................................447
7. Specifications
Main Machine (G180).................................................................................................................................449
Options...........................................................................................................................................................452
Roll Feeder (B852)....................................................................................................................................452
11

Folder (D889)............................................................................................................................................452
Manual Feeder (D333)............................................................................................................................453
Paper Cassette B853................................................................................................................................454
Main Machine Configuration.......................................................................................................................455
12

1. Installation
Preparation
Environment
1. Temperature Range: 10 °C to 30 °C (50 °F to 86 °F)
2. Humidity Range: 15% to 90% RH
3. Ambient Illumination: Less than 1,500 Lux (do not expose the machine directly to light from the sun).
4. Ventilation: More than 30 m3/hr/person in the work area
5. Ambient Dust: Less than 0.10 mg/m3
6. If the installation area has air-conditioners or heaters, put the machine in a location where:
• There are no sudden temperature changes from low to high, or high to low.
• The machine will not be directly exposed to cool air from an air conditioner in the summer.
• The machine will not be directly exposed to reflected heat from a space heater in the winter.
7. Do not install the machine in an area filled with gases that can cause corrosion.
8. Do not install the machine in areas higher than 2,000 m (6,600 ft) above sea level.
13
1

9. Put the machine on a strong and level surface.
• The floor must be able to support a load of more than 2.94 kPa (300 kgf/m2).
10. Do not install the machine in an area where there are frequent strong vibrations.
Minimum Space Requirements
1. Front: 1000 mm (40")
2. Back: 600 mm (23")
3. Right: 600 mm (23")
4. Left: 600 mm (23")
Machine Level
1. Front to back: Not more than 5 mm from level
2. Right to left: Not more than 0.15/1000 mm from level.
1. Installation
14
1

Power Source
• This machine is provided with a circuit breaker that cuts the power supply to the main machine in case
of a current overload or short circuit. The machine must be installed in a building where circuit breakers
(and equivalent devices) can operate properly.
1. Input Voltage Level:
• 120V, 60 Hz, 15 A or more
• 220-240V, 50/60 Hz, 10A or more
2. Permissible Voltage Fluctuation: ±10%
3. Do not set objects on the power cord.
• Make sure the plug is firmly inserted in the outlet.
• Do not connect the machine to a power source that is shared with other equipment.
Installation Overview
Installation Flow
• The Roll Feeder (B852) is required for this installation. You can also install a universal Paper Cassette
in the roll feeder. You cannot install the paper cassette without the roll feeder.
Here is a summary of the sequence recommended for installation of all these options together.
Installation Flow Diagram
Pre-Installation
Remove the machine from its box. Remove all packing material and tape. Put the machine on the roll
feeder. The roll feeder must be installed.

Roll Feeder Installation

Install Paper Cassette

Preparation
15
1

SP and User Tool Settings for Installation
Do all the SP and User Tool settings for the machine and installed options.

Final Installation
Complete the installation of the machine after you put it on the roll feeder and after you install all options.
Do some sample prints to check the operation of the machine and installed options.

MFP Options (Board/SD Card Options)
Install the MFP options and do a function check.

Folder Unit
Install the Folder Unit last. The MFP options must be installed before the folder unit because the folder
unit will block access to the board and SD card slots.
SP and User Tool Settings Required for Installation
This is a summary of the important SP and User Tool settings that are necessary for this installation.
Main Machine Installation
SP2801-2 Lot Number 1 Enter the toner lot numbers at installation before
doing SP2801-1
SP2801-3 Lot Number 2
SP2801-1 Developer Initial Setting Mixes developer and initializes the ID sensor.
SP2923-1 Execute Cleaning Blade
Replace Mode
Applies a thin layer of toner to the drum. This
prevents scratches on the drum when the machine
power comes on for the first time.
SP3001 ID Sensor Initial Setting -
Initialization
Initializes the ID sensor after toner has been
applied to the drum.
[Menu]
Paper Size
Paper Type
[Menu]> "Paper Input"> "Paper
Size"/"Paper Type"> Tray n
Sets the paper size/paper type for each tray:
• Tray 1: Roll 1
• Tray 2: Roll 2
• Tray 3: Cassette
• Bypass
1. Installation
16
1

[Menu]
Language
[Menu]:> "Language" Select the desired language if it has not been
selected.
[Menu]
Date
Time
[Menu]> "Maintenance">
"Timer Settings"> "Set Date" and
"Set Time"
Check the date and time setting. If they are not
correct, set the correct date and time.
Roll Feeder Installation
SP Adjustment
1920 Cut Length Adjustment
Sets the cut length settings for the rolls installed in the roll feeder. These settings are
different for each machine. The settings are on a label attached to the right side of the
roll feeder drawer.
1920-111 Cut Length Adjustment: 1st Roll:297
mm:Plain Paper
Adjust for 1st Roll
1920-115 Cut Length Adjustment: 1st Roll:
1189 mm:Plain Paper
1920-211 Cut Length Adjustment: 2nd Roll:
297 mm:Plain Paper
Adjust for 2nd Roll
1920-215 Cut Length Adjustment: 2nd Roll:
1189 mm:Plain Paper
1001-1 Leading Edge Registration – 1st Roll Adjust for 1st roll.
1001-2 Leading Edge Registration – 2nd
Roll
Adjust for 2nd roll.
1002-1 Side-to-Side Registration – 1st Roll Adjust for 1st roll
1002-2 Side-to-Side Registration – 2nd Roll Adjust for 2nd roll.
Paper Cassette
1001-3 Leading Edge Registration –
Cassette
Adjust for Paper Cassette B853.
1002-3 Side-to-Side Registration – Cassette
Preparation
17
1

MFP Options
5985-1 Device Setting – On Board NIC Both SP codes must be set to "1" to
enable these features.
5985-2 Device Setting – On Board USB
Operation Panel
Overview of the Operation Panel
1. Display
Displays current printer status and error messages. Energy save mode turns off the backlight.
2. Selection keys
These dynamic keys change their function depending on the operation or menu mode. The current functions
will be clearly labeled above these keys on the display panel above.
3. [Escape]
In the menu mode or SP mode, returns the display to the previous level. Press repeatedly to leave menu
mode and return to standby.
4. Scroll keys
1. Installation
18
1

During menu item or setting selection: press [] or [] to move the highlight up or down, or press [] or
[] to move the highlight left or right, then press [OK] to make the selection. In the menu mode, these
arrows appear in the upper right corner to show you how to make the next selection.
5. [OK]
Press this key to select the item or heading currently highlighted on the operation panel.
6. Data In indicator
Flashes while the printer is receiving a print job. Lights when there is a job to be printed.
7. Alert indicator
Lights when an error occurs. Follow prompts on the screen to solve the problem.
8. Power indicator
Lights when the machine is ready to use. Remains off when the power switch is turned off, or when the
machine is in the energy save mode.
9. [Job Reset]
Press to cancel a print job in progress.
10. [Menu]
Press to open the menu tree. A summary of the menu tree appears in Section 5 of this manual. For more,
please refer to the operating instructions.
11. [Online]
Lights when the printer is online, goes off when the printer is off line. Press this key to toggle the printer
offline/online.
Operation Panel Instructions
The operation panel procedures described in this service manual are abbreviated to reduce the needless
repetition of words and make procedures easier and faster to read.
Symbol in Text What It Means
[Escape] Square brackets denote the name of the operation panel key to press.
[]*[] for 3 sec. The asterisk indicates keys that should be pressed at the same time. "Press and
hold down the up and down keys together for 3 seconds.
>A right angle bracket denotes what should appear next on the display, or
indicates the next key to press.
" " Quotation marks denote items (selections, messages, etc.) that appear the
display panel of the machine after the previous key press.
[] or [] Press either the up or down arrow key on the operation panel.
Preparation
19
1