Aficio B003, B004, B006, B007 Service Manual
RICOH GROUP COMPANIES
B003/B004/B006/B007
SERVICE MANUAL
001124MIU
®
®
B003/B004/B006/B007
SERVICE MANUAL
RICOH GROUP COMPANIES
B003/B004/B006/B007
SERVICE MANUAL
001124MIU
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interest of Ricoh Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
FASHION AND DISTRIBUTED WITHOUT THE PRIOR
PERMISSION OF RICOH CORPORATION.
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trademarks or the property of their respective companies.
They are used throughout this book in an informational or editorial fashion
only and for the benefit of such companies. No such use, or the use of
any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.
2001 RICOH Corporation. All rights reserved.
WARNING
The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Corporation. Users of this
manual should be either service trained or
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Corporation
LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
B003 3502 Aficio 1035 2535
B004 4502 Aficio 1045 2545
B006 3502p Aficio 1035P 2535p
B007 4502p Aficio 1045P 2545p
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 4/2001 Original Printing
Rev. 04/2002
B003/B004/B006/B007
TABLE OF CONTENTS
INSTALLATION PROCEDURE
1. INSTALLATION PROCEDURE................................................... 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................................1-1
1.1.1 ENVIRONMENT ...............................................................................1-2
1.1.2 MACHINE LEVEL.............................................................................1-2
1.1.3 MINIMUM SPACE REQUIREMENTS...............................................1-3
1.1.4 POWER REQUIREMENTS ..............................................................1-3
1.1.5 INSTALLABLE OPTION TABLE....................................................... 1.4
1.2 INSTALLATION FLOW CHART ................................................................1-5
1.3 MAIN MACHINE INSTALLATION..............................................................1-6
1.3.1 ACCESSORY CHECK......................................................................1-6
1.3.2 INSTALLATION PROCEDURE ........................................................1-7
Development Unit and PCU..................................................................1-8
Toner Bottle ........................................................................................1-11
Paper Trays ........................................................................................1-12
Initialize TD Sensor and Developer ....................................................1-14
Set Paper Size for Paper Trays ..........................................................1-15
Electrical Total Counter.......................................................................1-16
HDD Caution Decal (for only NA models)...........................................1-16
1.4 PAPER TRAY UNIT INSTALLATION......................................................1-17
1.4.1 ACCESSORY CHECK....................................................................1-17
1.4.2 INSTALLATION PROCEDURE ......................................................1-18
1.5 1-BIN TRAY UNIT INSTALLATION .........................................................1-22
1.5.1 ACCESSORY CHECK....................................................................1-22
1.5.2 INSTALLATION PROCEDURE ......................................................1-23
1.6 BRIDGE UNIT INSTALLATION...............................................................1-29
1.6.1 ACCESSORY CHECK....................................................................1-29
1.6.2 INSTALLATION PROCEDURE ......................................................1-30
1.7 1000-SHEET FINISHER INSTALLATION ...............................................1-32
1.7.1 ACCESSORY CHECK....................................................................1-32
1.7.2 INSTALLATION PROCEDURE ......................................................1-33
1.8 TWO-TRAY FINISHER INSTALLATION .................................................1-36
1.8.1 ACCESSORY CHECK....................................................................1-36
1.8.2 INSTALLATION PROCEDURE ......................................................1-37
1.9 PUNCH UNIT INSTALLATION................................................................1-40
1.9.1 ACCESSORY CHECK....................................................................1-40
1.9.2 INSTALLATION PROCEDURE ......................................................1-41
1.10 AUTO REVERSE DOCUMENT FEEDER INSTALLATION...................1-44
1.10.1 ACCESSORY CHECK..................................................................1-44
1.10.2 INSTALLATION PROCEDURE ....................................................1-45
1.11 LCT INSTALLATION .............................................................................1-47
1.11.1 ACCESSORY CHECK..................................................................1-47
SM i B003/B004/B006/B007
Rev. 04/2002
1.11.2 INSTALLATION PROCEDURE ....................................................1-48
1.12 PLATEN COVER INSTALLATION ........................................................1-50
1.13 KEY COUNTER INSTALLATION ..........................................................1-51
1.14 ANTI-CONDENSATION HEATER.........................................................1-53
1.15 TRAY HEATER .....................................................................................1-55
1.16 TRAY HEATER (OPTIONAL PAPER TRAY UNIT) ...............................1-56
1.17 OPTIONAL USER ACCOUNT ENHANCEMENT UNIT.........................1.57
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE SCHEDULE .............................. 2-1
2.1 PM TABLE.................................................................................................2-1
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT........................................ 3-1
3.1 GENERAL CAUTIONS..............................................................................3-1
3.1.1 LASER UNIT ....................................................................................3-1
3.1.2 USED TONER ..................................................................................3-1
3.2 SPECIAL TOOLS AND LUBRICANTS ......................................................3-2
3.2.1 SPECIAL TOOLS .............................................................................3-2
3.2.2 LUBRICANTS...................................................................................3-2
3.2.3 SYMBOLS USED IN TEXT...............................................................3-2
3.3 FRONT DOOR ..........................................................................................3-3
3.4 DUPLEX UNIT...........................................................................................3-3
3.5 UPPER RIGHT COVER ............................................................................3-4
3.6 BY-PASS TRAY ........................................................................................3-5
3.7 REAR COVERS ........................................................................................3-6
3.7.1 REAR UPPER COVER.....................................................................3-6
3.7.2 REAR LOWER COVER....................................................................3-6
3.8 LEFT COVERS..........................................................................................3-7
3.8.1 LEFT UPPER COVER......................................................................3-7
3.9 SCANNER UNIT........................................................................................3-8
3.9.1 ARDF................................................................................................3-8
3.9.2 EXPOSURE GLASS.........................................................................3-9
3.9.3 SCANNER EXTERIOR PANELS/OPERATION PANEL.................3-10
3.9.4 LENS BLOCK/SBU ASSEMBLY ....................................................3-11
3.9.5 ORIGINAL SIZE SENSORS...........................................................3-12
3.9.6 EXPOSURE LAMP.........................................................................3-13
3.9.7 SCANNER HP SENSOR/PLATEN COVER SENSOR ...................3-14
3.9.8 SCANNER MOTOR........................................................................3-15
3.9.9 LAMP STABILIZER AND SCANNER MOTOR DRIVE BOARD .....3-16
3.9.10 SCANNER WIRE..........................................................................3-17
3.10 LASER UNIT .........................................................................................3-21
3.10.1 CAUTION DECAL LOCATIONS...................................................3-21
3.10.2 LASER UNIT ................................................................................3-22
3.10.3 POLYGON MIRROR MOTOR ......................................................3-23
3.10.4 LASER SYNCHRONIZATION DETECTOR..................................3-24
B003/B004/B006/B007 ii SM
Rev. 02/2002
3.10.5 LD UNIT........................................................................................3-24
Laser beam pitch adjustment..............................................................3-25
3.11 PHOTOCONDUCTOR UNIT (PCU) ......................................................3-26
3.11.1 PCU..............................................................................................3-26
3.11.2 DRUM...........................................................................................3-27
3.11.3 PICK-OFF PAWLS .......................................................................3-28
3.11.4 CHARGE ROLLER CLEANING PAD & ROLLER BRUSH ............3-29
3.11.5 DRUM CLEANING BLADE...........................................................3-31
3.11.6 ID SENSOR..................................................................................3-31
3.12 DEVELOPMENT ...................................................................................3-32
3.12.1 DEVELOPMENT UNIT .................................................................3-32
3.12.2 DEVELOPMENT FILTER .............................................................3-33
3.12.3 DEVELOPMENT ROLLER ...........................................................3-33
3.12.4 DEVELOPER................................................................................3-34
3.12.5 TD SENSOR.................................................................................3-36
3.13 TRANSFER UNIT..................................................................................3-37
3.13.1 TRANSFER BELT UNIT...............................................................3-37
3.13.2 TRANSFER BELT ........................................................................3-38
3.13.3 TRANSFER BELT CLEANING BLADE AND TONER OVERFLOW
SENSOR.......................................................................................3-39
3.14 PAPER FEED........................................................................................3-40
3.14.1 PICK-UP, SEPARATION, AND FEED ROLLERS ........................3-40
3.14.2 LOWER RIGHT COVER...............................................................3-41
3.14.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED
CLUTCHES ...................................................................................3-42
3.14.4 UPPER PAPER FEED UNIT FOR TRAY 1 ..................................3-43
3.14.5 LOWER PAPER FEED UNIT FOR TRAY 2 .................................3-44
3.14.6 PAPER END/PAPER HEIGHT/RELAY SENSORS ......................3-45
3.14.7 REGISTRATION SENSOR...........................................................3-46
3.14.8 TRAY LIFT MOTOR .....................................................................3-48
3.14.9 FEED/DEVELOPMENT MOTOR..................................................3-49
3.15 FUSING.................................................................................................3-50
3.15.1 FUSING UNIT...............................................................................3-50
3.15.2 FUSING UNIT EXIT GUIDE .........................................................3-51
3.15.3 HOT ROLLER STRIPPERS .........................................................3-51
3.15.4 FUSING LAMPS...........................................................................3-52
3.15.5 THERMISTORS AND THERMOSTATS .......................................3-54
3.15.6 FUSING ROLLER/PRESSURE ROLLER.....................................3-55
3.16 BY-PASS TRAY ....................................................................................3-57
3.16.1 COVER REPLACEMENT.............................................................3-57
3.16.2 BY-PASS PAPER FEED AND PICK-UP ROLLER
REPLACEMENT ...........................................................................3-58
3.16.3 BY-PASS SEPARATION ROLLER REPLACEMENT...................3-59
3.16.4 PAPER END SENSOR AND PICK-UP SOLENOID
REPLACEMENT ...........................................................................3-60
3.16.5 PAPER SIZE SENSOR BOARD REPLACEMENT.......................3-61
3.16.6 BY-PASS TABLE REMOVAL .......................................................3-62
3.16.7 PAPER FEED CLUTCH REPLACEMENT....................................3-63
SM iii B003/B004/B006/B007
3.17 DUPLEX UNIT.......................................................................................3-64
3.17.1 DUPLEX COVER REMOVAL.......................................................3-64
3.17.2 DUPLEX ENTRANCE SENSOR REPLACEMENT.......................3-65
3.17.3 DUPLEX EXIT SENSOR REPLACEMENT ..................................3-66
3.18 DRIVE AREA.........................................................................................3-67
3.18.1 REGISTRATION CLUTCH AND TRANSFER BELT
CONTACT CLUTCH.....................................................................3-67
3.18.2 MAIN MOTOR..............................................................................3-68
3.18.3 TONER SUPPLY MOTOR............................................................ 3-69
3.19 PRINTED CIRCUIT BOARDS...............................................................3-70
3.19.1 HIGH VOLTAGE POWER SUPPLY.............................................3-70
3.19.2 I/O BOARD...................................................................................3-71
3.19.3 BICU BOARD...............................................................................3-72
3.19.4 PSU.............................................................................................. 3-72
3.20 HARD DISK/CONTROLLER BOARD.................................................... 3-73
3.21 COPY ADJUSTMENTS: PRINTING/SCANNING..................................3-74
3.21.1 PRINTING ....................................................................................3-74
Registration - Leading Edge/Side-to-Side...........................................3-74
Blank Margin.......................................................................................3-75
Main Scan Magnification.....................................................................3-75
Parallelogram Image Adjustment........................................................3-76
3.21.2 SCANNING...................................................................................3-77
Registration: Platen Mode...................................................................3-77
Magnification.......................................................................................3-77
Sub Scan Magnification......................................................................3-77
3.21.3 ADF IMAGE ADJUSTMENT.........................................................3-78
Registration.........................................................................................3-78
3.21.4 TOUCH SCREEN CALIBRATION................................................3-79
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................ 4-1
4.1 SERVICE CALL CONDITIONS.................................................................4-1
4.1.1 SUMMARY.......................................................................................4-1
4.1.2 SC CODE DESCRIPTIONS .............................................................4-2
4.2 ELECTRICAL COMPONENT DEFECTS ................................................4-16
4.2.1 SENSORS......................................................................................4-16
4.2.2 SWITCHES.....................................................................................4-17
4.3 BLOWN FUSE CONDITIONS.................................................................4-18
4.4 LEDS.......................................................................................................4-18
4.5 TEST POINTS.........................................................................................4-18
SERVICE TABLES
5. SERVICE TABLES...................................................................... 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 SERVICE PROGRAM MODE OPERATION.....................................5-1
B003/B004/B006/B007 iv SM
Entering and Exiting SP mode..............................................................5-1
SP Mode Button Summary...................................................................5-2
Switching Between SP Mode and Copy Mode for Test Printing ...........5-3
Selecting the Program Number.............................................................5-3
5.1.2 SERVICE PROGRAM MODE TABLES............................................5-4
SP1-xxx: Feed......................................................................................5-4
SP2-xxx: Drum......................................................................................5-7
SP3-xxx: Process................................................................................5-15
SP4-xxx: Scanner...............................................................................5-16
SP5-xxx: Mode ...................................................................................5-29
SP6-xxx: Peripherals..........................................................................5-36
SP7-xxx: Data Log..............................................................................5-38
5.1.3 TEST PATTERN PRINTING: SP2-902...........................................5-47
Test Pattern Table (SP2-902-2: IPU Test Print)..................................5-47
Test Pattern Table: SP2-902-3 Printing Test Patterns........................5-48
5.1.4 INPUT CHECK...............................................................................5-49
Main Machine Input Check: SP5-803 .................................................5-49
ARDF Input Check: SP6-007..............................................................5-53
5.1.5 OUTPUT CHECK...........................................................................5-54
Main Machine Output Check: SP5-804...............................................5-54
ARDF Output Check: SP6-008)..........................................................5-56
5.1.6 SMC PRINT OUT LISTS: SP5-990.................................................5-56
5.1.7 NIP BAND WIDTH ADJUSTMENT: SP1-109.................................5-60
5.1.8 MEMORY ALL CLEAR: SP5-801...................................................5-61
5.1.9 SOFTWARE RESET......................................................................5-62
5.1.10 SYSTEM SETTINGS AND COPY SETTING RESET...................5-62
System Setting Reset.........................................................................5-62
Copier Setting Reset...........................................................................5-63
5.2 SOFTWARE DOWNLOAD......................................................................5-64
5.3 UPLOADING/DOWNLOADING NVRAM DATA.......................................5-65
5.3.1 UPLOADING NVRAM DATA (SP5-824).........................................5-65
5.3.2 DOWNLOADING NVRAM DATA (SP5-825) ..................................5-66
5.4 SELF-DIAGNOSTIC MODE....................................................................5-67
5.4.1 SELF-DIAGNOSTIC MODE AT POWER ON.................................5-67
5.4.2 DETAILED SELF-DIAGNOSTIC MODE.........................................5-68
Executing Detailed Self-Diagnosis......................................................5-68
5.5 USER PROGRAM MODE.......................................................................5-70
5.5.1 HOW TO USE UP MODE ...............................................................5-70
UP Mode Initial Screen: User Tools/Counter Display..........................5-70
System Settings..................................................................................5-70
Copier/Document Server Features.....................................................5-71
Printer, Facsimile, Scanner Settings................................................... 5-71
Counter...............................................................................................5-72
5.6 DIP SWITCHES.......................................................................................5-73
SM v B003/B004/B006/B007
DETAILED DESCRIPTIONS
6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW...............................................................................................6-1
6.1.1 COMPONENT LAYOUT...................................................................6-1
6.1.2 PAPER PATH...................................................................................6-3
6.1.3 DRIVE LAYOUT...............................................................................6-4
6.2 BOARD STRUCTURE...............................................................................6-5
6.2.1 BLOCK DIAGRAM............................................................................6-5
6.2.2 CONTROLLER.................................................................................6-7
6.3 COPY PROCESS OVERVIEW .................................................................6-9
Exposure...............................................................................................6-9
Drum charge.........................................................................................6-9
Laser exposure.....................................................................................6-9
Development.........................................................................................6-9
Image transfer.....................................................................................6-10
Separation ..........................................................................................6-10
ID sensor ............................................................................................6-10
Cleaning..............................................................................................6-10
Quenching ..........................................................................................6-10
6.4.1 OVERVIEW....................................................................................6-11
SCANNER DRIVE ..............................................................................6-12
Book Mode..........................................................................................6-12
ADF mode...........................................................................................6-12
6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE.........................6-13
6.5 IMAGE PROCESSING............................................................................6-15
6.5.1 OVERVIEW....................................................................................6-15
6.5.2 SBU (SENSOR BOARD UNIT).......................................................6-16
6.5.3 AUTO IMAGE DENSITY (ADS)......................................................6-17
6.5.4 IPU (IMAGE PROCESSING UNIT).................................................6-18
Overview............................................................................................. 6-18
6.5.5 IMAGE PROCESSING MODES.....................................................6-19
6.5.6 SUMMARY OF IMAGE PROCESSING FUNCTIONS....................6-21
6.5.7 IMAGE PROCESSING STEPS AND RELATED SP MODES.........6-22
Text Mode...........................................................................................6-22
Text/Photo Mode ................................................................................6-23
Photo Mode ........................................................................................6-24
Pale (Low-Density Mode)....................................................................6-25
Generation Copy Mode.......................................................................6-26
Auto shading (shading correction)......................................................6-27
Background erase...............................................................................6-27
Independent dot erase........................................................................6-28
Filtering...............................................................................................6-29
Pre-Filter.............................................................................................6-29
Text Mode...........................................................................................6-30
Photo Mode ........................................................................................6-31
Text/Photo Mode ................................................................................6-32
Low Density Mode..............................................................................6-33
B003/B004/B006/B007 vi SM
Generation Mode................................................................................6-33
Main scan magnification and reduction...............................................6-34
γ correction..........................................................................................6-34
Gradation processing..........................................................................6-34
Line width correction...........................................................................6-35
6.6 LASER EXPOSURE................................................................................6-36
6.6.1 OVERVIEW....................................................................................6-36
6.6.2 AUTO POWER CONTROL (APC)..................................................6-37
6.6.3 DUAL BEAM WRITING..................................................................6-38
6.6.4 LASER BEAM PITCH CHANGE MECHANISM..............................6-39
6.6.5 LD SAFETY SWITCHES................................................................6-40
6.7 PHOTOCONDUCTOR UNIT (PCU)........................................................6-41
6.7.1 OVERVIEW....................................................................................6-41
6.7.2 DRIVE MECHANISM......................................................................6-42
6.7.3 DRUM PAWLS...............................................................................6-42
6.7.4 DRUM TONER SEALS...................................................................6-42
6.8 DRUM CHARGE .....................................................................................6-43
6.8.1 OVERVIEW....................................................................................6-43
6.8.2 CHARGE ROLLER VOLTAGE CORRECTION..............................6-44
Correction for Environmental Conditions............................................6-44
Correction for paper width and thickness (by-pass tray only) .............6-45
6.8.3 ID SENSOR PATTERN PRODUCTION TIMING............................6-46
6.8.4 DRUM CHARGE ROLLER CLEANING..........................................6-46
6.9 DEVELOPMENT .....................................................................................6-47
6.9.1 OVERVIEW....................................................................................6-47
6.9.2 DRIVE MECHANISM......................................................................6-48
6.9.3 DEVELOPER MIXING....................................................................6-48
6.9.4 DEVELOPMENT BIAS...................................................................6-49
Mechanism .........................................................................................6-49
Correction for paper width and thickness (by-pass tray only) .............6-49
6.9.5 TONER SUPPLY............................................................................6-50
Toner bottle replenishment mechanism..............................................6-50
Toner supply mechanism....................................................................6-51
Sensor Control Mode..........................................................................6-52
Image Pixel Count Mode.....................................................................6-53
6.9.6 TONER NEAR END/END DETECTION.........................................6-53
6.9.7 TONER END RECOVERY .............................................................6-54
6.9.8 TONER SUPPLY WITH ABNORMAL SENSORS ..........................6-54
DRUM CLEANING AND TONER RECYCLING..................................6-55
6.10.1 DRUM CLEANING........................................................................6-55
6.10.2 TONER RECYCLING...................................................................6-55
6.11 PAPER FEED........................................................................................6-56
6.11.1 OVERVIEW..................................................................................6-56
6.11.2 PAPER FEED DRIVE...................................................................6-57
6.11.3 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM6-57
6.11.4 PAPER LIFT.................................................................................6-58
6.11.5 PAPER END DETECTION...........................................................6-59
6.11.6 PAPER REGISTRATION..............................................................6-59
6.11.7 PAPER SIZE DETECTION...........................................................6-60
SM vii B003/B004/B006/B007
6.12 BY-PASS TRAY.................................................................................................6-61
6.12.1 OVERVIEW.............................................................................................. 6-61
6.12.2 BY-PASS TRAY OPERATION................................................................. 6-62
6.12.3 BY-PASS PAPER SIZE DETECTION...................................................... 6-63
6.13 DUPLEX UNIT ................................................................................................... 6-64
6.13.1 OVERVIEW.............................................................................................. 6-64
6.13.2 DUPLEX DRIVE LAYOUT .......................................................................6-65
6.13.3 DUPLEX BASIC OPERATION................................................................. 6-66
LARGER THAN A4 LENGTHWISE/LT LENGTHWISE ................................. 6-66
UP TO A4 LENGTHWISE/LT LENGTHWISE................................................ 6-66
6.13.4 DUPLEX UNIT FEED IN AND EXIT MECHANISM.................................. 6-67
FEED-IN.........................................................................................................6-67
INVERSION AND EXIT..................................................................................6-67
6.14 IMAGE TRANSFER AND PAPER SEPARATION.............................................6-68
6.14.1 OVERVIEW.............................................................................................. 6-68
6.14.2 BELT DRIVE MECHANISM ..................................................................... 6-69
6.14.3 TRANSFER BELT UNIT CONTACT MECHANISM .................................6-69
6.14.4 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM ............6-70
6.14.5 TRANSFER BELT CHARGE ...................................................................6-71
MECHANISM ................................................................................................. 6-71
CORRECTION FOR PAPER WIDTH AND THICKNESS ..............................6-72
CURRENTS APPLIED TO LEADING EDGE AND IMAGE AREAS, AND FOR
BY-PASS FEED .........................................................................................6-73
6.14.6 TRANSFER BELT CLEANING MECHANISM .........................................6-74
6.15 IMAGE FUSING AND PAPER EXIT..................................................................6-75
6.15.1 OVERVIEW.............................................................................................. 6-75
6.15.2 FUSING DRIVE........................................................................................ 6-76
6.15.3 FUSING DRIVE RELEASE MECHANISM ...............................................6-76
6.15.4 FUSING ENTRANCE GUIDE SHIFT MECHANISM ................................6-77
6.15.5 EXIT GUIDE PLATE AND DE-CURLER ROLLERS ................................6-77
6.15.6 PRESSURE ROLLER ..............................................................................6-78
6.15.7 CLEANING MECHANISM........................................................................ 6-78
6.15.8 FUSING TEMPERATURE CONTROL..................................................... 6-79
TEMPERATURE CONTROL ......................................................................... 6-79
FUSING IDLING TEMPERATURE ................................................................6-80
6.15.9 OVERHEAT PROTECTION..................................................................... 6-80
6.16 ENERGY SAVER MODES ................................................................................6-81
6.16.1 OVERVIEW.............................................................................................. 6-81
6.16.2 ENERGY SAVER MODE .........................................................................6-82
ENTERING THE ENERGY SAVER MODE ...................................................6-82
WHAT HAPPENS IN ENERGY SAVER MODE ............................................6-82
RETURN TO STAND-BY MODE ...................................................................6-82
6.16.3 AUTO OFF MODE ................................................................................... 6-83
ENTERING OFF STAND-BY AND OFF MODES ..........................................6-83
OFF STAND-BY MODE.................................................................................6-83
OFF MODE.................................................................................................... 6-83
RETURNING TO STAND-BY MODE............................................................. 6-83
Rev. 09/2002
SPECIFICATIONS
7. SPECIFICATIONS........................................................................ 7-1
7.1 GENERAL SPECIFICATIONS...................................................................7-1
7.2 MACHINE CONFIGURATION ...................................................................7-3
B003/B004/B006/B007 viii SM
Rev. 09/2002
7.3 OPTIONAL EQUIPMENT ..........................................................................7-5
AUTO REVERSE DOCUMENT FEEDER B351
1. REPLACEMENT AND ADJUSTMENT ........................................ 8-1
1.1 COVERS ...................................................................................................8-1
1.2 ORIGINAL FEED UNIT .............................................................................8-2
1.3 ORIGINAL PICK-UP ROLLER...................................................................8-2
1.4 ORIGINAL FEED BELT.............................................................................8-3
1.5 SKEW CORRECTION/INTERVAL/ REGISTRATION/ORIGINAL WIDTH
SENSORS........................................................................................................8-4
1.6 ORIGINAL LENGTH SENSORS ...............................................................8-5
1.7 SEPARATION ROLLER ............................................................................8-5
1.8 INVERTER /ORIGINAL SET SENSORS...................................................8-6
1.9 PICK-UP MOTOR/ORIGINAL STOPPER HP SENSOR/PICK-UP HP
SENSOR ...................................................................................................8-6
1.10 SCANNER MOTOR AND INVERTER MOTOR.......................................8-7
1.11 FEED MOTOR, SKEW CORRECTION ROLLER CLUTCH ...................8-8
1.12 EXIT SENSOR ........................................................................................8-9
1.13 STAMP SOLENOID.................................................................................8-9
1.14 CONTROLLER BOARD ..........................................................................8-9
2 TROUBLESHOOTING ................................................................ 8-10
2.1 TIMING CHARTS ....................................................................................8-10
2.1.1 A4(S)/LT(S) SINGLE-SIDE ORIGINAL MODE ...............................8-10
2.1.2 A4(S)/LT(S) DOUBLE-SIDED ORIGINAL MODE...........................8-11
2.2 JAM DETECTION....................................................................................8-12
3 SERVICE TABLES...................................................................... 8-13
3.1 DIP SWITCHES.......................................................................................8-13
3.2 TEST POINTS .........................................................................................8-13
3.3 FUSES ....................................................................................................8-13
4 DETAILED DESCRIPTION ......................................................... 8-14
4.1 MAIN COMPONENTS.............................................................................8-14
DRIVE LAYOUT .................................................................................8-15
4.3 ORIGINAL SIZE DETECTION.................................................................8-16
4.3.1 BASIC MECHANISM ......................................................................8-16
4.3.2 MIXED ORIGINAL SIZE MODE .....................................................8-18
4.4 ORIGINAL FEED-IN MECHANISM ......................................................... 8-19
4.4.1 PICK AND SEPARATION...............................................................8-19
4.4.2 ORIGINAL SKEW CORRECTION..................................................8-20
4.4.3 REDUCING THE INTERVAL BETWEEN PAGES.......................... 8-20
4.5 ORIGINAL TRANSPORT AND EXIT.......................................................8-21
4.5.1 SINGLE-SIDED ORIGINALS..........................................................8-21
4.5.2 DOUBLE-SIDED ORIGINALS ........................................................8-22
4.6 STAMP ....................................................................................................8-23
4.7 DF70 SOFTWARE MODIFICATION HISTORY……………………………8-24
SM ix B003/B004/B006/B007
LARGE CAPACITY TRAY A683
Rev. 09/2002
1. OVERALL MACHINE INFORMATION......................................... 9-1
1.1 SPECIFICATIONS.....................................................................................9-1
1.2 MECHANICAL COMPONENT LAYOUT ...................................................9-2
1.3 ELECTRICAL COMPONENT LAYOUT.....................................................9-3
1.4 ELECTRICAL COMPONENT DESCRIPTION........................................... 9-4
1.5 DRIVE LAYOUT ........................................................................................9-5
2. DETAILED DESCRIPTIONS ........................................................ 9-6
2.1 PAPER FEED MECHANISM..................................................................... 9-6
2.2 TRAY LIFT AND PAPER HEIGHT DETECTION MECHANISM................ 9-7
Tray lifting conditions ............................................................................9-7
Tray lowering conditions .......................................................................9-7
2.3 TRAY UNIT SLIDE MECHANISM .............................................................9-8
3. SERVICE TABLES....................................................................... 9-9
3.1 DIP SWITCHES.........................................................................................9-9
3.2 TEST POINTS ...........................................................................................9-9
3.3 SWITCHES................................................................................................9-9
3.4 FUSES ......................................................................................................9-9
4. REPLACEMENT AND ADJUSTMENT ...................................... 9-10
4.1 COVER REPLACEMENT........................................................................ 9-10
Tray Cover ..........................................................................................9-10
Front Cover.........................................................................................9-10
Rear Cover .........................................................................................9-10
Right Lower Cover ..............................................................................9-10
Upper Cover .......................................................................................9-10
4.2 ROLLER REPLACEMENT ......................................................................9-11
4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS .............9-11
Pick-up Roller .....................................................................................9-11
Paper Feed Roller...............................................................................9-11
Separation Roller ................................................................................9-11
4.3 TRAY LIFT AND PAPER END SENSOR REPLACEMENT.....................9-12
Tray Lift Sensor ..................................................................................9-12
Paper End Sensor ..............................................................................9-12
4.4 RELAY SENSOR REPLACEMENT.........................................................9-13
4.5 SIDE FENCE POSITION CHANGE.........................................................9-14
B003/B004/B006/B007 x SM
PAPER TRAY UNIT A682
1. REPLACEMENT AND ADJUSTMENT...................................... 10-1
1.1 COVER REPLACEMENT........................................................................10-1
Right Cover.........................................................................................10-1
Rear Cover .........................................................................................10-1
1.2 ROLLER REPLACEMENT......................................................................10-2
1.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS.............10-2
Pick-up Roller .....................................................................................10-2
Paper Feed Roller...............................................................................10-2
Separation Roller................................................................................10-2
1.3 TRAY MOTOR REPLACEMENT.............................................................10-3
1.4 PAPER FEED AND RELAY CLUTCH REPLACEMENT.........................10-4
1.5 PAPER FEED UNIT REPLACEMENT..................................................... 10-5
Upper Paper Feed Unit.......................................................................10-6
Lower Paper Feed Unit.......................................................................10-6
1.6 PAPER END, TRAY LIFT, AND RELAY SENSOR REPLACEMENT......10-7
Paper End Sensor ..............................................................................10-7
Tray Lift Sensor ..................................................................................10-7
Relay Sensor......................................................................................10-7
2. SERVICE TABLES.................................................................... 10-8
2.1 DIP SWITCHES.......................................................................................10-8
2.2 TEST POINTS.........................................................................................10-8
2.3 SWITCHES..............................................................................................10-8
2.4 FUSES ....................................................................................................10-8
3. DETAILED DESCRIPTIONS..................................................... 10-9
3.1 MECHANICAL COMPONENT LAYOUT .................................................10-9
3.2 ELECTRICAL COMPONENT LAYOUT.................................................10-10
3.3 ELECTRICAL COMPONENT DESCRIPTION.......................................10-11
3.4 DRIVE LAYOUT....................................................................................10-12
3.5 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM........ 10-13
3.6 PAPER LIFT MECHANISM...................................................................10-14
3.7 PAPER END DETECTION....................................................................10-16
3.8 PAPER HEIGHT DETECTION..............................................................10-17
4. SPECIFICAT ION S................................................................... 10-18
BRIDGE UNIT A688
1. OVERALL MACHINE INFORMAT ION...................................... 11-1
1.1 SPECIFICATIONS...................................................................................11-1
1.2 MECHANICAL COMPONENT LAYOUT .................................................11-2
1.3 ELECTRICAL COMPONENT LAYOUT...................................................11-3
1.4 ELECTRICAL COMPONENT DESCRIPTION.........................................11-3
1.5 DRIVE LAYOUT......................................................................................11-4
SM xi B003/B004/B006/B007
2. DETAILED DESCRIPTION ....................................................... 11-5
2.1 JUNCTION GATE MECHANISM.............................................................11-5
3. REPLACEMENT AND ADJUSTMENT...................................... 11-6
3.1 EXIT SENSOR REPLACEMENT.............................................................11-6
1 BIN TRAY B376
1. OVERALL MACHINE INFORMAT ION...................................... 12-1
1.1 SPECIFICATIONS...................................................................................12-1
1.2 MECHANICAL COMPONENT AND DRIVE LAYOUT.............................12-2
1.3 ELECTRICAL COMPONENT LAYOUT...................................................12-3
1.4 ELECTRICAL COMPONENT DESCRIPTION.........................................12-3
2. DETAILED DESCRIPTIONS..................................................... 12-4
2.1 BASIC OPERATION................................................................................12-4
3. REPLACEMENT AND ADJUSTMENT...................................... 12-5
3.1 COVER REMOVAL.................................................................................12-5
Front Cover.........................................................................................12-5
Upper Cover .......................................................................................12-5
Rear Cover .........................................................................................12-5
3.2 PAPER SENSOR REPLACEMENT........................................................12-6
3.3 ENTRANCE AND PAPER LIMIT SENSOR REPLACEMENT.................12-7
Paper Limit Sensor.............................................................................12-7
Entrance Sensor.................................................................................12-7
1,000 SHEET FINISHER A681
1. OVERALL MACHINE INFORMAT ION...................................... 13-1
1.1 SPECIFICATIONS...................................................................................13-1
1.2 MECHANICAL COMPONENT LAYOUT .................................................13-2
1.3 ELECTRICAL COMPONENT LAYOUT...................................................13-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS......................................13-4
1.5 DRIVE LAYOUT......................................................................................13-6
2. DETAILED DESCRIPTIONS..................................................... 13-7
2.1 JUNCTION GATE MECHANISM.............................................................13-7
Staple mode........................................................................................13-7
No staple mode...................................................................................13-7
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM............................13-8
2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM.................................13-9
2.4 STAPLER..............................................................................................13-10
2.5 FEED OUT MECHANISM .....................................................................13-11
2.6 SHIFT TRAY UP/DOWN MECHANISM ................................................ 13-12
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM..........................................13-13
2.8 JAM CONDITIONS................................................................................13-14
B003/B004/B006/B007 xii SM
2.9 TIMING CHARTS..................................................................................13-15
2.9.1 NO STAPLE MODE (A4 SIDEWAYS, 3 SHEETS/2SETS)...........13-15
2.9.2 STAPLE MODE (A4 SIDEWAYS, 2 SHEETS/2 SETS)................13-16
3. SERVICE TABLE.................................................................... 13-17
3.1 DIP SWITCH TABLE.............................................................................13-17
3.2 TEST POINTS.......................................................................................13-17
3.3 FUSES ..................................................................................................13-17
4. REPLACEMENT AND ADJUSTMENT.................................... 13-18
4.1 COVER REMOVAL...............................................................................13-18
Front Door.........................................................................................13-18
Front Cover.......................................................................................13-18
Rear Cover .......................................................................................13-18
Upper Cover .....................................................................................13-18
Lower Left Cover ..............................................................................13-19
Front Shift Tray Cover.......................................................................13-19
Rear Shift Tray Cover.......................................................................13-19
Shift Tray ..........................................................................................13-19
4.2 ENTRANCE SENSOR REPLACEMENT............................................... 13-20
4.3 EXIT SENSOR REPLACEMENT...........................................................13-21
4.4 STACK HEIGHT SENSOR REPLACEMENT........................................13-22
4.5 POSITIONING ROLLER REPLACEMENT............................................13-23
4.6 STAPLER REPLACEMENT..................................................................13-24
TWO TRAY FINISHER B352
1. REPLACEMENT AND ADJUSTMENT...................................... 14-1
1.1 COVERS.................................................................................................14-1
1.1.1 EXTERNAL COVERS.....................................................................14-1
1.1.2 INNER COVER...............................................................................14-1
1.2 POSITIONING ROLLER..........................................................................14-2
1.3 TRAY 1 EXIT SENSOR...........................................................................14-2
1.4 ENTRANCE SENSOR/STAPLER TRAY ENTRANCE SENSOR............14-3
1.5 STAPLER TRAY......................................................................................14-3
1.6 UPPER STACK HEIGHT SENSORS/TRAY 1 UPPER LIMIT SWITCH..14-4
1.7 EXIT GUIDE PLATE MOTOR..................................................................14-5
1.8 LIFT MOTORS ........................................................................................14-5
1.9 LOWER EXIT SENSOR..........................................................................14-7
1.10 LOWER STACK HEIGHT SENSORS ...................................................14-8
1.11 TRAY 2 SHUNT POSITION SENSOR ..................................................14-8
1.12 STAPLER UNIT.....................................................................................14-9
1.13 STAPLER ROTATION HP SENSOR.....................................................14-9
1.14 TRAY 1 INTERIOR..............................................................................14-10
1.14.1 TRAY 1 COVERS.......................................................................14-10
tray Shift Sensors and tray release sensor.......................................14-11
1.14.3 TRAY 1 SHIFT MOTOR.............................................................14-11
1.14.4 BACK FENCE LOCK CLUTCH ..................................................14-11
SM xiii B003/B004/B006/B007
1.15 FINISHER MAIN BOARD....................................................................14-12
1.16 PUNCH HOLE POSITION ADJUSTMENT..........................................14-12
2. TROUBLESHOOTIN G............................................................ 14-13
2.1 TIMING CHARTS..................................................................................14-13
2.1.1 A4(S)/LT(S) SHIFT MODE WITH PUNCH – TRAY 1...................14-13
2.1.2 A4(S)/LT(S) SHIFT MODE WITH PUNCH – TRAY 2...................14-14
2.1.3 A4(S)/LT(S) STAPLE MODE WITH PUNCH................................14-15
2.2 JAM DETECTION..................................................................................14-16
3. SERVICE TABLES.................................................................. 14-17
3.1 DIP SWITCH SETTINGS ......................................................................14-17
3.2 TEST POINTS.......................................................................................14-17
3.3 FUSES ..................................................................................................14-17
4. DETAILED DESCRIPTIONS................................................... 14-18
4.1 GENERAL LAYOUT..............................................................................14-18
4.2 DRIVE LAYOUT....................................................................................14-19
4.3 JUNCTION GATES...............................................................................14-20
4.4 TRAY SHIFTING................................................................................... 14-21
4.4.1 TRAY SHIFT MECHANISMS .......................................................14-21
Tray 1 (Upper Tray)..........................................................................14-21
Tray 2 (Lower Tray)..........................................................................14-22
4.5 TRAY UP/DOWN MECHANISMS .........................................................14-23
4.5.1 TRAY 1.........................................................................................14-23
Introduction.......................................................................................14-23
Normal and sort/stack modes...........................................................14-23
Staple mode......................................................................................14-24
Tray 1 release mechanism................................................................14-25
4.5.2 TRAY 2.........................................................................................14-27
4.5.3 PRE-STACK MECHANISM..........................................................14-28
4.6 JOGGER UNIT PAPER POSITIONING MECHANISM..........................14-29
Vertical Paper Alignment ..................................................................14-29
Horizontal Paper Alignment..............................................................14-29
4.7 STAPLER MECHANISM.......................................................................14-30
4.7.1 STAPLER MOVEMENT................................................................14-30
Stapler Rotation................................................................................14-30
Side-to-Side Movement....................................................................14-30
4.7.2 STAPLER.....................................................................................14-31
4.7.3 FEED OUT AND TRANSPORT....................................................14-32
4.8 PUNCH UNIT (OPTIONAL)...................................................................14-33
4.8.1 PUNCH DRIVE MECHANISM......................................................14-33
4.8.2 PUNCH WASTE COLLECTION...................................................14-34
B003/B004/B006/B007 xiv SM
NINE-TRAY MAILBOX AND BRIDGE UNIT G909/G912
1. OVERALL MACHINE INFORMAT ION...................................... 15-1
1.1 SPECIFICATIONS...................................................................................15-1
1.2 COMPONENT LAYOUT..........................................................................15-2
1.2.1 MECHANICAL COMPONENT LAYOUT.........................................15-2
1.2.2 DRIVE LAYOUT.............................................................................15-3
1.3 ELECTRICAL COMPONENT DESCRIPTIONS......................................15-4
2. DETAILED DESCRIPTIONS..................................................... 15-6
2.1 BASIC OPERATION................................................................................15-6
Proof Tray...........................................................................................15-6
Bridge Unit..........................................................................................15-6
Trays...................................................................................................15-6
2.2 PROOF TRAY SENSORS.......................................................................15-7
2.2.1 PAPER SENSOR...........................................................................15-7
2.2.2 PAPER OVERFLOW SENSOR......................................................15-7
2.3 TRAY SENSORS....................................................................................15-8
2.3.1 PAPER SENSOR...........................................................................15-8
2.3.2 PAPER OVERFLOW SENSOR......................................................15-8
2.3.3 TRAY EXIT SENSOR.....................................................................15-8
2.4 TIMING CHART AND MISFEED DETECTION........................................15-9
3. INSTALLATION PROCEDURE............................................... 15-11
3.1 MAILBOX (G909)..................................................................................15-11
3.1.1 ACCESSORY CHECK..................................................................15-11
3.1.2 REQUIREMENT OPTIONS FOR MAIN MACHINE......................15-11
3.1.3 INSTALLATION PROCEDURE....................................................15-12
1.2 BRIDGE UNIT FOR MAILBOX (G912)..................................................15-15
1.2.1 ACCESSORY CHECK..................................................................15-15
1.2.2 INSTALLATION PROCEDURE....................................................15-16
4. REPLACEMENT AND ADJUSTMENT.................................... 15-21
4.1 PROOF TRAY UNIT..............................................................................15-21
4.1.1 PROOF TRAY SENSOR AND PAPER
OVERFLOW SENSORS ...............................................................15-21
4.1.2 PROOF TRANSPORT UNIT ........................................................15-21
4.2 TRAY UNIT............................................................................................15-22
4.2.1 TRAYS..........................................................................................15-22
4.2.2 PAPER SENSOR, PAPER OVERFLOW SENSOR,
AND TRAY EXIT SENSOR ..........................................................15-23
Paper Overflow Sensor.....................................................................15-23
Paper Sensor....................................................................................15-23
Tray Exit Sensor (above the 1st tray, and in the 3rd, 6th,
and 9th trays)....................................................................................15-23
4.2.3 MAIN CONTROL BOARD ............................................................15-24
4.2.4 TRAY EXIT SENSOR ADJUSTMENT..........................................15-25
SM xv B003/B004/B006/B007
Rev. 09/2002
5. SERVICE TABLES................................................................... 15-27
5.1 DIP SWITCHES/VRIABLE RESISTORS/LEDS.....................................15-27
5.1.1 DIP SWITCHES............................................................................15-27
5.1.2 VARIABLE RESISTORS ..............................................................15-28
5.1.3 LEDS .....................................................................................................
FIRMWARE HISTORY
1. FIRMWARE HISTORY ............................................................... 16-1
1.1 FIRMWARE HISTORY ............................................................................16-1
1.1.1 B003/B004/B006/B007 ENGINE (BICU) FIRMWARE HISTORY ..............16-1
1.1.2 B003/B004/B006/B007 LANGUAGE MODIFICATION HISTORY..............16-3
1.1.3 B003/B004/B006/B007 CONTROLLER SOFTWARE MOD HISTORY .....16-4
1.1.4 B003/B004/B006/B007 LCDC SOFTWARE MODIFICATION HISTORY ..16-8
1.1.5 B003/B004/B006/B007 STAMP SOFTWARE MODIFICATION HISTORY 16-9
B003/B004/B006/B007 xvi SM
B361/B362
PRINTER/SCANNER CONTROLLERS
TABLE OF CONTENTS
INSTALLATION
1. INSTALLA T ION.......................................................................... 1-1
1.1 INSTALLATION REQUIREMENTS...........................................................1-1
1.2 PRINTER INSTALLATION........................................................................1-1
1.3 POSTSCRIPT UNIT (G577)......................................................................1-7
1.4 MEMORY (G578/G579) ............................................................................1-8
1.5 NIB (G574)................................................................................................1-9
1.6 IEEE1394 INTERFACE (G590)...............................................................1-10
1.7 CHECKING THE CONNECTIONS..........................................................1-11
TROUBLESHOOTING
2. TROUBLESHOOTING ................................................................ 2-1
2.1 CONTROLLER ERRORS..........................................................................2-1
2.2 LEDS AND TEST POINTS........................................................................2-1
SERVICE TABLES
3. SERVICE TABLES...................................................................... 3-1
3.1 SERVICE PROGRAM MODE....................................................................3-1
3.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE...........3-1
3.2 PRINTER SERVICE MODE......................................................................3-2
3.2.1 SERVICE MODE TABLE..................................................................3-2
3.2.2 SP MODES RELATED TO PRINTER CONTROLLER.....................3-2
3.3 SCANNER SERVICE MODE.....................................................................3-3
3.3.1 SCANNER PROGRAM MODE TABLE.............................................3-3
3.4 FIRMWARE UPDATE PROCEDURE......................................................3-11
3.5 POWER-ON SELF TEST........................................................................3-11
3.6 SELF DIAGNOSTIC TEST......................................................................3-11
3.7 USER PROGRAM MODE.......................................................................3-12
3.7.1 PRINTER USER PROGRAM MODE..............................................3-12
3.7.2 SCANNER USER PROGRAM MODE............................................3-13
SM i B003/B004/B006/B007
Rev. 02/2002
DETAILED DESCRIPTIONS
4. DETAILED SECTION DESCRIPTIONS ...................................... 4-1
4.1 OVERVIEW ...............................................................................................4-1
4.2 CONTROLLER FUNCTIONS ....................................................................4-2
4.2.1 SAMPLE PRINT ...............................................................................4-2
4.2.2 LOCKED PRINT ...............................................................................4-2
4.2.3 PAPER SOURCE SELECTION........................................................4-3
4.2.4 AUTO CONTINUE............................................................................4-4
4.2.5 PAPER OUTPUT TRAY ...................................................................4-5
4.2.6 DUPLEX PRINTING .........................................................................4-5
4.2.7 STAPLING........................................................................................4-6
4.2.8 PUNCHING ......................................................................................4-6
4.3 SCANNER FUNCTIONS ...........................................................................4-7
4.3.1 IMAGE PROCESSING FOR SCANNER MODE ..............................4-7
4.4 NIB ............................................................................................................4-8
4.4.1 BLOCK DIAGRAM............................................................................4-8
4.4.2 LED INDICATORS............................................................................4-8
4.5 IEEE1394 INTERFACE.............................................................................4-9
4.5.1 SPECIFICATIONS............................................................................4-9
4.5.2 IEEE1394 .........................................................................................4-9
4.5.3 BLOCK DIAGRAM..........................................................................4-10
4.5.4 PIN ASSIGNMENT.........................................................................4-10
4.5.5 REMARKS ABOUT THIS INTERFACE KIT....................................4-11
4.5.6 TROUBLESHOOTING NOTES ......................................................4-11
4.6 CONTROLLER SOFTWARE HISTORY……………………………………..4-12
4.6.1 CONTROLLER SOFTWARE MODIFICATION HISTORY………...…4-12
SPECIFICATIONS
SPECIFICATIONS............................................................................ 5-1
1 GENERAL SPECIFICATIONS......................................................................5-1
1.1 PRINTER.............................................................................................5-1
1.2 SCANNER ...........................................................................................5-3
2 SOFTWARE ACCESSORIES ......................................................................5-4
2.1 PRINTER.............................................................................................5-4
2.2 SCANNER ...........................................................................................5-5
3 MEACHINE CONFIGURATION....................................................................5-6
3.1 SYSTEM COMPONENTS ...................................................................5-6
B003/B004/B006/B007 ii SM
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