Ricoh af1060 Service Manual

MODEL MT

(Machine Code: B064/B065)

SERVICE MANUAL

Subject to change

Ricoh Technical Service

April 26, 2002

!

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the copier power cord is unplugged.

2. The wall outlet should be near the copier and easily accessible.

3. Note that some components of the copier 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 copier completes the warm-up period
(the Start key starts blinking red and green alternatively), keep hands away
from the mechanical and the electrical components as the copier starts
making copies 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 copier is operating. Be careful to avoid touching those components with
your bare hands.

HEALTH SAFETY CONDITIONS

1. Never operate the copier without the ozone filters installed.

2. Always replace the ozone filters with the specified ones at the specified
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 copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on
those models.

2. The NVRAM on the system control board has a lithium battery which can
explode if replaced incorrectly. Replace the NVRAM only with an identical
one. The manufacturer recommends replacing the entire NVRAM. Do not
recharge or burn this battery. Used NVRAM must be handled in accordance
with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly
when exposed to an open flame.

2. Dispose of used toner, 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 or der to dispose of them later, do not
put more than 100 batteries per sealed box. Storing larger numbers or not
sealing them apart may lead to chemical reactions and heat build-up.

LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair of
laser-based optical units in the field. The optical housing unit can only be repaired
in a factory or at a location with the requisite equipment. The laser subsystem is
replaceable in the field by a qualified Customer Engineer. The laser chassis is not
repairable in the field. Customer engineers are therefore directed to return all
chassis and laser subsystems to the factory or service depot when replacement of
the optical subsystem is required.

!

WARNING
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.

!

WARNING
WARNING: Turn off the main switch before atte mpting any of the

procedures in the Laser Unit section. Laser beams can
seriously damage your eyes.

CAUTION MARKING:

What This Manual Contains

This preliminary manual describes the installation procedures for the B064/B065
Copier and its peripheral devices:

Main unit

• B064/065 Copier with ADF, Tandem Tray

Peripherals

• B473 LCT. (Attached to the right side of the machine). Provides an additional
feed station of 4,000 sheets.

• B474 LG/B4 Feeder Kit (Attached to B473 LCT). Converts the LCT to a feed
station for legal or B4 size paper.)

• B475 A3/DLT Feeder Kit (Installed in Tandem Tray). Converts the top tray to a
feed station for A3 paper.

• B468/B469 3000-Sheet Finishers (Attached to B064/B065). Both finishers
provide punch, staple, and shift capability. The B468 provides saddle-stitching
with staples, the B469 does not provide saddle-stitching.

• B470 Cover Interposer Tray (Attached to B468/B469). Mounted on top of the
B468/B469 finisher, provides a feed station for inserting cover sheets.

• B471 9-Bin Mailbox (Attached to B468/B469). Mounted on top of the B468/B469
provides 9 output trays, each assigned to a different user.

Conventions in this Manual

This manual uses several symbols.

Symbol What it means

☛

!

"

#

$
%

Refer to section number
See Core Tech Manual for detail s
Screw
Connector
E-ring
Clip ring

Long Edge Feed (LEF)Short Edge Feed (SEF)

TABLE OF CONTENTS

1. INSTALLA TION .......................................................................... 1-1

1.1 INSTALLATION REQUIREMENTS...........................................................1-1

1.1.1 OPERATING ENVIRONMENT.........................................................1-1

1.1.2 MACHINE LEVEL.............................................................................1-2

1.1.3 MINIMUM SPACE REQUIREMENTS...............................................1-3

1.1.4 DIMENSIONS...................................................................................1-3

1.1.5 POWER REQUIREMENTS..............................................................1-4

1.2 MAIN MACHINE (B064/B065)...................................................................1-5

1.2.1 ACCESSORY CHECK......................................................................1-5

1.2.2 INSTALLATION PROCEDURE........................................................1-6

Removing Tapes and Retainers ...........................................................1-6

Connecting the ADF..............................................................................1-8

Removing and Filling the Development Unit.........................................1-9

Re-installing the Development Unit.....................................................1-11

Initializing the Drum Settings.............................................................. 1-12

Tandem Tray ......................................................................................1-13

Machine Level.....................................................................................1-15

Date/Time Setting...............................................................................1-15

SP Codes............................................................................................1-15

1.3 A3/DLT FEEDER KIT (B475)...................................................................1-16

1.3.1 ACCESSORY CHECK....................................................................1-16

1.3.2 INSTALLATION PROCEDURE......................................................1-17

1.4 LCT (B473)..............................................................................................1-19

1.4.1 ACCESSORY CHECK....................................................................1-19

1.4.2 INSTALLATION PROCEDURE......................................................1-20

Removing Tape ..................................................................................1-20

Preparing the Main Machine...............................................................1-21

Installing the LCT................................................................................1-21

1.5 LG/B4 FEEDER KIT (B474)....................................................................1-23

1.5.1 ACCESSORY CHECK....................................................................1-23

1.5.2 INSTALLATION PROCEDURE......................................................1-24

1.6 3000-SHEET FINISHERS (B468/B469)..................................................1-27

1.6.1 ACCESSORY CHECK....................................................................1-27

1.6.2 INSTALLATION PROCEDURE......................................................1-28

Removing Tapes and Retainers .........................................................1-28

B468/B469 Installation........................................................................1-29

Selecting the Staple Supply Name ..................................................... 1-31

Enabling Booklet Binding....................................................................1-31

1.7 PUNCH UNIT (B377)...............................................................................1-32

1.7.1 ACCESSORY CHECK....................................................................1-32

1.7.2 INSTALLATION PROCEDURE......................................................1-33

1.8 COVER INTERPOSER TRAY (B470).....................................................1-35

1.8.1 ACCESSORY CHECK....................................................................1-35

1.8.2 INSTALLATION PROCEDURE......................................................1-36

Removing Tapes and Retainers .........................................................1-36

i

1.9 9-BIN MAILBOX (B471)...........................................................................1-39

1.9.1 ACCESSORY CHECK....................................................................1-39

1.9.2 INSTALLATION PROCEDURE......................................................1-40

Removing Tapes and Retainers .........................................................1-40

Installation...........................................................................................1-40

1.10 PRINTER/SCANNER KIT (G338), PRINTER KIT (G339).....................1-42

1.10.1 ACCESSORY CHECK..................................................................1-42

1.10.2 INSTALLATION PROCEDURE....................................................1-43

Inserting DIMMs..................................................................................1-43

Installation Procedure.........................................................................1-44

1.11 PS3 (B525-08).......................................................................................1-46

1.11.1 INSTALLATION PROCEDURE....................................................1-46

1.12 USB 2.0 (B525-01)................................................................................1-47

1.12.1 ACCESSORY CHECK..................................................................1-47

1.12.2 INSTALLATION PROCEDURE....................................................1-48

1.12.3 USB SP SETTINGS......................................................................1-49

1.13 IEEE1394 (G561) FIREWIRE INTERFACE ..........................................1-50

1.13.1 ACCESSORY CHECK..................................................................1-50

1.13.2 INSTALLATION PROCEDURE....................................................1-51

1.13.3 UP MODE SETTINGS FOR IEEE 1394 .......................................1-52

1.13.4 SP MODE SETTINGS FOR IEEE 1394........................................1-53

1.14 802.11B WIRELESS LAN (G628)..........................................................1-54

1.14.1 ACCESSORY CHECK..................................................................1-54

1.14.2 INSTALLATION PROCEDURE....................................................1-55

1.14.3 UP MODE SETTINGS FOR WIRELESS LAN..............................1-56

1.14.4 SP MODE SETTINGS FOR 802.11B WIRELESS LAN................1-58

2. PREVENTIVE MAINTENANCE................................................... 2-1

2.1 PM TABLES ..............................................................................................2-1

2.1.1 MAIN MACHINE...............................................................................2-1

2.1.2 ADF ..................................................................................................2-4

2.1.3 OPTIONAL PERIPHERAL DEVICES...............................................2-5

LCT (Large Capacity Tray) B473..........................................................2-5

Cover Interposer Tray B470..................................................................2-5

3000-Sheet Finisher with 50-sheet stapler and Saddle-Stitching

B468B469.............................................................................................2-5

2.2 RELATED SP CODES ..............................................................................2-5

3. REPLACEMENT AND ADJUSTMENT........................................ 3-1

3.1 GENERAL CAUTIONS..............................................................................3-1

3.1.1 DRUM...............................................................................................3-1

3.1.2 DRUM UNIT .....................................................................................3-1

3.1.3 TRANSFER BELT UNIT...................................................................3-2

3.1.4 SCANNER UNIT...............................................................................3-2

3.1.5 LASER UNIT ....................................................................................3-2

3.1.6 CHARGE CORONA..........................................................................3-3

3.1.7 DEVELOPMENT ..............................................................................3-3

3.1.8 CLEANING.......................................................................................3-4

3.1.9 FUSING UNIT...................................................................................3-4

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3.1.10 PAPER FEED.................................................................................3-4

3.1.11 USED TONER................................................................................3-4

3.2 SPECIAL TOOLS AND LUBRICANTS................................................3-5

3.2.1 SPECIAL TOOLS.............................................................................3-5

3.2.2 LUBRICANTS...................................................................................3-5

3.3 OPERATION PANEL AND EXTERNAL COVERS....................................3-6

3.3.1 OPERATION PANEL........................................................................3-6

3.3.2 FRONT DOOR .................................................................................3-6

3.3.3 RIGHT COVERS..............................................................................3-7

3.3.4 LEFT COVERS.................................................................................3-8

3.3.5 REAR COVERS ...............................................................................3-9

3.4 SCANNER...............................................................................................3-10

3.4.1 ADF AND TOP COVERS ...............................................................3-10

ADF.....................................................................................................3-10

Top Covers.........................................................................................3-11

3.4.2 EXPOSURE GLASS.......................................................................3-12

3.4.3 SCANNER ORIGINAL SIZE SENSORS.........................................3-13

3.4.4 LENS BLOCK.................................................................................3-14

3.4.5 EXPOSURE LAMP.........................................................................3-15

3.4.6 LAMP REGULATOR.......................................................................3-16

3.4.7 SCANNER MOTOR DRIVE BOARD (SDRB).................................3-17

3.4.8 SCANNER MOTOR........................................................................3-18

3.4.9 SCANNER HP SENSOR................................................................3-19

3.4.10 SCANNER WIRE REPLACEMENT..............................................3-20

Preparation for Removal.....................................................................3-20

Wire Removal: Back...........................................................................3-21

Wire Removal: Front...........................................................................3-22

Attaching the New Wire ......................................................................3-23

3.4.11 SCANNER HEATER.....................................................................3-25

3.5 LASER UNIT...........................................................................................3-26

3.5.1 CAUTION DECALS........................................................................3-26

3.5.2 LD UNIT AND POLYGON MOTOR................................................3-27

3.5.3 LASER SYNCHRONIZATION DETECTOR REPLACEMENT........3-29

3.5.4 LASER UNIT ALIGNMENT.............................................................3-30

3.6 DRUM UNIT ............................................................................................3-32

3.6.1 DEVELOPMENT UNIT REMOVAL.................................................3-32

Removal..............................................................................................3-32

Re-installation.....................................................................................3-33

Replacement with a used Development Unit......................................3-33

3.6.2 CHARGE CORONA UNIT..............................................................3-34

3.6.3 CHARGE CORONA WIRE AND GRID...........................................3-35

3.6.4 CHARGE CORONA WIRE CLEANING PADS...............................3-36

3.6.5 OPC DRUM REMOVAL..................................................................3-37

3.6.6 QUENCHING LAMP.......................................................................3-38

3.6.7 DRUM POTENTIAL SENSOR........................................................3-38

3.6.8 CLEANING FILTER........................................................................3-39

3.6.9 CLEANING BLADE.........................................................................3-39

3.6.10 CLEANING BRUSH......................................................................3-40

3.6.11 PICK-OFF PAWLS.......................................................................3-41

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3.6.12 ID SENSOR..................................................................................3-41

3.6.13 DRUM MOTOR.............................................................................3-42

3.6.14 TONER COLLECTION BOTTLE..................................................3-43

3.6.15 TONER SEPARATION UNIT........................................................3-43

3.6.16 OZONE FILTERS.........................................................................3-44

3.6.17 OPTICS DUST FILTER................................................................3-44

3.6.18 INTERNAL DUST FILTER ............................................................3-44

3.7 DEVELOPMENT UNIT............................................................................3-45

3.7.1 DEVELOPER REPLACEMENT......................................................3-45

3.7.2 DEVELOPMENT FILTER............................................................... 3-47

3.7.3 ENTRANCE SEAL AND SIDE SEALS ...........................................3-48

3.7.4 TD SENSOR...................................................................................3-49

3.7.5 TONER END SENSOR ..................................................................3-49

3.7.6 TONER SUPPLY MOTOR..............................................................3-50

3.7.7 DEVELOPMENT MOTOR..............................................................3-51

3.8 TRANSFER BELT UNIT..........................................................................3-52

3.8.1 TRANSFER BELT UNIT.................................................................3-52

3.8.2 TRANSFER BELT ..........................................................................3-53

3.8.3 TRANSFER ROLLER CLEANING BLADE.....................................3-55

3.8.4 DISCHARGE PLATE......................................................................3-56

3.8.5 TRANSFER POWER PACK...........................................................3-57

3.9 FUSING UNIT..........................................................................................3-58

3.9.1 FUSING UNIT.................................................................................3-58

3.9.2 FUSING UNIT THERMISTORS AND THERMOSTATS.................3-59

3.9.3 WEB CLEANING ROLLER.............................................................3-60

Web Unit Disassembly........................................................................3-60

Web Unit Assembly.............................................................................3-61

3.9.4 WEB MOTOR AND WEB END SENSOR.......................................3-62

3.9.5 PRESSURE ROLLER CLEANING UNIT........................................3-63

3.9.6 FUSING LAMPS, HOT ROLLER, AND PRESSURE ROLLER.......3-64

Important Notes about Fusing Unit Assembly.....................................3-67

3.9.7 PRESSURE ROLLER.....................................................................3-68

3.9.8 STRIPPER PAWLS........................................................................3-69

3.9.9 NIP BAND WIDTH ADJUSTMENT.................................................3-70

3.9.10 FUSING UNIT EXIT SENSOR......................................................3-71

3.9.11 FUSING/EXIT MOTOR.................................................................3-72

3.9.12 FUSING EXIT AND EXIT UNIT ENTRANCE SENSORS.............3-73

3.10 DUPLEX UNIT.......................................................................................3-74

3.10.1 DUPLEX UNIT REMOVAL ...........................................................3-74

3.10.2 DUPLEX UNIT SIDE-TO-SIDE ADJUSTMENT............................3-75

3.10.3 JOGGER FENCE ADJUSTMENT................................................3-75

3.10.4 DUPLEX MOTORS.......................................................................3-76

Duplex Inverter Motor.........................................................................3-76

Duplex Jogger and Transport Motors..................................................3-77

3.10.5 DUPLEX TRANSPORT CLUTCH/JOGGER HP SENSOR...........3-78

3.10.6 DUPLEX ENTRANCE SENSOR ..................................................3-79

3.10.7 DUPLEX TRANSPORT SENSOR 3.............................................3-80

3.10.8 INVERTER EXIT SENSOR, TRANSPORT SENSORS 1 & 2.......3-81

3.10.9 DUPLEX JOGGER BELT ADJUSTMENT.................................... 3-82

iv

3.11 PAPER FEED........................................................................................3-83

3.11.1 PAPER TRAY REMOVAL............................................................3-83

Tandem Tray Removal.......................................................................3-83

3.11.2 REAR FENCE RETURN SENSOR REPLACEMENT...................3-85

3.11.3 REAR FENCE HP SENSOR REPLACEMENT.............................3-86

3.11.4 TANDEM RIGHT TRAY PAPER SENSOR REPLACEMENT.......3-87

3.11.5 BOTTOM PLATE LIFT WIRE REPLACEMENT ...........................3-88

3.11.6 TANDEM LCT PAPER SIZE CHANGE........................................3-90

3.11.7 PICK-UP, FEED, SEPARATION ROLLER REPLACEMENT .......3-93

3.11.8 FEED UNIT...................................................................................3-94

3.11.9 SEPARATION ROLLER PRESSURE ADJUSTMENT..................3-96

3.11.10 RELAY SENSOR........................................................................3-97

3.11.11 BY-PASS PAPER SIZE DETECTION BOARD...........................3-98

3.11.12 BY-PASS TRAY ROLLERS........................................................3-99

3.11.13 BY-PASS SEPARATION ROLLER PRESSURE

ADJUSTMENT .........................................................................3-100

3.11.14 REGISTRATION SENSOR.......................................................3-101

3.11.15 REGISTRATION AND BY-PASS UNIT REMOVAL..................3-102

3.12 PCBS AND HDD .................................................................................3-104

3.12.1 BCU BOARD (BASE ENGINE CONTROL UNIT).......................3-104

3.12.2 CONTROLLER BOARD .............................................................3-105

3.12.3 IPU BOARD (IMAGE PROCESSING UNIT)...............................3-106

3.12.4 DEVELOPMENT POWER PACK ...............................................3-106

3.12.5 PSU, PFC BOARDS...................................................................3-107

3.12.6 HDD ............................................................................................3-107

3.12.7 NVRAM.......................................................................................3-108

3.13 ADF.....................................................................................................3-109

3.13.1 ADF COVERS............................................................................3-109

3.13.2 FEED UNIT.................................................................................3-110

3.13.3 FEED BELT AND PICK-UP ROLLER.........................................3-111

3.13.4 SEPARATION ROLLER.............................................................3-112

3.13.5 REGISTRATION SENSOR.........................................................3-113

3.13.6 ADF CONTROL BOARD............................................................3-114

3.13.7 ORIGINAL WIDTH, INTERVAL, AND SKEW CORRECTION

SENSORS..................................................................................3-115

3.13.8 ORIGINAL LENGTH SENSORS ................................................3-116

3.13.9 DF POSITION AND APS SENSOR............................................3-117

3.13.10 OTHER ADF SENSORS ..........................................................3-118

3.13.11 BOTTOM PLATE LIFT MOTOR ...............................................3-119

3.13.12 FEED MOTOR..........................................................................3-120

3.13.13 EXIT MOTOR AND TRANSPORT MOTOR .............................3-121

3.13.14 PICK-UP ROLLER MOTOR AND HP SENSOR.......................3-122

3.13.15 CIS POWER SUPPLY BOARD AND CIS UNIT .......................3-123

3.13.16 ADF EXIT SENSOR.................................................................3-124

3.14 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING ...................3-125

3.14.1 PRINTING ..................................................................................3-125

Registration - Leading Edge/Side-to-Side.........................................3-125

Blank Margin.....................................................................................3-126

Registration Buckle Adjustment........................................................3-126

v

3.14.2 SCANNING.................................................................................3-127

Registration: Platen Mode.................................................................3-127

Magnification.....................................................................................3-127

3.14.3 ADF SCANNING ADJUSTMENTS.............................................3-128

Vertical Black Lines ..........................................................................3-128

DIP Switch Settings (ADF Main Board).............................................3-128

ADF Skew Correction.......................................................................3-129

3.15 TOUCH SCREEN CALIBRATION.......................................................3-130

4. TROUBLESHOOTING ................................................................ 4-1

4.1 PROGRAM DOWNLOAD..........................................................................4-1

4.1.1 OVERVIEW......................................................................................4-1

4.1.2 RECOVERY METHODS...................................................................4-1

4.1.3 IMPORTANT SP CODES.................................................................4-2

4.1.4 DOWNLOAD ERROR CODES.........................................................4-3

4.2 CONTROLLER BOARD SELF-DIAGNOSTIC TEST.................................4-5

4.3 JAM DETECTION......................................................................................4-6

4.3.1 SENSOR LOCATIONS.....................................................................4-6

4.3.2 TIMING CHARTS.............................................................................4-7

Feed, Transport, Feed Out: Face-up ....................................................4-7

Transport, Inverter, Feed Out: Face-down............................................4-8

Duplex Transport..................................................................................4-9

4.4 SERVICE CALL CONDITIONS...............................................................4-10

4.4.1 SUMMARY.....................................................................................4-10

4.4.2 SC CODE DESCRIPTIONS ...........................................................4-11

Scanning System................................................................................4-11

Image Development System (1) .........................................................4-14

Image Development System (2) .........................................................4-19

Feed, Transport, Duplexing, and Fusing Systems..............................4-20

Data Communication..........................................................................4-23

Peripherals.......................................................................................... 4-25

Overall System ...................................................................................4-28

Miscellaneous.....................................................................................4-31

4.4.3 ADDITIONAL SC CODES PRINTED IN SMC REPORT ................4-33

4.5 BLOWN FUSE CONDITIONS.................................................................4-35

4.6 COMMON PROBLEMS...........................................................................4-35

5. SERVICE TABLES...................................................................... 5-1

5.1 SERVICE PROGRAM MODE....................................................................5-1

5.1.1 SERVICE PROGRAM MODE OPERATION.....................................5-1

To Enter and Exit the SP Mode ............................................................5-1

To Switch to the Copy Window for Test Printing...................................5-1

Using the SP Mode...............................................................................5-2

SP Mode Button Summary...................................................................5-3

5.2 RESETS....................................................................................................5-4

5.2.1 MEMORY ALL CLEAR: SP5801 ......................................................5-4

5.2.2 SOFTWARE RESET........................................................................5-5

5.3 TEST PATTERN PRINTING......................................................................5-6

5.3.1 IPU FRONT/BACK TEST PATTERNS: SP2902 001,002.................5-6

vi

Test Pattern Table................................................................................5-7

5.3.2 PRINTING TEST PATTERN: SP2902 003.......................................5-8

5.3.3 IPU PRINTING TEST PATTERN: SP2902 004................................5-9

5.4 SOFTWARE UPDATE.............................................................................5-10

5.4.1 OVERVIEW....................................................................................5-10

5.4.2 SOFTWARE UPDATE PROCEDURE............................................5-11

GW Controller/BCU Update................................................................5-11

Forced Update....................................................................................5-12

Stamp Data Update............................................................................5-12

Operation Panel Software Update......................................................5-13

Printer Update.....................................................................................5-13

Scanner Update..................................................................................5-14

NIB Update.........................................................................................5-14

NetFile Firmware Update....................................................................5-14

NVRAM Firmware Update..................................................................5-15

5.5 USER TOOLS.........................................................................................5-16

5.5.1 OVERVIEW....................................................................................5-16

5.5.2 SYSTEM SETTINGS......................................................................5-17

5.5.3 COPIER/DOCUMENT SERVER FEATURES ................................5-18

5.5.4 PRINTER........................................................................................ 5-20

5.5.5 SCANNER......................................................................................5-21

5.5.6 INQUIRY.........................................................................................5-21

5.5.7 COUNTER......................................................................................5-21

5.6 SERVICE PROGRAM MODE TABLES...................................................5-22

5.6.1 COPIER SERVICE TABLE.............................................................5-22

SP1-xxx Feed.....................................................................................5-22

SP2-xxx Drum.....................................................................................5-26

SP3xxx Processing.............................................................................5-40

SP4-xxx Scanner................................................................................5-42

SP5-xxx Mode ....................................................................................5-52

SP6-xxx Peripherals...........................................................................5-68

SP7-xxx Data Logs.............................................................................5-71

5.6.2 PRINTER SERVICE TABLE...........................................................5-78

5.6.3 SCANNER SERVICE TABLE.........................................................5-79

5.7 INPUT/OUTPUT CHECK ........................................................................5-86

5.7.1 INPUT CHECK: SP5803.................................................................5-86

5.7.2 OUTPUT CHECK: SP5804.............................................................5-91

5.7.3 ADF INPUT CHECK: SP6007 ........................................................5-92

5.7.4 ADF OUTPUT CHECK: SP6008 ....................................................5-93

6. DETAILED DESCRIPTIONS....................................................... 6-1

6.1 OVERVIEW...............................................................................................6-1

6.1.1 PAPER PATH (WITH COVER INTERPOSER TRAY)......................6-3

6.1.2 PAPER PATH (WITH 9-BIN MAILBOX) ...........................................6-4

6.1.3 DRIVE LAYOUT...............................................................................6-5

6.2 BOARD STRUCTURE...............................................................................6-6

6.2.1 BLOCK DIAGRAM............................................................................6-6

6.2.2 COMPONENT DESCRIPTIONS ......................................................6-7

BCU (Base Engine Control Unit)...........................................................6-7

vii

Controller Board....................................................................................6-7

MB (Mother Board)...............................................................................6-7

IPU (Image Processing Unit)................................................................6-7

SBU (Sensor Board Unit)......................................................................6-8

PFC (Paper Feed Control)....................................................................6-8

SDRB (Scanner Driver Board)..............................................................6-8

VIB (Video Interface Board)..................................................................6-8

DRB (Drive Board)................................................................................6-8

CNB (Connection Board)......................................................................6-8

HDD (Hard Disk Drive)..........................................................................6-9

6.3 COPY PROCESS OVERVIEW ...............................................................6-10

6.4 ADF.........................................................................................................6-12

6.4.1 OVERVIEW....................................................................................6-12

6.4.2 ADF DRIVE LAYOUT..................................................................... 6-13

6.4.3 PICK-UP ROLLER LIFT .................................................................6-14

6.4.4 BOTTOM PLATE LIFT....................................................................6-15

6.4.5 ORIGINAL SEPARATION..............................................................6-16

6.4.6 ORIGINAL TRANSPORT............................................................... 6-17

6.4.7 ORIGINAL SKEW CORRECTION.................................................. 6-18

6.4.8 ORIGINAL SIZE DETECTION........................................................6-20

6.4.9 ADF SCANNING.............................................................................6-23

6.4.10 JAM DETECTION.........................................................................6-24

6.5 SCANNING..............................................................................................6-25

6.5.1 OVERVIEW....................................................................................6-25

6.5.2 SCANNER DRIVE..........................................................................6-26

6.5.3 ORIGINAL SIZE DETECTION........................................................6-27

Sensors...............................................................................................6-27

Detection Timing.................................................................................6-28

6.5.4 SCANNING MAGNIFICATION.......................................................6-29

Book Mode..........................................................................................6-29

6.5.5 AUTO IMAGE DENSITY (ADS)......................................................6-30

Xenon Lamp ! CCD ADS..................................................................6-30

CIS ADS .............................................................................................6-30

6.6 IMAGE PROCESSING............................................................................6-31

6.6.1 OVERVIEW....................................................................................6-31

6.6.2 IMAGE PROCESSING FLOW........................................................6-32

6.6.3 IMAGE PROCESSING MODES.....................................................6-33

6.6.4 IMAGE QUALITY SP ADJUSTMENTS...........................................6-34

6.6.5 RELATION BETWEEN THE SP AND UP SETTINGS ....................6-40

6.6.6 IMAGE PROCESSING TROUBLESHOOTING ..............................6-42

6.7 LASER EXPOSURE................................................................................6-45

6.7.1 OVERVIEW....................................................................................6-45

OPTICAL PATH..................................................................................6-46

6.7.3 FOUR-BEAM EXPOSURE.............................................................6-47

6.7.4 COOLING FAN...............................................................................6-48

6.7.5 LD SAFETY SWITCHES................................................................6-49

6.8 DRUM UNIT ............................................................................................6-50

6.8.1 OVERVIEW....................................................................................6-50

6.8.2 OPC DRUM....................................................................................6-51

viii

6.8.3 DRUM DRIVE.................................................................................6-51

6.8.4 DRUM CHARGE.............................................................................6-51

6.8.5 CHARGE CORONA WIRE CLEANING..........................................6-52

6.8.6 DRUM PICK-OFF MECHANISM.................................................... 6-53

6.8.7 DRUM CLEANING..........................................................................6-54

6.8.8 DRUM VENTILATION AND OZONE FILTER.................................6-55

6.8.9 TONER RECYCLING.....................................................................6-56

6.8.10 WASTE TONER COLLECTION ...................................................6-57

Mechanism .........................................................................................6-57

Error Detection....................................................................................6-57

6.8.11 PROCESS CONTROL..................................................................6-58

What Happens at Power On...............................................................6-58

Drum Potential Sensor Calibration......................................................6-59

Development Bias, Bias Grid, and LD Adjustment..............................6-60

ID Sensor Calibration (Vsg)................................................................6-62

TD Sensor Calibration (Vref)...............................................................6-62

6.9 DEVELOPMENT AND TONER SUPPLY................................................6-63

6.9.1 OVERVIEW....................................................................................6-63

Development Unit...............................................................................6-63

Toner Supply ......................................................................................6-64

6.9.2 DEVELOPMENT UNIT...................................................................6-65

6.9.3 DEVELOPER/TONER MIXING (AGITATION)................................6-66

6.9.4 DEVELOPMENT BIAS...................................................................6-67

6.9.5 TONER SUPPLY............................................................................6-68

6.9.6 DEVELOPMENT UNIT DRIVE AND VENTILATION......................6-69

6.9.7 TONER END SENSOR ..................................................................6-70

6.9.8 SHUTTER MECHANISM................................................................6-70

6.9.9 TONER BOTTLE SUPPLY AND VENTILATION............................6-71

6.9.10 TONER SUPPLY CONTROL .......................................................6-72

Sensor Control Mode..........................................................................6-72

Pixel Count Toner Supply Mode.........................................................6-73

TD Sensor Initialization.......................................................................6-74

Determining Vref.................................................................................6-74

Toner Supply without ID Sensor and TD Sensors.............................. 6-75

Abnormal TD Sensor Output...............................................................6-75

Abnormal ID Sensor Output................................................................6-75

Toner End Detection...........................................................................6-76

Toner End Recovery...........................................................................6-76

6.10 IMAGE TRANSFER AND PAPER SEPARATION.................................6-77

6.10.1 OVERVIEW..................................................................................6-77

6.10.2 TRANSFER BELT LIFT................................................................6-78

Mechanism .........................................................................................6-78

Timing.................................................................................................6-79

6.10.3 TRANSFER BELT CHARGE........................................................6-80

6.10.4 TRANSFER CURRENT SETTINGS.............................................6-81

6.10.5 TRANSFER CURRENT CIRCUIT................................................6-82

6.10.6 TRANSFER BELT DRIVE AND PAPER TRANSPORT................6-83

6.10.7 TRANSFER BELT CLEANING.....................................................6-84

6.10.8 ANTI-CONDENSATION HEATER................................................6-85

ix

6.11 PAPER FEED........................................................................................6-86

6.11.1 OVERVIEW..................................................................................6-86

Tray Capacities...................................................................................6-87

Built-in Feed Stations..........................................................................6-87

By-pass Feed......................................................................................6-87

Paper Registration..............................................................................6-87

Jam Removal......................................................................................6-87

6.11.2 DRIVE...........................................................................................6-88

6.11.3 TRAY AND PAPER LIFT MECHANISM – TRAY 2,3....................6-89

Bottom Plate Lift .................................................................................6-89

Lift Sensor...........................................................................................6-90

6.11.4 PAPER FEED AND SEPARATION MECHANISM........................6-91

Paper Feed and Separation: No Paper Present .................................6-91

Paper Feed and Separation................................................................6-92

Separation Roller Release Mechanism...............................................6-93

6.11.5 PAPER NEAR-END AND PAPER END – TRAYS 2 AND 3.........6-94

6.11.6 PAPER SIZE DETECTION...........................................................6-95

Tandem Tray (Tray 1).........................................................................6-95

Universal Paper Cassettes (Tray 2, 3)................................................6-95

6.11.7 ANTI-CONDENSATION HEATERS..............................................6-96

6.11.8 TANDEM TRAY – TRAY 1...........................................................6-97

Overview............................................................................................. 6-97

Connecting the Left and Right Sides of the Tray................................6-98

Paper Lift/Remaining Paper Detection................................................6-99

Fence Drive ......................................................................................6-101

Rear Fence Drive..............................................................................6-102

Tray Side-to-side Positioning............................................................6-103

6.11.9 TRAY POSITIONING MECHANISM – TRAYS 1 TO 3...............6-104

6.11.10 BY-PASS TRAY........................................................................6-105

By-pass Feed and Separation ..........................................................6-105

By-pass Tray Paper End Detection...................................................6-106

By-pass Paper Size Detection..........................................................6-107

6.11.11 PAPER REGISTRATION..........................................................6-108

Overview........................................................................................... 6-108

Paper Registration Drive...................................................................6-109

Jam Removal at Paper Registration.................................................6-110

6.12 IMAGE FUSING AND PAPER EXIT....................................................6-111

6.12.1 OVERVIEW................................................................................6-111

6.12.2 FUSING MECHANISM...............................................................6-112

6.12.3 PRESSURE ROLLER.................................................................6-113

6.12.4 HOT ROLLER CLEANING .........................................................6-114

Overview........................................................................................... 6-114

Web Drive.........................................................................................6-115

Web Near-end ..................................................................................6-115

Web End...........................................................................................6-115

6.12.5 FUSING UNIT ENTRANCE GUIDE............................................6-116

6.12.6 FUSING UNIT DRIVE.................................................................6-117

6.12.7 CPM DOWN MODE....................................................................6-118

6.12.8 FUSING TEMPERATURE CONTROL........................................6-118

x

6.12.9 EXIT............................................................................................6-120

6.12.10 EXIT JUNCTION GATE............................................................6-121

6.13 DUPLEX UNIT.....................................................................................6-122

6.13.1 OVERVIEW................................................................................6-122

6.13.2 DUPLEX DRIVE.........................................................................6-123

6.13.3 INVERTER OPERATION...........................................................6-124

Inverter Feed-in and Jogging............................................................6-124

Inverter Feed-out..............................................................................6-125

6.13.4 DUPLEX TRAY FEED................................................................6-126

6.13.5 DUPLEX INTERLEAVE FEED ...................................................6-127

6.14 ENERGY SAVER MODES..................................................................6-129

6.14.1 OVERVIEW................................................................................6-129

6.14.1 ENERGY SAVER MODE............................................................6-130

Entering the energy saver mode.......................................................6-130

What happens in energy saver mode...............................................6-130

Return to stand-by mode..................................................................6-130

6.14.2 LOW POWER MODE.................................................................6-131

Entering the low power mode ...........................................................6-131

What happens in low power mode....................................................6-131

Return to stand-by mode..................................................................6-131

6.14.3 AUTO OFF MODE......................................................................6-132

Entering auto off mode......................................................................6-132

What happens in auto off mode........................................................6-132

Returning to stand-by mode..............................................................6-132

Disabling auto off mode....................................................................6-132

6.14.4 NIGHT MODE.............................................................................6-133

Entering night stand-by and night modes..........................................6-133

What happens in night stand-by and night modes............................6-133

Returning to stand-by mode..............................................................6-133

xi

PERIPHERALS
A3/DLT FEEDER KIT (B475)

1. REPLACEMENT AND ADJUSTMENT..................................B475-1

1.1 BOTTOM PLATE LIFT WIRE REPLACEMENT................................. B475-1

1.1.1 REMOVING THE LIFT WIRE.................................................... B475-1

1.1.2 INSTALLING THE LIFT WIRE................................................... B475-2

2. DETAILS...............................................................................B475-3

LCT (B473)

1. REPLACEMENT AND ADJUSTMENT..................................B473-1

1.1 EXTERNAL COVERS ........................................................................ B473-1

1.2 PICK-UP/FEED/SEPARATION ROLLERS......................................... B473-2

1.3 PICK-UP SOLENOID......................................................................... B473-3

1.4 PAPER END SENSOR, UPPER COVER SWITCHES....................... B473-4

1.5 TRAY MOTOR.................................................................................... B473-5

1.6 PAPER STACK SENSOR.................................................................. B473-5

1.7 PAPER SIZE ADJUSTMENT............................................................. B473-6

2. DETAILS...............................................................................B473-7

2.1 OVERVIEW........................................................................................ B473-7

2.1.1 LCT MAIN COMPONENTS....................................................... B473-7

2.1.2 LCT DRIVE LAYOUT................................................................. B473-9

2.2 PAPER FEED AND SEPARATION.................................................. B473-10

2.2.1 STARTING PAPER FEED....................................................... B473-10

2.2.2 FEED AND SEPARATION...................................................... B473-11

2.3 PAPER LIFT..................................................................................... B473-12

2.4 PAPER HEIGHT DETECTION......................................................... B473-14

2.5 PAPER END DETECTION............................................................... B473-15

3000-SHEET FINISHERS (B468/B469)

1. REPLACEMENT AND ADJUSTMENT..................................B468-1

1.1 EXTERNAL COVERS ........................................................................ B468-1

1.2 POSITIONING ROLLER..................................................................... B468-2

1.3 INNER COVER...................................................................................B468-2

1.4 BRUSH ROLLER................................................................................ B468-3

1.5 LOWER TRAY PAPER HEIGHT SENSORS 1, 2............................... B468-4

1.6 PROOF TRAY EXIT AND FULL SENSORS ...................................... B468-5

1.7 EXIT SENSOR ................................................................................... B468-6

1.8 FINISHER, STAPLER ENTRANCE SENSORS................................. B468-7

1.9 SADDLE-STITCH STAPLER REPLACEMENT.................................. B468-8

xii

1.10 PUNCH POSITION ADJUSTMENT................................................ B468-10

1.11 JAM DETECTION........................................................................... B468-11

1.12 DIP SW 100 (MAIN BOARD).......................................................... B468-12

2. DETAILS.............................................................................B468-13

2.1 OVERVIEW...................................................................................... B468-13

2.2 DRIVE LAYOUT............................................................................... B468-14

2.3 TRAY/STAPLER JUNCTION GATES.............................................. B468-16

2.4 PRE-STACKING............................................................................... B468-17

2.5 VERTICAL LIFT MECHANISM......................................................... B468-18

2.5.1 OVERVIEW............................................................................. B468-18

2.5.2 UPPER TRAY.......................................................................... B468-19

Just After the Power is Switched on ............................................ B468-19

Height Adjustment During Feed-Out............................................ B468-19

Upper Tray Full............................................................................ B468-19

2.5.3 LOWER TRAY......................................................................... B468-20

Just After the Power is Switched on ............................................ B468-20

Positioning the Lower Tray for Feed-out...................................... B468-20

Lower Tray Height Adjustment During Feed-out .......................... B468-20

Lower Tray Full............................................................................ B468-21

2.6 SHIFT MECHANISM........................................................................ B468-22

2.7 PAPER POSITIONING..................................................................... B468-23

2.8 STAPLER......................................................................................... B468-24

2.8.1 STAPLING MECHANISM........................................................ B468-24

2.8.2 STAPLER MOVEMENT........................................................... B468-25

Horizontal Stapler Movement.......................................................B468-25

Rotational Stapler Movement....................................................... B468-26

2.8.3 FEED OUT .............................................................................. B468-27

2.9 BOOKLET FINISHING ..................................................................... B468-28

2.9.1 OVERVIEW............................................................................. B468-28

2.9.2 BOOKLET STAPLING AND FOLDING....................................B468-28

2.9.3 INITIAL FOLDING....................................................................B468-29

2.9.4 FINAL FOLDING AND FEED-OUT.......................................... B468-30

PUNCH UNIT (B377)

1. REPLACEMENT AND ADJUSTMENT..................................B377-1

1.1 PUNCH POSITION ADJUSTMENT.................................................... B377-1

2. DETAILS...............................................................................B377-2

2.1.1 PUNCH DRIVE MECHANISM................................................... B377-2

2.1.2 PUNCH WASTE COLLECTION................................................ B377-4

COVER INTERPOSER TRAY (B470)

1. REPLACEMENT AND ADJUSTMENT..................................B470-1

1.1 EXTERNAL COVERS ........................................................................ B470-1

xiii

1.2 FEED UNIT AND PICK-UP ROLLER................................................. B470-2

1.3 FEED BELT........................................................................................ B470-3

1.4 GUIDE PLATE ADJUSTMENT........................................................... B470-4

1.5 MAIN BOARD..................................................................................... B470-5

1.6 MOTOR REPLACEMENT.................................................................. B470-6

1.6.1 VERTICAL TRANSPORT MOTOR............................................ B470-6

1.6.2 BOTTOM PLATE LIFT MOTOR ................................................ B470-6

1.6.3 FEED MOTOR, TRANSPORT MOTOR .................................... B470-7

2. DETAILS...............................................................................B470-8

2.1 OVERVIEW........................................................................................ B470-8

2.1.1 MAIN LAYOUT.......................................................................... B470-8

2.1.2 DRIVE LAYOUT........................................................................ B470-9

2.1.3 PAPER SIZE DETECTION...................................................... B470-10

2.1.4 PAPER PATH.......................................................................... B470-13

2.2 PAPER FEED................................................................................... B470-14

Power On..................................................................................... B470-14

Paper Separation and Feed......................................................... B470-14

Bottom Tray Lift ........................................................................... B470-14

Paper Near-end........................................................................... B470-14

Paper End.................................................................................... B470-14

9-BIN MAILBOX (B471)

1. REPLACEMENT AND ADJUSTMENT..................................B471-1

1.1 COVERS AND TRAYS....................................................................... B471-1

1.2 SENSORS.......................................................................................... B471-2

1.3 MAIN MOTOR AND CONTROL BOARD ........................................... B471-3

2. DETAILS...............................................................................B471-4

2.1 OVERVIEW........................................................................................ B471-4

2.1.1 MAIN COMPONENT LAYOUT.................................................. B471-4

2.1.2 DRIVE LAYOUT........................................................................ B471-5

2.1.3 PAPER PATH............................................................................ B471-6

2.2 BASIC OPERATION........................................................................... B471-7

2.2.1 PAPER PATH............................................................................ B471-7

2.3 OVERFLOW DETECTION................................................................. B471-8

2.3.1 OVERVIEW............................................................................... B471-8

2.3.2 DETECTION TIMING................................................................ B471-9

2.4 PAPER MISFEED DETECTION TIMING......................................... B471-10

2.4.1 A4 SIDEWAYS (LEF) ! 1ST BIN TRAY................................. B471-10

2.4.2 A4 SIDEWAYS (LEF) ! 2ND ~ 9TH BIN TRAY..................... B471-10

PRINTER/SCANNER KIT (G338), PRINTER UNIT (G339)

1. DETAILS...............................................................................G338-1

1.1 MACHINE LAYOUT............................................................................G338-1

xiv

1.2 CONTROLLER BOARD.....................................................................G338-2

1.2.1 CONTROLLER BOARD LAYOUT.............................................G338-2

1.2.2 CONTROLLER BOARD DIP SWITCHES..................................G338-4

1.2.3 LED INDICATORS.....................................................................G338-4

1.3 ETHERNET BOARD ..........................................................................G338-5

1.3.1 ETHERNET BOARD LAYOUT ..................................................G338-5

1.3.2 ETHERNET BOARD OPERATION............................................G338-6

1.4 IEEE1394 BOARD (FIREWIRE).........................................................G338-7

1.4.1 OVERVIEW...............................................................................G338-7

1.5 USB....................................................................................................G338-9

1.5.1 SPECIFICATIONS.....................................................................G338-9

1.5.2 USB 1.1/2.0...............................................................................G338-9

1.5.3 USB CONNECTORS...............................................................G338-10

1.5.4 PIN ASSIGNMENT..................................................................G338-10

1.5.5 REMARKS ABOUT USB.........................................................G338-11

Related SP Mode.........................................................................G338-11

1.6 IEEE802.11B (WIRELESS LAN)......................................................G338-12

1.6.1 SPECIFICATIONS...................................................................G338-12

1.6.2 BLOCK DIAGRAM...................................................................G338-13

1.6.3 TRANSMISSION MODES.......................................................G338-14

Ad Hoc Mode...............................................................................G338-14

Infrastructure Mode......................................................................G338-14

1.6.4 SECURITY FEATURES..........................................................G338-15

Using the SSID in Ad hoc mode ..................................................G338-15

1.6.5 WIRELESS LAN TROUBLESHOOTING NOTES....................G338-16

Communication Status.................................................................G338-16

Channel Settings .........................................................................G338-16

Troubleshooting Procedure..........................................................G338-17

2. SPECIFICAT ION S...............................................................G338-18

2.1 SCANNER........................................................................................G338-18

2.2 PRINTER..........................................................................................G338-19

2.3 CONTROLLER BOARD CONFIGURATION....................................G338-20

2.4 SOFTWARE ACCESSORIES..........................................................G338-21

2.4.1 PRINTER.................................................................................G338-21

Printer Drivers..............................................................................G338-21

Printer Utility Software .................................................................G338-21

2.5 PAPER SIZES SUPPORTED BY THE PRINTER............................G338-22

2.6 USB SPECIFICATIONS.............................................................G338-23

2.7 IEEE 802.11B SPECIFICATIONS ..............................................G338-23

xv

SPECIFICATIONS

SPECIFICATIONS.....................................................................SPEC-1

1. GENERAL SPECIFICATIONS.............................................................SPEC-1

1.1 COPIER .......................................................................................SPEC-1

1.2 ADF .............................................................................................SPEC-2

1.3 POWER CONSUMPTION...........................................................SPEC-3

2. MACHINE CONFIGURATION.............................................................SPEC-4

3. OPTIONAL EQUIPMENT....................................................................SPEC-5

3.1 A3/DLT KIT B475 ........................................................................SPEC-5

3.2 LCT (LARGE CAPACITY TRAY) B473........................................SPEC-5

3.3 3000-SHEET FINISHER WITH SADDLE-STITCH AND

50-SHEET STAPLER B468.........................................................SPEC-5

3.3.1 UPPER TRAY.....................................................................SPEC-5

3.3.2 LOWER TRAY....................................................................SPEC-6

3.3.3 PROOF TRAY.....................................................................SPEC-6

3.3.4 STAPLE SPECIFICATIONS...............................................SPEC-6

3.3.5 LOWER TRAY....................................................................SPEC-6

3.4 3000-SHEET FINISHER WITH 50-SHEET STAPLER B468.......SPEC-7

3.4.1 LOWER TRAY....................................................................SPEC-7

3.4.2 PROOF TRAY.....................................................................SPEC-7

3.4.3 STAPLE SPECIFICATIONS...............................................SPEC-7

3.4.4 LOWER TRAY....................................................................SPEC-7

3.5 PUNCH UNIT FOR B468/B469...................................................SPEC-8

3.6 COVER INTERPOSER TRAY B470............................................SPEC-8

3.7 9-BIN MAILBOX B471.................................................................SPEC-9

xvi

26 April, 2002 INSTALLATION REQUIREMENTS

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 OPERATING ENVIRONMENT

1. Temperature Range:

2. Humidity Range:

3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight or

4. Ventilation: Room air should turn over at least 3 times per hour

5. Ambient Dust: Less than 0.10 mg/m

Humidity

80%

54%

Recommended: 15°C to 25°C (59°F to 77°F)
Possible: 10°C to 32°C (50°F to 90°F)

15% to 80% RH (27°C 80%, 32°C 54%)

strong light.)

3

Operation range

Installation

15%

10°C

(50°F)

27°C

(80.6°F)

32°C

(89.6°F)

Temperature

B039I502.WMF

6. If the place of installation is air-conditioned or heated, do not place the machine
where it will be:

1) Subjected to sudden temperature changes

2) Directly exposed to cool air from an air-conditioner

3) Directly exposed to heat from a heater

1-1

INSTALLATION REQUIREMENTS 26 April, 2002

7. Do not place the machine where it will be expos ed to corrosive gases.

8. Do not install the machine at any location over 2,000 m (6,500 feet) above sea
level.

9. Place the copier on a strong and level base with the front and back of the
machine within ±5 mm (0.2") of level.

10. Do not place the machine where it may be subjected to strong vibrations.

11. Do not connect the machine to a power source shared with another electrical
appliance.

12. The machine can generate a an electromagnetic field which could interfere with
radio or television reception.

1.1.2 MACHINE LEVEL

1. Front to back:

2. Right to left:

The machine legs may be screwed up or down in order to level the machine. Set a
carpenter’s level on the exposure glass.

Within ±5 mm (0.2") of level
Within ±5 mm (0.2") of level

1-2

26 April, 2002 INSTALLATION REQUIREMENTS

1.1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing minimum clearance as shown
below. The same amount of clearance is necessary when optional peripheral
devices are installed.

50 mm (2") Back

Installation

100 mm (4") Left

1.1.4 DIMENSIONS

1,198 mm (43.2")

700 mm (27.6") Front

480 mm (18.9")

40 mm (1.6") Right

B064I001.WMF

425 mm (16.7")

1,165 mm (45.9")

1,014 mm (39.9")

620 mm (24.4")

90 mm (3.5")

690 mm (27.2")734 mm (28.9")

314 mm (12.4")

B064I003.WMF

750 mm (29.5")

458 mm (18")

B064I002.WMF

1-3

INSTALLATION REQUIREMENTS 26 April, 2002

1.1.5 POWER REQUIREMENTS

!

CAUTION

1. Make sure that the wall outlet is near the main machine and easily
accessible. Make sure the plug is firmly inserted in the outlet.

2. Avoid multi-wiring.

3. Be sure to ground the machine.

4. Never set anything on the power cord.

North America 120 V, 60 Hz: More th an 12 AInput voltage level
Europe/Asia 220 V ~ 240 V, 50 Hz/60 Hz: more than 8 A

Permissible voltage fluctuation

!

CAUTION
Never turn off the main power switch when the power LED is lit or flashing.
To avoid damaging the hard disk or memory, press the operation power
switch to switch the power off, wait for the power LED to go off, and then
switch the main power switch off.

±10%

The Main Power LED (!) lights or flashes at the following times:

• While the platen cover or ADF is open

• While the main machine is communicating with the network server

• While the machine is accessing the hard disk or memory when reading or

writing data.

There are two power switches on the machine:

• Main Power Switch.
Located on the front left corner of the mac hine a nd cov er ed by a plastic cover.
This switch should always remain on unless the machine is being serviced.

• Operation Power Switch.
Located on the right side of the operation panel. This is the switch normally used
by the customer to power the machine on and off.

1-4

26 April, 2002 MAIN MACHINE (B064/B065)

1.2 MAIN MACHINE (B064/B065)

1.2.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Model Name Decal................................................................ 1

2. Operation Instructions............................................................ 2

3. NECR with Envelope............................................................. 1

4. Operation Panel Brand Decal................................................ 1

5. Paper Size Decal................................................................... 1

6. Decal – Face Up.................................................................... 1

7. Leveling Shoes...................................................................... 2

8. Operation Instruction Holder.................................................. 1

9. Decal – Cleaning ................................................................... 1

Installation

1-5

MAIN MACHINE (B064/B065) 26 April, 2002

1.2.2 INSTALLATION PROCEDURE

Removing Tapes and Retainers

!

CAUTION
To avoid serious injury, do not connect the power plug to the machine until
you are instructed to do so.

[C]

[A]

[B]

B064I403.WMF

[D]

1. Unpack the machine and remove all the wrapping.

2. Remove all filament tape from the front [A] of the machine.

B064I404.WMF

3. Open the lower tray [B] and remove the operating instructions holder and foot
risers.

4. Open the ADF feed cover and remove the tape and retainer [C].

5. Remove the tape from the back [D] of the machine.
NOTE: Save the filament tape and shipping retainers to prepare the machine

for shipping in the future.

1-6

26 April, 2002 MAIN MACHINE (B064/B065)

6. Raise the ADF and remove all the
tape and shipping retainers around the
exposure glass [A] and operation

[B]

panel.

7. Remove the shipping retaining sheet
[B] under the white pad.

[A]

B064I005.WMF

[C]

8. Open the front door, open the toner
bottle holder [C], then remove all tape
and shipping retainers.

Installation

9. Remove the PCU inner cover [D] ("
x2) and disconnect the fan motor [E]
(# x 1).

B064I007.WMF

[E]

[D]

B064I008.WMF

1-7

MAIN MACHINE (B064/B065) 26 April, 2002

10. Lower the transfer unit by turning its
knob [A].

11. Remove the bracket [B], and the red
tag from the transfer belt (" x1).

12. Remove the pin [C], and the red tag
from the cleaning plate.

[C]

[B]

13. Open the tandem tray (top paper
tray) and remove the metal retainer
bracket [D] (" x1), wire, and red tag.

Connecting the ADF

Connect the ADF plug [A] to the
connector on the back of the machine.

[D]

[A]

B064I009.WMF

B064I401.WMF

1-8

[A]

B064I405.WMF

26 April, 2002 MAIN MACHINE (B064/B065)

Removing and Filling the Development Unit

1. Remove shutter cover [A] of the toner
supply unit (" x1).

2. Remove the lock screw [B] from the toner
bottle open/close bracket.

3. Make sure that the shipping tape at [C]
has been removed.

4. Pull the toner bottle holder out and swing
the toner bottle holder to the right.

NOTE: After re-installation, the tab [D]

should be behind the stay and
its pin below should be in the
open track below.

5. Remove the face plate [E] of the
development unit (knob x1, " x2).

[A]

[C]

Installation

[D]

[B]

B064I300.WMF

6. Disconnect the development unit [F]
(# x2).
NOTE: If the LCT is installed, you may

need to disconnect it so the front
door can open far enough to
allow removal of the
development unit.

7. Close the supply pipe shutter [G], and
then while allowing the development unit
[H] to slip to the right, slowly pull it out of
the machine.

[H]

[G]

[F]

[E]

B064I302.WMF

B064I303.WMF

1-9

MAIN MACHINE (B064/B065) 26 April, 2002

8. Remove the toner hopper [A] (" x2).

9. Rotate the toner hopper [B] slightly

[A]

10° to 20° as you slide it up to
remove it.

[B]

B064I304.WMF

10. While turning the knob [C] slowly,
pour in one pack of developer [D]
from one end of the development
unit to the other.
NOTE: Make sure that the

developer is evenly
distributed. Note the
developer lot number
printed on the top edge of
the bag. You will need the
lot number when you
execute SP2963
(Installation Mode).

11. Assembly the developer unit then
re-install it in the machine.

12. Follow the instructions printed on
the inside of the front door to install
the toner bottle.
NOTE: If the door does not close,

make sure that the pipe line
shutter is rotated down.
(See Step 7 above.)

[D]

[C]

B064I305.WMF

1-10

26 April, 2002 MAIN MACHINE (B064/B065)

Re-installing the Development Unit

[A]

B064I310.WMF

When re-installing the development unit, engage the plate ➀ on the front of the
development unit with the silver pin [A] inside the machine, then slide it to the left

➁

toward the drum.

If the unit is installed correctly, you should see the pin above the plate, and the
plate should be flat against the front of the development unit.

Installation

If the development unit will not move past the pin, the couplin gs are not aligned
correctly at the back of the machine. Turn the gear on the front of the developer
unit until the couplings engage at the rear of the machine.

Before closing the front door, make sure that the pipe line shutter is rotated down
to the open position.

1-11

MAIN MACHINE (B064/B065) 26 April, 2002

Initializing the Drum Settings

After switching on the machine, you must execute SP2963 (Installation Mode)
within 60 seconds to 1) Initialize the developer and force toner supply to the
development unit, and 2) Initialize the auto process control settings.

• SP2963 must be executed before sample copying or test printing.

• If you do not press “Execute” in Step 2 in the following procedure within 60

seconds after the machine is switched on, the auto process control features
(potential sensor calibration, Vsg, Vref , et c.) will not initialize co rrectly.

• If the machine starts the auto process control routine before you have a chance

to press Execute, switch the machine off and try again.

1. Connect the power cord.

2. Within one minute, before the auto process control settings initialize, execute
SP2963.

• Press Clear Modes ".

• On the operation panel keypad, press #$%.

• Hold down Clear/Stop & for more than 3 seconds.

• Press “Copy SP” on the touch-panel.

• Press '()*.

• Press Enter +.

• Enter the Developer Lot No. with the key display, then press “Execute”.

About four minutes is required to initialize toner supply and the auto process
control settings.

3. Press “Exit” to leave the SP mode.

4. Attach the appropriate decals (provided) to the paper trays.

5. Check copy quality and machine operation.

NOTE: At installation, use SP2963 to enter the lot number, initialize the developer,

and to force toner supply to the toner hopper.
After replacing developer in a machine that has already been installed, do
not use SP2963; execute SP2801 (TD Sensor Initial Setting) instead to
enter the lot number and initialize the TD sensor. (☛ 3.7.1)

1-12

26 April, 2002 MAIN MACHINE (B064/B065)

Tandem Tray

Before shipping the machine, the tandem tray is set for A4 or LT LEF and must be
adjusted if the customer wants to use the tandem tray for another paper size.

Feed Station Allowed Size

Tandem Tray (Tray 1) A4 LEF, LT LEF
Universal Trays (Trays 1, 2) A3, B4, A4 SEF, DLT, LG, LT SEF

1. Open the front cover.

2. Completely pull out the tandem feed
tray [A] so that the right tandem tray
[B] separates from the left tandem
tray.

Installation

[B]

[A]

B064I564.WMF

3. Remove the right tandem inner cover
[C].

4. Re-position the side fences [D] ("
x2). The outer slot position is used
when loading A4 size paper.

5. Re-install the right tandem in ner
cover [C].

[D]

[C]

B064I565.WMF

1-13

MAIN MACHINE (B064/B065) 26 April, 2002

[B]

6. Remove the tray cover [A] (" x2).

7. Remove the motor cover [B] (" x4).

[A]

B064I566.WMF

[C]

8. Re-position the side fences [C] (" x8).
The outer slot position is used when
loading A4 size paper.

9. Re-install the motor cover and the tray
cover.

10. Remove the rear bottom plate [D]
(" x1).

11. Re-position the return position sensor
bracket [E] (" x1). To use the paper
tray for A4 size, put the screw in the
left hole as shown. (For LT size, the
screw should be placed on the right.)

12. Re-install the rear bottom plate.

B064I523.WMF

[D]

[E]

13. Change the paper size using SP5959­001 (Paper Size – Tray 1). For details,
see SP5959 in section “5. Service
Tables”.

1-14

B064I024.WMF

26 April, 2002 MAIN MACHINE (B064/B065)

Machine Level

1. Set a stand [A] at each corner of the
machine.

2. Place a level on the exposure glass
and use a wrench to turn each nut [B]
and level the machine to ±5 mm of the
horizontal.

3. Check the machine operation. With

[B]

the customer, determine the best
place to attach the cleaning reminder
decal.

Installation

[A]

Date/Time Setting

Use the User Tools menu to set the current date and time.

• On the operation panel, press the User Tools key.

• On the touch-panel, press “System Settings”.

• Press the “Timer Setting” tab.

• Press “Set Date” the enter the date.

• Press “Set Time” to enter the time.

SP Codes

SP5812 001~002

SP5841 001 Supply Name Setting

SP7825 Total Counter Reset

Service Telephone
Number Settings

– Toner Name
Setting: Black

Execute this SP and enter the contact
numbers of the custom engineer. Th ese are
the numbers displayed when a serv ice call is
issued.

This name appears when the user presses t he
Inquiry on the User Tools scre en.

Execute after installation and af t er maki ng al l
test copies to reset the electronic cou nt er
total.

B064I010.WMF

1-15

A3/DLT FEEDER KIT (B475) 26 April, 2002

1.3 A3/DLT FEEDER KIT (B475)

1.3.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. A3/DLT Tray .......................................................................... 1

2. Short connector ..................................................................... 1

3. Page size decals.................................................................... 1

3

2

B475I001.WMF

1

1-16

26 April, 2002 A3/DLT FEEDER KIT (B475)

1.3.2 INSTALLATION PROCEDURE

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

1. Draw out the tandem tray completely
to separate the left and right sides of
the tray, then remove the front cover
[A] (" x2).

2. Push in the right tandem tray [B].

[B]

[A]

Installation

3. Remove the left tandem tray [C]
(" x5). Save these screws.

B475I707.WMF

[C]

B475I708.WMF

1-17

A3/DLT FEEDER KIT (B475) 26 April, 2002

4. Remove the right tandem tray [A] ("
x2). Save these screws.

5. Connect the short connector [B] to the
right tandem tray terminal [C].

[A]

B475I709.WMF

6. Remove the stay [D] (" x2) and re­install it.

7. Attach the A3/DLT tray [E], using the
screws removed earlier.

8. Re-install the front cover.

9. Switch the machine on, enter the SP
mode and select the paper size for
Tray 1 with SP5959 001 (Paper Size –
Tray 1) For details, see SP5959 in
section “5. Service Tables”.

10. Attach the appropriate decal for the
selected paper size.

[C]

[D]

[B]

B475I201.WMF

[E]

B475I202.WMF

1-18

26 April, 2002 LCT (B473)

1.4 LCT (B473)

1.4.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Flat-head shoulder screw - M4x6........................................... 1

2. Upper docking pins (grooved)................................................ 2

3. Lower docking pin (not grooved)............................................ 1

4. Installation Instructions .......................................................... 1

5. Paper Set Decal..................................................................... 1

Installation

1-19

LCT (B473) 26 April, 2002

1.4.2 INSTALLATION PROCEDURE

Removing Tape

[B]

[A]

[C]

B473I001.WMF

B473I002.WMF

1. Remove the filament tape from the body [A] and top cover [B] of the LCT.

2. Remove the tape under the lid [C] of the LCT.

1-20

26 April, 2002 LCT (B473)

Preparing the Main Machine

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

1. Remove the LCT installation cover
[A] from the right side of the machine.
(# x2).

2. Save the screw on the left [B]. You
will need it to install the LCT.

[C]

3. Remove the LCT connector cover [C]
(x1) and the covers over the holes for
the docking pins [D]. (x3)

[A]

Installation

Installing the LCT

1. Insert the two upper docking pins
(grooved) [A] into the upper slots
and the lower docking pin [B] into
the lower slot.

[B]

[D]

B473I003.WMF

[A]

1-21

[B]

B473I004.WMF

LCT (B473) 26 April, 2002

[D]

[C]

[B] [A]

2. Align the holes on the side of the LCT
[A] with the docking pins on the side of
the machine [B], then slowly push the
LCT onto the pins.
NOTE: The release button [C] is used

to unlock the LCT so it can be
disconnected from the
machine.

3. Connect the plug [D] of the LCT power
cord to the side of the machine.

4. Insert the flat-head shoulder screw [E]
into the hole and fasten it to lock the
release lever in place.

For easier access to the hole for the
screw [E], you can remove the right
panel [F] (" x2).

B473I005.WMF

[E]

[F]

B473I006.WMF

5. Switch the machine on and execute
SP5959 005 (Paper Size – Tray 4
(LCT)) to select the paper size. For
details, see SP5959 in section “5.
Service Tables.”

1-22

26 April, 2002 LG/B4 FEEDER KIT (B474)

1.5 LG/B4 FEEDER KIT (B474)

1.5.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Tapping screws - M4x8.......................................................... 4

2. Tapping hex screws - M4x8................................................... 6

3. Harness clamp....................................................................... 1

4. B4/LG frame .......................................................................... 1

5. Front bracket.......................................................................... 1

6. Rear bracket.......................................................................... 1

7. Bottom plate extension .......................................................... 1

8. Cover..................................................................................... 1

Installation

1-23

LG/B4 FEEDER KIT (B474) 26 April, 2002

1.5.2 INSTALLATION PROCEDURE

If the LCT is connected to the machine

1. Open the cover and remove the paper.

[A]

2. Lower the LCT tray. Cover the near end
sensor [A], then press the tray down button
[B] to lower the tray bottom plate.

3. Disconnect the LCT from the machine
(☛ 1.4.2).

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

[B]

B474I507.WMF

4. Remove the LCT upper cover [C].

[C]

B474I504.WMF

1-24

26 April, 2002 LG/B4 FEEDER KIT (B474)

5. Remove the LCT cover [A] (" x1).

6. Remove the right stay [B] and re­attach it below (" x2).

7. Remove the right cover [C] (" x2).

8. Attach the front bracket [D] with the
beveled corner down (" x2).
NOTE: If the brackets are difficult to

install, raise the bottom plate
with your hand.

9. Attach the rear bracket [E] with the
beveled corner down (" x2).

10. Attach the bottom plate extension [F]
with the hex nuts (" x4).

[B]

[C]

B474I001.WMF

[E]

[A]

[F]

Installation

11. Align the positioning pin [G].

12. Attach the B4/LG frame [H] with the
hex nuts (" x2).

The kit is set for B4. If you need to
change the paper size to LG, do the
following steps.

1-25

[D]

[H]

B474I502.WMF

[G]

B474I553.WMF

LG/B4 FEEDER KIT (B474) 26 April, 2002

13. Move the front side fence [A] to the LG
position and fasten (" x1).

14. Move the rear side fence [B] to the LG
position and fasten (" x1).

15. Change the position of the lower limit
sensor [C] (" x1).

16. Attach the harness (not shown) to the
back of the plate and secure the
sensor connector wire.

[B]

[A]

B474I555.WMF

17. Attach the LCT cover [D] provided with
the kit (" x1).

18. Re-attach the right cover [E] (" x2).

19. Connect the LCT to the machine
(☛ 1.4.2).

20. Switch the machine on, enter the SP
mode, then use SP5959 005 (Paper
Size – Tray 4 (LCT) to select the new
paper size. For details, see SP5959 in
section “5. Service Tables”.

1-26

[C]

B474I508.WMF

[D]

[E]

B474I506.WMF

26 April, 2002 3000-SHEET FINISHERS (B468/B469)

1.6 3000-SHEET FINISHERS (B468/B469)

1.6.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Rear joint bracket................................................................... 1

2. Front joint bracket.................................................................. 1

3. Upper output tray................................................................... 1

4. Lower output tray................................................................... 1

5. Tapping screws - M3x6.......................................................... 2

6. Tapping screws - M4x8.......................................................... 4

7. Tapping screws - M4x14........................................................ 4

8. Cushion (with double-sided tape) .......................................... 1

9. Ground (earth) plate .............................................................. 1

10. Installation Instructions.......................................................... 1

Installation

1-27

3000-SHEET FINISHERS (B468/B469) 26 April, 2002

1.6.2 INSTALLATION PROCEDURE

This section describes the common installation instructions for two peripheral
devices:

• B468 Finisher, capable of punching, shifting, stapling, and saddle-stitching with

staples.

• B469 Finisher, capable of punching, shifting, and stapling but with no saddle-

stitching unit.

NOTE: Differences in the installation procedure are noted as “B468” or “B469”.

Removing Tapes and Retainers

B469B468

B468I001.WMF

1. Unpack the machine and remove
all the wrapping.

2. Remove all filament tape and
shipping retainers from the front
of the finisher.

3. Open the front door [A] and
remove all the tape and shipping
retainers from inside the finisher.

B469I001.WMF

[A]

B468I002.WMF

1-28

26 April, 2002 3000-SHEET FINISHERS (B468/B469)

B468/B469 Installation

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

1. Install the front [A] and rear [B] joint
brackets (" x2 each, M4x14).

[B]

2. Install the ground plate [C] (" x2,
M3x6).

Installation

3. Peel the cover tape from the sponge
cushion [D], then install it in the upper
slot.

4. Remove the screw [E] to release the
lock lever (" x1).

5. Align the brackets [F] with the slots in
the finisher.

6. Slowly and carefully, to avoid bending
the entrance guide plates of the
finisher, push the finisher against the
side of the machine until the brackets
enter the slots.

7. Using the screw [E] removed above,
secure the lock lever [G] (" x1).

8. Connect the plug [H] of the finisher
power cord to the connector on the
machine.

[C]

[E]

[G]

[D]

[A]

B468I003.WMF

[H]

[F]

B468I004.WMF

!

CAUTION
Always move the finisher slowly to avoid bending the entrance guide
plates. Bent guide plates could interfere with paper transport from the
finisher to the machine.

1-29

3000-SHEET FINISHERS (B468/B469) 26 April, 2002

[D]

B468

[C]

[B]

[A]

B468I005.WMF

B469

[E]

B468

1. Install the lower output tray [A] (" x2).
NOTE: Only the lower output tray has a movable support tray [B].

[F]

B469I005.WMF

2. Install the upper output tray [C] (" x2).

3. Attach the staple position decal [D] to the ADF.

B469

1. Install the output tray [E] (" x2).

2. Attach the staple position decal [F].

1-30

26 April, 2002 3000-SHEET FINISHERS (B468/B469)

Selecting the Staple Supply Name

Enter the SP mode and execute the follow i ng informa ti on.

5841*

Supply Name Setting

005 Staple Std Enter the name of the staples in use for normal st apl ing

006 Staple Bind Enter the name of the staples in use for boo kl et stapling

These names appear when the user presses the Inquiry
button on the initial User Tools scre en.

(not booklet stapling). This set t i ng should be done for both
the B468 and B469.

(saddle-stitching). This setti ng i s requi r ed only for the
B468.

Enabling Booklet Binding

To enable booklet binding, you must select the ‘center stapling’ position.

1. Press the User Tools key.

2. Touch “Copier/Document Server Features”.

3. Touch the “Input/Output” tab, then access “Select Stapling Position”.

4. Touch any “Stapling Position” button and touch the center stapling symbol.

5. Exit the User Tools mode. Specify the number of copies, touch the center
stapling symbol on the operation panel, then start the print job.

These SP adjustments are available but not required at installation.

Installation

SP6902 Fold Position

Adjustment

SP6120

Staple Jogger
Adjustment

Use this SP to fine adjust the fold and staple positions if th ey
are not aligned correctly. See “5. Service Tables”.

Allows fine adjustment of the staple unit jogger fences for
different paper sizes, if required. See “5. Service Tables”.

1-31

PUNCH UNIT (B377) 26 April, 2002

1.7 PUNCH UNIT (B377)

1.7.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Punch unit.............................................................................. 1

2. Sensor arm............................................................................ 1

3. Hopper................................................................................... 1

4. Step screw............................................................................. 1

5. Spring.................................................................................... 1

6. Spacer (2 mm)....................................................................... 1

7. Spacer (1 mm)....................................................................... 1

8. Tapping screw - M3x8............................................................ 1

9. Tapping screw - M3x10.......................................................... 2

1-32

26 April, 2002 PUNCH UNIT (B377)

1.7.2 INSTALLATION PROCEDURE

[A]

[B]

B377I201.WMF

Installation

[C]

[E]

[D]

B377I202.WMF

!

CAUTION

[F]

Switch off the main machine and unplug its power cord.

1. If the finisher is connected to the machine, disconnect it.

2. Unpack the punch unit and remove all tapes and shipping retainers.

3. Open the front door and remove the rear cover [A] (" x4).

4. Remove the bracket [B] (" x2) and paper guide [C] (" x1).

B377I103.WMF

5. Remove the plastic knockout [D].

6. Install the sensor arm [E] (" x1).

7. Install the spring [F].

1-33

PUNCH UNIT (B377) 26 April, 2002

[A]

[C]

[B]

B377I203.WMF

[D]

B377I105.WMF

[F]

[E]

B377I106.WMF

8. Remove the shipping bracket [A] (" x2).

9. Position the 2 mm spacer [B] and secure the punch unit (" x2).

10. Secure the punch unit at the front with the shoulder screw [C] (" x1).

11. Connect the harnesses [D] and clamp them as shown.
NOTE: No special DIP switch settings are required for this punch unit. The

punch unit sends an identification signal to the machine, so it knows
what type of punch unit has been installed.

12. Slide the hopper [E] into the machine.

13. Fasten the two 1 mm spacers [F] to the rear frame. These may be used during
future adjustments.
NOTE: The spacers are used to adjust the horizontal positioning of the holes.

14. Reassemble the finisher an d check the punch op er ati o n.

1-34

26 April, 2002 COVER INTERPOSER TRAY (B470)

1.8 COVER INTERPOSER TRAY (B470)

1.8.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Shoulder screws.................................................................... 3

2. Upper front door extension.................................................... 1

3. Lower front door extension.................................................... 1

4. Lower cover extension........................................................... 1

5. Lower plate............................................................................ 1

6. Cover spacer ......................................................................... 2

*1

7. Tapping screws - M3x6.......................................................... 5

8. Tapping screws - M4x8.......................................................... 4

9. Tapping screws - M4x6.......................................................... 2

10. Installation Instructions.......................................................... 1

*1:

The extra spacer is provided for the B478 3000-Sheet Finisher.

Installation

1-35

COVER INTERPOSER TRAY (B470) 26 April, 2002

1.8.2 INSTALLATION PROCEDURE

NOTE: If the B468/B469/B478 Finisher is connected to the machine, disconnect it.

Removing Tapes and Retainers

1. Remove all the filament tape and
shipping retainers.

2. Remove the cover [A] of the relay
connector.

3. Remove the bracket [B] (" x1).
NOTE: Loosen the screw. Do not

remove it.

4. Remove the guide plate [C]
(" x2).

[A]

B470I001.WMF

[B]

[C]

B470I002.WMF

1-36

26 April, 2002 COVER INTERPOSER TRAY (B470)

[A]

[E]

[F]

[D]

[C]

Installation

[B]

B470I003.WMF

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

5. Attach the three shoulder screws [A] (" x3).

6. Attach the bottom plate [B] (" x2, M3x6).

7. Remove the ground plate [C] from the finisher, then attach it to the bottom plate
(" x2, M3x6).

8. Attach the lower front door extension [D] (" x2, M4x8).

9. Attach the upper front door extension [E] (" x2, M4x8).

10. Attach the lower cover extension [F] (" x2, M4x6).

1-37

COVER INTERPOSER TRAY (B470) 26 April, 2002

[D]

11. Insert the spacer [A] and snap it

[C]

into position.

12. Lower the transport guide plate [B].

13. Pick up the cover interposer, align
the keyholes [C] with the shoulder
screws [D], then set the cover
interposer onto the screws.

14. Secure the cover interposer with
the tapping screw [E] (" x1, M3x6).

15. Raise the transport guide plate [B]
to close it.

16. Take the sponge cushion [F] out of
the finisher and set it on the right
side of the cover interposer.

17. Attach the guide plate [G]
(removed from the finisher) to the
cover interposer (" x2).

18. Release the lock lever [H] on the
LCT (" x1).

19. Slowly and carefully, to avoid
bending the entrance guide plates
of the finisher, push the finisher
against the side of the machine
until the brackets [I] enter the slots.

20. Secure the lock lever [H] (" x1).

[H]

[A]

[F]

[B]

[G]

[I]

[E]

B470I004.WMF

B470I005.WMF

!

CAUTION
Dock the finisher carefully to avoid bending the entrance guide plates. Bent
guide plates could interfere with paper transport from the finisher to the
machine.

1-38

26 April, 2002 9-BIN MAILBOX (B471)

1.9 9-BIN MAILBOX (B471)

1.9.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Trays...................................................................................... 9

2. Guide plate ............................................................................ 1

3. Decals (bin display) ............................................................... 1

4. Tapping screws - M3x8.......................................................... 6

5. Installation Instructions .......................................................... 1

Installation

1-39

9-BIN MAILBOX (B471) 26 April, 2002

1.9.2 INSTALLATION PROCEDURE

Removing Tapes and Retainers

1. Remove the filament tape [A].
NOTE: Handle the mailbox carefully.

The corner leaf [B] can be
damaged easily.

[A]

[B]

B471I001.WMF

Installation

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

If the Cover Interposer Tray B470 is installed on the Finisher B468/B469, remove it.
The cover interposer tray and mailbox cannot be installed on the finisher at the
same time.

1. Remove the top cover [A] of the finisher
(" x1).

[A]

2. Remove the bracket [B] (" x1).
NOTE: Loosen the screw. Do not

remove it.

[B]

1-40

B471I002.WMF

26 April, 2002 9-BIN MAILBOX (B471)

3. Attach the guide plate [A] to the top
of the finisher (" x2, M3x8).

4. Attach the mailbox [B] to the top of
the finisher (" x4, M3x8).

5. Attach the 9 trays [C] to the mailbox.

[A]

Installation

B471I003.WMF

[B]

[C]

[D]

6. Give the decals [D] to the customer
for notation and pasting at the
correct location.

B471I004.WMF

1-41

PRINTER/SCANNER KIT (G338), PRINTER KIT (G339) 26 April, 2002

1.10 PRINTER/SCANNER KIT (G338), PRINTER KIT (G339)

1.10.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Scanner/Printer DIMM (G338) or Printer DIMM (G339) ........ 1

2. Centronics Interface.............................................................. 1

3. NIB........................................................................................ 1

4. Screws - M3x8....................................................................... 2

5. Ferrite Core........................................................................... 1

6. Key Top Assembly ................................................................ 1

7. Operating Instructions – Printer............................................. 1

8. Installation Instructions.......................................................... 1

9. FCC Label ............................................................................ 1

10. Software CD-ROM ................................................................ 3

1-42

26 April, 2002 PRINTER/SCANNER KIT (G338), PRINTER KIT (G339)

1.10.2 INSTALLATION PROCEDURE

Inserting DIMMs

Read this section carefully before installation so you know how to insert the DIMMs
correctly.

!

CAUTION
Follow the procedure below to connect the DIMMs to the controller board.
Incorrect insertion can damage the controller board or cause a bad
connection between the DIMM and controller contacts. If the upper contact
is pressed in and bent, the resulting poor connection could cause the
entire system to not operate.

[A]

[B]

Installation

[C]

G338I901.WMF

1. Hold the ROM DIMM with the edge connector [A] pointing toward the slot and
the notch [B] on the DIMM in the upper right corner.

2. Insert the edge connector [C] into the slot at a 30-degree angle from the
surface of the board.
NOTE: If the angle is too low, the upper contact could bend.

3. Move the outside edge of the ROM DIMM up and down slightly until it works
into the connector, then gently press it down level with the controller board.

1-43

PRINTER/SCANNER KIT (G338), PRINTER KIT (G339) 26 April, 2002

Installation Procedure

[D]

[C]

[E]

G338I201.WMF

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

NOTE: The printer/scanner unit requires at least 128 MB of memory (more is

recommended). Memory chips are not packaged with this unit.

[A]

[F]

[B]

1. Disconnect the ADF cable.

2. Remove the rear upper cover (" x2).

3. Remove the controller cover (" x10).

!

CAUTION

Make sure that the DIMMs are inserted correctly. (☛☛☛☛ 1.10.2)

4. Insert the SDRAM DIMM (expansion memory 128 MB or 256 MB) [A] into
PC133 on the controller.

5. Insert the ROM DIMM [B] (printer/scanner) board into Slot 1.

6. Remove the Centronics connector cover [C] and insert the Centronics
connector [D] into CN310 and fasten with the provided screws (" x2).

Rating voltage of interface connectors: Max. DC 5V

7. Remove the slot covers [E] (" x2).

8. Install the NIB [F] into CN311 (" x1).
Rating voltage of interface connectors: Max. DC 5V

1-44

26 April, 2002 PRINTER/SCANNER KIT (G338), PRINTER KIT (G339)

9. Make sure that the following SP commands are set correctly.

• SP5811 – Machine No. Setting

• SP5907 – Plug & Play

10. Attach the provided decal near the machine name on the copier.

11. Wrap the Ethernet cable three times inside the ferrite core, close the ferrite
core, then connect the modular jack to the NIB.

12. Follow the procedures in the instruction manuals to perform the user settings.

13. Replace the key top assembly [G].

[G]

Installation

G338I402.WMF

1-45

PS3 (B525-08) 26 April, 2002

1.11 PS3 (B525-08)

1.11.1 INSTALLATION PROCEDURE

[A]

B064I204.WMF

1. Remove the rear upper cover (" x2).

2. Remove the controller cover (" x9).

3. Insert the PS3 module [A] into Slot 2.

!

CAUTION

Make sure that the DIMM is inserted correctly. (☛☛☛☛1.10.2)

1-46

26 April, 2002 USB 2.0 (B525-01)

1.12 USB 2.0 (B525-01)

1.12.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. USB 2.0 PCB......................................................................... 1

Installation

1-47

USB 2.0 (B525-01) 26 April, 2002

1.12.2 INSTALLATION PROCEDURE

[A]

[B]

B064I202.WMF

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

1. Remove the rear upper cover (" x2).

2. Remove the controller cover (" x9).

3. Remove the slot cover [A] (" x2).

4. Insert the USB board [B] into the PCI slot.

5. Fasten the slot cover to the USB board (" x2).

6. Use SP5990 005 to print a Self-Diagnostic Report with the system settings and
confirm that the machine correctly recognizes the interface.

1-48

26 April, 2002 USB 2.0 (B525-01)

1.12.3 USB SP SETTINGS

The following SP commands are available. However, only one setting may require
adjustment and this setting should be performed only if the customer is
experiencing USB data transmission errors.

NOTE: Do not change the settings marked “DFU”. These settings are for design

and factory use only.

To enter the SP mode:

Installation

1. Press Clear Modes

"

2. On the operation panel keypad, press #$%.

3. Hold down Clear/Stop & for more than 3 seconds.

4. Press “Copy SP” on the touch-panel to open the SP command selection
screen.

14APR 2002 03:25

SP Mode (Service)

SP1XXX

SP2XXX
SP3XXX
SP4XXX
SP5XXX
SP6XXX
SP7XXX
SP8XXX

Feed
Drum

Process

Periphs

Data Log2

Scanner
Mode

Data Log

Close All Copy Window SP DirectOpen All

Group

COPY: SP1-001-001

Page

Line

Line

Page

Group

Initial 0

X-XXX-XXX

21

Prev Page Next Page

Exit

B064I999.WMF

5. Enter ,-...

SP No. Name Function

5844 001 Transfer Rate

5844 002 Vendor ID
5844 003 Product ID
5844 004 Dev. Release Num

Adjusts the USB transfer rate. Do not change the setting
unless there is a data transfer error using the USB high
speed mode.

HS/FS: High speed/Full speed auto adjust

(480Mbps/12Mbps)
FS: Full speed (12Mbps fixed)
Displays the vendor ID. DFU
Displays the product ID. DFU
Displays the development release version number. DFU

1-49

IEEE1394 (G561) FIREWIRE INTERFACE 26 April, 2002

1.13 IEEE1394 (G561) FIREWIRE INTERFACE

1.13.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. IEEE-1394 Cable 2M 4PI...................................................... 1

2. IEEE-1394 Cable 2M 6PI...................................................... 1

3. PCB GW1394........................................................................ 1

1-50

26 April, 2002 IEEE1394 (G561) FIREWIRE INTERFACE

1.13.2 INSTALLATION PROCEDURE

[A]

Installation

[B]

[C]

B064I205.WMF

!

CAUTION
Switch the machine off and unplug the machine before starting the
following procedure.

1. Remove the rear upper cover (" x2).

2. Remove the controller cover (" x9).

3. Remove the slot cover [A] (" x2).

4. Attach the IEEE1394 board [B].

5. Use the provided cable to connect the machine and the computer.

6. Make sure that the jumper is on TB2 [C].

7. Print a system settings list and confirm that the machine correctly recognizes
the interface.

1-51

IEEE1394 (G561) FIREWIRE INTERFACE 26 April, 2002

1.13.3 UP MODE SETTINGS FOR IEEE 1394

Enter the UP mode and follow the procedure below to perform the initial interface
settings for IEEE 1394. These settings take effect every time the machine is
powered on.

1. Press User Tools/Counter.

2. On the touch panel, press System Settings.

3. Press Interface Settings.

System Intialization Settings End

Select the desired settings.

Network Parallel Interface

IP Address

Subnet Mask

IP Over 1394

SCSI Print

IEEE 1394 IEEE 802.1b

0000.0000.0000.0000

0000.0000.0000.0000

Enabled

Enabled

SCSI Print Bi-directional On

B064I998.WMF

4. Press the key and enter the following settings:

• IP Address

• Subnet Mask

• IP Over 1394. Enable or disable this setting as required. This setting enables

IP Over 1394 as the default setting for the printing method.

• SCSI Print. Enable or disable this setting as required. This setting enables
SCSI Print as the default setting for the printing method.

• SCSI Print Bi-directional. Switch bi-directional printing on or off for SCSI print.

1-52

26 April, 2002 IEEE1394 (G561) FIREWIRE INTERFACE

1.13.4 SP MODE SETTINGS FOR IEEE 1394

The following SP commands can be set for IEEE 1394.
To enter the SP mode:

1. Press Clear Modes

"

2. On the operation panel keypad, press #$%.

3. Hold down Clear/Stop & for more than 3 seconds.

4. Press “Copy SP” on the touch-panel to open the SP command selection
screen.

14APR 2002 03:25

SP Mode (Service)

SP1XXX

SP2XXX
SP3XXX
SP4XXX
SP5XXX
SP6XXX
SP7XXX
SP8XXX

Feed
Drum

Process

Periphs

Data Log2

Scanner
Mode

Data Log

Close All Copy Window SP DirectOpen All

Group

COPY: SP1-001-001

Page

Line

Line

Page

Group

Initial 0

X-XXX-XXX

21

Prev Page Next Page

Exit

B064I999.WMF

5. Enter ,-*(.

Installation

SP No. Name Function

5839 004 Device Name

Sets the names for all the physical devices connected ot
the the IEEE 1394 firewire network.

5839 007 Cycle Master

Enables or disables cycle master function of the IEEE 1394
standard bus.

5839 008 BCR Mode Sets the BCR (Broadcast Channel Register) setting for the

Auto Node operation for the standard IEEE1394 bus for
when IRM is not in use. Three settings are available: 00,
01, 11.

5839 009 IRM 1394a Check

Determines whether an IRM check for IEEE 1394 is
conducted for the Auto Node when IRM is not used.

5839 010 Unique ID Enables the “Node_Unique_Id” setting for enumeration on

the standard IEEE 1394 bus.

5839 011 Logout Determines how successive initiator login in requests are

handled during login in for SBP-2.
5839 012 Login Enables or disables exclusive login for SBP-2.
5839 013 Login MAX

Sets the limit for the number of logins for SBP-2. Range: 1

~ 62.

1-53

802.11B WIRELESS LAN (G628) 26 April, 2002

1.14 802.11B WIRELESS LAN (G628)

1.14.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty

1. Wireless LAN PCB (GW-WLAN)........................................... 1

2. Antenna (GW-WLAN) (options)............................................. 2

3. Card (GW-WLAN) ................................................................. 1

4. Wireless LAN Insructions...................................................... 1

1-54

26 April, 2002 802.11B WIRELESS LAN (G628)

1.14.2 INSTALLATION PROCEDURE

40 ~ 60 mm

[E]

Installation

[A]

[C]

[B]

[D]

!

CAUTION

B064I206.WMF

Switch the machine off and unplug the machine before starting the
following procedure.

1. Remove the rear upper cover (" x2).

2. Remove the controller cover (" x9).

3. Remove the slot cover [A] (" x2).

4. Insert the wireless LAN board [B] into the PCI Slot 1.

5. Fasten the slot cover to the wireless LAN board (" x2).

6. Set the jumper [C] between pins 3 and 4 on the wireless LAN board.

B064I207.WMF

7. Insert the LAN PC card [D] into the wireless LAN board.

8. Connect the antennas. Use the provided double-sided tape to attach the
antennas [E] to the side of the machine.

NOTE: 1) Set the antennas 40~60 mm apart (1.5~2.5”).

2) Attach the antennas where they will not be moved or damaged by
opening and closing the door of the machine.

3) Set up the antenna in an area that is free of interference from electrical
equipment that generates a strong electromagnetic field.

4) Always remove the antenna before moving the machine.

5) If reception is poor, move the machine and antenna closer to the access
point.

9. Print a system settings list and confirm that the machine correctly recognizes
the interface.

1-55

802.11B WIRELESS LAN (G628) 26 April, 2002

1.14.3 UP MODE SETTINGS FOR WIRELESS LAN

Enter the UP mode and follow the procedure below to perform the initial interface
settings for IEEE 802.11. These settings take effect every time the machine is
powered on.

NOTE: The wireless LAN cannot be used if Ethernet is being used.

1. Press the User Tools/Counter key.

2. On the touch panel, press System Settings.
NOTE: The Network I/F (default: Ethernet) must be set for either Ethernet or

wireless LAN.

3. Select Interface Settings ! Network (tab) ! Network I/F Settting

4. Select either “Ethernet” or “IEEE 802.11b”.

5. Press IEEE 802.11b. Only the wireless LAN options are displayed.

System Intialization Settings

Select the desired settings.

Network Parallel Interface IEEE 1394

Transmission Speed

SSID Setting

Channel

WEP (Privacy) Setting

802.11 Ad Hoc Mode

ASSID

11

Disabled

IEEE 802.1b

Bandwidth Status

1/2

End

NextPrevious

B064I997.WMF

6. Transmission Mode. Select either “Ad Hoc Mode” or “Infrastructure Mode”.

7. SSID Setting. Enter the SSID setting. (The setting is case sensitive.)

8. Channel. This setting is required when Ad Hoc Mode is selected.
Range: 1 ~ 14 (default: 11)
NOTE: The allowed range for the channel settings may vary for different

countries.

1-56

26 April, 2002 802.11B WIRELESS LAN (G628)

9. WEP (Privacy) Setting. The WEP (Wired Equivalent Privacy) setting is
designed to protect wireless data transmission. In order to unlock encoded
data, the same WEP key is required on the receiving side. There are 64 bit and
128 bit WEP keys.

Range of Allowed Settings:

64 bit 10 characters
128 bit 26 characters

10. Bandwidth Status. This setting is enabled only for the Infrastructure Mode.
Press here to display the current status of the bandwidth. One of the following
is displayed to reflect the reception status of the wireless LAN:

Good 76 ~ 100%
Fair 41 ~ 75%
Poor 21 ~ 40%
Unavailable 0 ~ 20%

11. Transmission Speed. Press the Next button to display more settings, then
select the transmission speed for the mode: Auto, 11 Mbps, 5.5 Mbps, 2 Mbps,
1 Mbps (default: Auto). This setting should match the distance between the
closest machine or access point, depending on which mode is selected.
NOTE: For the Ad Hoc Mode, this is the distance between the machine and

the closest PC in the network. For the Infrastructure Mode, this is the
distance between the machine and the closest access point.

Installation

11 Mbps 140 m (153 yd.)

5.5 Mbps 200 m (219 yd.)
2 Mbps 270 m (295 yd.)
1 Mbps 400 m (437 yd.)

12. To initialize the wireless LAN settings, use page 2/2. Press Execute to initialize
the following settings:

• Transmission mode

• Channel

• Transmission Speed

• WEP

• SSID

• WEP Key

1-57

802.11B WIRELESS LAN (G628) 26 April, 2002

1.14.4 SP MODE SETTINGS FOR 802.11B WIRELESS LAN

The following SP commands can be set for 802.11b

1. Press Clear Modes

"

2. On the operation panel keypad, press #$%.

3. Hold down Clear/Stop & for more than 3 seconds.

4. Press “Copy SP” on the touch-panel to open the SP command selection
screen.

14APR 2002 03:25

SP Mode (Service)

SP1XXX

SP2XXX
SP3XXX
SP4XXX
SP5XXX
SP6XXX
SP7XXX
SP8XXX

Feed
Drum

Process
Scanner
Mode
Periphs

Data Log
Data Log2

Close All Copy Window SP DirectOpen All

Group

COPY: SP1-001-001

Page

Line

Line

Page

Group

Initial 0

X-XXX-XXX

21

Prev Page Next Page

Exit

B064I999.WMF

5. Enter ,-.$.

SP No. Name Function

5840 004 SSID Used to confirm the current SSID setting.
5840 006 Channel MAX Sets the maximum range of the channel settings for the

country.

5840 007 Channel MIN
5840 010 WEP Key Used to confirm the current WEP key setting.

5840 011 WEP Key Select Used to select the WEP key (Default: 00).
5840 020 WEP Mode Used to display the maximum length of the string that can

Sets the minimum range of the channels settings allowed
for your country.

be used for the WEP Key entry.

1-58

26 April, 2002 PM TABLES

2. PREVENTIVE MAINTENANCE

2.1 PM TABLES

The amounts mentioned (K=1,000) as the PM interval indicate the number of prints
or copies unless stated otherwise. These numbers are based on the PM counter.

Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect,

EM: Emergency Maintenance

!

WARNING
Turn off the main power switch and unplug the machine before performing
any procedure in this section. Laser beams can seriously damage the eyes.

2.1.1 MAIN MACHINE

EM 300K 450K 600K Expected K Note

SCANNER OPTICS

1st, 2nd, 3rd Mirror C C C Optics cloth
Exposure Glass C C C C Dry cloth or alcohol
Scanner Guide Rails L L L After cleaning with alcohol,

lubricate scanner guide rails

with Grease 501.
Toner Shield Glass C C C C Optics cloth
Reflector C C C Optics cloth

Preventive

Maintenance

EM 300K 450K 600K Expected K Note

AROUND THE DRUM

Charge Corona Grid R R 450 Blower brush.
Charge Corona Wire R C R 450 Alcohol, or clean damp cloth.
Charge Wire Cleaning

Pad
Cleaning Blade R R 500
Cleaning Brush R R 500
Charge Corona Casing C C Alcohol, or clean damp cloth.
Internal Dust Filter C C C Blower brush.
ID Sensor

Pick-off Pawls I I Replace if necessary.
Potential Sensor C C C Blower brush.
Quenching Lamp C C C Dry cloth.
Transfer Entrance Stay C C C Dry cloth.
Ozone Filter (Top) R R
Cleaning Filter R R
Cleaning Side Seal C C C Dry cloth.
Cleaning Entrance Seal C C C Dry cloth.

R R 450

CCC

Blower brush. Do SP 3001 002

after cleaning.

2-1

PM TABLES 26 April, 2002

EM 300K 450K 600K Expected K Note

DEVELOPMENT UNIT

Developer R R (☛ 3.7.1)
Development Roller

Shaft
Development Roller C C
Development Filter R I R Blower brush.
Development Sleeve

Surface
Drive Gears C C C Blower brush.
Entrance Seal C C C Blower brush, dry cloth.
Side Seals C C C Blower brush, dry cloth.
Toner Bottle Holder C C C Dry cloth.
Paddle Roller Shaft C C C Blower brush, dry cloth.
Used Toner Separation

Unit

EM 300K 450K 600K Expected K Note

PAPER FEED

Registration Rollers C C Alcohol
Relay Rollers C C Alcohol
Paper Dust Mylar C C C Dry cloth
Registration Sensor C C Blower brush
Relay Sensor C C Blo wer brus h
Feed Rollers R R 450
Pick-up Rollers R R 450
Separation Rollers R R 450
By-pass Feed Rollers R R 450
By-pass Pick-up Rollers R R 450
By-pass Separatio n

Rollers
By-pass Paper End

Sensor
Grip Rollers C C Dry cloth, blower brush
Paper Feed Guide Plate C C Dry cloth
Vertical Transport

Rollers
Paper Feed Sensors C C C Blower brush
Paper End Sensors C C C Blower brush

CC

CCC

IR

R R 450
CC

CCC

Clean with blower brush and

dry cloth every time the

developer is replaced.

Dry cloth.

See NOTE below this table.

See NOTE below this table.

Dry cloth, blower brush

Alcohol

NOTE: Replace pick-up, feed and separation rollers as a set. Check the counter

value for each paper tray station with SP7204 (Copy Counter – Paper
Trays). If the value has reached 300K, replace the rollers. After replacing
the rollers, reset the counter with SP7816 (Copy Counter Reset).

2-2

26 April, 2002 PM TABLES

EM 300K 450K 600K Expected K Note

TRANSFER BELT UNIT

Transfer Belt C R C 750
Transfer Roller

Cleaning Blade
Transfer Entrance

Guide Plate
Transfer Drive Roller C C Dry cloth
Transfer Drum Roller C C Dry cloth
Transfer Bias Roller C C Dry cloth
Transfer Exit Guide

Plate
Discharge Plate R R

EM 300K 500K 600K Expected K Note

FUSING UNIT AND PAPER EXIT

Cleaning Web R R
Cleaning Web Pressure

Roller
Cleaning Web Pressure

Roller Bearings
De-Curler Rollers C C Alcohol
Exit Rollers C C Alcohol
Exit Static Discharge

Brush
Fusing Entrance Guide

Plate
Fusing Exit Guide Plate C C Dry cloth.
Hot Roller R 600
Hot Roller Bearings R 1000
Hot Roller Strippers R R 600
Pressure Cleaning

Roller
Pressure Cleaning

Roller Bearings
Pressure Cleaning

Roller Spring Plate
Pressure Roller R 600
Pressure Roller

Bearings
Thermistors I I I
Transport Rollers C C Alcohol
Fusing Lamp I I I

CC

CC

CC

RR
RIR

R 750

R
R

II

II

I R I 600

Use dry cloth to clean transfer

belt. Always replace transfer

belt and transfer roller cleaning

blade together.

Dry cloth

Dry cloth

Replace roller and bushings

together.

Dry cloth.

Replace hot roller, bearings

together.

Replace as a set.

Replace pressure roller and

bearings together.

Preventive

Maintenance

2-3

PM TABLES 26 April, 2002

EM 300K 450K 600K Expected K Note

DUPLEX

Entrance Sensor C C C Blower brush
Inverter Exit Rollers C C Alcohol
Transport Rollers C C Dry cloth
Reverse Trigger Rollers C C Dry cloth
Inverter Entrance Roller C C Dry cloth
Entrance Anti-Static

Brush
Reverse Junction Gate C C C Dry cloth

CC

Blower brush

2.1.2 ADF

EM 80K 160K 240K Expected K Note

The PM interval is for the number of originals that have been fed.

Pick-up Roller C R R R
Separation Roller C R R R
Paper Feed Belt C R R R
CIS Glass C C C Dry cloth
White Guide Plate C C C Dry cloth
Sensors C C C C Blower brush.
Platen Cover Sheet C C C C Water or alcohol
Drive Gears L L L Grease G501.
Transport Rollers C C C
Entrance Roller C C C
White Platen Roller C C C
Pre-Scanning Roller C C C
Scanning Roller C C C
Exit Roller CCC

Water or alcohol, belt cleaner

to clean paper feed belt.

Replace these items together.

Water or alcohol

2-4

26 April, 2002 RELATED SP CODES

2.1.3 OPTIONAL PERIPHERAL DEVICES

LCT (Large Capacity Tray) B473

EM 300K 450K 600K Expected K Note

ROLLERS

Pick-up Roller R R 450
Feed Roller R R 450
Separation Roller R R 450

NOTE: Replace pick-up, feed and separation rollers as a set. Check the counter

value for each paper tray station with SP7204 (Copy Counter – Paper
Trays). If the value has reached 300K, replace the rollers. After replacing
the rollers, reset the counter with SP7816 (Copy Counter Reset).

Cover Interposer Tray B470

EM 80K 160K 240K Note

The PM interval is for the number of sheets that have been fed.

Feed Belt R R R
Pick-up Roller R R R
Separation Roller

Driver Rollers C C C
Idle Rollers C C C
Discharge Brush C C C
Bushings L Lubricate with silicone oil if noisy.
Sensors C C C Blower brush.
Feed Drive Gear L Lubricate with silicone oil if noisy.

RRR

Replace as a set.

Damp clean cloth.

See

below this table.

NOTE

Preventive

Maintenance

3000-Sheet Finisher with 50-sheet stapler and Saddle-Stitching B468B469

EM 300K 450K 600K Note

Driver Rollers C C C
Idle Rollers C C C
Discharge Brush C C C
Bushings L Lubricate with silicone oil if noisy.
Sensors C C C Blower brush.
Jogger Fences I I I Make sure screws are tight.

Dry cloth

2.2 RELATED SP CODES

This is a list of the PM related SP codes. For details, refer to Section “5 Service
Tables”.

7803* PM Counter Display Displays the PM cou nt since the last PM.
7804* PM Counter Reset Resets the PM count.

2-5

26 April, 2002 GENERAL CAUTIONS

3. REPLACEMENT AND ADJUSTMENT

3.1 GENERAL CAUTIONS

Do not turn off either of the power switches while any of the electrical components
are active. Doing so might cause damage to units such as the transfer belt, drum,
and development unit when they are pulled out of or put back into the copier.

3.1.1 DRUM

An organic photoconductor (OPC) drum is more sensitive to light and ammonia gas
than a selenium drum. Follow the cautions below when handling an OPC drum.

1. Never expose the drum to direct sunlight.

2. Never expose the drum to direct light of more than 1,000 Lux for more than a
minute.

3. Never touch the drum surface with bare hands. When the drum surface is
touched with a finger or becomes dirty, wipe it with a dry cloth or clean it with
wet cotton. Wipe with a dry cloth after cleaning with wet cotton.

4. Never use alcohol to clean the drum; alcohol dissolves the drum surface.

5. Store the drum in a cool, dry place away from heat.

6. Take care not to scratch the drum as the drum layer is thin and is easily
damaged.

7. Never expose the drum to corrosive gases such as ammonia gas.

8. Always keep the drum in the protective sheet when keeping the drum unit, or
the drum itself, out of the copier. Doing so avoids exposing it to bright light or
direct sunlight, and will protect it from light fatigue.

9. Dispose of used drums in accordance with local regulations.

10. When installing a new drum, execute SP2962 (Adjustment of Drum
Conditions).

Adjustment

Replacement

3.1.2 DRUM UNIT

1. Before pulling o ut the drum unit, place a sheet of paper under the drum unit to
catch any spilt toner.

2. Make sure that the drum unit is set in position and the drum stay is secured
with a screw before the main switch is turned on. If the drum unit is loose, poor
contact of the drum connectors may cause electrical noise, resulting in
unexpected malfunctions (RAM data change is the worst case).

3. To prevent drum scratches, remove the development unit before removing the
drum unit.

3-1

GENERAL CAUTIONS 26 April, 2002

3.1.3 TR ANSFER BELT UNIT

1. Never touch the transfer belt surface with bare hands.

2. Take care not to scratch the transfer belt, as the surface is easily damaged.

3. Before installing the new transfer belt, clean all the rollers and the in ner part of
the transfer belt with a dry cloth to prevent the belt from slipping.

3.1.4 SCANNER UNIT

1. When installing the exposure glass, make sure that the white paint is at the rear
left corner.

2. Clean the exposure glass with alcohol or glass cleaner to reduce the amount of
static electricity on the glass surface.

3. Use a cotton pad with water or a blower brush to clean the mirrors and lens.

4. Do not bend or crease the exposure lamp flat cable.

5. Do not disassemble the lens un it. Doing so will throw the lens and the copy
image out of focus.

6. Do not turn any of the CCD positionin g screws. Doing so will throw the CCD out
of position.

3.1.5 LASER UNIT

1. Do not loosen the screws that secure the LD drive board to the laser diode
casing. Doing so would throw the LD unit out of adjustment.

2. Do not adjust the variable resistors on the LD unit, as they are adjusted in the
factory.

3. The polygon mirror and F-theta lenses are very sensitive to dust. Do not open
the optical housing unit.

4. Do not touch the glass surface of the polygon mirror motor unit with bare
hands.

5. After replacing the LD unit, do the laser beam pitch adjustment. Otherwise, an
SC condition will be generated.

3-2

26 April, 2002 GENERAL CAUTIONS

3.1.6 CHARGE CORONA

1. Clean the corona wires with a dry cloth. Do not use sandpaper or solvent.

2. Clean the charge corona casing with water first to remove NOx based
compounds. Then clean it with alcohol if any toner still remains on the casing.

3. Clean the end block with a blower brush first to remove toner and paper dust.
Then clean with alcohol if any toner still remains.

4. Do not touch the corona wires with bare hands. Oil stains from fingers may
cause uneven image density on copies.

5. Make sure that the wires are correctly between the cleaner pads and that there
is no foreign material (iron filings, etc.) on the casing.

6. When installing new corona wires, do not bend or scratch the wire surface.
Doing so may cause uneven charge. Also be sure that the corona wires are
correctly positioned in the end blocks.

7. Clean the grid plate with a blower brush (not with a dry cloth).

8. Do not touch the charge grid plate with bare hands. Also, do not bend the
charge grid plate or make any dent in it. Doing so may cause uneven charge.

Adjustment

Replacement

3.1.7 DEVELOPMENT

1. Be careful not to nick or scratch the development roller.

2. Place the development unit on a sheet of paper after removing it from the
copier.

3. Never disassemble the development roller assembly. The position of the doctor
plate is set with special tools and instruments at the factory to ensure the
proper gap between the doctor blade and the development roller.

4. Clean the drive gears after removing used developer.

5. Dispose of used developer in accordance with local regulations.

6. Never load types of developer and toner into the development unit other than
specified for this model. Doing so will cause poor copy quality and toner
scattering.

7. Immediately after installing new developer, the TD sensor initial setting
procedure should be performed with SP2810 (TD Sensor Initialization) to avoid
damage to the copier. Do not perform the TD sensor initial setting with used
developer. Do not make any copies before doing the TD sensor initial setting.

8. When using a vacuum cleaner to clean the develop ment unit casing, al ways
ground the casing with your fingers to avoid damaging the toner density sensor
with static electricity.

9. When replacing the TD sensor, replace the developer, then execute SP2801
(TD Sensor Initialization) and SP2962 (Adjustment of Drum Conditions).

3-3

GENERAL CAUTIONS 26 April, 2002

3.1.8 CLEANING

1. When servicing the cleaning section, be careful not to damage the edge of the
cleaning blade.

2. Do not touch the cleaning blade with bare hands.

3. Before disassembling the cleaning section, place a sheet of paper under it to
catch any toner falling from it.

3.1.9 FUSING UNIT

1. After installing the fusing thermistor, make sure that it is in contac t with the hot
roller and that it is movable.

2. Be careful not to damage the edges of the hot roller strippers or their tension
springs.

3. Do not touch the fusing lamp and rollers with bare hands.

4. Make sure that the fusing lamp is positioned correctly and that it does not touch
the inner surface of the hot roller.

3.1.10 PAPER FEED

1. Do not touch the surface of the pick-up, feed, and separation rollers.

2. To avoid paper misfeeds, the side fences and end fence of the paper tray must
be positioned correctly to align with the actual paper size.

3.1.11 USED TONER

1. We recommend checking the amount of used toner at every EM.

2. Dispose of used toner in accordance with local regulations. Never throw toner
into an open flame, for toner dust may ignite.

3-4

26 April, 2002 SPECIAL TOOLS AND LUBRICANTS

3.2 SPECIAL TOOLS AND LUBRICANTS

3.2.1 SPECIAL TOOLS

Part No. Description

A0069104 Scanner Positioning Pin (4 pcs./set)
A2929500 Test Chart – S5S (10 pcs./set)

A0299387 Digital Multimeter – FLU KE 87
N8036701 Flash Memory Card – 4 MB
N8036701 Case – Flash Memory Card
G0219350 Loop Back Connector

3.2.2 LUBRICANTS

Part No. Description

A2579300 Grease Barrierta – JFE 5 5/2

52039502 Silicon Grease G- 501

Adjustment

Replacement

3-5

OPERATION PANEL AND EXTERNAL COVERS 26 April, 2002

3.3 OPERATION PANEL AND EXTERNAL COVERS

3.3.1 OPERATION PANEL

[A]

[B]

B064R801.WMF

[A]: Shoulder screws (! x2)
[B]: Operation panel (" x1)

3.3.2 FRONT DOOR

[A]

[B]

B064R802.WMF

While supporting the front door [A] with one hand, press down on the hinge bracket
[B] then raise the door slightly to remove it.

3-6

26 April, 2002 OPERATION PANEL AND EXTERNAL COVERS

3.3.3 RIGHT COVERS

[C]

[B]

[A]

Adjustment

Replacement

[E]

B064R803.WMF

[D]

1. LCT entrance guide cover [A] (! x2)

2. Right upper cover [B] (! x2)

• To remove the right cover, remove the LCT entrance guide plate, open the
by-pass tray, then slide the right upper cover down to remove it.

• When re-attachi ng, before tightening the screws make sure that 1) the tabs
[C] on the cover are engaged with the grooves on the machine, and 2) the
catches on the cover are engaged with the shoulder screws.

3. Lower right cover [D] (! x2)

• After removing the screws, slide the cover down to remove it.

• When re-attachi ng, before tightening the screws make sure that the t abs [E]

on the cover are engaged with the grooves on the machine.

3-7

OPERATION PANEL AND EXTERNAL COVERS 26 April, 2002

3.3.4 LEFT COVERS

[A]

[B]

B064R804.WMF

[A]: Left upper cover (! x2)

• Slide down to remove.

• When re-attachin g, before tightening the scr ews make sure that 1) the tabs

on the cover are engaged with the grooves on the machine, and 2) the
catches on the cover are engaged with the shoulder screws.

[B]: Left lower cover (! x2)

• Slide down to remove.

• When re-attachin g, before tightening the scr ews make sure that the tabs on

the cover are engaged with the grooves on the machine.

3-8

26 April, 2002 OPERATION PANEL AND EXTERNAL COVERS

3.3.5 REAR COVERS

[A]

[B]

Adjustment

Replacement

[C]

B064R805.WMF

[A]: Disconnect the ADF plug.
[B]: Rear upper cover (! x3)

• Slide down to remove.

• When re-attachin g, before tightening the scr ews make sure that the tabs on

the cover are engaged with the shoulder screws.

[C]: Rear lower cover (! x2)

• When re-attachin g, before tightening the scr ews make sure that the tabs on
the cover are engaged with the shoulder screws.

3-9

SCANNER 26 April, 2002

3.4 SCANNER

3.4.1 ADF AND TOP COVERS

ADF

[D]

B064R907.WMF

[C]

[A]

[B]

[E]

[E]

Rear upper cover. (☛ 3.3.5)
[A]: Cable bracket (! x1)

[B]: Controller/IPU panel (! x2)

• Swing open the panel so you can see the back.

[C]: Connector cover (! x2)
[D]: Connector (2nd from the top) (" x1)
[E]: ADF base left and right plates (! x2)

• While holding the ADF firmly, slide the ADF back and lift the large end of the
keyholes over the shoulder screws.

3-10

B064R906.WMF

26 April, 2002 SCANNER

Top Covers

[A]

[B]

[C]

[D]

Adjustment

Replacement

ADF (☛ 3.4.1)
[A]: Top inside cover (! x2)

[B]: Top left cover (! x1)
[C]: Top right cover (! x1)
[D]: Operation panel (! x1) (☛ 3.3)

B064R010.WMF

3-11

SCANNER 26 April, 2002

3.4.2 EXPOSURE GLASS

[A]

[B]

[D]

[C]

B064R001.WMF

[A]: Rear scale (! x3)
[B]: Left cover (! x3)
[C]: ADF exposure glass
[D]: Exposure glass

NOTE: Lift out the exposure glass and left scale together. The left scale is

permanently attached to the exposure glass with double-sided tape. Do not
remove the left scale from the exposure glass.

When re-installing the exposure glass:

• Position the exposure glass first. Make sure that the arrow mark is in the upper
left corner.

• When re-insta lling the left cover, make sure it is seated correctly.

3-12

26 April, 2002 SCANNER

3.4.3 SCANNER ORIGINAL SIZE SENSORS

[A]

[B]

B064R004.WMF

Adjustment

Replacement

Exposure glass (☛ 3.4.2)
[A]: Original length sensor (! x1, " x1)

NOTE: In North America, two length sensors are provided.

[B]: Original width sensor (! x1, " x1)

3-13

SCANNER 26 April, 2002

3.4.4 LENS BLOCK

[A]

[C]

[D]

[B]

B064R002.WMF

B064R003.WMF

Exposure glass (☛ 3.4.2)
Operation panel (☛ 3.3)

[A]: Top right cover (! x1)
[B]: Right upper stay (! x2)
[C]: Lens cover (! x2)
[D]: Lens block (! x2, " x3)

NOTE: To avoid damaging the lens block, never set it down on the side with the

PCB; turn it over with the PCB up.

Re-assemble the machine, then perform the scanner and printer adjustments.
(☛ 3.14)

3-14

26 April, 2002 SCANNER

3.4.5 EXPOSURE LAMP

[D]

[B]

[A]

[C]

B064R005.WMF

Adjustment

Replacement

Exposure glass (☛ 3.4.2)
Push the 1st scanner [A] to the cutout [B] in the scanner frame.

[C]: Exposure lamp cover (! x2)
[D]: Exposure lamp (! x3, " x1)

NOTE: Never touch the surface of the exposure lamp with bare fingers.

3-15

SCANNER 26 April, 2002

3.4.6 LAMP REGULATOR

[A]

[B]

[C]

B064R073.WMF

Operation panel (☛ 3.3.1)
Exposure glass (☛ 3.4.2)
Exposure lamp cover and exposure lamp (☛ 3.4.5)

[A]: Metal strip reflector

NOTE: Avoid touching the surface of the reflector and do not bend it.
[B]: Lamp regulator ribbon connector
[C]: Lamp regulator (! x 4, " x1)

3-16

26 April, 2002 SCANNER

3.4.7 SCANNER MOTOR DRIVE BOARD (SDRB)

[A]

Adjustment

Replacement

Rear upper cover (☛ 3.3.5)
[A]: Scanner motor drive board (! x3, " x3)

B064R007.WMF

3-17