Ricoh A 2045, A 2035 Service Manual

Name: Ricoh A 2045
Brand: Ricoh
SKU: 4665673
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B079/B082

SERVICE MANUAL

001634MIU

RICOH GROUP COMPANIES

B079/B082

MANUAL SERVICE

RICOH GROUP COMPANIES

B079/B082

SERVICE MANUAL

001634MIU

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NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.

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They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies. No such use, or the use of any trade name, or web site is intended to convey endorsement or other affiliation with Ricoh products.

WARNING

The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.

Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection.

Ricoh Corporation

LEGEND

PRODUCT CODE		COMPANY
	GESTETNER	LANIER	RICOH	SAVIN
B079	3532	LD035	Aficio 2035	4035
B082	4532	LD045	Aficio 2045	4045

DOCUMENTATION HISTORY

REV. NO.	DATE	COMMENTS
*	05/2003	Original Printing

B079/B082

INSTALLATION

1. INSTALLATION PROCEDURE....................................................	1-1
1.1 INSTALLATION REQUIREMENTS ............................................................	1-1
1.1.1 ENVIRONMENT ................................................................................	1-2
1.1.2 MACHINE LEVEL..............................................................................	1-2
1.1.3 MINIMUM SPACE REQUIREMENTS ...............................................	1-3
1.1.4 POWER REQUIREMENTS ...............................................................	1-5
1.2 INSTALLATION FLOW CHART .................................................................	1-6
1.3 MAIN MACHINE INSTALLATION...............................................................	1-7
1.3.1 ACCESSORY CHECK ......................................................................	1-7
1.3.2 INSTALLATION PROCEDURE .........................................................	1-8
Development Unit and PCU..................................................................	1-9
Toner Bottle ........................................................................................	1-12
Paper Trays ........................................................................................	1-13
Initialize TD Sensor and Developer.....................................................	1-15
Set Paper Size for Paper Trays ..........................................................	1-16
Electrical Total Counter.......................................................................	1-17
HDD Caution Decal.............................................................................	1-17
Exposure Glass Cleaner .....................................................................	1-17
1.4 PAPER TRAY UNIT INSTALLATION (B542) ...........................................	1-18
1.4.1 ACCESSORY CHECK ....................................................................	1-18
1.4.2 PAPER TRAY UNIT INSTALLATION PROCEDURE ......................	1-19
1.5 CABINET INSTALLATION PROCEDURE................................................	1-23
1.6 1-BIN TRAY UNIT INSTALLATION (B544) ..............................................	1-26
1.6.1 ACCESSORY CHECK ....................................................................	1-26
1.6.2 1-BIN TRAY INSTALLATION PROCEDURE...................................	1-27
1.7 BRIDGE UNIT INSTALLATION (B538) ....................................................	1-33
1.7.1 ACCESSORY CHECK ....................................................................	1-33
1.7.2 BRIDGE UNIT INSTALLATION PROCEDURE ...............................	1-34
1.8 TWO-TRAY FINISHER INSTALLATION (B545).......................................	1-36
1.8.1 ACCESSORY CHECK ....................................................................	1-36
1.8.2 TWO-TRAY FINISHER INSTALLATION PROCEDURE .................	1-37
1.9 PUNCH UNIT INSTALLATION (B377) .....................................................	1-40
1.9.1 ACCESSORY CHECK ....................................................................	1-40
1.9.2 PUNCH UNIT INSTALLATION PROCEDURE ................................	1-41
1.10 ARDF INSTALLATION (B541)................................................................	1-44
1.10.1 ACCESSORY CHECK...................................................................	1-44
1.10.2 ARDF INSTALLATION PROCEDURE...........................................	1-45
1.10.3 ARDF SKEW ADJUSTMENT ........................................................	1-48
1.11 LCT INSTALLATION (B543)...................................................................	1-49
1.11.1 ACCESSORY CHECK...................................................................	1-49

B079/B082

1.11.2 LCT INSTALLATION PROCEDURE..............................................	1-50
1.12 PLATEN COVER INSTALLATION (G329) .............................................	1-52
1.13 BOOKLET FINISHER INSTALLATION (B546).......................................	1-53
1.13.1 ACCESSORY CHECK...................................................................	1-53
1.13.2 BOOKLET FINISHER INSTALLATION PROCEDURE..................	1-54
1.14 1000 SHEET FINISHER (B408) .............................................................	1-59
1.14.1 ACCESSORY CHECK...................................................................	1-59
1.14.2 1000 SHEET FINISHER INSTALLATION PROCEDURE..............	1-60
1.14.3 CHECK ALL CONNECTIONS .......................................................	1-63
1.15 KEY COUNTER INSTALLATION (A674)................................................	1-64
1.16 ANTI-CONDENSATION HEATER..........................................................	1-66
1.17 TRAY HEATER ......................................................................................	1-68
1.18 TRAY HEATER (OPTIONAL PAPER TRAY UNIT) ................................	1-69
1.19 OPTIONAL USER ACCOUNT ENHANCEMENT UNIT (B443) ..............	1-70
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE SCHEDULE...............................	2-1
2.1 PM TABLE..................................................................................................	2-1
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ........................................	3-1
3.1 GENERAL CAUTIONS ...............................................................................	3-1
3.1.1 LASER UNIT .....................................................................................	3-1
3.1.2 USED TONER ...................................................................................	3-1
3.2 SPECIAL TOOLS AND LUBRICANTS .......................................................	3-2
3.2.1 SPECIAL TOOLS ..............................................................................	3-2
3.2.2 LUBRICANTS....................................................................................	3-2
3.2.3 SYMBOLS USED IN TEXT................................................................	3-2
3.3 FRONT DOOR ...........................................................................................	3-3
3.4 DUPLEX UNIT............................................................................................	3-3
3.5 UPPER RIGHT COVER .............................................................................	3-4
3.6 BY-PASS TRAY .........................................................................................	3-5
3.7 REAR COVERS .........................................................................................	3-6
3.7.1 REAR UPPER COVER .....................................................................	3-6
3.7.2 REAR LOWER COVER.....................................................................	3-6
3.8 LEFT COVERS...........................................................................................	3-7
3.8.1 LEFT UPPER COVER.......................................................................	3-7
3.9 SCANNER UNIT.........................................................................................	3-8
3.9.1 ARDF.................................................................................................	3-8
3.9.2 EXPOSURE GLASS..........................................................................	3-9
3.9.3 SCANNER EXTERIOR PANELS/OPERATION PANEL..................	3-10
3.9.4 LENS BLOCK/SBU ASSEMBLY .....................................................	3-11
3.9.5 ORIGINAL SIZE SENSORS ............................................................	3-12
3.9.6 EXPOSURE LAMP..........................................................................	3-13
3.9.7 SCANNER HP SENSOR/PLATEN COVER SENSOR ....................	3-14

B079/B082

3.9.8 SCANNER MOTOR.........................................................................	3-15
3.9.9 LAMP STABILIZER AND SCANNER MOTOR DRIVE BOARD ......	3-16
3.9.10 SCANNER WIRE...........................................................................	3-17
3.10 LASER UNIT ..........................................................................................	3-21
3.10.1 CAUTION DECAL LOCATIONS ....................................................	3-21
3.10.2 LASER UNIT..................................................................................	3-22
3.10.3 POLYGON MIRROR MOTOR .......................................................	3-24
3.10.4 LASER SYNCHRONIZATION DETECTOR...................................	3-25
3.10.5 LD UNIT.........................................................................................	3-25
Laser beam pitch adjustment..............................................................	3-26
3.11 PHOTOCONDUCTOR UNIT (PCU) .......................................................	3-27
3.11.1 PCU ...............................................................................................	3-27
3.11.2 DRUM............................................................................................	3-28
3.11.3 PICK-OFF PAWLS ........................................................................	3-30
Pick-off pawl position adjustment........................................................	3-30
3.11.4 CHARGE ROLLER AND CLEANING ROLLER .............................	3-31
3.11.5 DRUM CLEANING BLADE 2.........................................................	3-32
3.11.6 DRUM CLEANING BLADE 1.........................................................	3-33
3.12 DEVELOPMENT ....................................................................................	3-34
3.12.1 DEVELOPMENT UNIT ..................................................................	3-34
3.12.2 DEVELOPMENT FILTER ..............................................................	3-35
3.12.3 DEVELOPMENT ROLLER ............................................................	3-35
3.12.4 DEVELOPER.................................................................................	3-36
3.12.5 TD SENSOR..................................................................................	3-38
3.13 TRANSFER UNIT...................................................................................	3-39
3.13.1 TRANSFER BELT UNIT ................................................................	3-39
3.13.2 TRANSFER BELT .........................................................................	3-40
3.13.3 TRANSFER BELT CLEANING BLADE AND TONER
OVERFLOW SENSOR..................................................................	3-41
3.14 PAPER FEED.........................................................................................	3-42
3.14.1 PICK-UP, SEPARATION, AND FEED ROLLERS .........................	3-42
3.14.2 LOWER RIGHT COVER................................................................	3-43
3.14.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED
CLUTCHES ...................................................................................	3-44
3.14.4 UPPER PAPER FEED UNIT FOR TRAY 1 ...................................	3-45
3.14.5 LOWER PAPER FEED UNIT FOR TRAY 2...................................	3-46
3.14.6 PAPER END/PAPER HEIGHT/RELAY SENSORS .......................	3-47
3.14.7 REGISTRATION SENSOR............................................................	3-48
3.14.8 TRAY LIFT MOTOR ......................................................................	3-50
3.14.9 FEED/DEVELOPMENT MOTOR...................................................	3-51
3.15 FUSING UNIT.........................................................................................	3-52
3.15.1 FUSING UNIT REMOVAL .............................................................	3-52
3.15.2 FUSING UNIT EXIT GUIDE...........................................................	3-53
3.15.3 HOT ROLLER STRIPPERS...........................................................	3-53
3.15.4 FUSING LAMPS ............................................................................	3-54
3.15.5 THERMISTORS AND THERMOSTATS ........................................	3-56
3.15.6 FUSING ROLLER/PRESSURE ROLLER......................................	3-57
3.15.7 FUSING UNIT SIDE FAN ..............................................................	3-59
3.15.8 FUSING UNIT CORNER FAN .......................................................	3-61

iii

B079/B082

3.16 PAPER FEED.........................................................................................	3-62
3.16.1 IDLE ROLLER DUST BLADE ........................................................	3-62
3.16.2 COVER REPLACEMENT ..............................................................	3-63
3.16.3 BY-PASS PAPER FEED AND PICK-UP ROLLER REPLACEMENT
........................................................................................................	3-64
3.16.4 BY-PASS SEPARATION ROLLER REPLACEMENT ....................	3-65
3.16.5 PAPER END SENSOR AND PICK-UP SOLENOID
REPLACEMENT............................................................................	3-66
3.16.6 PAPER SIZE SENSOR BOARD REPLACEMENT ........................	3-67
3.16.7 BY-PASS TABLE REMOVAL ........................................................	3-68
3.16.8 PAPER FEED CLUTCH REPLACEMENT.....................................	3-69
3.16.9 REGISTRATION ROLLER DUST BLADE .....................................	3-70
3.17 DUPLEX UNIT........................................................................................	3-71
3.17.1 DUPLEX COVER REMOVAL ........................................................	3-71
3.17.2 DUPLEX ENTRANCE SENSOR REPLACEMENT........................	3-72
3.17.3 DUPLEX EXIT SENSOR REPLACEMENT ...................................	3-73
3.18 DRIVE AREA..........................................................................................	3-74
3.18.1 REGISTRATION CLUTCH AND TRANSFER BELT CONTACT
CLUTCH........................................................................................	3-74
3.18.2 MAIN MOTOR ...............................................................................	3-75
3.18.3 TONER SUPPLY MOTOR.............................................................	3-76
3.19 PRINTED CIRCUIT BOARDS ................................................................	3-77
3.19.1 HIGH VOLTAGE POWER SUPPLY ..............................................	3-77
3.19.2 IOB ................................................................................................	3-78
IOB DIP Switch Settings (SW101) ......................................................	3-79
3.19.3 BICU BOARD ................................................................................	3-80
3.19.4 PSU ...............................................................................................	3-80
3.20 HARD DISK, CONTROLLER BOARD ....................................................	3-81
3.21 COPY ADJUSTMENTS: PRINTING/SCANNING ...................................	3-82
3.21.1 PRINTING......................................................................................	3-82
Registration - Leading Edge/Side-to-Side...........................................	3-82
Blank Margin.......................................................................................	3-83
Main Scan Magnification.....................................................................	3-83
Parallelogram Image Adjustment........................................................	3-84
3.21.2 SCANNING....................................................................................	3-85
Registration: Platen Mode...................................................................	3-85
Magnification.......................................................................................	3-85
3.21.3 ADF IMAGE ADJUSTMENT..........................................................	3-86
Registration.........................................................................................	3-86
3.21.4 TOUCH SCREEN CALIBRATION .................................................	3-87
TROUBLESHOOTING
4. TROUBLESHOOTING .................................................................	4-1
4.1 SERVICE CALL CONDITIONS ..................................................................	4-1
4.1.1 SUMMARY ........................................................................................	4-1
4.1.2 SC CODE DESCRIPTIONS ..............................................................	4-2
4.2 ELECTRICAL COMPONENT DEFECTS..................................................	4-24

B079/B082

4.2.1 SENSORS.......................................................................................	4-24
4.2.2 SWITCHES......................................................................................	4-25
4.3 BLOWN FUSE CONDITIONS ..................................................................	4-25
4.4 LEDS ........................................................................................................	4-26
4.5 TEST POINTS ..........................................................................................	4-26
SERVICE TABLES
5. SERVICE TABLES.......................................................................	5-1
5.1 SERVICE PROGRAM MODE.....................................................................	5-1
5.1.1 SERVICE PROGRAM MODE OPERATION......................................	5-1
Entering and Exiting SP mode ..............................................................	5-1
SP Mode Button Summary ...................................................................	5-2
Switching Between SP Mode and Copy Mode for Test Printing............	5-3
Selecting the Program Number.............................................................	5-3
5.1.2 SERVICE TABLE KEY ......................................................................	5-4
5.1.3 SERVICE TABLES ............................................................................	5-5
SP1-xxx: Feed ......................................................................................	5-5
SP2-xxx: Drum......................................................................................	5-8
SP3-xxx: Process................................................................................	5-17
SP4-xxx: Scanner ...............................................................................	5-18
SP5-xxx: Mode....................................................................................	5-41
SP6-xxx: Peripherals ..........................................................................	5-59
SP7-xxx: Data Log ..............................................................................	5-61
5.1.4 TEST PATTERN PRINTING: SP2-902............................................	5-70
Test Pattern Table (SP2-902-2: IPU Test Print)..................................	5-70
Test Pattern Table: SP2-902-3 Printing Test Patterns ........................	5-71
5.1.5 INPUT CHECK ................................................................................	5-72
Main Machine Input Check: SP5-803..................................................	5-72
ARDF Input Check: SP6-007 ..............................................................	5-76
5.1.6 OUTPUT CHECK ............................................................................	5-77
Main Machine Output Check: SP5-804...............................................	5-77
ARDF Output Check: SP6-008) ..........................................................	5-79
5.1.7 SMC PRINT OUT LISTS: SP5-990 .................................................	5-79
5.1.8 NIP BAND WIDTH ADJUSTMENT: SP1-109 ..................................	5-83
5.1.9 MEMORY CLEAR: SP5-801............................................................	5-84
5.1.10 SOFTWARE RESET .....................................................................	5-85
5.1.11 SYSTEM SETTINGS AND COPY SETTING RESET ....................	5-86
System Setting Reset .........................................................................	5-86
Copier Setting Reset...........................................................................	5-87
5.2 SOFTWARE DOWNLOAD .......................................................................	5-88
5.3 UPLOADING/DOWNLOADING NVRAM DATA........................................	5-89
5.3.1 UPLOADING NVRAM DATA (SP5-824)..........................................	5-89
5.3.2 DOWNLOADING NVRAM DATA (SP5-825) ...................................	5-90
5.4 SELF-DIAGNOSTIC MODE .....................................................................	5-91
5.4.8 SELF-DIAGNOSTIC MODE AT POWER ON..................................	5-91
5.4.9 DETAILED SELF-DIAGNOSTIC MODE..........................................	5-92
Executing Detailed Self-Diagnosis ......................................................	5-92

B079/B082

5.5 USER PROGRAM MODE ........................................................................	5-94
5.5.8 HOW TO USE UP MODE................................................................	5-94
UP Mode Initial Screen: User Tools/Counter Display..........................	5-94
System Settings ..................................................................................	5-94
Copier/Document Server Features .....................................................	5-95
Printer, Facsimile, Scanner Settings ...................................................	5-95
Counter ...............................................................................................	5-96
5.6 DIP SWITCHES........................................................................................	5-97
5.7 USING THE DEBUG LOG........................................................................	5-98
5.7.1 CAPTURING DEBUGGING INFORMATION...................................	5-98
Switching On the Debug Log Feature .................................................	5-98
Setting the Timing for Debug Log Acquisition .....................................	5-99
Selecting a Module for Retrieval .......................................................	5-100
5.7.2 RETRIEVING THE DEBUG LOG .................................................	5-102
Recording Errors Manually ...............................................................	5-102
Copying the Debug Log to the IC Card .............................................	5-102
Converting the Debug Log to Binary Data ........................................	5-102
Analyzing the Debug Log Binary Data ..............................................	5-103
DETAILED SECTION DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS .......................................	6-1
6.1 OVERVIEW ................................................................................................	6-1
6.1.1 COMPONENT LAYOUT....................................................................	6-1
6.1.2 PAPER PATH....................................................................................	6-3
6.1.3 DRIVE LAYOUT ................................................................................	6-4
6.2 BOARD STRUCTURE................................................................................	6-5
6.2.1 BLOCK DIAGRAM.............................................................................	6-5
6.2.2 CONTROLLER ..................................................................................	6-7
6.3 COPY PROCESS OVERVIEW.................................................................	6-10
Exposure.............................................................................................	6-10
Drum charge .......................................................................................	6-10
Laser exposure ...................................................................................	6-10
Development.......................................................................................	6-10
Image transfer.....................................................................................	6-11
Separation ..........................................................................................	6-11
ID sensor ............................................................................................	6-11
Cleaning..............................................................................................	6-11
Quenching ..........................................................................................	6-11
6.4 SCANNING...............................................................................................	6-12
6.4.1 OVERVIEW .....................................................................................	6-12
6.4.2 SCANNER DRIVE ...........................................................................	6-13
Book Mode..........................................................................................	6-13
ADF mode...........................................................................................	6-13
6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE..........................	6-14
6.5 IMAGE PROCESSING .............................................................................	6-16
6.5.1 OVERVIEW .....................................................................................	6-16
6.5.2 SBU (SENSOR BOARD UNIT)........................................................	6-17

B079/B082

6.5.3 AUTO IMAGE DENSITY (ADS).......................................................	6-18
6.5.4 IPU (IMAGE PROCESSING UNIT) .................................................	6-19
Overview.............................................................................................	6-19
6.5.5 IMAGE PROCESSING MODES ......................................................	6-20
6.5.6 SUMMARY OF IMAGE PROCESSING FUNCTIONS .....................	6-22
6.5.7 IMAGE PROCESSING STEPS AND RELATED SP MODES..........	6-23
Text Mode...........................................................................................	6-23
Text/Photo Mode.................................................................................	6-24
Photo Mode.........................................................................................	6-25
Pale (Low-Density Mode)....................................................................	6-26
Generation Copy Mode.......................................................................	6-27
6.5.8 PRE-FILTERING .............................................................................	6-28
6.5.9 BACKGROUND ERASE..................................................................	6-29
6.5.10 INDEPENDENT DOT ERASE .......................................................	6-30
6.5.11 LINE WIDTH CORRECTION.........................................................	6-31
6.5.12 FILTERING....................................................................................	6-32
Interactive SP Codes ..........................................................................	6-32
Text Mode MTF Filter..........................................................................	6-36
Text/Photo, Photo Mode Filter ............................................................	6-37
Pale, Generation Mode Filter ..............................................................	6-38
Photo Mode Smoothing for Dithering ..................................................	6-39
Photo Mode Grayscale .......................................................................	6-39
Photo Mode Image Quality .................................................................	6-40
6.5.13 OTHERS........................................................................................	6-41
Vertical Black Line Correction.............................................................	6-41
Density Settings ..................................................................................	6-42
ADS Level...........................................................................................	6-43
6.5.14 PRACTICAL APPLICATION OF SP MODES ................................	6-44
Solving Problems ................................................................................	6-44
Recommended Settings for MTF Filters .............................................	6-45
6.6 PHOTOCONDUCTOR UNIT (PCU) .........................................................	6-47
6.6.1 OVERVIEW .....................................................................................	6-47
6.6.2 DRIVE MECHANISM.......................................................................	6-48
6.6.3 DRUM PAWLS ................................................................................	6-48
6.6.4 DRUM TONER SEALS....................................................................	6-48
6.6.5 DRUM CLEANING ..........................................................................	6-49
6.7 DRUM CHARGE.......................................................................................	6-50
6.7.1 OVERVIEW .....................................................................................	6-50
6.7.2 CHARGE ROLLER VOLTAGE CORRECTION ...............................	6-51
Correction for Environmental Conditions ............................................	6-51
6.7.3 ID SENSOR PATTERN PRODUCTION TIMING.............................	6-52
6.7.4 DRUM CHARGE ROLLER CLEANING...........................................	6-52
6.7.5 CORRECTION FOR PAPER WIDTH AND THICKNESS ................	6-53
6.7.6 DEVELOPMENT BIAS ....................................................................	6-54
Mechanism .........................................................................................	6-54
Correction for paper width and thickness (by-pass tray only)..............	6-54
6.8 DEVELOPMENT ......................................................................................	6-55
6.8.1 OVERVIEW .....................................................................................	6-55
6.8.2 DRIVE MECHANISM.......................................................................	6-56

vii

B079/B082

6.8.3 DEVELOPER MIXING.....................................................................	6-56
6.8.4 DEVELOPMENT BIAS ....................................................................	6-57
Mechanism .........................................................................................	6-57
Correction for paper width and thickness (by-pass tray only)..............	6-57
6.8.5 TONER SUPPLY.............................................................................	6-58
Toner bottle replenishment mechanism ..............................................	6-58
Toner supply mechanism....................................................................	6-59
Toner density control ..........................................................................	6-60
Sensor Control Mode ..........................................................................	6-60
Image Pixel Count Mode.....................................................................	6-61
6.8.6 TONER NEAR END/END DETECTION ..........................................	6-61
6.8.7 TONER END RECOVERY ..............................................................	6-62
6.8.8 TONER SUPPLY WITH ABNORMAL SENSORS ...........................	6-62
6.9 DRUM CLEANING AND TONER RECYCLING........................................	6-63
6.9.1 DRUM CLEANING ..........................................................................	6-63
6.9.2 TONER RECYCLING ......................................................................	6-63
6.10 PAPER FEED.........................................................................................	6-64
6.10.1 OVERVIEW ...................................................................................	6-64
6.10.2 PAPER FEED DRIVE ....................................................................	6-65
6.10.3 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM 6-65
6.10.4 PAPER LIFT ..................................................................................	6-66
6.10.5 PAPER END DETECTION ............................................................	6-67
6.10.6 PAPER REGISTRATION...............................................................	6-68
6.10.7 PAPER SIZE DETECTION............................................................	6-69
6.11 BY-PASS TRAY .....................................................................................	6-70
6.11.1 OVERVIEW ...................................................................................	6-70
6.11.2 BY-PASS TRAY OPERATION.......................................................	6-71
6.11.3 BY-PASS PAPER SIZE DETECTION ...........................................	6-72
6.12 DUPLEX UNIT........................................................................................	6-73
6.12.1 OVERVIEW ...................................................................................	6-73
6.12.2 DUPLEX DRIVE LAYOUT .............................................................	6-74
6.12.3 DUPLEX BASIC OPERATION.......................................................	6-75
Larger than A4 lengthwise/LT lengthwise ...........................................	6-75
Up to A4 lengthwise/LT lengthwise .....................................................	6-75
6.12.4 DUPLEX UNIT FEED IN AND EXIT MECHANISM........................	6-76
Feed-in................................................................................................	6-76
Inversion and Exit ...............................................................................	6-76
6.13 IMAGE TRANSFER AND PAPER SEPARATION ..................................	6-77
6.13.1 OVERVIEW ...................................................................................	6-77
6.13.2 BELT DRIVE MECHANISM...........................................................	6-78
6.13.3 TRANSFER BELT UNIT CONTACT MECHANISM .......................	6-78
6.13.4 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM ..	6-79
6.13.5 TRANSFER BELT CHARGE .........................................................	6-80
Mechanism .........................................................................................	6-80
Correction for paper width and thickness............................................	6-81
Currents applied to leading edge and image areas, and for by-pass feed
............................................................................................................	6-82
6.13.6 TRANSFER BELT CLEANING MECHANISM ...............................	6-83
6.14 IMAGE FUSING AND PAPER EXIT.......................................................	6-84

B079/B082

viii

6.14.1 OVERVIEW ...................................................................................	6-84
6.14.2 FUSING DRIVE .............................................................................	6-85
6.14.3 FUSING DRIVE RELEASE MECHANISM.....................................	6-85
6.14.4 FUSING ENTRANCE GUIDE SHIFT MECHANISM ......................	6-86
6.14.5 EXIT GUIDE PLATE AND DE-CURLER ROLLERS ......................	6-86
6.14.6 PRESSURE ROLLER....................................................................	6-87
6.14.7 CLEANING MECHANISM .............................................................	6-88
6.14.8 HOT ROLLER STRIPPER CLEANING..........................................	6-89
6.14.9 FUSING TEMPERATURE CONTROL...........................................	6-91
Temperature Control...........................................................................	6-92
Fusing Idling Temperature ..................................................................	6-93
6.14.10 CPM DOWN FOR THICK PAPER ...............................................	6-94
6.14.11 COOLING AND OVERHEAT PROTECTION...............................	6-95
6.14.12 TONER SCATTER PREVENTION ..............................................	6-96
6.15 ENERGY SAVER MODES .....................................................................	6-97
6.15.1 OVERVIEW ...................................................................................	6-97
6.15.2 ENERGY SAVER MODE...............................................................	6-98
Entering the energy saver mode.........................................................	6-98
What happens in energy saver mode .................................................	6-98
Return to stand-by mode ....................................................................	6-98
6.15.3 AUTO OFF MODE.........................................................................	6-99
Entering off stand-by and off modes ...................................................	6-99
Off Stand-by mode..............................................................................	6-99
Off Mode .............................................................................................	6-99
Returning to stand-by mode................................................................	6-99
SPECIFICATIONS
7. SPECIFICATIONS........................................................................	7-1
7.1 GENERAL SPECIFICATIONS....................................................................	7-1
7.2 MACHINE CONFIGURATION ....................................................................	7-3

BOOKLET FINISHER B546

SEE SECTION B546 FOR DETAILED TABLE OF CONTENTS

AUTO REVERSE DOCUMENT FEEDER B541

SEE SECTION B541 FOR DETAILED TABLE OF CONTENTS

LARGE CAPACITY TRAY B543

SEE SECTION B543 FOR DETAILED TABLE OF CONTENTS

PAPER TRAY UNIT B542

SEE SECTION B542 FOR DETAILED TABLE OF CONTENTS

B079/B082

1-BIN TRAY B544

SEE SECTION B544 FOR DETAILED TABLE OF CONTENTS

1000 SHEET FINISHER B408

SEE SECTION B408 FOR DETAILED TABLE OF CONTENTS

2 TRAY FINISHER B545

SEE SECTION B545 FOR DETAILED TABLE OF CONTENTS

BRIDGE UNIT B538

SEE SECTION B538 FOR DETAILED TABLE OF CONTENTS

PRINTER OPTION B548

SEE SECTION B548 FOR DETAILED TABLE OF CONTENTS

FAX OPTION B547

SEE SECTION B547 FOR DETAILED TABLE OF CONTENTS

B079/B082

IIMPORTANT 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.

1.SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

LASER SAFETY

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

WARNING

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

WARNING

WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes.

CAUTION MARKING:

Conventions in this Manual

This manual uses several symbols.

Symbol	What it means
!	Refer to section number
	See Core Tech Manual for details
	Screw
	Connector
	E-ring
	Clip ring








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

INSTALLATION

AUTO REVERSE DOCUMENT FEEDER B541

FAX OPTION B547

PREVENTIVE MAINTENANCE

PAPER TRAY UNIT B542

PRINTER OPTION B548

REPLACEMENT AND ADJUSTMENT

LARGE CAPACITY TRAY B543

TROUBLESHOOTING

BOOKLET FINISHER B546 1000 SHEET FINISHER B408 2-TRAY FINISHER B545

SERVICE TABLES

DETAILED DESCRIPTIONS

SPECIFICATIONS

1-BIN TRAY B544

BRIDGE UNIT B538

TAB	POSITION 1


TAB	POSITION 2


TAB	POSITION 3


TAB	POSITION 4


TAB	POSITION 5


TAB	POSITION 6


TAB	POSITION 7


TAB	POSITION 8

INSTALLATION

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