Ricoh B003, B004, B006, B007 Service Manual
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B003/B004/B006/B007
SERVICE MANUAL
001124MIU
RICOH GROUP COMPANIES
LEGEND
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PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
B003 3502 Aficio 1035 2535
B004 4502 Aficio 1045 2545
B006 3502p Aficio 1035P 2535p
B007 4502p Aficio 1045P 2545p
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 4/2001 Original Printing
Rev. 04/2002
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B003/B004/B006/B007
TABLE OF CONTENTS
INSTALLATION PROCEDURE
1. INSTALLATION PROCEDURE................................................... 1-1
1.1 INSTALLATION REQUIREMENTS...........................................................1-1
1.1.1 ENVIRONMENT...............................................................................1-2
1.1.2 MACHINE LEVEL.............................................................................1-2
1.1.3 MINIMUM SPACE REQUIREMENTS...............................................1-3
1.1.4 POWER REQUIREMENTS..............................................................1-3
1.1.5 INSTALLABLE OPTION TABLE.......................................................1.4
1.2 INSTALLATION FLOW CHART................................................................1-5
1.3 MAIN MACHINE INSTALLATION..............................................................1-6
1.3.1 ACCESSORY CHECK......................................................................1-6
1.3.2 INSTALLATION PROCEDURE........................................................1-7
Development Unit and PCU..................................................................1-8
Toner Bottle........................................................................................1-11
Paper Trays........................................................................................1-12
Initialize TD Sensor and Developer ....................................................1-14
Set Paper Size for Paper Trays.......................................................... 1-15
Electrical Total Counter.......................................................................1-16
HDD Caution Decal (for only NA models)...........................................1-16
1.4 PAPER TRAY UNIT INSTALLATION......................................................1-17
1.4.1 ACCESSORY CHECK....................................................................1-17
1.4.2 INSTALLATION PROCEDURE......................................................1-18
1.5 1-BIN TRAY UNIT INSTALLATION.........................................................1-22
1.5.1 ACCESSORY CHECK....................................................................1-22
1.5.2 INSTALLATION PROCEDURE......................................................1-23
1.6 BRIDGE UNIT INSTALLATION...............................................................1-29
1.6.1 ACCESSORY CHECK....................................................................1-29
1.6.2 INSTALLATION PROCEDURE......................................................1-30
1.7 1000-SHEET FINISHER INSTALLATION...............................................1-32
1.7.1 ACCESSORY CHECK....................................................................1-32
1.7.2 INSTALLATION PROCEDURE......................................................1-33
1.8 TWO-TRAY FINISHER INSTALLATION.................................................1-36
1.8.1 ACCESSORY CHECK....................................................................1-36
1.8.2 INSTALLATION PROCEDURE......................................................1-37
1.9 PUNCH UNIT INSTALLATION................................................................1-40
1.9.1 ACCESSORY CHECK....................................................................1-40
1.9.2 INSTALLATION PROCEDURE......................................................1-41
1.10 AUTO REVERSE DOCUMENT FEEDER INSTALLATION...................1-44
1.10.1 ACCESSORY CHECK..................................................................1-44
1.10.2 INSTALLATION PROCEDURE....................................................1-45
1.11 LCT INSTALLATION.............................................................................1-47
1.11.1 ACCESSORY CHECK..................................................................1-47
SM i B003/B004/B006/B007
Rev. 04/2002
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1.11.2 INSTALLATION PROCEDURE....................................................1-48
1.12 PLATEN COVER INSTALLATION........................................................1-50
1.13 KEY COUNTER INSTALLATION..........................................................1-51
1.14 ANTI-CONDENSATION HEATER.........................................................1-53
1.15 TRAY HEATER.....................................................................................1-55
1.16 TRAY HEATER (OPTIONAL PAPER TRAY UNIT)...............................1-56
1.17 OPTIONAL USER ACCOUNT ENHANCEMENT UNIT.........................1.57
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE SCHEDULE.............................. 2-1
2.1 PM TABLE.................................................................................................2-1
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT........................................ 3-1
3.1 GENERAL CAUTIONS..............................................................................3-1
3.1.1 LASER UNIT ....................................................................................3-1
3.1.2 USED TONER..................................................................................3-1
3.2 SPECIAL TOOLS AND LUBRICANTS......................................................3-2
3.2.1 SPECIAL TOOLS.............................................................................3-2
3.2.2 LUBRICANTS................................................................................... 3-2
3.2.3 SYMBOLS USED IN TEXT...............................................................3-2
3.3 FRONT DOOR ..........................................................................................3-3
3.4 DUPLEX UNIT...........................................................................................3-3
3.5 UPPER RIGHT COVER............................................................................3-4
3.6 BY-PASS TRAY ........................................................................................3-5
3.7 REAR COVERS ........................................................................................3-6
3.7.1 REAR UPPER COVER.....................................................................3-6
3.7.2 REAR LOWER COVER....................................................................3-6
3.8 LEFT COVERS..........................................................................................3-7
3.8.1 LEFT UPPER COVER......................................................................3-7
3.9 SCANNER UNIT........................................................................................3-8
3.9.1 ARDF ................................................................................................3-8
3.9.2 EXPOSURE GLASS.........................................................................3-9
3.9.3 SCANNER EXTERIOR PANELS/OPERATION PANEL.................3-10
3.9.4 LENS BLOCK/SBU ASSEMBLY ....................................................3-11
3.9.5 ORIGINAL SIZE SENSORS...........................................................3-12
3.9.6 EXPOSURE LAMP.........................................................................3-13
3.9.7 SCANNER HP SENSOR/PLATEN COVER SENSOR...................3-14
3.9.8 SCANNER MOTOR........................................................................3-15
3.9.9 LAMP STABILIZER AND SCANNER MOTOR DRIVE BOARD .....3-16
3.9.10 SCANNER WIRE..........................................................................3-17
3.10 LASER UNIT.........................................................................................3-21
3.10.1 CAUTION DECAL LOCATIONS...................................................3-21
3.10.2 LASER UNIT ................................................................................3-22
3.10.3 POLYGON MIRROR MOTOR......................................................3-23
3.10.4 LASER SYNCHRONIZATION DETECTOR.................................. 3-24
B003/B004/B006/B007 ii SM
Rev. 02/2002
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3.10.5 LD UNIT........................................................................................3-24
Laser beam pitch adjustment..............................................................3-25
3.11 PHOTOCONDUCTOR UNIT (PCU)......................................................3-26
3.11.1 PCU..............................................................................................3-26
3.11.2 DRUM...........................................................................................3-27
3.11.3 PICK-OFF PAWLS.......................................................................3-28
3.11.4 CHARGE ROLLER CLEANING PAD & ROLLER BRUSH............3-29
3.11.5 DRUM CLEANING BLADE...........................................................3-31
3.11.6 ID SENSOR..................................................................................3-31
3.12 DEVELOPMENT ...................................................................................3-32
3.12.1 DEVELOPMENT UNIT.................................................................3-32
3.12.2 DEVELOPMENT FILTER.............................................................3-33
3.12.3 DEVELOPMENT ROLLER...........................................................3-33
3.12.4 DEVELOPER................................................................................3-34
3.12.5 TD SENSOR.................................................................................3-36
3.13 TRANSFER UNIT..................................................................................3-37
3.13.1 TRANSFER BELT UNIT...............................................................3-37
3.13.2 TRANSFER BELT........................................................................3-38
3.13.3 TRANSFER BELT CLEANING BLADE AND TONER OVERFLOW
SENSOR.......................................................................................3-39
3.14 PAPER FEED........................................................................................3-40
3.14.1 PICK-UP, SEPARATION, AND FEED ROLLERS ........................3-40
3.14.2 LOWER RIGHT COVER...............................................................3-41
3.14.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED
CLUTCHES...................................................................................3-42
3.14.4 UPPER PAPER FEED UNIT FOR TRAY 1..................................3-43
3.14.5 LOWER PAPER FEED UNIT FOR TRAY 2.................................3-44
3.14.6 PAPER END/PAPER HEIGHT/RELAY SENSORS......................3-45
3.14.7 REGISTRATION SENSOR...........................................................3-46
3.14.8 TRAY LIFT MOTOR.....................................................................3-48
3.14.9 FEED/DEVELOPMENT MOTOR..................................................3-49
3.15 FUSING.................................................................................................3-50
3.15.1 FUSING UNIT...............................................................................3-50
3.15.2 FUSING UNIT EXIT GUIDE .........................................................3-51
3.15.3 HOT ROLLER STRIPPERS .........................................................3-51
3.15.4 FUSING LAMPS...........................................................................3-52
3.15.5 THERMISTORS AND THERMOSTATS.......................................3-54
3.15.6 FUSING ROLLER/PRESSURE ROLLER.....................................3-55
3.16 BY-PASS TRAY....................................................................................3-57
3.16.1 COVER REPLACEMENT.............................................................3-57
3.16.2 BY-PASS PAPER FEED AND PICK-UP ROLLER
REPLACEMENT...........................................................................3-58
3.16.3 BY-PASS SEPARATION ROLLER REPLACEMENT...................3-59
3.16.4 PAPER END SENSOR AND PICK-UP SOLENOID
REPLACEMENT...........................................................................3-60
3.16.5 PAPER SIZE SENSOR BOARD REPLACEMENT.......................3-61
3.16.6 BY-PASS TABLE REMOVAL.......................................................3-62
3.16.7 PAPER FEED CLUTCH REPLACEMENT....................................3-63
SM iii B003/B004/B006/B007
3.17 DUPLEX UNIT.......................................................................................3-64
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3.17.1 DUPLEX COVER REMOVAL.......................................................3-64
3.17.2 DUPLEX ENTRANCE SENSOR REPLACEMENT.......................3-65
3.17.3 DUPLEX EXIT SENSOR REPLACEMENT ..................................3-66
3.18 DRIVE AREA.........................................................................................3-67
3.18.1 REGISTRATION CLUTCH AND TRANSFER BELT
CONTACT CLUTCH.....................................................................3-67
3.18.2 MAIN MOTOR..............................................................................3-68
3.18.3 TONER SUPPLY MOTOR............................................................ 3-69
3.19 PRINTED CIRCUIT BOARDS............................................................... 3-70
3.19.1 HIGH VOLTAGE POWER SUPPLY.............................................3-70
3.19.2 I/O BOARD...................................................................................3-71
3.19.3 BICU BOARD...............................................................................3-72
3.19.4 PSU..............................................................................................3-72
3.20 HARD DISK/CONTROLLER BOARD ....................................................3-73
3.21 COPY ADJUSTMENTS: PRINTING/SCANNING..................................3-74
3.21.1 PRINTING ....................................................................................3-74
Registration - Leading Edge/Side-to-Side...........................................3-74
Blank Margin.......................................................................................3-75
Main Scan Magnification.....................................................................3-75
Parallelogram Image Adjustment........................................................3-76
3.21.2 SCANNING...................................................................................3-77
Registration: Platen Mode...................................................................3-77
Magnification.......................................................................................3-77
Sub Scan Magnification......................................................................3-77
3.21.3 ADF IMAGE ADJUSTMENT.........................................................3-78
Registration.........................................................................................3-78
3.21.4 TOUCH SCREEN CALIBRATION................................................3-79
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................ 4-1
4.1 SERVICE CALL CONDITIONS.................................................................4-1
4.1.1 SUMMARY.......................................................................................4-1
4.1.2 SC CODE DESCRIPTIONS .............................................................4-2
4.2 ELECTRICAL COMPONENT DEFECTS ................................................4-16
4.2.1 SENSORS......................................................................................4-16
4.2.2 SWITCHES.....................................................................................4-17
4.3 BLOWN FUSE CONDITIONS.................................................................4-18
4.4 LEDS.......................................................................................................4-18
4.5 TEST POINTS.........................................................................................4-18
SERVICE TABLES
5. SERVICE TABLES...................................................................... 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 SERVICE PROGRAM MODE OPERATION.....................................5-1
B003/B004/B006/B007 iv SM
Entering and Exiting SP mode..............................................................5-1
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SP Mode Button Summary...................................................................5-2
Switching Between SP Mode and Copy Mode for Test Printing ...........5-3
Selecting the Program Number.............................................................5-3
5.1.2 SERVICE PROGRAM MODE TABLES............................................5-4
SP1-xxx: Feed......................................................................................5-4
SP2-xxx: Drum......................................................................................5-7
SP3-xxx: Process................................................................................5-15
SP4-xxx: Scanner...............................................................................5-16
SP5-xxx: Mode ...................................................................................5-29
SP6-xxx: Peripherals..........................................................................5-36
SP7-xxx: Data Log..............................................................................5-38
5.1.3 TEST PATTERN PRINTING: SP2-902........................................... 5-47
Test Pattern Table (SP2-902-2: IPU Test Print)..................................5-47
Test Pattern Table: SP2-902-3 Printing Test Patterns........................5-48
5.1.4 INPUT CHECK...............................................................................5-49
Main Machine Input Check: SP5-803 .................................................5-49
ARDF Input Check: SP6-007..............................................................5-53
5.1.5 OUTPUT CHECK...........................................................................5-54
Main Machine Output Check: SP5-804...............................................5-54
ARDF Output Check: SP6-008)..........................................................5-56
5.1.6 SMC PRINT OUT LISTS: SP5-990.................................................5-56
5.1.7 NIP BAND WIDTH ADJUSTMENT: SP1-109.................................5-60
5.1.8 MEMORY ALL CLEAR: SP5-801...................................................5-61
5.1.9 SOFTWARE RESET......................................................................5-62
5.1.10 SYSTEM SETTINGS AND COPY SETTING RESET...................5-62
System Setting Reset.........................................................................5-62
Copier Setting Reset...........................................................................5-63
5.2 SOFTWARE DOWNLOAD......................................................................5-64
5.3 UPLOADING/DOWNLOADING NVRAM DATA.......................................5-65
5.3.1 UPLOADING NVRAM DATA (SP5-824).........................................5-65
5.3.2 DOWNLOADING NVRAM DATA (SP5-825)..................................5-66
5.4 SELF-DIAGNOSTIC MODE....................................................................5-67
5.4.1 SELF-DIAGNOSTIC MODE AT POWER ON.................................5-67
5.4.2 DETAILED SELF-DIAGNOSTIC MODE.........................................5-68
Executing Detailed Self-Diagnosis......................................................5-68
5.5 USER PROGRAM MODE.......................................................................5-70
5.5.1 HOW TO USE UP MODE ...............................................................5-70
UP Mode Initial Screen: User Tools/Counter Display..........................5-70
System Settings..................................................................................5-70
Copier/Document Server Features.....................................................5-71
Printer, Facsimile, Scanner Settings...................................................5-71
Counter...............................................................................................5-72
5.6 DIP SWITCHES.......................................................................................5-73
SM v B003/B004/B006/B007
DETAILED DESCRIPTIONS
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6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW...............................................................................................6-1
6.1.1 COMPONENT LAYOUT...................................................................6-1
6.1.2 PAPER PATH...................................................................................6-3
6.1.3 DRIVE LAYOUT...............................................................................6-4
6.2 BOARD STRUCTURE...............................................................................6-5
6.2.1 BLOCK DIAGRAM............................................................................6-5
6.2.2 CONTROLLER.................................................................................6-7
6.3 COPY PROCESS OVERVIEW .................................................................6-9
Exposure...............................................................................................6-9
Drum charge.........................................................................................6-9
Laser exposure.....................................................................................6-9
Development.........................................................................................6-9
Image transfer.....................................................................................6-10
Separation .......................................................................................... 6-10
ID sensor ............................................................................................6-10
Cleaning..............................................................................................6-10
Quenching ..........................................................................................6-10
6.4.1 OVERVIEW....................................................................................6-11
SCANNER DRIVE ..............................................................................6-12
Book Mode..........................................................................................6-12
ADF mode...........................................................................................6-12
6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE.........................6-13
6.5 IMAGE PROCESSING............................................................................6-15
6.5.1 OVERVIEW....................................................................................6-15
6.5.2 SBU (SENSOR BOARD UNIT).......................................................6-16
6.5.3 AUTO IMAGE DENSITY (ADS) ......................................................6-17
6.5.4 IPU (IMAGE PROCESSING UNIT).................................................6-18
Overview.............................................................................................6-18
6.5.5 IMAGE PROCESSING MODES.....................................................6-19
6.5.6 SUMMARY OF IMAGE PROCESSING FUNCTIONS....................6-21
6.5.7 IMAGE PROCESSING STEPS AND RELATED SP MODES.........6-22
Text Mode...........................................................................................6-22
Text/Photo Mode ................................................................................6-23
Photo Mode ........................................................................................6-24
Pale (Low-Density Mode)....................................................................6-25
Generation Copy Mode.......................................................................6-26
Auto shading (shading correction)......................................................6-27
Background erase...............................................................................6-27
Independent dot erase........................................................................6-28
Filtering...............................................................................................6-29
Pre-Filter.............................................................................................6-29
Text Mode...........................................................................................6-30
Photo Mode ........................................................................................6-31
Text/Photo Mode ................................................................................6-32
Low Density Mode..............................................................................6-33
B003/B004/B006/B007 vi SM
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