B089/B093SERVICE MANUAL

001783MIURICOH GROUP COMPANIES

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B089/B

093SERVIC

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RICOH GROUP COMPANIES

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B089/B093SERVICE MANUAL

001783MIU

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It is the reader's responsibility when discussing the information containedwithin this document to maintain a level of confidentiality that is in the bestinterest of Ricoh Corporation and its member companies.

NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANYFASHION AND DISTRIBUTED WITHOUT THE PRIOR

PERMISSION OF RICOH CORPORATION.

All product names, domain names or product illustrations, includingdesktop images, used in this document are trademarks, registeredtrademarks or the property of their respective companies.They are used throughout this book in an informational or editorial fashiononly and for the benefit of such companies. No such use, or the use ofany trade name, or web site is intended to convey endorsement or otheraffiliation with Ricoh products.

2003 RICOH Corporation. All rights reserved.

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The Service Manual contains informationregarding service techniques, procedures,processes and spare parts of office equipmentdistributed by Ricoh Corporation. Users of thismanual should be either service trained orcertified by successfully completing a RicohTechnical Training Program.

Untrained and uncertified users utilizinginformation contained in this service manual torepair or modify Ricoh equipment risk personalinjury, damage to property or loss of warrantyprotection.

Ricoh Corporation

WARNING

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LEGENDPRODUCT CODE COMPANY

GESTETNER LANIER RICOH SAVINB089 DSm622 LD122 Aficio 2022 4022B093 DSm627 LD127 Aficio 2027 4027

DOCUMENTATION HISTORYREV. NO. DATE COMMENTS

* 10/2003 Original Printing

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B089/B093TABLE OF CONTENTS

OVERALL INFORMATION

1. OVERALL MACHINE INFORMATION......................................... 1-11.1 SPECIFICATIONS...............................................................................1-1

1.2 MACHINE CONFIGURATION...................................................................1-41.2.1 SYSTEM COMPONENTS ................................................................1-41.2.2 INSTALLABLE OPTIONAL TABLE...................................................1-6

Copier options.......................................................................................1-6Fax option .............................................................................................1-6Printer/scanner options .........................................................................1-6

1.3 PAPER PATH............................................................................................1-71.4 MECHANICAL COMPONENT LAYOUT ...................................................1-81.5 ELECTRICAL COMPONENT DESCRIPTIONS ......................................1-101.6 DRIVE LAYOUT ......................................................................................1-131.7 COPY PROCESS....................................................................................1-14

1.7.1 OVERVIEW ....................................................................................1-141.8 BOARD STRUCTURE.............................................................................1-16

1.8.1 OVERVIEW ....................................................................................1-161.8.2 CONTROLLER ...............................................................................1-18

DETAILED DESCRIPTIONS

2. DETAILED SECTION DESCRIPTIONS....................................... 2-12.1 SUMMARY ................................................................................................2-12.2 SCANNING................................................................................................2-2

2.2.1 OVERVIEW ......................................................................................2-22.2.2 SCANNER DRIVE ............................................................................2-32.2.3 ORIGINAL SIZE DETECTION IN PLATEN MODE...........................2-4

2.3 IMAGE PROCESSING ..............................................................................2-62.3.1 OVERVIEW ......................................................................................2-62.3.2 SBU (SENSOR BOARD UNIT).........................................................2-72.3.3 AUTO IMAGE DENSITY...................................................................2-82.3.4 IPU (IMAGE PROCESSING UNIT)...................................................2-92.3.5 VIDEO CONTROL UNIT (VCU)......................................................2-21

2.4 LASER EXPOSURE................................................................................2-222.4.1 OVERVIEW ....................................................................................2-222.4.2 AUTO POWER CONTROL (APC)..................................................2-232.4.3 LD SAFETY SWITCH.....................................................................2-24

2.5 PHOTOCONDUCTOR UNIT (PCU) ........................................................2-252.5.1 OVERVIEW ....................................................................................2-252.5.2 DRIVE.............................................................................................2-262.5.3 NEW PCU DETECTION.................................................................2-27

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2.6 DRUM CHARGE .....................................................................................2-282.6.1 OVERVIEW ....................................................................................2-282.6.1 CHARGE ROLLER VOLTAGE CORRECTION ..............................2-292.6.2 ID SENSOR PATTERN PRODUCTION TIMING............................2-302.6.3 DRUM CHARGE ROLLER CLEANING..........................................2-31

2.7 DEVELOPMENT .....................................................................................2-322.7.1 OVERVIEW ....................................................................................2-322.7.2 DRIVE.............................................................................................2-332.7.3 DEVELOPER MIXING....................................................................2-342.7.4 DEVELOPMENT BIAS ...................................................................2-352.7.5 TONER SUPPLY............................................................................2-362.7.6 TONER DENSITY CONTROL ........................................................2-382.7.7 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS...........2-422.7.8 TONER NEAR END/END DETECTION AND RECOVERY............2-42

2.8 DRUM CLEANING AND TONER RECYCLING.......................................2-442.8.1 DRUM CLEANING..........................................................................2-442.8.2 TONER RECYCLING .....................................................................2-45

2.9 PAPER FEED..........................................................................................2-462.9.1 OVERVIEW ....................................................................................2-462.9.2 PAPER FEED DRIVE MECHANISM ..............................................2-472.9.3 PAPER FEED AND SEPARATION MECHANISM..........................2-482.9.4 PAPER LIFT MECHANISM ............................................................2-492.9.5 PAPER END DETECTION .............................................................2-502.9.6 PAPER HEIGHT DETECTION .......................................................2-512.9.7 FEED PRESSURE ADJUSTMENT FOR PAPER SIZE..................2-522.9.8 PAPER SIZE DETECTION.............................................................2-552.9.9 SPECIAL PAPER SETTING...........................................................2-562.9.10 SIDE AND END FENCES.............................................................2-572.9.11 PAPER REGISTRATION..............................................................2-58

2.10 IMAGE TRANSFER AND PAPER SEPARATION.................................2-592.10.1 OVERVIEW ..................................................................................2-592.10.2 IMAGE TRANSFER CURRENT TIMING......................................2-602.10.3 TRANSFER ROLLER CLEANING................................................2-612.10.4 PAPER SEPARATION MECHANISM...........................................2-61

2.11 IMAGE FUSING AND PAPER EXIT......................................................2-622.11.1 OVERVIEW ..................................................................................2-622.11.2 FUSING DRIVE AND RELEASE MECHANISM ...........................2-632.11.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM.....................2-642.11.4 PRESSURE ROLLER...................................................................2-652.11.5 CLEANING MECHANISM ............................................................2-652.11.6 FUSING TEMPERATURE CONTROL..........................................2-662.11.7 OVERHEAT PROTECTION .........................................................2-682.11.8 PAPER EXIT ................................................................................2-68

2.12 ENERGY SAVER MODES ....................................................................2-692.12.1 OVERVIEW ..................................................................................2-692.12.2 ENERGY SAVER MODE..............................................................2-702.12.3 AUTO OFF MODE........................................................................2-71

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INSTALLATION

3. INSTALLATION PROCEDURE.................................................... 3-13.1 INSTALLATION REQUIREMENTS ...........................................................3-1

3.1.1 ENVIRONMENT ...............................................................................3-13.1.2 MACHINE LEVEL.............................................................................3-13.1.3 MINIMUM SPACE REQUIREMENTS...............................................3-23.1.4 POWER REQUIREMENTS ..............................................................3-3

3.2 COPIER INSTALLATION ..........................................................................3-43.2.1 POWER SOCKETS FOR PERIPHERALS .......................................3-43.2.2 INSTALLATION FLOW CHART .......................................................3-53.2.3 ACCESSORY CHECK......................................................................3-63.2.4 INSTALLATION PROCEDURE ........................................................3-7

3.3 PAPER TRAY UNIT INSTALLATION ......................................................3-113.3.1 ACCESSORY CHECK....................................................................3-113.3.2 INSTALLATION PROCEDURE ......................................................3-11

3.4 LCT INSTALLATION ...............................................................................3-143.4.1 ACCESSORY CHECK....................................................................3-143.4.2 INSTALLATION PROCEDURE ......................................................3-14

3.5 AUTO REVERSE DOCUMENT FEEDER INSTALLATION.....................3-173.5.1 ACCESSORY CHECK....................................................................3-173.5.2 INSTALLATION PROCEDURE ......................................................3-18

3.6 INTERCHANGE UNIT INSTALLATION...................................................3-223.6.1 COMPONENT CHECK...................................................................3-223.6.2 INSTALLATION PROCEDURE ......................................................3-23

3.7 1-BIN TRAY UNIT INSTALLATION .........................................................3-253.7.1 COMPONENT CHECK...................................................................3-253.7.2 INSTALLATION PROCEDURE ......................................................3-26

3.8 SHIFT TRAY............................................................................................3-293.8.1 COMPONENT CHECK...................................................................3-293.8.2 INSTALLATION PROCEDURE ......................................................3-30

3.9 BY-PASS FEED UNIT INSTALLATION...................................................3-323.9.1 COMPONENTS CHECK ................................................................3-323.9.2 INSTALLATION PROCEDURE ......................................................3-33

3.10 DUPLEX UNIT INSTALLATION ............................................................3-353.10.1 ACCESSORY CHECK..................................................................3-353.10.2 INSTALLATION PROCEDURE ....................................................3-36

3.11 BRIDGE UNIT INSTALLATION.............................................................3-383.11.1 ACCESSORY CHECK..................................................................3-383.11.2 INSTALLATION PROCEDURE ....................................................3-39

3.12 1000-SHEET FINISHER INSTALLATION .............................................3-413.12.1 ACCESSORY CHECK..................................................................3-413.12.2 INSTALLATION PROCEDURE ....................................................3-42

3.13 500-SHEET FINISHER INSTALLATION ...............................................3-453.13.1 ACCESSORY CHECK..................................................................3-453.13.2 INSTALLATION PROCEDURE ....................................................3-46

3.14 PLATEN COVER INSTALLATION ........................................................3-483.15 KEY COUNTER INSTALLATION ..........................................................3-49

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3.16 OPTICS ANTI-CONDENSATION HEATER...........................................3-513.17 TRAY HEATER .....................................................................................3-523.18 TRAY HEATER (OPTIONAL PAPER TRAY UNIT) ...............................3-543.19 TRAY HEATER (OPTIONAL LCT) ........................................................3-573.20 OPTIONAL BOARDS AND DIMMS.......................................................3-60

3.20.1 REMOVING THE COVERS..........................................................3-603.20.2 PRINTER/SCANNER MODULE (B577) .......................................3-61

Printer/Scanner Module ROM DIMM Installation ................................3-623.20.3 128 MB MEMORY (G331) ............................................................3-633.20.4 HDD (B592) ..................................................................................3-643.20.5 NIB (B525-17)...............................................................................3-663.20.6 IEEE 1394 INTERFACE KIT (G336).............................................3-673.20.7 IEEE 802.11B INTERFACE KIT (B515)........................................3-693.20.8 USB 2.0 BOARD (B525-01)..........................................................3-733.20.9 BLUETOOTH UNIT 2045 (G354) .................................................3-753.20.10 POSTSCRIPT 3 UNIT (G354-05) ...............................................3-773.20.11 FILE FORMAT CONVERTER (B519).........................................3-783.20.12 CHECK ALL CONNECTIONS ....................................................3-793.20.12 USER ACCOUNT ENHANCEMENT UNIT (B443) .....................3-80

SERVICE TABLES4. SERVICE TABLES....................................................................... 4-1

4.1 GENERAL CAUTION ................................................................................4-14.1.1 PCU (PHOTOCONDUCTOR UNIT) .................................................4-14.1.2 TRANSFER ROLLER UNIT..............................................................4-14.1.3 SCANNER UNIT...............................................................................4-14.1.4 LASER UNIT ....................................................................................4-24.1.5 FUSING UNIT...................................................................................4-24.1.6 PAPER FEED...................................................................................4-24.1.7 OTHERS...........................................................................................4-2

4.2 SERVICE PROGRAM MODE....................................................................4-34.2.1 SERVICE PROGRAM MODE OPERATION.....................................4-3

Entering and Exiting SP mode ..............................................................4-3SP Mode Button Summary ...................................................................4-4Switching Between SP Mode and Copy Mode for Test Printing ...........4-5Selecting the Program Number.............................................................4-5

4.2.2 SERVICE PROGRAM MODE TABLES............................................4-6SP1XXX: Feed......................................................................................4-7SP2XXX: Drum ...................................................................................4-16SP4-XXX: Scanner .............................................................................4-27SP5XXX: Mode...................................................................................4-34SP6XXX: Peripherals..........................................................................4-57SP7XXX: Data Log ...........................................................................4-59SP8-xxx: Data Log2............................................................................4-66

4.2.3 TEST PATTERN PRINTING (SP2902-3) .......................................4-994.2.4 INPUT CHECK .............................................................................4-100

Main Machine Input Check (SP5803) ...............................................4-100ARDF Input Check (SP6007)............................................................4-103

Rev. 12/2003

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Finisher Input Check (SP6117).........................................................4-1044.2.5 OUTPUT CHECK .........................................................................4-106

Main Machine Output Check (SP5804).............................................4-106ARDF Output Check (SP6008) .........................................................4-108Finisher Output Check (SP6118) ......................................................4-108

4.2.6 SMC DATA LISTS (SP5990) ........................................................4-1094.2.7 MEMORY ALL CLEAR (SP5801) .................................................4-109

Using a Flash Memory Card .............................................................4-109Without Using a Flash Memory Card ................................................4-111

4.2.8 UPLOADING/DOWNLOADING NVRAM DATA............................4-112Uploading NVRAM Data (SP5824) ...................................................4-112Downloading NVRAM Data (SP5825)...............................................4-113

4.2.9 APS OUTPUT DISPLAY (SP4301)...............................................4-1144.2.10 DF APS SENSOR OUTPUT DISPLAY (SP6901).......................4-1154.2.11 NIP BAND WIDTH MEASUREMENT (SP1109) .........................4-116

4.3 PROGRAM DOWNLOAD......................................................................4-1174.4 SOFTWARE RESET .............................................................................4-1184.5 SYSTEM SETTINGS AND COPY SETTING RESET............................4-119

4.5.1 SYSTEM SETTING RESET .........................................................4-1194.5.2 COPIER SETTING RESET ..........................................................4-120

4.6 USER TOOLS .......................................................................................4-1214.6.1 HOW TO USE UP MODE.............................................................4-121

UP Mode Initial Screen: User Tools/Counter Display........................4-121System Settings................................................................................4-121Copier/Document Server Features ...................................................4-121Printer, Facsimile, Scanner Settings.................................................4-122Inquiry ...............................................................................................4-122Counter .............................................................................................4-123

4.7 LEDS .....................................................................................................4-124Controller ..........................................................................................4-124SBCU................................................................................................4-124IPU....................................................................................................4-124

4.8 DIP SWITCHES.....................................................................................4-124Controller: DIP SW2..........................................................................4-124SBCU: DIP SW102 ...........................................................................4-124

4.9 SPECIAL TOOLS AND LUBRICANTS ............................................4-1254.9.1 SPECIAL TOOLS .........................................................................4-1254.9.2 LUBRICANTS...............................................................................4-125

4.10 USING THE DEBUG LOG...................................................................4-1264.10.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG .........4-1264.10.2 RETRIEVING THE DEBUG LOG FROM THE HDD..................4-1294.10.3 RECORDING ERRORS MANUALLY .........................................4-130

PREVENTIVE MAINTENANCE

5. PREVENTIVE MAINTENANCE.................................................... 5-15.1 PM TABLE.................................................................................................5-1

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REPLACEMENT AND ADJUSTMENT

6. REPLACEMENT AND ADJUSTMENT ........................................ 6-16.1 SCANNER UNIT........................................................................................6-1

6.1.1 EXPOSURE GLASS.........................................................................6-16.1.2 SCANNER EXTERIOR/OPERATION PANEL ..................................6-26.1.3 LENS BLOCK ASSEMBLY...............................................................6-36.1.4 ORIGINAL SIZE SENSORS .............................................................6-46.1.5 EXPOSURE LAMP...........................................................................6-56.1.6 SCANNER MOTOR/LAMP STABILIZER..........................................6-66.1.7 SCANNER WIRES ...........................................................................6-7

6.2 LASER UNIT ...........................................................................................6-106.2.1 CAUTION DECAL LOCATIONS.....................................................6-106.2.2 LASER UNIT ..................................................................................6-116.2.3 POLYGON MIRROR MOTOR ........................................................6-126.2.4 LD UNIT..........................................................................................6-126.2.5 LASER SYNCHRONIZATION DETECTOR....................................6-13

6.3 PHOTOCONDUCTOR UNIT (PCU) ........................................................6-146.3.1 PCU................................................................................................6-14

6.4 TRANSFER UNIT....................................................................................6-156.4.1 TRANSFER ROLLER UNIT............................................................6-156.4.2 IMAGE DENSITY SENSOR ...........................................................6-16

6.5 FUSING/EXIT ..........................................................................................6-176.5.1 FUSING UNIT.................................................................................6-176.5.2 THERMISTORS..............................................................................6-176.5.3 THERMOFUSE ..............................................................................6-186.5.4 HOT ROLLER AND FUSING LAMP...............................................6-206.5.5 PRESSURE ROLLER/CLEANING ROLLER .................................6-216.5.6 PAPER EXIT SENSOR/PAPER OVERFLOW SENSOR................6-22

6.6 PAPER FEED..........................................................................................6-236.6.1 FEED ROLLERS: TRAY 1..............................................................6-236.6.2 FEED ROLLER: TRAY 2 ................................................................6-246.6.3 PAPER END SENSOR...................................................................6-256.6.4 PAPER TRAY LIFT MOTORS........................................................6-266.6.5 REGISTRATION CLUTCH .............................................................6-276.6.6 PAPER FEED CLUTCHES.............................................................6-286.6.7 RELAY CLUTCHES........................................................................6-296.6.8 PAPER SIZE DETECTOR..............................................................6-306.6.9 REGISTRATION SENSOR.............................................................6-316.6.10 RELAY SENSORS .......................................................................6-32

6.7 PCBS AND OTHER ITEMS.....................................................................6-336.7.1 CONTROLLER BOARD .................................................................6-336.7.2 SBCU BOARD................................................................................6-346.7.3 POWER PACK ...............................................................................6-346.7.4 MAIN MOTOR ................................................................................6-356.7.5 PSU ................................................................................................6-36

6.8 COPY ADJUSTMENTS: PRINTING/SCANNING....................................6-376.8.1 PRINTING ......................................................................................6-37

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6.8.2 SCANNING.....................................................................................6-406.8.3 ADF IMAGE ADJUSTMENT...........................................................6-426.8.4 TOUCH SCREEN CALIBRATION ..................................................6-43

6.9 IDENTIFYING SKEWED, TRAPEZOID ANDPARALLELOGRAM IMAGES................................................................. 6-44

6.9.1 SKEWED IMAGES .........................................................................6-446.9.2 TRAPEZOID IMAGES ....................................................................6-446.9.3 PARALLELOGRAM IMAGES .........................................................6-45

6.10 CHECKING THE IMAGE WITH THE TRIMMING PATTERN................6-466.11 CORRECTING THE IMAGES ...............................................................6-47

6.11.1 CORRECTING SKEWED IMAGES ..............................................6-476.11.2 CORRECTING TRAPEZOID IMAGES .........................................6-50

TOUBLESHOOTING

7. TROUBLESHOOTING ................................................................. 7-17.1 SERVICE CALL CONDITIONS .................................................................7-1

7.1.1 SUMMARY .......................................................................................7-17.1.2 SC CODE DESCRIPTIONS .............................................................7-2

7.2 SELF-DIAGNOSTIC MODE ....................................................................7-167.2.1 SELF-DIAGNOSTIC MODE AT POWER ON .................................7-167.2.2 DETAILED SELF-DIAGNOSTIC MODE.........................................7-17

Executing Detailed Self-Diagnosis ......................................................7-177.3 PAPER FEED TROUBLESHOOTING.....................................................7-197.4 SKEWED IMAGE ....................................................................................7-207.5 ELECTRICAL COMPONENT DEFECTS ................................................7-21

7.5.1 SENSORS ......................................................................................7-217.5.2 SWITCHES.....................................................................................7-23

7.6 BLOWN FUSE CONDITIONS .................................................................7-24

PAPER TRAY UNIT (A860/B390)

1. OVERALL MACHINE INFORMATION......................................... 8-11.1 SPECIFICATIONS.....................................................................................8-11.2 MECHANICAL COMPONENT LAYOUT ...................................................8-21.3 ELECTRICAL COMPONENT LAYOUT.....................................................8-31.4 ELECTRICAL COMPONENT DESCRIPTION...........................................8-41.5 DRIVE LAYOUT ........................................................................................8-5

2. DETAILED DESCRIPTIONS ........................................................ 8-62.1 PAPER FEED AND SEPARATION MECHANISM ....................................8-62.2 PAPER LIFT MECHANISM .......................................................................8-72.3 PAPER END DETECTION ........................................................................8-92.4 PAPER HEIGHT DETECTION ................................................................8-102.5 PAPER SIZE DETECTION......................................................................8-12

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2.6 SIDE AND END FENCES .......................................................................8-13Side Fences........................................................................................8-13End Fence ..........................................................................................8-13

3. REPLACEMENT AND ADJUSTMENT ...................................... 8-143.1 FEED ROLLER REPLACEMENT............................................................8-143.2 TRAY MAIN BOARD REPLACEMENT ...................................................8-153.3 TRAY MOTOR REPLACEMENT.............................................................8-153.4 RELAY CLUTCH REPLACEMENT .........................................................8-163.5 UPPER PAPER FEED CLUTCH REPLACEMENT .................................8-173.6 LOWER PAPER FEED CLUTCH REPLACEMENT ................................8-183.7 LIFT MOTOR REPLACEMENT...............................................................8-193.8 PAPER END SENSOR REPLACEMENT................................................8-203.9 VERTICAL TRANSPORT SENSOR REPLACEMENT ............................8-203.10 PAPER SIZE SWITCH REPLACEMENT ..............................................8-21

LCT (A862/B391)

1. OVERALL MACHINE INFORMATION......................................... 9-11.1 SPECIFICATIONS.....................................................................................9-11.2 MECHANICAL COMPONENT LAYOUT ...................................................9-21.3 ELECTRICAL COMPONENT LAYOUT.....................................................9-31.4 ELECTRICAL COMPONENT DESCRIPTIONS ........................................9-4

2. DETAILED SECTION DESCRIPTIONS ....................................... 9-52.1 PAPER FEED............................................................................................9-52.2 REVERSE ROLLER AND PICK-UP ROLLER RELEASE .........................9-62.3 TRAY LIFT.................................................................................................9-72.4 NEAR END/END DETECTION..................................................................9-82.5 RIGHT TRAY SIDE FENCE ......................................................................9-92.6 LEFT TRAY REAR FENCE .......................................................................9-92.7 RIGHT TRAY PAPER END DETECTION................................................9-10

3. REPLACEMENT AND ADJUSTMENT ...................................... 9-113.1 DETACHING THE TRAY FROM THE MAINFRAME...............................9-113.2 REAR FENCE HP SENSOR ...................................................................9-113.3 CHANGING THE TRAY PAPER SIZE ....................................................9-123.4 LEFT TRAY PAPER END SENSOR .......................................................9-123.5 TRAY LIFT MOTOR ................................................................................9-133.6 TRAY MOTOR.........................................................................................9-143.7 PAPER FEED CLUTCH AND RELAY CLUTCH......................................9-153.8 PAPER FEED UNIT ................................................................................9-163.9 UPPER LIMIT, RIGHT TRAY PAPER END,

AND RELAY SENSORS .........................................................................9-173.10 REAR FENCE MOTOR .........................................................................9-183.11 PICK-UP/PAPER FEED/REVERSE ROLLERS.....................................9-19

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AUTO REVERSE DOCUMENT FEEDER (B386)

1. OVERALL MACHINE INFORMATION....................................... 10-11.1 SPECIFICATIONS...................................................................................10-11.2 MECHANICAL COMPONENT LAYOUT .................................................10-21.3 ELECTRICAL COMPONENT LAYOUT...................................................10-31.4 ELECTRICAL COMPONENT DESCRIPTION.........................................10-41.5 DRIVE LAYOUT ......................................................................................10-5

2. DETAILED SECTION DESCRIPTIONS ..................................... 10-62.1 ORIGINAL SIZE DETECTION.................................................................10-62.2 MIXED ORIGINAL SIZE MODE ..............................................................10-92.3 PICK-UP AND SEPARATION ...............................................................10-102.4 ORIGINAL TRANSPORT AND EXIT.....................................................10-11

2.4.1 SINGLE-SIDED ORIGINALS........................................................10-112.4.2 DOUBLE-SIDED ORIGINALS ......................................................10-122.4.3 ORIGINAL TRAILING EDGE SENSOR........................................10-13

2.5 STAMP ..................................................................................................10-142.6 TIMING CHART.....................................................................................10-152.7 CONDITION OF JAM DETECTION.......................................................10-162.8 OVERALL ELECTRICAL CIRCUIT .......................................................10-17

3. SERVICE TABLES................................................................... 10-183.1 DIP SWITCHES.....................................................................................10-18

4. REPLACEMENT AND ADJUSTMENT .................................... 10-194.1 DF EXIT TABLE AND COVER ..............................................................10-194.2 ORIGINAL FEED UNIT .........................................................................10-204.3 LEFT COVER........................................................................................10-214.4 PICK-UP ROLLER.................................................................................10-224.5 FEED BELT...........................................................................................10-234.6 SEPARATION ROLLER ........................................................................10-244.7 ORIGINAL SET/ORIGINAL REVERSE SENSOR .................................10-254.8 ORIGINAL SIZE SENSOR ....................................................................10-264.9 ORIGINAL FEED DRIVE.......................................................................10-27

DF Feed Clutch.................................................................................10-27Pick-up Solenoid ...............................................................................10-27Transport Motor ................................................................................10-27DF Feed Motor..................................................................................10-27

4.10 REGISTRATION SENSOR..................................................................10-284.11 STAMP SOLENOID AND ORIGINAL EXIT SENSOR .........................10-29

INTERCHANGE UNIT (B300/B416)

1. OVERALL MACHINE INFORMATION....................................... 11-11.1 SPECIFICATIONS...................................................................................11-11.2 MECHANICAL COMPONENT LAYOUT .................................................11-2

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1.3 DRIVE LAYOUT ......................................................................................11-3

2. DETAILED DESCRIPTION ........................................................ 11-42.1 JUNCTION GATE MECHANISM.............................................................11-4

To the Exit Tray or Bridge Unit(for the Upper Tray on top of the Bridge Unit, or the Finisher) ............11-4To the 1-bin Tray ................................................................................11-4To the Duplex Unit ..............................................................................11-4

3 REPLACEMENT AND ADJUSTMENT ....................................... 11-53.1 EXIT SENSOR REPLACEMENT.............................................................11-5

1-BIN TRAY UNIT (A898/B413)

1. OVERALL INFORMATION ........................................................ 12-11.1 SPECIFICATIONS...................................................................................12-11.2 MECHANICAL COMPONENT LAYOUT .................................................12-21.3 ELECTRICAL COMPONENT LAYOUT...................................................12-31.4 ELECTRICAL COMPONENT DESCRIPTION.........................................12-3

2. DETAILED SECTION DESCRIPTIONS ..................................... 12-42.1 BASIC OPERATION................................................................................12-4

3. REPLACEMENT AND ADJUSTMENT ...................................... 12-53.1 PAPER SENSOR REMOVAL..................................................................12-5

SHIFT TRAY UNIT (B313/B459)

1. OVERALL MACHINE INFORMATION....................................... 13-11.1 SPECIFICATIONS...................................................................................13-11.2 COMPONENT LAYOUT..........................................................................13-2

2. DETAILED SECTION DESCRIPTIONS ..................................... 13-32.1 BASIC OPERATION................................................................................13-32.2 PRIMARY MECHANISMS.......................................................................13-4

2.2.1 TRAY SHIFT...................................................................................13-42.2.2 HALF TURN DETECTION..............................................................13-5

3. REPLACEMENT AND ADJUSTMENT ...................................... 13-63.1 TRAY COVER REPLACEMENT .............................................................13-6

3.1.1 TRAY COVER REMOVAL..............................................................13-63.1.2 TRAY COVER ATTACHMENT.......................................................13-6

3.2 TRAY MOTOR AND HALF TURN SENSOR REPLACEMENT ...............13-73.2.1 REPLACING THE TRAY MOTOR..................................................13-73.2.2 REPLACING THE HALF TURN SENSOR:.....................................13-7

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BY-PASS (A899/B415)

1. OVERALL MACHINE INFORMATION....................................... 14-11.1 SPECIFICATIONS...................................................................................14-11.2 MECHANICAL COMPONENT LAYOUT .................................................14-11.3 ELECTRICAL COMPONENT LAYOUT...................................................14-21.4 ELECTRICAL COMPONENT DESCRIPTION.........................................14-2

2. DETAILED DESCRIPTIONS ...................................................... 14-32.1 BASIC OPERATION................................................................................14-32.2 PAPER SIZE DETECTION......................................................................14-4

3. REPLACEMENT AND ADJUSTMENT ...................................... 14-53.1 PAPER FEED ROLLER/FRICTION PAD/PAPER END SENSOR...........14-53.2 PAPER SIZE SENSOR BOARD..............................................................14-63.3 PAPER FEED CLUTCH ..........................................................................14-7

DUPLEX (A896/B414)

1. OVERALL MACHINE INFORMATION....................................... 15-11.1 SPECIFICATIONS...................................................................................15-11.2 MECHANICAL COMPONENT LAYOUT .................................................15-21.3 ELECTRICAL COMPONENT LAYOUT...................................................15-31.4 ELECTRICAL COMPONENT DESCRIPTION.........................................15-41.5 DRIVE LAYOUT ......................................................................................15-5

2. DETAILED DESCRIPTIONS ...................................................... 15-62.1 BASIC OPERATION................................................................................15-6

Longer than A4 sideways/LT sideways...............................................15-6Up to A4 sideways/LT sideways .........................................................15-7

2.2 FEED IN AND EXIT MECHANISM ..........................................................15-8When paper is fed into duplex unit:.....................................................15-8Inversion and Exit: ..............................................................................15-8

3. REPLACEMENT AND ADJUSTMENT ...................................... 15-93.1 COVER REMOVAL .................................................................................15-93.2 ENTRANCE SENSOR REPLACEMENT...............................................15-103.3 EXIT SENSOR REPLACEMENT...........................................................15-11

BRIDGE UNIT (A897/B417)

1. OVERALL MACHINE INFORMATION....................................... 16-11.1 SPECIFICATIONS...................................................................................16-11.2 MECHANICAL COMPONENT LAYOUT .................................................16-21.3 ELECTRICAL COMPONENT LAYOUT...................................................16-3

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1.4 ELECTRICAL COMPONENT DESCRIPTION.........................................16-41.5 DRIVE LAYOUT ......................................................................................16-5

2. DETAILED DESCRIPTION ........................................................ 16-62.1 JUNCTION GATE MECHANISM.............................................................16-6

3. REPLACEMENT AND ADJUSTMENT ...................................... 16-73.1 BRIDGE UNIT DRIVE MOTOR REPLACEMENT ...................................16-73.2 TRAY EXIT SENSOR REPLACEMENT ..................................................16-83.3 RELAY SENSOR REPLACEMENT.........................................................16-8

1,000-SHEET FINISHER (B408)1. REPLACEMENT AND ADJUSTMENT ...................................... 17-1

1.1 MAIN PCB ...............................................................................................17-11.2 STAPLER UNIT.......................................................................................17-21.3 MOTORS.................................................................................................17-3

1.3.1 SHIFT MOTOR...............................................................................17-31.3.2 STAPLER MOTOR.........................................................................17-31.3.3 UPPER TRANSPORT MOTOR AND EXIT MOTOR ......................17-31.3.4 LOWER TRANSPORT MOTOR .....................................................17-4

1.4 MOTORS AND SENSORS......................................................................17-51.4.1 PREPARATION..............................................................................17-51.4.2 STACK HEIGHT SENSOR .............................................................17-61.4.3 STAPLER TRAY PAPER SENSOR................................................17-61.4.4 LOWER TRAY LIFT MOTOR .........................................................17-61.4.5 STACK FEED-OUT MOTOR ..........................................................17-7

2. TROUBLESHOOTING ............................................................... 17-82.1 JAM DETECTION....................................................................................17-8

3. SERVICE TABLES..................................................................... 17-93.1 DIP SWITCH SETTINGS ........................................................................17-9

4. DETAILED DESCRIPTIONS .................................................... 17-104.1 GENERAL LAYOUT ..............................................................................17-104.2 ELECTRICAL COMPONENT LAYOUT.................................................17-114.3 ELECTRICAL COMPONENT DESCRIPTION.......................................17-134.4 DRIVE LAYOUT ....................................................................................17-154.5 JUNCTION GATES ...............................................................................17-17

Upper tray mode ...............................................................................17-17Sort/stack mode................................................................................17-17Staple mode......................................................................................17-17

4.6 UPPER TRAY........................................................................................17-184.7 LOWER TRAY UP/DOWN MECHANISMS ...........................................17-194.8 PAPER SHIFT MECHANISM ................................................................17-204.9 JOGGER UNIT PAPER POSITIONING MECHANISM..........................17-214.10 EXIT GUIDE PLATE............................................................................17-224.11 STAPLER MECHANISM .....................................................................17-23

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4.12 STAPLER UNIT MOVEMENT MECHANISM ......................................17-24 4.13 PAPER FEED-OUT MECHANISM ......................................................17-25

5. OVERALL MACHINE INFORMATION..................................... 17-26 5.1 SPECIFICATIONS.................................................................................17-26

Upper Tray........................................................................................17-26 Lower Tray........................................................................................17-26

500-SHEET FINISHER (G302/B442) 1. REPLACEMENT AND ADJUSTMENT ...................................... 18-1

1.1 EXTERIOR ..............................................................................................18-1 1.2 ENTRANCE UPPER GUIDE / PAPER EXIT UNIT..................................18-4 1.3 ENTRANCE LOWER GUIDE ..................................................................18-5 1.4 PAPER EXIT UNIT GEAR / PADDLE ROLLER SOLENOID...................18-5 1.5 STAPLER UNIT.......................................................................................18-6 1.6 JOGGER TRAY UNIT .............................................................................18-6 1.7 PAPER EXIT SENSOR FEELER ............................................................18-7 1.8 MAIN MOTOR .........................................................................................18-7 1.9 JOGGER MOTOR ...................................................................................18-8 1.10 CONTROL BOARD ...............................................................................18-8 1.11 OUTPUT TRAY UNIT............................................................................18-9

2. DETAILED DESCRIPTIONS .................................................... 18-10 2.1 OVERALL MACHINE INFORMATION ..................................................18-10

2.1.1 COMPONENT LAYOUT ...............................................................18-10 Mechanical component layout ..........................................................18-10 Drive layout.......................................................................................18-11

2.1.2 ELECTRICAL COMPONENT DESCRIPTIONS ...........................18-12 2.2 DETAILED SECTION DESCRIPTIONS ................................................18-14

2.2.1 OUTPUT TRAY MECHANISM .....................................................18-14 Stack height detection.......................................................................18-14 Output tray up/down mechanism ......................................................18-15

2.2.2 PAPER FEED...............................................................................18-16 Overview...........................................................................................18-16 Straight feed out mode......................................................................18-16 Shift sorting mode.............................................................................18-17 Stapling mode...................................................................................18-19

2.2.3 JAM CONDITIONS.......................................................................18-20 2.2.4 ERROR DETECTION...................................................................18-20

3. OVERALL MACHINE INFORMATION..................................... 18-21 3.1 SPECIFICATIONS..................................................................................18-21

DataOverwriteSecurity Unit B692/B694 SEE SECTION B692/B694 FOR DETAILED TABLE OF CONTENTS

Rev. 05/2004

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B089/B093 xiv SM

FAX OPTION B576TABLE OF CONTENTS

INSTALLATION

1. INSTALLATION............................................................................ 1-11.1 CAUTIONS AND WARNINGS...................................................................1-11.2 FAX OPTION TYPE 2027 INSTALLATION ...............................................1-21.3 G3 INTERFACE UNIT TYPE 2027 INSTALLATION .................................1-5

TROUBLESHOOTING

2. TROUBLESHOOTING ................................................................. 2-12.1 ERROR CODES........................................................................................2-12.2 FAX SC CODES........................................................................................2-9

SERVICE TABLES

3. SERVICE TABLES....................................................................... 3-13.1 SERVICE PROGRAM MODE....................................................................3-1

3.1.1 SERVICE PROGRAM MODE OPERATION.....................................3-1Entering and Exiting SP mode ..............................................................3-1SP2-XXX (RAM Data)...........................................................................3-3SP3-XXX (Machine Settings)................................................................3-3SP4-XXX (ROM Versions) ....................................................................3-5SP5-XXX (RAM Clear)..........................................................................3-5SP6-XXX (Reports)...............................................................................3-6SP7-XXX (Test) ....................................................................................3-8

3.2 BIT SWITCHES.........................................................................................3-93.2.1 SYSTEM SWITCHES.......................................................................3-93.2.2 IFAX SWITCHES............................................................................3-213.2.3 PRINTER SWITCHES....................................................................3-213.2.4 COMMUNICATION SWITCHES.....................................................3-273.2.5 G3-1 SWITCHES............................................................................3-353.2.6 G3-2 SWITCHES............................................................................3-433.2.7 FAX SWITCHES.............................................................................3-51

3.3 NCU PARAMETERS ...............................................................................3-553.4 DEDICATED TRANSMISSION PARAMETERS......................................3-65

3.4.1 PROGRAMMING PROCEDURE....................................................3-653.4.2 PARAMETERS...............................................................................3-66

3.5 SERVICE RAM ADDRESSES.................................................................3-69

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DETAILED DESCRIPTIONS

4. DETAILED SECTION DESCRIPTIONS ....................................... 4-14.1 OVERVIEW ...............................................................................................4-14.2 BOARDS ...................................................................................................4-2

4.2.1 FCU ..................................................................................................4-24.2.2 MBU..................................................................................................4-34.2.3 NCU (US) .........................................................................................4-44.2.4 NCU (EUROPE/ASIA) ......................................................................4-54.2.5 SG3-D BOARD.................................................................................4-6

4.3 ADDRESS BOOK......................................................................................4-74.3.1 ADDRESS BOOK BACKUP .............................................................4-7

Overview of Data Backup .....................................................................4-7SP Modes .............................................................................................4-9

SPECIFICATIONS

5. SPECIFICATIONS........................................................................ 5-11. GENERAL SPECIFICATIONS.....................................................................5-12. CAPABILITIES OF PROGRAMMABLE ITEMS...........................................5-23. MACHINE CONFIGURATION.....................................................................5-3

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B089/B093 xvi SM

INTERNET FAX (IFAX)TABLE OF CONTENTS

INSTALLATION1. INSTALLATION............................................................................ 1-1

1.1 IFAX INSTALLATION ................................................................................1-11.2 INITIAL SETTINGS ...................................................................................1-1

TROUBLESHOOTING

2. TROUBLESHOOTING ................................................................. 2-12.1 ERROR CODES FOR LAN COMMUNICATION .......................................2-12.2 TROUBLESHOOTING PROCEDURES ....................................................2-6

SERVICE TABLES

3. SERVICE TABLES AND PROCEDURES.................................... 3-13.1 ACCESSING IFAX BIT SWITCHES ..........................................................3-13.2 SP1102 IFAX SWITCH..............................................................................3-23.3 FIRMWARE UPDATE PROCEDURE........................................................3-83.4 IFAX RAM ADDRESSES...........................................................................3-9

DETAILED DESCRIPTIONS

4. DETAILED SECTION DESCRIPTIONS ....................................... 4-14.1 INTERNET FAX.........................................................................................4-1

4.1.1 INTERNET FAX FEATURES............................................................4-14.1.2 DNS SERVICE .................................................................................4-2

4.2 INTERNET MAIL COMMUNICATION .......................................................4-34.2.1 MAIL TRANSMISSION.....................................................................4-3

Procedure .............................................................................................4-3Data Formats ........................................................................................4-3Errors ....................................................................................................4-3Results..................................................................................................4-4Selectable Options................................................................................4-4Secure Internet Transmission ...............................................................4-5

4.2.2 MAIL RECEPTION ...........................................................................4-6POP3/IMAP4 Mail Reception Procedure ..............................................4-6Characteristics of POP3/IMAP4 Reception...........................................4-7SMTP Reception...................................................................................4-7SMTP Reception Characteristics ..........................................................4-8Delivery: Transferring Mail Received With SMTP (Off Ramp Gateway)4-9Overview...............................................................................................4-9Handling Mail Reception Errors ..........................................................4-12

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Printing Received Mail ........................................................................4-13Multi-part Messages............................................................................4-13Manual e-mail reception......................................................................4-13Secure Internet Reception ..................................................................4-13

4.2.3 MAIL BROADCASTING (E-MAIL AND G3 FAX ARE COMBINED)4-144.2.4 TRANSFER REQUEST..................................................................4-15

Operation at the Transfer Requester ..................................................4-15Operation at the Transfer Station........................................................4-17

4.2.5 AUTOROUTING .............................................................................4-194.2.6 TRANSFER BOX............................................................................4-19

4.3 E-MAIL OPTIONS (SUB TX MODE) .......................................................4-204.3.1 SUBJECT AND LEVEL OF IMPORTANCE....................................4-20

How the Subject Differs According to Mail Type .................................4-20Subjects Displayed on the PC ............................................................4-20

4.3.2 E-MAIL MESSAGES.......................................................................4-214.3.3 MESSAGE DISPOSITION NOTIFICATION (MDN) ........................4-22

Handling Mail ......................................................................................4-23Handling Reports ................................................................................4-24Return Receipt Conditions ..................................................................4-25

SPECIFICATIONS

5. SPECIFICATIONS........................................................................ 5-11. IFAX SPECIFICATIONS.............................................................................5-1

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PRINTER/SCANNER B577TABLE OF CONTENTS

INSTALLATION

1. INSTALLATION............................................................................ 1-11.1 INSTALLATION REQUIREMENTS ...........................................................1-11.2 PRINTER/SCANNER INSTALLATION......................................................1-1

TROUBLESHOOTING

2. TROUBLESHOOTING ................................................................. 2-12.1 CONTROLLER ERRORS..........................................................................2-1

SERVICE TABLES

3. SERVICE TABLES....................................................................... 3-13.1 PRINTER SERVICE MODE ......................................................................3-1

Service Table Key.................................................................................3-13.1.2 PRINTER SERVICE MODE TABLES...............................................3-13.1.3 SP MODES RELATED TO THE PRINTER CONTROLLER .............3-2

3.2 SCANNER SERVICE MODE.....................................................................3-33.2.1 SCANNER PROGRAM MODE TABLE.............................................3-3

DETAILED DESCRIPTIONS

4. DETAILS....................................................................................... 4-14.1 ETHERNET BOARD .................................................................................4-1

4.1.1 ETHERNET BOARD LAYOUT .........................................................4-14.1.2 ETHERNET BOARD OPERATION...................................................4-2

4.2 IEEE1394 BOARD (FIREWIRE)................................................................4-34.2.1 OVERVIEW ......................................................................................4-3

4.3 USB ...........................................................................................................4-54.3.1 SPECIFICATIONS............................................................................4-54.3.2 USB 1.1/2.0 ......................................................................................4-54.3.3 USB CONNECTORS........................................................................4-64.3.4 PIN ASSIGNMENT...........................................................................4-64.3.5 REMARKS ABOUT USB ..................................................................4-7

Related SP Mode..................................................................................4-74.4 IEEE 802.11B (WIRELESS LAN) ..............................................................4-8

4.4.1 SPECIFICATIONS............................................................................4-8LED Indicators ......................................................................................4-8

4.4.2 TRANSMISSION MODES ................................................................4-9

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Ad Hoc Mode ........................................................................................4-9Infrastructure Mode...............................................................................4-9

4.4.3 SECURITY FEATURES .................................................................4-10Using the SSID in Ad hoc mode .........................................................4-10

4.4.4 WIRELESS LAN TROUBLESHOOTING NOTES...........................4-11Communication Status........................................................................4-11Channel Settings ................................................................................4-11Troubleshooting Procedure.................................................................4-12

4.5 BLUETOOTH...........................................................................................4-134.5.1 SPECIFICATIONS..........................................................................4-134.5.2 BLUETOOTH PROFILES ...............................................................4-144.5.3 BLUETOOTH SECURITY FEATURES...........................................4-14

4.6 FILE FORMAT CONVERTER (MLB)........................................................4-15

SPECIFICATIONS

SPECIFICATIONS............................................................................. 5-11. SYSTEM COMPONENTS ...........................................................................5-12. LED INDICATORS ......................................................................................5-23. PRINTER SPECIFICATIONS......................................................................5-24. USB SPECIFICATIONS ..............................................................................5-45. IEEE 802.11B SPECIFICATIONS ...............................................................5-46. IEEE 1394 SPECIFICATIONS.....................................................................5-47. BLUETOOTH SPECIFICATIONS................................................................5-38. SCANNER SPECIFICATIONS ....................................................................5-49. SOFTWARE ACCESSORIES .....................................................................5-5

9.1 PRINTER..............................................................................................5-59.2 SCANNER ............................................................................................5-6

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