ricoh [b222,b224] aficio mp-c3500,mp-c4500 parts & service manual

B222/B224 SERVICE MANUAL002825MIU (rev. 11/28/06)

B222/B224 SERVICE MANUAL(BOOK 1 OF 2) MAINFRAME

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B222/B224 SERVICE MANUALBook 1 of 2 MAINFRAME

002825MIU

WARNINGThe Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection. Ricoh Corporation

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LEGENDPRODUCT CODE B222 B224 GESTETNER DSc535 DSc545 COMPANY LANIER LD435c LD445c RICOH Aficio MP C3500 Aficio MP C4500 SAVIN C3535 C4540

DOCUMENTATION HISTORYREV. NO. * DATE 09/2006 COMMENTS Original Printing

B222/B224TABLE OF CONTENTSINSTALLATION1. INSTALLATION ............................................................................1-11.1 INSTALLATION REQUIREMENTS ............................................................1-1 1.1.1 ENVIRONMENT ................................................................................1-1 1.1.2 MACHINE LEVEL..............................................................................1-1 1.1.3 MACHINE SPACE REQUIREMENTS ...............................................1-2 1.1.4 POWER REQUIREMENTS ...............................................................1-2 1.2 OPTIONAL UNIT COMBINATIONS ...........................................................1-3 1.2.1 MACHINE OPTIONS.........................................................................1-3 1.2.2 CONTROLLER OPTIONS.................................................................1-4 1.2.3 FAX OPTIONS ..................................................................................1-4 1.2.4 OTHER OPTIONS.............................................................................1-5 1.3 COPIER INSTALLATION ...........................................................................1-6 1.3.1 POWER SOCKETS FOR PERIPHERALS ........................................1-6 1.3.2 INSTALLATION FLOW CHART ........................................................1-6 1.3.3 ACCESSORY CHECK ......................................................................1-7 1.3.4 INSTALLATION PROCEDURE .........................................................1-9 Tapes and Retainers...........................................................................1-10 Developer and Toner Bottles ..............................................................1-10 Paper Trays ........................................................................................1-11 Emblem and Decals............................................................................1-12 Fire Prevention Cover .........................................................................1-13 Manual Pocket Attachment .................................................................1-13 Initialize the Developer........................................................................1-13 Settings Relevant to the Service Contract ..........................................1-14 1.3.5 MOVING THE MACHINE ................................................................1-15 1.3.6 TRANSPORTING THE MACHINE ..................................................1-15 1.4 PAPER FEED UNIT (B800)......................................................................1-17 1.4.1 ACCESSORY CHECK ....................................................................1-17 1.4.2 INSTALLATION PROCEDURE .......................................................1-18 1.5 LCT (B801) ...............................................................................................1-21 1.5.1 ACCESSORY CHECK ....................................................................1-21 1.5.2 INSTALLATION PROCEDURE .......................................................1-22 1.6 AUTO REVERSE DOCUMENT FEEDER (B802).....................................1-25 1.6.1 COMPONENT CHECK....................................................................1-25 1.6.2 INSTALLATION PROCEDURE .......................................................1-25 1.7 1-BIN TRAY UNIT (B803).........................................................................1-29 1.7.1 COMPONENT CHECK....................................................................1-29 1.7.2 INSTALLATION PROCEDURE .......................................................1-29

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1.8 BRIDGE UNIT (B227)...............................................................................1-32 1.8.1 COMPONENT CHECK....................................................................1-32 1.8.2 INSTALLATION PROCEDURE .......................................................1-32 1.9 1000-SHEET FINISHER (B408) ...............................................................1-35 1.9.1 ACCESSORY CHECK ....................................................................1-35 1.9.2 INSTALLATION PROCEDURE .......................................................1-36 1.10 2000/3000-SHEET (BOOKLET) FINISHER (B804/B805)...................1-38 1.10.1 ACCESSORY CHECK...............................................................1-38 1.10.2 INSTALLATION PROCEDURE..................................................1-39 Support Tray Installation .....................................................................1-43 1.11 PUNCH UNIT......................................................................................1-44 1.11.1 COMPONENT CHECK ..............................................................1-44 1.11.2 INSTALLATION PROCEDURE..................................................1-45 1.12 MECHANICAL COUNTER (NA ONLY)...............................................1-49 1.12.1 INSTALLATION PROCEDURE..................................................1-49 1.13 KEY COUNTER BRACKET ................................................................1-51 1.13.1 INSTALLATION PROCEDURE..................................................1-51 1.14 KEY COUNTER INTERFACE UNIT ...................................................1-53 1.14.1 INSTALLATION PROCEDURE..................................................1-53 1.15 ANTI-CONDENSATION HEATER (SCANNER) .................................1-55 1.15.1 INSTALLATION PROCEDURE..................................................1-55 1.16 TRAY HEATER...................................................................................1-57 1.16.1 INSTALLATION PROCEDURE..................................................1-57 1.17 CONTROLLER OPTIONS ..................................................................1-58 1.17.1 OVERVIEW ...............................................................................1-58 I/F Card Slots......................................................................................1-58 SD Card Slots .....................................................................................1-58 1.17.2 SD CARD APPLI MOVE ............................................................1-59 Overview.............................................................................................1-59 Move Exec ..........................................................................................1-60 Undo Exec ..........................................................................................1-61 1.17.3 POSTSCRIPT 3 .........................................................................1-61 1.17.4 FILE FORMAT CONVERTER....................................................1-62 1.17.5 IEEE1394 (FIREWIRE)..............................................................1-63 Installation Procedure .........................................................................1-63 UP Mode Settings for IEEE 1394........................................................1-64 SP Mode Settings for IEEE 1394 ........................................................1-64 1.17.6 IEEE1284...................................................................................1-65 Installation Procedure .........................................................................1-65 1.17.7 IEEE 802.11B (WIRELESS LAN)...............................................1-66 Installation Procedure .........................................................................1-66 UP Mode Settings for Wireless LAN ...................................................1-67 SP Mode Settings for IEEE 802.11b Wireless LAN ............................1-69 1.17.8 BLUETOOTH .............................................................................1-69 1.17.9 COPY DATA SECURITY UNIT..................................................1-70 User Tool Setting ................................................................................1-72

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1.17.10 DATA OVERWRITE SECURITY UNIT TYPE D (B735) .........1-72 Before You Begin the Procedure ........................................................1-72 Seal Check and Removal ...................................................................1-73 Installation Procedure .........................................................................1-73 1.17.11 USB HOST INTERFACE........................................................1-76 1.17.12 PICTBRIDGE .........................................................................1-76 1.17.13 BROWSER UNIT TYPE B......................................................1-77 Installation Procedure .........................................................................1-77 Update Procedure...............................................................................1-79 1.17.14 REMOTE COMMUNICATION GATE INSTALLATION...........1-79 Component Check ..............................................................................1-79 Installation Procedure .........................................................................1-80 1.17.15 CHECK ALL CONNECTIONS ................................................1-82

PREVENTIVE MAINTENANCE2. PREVENTIVE MAINTENANCE ....................................................2-12.1 SETTINGS..................................................................................................2-1 2.1.1 BEFORE REMOVING THE OLD PM PARTS ...................................2-1 2.1.2 AFTER INSTALLING THE NEW PM PARTS ....................................2-2 2.1.3 PREPARATION BEFORE OPERATION CHECK..............................2-2 2.1.4 OPERATION CHECK........................................................................2-3 2.2 MAINTENANCE TABLES...........................................................................2-4 2.2.1 PREVENTIVE MAINTENANCE TABLES ..........................................2-4 Mainframe.............................................................................................2-4 ARDF ....................................................................................................2-7 Two-tray Paper Feed Unit.....................................................................2-8 LCT .......................................................................................................2-8 2000/3000-Sheet (Booklet) Finisher .....................................................2-8 2000/3000-Sheet (Booklet) Finisher Punch Kit .....................................2-9 1000-Sheet Finisher..............................................................................2-9 2.2.2 OTHERS IN MAINFRAME ................................................................2-9

REPLACEMENT AND ADJUSTMENT3. REPLACEMENT AND ADJUSTMENT.........................................3-13.1 BEFOREHAND...........................................................................................3-1 3.2 SPECIAL TOOLS .......................................................................................3-2 3.3 IMAGE ADJUSTMENT ...............................................................................3-3 3.3.1 SCANNING .......................................................................................3-3 Scanner sub-scan magnification...........................................................3-3 Scanner leading edge and side-to-side registration ..............................3-3 3.3.2 ARDF.................................................................................................3-4 ARDF side-to-side, leading edge registration and trailing edge ............3-4 ARDF sub-scan magnification ..............................................................3-5

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3.3.3 REGISTRATION................................................................................3-5 Image Area ...........................................................................................3-5 Leading Edge........................................................................................3-6 Side to Side ..........................................................................................3-6 Adjustment Standard ............................................................................3-6 Paper Registration Standard.................................................................3-6 Adjustment Procedure ..........................................................................3-6 3.3.4 ERASE MARGIN ADJUSTMENT ......................................................3-7 3.3.5 COLOR REGISTRATION..................................................................3-7 Line Position Adjustment ......................................................................3-7 3.3.6 PRINTER GAMMA CORRECTION ...................................................3-8 Copy Mode ...........................................................................................3-8 Printer Mode .......................................................................................3-13 3.4 EXTERIOR COVERS ...............................................................................3-15 3.4.1 FRONT DOOR ................................................................................3-15 3.4.2 LEFT COVER ..................................................................................3-16 3.4.3 REAR COVER.................................................................................3-16 3.4.4 RIGHT REAR COVER.....................................................................3-17 3.4.5 OPERATION PANEL.......................................................................3-17 3.4.6 PAPER EXIT COVER......................................................................3-18 3.4.7 INNER TRAY...................................................................................3-19 3.4.8 DUST FILTER .................................................................................3-20 3.4.9 OZONE FILTER ..............................................................................3-20 Ozone filters for scanner unit ..............................................................3-20 Ozone filter for IH inverter...................................................................3-21 3.5 SCANNER UNIT.......................................................................................3-22 3.5.1 EXPOSURE GLASS........................................................................3-22 3.5.2 ORIGINAL LENGTH/WIDTH SENSORS.........................................3-23 3.5.3 EXPOSURE LAMP..........................................................................3-23 3.5.4 SCANNER MOTOR.........................................................................3-26 3.5.5 SENSOR BOARD UNIT (SBU)........................................................3-27 When reassembling ............................................................................3-27 3.5.6 EXPOSURE LAMP STABILIZER ....................................................3-27 3.5.7 SIO (SCANNER IN/OUT) BOARD...................................................3-28 3.5.8 SCANNER HP SENSOR.................................................................3-28 3.5.9 PLATEN COVER SENSOR.............................................................3-29 3.5.10 FRONT SCANNER WIRE..........................................................3-30 Reassembling the Front Scanner Wire ...............................................3-30 3.5.11 REAR SCANNER WIRE ............................................................3-32 Reassembling the Rear Scanner Wire................................................3-34 3.5.12 TOUCH PANEL POSITION ADJUSTMENT ..............................3-35 3.6 LASER OPTICS .......................................................................................3-36 3.6.1 CAUTION DECAL LOCATION ........................................................3-36 3.6.2 LASER OPTICS HOUSING UNIT ...................................................3-36 Preparing the new laser optics housing unit .......................................3-37 Before removing the old laser optics housing unit ..............................3-37

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Recovery procedure for no replacement preparation of laser optics housing unit ........................................................................................3-38 Removing the old laser optics housing unit.........................................3-39 Installing a new Laser Optics Housing Unit.........................................3-40 After installing the new laser optics housing unit ................................3-40 3.6.3 POLYGON MIRROR MOTOR AND DRIVE BOARD.......................3-42 3.6.4 SHUTTER MOTOR .........................................................................3-43 3.7 IMAGE CREATION ..................................................................................3-46 3.7.1 PCU.................................................................................................3-46 3.7.2 DRUM UNIT AND DEVELOPMENT UNIT ......................................3-47 Developer ...........................................................................................3-49 3.7.3 TONER COLLECTION BOTTLE .....................................................3-50 3.7.4 SECOND DUCT FAN ......................................................................3-51 When reinstalling the second duct fan ................................................3-52 3.7.5 THIRD DUCT FAN ..........................................................................3-52 When reinstalling the third duct fan.....................................................3-53 3.7.6 TONER PUMP UNIT .......................................................................3-53 When you install the new toner pump unit ..........................................3-56 3.7.7 TONER END SENSOR ...................................................................3-59 3.8 IMAGE TRANSFER..................................................................................3-60 3.8.1 IMAGE TRANSFER BELT UNIT .....................................................3-60 3.8.2 IMAGE TRANSFER BELT CLEANING UNIT ..................................3-60 3.8.3 IMAGE TRANSFER BELT...............................................................3-61 When reinstalling the image transfer belt............................................3-65 3.9 PAPER TRANSFER .................................................................................3-67 3.9.1 PAPER TRANSFER ROLLER UNIT ...............................................3-67 3.9.2 PAPER TRANSFER UNIT...............................................................3-67 3.9.3 HIGH VOLTAGE SUPPLY BOARD - DISCHARGE PLATE ............3-69 3.9.4 ID SENSOR BOARD .......................................................................3-70 Cleaning for ID sensors ......................................................................3-71 After installing a new ID sensor unit/board..........................................3-71 3.9.5 TEMPERATURE AND HUMIDITY SENSOR ..................................3-72 3.10 DRIVE UNIT .......................................................................................3-73 3.10.1 GEAR UNIT ...............................................................................3-74 When installing the drive unit ..............................................................3-79 Adjustment after replacing the gear unit .............................................3-79 3.10.2 REGISTRATION MOTOR..........................................................3-80 3.10.3 PAPER FEED MOTOR..............................................................3-80 3.10.4 DRUM/DEVELOPMENT MOTORS FOR M, C, AND Y .............3-81 3.10.5 DRUM/DEVELOPMENT MOTOR-K ..........................................3-82 3.10.6 ITB DRIVE MOTOR ...................................................................3-83 3.10.7 FUSING/PAPER EXIT MOTOR .................................................3-83 3.10.8 IMAGE TRANSFER BELT CONTACT MOTOR.........................3-84 3.10.9 PAPER TRANSFER CONTACT MOTOR..................................3-84 3.10.10 DUPLEX INVERTER MOTOR................................................3-85 3.10.11 DUPLEX/BY-PASS MOTOR ..................................................3-86

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3.10.12 TONER TRANSPORT MOTOR .............................................3-87 3.10.13 TONER COLLECTION UNIT..................................................3-88 3.10.14 PAPER FEED CLUTCHES ....................................................3-89 3.10.15 DEVELOPMENT CLUTCH-Y .................................................3-91 3.10.16 DEVELOPMENT CLUTCHES FOR M AND C .......................3-92 3.10.17 DEVELOPMENT CLUTCH-K .................................................3-93 3.11 FUSING ..............................................................................................3-94 3.11.1 FUSING UNIT ............................................................................3-94 3.11.2 FUSING LAMP...........................................................................3-94 3.11.3 PRESSURE ROLLER AND PRESSURE ROLLER BEARING ..3-96 When re-installing the pressure roller .................................................3-99 3.11.4 FERRITE ROLLER GEAR .......................................................3-101 3.11.5 FUSING ROLLER BUSHING AND TENSION ROLLER BUSHING ...............................................................................................3-101 When re-installing the fusing roller bushing and tension roller bushing ............................................................................................3-102 3.11.6 TENSION ROLLER..................................................................3-103 When re-installing the tension roller..................................................3-103 3.11.7 FUSING BELT, HEATING ROLLER, HEATING ROLLER BUSHING AND FUSING ROLLER.........................................................3-103 When re-installing the fusing belt, heating roller, fusing roller and heating roller bushing........................................................................3-105 3.11.8 LUBRICANT ROLLER BUSHING ............................................3-106 3.11.9 LUBRICANT ROLLER AND CLEANING ROLLER ..................3-106 3.11.10 HEATING ROLLER THERMISTOR .....................................3-107 3.11.11 PRESSURE ROLLER THERMOSTAT.................................3-107 3.11.12 PRESSURE ROLLER THERMISTOR..................................3-108 3.11.13 FUSING ROLLER ONE-WAY CLUTCH AND IDLE GEAR ..3-108 When re-installing the idle gear ........................................................3-109 3.11.14 FUSING FAN........................................................................3-109 When installing the fusing fan ...........................................................3-110 PAPER EXIT FAN ................................................................3-110 3.11.15 When installing the paper exit fan .....................................................3-111 3.11.16 IH (INDUCTION HEATING) INVERTER FAN ......................3-111 When installing the IH inverter fan ....................................................3-111 3.11.17 THERMOPILE ......................................................................3-111 3.11.18 FUSING BELT SENSOR AND FERRITE ROLLER HP SENSOR .............................................................................................3-112 3.11.19 IH COIL FAN ........................................................................3-113 3.11.20 IH COIL UNIT .......................................................................3-114 3.12 PAPER FEED ...................................................................................3-116 3.12.1 PAPER FEED UNIT.................................................................3-116 3.12.2 PICK-UP, FEED AND SEPARATION ROLLERS.....................3-116 Tray 1 and Tray 2 .............................................................................3-116 3.12.3 TRAY LIFT MOTOR.................................................................3-117

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3.12.4 VERTICAL TRANSPORT, PAPER OVERFLOW, PAPER END AND PAPER FEED SENSOR ................................................................3-117 3.12.5 REGISTRATION SENSOR ......................................................3-118 3.12.6 BY-PASS PAPER SIZE SENSOR SWITCH ............................3-119 When reinstalling this switch.............................................................3-119 3.12.7 BY-PASS BOTTOM TRAY ......................................................3-120 3.12.8 BY-PASS PAPER END SENSOR............................................3-122 3.12.9 BY-PASS PICK-UP, FEED AND SEPARATION ROLLER, TORQUE LIMITER .................................................................................3-123 3.12.10 BY-PASS FEED CLUTCH....................................................3-123 3.12.11 PAPER EXIT UNIT...............................................................3-124 3.12.12 FUSING EXIT, PAPER OVERFLOW, JUNCTION PAPER JAM AND PAPER EXIT SENSOR..................................................................3-125 3.12.13 JUNCTION GATE 1 MOTOR ...............................................3-126 3.13 DUPLEX UNIT ..................................................................................3-127 3.13.1 DUPLEX UNIT .........................................................................3-127 3.13.2 DUPLEX DOOR SENSOR.......................................................3-128 3.13.3 DUPLEX ENTRANCE SENSOR..............................................3-128 3.13.4 DUPLEX EXIT SENSOR .........................................................3-129 3.14 ELECTRICAL COMPONENTS .........................................................3-130 3.14.1 CONTROLLER UNIT ...............................................................3-130 3.14.2 CONTROLLER BOX RIGHT COVER ......................................3-130 3.14.3 CONTROLLER BOX................................................................3-131 When opening the controller box ......................................................3-131 When removing the controller box ....................................................3-131 3.14.4 IOB (IN/OUT BOARD) .............................................................3-133 3.14.5 BCU .........................................................................................3-133 When installing the new BCU ...........................................................3-134 3.14.6 IPU...........................................................................................3-134 3.14.7 PSU .........................................................................................3-135 PSU bracket......................................................................................3-135 PSU board ........................................................................................3-135 3.14.8 ITB POWER SUPPLY BOARD ................................................3-136 3.14.9 HIGH VOLTAGE SUPPLY BOARD .........................................3-136 3.14.10 HIGH VOLTAGE SUPPLY BOARD BRACKET....................3-137 3.14.11 IH INVERTER.......................................................................3-137 3.14.12 CONTROLLER BOARD .......................................................3-138 When installing the new controller board ..........................................3-139 3.14.13 MOTHER BOARD ................................................................3-139 3.14.14 HDD FAN .............................................................................3-141 3.14.15 HDD .....................................................................................3-141 When installing a new HDD unit .......................................................3-142 Disposal of HDD Units ......................................................................3-142 Reinstallation ....................................................................................3-142 3.14.16 NVRAM REPLACEMENT PROCEDURE.............................3-143 NVRAM on the BCU .........................................................................3-143

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NVRAM on the Controller .................................................................3-144

TROUBLESHOOTING4. TROUBLESHOOTING..................................................................4-14.1 PROCESS CONTROL ERROR CONDITIONS ..........................................4-1 4.1.1 DEVELOPER INITIALIZATION RESULT ..........................................4-1 4.1.2 PROCESS CONTROL SELF-CHECK RESULT................................4-2 Vsg Adjustment Result..........................................................................4-5 4.1.3 LINE POSITION ADJUSTMENT RESULT ........................................4-6 4.2 SCANNER TEST MODE ............................................................................4-8 4.2.1 VPU TEST MODE .............................................................................4-8 4.2.2 IPU TEST MODE...............................................................................4-8 SP4-904-1 Register Access..................................................................4-8 SP4-904-2 Image Path .........................................................................4-8 4.3 SERVICE CALL CONDITIONS ................................................................4-10 4.3.1 SUMMARY ......................................................................................4-10 SC Code Classification .......................................................................4-11 4.4 SC TABLE ................................................................................................4-14 4.5 TROUBLESHOOTING GUIDE .................................................................4-97 4.5.1 IMAGE QUALITY.............................................................................4-97 4.5.2 LINE POSITION ADJUSTMENT .....................................................4-99 4.6 JAM DETECTION...................................................................................4-108 4.6.1 PAPER JAM DISPLAY ..................................................................4-108 4.6.2 JAM CODES AND DISPLAY CODES ...........................................4-108 Paper Size Code...............................................................................4-115 Sensor Locations ..............................................................................4-116 4.7 ELECTRICAL COMPONENT DEFECTS................................................4-117 4.7.1 SENSORS.....................................................................................4-117 4.7.2 BLOWN FUSE CONDITIONS .......................................................4-123 Power Supply Unit ............................................................................4-123 IH Inverter .........................................................................................4-124

SERVICE TABLES5. SERVICE TABLES .......................................................................5-15.1 SERVICE PROGRAM MODE.....................................................................5-1 5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE............5-1 Entering SP Mode.................................................................................5-1 Exiting SP Mode ...................................................................................5-1 5.1.2 TYPES OF SP MODES.....................................................................5-1 SP Mode Button Summary ...................................................................5-2 Switching Between SP Mode and Copy Mode for Test Printing ...........5-3 Selecting the Program Number.............................................................5-3 Exiting Service Mode ............................................................................5-4

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Service Mode Lock/Unlock ...................................................................5-4 5.1.3 REMARKS.........................................................................................5-5 Display on the Control Panel Screen ....................................................5-5 Others ...................................................................................................5-6 5.2 COPY SERVICE MODE .............................................................................5-7 5.2.1 SERVICE MODE TABLE...................................................................5-7 SP1-XXX (Feed) ...................................................................................5-7 SP2-XXX (Drum).................................................................................5-30 SP3-XXX (Process) ..........................................................................5-162 SP4-XXX (Scanner) ..........................................................................5-214 SP5-XXX (Mode) ..............................................................................5-254 SP6-XXX (Peripherals) .....................................................................5-317 SP7-XXX (Data Log).........................................................................5-328 SP8-xxx: Data Log2 ..........................................................................5-363 SP9-XXX: Others ..............................................................................5-417 5.2.2 INPUT CHECK TABLE..................................................................5-423 Copier ...............................................................................................5-423 1000-Sheet Booklet Finisher (B793) .................................................5-429 2000/3000-Sheet (Booklet) Finisher (B804, B805) ...........................5-429 1000-Sheet Finisher (B408)..............................................................5-433 Table 1: Paper Height Sensor...........................................................5-434 Table 2: Paper Size Switch (Tray 2) .................................................5-435 Table 3: Paper Size (By-pass Table) ................................................5-436 Table 4: APS Original Size Detection ...............................................5-437 5.2.3 OUTPUT CHECK TABLE..............................................................5-438 Copier ...............................................................................................5-438 1000-Sheet Booklet Finisher (B793) .................................................5-450 1000-Sheet Finisher (B408)..............................................................5-450 2000/3000-Sheet (Booklet) Finisher .................................................5-451 5.2.4 TEST PATTERN PRINTING .........................................................5-453 5.3 PRINTER SERVICE MODE ...................................................................5-455 5.3.1 SP1-XXX (SERVICE MODE) ........................................................5-455 5.4 SCANNER SP MODE ............................................................................5-459 5.4.1 SP1-XXX (SYSTEM AND OTHERS).............................................5-459 5.4.2 SP2-XXX (SCANNING-IMAGE QUALITY) ....................................5-460 5.5 REBOOT/SYSTEM SETTING RESET ...................................................5-461 5.5.1 SOFTWARE RESET .....................................................................5-461 5.5.2 SYSTEM SETTINGS AND COPY SETTING RESET....................5-461 System Setting Reset .......................................................................5-461 Copier Setting Reset.........................................................................5-461 5.6 FIRMWARE UPDATE.............................................................................5-463 5.6.1 TYPE OF FIRMWARE...................................................................5-463 5.6.2 BEFORE YOU BEGIN...................................................................5-464 5.6.3 UPDATING FIRMWARE ...............................................................5-465 5.6.4 UPDATING THE LCDC FOR THE OPERATION PANEL..............5-467 5.6.5 DOWNLOADING STAMP DATA ...................................................5-468

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5.6.6 NVRAM DATA UPLOAD/DOWNLOAD .........................................5-469 Uploading Content of NVRAM to an SD card ...................................5-469 Downloading an SD Card to NVRAM................................................5-469 5.6.7 ADDRESS BOOK UPLOAD/DOWNLOAD ....................................5-470 Information List .................................................................................5-470 Download..........................................................................................5-471 Upload ..............................................................................................5-471 5.6.8 INSTALLING ANOTHER LANGUAGE ..........................................5-472 5.6.9 HANDLING FIRMWARE UPDATE ERRORS................................5-474 Error Message Table ........................................................................5-474 5.7 SD CARD APPLI MOVE.........................................................................5-477 5.7.1 OVERVIEW ...................................................................................5-477 5.7.2 MOVE EXEC .................................................................................5-478 5.7.3 UNDO EXEC .................................................................................5-479 5.8 CONTROLLER SELF-DIAGNOSTICS ...................................................5-480 5.8.1 OVERVIEW ...................................................................................5-480 5.9 USING THE DEBUG LOG......................................................................5-481 5.9.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG............5-481 5.9.2 RETRIEVING THE DEBUG LOG FROM THE HDD......................5-486 5.9.3 RECORDING ERRORS MANUALLY ............................................5-486 5.9.4 NEW DEBUG LOG CODES ..........................................................5-486 SP5857-015 Copy SD Card-to-SD Card: Any Desired Key ..............5-486 SP5857-016 Create a File on HDD to Store a Log ...........................5-487 SP5857-017 Create a File on SD Card to Store a Log .....................5-487 5.10 DIP SWITCHES ................................................................................5-488 5.10.1 CONTROLLER BOARD...........................................................5-488 5.10.2 BCU BOARD ...........................................................................5-488

DETAILED DESCRIPTIONS6. DETAILED SECTION DESCRIPTIONS........................................6-16.1 OVERVIEW ................................................................................................6-1 6.1.1 COMPONENT LAYOUT....................................................................6-1 6.1.2 PAPER PATH....................................................................................6-2 6.1.3 DRIVE LAYOUT ................................................................................6-3 6.1.4 BOARD STRUCTURE.......................................................................6-5 Overview...............................................................................................6-5 6.1.5 PRINTING PROCESS.......................................................................6-6 6.2 PROCESS CONTROL................................................................................6-9 6.2.1 OVERVIEW .......................................................................................6-9 6.2.2 POTENTIAL CONTROL ....................................................................6-9 Overview...............................................................................................6-9 Process Control Self Check ..................................................................6-9 6.2.3 PROCESS CONTROL SELF CHECK PROCEDURE .....................6-12 6.2.4 TONER DENSITY ADJUSTMENT MODE.......................................6-14 6.2.5 TONER SUPPLY CONTROL ..........................................................6-14

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Overview.............................................................................................6-14 Toner Supply Control Modes ..............................................................6-15 6.2.6 TONER NEAR END/TONER END DETECTION.............................6-15 6.2.7 DEVELOPER INITIALIZATION .......................................................6-16 6.3 SCANNING...............................................................................................6-18 6.3.1 OVERVIEW .....................................................................................6-18 6.3.2 SCANNER DRIVE ...........................................................................6-19 6.3.3 ORIGINAL SIZE DETECTION.........................................................6-20 6.3.4 ANTI-CONDENSATION HEATER...................................................6-21 6.4 IMAGE PROCESSING .............................................................................6-22 6.4.1 OVERVIEW .....................................................................................6-22 6.4.2 SBU (SENSOR BOARD UNIT) .......................................................6-22 6.4.3 IPU (IMAGE PROCESSING UNIT) .................................................6-23 6.5 LASER EXPOSURE.................................................................................6-24 6.5.1 OVERVIEW .....................................................................................6-24 6.5.2 OPTICAL PATH...............................................................................6-25 6.5.3 LASER SYNCHRONIZING DETECTORS.......................................6-26 Overview.............................................................................................6-26 6.5.4 LD SAFETY SWITCH......................................................................6-27 6.5.5 AUTOMATIC LINE POSITION ADJUSTMENT ...............................6-29 Overview.............................................................................................6-29 Summary of Each Adjustment ............................................................6-29 Adjustment Conditions ........................................................................6-30 Main Scan Skew Adjustment ..............................................................6-32 ID Sensors ..........................................................................................6-32 6.5.6 SHUTTER MECHANISM.................................................................6-33 6.6 PCU (PHOTO CONDUCTOR UNIT) ........................................................6-34 6.6.1 OVERVIEW .....................................................................................6-34 6.6.2 AROUND THE DRUM .....................................................................6-35 Drum Drive..........................................................................................6-35 Phase Control Mechanism..................................................................6-35 Drum Charge and Quenching .............................................................6-36 Drum Cleaning ....................................................................................6-37 6.6.3 DEVELOPMENT .............................................................................6-38 Development Operation ......................................................................6-38 Drive ...................................................................................................6-39 Developer Agitation.............................................................................6-39 Development Bias...............................................................................6-40 New Unit Detection .............................................................................6-41 6.7 TONER SUPPLY......................................................................................6-42 6.7.1 OVERVIEW .....................................................................................6-42 6.7.2 TONER SUPPLY MECHANISM ......................................................6-43 Toner supply from toner bottle to toner attraction pump .....................6-43 Toner Near End Detection ..................................................................6-43 Toner supply from toner attraction pump to development unit ............6-44 6.7.3 TONER CARTRIDGE......................................................................6-45

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RFID (Radio Frequency ID) ................................................................6-45 6.8 WASTE TONER COLLECTION ...............................................................6-46 6.8.1 TONER COLLECTION PATH AND DRIVE .....................................6-46 From PCU...........................................................................................6-46 From Image Transfer Belt Unit............................................................6-46 Used Toner Distribution Mechanism ...................................................6-47 6.8.2 TONER COLLECTION BOTTLE SET/ NEAR-FULL/ FULL DETECTION.............................................................................................6-47 6.9 IMAGE TRANSFER AND PAPER SEPARATION ....................................6-49 6.9.1 IMAGE TRANSFER.........................................................................6-49 Overview.............................................................................................6-49 ITB (Image Transfer Belt) Drive ..........................................................6-50 ITB Current .........................................................................................6-51 Transfer belt cleaning .........................................................................6-52 ITB (Image Transfer Belt) Contact ......................................................6-53 Transfer Belt Sensor ...........................................................................6-54 6.9.2 PAPER TRANSFER AND SEPARATION .......................................6-55 Overview.............................................................................................6-55 PTR (Paper Transfer Roller) Drive......................................................6-55 PTR (Paper Transfer Roller) Contact and Separation.........................6-56 6.10 PAPER FEED .....................................................................................6-58 6.10.1 OVERVIEW ...............................................................................6-58 6.10.2 DRIVE TRAY 1, TRAY 2, AND BY-PASS TRAY ....................6-59 Tray 1 and Tray2 ................................................................................6-59 By-pass Tray.......................................................................................6-59 6.10.3 PAPER PICK-UP .......................................................................6-60 6.10.4 PAPER LIFT TRAYS 1 AND 2 ................................................6-61 6.10.5 PAPER SIZE DETECTION TRAYS 1 & 2...............................6-61 6.10.6 PAPER HEIGHT DETECTION TRAYS 1 & 2 .........................6-63 6.10.7 PAPER END DETECTION TRAYS 1 & 2 ...............................6-64 6.10.8 REGISTRATION ........................................................................6-65 6.10.9 PAPER FEED LINE SPEED ......................................................6-65 6.10.10 TRAY LOCK MECHANISM ....................................................6-66 Tray Lock at the Front.........................................................................6-66 Tray Lock at the Rear .........................................................................6-67 6.10.11 PAPER DUST COLLECTION.................................................6-67 6.10.12 BY-PASS PAPER SEPARATION...........................................6-68 6.10.13 BY-PASS PAPER SIZE DETECTION ....................................6-68 6.11 FUSING ..............................................................................................6-69 6.11.1 OVERVIEW ...............................................................................6-69 6.11.2 FUSING UNIT DRIVE ................................................................6-70 Belt and Rollers ..................................................................................6-70 Lubricant Mechanism..........................................................................6-70 6.11.3 IH (INDUCTION HEATING) SYSTEM .......................................6-71 Basic IH System .................................................................................6-71 Paper Size Correction.........................................................................6-71

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6.11.4 PRESSURE RELEASE MECHANISM.......................................6-72 6.11.5 FUSING TEMPERATURE CONTROL.......................................6-73 Components .......................................................................................6-73 Fusing Temperatures..........................................................................6-74 Temperature Corrections ....................................................................6-79 Overheat Protection ............................................................................6-80 6.11.6 CPM DOWN SYSTEM...............................................................6-80 CPM Down Control .............................................................................6-80 6.11.7 ENERGY SAVER MODES ........................................................6-82 Overview.............................................................................................6-82 Panel Off Mode ...................................................................................6-82 Auto Off Mode.....................................................................................6-83 6.11.8 NEW UNIT DETECTION ...........................................................6-84 Fusing Unit, Image Transfer Belt Unit .................................................6-84 PCU, Development Unit......................................................................6-84 6.12 PAPER EXIT.......................................................................................6-85 6.12.1 OVERVIEW ...............................................................................6-85 6.12.2 JUNCTION GATE MECHANISM ...............................................6-86 To the Standard Tray ..........................................................................6-86 To the 1-bin Tray or Duplex Unit .........................................................6-87 6.13 DUPLEX UNIT ....................................................................................6-88 6.13.1 OVERVIEW ...............................................................................6-88 6.13.2 DUPLEX DRIVE.........................................................................6-89 6.13.3 INVERTER MECHANISM..........................................................6-90 6.13.4 DUPLEX OPERATION ..............................................................6-91 Up to A4/LT (81/2" x 11") LEF ............................................................6-91 From A4/LT (8 1/2" x 11") LEF to 400mm length ................................6-91 6.14 PRINTER FUNCTIONS ......................................................................6-93 6.14.1 OVERVIEW ...............................................................................6-93 6.14.2 HARD DISK ...............................................................................6-95 Overview.............................................................................................6-95 6.14.3 CONTROLLER FUNCTIONS ....................................................6-95 Sample Print .......................................................................................6-95 Locked Print........................................................................................6-96 Hold Print ............................................................................................6-96 Stored Print/ Store and Print ...............................................................6-96 6.14.4 JOB SPOOLING ........................................................................6-96 Related SP Modes ..............................................................................6-97 Paper Source Selection ......................................................................6-97 Auto Continue .....................................................................................6-98 6.15 PICTBRIDGE....................................................................................6-100 6.15.1 GENERAL FUNCTION ............................................................6-100 Photo image format...........................................................................6-100 6.15.2 PRINTING FUNCTION LIST....................................................6-100 6.15.3 PRINTING FUNCTION DESCRIPTION...................................6-101 Single image printing ........................................................................6-101

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Selected image printing ....................................................................6-102 DPOF (Digital Print Order Format) printing .......................................6-102 All image printing ..............................................................................6-102 Index printing ....................................................................................6-102 Trimming...........................................................................................6-102 Multiple number printing....................................................................6-102 Date and file name printing ...............................................................6-103 Image print size (Fixed size printing) ................................................6-104 Multi-Image-Layout (N-up) ................................................................6-105 Edge-to-edge borderless printing......................................................6-106 Printing quality ..................................................................................6-106 Color matching..................................................................................6-107 Paper type specification....................................................................6-107 Form printing.....................................................................................6-107 Camera memo printing .....................................................................6-108 6.16 COPY DATA SECURITY UNIT.........................................................6-109 6.16.1 GENERAL FUNCTION ............................................................6-109 When copying on a machine with an optional Copy Data Security Unit .....................................................................................6-109 When copying on a machine without an optional Copy Data Security Unit ...................................................................................................6-110 Setting...............................................................................................6-110 Related SC .......................................................................................6-110 6.16.2 MASK TYPE FOR COPYING ..................................................6-110 6.17 FILE FORMAT CONVERTER (MLB) ................................................6-112 6.18 DATA OVERWRITE SECURITY UNIT (B735) .................................6-113 6.18.1 AUTO ERASE MEMORY.........................................................6-113 Types of Data Overwritten and Not Overwritten ...............................6-113 Overwrite timing ................................................................................6-114

SPECIFICATIONS7. SPECIFICATIONS ........................................................................7-17.1 GENERAL SPECIFICATIONS....................................................................7-1 7.1.1 MAIN FRAME ....................................................................................7-1 7.2 PRINTER....................................................................................................7-5 7.3 SCANNER ..................................................................................................7-7 7.4 SUPPORTED PAPER SIZES.....................................................................7-8 7.4.1 PAPER FEED....................................................................................7-8 7.4.2 PAPER EXIT ...................................................................................7-10 2000/3000 Sheet Booklet Finisher ......................................................7-10 1000-Sheet Finisher............................................................................7-13 7.4.3 PLATEN/ARDF ORIGINAL SIZE DETECTION ...............................7-16 7.5 SOFTWARE ACCESSORIES ..................................................................7-18 7.5.1 PRINTER DRIVERS........................................................................7-18 7.5.2 SCANNER AND LAN FAX DRIVERS..............................................7-19

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7.5.3 UTILITY SOFTWARE......................................................................7-19 7.6 MACHINE CONFIGURATION ..................................................................7-21 7.7 OPTIONAL EQUIPMENT .........................................................................7-24 7.7.1 ARDF...............................................................................................7-24 7.7.2 PAPER FEED UNIT ........................................................................7-25 7.7.3 LARGE CAPACITY TRAY...............................................................7-25 7.7.4 3000-SHEET FINISHER..................................................................7-26 7.7.5 2000-SHEET BOOKLET FINISHER................................................7-28 7.7.6 PUNCH UNIT FOR 2000/3000-SHEET (BOOKLET) FINISHER .....7-30 7.7.7 1000-SHEET FINISHER..................................................................7-31 Upper Tray..........................................................................................7-31 Lower Tray..........................................................................................7-31 7.7.8 BRIDGE UNIT .................................................................................7-32 7.7.9 1-BIN TRAY UNIT ...........................................................................7-33

SEE B222/B224 SERVICE MANUAL BOOK 2 OF 2 FOR ACCESSORIES: FAX OPTION B771SEE SECTION B771 FOR DETAILED TABLE OF CONTENTS

AUTO REVERSE DOCUMENT FEEDER B802SEE SECTION B802 FOR DETAILED TABLE OF CONTENTS

1 BIN TRAY UNIT B803SEE SECTION B803 FOR DETAILED TABLE OF CONTENTS

BOOKLET FINISHER/FINISHER B804/B805SEE SECTION B804/B805 FOR DETAILED TABLE OF CONTENTS

SCANNER ACCESSIBILITY OPTION TYPE 4045 B838SEE SECTION B838 FOR DETAILED TABLE OF CONTENTS

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Read This FirstImportant Safety NoticesPrevention of Physical Injury1. 2. 3. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. The wall outlet should be near the copier and easily accessible. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 4. The copier drives some of its components when it completes the warm-up period. Be careful to keep hands away from the mechanical and electrical components as the copier starts operation. 5. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands.

Health Safety Conditions1. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Immediately wash eyes with plenty of water. If unsuccessful, get medical attention. 2. The copier, which use high voltage power source, can generate ozone gas. High ozone density is harmful to human health. Therefore, the machine must be installed in a well-ventilated room.

Observance of Electrical Safety StandardsThe copier and its peripherals must be serviced by a customer service representative who has completed the training course on those models. Keep the machine away from flammable liquids, gases, and aerosols. A fire or an explosion might occur. The Controller board on this machine contains a lithium battery. The danger of explosion exists if a battery of this type is incorrectly replaced. Replace only with the same or an equivalent type recommended by the manufacturer. Discard batteries in accordance with the manufacturer's instructions and local regulations.

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The optional fax and memory expansion units contain lithium batteries, which can explode if replaced incorrectly. Replace only with the same or an equivalent type recommended by the manufacturer. Do not recharge or burn the batteries. Used batteries must be handled in accordance with local regulations.

Safety and Ecological Notes for Disposal1. 2. 3. 4. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor in accordance with local regulations. (These are non-toxic supplies.) Dispose of replaced parts in accordance with local regulations. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

Laser SafetyThe Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required. Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. WARNING: Turn off the main switch before attempting any of the procedures in the Laser Optics Housing Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:

Symbols, Abbreviations and TrademarksThis manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations are as follows:

See or Refer to Clip ring Screw Connector Clamp E-ring SEF LEF Short Edge Feed Long Edge Feed

TrademarksMicrosoft, Windows, and MS-DOS are registered trademarks of Microsoft Corporation in the United States and /or other countries. PostScript is a registered trademark of Adobe Systems, Incorporated. PCL is a registered trademark of Hewlett-Packard Company. Ethernet is a registered trademark of Xerox Corporation. PowerPC is a registered trademark of International Business Machines Corporation. Other product names used herein are for identification purposes only and may be trademarks of their respective companies. We disclaim any and all rights involved with those marks.

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AUTO REVERSE DOCUMENT FEEDER B802 FAX OPTION B771 PREVENTIVE MAINTENANCE

BOOKLET FINISHER/FINISHER B804/B805

1 BIN TRAY UNIT B803

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TAB POSITION 8

TAB POSITION 7

SPECIFICATIONS

TAB POSITION 6

DETAILED DESCRIPTIONS

TAB POSITION 5

SERVICE TABLES

TAB POSITION 4

TROUBLESHOOTING

TAB POSITION 3

REPLACEMENT AND ADJUSTMENT

TAB POSITION 2

TAB POSITION 1

INSTALLATION

INSTALLATION

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Installation Requirements

1. INSTALLATION1.1 INSTALLATION REQUIREMENTS1.1.1 ENVIRONMENT

1. 2. 3. 4. 5.

Temperature Range: 10C to 32C (50F to 89.6F) Humidity Range: 15% to 80% RH Ambient Illumination: Less than 1500 lux (do not expose to direct sunlight) Ventilation: 3 times/hr/person or more Do not let the machine get exposed to the following: 1) Cool air from an air conditioner 2) Heat from a heater

6. 7. 8. 9.

Do not install the machine in areas that are exposed to corrosive gas. Install the machine at locations lower than 2,500 m (8,200 ft.) above sea level. Install the machine on a strong, level base. (Inclination on any side must be no more than 5 mm.) Do not install the machine in areas that get strong vibrations.

1.1.2 MACHINE LEVELFront to back: Within 5 mm (0.2") Right to left: Within 5 mm (0.2")SM 1-1 B222/B224

Installation

Installation Requirements

1.1.3 MACHINE SPACE REQUIREMENTSThis machine, which uses high voltage power sources, can generate ozone gas. High ozone density is harmful to human health. Therefore, the machine must be installed in a well-ventilated room.

A: Over 100 mm (3.9") B: Over 100 mm (3.9") C: Over 550 mm (21.7") D: Over 750 mm (29.5") Put the machine near the power source with the clearance shown above.

1.1.4 POWER REQUIREMENTSInsert the plug firmly in the outlet. Do not use an outlet extension plug or cord. Ground the machine. 1. Input voltage level: 120 V, 60 Hz: More than 12 A 220 V to 240 V, 50 Hz/60 Hz: More than 8 A 2. 3. Permissible voltage fluctuation: 10 % Do not put things on the power cord.

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Optional Unit Combinations

1.2 OPTIONAL UNIT COMBINATIONS1.2.1 MACHINE OPTIONS

No. 1 2 3 4 5 6

Options 2-tray paper feed unit Large capacity tray Platen cover ARDF 1-bin tray unit Bridge unit -

Remarks

One from No.1 or No.2

One from No.3 or No.4

One from No.7, No.8 or No.10; 7 2000-sheet booklet finisher Requires No.6 and one from No.1 and No.2. One from No.7, No.8 or No.10; 8 3000-sheet finisher Requires No.6 and one from No.1 and No.2. 9 *Punch kit (3 types) No.7 or 8 required; One of the three types One from No.7, No.8 or No.10; 10 1000-sheet finisher Requires No.6 and one from No.1 and No.2. 11 Scanner Accessibility Option

*: Child options (Child options require a parent option.)

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1.2.2 CONTROLLER OPTIONSNo. 1 2 3 4 5 6 7 8 9 11 12 13 IEEE 1394 Bluetooth IEEE 802.11b IEEE 1284 USB Host Interface Unit File Format Converter PostScript 3 PictBridge Option Data Overwrite Security Unit Type D Browser Unit Copy Data Security Unit VM Card Type C SD card slot 3 (during installation only) SD card slot 3 (during installation only) No.7 to No.9 (SD card slot 2) I/F Slot B I/F Slot D Options Remarks

No. 1 to No. 4 (I/F Slot A)

1.2.3 FAX OPTIONSNo. 1 2 3 4 Options Fax Option Type C4500 *Memory Unit Type B 32MB *Hand Set Type 1018 G3 Interface Unit Type C4500 Requires No.1. Requires No.1. (NA Only) Remarks

*: Child options (Child options require a parent option.)

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1.2.4 OTHER OPTIONSNo. 1 2 Options Copy Data Security Unit Type A Optional Counter Interface Unit Type A Remarks

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Copier Installation

1.3 COPIER INSTALLATIONMake sure that the image transfer belt is in its correct position before you move the machine. Otherwise, the image transfer belt and the black PCU can be damaged.

1.3.1 POWER SOCKETS FOR PERIPHERALSRating voltage for peripherals. Make sure to plug the cables into the correct sockets.

1.3.2 INSTALLATION FLOW CHARTThis flow chart shows the best procedure for installation.

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Copier InstallationInstallation

You need the optional paper tray unit or the LCT if you want to install the finisher (B408, B804 or B805). The punch unit is for 2000-sheet booklet finisher (B804) and 3000-sheet finisher (B805).

1.3.3 ACCESSORY CHECKCheck the quantity and condition of these accessories. Description 1. 2. Operating Instruction - Troubleshooting Operating Instruction - About This Machine Q'ty 1 1

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Copier Installation Description 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15 16 17 18 19 20 21 22 23 24 Operating Instruction - Security Operation Instruction - Quick Reference Guide Operation Instruction - Printer Quick Reference Operation Instruction - Scanner Quick Reference CD-ROM - Instruction - RIC CD-ROM - Instruction - SAV CD-ROM - Instruction - GES CD-ROM - Instruction - LAN CD-ROM - Printer Instruction - RIC CD-ROM - Printer Instruction - SAV CD-ROM - Printer Instruction - GES CD-ROM - Printer Instruction - NRG CD-ROM - Printer Instruction - LAN CD-ROM - Printer Instruction - INF CD-ROM - Scanner Instruction - RIC CD-ROM - Scanner Instruction - SAV CD-ROM - Scanner Instruction - GES CD-ROM - Scanner Instruction - NRG CD-ROM - Scanner Instruction - LAN Model Name Decal Stamp Cloth Holder Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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Copier Installation Description 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Exposure Glass Cleaning Cloth Rivet Operating Instructions Holder Ferrite Core Power Supply Cord Cover Decal - Paper Size Emblem Cover Sheet - Eula: 16 Languages Sheet - Caution 16 Languages Decal - Caution - Original Sheet Data Warranty Sheet (Chinese) Sheet - Name - Tel Q'ty 1 2 1 1 1 1 1 1 1 1 1 1 1 1Installation B222/B224

1.3.4 INSTALLATION PROCEDURERemove the tape from the development units before you turn the main switch on. The development units can be severely damaged if you do not remove the tape. Put the machine on the paper tray unit or the LCT first if you install an optional paper tray unit or the optional LCT at the same time. Then install the machine and other options. Keep the shipping retainers after you install the machine. You may need them in the future if you transport the machine to another location.

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Copier Installation

Tapes and Retainers

1. 2. 3. 4. 5. 6. 7.

Remove all the tapes and retainers on the machine. Remove all the tapes and retainers in trays 1 and 2, and then take out the power cord from tray 1 (if applicable). Remove the scanner unit stay [A]. Open the front door [B], and then remove the jam location sheet [C]. Keep the scanner unit stay [A] inside the front door [B]. Reattach the jam location sheet. Close the front door.

Developer and Toner Bottles

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Copier Installation 1. Open the front door [A]. GSA model (-58) and EU models (-67/-26) do not require steps from 2 to 7. Skip to step 8 if you install these models. 2. Remove the stopper [B] ( x 1).Installation

This stopper locks the drum positioning plate lever. 3. 4. 5. Release the image transfer unit lock lever [C], and turn the drum positioning plate lever [D] counterclockwise. Open the drum positioning plate [E]. Remove all tapes [F] from the four development units. When you remove the tape from the development unit, hold the development unit with your hand, and then pull the tape. 6. 7. 8. Close the drum positioning plate. Then lock the image transfer unit lock and turn the drum positioning plate lever clockwise. Lock the drum positioning plate lever with the stopper [B] ( Shake each toner bottle five or six times. x 1).

9.

Install each toner bottle [G] in the machine.

10. Close the front door.

Paper Trays1. Pull each paper tray out. Then adjust the side guides and end guide to match the paper size. To move the side guides, first pull out the tray fully. Then push down the green

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Copier Installation lock at the rear inside the tray.

2.

Pull out the feeler [A] for the output tray full detection mechanism.

Emblem and Decals

1.

Attach the correct emblem [A] and the cover [B] to the front door [C] of the machine, if the emblem is not attached. If you want to change the emblem that has been already attached, remove the panel with an object (not a sharp object) as shown [D], and then install the correct emblem.

2.

Attach the correct paper tray number and size decals to the paper trays [E]. Paper tray number and size decals are also used for the optional paper tray or the optional LCT. Keep these decals for use with these optional units.

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Copier Installation

Fire Prevention Cover

When the copier is installed on the floor without the optional paper tray unit or a table, the cover [A] must be attached to the copier. Install the cover [A] at the right side of the copier.

Manual Pocket Attachment

1. 2.

Attach the manual pocket [A] to the left side of the copier (snap rivet x 2). If a finisher has been installed, attach the manual pocket [B] to the rear side of the finisher (snap rivet x 2).

Initialize the Developer1. 2. Plug in the machine. Make sure that the platen or ARDF is closed and the main power is turned off.

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Copier Installation 3. Turn the main power switch on. The machine automatically starts the initialization procedure. The Start button LED ( ) turns green when this procedure has finished. 4. 5. Make copies of image samples (text, photo, and text/photo modes). Do the Automatic Color Calibration process (ACC) as follows: 1. 2. 3. 4. 5. 6. Print the ACC test pattern (User tools > Maintenance > ACC > Start). Put the printout on the exposure glass. Put 10 sheets of white paper on top of the test chart. Close the ARDF or the platen cover. Press Start Scanning on the LCD panel. The machine starts the ACC.

Check that the sample image has been copied normally.

Settings Relevant to the Service ContractChange the necessary settings for the following SP modes if the customer has made a service contract. You must select one of the counter methods (developments/prints) in accordance with the contract ( SP5-045-001).

Item

SP No.

Function Specifies if the counting method used in meter charge mode is based on

Default

Counting method

SP5-045-001

developments or prints. NOTE: You can set this one time only. You cannot change the setting after you have set it for the first time.

0: Developments

A3/11" x 17" double counting SP5-104-001

Specifies whether the counter is doubled for A3/11" x 17" paper. When you have to change this setting, contact your supervisor. No: Single counting

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Copier InstallationInstallation B222/B224

5812-002 programs the service station Service Tel. No. Setting SP5-812-001 through 004 fax number. The number is printed on the counter list when the meter charge mode is selected. This lets the user fax the counter data to the service station.

1.3.5 MOVING THE MACHINEThis section shows you how to manually move the machine from one floor to another floor. See the section Transporting the Machine if you have to pack the machine and move it a longer distance. 1. Remove all trays from the optional paper feed unit or LCT.

1.3.6 TRANSPORTING THE MACHINEMain Frame 1. 2. Do SP 4806-001 to move the scanner carriage from the home position. This prevents dust from falling into the machine during transportation. Remove the toner cartridges. This prevents toner flow into the toner supply tube, which is caused by vibration during transport. This can also cause the tube to be clogged with toner. 3. 4. 5. Make sure there is no paper left in the paper trays. Then fix down the bottom plates with a sheet of paper and tape. Empty the toner collection bottle. Then attach securing tape to stop the toner bottle from coming out. Do one of the following: Attach shipping tape to the covers and doors. Shrink-wrap the machine tightly. After you move the machine, make sure you do the "Auto Color Registration" as follows. This optimizes color registration. 1. 2. Do the "Forced Line Position Adj. Mode c" (SP2-111-3). Then do the "Forced Line Position Adj. Mode a" (SP2-111-1). To check if SP 2-111-1 was successful, watch the screen during the process. A message is displayed at the end. Also, you can check the result with SPSM 1-15

Copier Installation 2-194-10 to -12. Make sure that the side fences in the trays are correctly positioned to prevent color registration errors.

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Paper Feed Unit (B800)

1.4 PAPER FEED UNIT (B800)1.4.1 ACCESSORY CHECKCheck the quantity and condition of the accessories against the following list.

No. 1 2 3 4 5 6 7 Caster stand

Description

Qty 6 2 8 1 1 1 1

Securing bracket Screw (M3x6 x 6, M4x10 x 2) Spring Washer Screw Rear stand cover Left stand cover Front stand cover

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Installation


1.4.2 INSTALLATION PROCEDURETurn off the main switch of the copier and unplug the power cord before you start the installation procedure. You need two or more persons to lift the copier. The copier is highly unstable when lifted by one person, and may cause human injury or property damage. Do not lift the copier with the paper feed unit installed. Otherwise, the handle and grips may be damaged.

1. 2.

Remove all tape on the paper feed unit. Remove the paper trays and remove all tape and padding.

3. 4.

Grasp the handle [A] and grips [B] of the machine. Lift the copier and install it on the paper feed unit [C].

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Paper Feed Unit (B800)Installation

5. 6. 7. 8.

Remove tray 2 of the machine. Fasten the spring washer screw [D], using the cutout in the securing bracket [E] as a tool. Reinstall tray 2. Attach the securing brackets [E] (M4x10 x 1 each).

One of the securing brackets is used as a securing tool (the cutout [F] is used in step 6). But the cutout [G] is for attaching the tray heater. Therefore, attach the securing brackets [E] after installing the tray heater if you will install the tray heater.

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9.

Attach two caster stands [H] to front, right, and rear sides of the machine.

10. Attach the front stand cover [I], right stand cover [J] and rear stand cover [K] to the correct sides of the machine (M3x6 11. Load paper into the paper feed unit. 12. Turn on the main power switch of the machine. 13. Check the paper feed unit operation and copy quality. x 2: each).

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LCT (B801)

1.5 LCT (B801)1.5.1 ACCESSORY CHECKCheck the quantity and condition of the accessories against the following list.

No. 1 2 3 4 5 6 7 Caster stand

Description

Qty 6 2 8 1 1 1 1

Securing bracket Screw (M3x6 x 6, M4x10 x 2) Spring washer screw Rear stand cover Right stand cover Front stand cover

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Installation

LCT (B801)

1.5.2 INSTALLATION PROCEDURETurn off the main switch of the copier and unplug the power cord before you start the installation procedure. You need two or more persons to lift the copier. The copier is highly unstable when lifted by one person, and may cause human injury or property damage. Do not lift the copier with the paper feed unit installed. Otherwise, the handle and grips may be damaged.

1.

Remove all tapes and retainers in the LCT.

2. 3.

Grasp the handle [A] and grips [B] of the machine. Lift the copier and install it on the LCT [C].

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LCT (B801)Installation

4. 5. 6. 7.

Remove tray 2 of the machine. Fasten the spring washer screw [D], using the cutout in the securing bracket [E] as a tool. Reinstall tray 2. Attach the securing brackets [E] (M4x10 x 1each).

One of the securing brackets is used as a securing tool (the cutout [F] is used in step 6). But the cutout [G] is for attaching the tray heater. Therefore, attach the securing brackets [E] after installing the tray heater if you will install the tray heater.

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LCT (B801)

8.

Attach two caster stands [H] to the front, right, and rear sides of the machine.

9.

Attach the front stand cover [I], right stand cover [J] and rear stand cover [K] to the correct sides of the machine (M3x6 x 2 each).

10. Load paper into the LCT. 11. Turn on the main power switch of the machine. 12. Check the LCT operation and copy quality.

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Auto Reverse Document Feeder (B802)

1.6 AUTO REVERSE DOCUMENT FEEDER (B802)1.6.1 COMPONENT CHECKCheck the quantity and condition of the components against the following list.

No. 1 2 3 4 5 ARDF Decal Knob Screw Stud Screw Platen Plate

Description

Qty 1 1 2 2 1

1.6.2 INSTALLATION PROCEDUREUnplug the copier power cord before starting the following procedure. 1. Remove all tapes and shipping retainers.

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Installation

Auto Reverse Document Feeder (B802) 2. Remove the two screws already installed at the top rear of the machine.

3.

Insert the two stud screws [A] on the top of the machine.

4. 5. 6. 7.

Mount the ARDF [B] by aligning the screw keyholes [C] in the ARDF support plate over the stud screws. Slide the ARDF toward the front of the machine. Secure the ARDF with the two knob screws [D]. Connect the ARDF interface cable [E] to the machine.

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Auto Reverse Document Feeder (B802)Installation

8.

Remove two screws [F] from the bottom of the ARDF.

9.

Peel off the platen plate [G] and place it on the exposure glass. glass.

10. Align the rear left corner of the platen plate with the corner [H] on the exposure 11. Close the ARDF. 12. Open the ARDF and check that the platen plate is correctly attached.

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Auto Reverse Document Feeder (B802)

13. Attach the decal [I] to the top cover as shown. Choose the language you want. 14. Plug in and turn on the main power switch of the machine, and then check the ARDF operation. 15. Make a full size copy. Check that the registrations (side-to-side and leading edge) and image skew are correct. If they are not, adjust the registrations and image skew (refer to "Copy Adjustments" in the "Replacements and Adjustments section).

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1-Bin Tray Unit (B803)

1.7 1-BIN TRAY UNIT (B803)1.7.1 COMPONENT CHECKCheck the quantity and condition of the components against the following list.

No. 1 2 3 4 5

Description 1-Bin Tray Unit End-fence Tray Support Bar Screws (M3 x 16) Tray

Qty 1 1 1 2 1

1.7.2 INSTALLATION PROCEDUREUnplug the copier power cord before starting the following procedure. If the bridge unit (B227) has already been installed in the machine, remove it before installing 1-bin tray unit (B803). This will make it easier for you to do the following procedure. 1. 2. Remove all tapes. Open the right door of the machine.

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Installation

1-Bin Tray Unit (B803)

3. 4.

Remove the front right cover [A] ( Remove the inner cover [B] ( x 1).

x 1).

Keep this screw for step 5.

5.

Install the 1-bin tray unit [C] ( step 4]).

x 1,

x 1,

x 1 [This screw was removed in

6.

Attach the tray support bar [D] to the tray [E] as shown, and then attach the end-fence [F].

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1-Bin Tray Unit (B803)Installation

7. 8. 9.

Install the tray [G] (with the tray support bar) in the machine (M3 x 16: the machine. Turn on the main power switch of the machine.

x 2).

Reinstall the front right cover in the machine, and then close the right door of

10. Check the 1-bin tray unit operation.

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Bridge Unit (B227)

1.8 BRIDGE UNIT (B227)1.8.1 COMPONENT CHECKCheck the quantity and condition of the components against the following list.

No. 1 2 3 4 Bridge Unit Screw Knob screw

Description

Qty 1 1 1 1

Holder bracket

1.8.2 INSTALLATION PROCEDUREUnplug the copier power cord before starting the following procedure. 1. If you will install the 1-bin tray (B803) in the machine, install the 1-bin tray before you install the bridge unit (B227). This will make it easier for you to do the following procedure.

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Bridge Unit (B227) 2. If you will install a finisher (B408, B804, or B805) in the machine, install the finisher after you install the bridge unit (B227). 1. Remove all tapes.Installation

2. 3.

If the sensor feeler [A] is out, fold it into the machine. Open the right door of the machine.

4. 5. 6.

Remove the inner tray [B]. Remove the front right cover [C] ( Remove the connector cover [D] ( x 1). x 1).

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Bridge Unit (B227) 7. Install the bridge unit [E] in the machine.

8. 9.

Secure the bridge unit with the knob screw [F] and screw [G]. Reinstall the front right cover in the machine. Then close the right door of the machine. Open the bridge unit cover [H] when installing the front right cover. Otherwise, the bridge unit cover is an obstacle for attaching the front right cover.

10. Install the optional finisher (refer to the finisher installation procedure). If you will not install the finisher at this time, install the holder bracket [I]. Otherwise, the customer will damage the bridge unit if they pull up the bridge unit tray. When you install the finisher, you will need this bracket during the installation procedure. 11. Turn on the main power switch of the machine. 12. Check the bridge unit operation.

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1000-Sheet Finisher (B408)

1.9 1000-SHEET FINISHER (B408)1.9.1 ACCESSORY CHECKCheck the quantity and condition of the accessories against the following list.

No. 1 2 3 4 5 6 7 8 9 10

Description Front Joint Bracket Rear Joint Bracket Rear Joint Bracket Grounding Plate Copy Tray Staple Position Decal Screw - M4 x 14 Knob Screw - M4 x 10 Screw - M3 x 8 Knob Screw - M3 x 8

Qty 1 1 1 1 1 1 4 1 1 1

B222/B224 O --O O O O O O O O

O = Necessary, --- = Not necessary

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Installation

1000-Sheet Finisher (B408)

1.9.2 INSTALLATION PROCEDUREUnplug the main machine power cord before starting the following procedure. If this finisher will be installed on the B222 or B224 copier, the following options must be installed before installing this finisher. - Bridge Unit (B227) - Paper Feed Unit (B800) or LCT (B801)

1.

Unpack the finisher, and then remove the tapes [A] and stopper (

x 1).

2.

Install the front joint bracket [B], holder bracket [C] ( joint bracket [D] ( x 2 - M4 x 14).

x 2 - M4 x 14), and rear

The holder bracket [C] must be placed outside the front joint bracket [B]. The h

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Documents

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installation requirements

copier installation

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component check

b222b224 service manualbook

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