B222/B224

SERVICE MANUAL
(Book 1 of 2) 002825MIU

MAINFRAME

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

B222/B224
SERVICE MANUAL
Book 1 of 2
MAINFRAME

002825MIU

It is the reader's responsibility when discussing the information contained

within this document to maintain a level of confidentiality that is in the best
interest of Ricoh Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
FASHION AND DISTRIBUTED WITHOUT THE PRIOR
PERMISSION OF RICOH CORPORATION.
All product names, domain names or product illustrations, including
desktop images, used in this document are trademarks, registered
trademarks or the property of their respective companies.
They are used throughout this book in an informational or editorial fashion
only and for the benefit of such companies. No such use, or the use of
any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.

2006 RICOH Corporation. All rights reserved.

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

Ricoh Corporation

LEGEND
PRODUCT
CODE
B222
B224

COMPANY
GESTETNER
DSc535
DSc545

LANIER
LD435c
LD445c

RICOH
Aficio MP C3500
Aficio MP C4500

SAVIN
C3535
C4540

DOCUMENTATION HISTORY
REV. NO.
*

DATE
09/2006

COMMENTS
Original Printing

B222/B224
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION ............................................................................1-1
1.1 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 MAINTENANCE
2. PREVENTIVE MAINTENANCE ....................................................2-1
2.1 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 ADJUSTMENT

3. REPLACEMENT AND ADJUSTMENT.........................................3-1
3.1 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

TROUBLESHOOTING
4. TROUBLESHOOTING..................................................................4-1
4.1 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 TABLES
5. SERVICE TABLES .......................................................................5-1
5.1 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 DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS........................................6-1
6.1 OVERVIEW ................................................................................................6-1
6.1.1 COMPONENT LAYOUT....................................................................6-1
6.1.2 PAPER PATH....................................................................................6-2
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

SPECIFICATIONS
7. SPECIFICATIONS ........................................................................7-1
7.1 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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Rev. 11/2006

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 B771
SEE SECTION B771 FOR DETAILED TABLE OF CONTENTS

AUTO REVERSE DOCUMENT FEEDER B802

SEE SECTION B802 FOR DETAILED TABLE OF CONTENTS

1 BIN TRAY UNIT B803

SEE SECTION B803 FOR DETAILED TABLE OF CONTENTS

BOOKLET FINISHER/FINISHER B804/B805

SEE SECTION B804/B805 FOR DETAILED TABLE OF CONTENTS

SCANNER ACCESSIBILITY OPTION TYPE 4045 B838

SEE SECTION B838 FOR DETAILED TABLE OF CONTENTS

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Read This First

Important Safety Notices
Prevention of Physical Injury
1.

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

2.

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

3.

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 Conditions

1.

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 Standards

The 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.

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 Disposal

1.

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

2.

Dispose of used toner, the maintenance unit which includes developer or the organic
photoconductor in accordance with local regulations. (These are non-toxic supplies.)

3.

Dispose of replaced parts in accordance with local regulations.

4.

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

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

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 Trademarks

This 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

Short Edge Feed

LEF

Long Edge Feed

Trademarks
Microsoft, 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.

PREVENTIVE MAINTENANCE

REPLACEMENT AND ADJUSTMENT

TROUBLESHOOTING

TAB
POSITION 1
TAB
POSITION 5

DETAILED DESCRIPTIONS

1 BIN TRAY UNIT B803

TAB
POSITION 8

SPECIFICATIONS

TAB
POSITION 7

SERVICE TABLES

TAB
POSITION 6

BOOKLET FINISHER/FINISHER B804/B805

TAB
POSITION 2

FAX OPTION B771

TAB
POSITION 3

AUTO REVERSE DOCUMENT FEEDER B802

TAB
POSITION 4

INSTALLATION

INSTALLATION

Installation

Installation Requirements

1. INSTALLATION
1.1 INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT

1.

Temperature Range: 10C to 32C (50F to 89.6F)

2.

Humidity Range: 15% to 80% RH

3.

Ambient Illumination: Less than 1500 lux (do not expose to direct sunlight)

4.

Ventilation: 3 times/hr/person or more

5.

Do not let the machine get exposed to the following:

1) Cool air from an air conditioner
2) Heat from a heater

6.

Do not install the machine in areas that are exposed to corrosive gas.

7.

Install the machine at locations lower than 2,500 m (8,200 ft.) above sea level.

8.

Install the machine on a strong, level base. (Inclination on any side must be no more
than 5 mm.)

9.

Do not install the machine in areas that get strong vibrations.

1.1.2 MACHINE LEVEL

Front to back: Within 5 mm (0.2")
Right to left: Within 5 mm (0.2")

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Installation Requirements

1.1.3 MACHINE SPACE REQUIREMENTS

This 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 REQUIREMENTS

Insert 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.

Permissible voltage fluctuation: 10 %

3.

Do not put things on the power cord.

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Installation

Optional Unit Combinations

1.2 OPTIONAL UNIT COMBINATIONS

1.2.1 MACHINE OPTIONS

No.
1

Options

Remarks

2-tray paper feed unit

One from No.1 or No.2

Large capacity tray

Platen cover
One from No.3 or No.4

ARDF

1-bin tray unit

Bridge unit

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;

3000-sheet finisher

Requires No.6 and one from No.1 and

No.2.

*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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Optional Unit Combinations

1.2.2 CONTROLLER OPTIONS

No.

Options

IEEE 1394

Bluetooth

Remarks

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

3

IEEE 802.11b

IEEE 1284

USB Host Interface Unit

I/F Slot B

File Format Converter

I/F Slot D

PostScript 3

PictBridge Option

Data Overwrite Security Unit Type D

11

Browser Unit

SD card slot 3 (during installation only)

12

Copy Data Security Unit

13

VM Card Type C

SD card slot 3 (during installation only)

No.7 to No.9 (SD card slot 2)

1.2.3 FAX OPTIONS

No.

Options

Remarks

Fax Option Type C4500

*Memory Unit Type B 32MB

Requires No.1.

*Hand Set Type 1018

Requires No.1. (NA Only)

G3 Interface Unit Type C4500

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

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Installation

Optional Unit Combinations

1.2.4 OTHER OPTIONS

No.
1

SM

Options

Remarks

Copy Data Security Unit Type A

Optional Counter Interface Unit

Type A

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B222/B224

Copier Installation

1.3 COPIER INSTALLATION

Make 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 PERIPHERALS

Rating voltage for peripherals.
Make sure to plug the cables into the correct sockets.

1.3.2 INSTALLATION FLOW CHART

This flow chart shows the best procedure for installation.

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Installation

Copier Installation

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 CHECK

Check the quantity and condition of these accessories.
Description

Q'ty

1.

Operating Instruction - Troubleshooting

2.

Operating Instruction - About This Machine

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Copier Installation
Description

Q'ty

3.

Operating Instruction - Security

4.

Operation Instruction - Quick Reference Guide

5.

Operation Instruction - Printer Quick Reference

6.

Operation Instruction - Scanner Quick Reference

7.

CD-ROM - Instruction - RIC

8.

CD-ROM - Instruction - SAV

9.

CD-ROM - Instruction - GES

10.

CD-ROM - Instruction - LAN

11.

CD-ROM - Printer Instruction - RIC

12.

CD-ROM - Printer Instruction - SAV

13.

CD-ROM - Printer Instruction - GES

14.

CD-ROM - Printer Instruction - NRG

15

CD-ROM - Printer Instruction - LAN

16

CD-ROM - Printer Instruction - INF

17

CD-ROM - Scanner Instruction - RIC

18

CD-ROM - Scanner Instruction - SAV

19

CD-ROM - Scanner Instruction - GES

20

CD-ROM - Scanner Instruction - NRG

21

CD-ROM - Scanner Instruction - LAN

22

Model Name Decal

23

Stamp

24

Cloth Holder

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Description

Installation

Copier Installation
Q'ty

25

Exposure Glass Cleaning Cloth

26

Rivet

27

Operating Instructions Holder

28

Ferrite Core

29

Power Supply Cord

30

Cover

31

Decal - Paper Size

32

Emblem Cover

33

Sheet - Eula: 16 Languages

34

Sheet - Caution 16 Languages

35

Decal - Caution - Original

36

Sheet Data

37

Warranty Sheet (Chinese)

38

Sheet - Name - Tel

1.3.4 INSTALLATION PROCEDURE

Remove 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.

Remove all the tapes and retainers on the machine.

2.

Remove all the tapes and retainers in trays 1 and 2, and then take out the power
cord from tray 1 (if applicable).

3.

Remove the scanner unit stay [A].

4.

Open the front door [B], and then remove the jam location sheet [C].

5.

Keep the scanner unit stay [A] inside the front door [B].

6.

Reattach the jam location sheet.

7.

Close the front door.

Developer and Toner Bottles

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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).

This stopper locks the drum positioning plate lever.

3.

Release the image transfer unit lock lever [C], and turn the drum positioning
plate lever [D] counterclockwise.

4.

Open the drum positioning plate [E].

5.

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.

Close the drum positioning plate. Then lock the image transfer unit lock and turn
the drum positioning plate lever clockwise.

7.

Lock the drum positioning plate lever with the stopper [B] (

8.

Shake each toner bottle five or six times.

9.

Install each toner bottle [G] in the machine.

x 1).

10. Close the front door.

Paper Trays
1.

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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Installation

Copier Installation

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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Installation

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.

Attach the manual pocket [A] to the left side of the copier (snap rivet x 2).

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 Developer

1.

Plug in the machine.

2.

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.

Make copies of image samples (text, photo, and text/photo modes).

5.

Do the Automatic Color Calibration process (ACC) as follows:

6.

1.

Print the ACC test pattern (User tools > Maintenance > ACC > Start).

2.

Put the printout on the exposure glass.

3.

Put 10 sheets of white paper on top of the test chart.

4.

Close the ARDF or the platen cover.

5.

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 Contract

Change 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 (

Item

SP No.

SP5-045-001).

Function

Default

Specifies if the counting method used in

meter charge mode is based on
Counting
method

SP5-045-001

developments or prints. NOTE: You can

0:

set this one time only. You cannot

Developments

change the setting after you have set it

for the first time.
Specifies whether the counter is

A3/11" x 17"
double
counting

B222/B224

SP5-104-001

doubled for A3/11" x 17" paper. When

No: Single

you have to change this setting, contact

counting

your supervisor.

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