Description

SERVICE MANUAL TABLE OF CONTENTS

B022/B027 TABLE OF CONTENTS

1 OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 MACHINE CONFIGURATION
1.3 PAPER PATH
1.4 MECHANICAL COMPONENT LAYOUT
1.5 ELECTRICAL COMPONENT DESCRIPTIONS
1.6 DRIVE LAYOUT
1.7 COPY PROCESS
1.8 BOARD STRUCTURES

2. DETAILED SECTION DESCRIPTIONS
2.1 SCANNING
2.2 IMAGE PROCESSING
2.3 LASER EXPOSURE
2.4 PHOTOCONDUCTOR UNIT (PCU)
2.5 DRUM CHARGE
2.6 DEVELOPMENT
2.7 DRUM CLEANING AND TONER RECYCLING
2.8 PAPER FEED
2.9 IMAGE TRANSFER AND PAPER SEPARATION
2.10 IMAGE FUSING AND PAPER EXIT
2.11 ENERGY SAVER MODES

3. 3 INSTALLATION PROCEDURE
3.1 INSTALLATION REQUIREMENTS
3.2 COPIER INSTALLATION
3.3 PAPER TRAY UNIT INSTALLATION
3.4 LCT INSTALLATION
3.5 AUTO REVERSE DOCUMENT FEEDER INSTALLATION
3.6 INTERCHANGE UNIT INSTALLATION
3.7 1-BIN TRAY UNIT INSTALLATION
3.8 SHIFT TRAY
3.9 BY-PASS FEED UNIT INSTALLATION
3.10 DUPLEX UNIT INSTALLATION
3.11 BRIDGE UNIT INSTALLATION
3.12 1,000-SHEET FINISHER INSTALLATION
3.13 500-SHEET FINISHER INSTALLATION
3.14 PLATEN COVER INSTALLATION.
3.15 KEY COUNTER INSTALLATION
3.16 ANTI-CONDENSATION HEATER
3.17 TRAY HEATER
3.18 TRAY HEATER (OPTIONAL PAPER TRAY UNIT)
3.19 TRAY HEATER (OPTIONAL LCT)

4. SERVICE TABLES
4.1 GENERAL CAUTION
4.2 SERVICE PROGRAM MODE
4.3 PROGRAM DOWNLOAD
4.4 SOFTWARE RESET
4.5 SYSTEM SETTINGS AND COPY SETTING RESET
4.6 USER TOOLS
4.7 LEDS
4.8 DIP SWITCHES
4.9 SPECIAL TOOLS AND LUBRICANTS

5 PREVENTIVE MAINTENANCE SCHEDULE
5.1 PM TABLE

6. REPLACEMENT AND ADJUSTMENT
6.1 SCANNER UNIT
6.2 LASER UNIT
6.3 PHOTOCONDUCTOR UNIT (PCU)
6.4 TRANSFER UNIT
6.5 FUSING/EXIT
6.6 PAPER FEED
6.7 PCBS AND OTHER ITEMS
6.8 COPY ADJUSTMENTS: PRINTING/SCANNING

7. TROUBLESHOOTING
7.1 SERVICE CALL CONDITIONS
7.2 SELF-DIAGNOSTIC MODE
7.3 PAPER FEED TROUBLESHOOTING
7.4 SKEWED IMAGE
7.5 ELECTRICAL COMPONENT DEFECTS
7.6 BLOWN FUSE CONDITIONS

PAPER TRAY UNIT (A860/B390)
1 OVERALL MACHINE INFORMATION 
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTION
1.5 DRIVE LAYOUT

2 DETAILED DESCRIPTIONS 
2.1 PAPER FEED AND SEPARATION MECHANISM
2.2 PAPER LIFT MECHANISM
2.3 PAPER END DETECTION
2.4 PAPER HEIGHT DETECTION
2.5 PAPER SIZE DETECTION
2.6 SIDE AND END FENCES

3 REPLACEMENT AND ADJUSTMENT
3.1 FEED ROLLER REPLACEMENT
3.2 TRAY MAIN BOARD REPLACEMENT
3.3 TRAY MOTOR REPLACEMENT
3.4 RELAY CLUTCH REPLACEMENT
3.5 UPPER PAPER FEED CLUTCH REPLACEMENT
3.6 LOWER PAPER FEED CLUTCH REPLACEMENT
3.7 LIFT MOTOR REPLACEMENT
3.8 PAPER END SENSOR REPLACEMENT
3.9 VERTICAL TRANSPORT SENSOR REPLACEMENT
3.10 PAPER SIZE SWITCH REPLACEMENT

LCT (A862/B391)
1 OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTIONS

2 DETAILED SECTION DESCRIPTIONS
2.1 PAPER FEED
2.2 REVERSE ROLLER AND PICK-UP ROLLER RELEASE
2.3 TRAY LIFT
2.4 NEAR END/END DETECTION
2.5 RIGHT TRAY SIDE FENCE
2.6 LEFT TRAY REAR FENCE
2.7 RIGHT TRAY PAPER END DETECTION

3 REPLACEMENT AND ADJUSTMENT
3.1 DETACHING THE TRAY FROM THE MAINFRAME
3.2 REAR FENCE HP SENSOR
3.3 CHANGING THE TRAY PAPER SIZE
3.4 LEFT TRAY PAPER END SENSOR
3.5 TRAY LIFT MOTOR
3.6 TRAY MOTOR
3.7 PAPER FEED CLUTCH AND RELAY CLUTCH
3.8 PAPER FEED UNIT
3.9 UPPER LIMIT, RIGHT TRAY PAPER END, AND RELAY SENSORS
3.10 REAR FENCE MOTOR
3.11 PICK-UP/PAPER FEED/REVERSE ROLLERS

AUTO REVERSE DOCUMENT FEEDER (B386)
1 OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTION
1.5 DRIVE LAYOUT

2 DETAILED SECTION DESCRIPTIONS
2.1 ORIGINAL SIZE DETECTION
2.2 MIXED ORIGINAL SIZE MODE
2.3 PICK-UP AND SEPARATION
2.4 ORIGINAL TRANSPORT AND EXIT
2.4.1 SINGLE-SIDED ORIGINALS
2.4.2 DOUBLE-SIDED ORIGINALS
2.4.3 ORIGINAL TRAILING EDGE SENSOR
2.5 STAMP
2.6 TIMING CHART
2.7 CONDITION OF JAM DETECTION
2.8 OVERALL ELECTRICAL CIRCUIT

3 SERVICE TABLES
3.1 DIP SWITCHES

4 REPLACEMENT AND ADJUSTMENT
4.1 DF EXIT TABLE AND COVER
4.2 ORIGINAL FEED UNIT
4.3 LEFT COVER
4.4 PICK-UP ROLLER
4.5 FEED BELT
4.6 SEPARATION ROLLER
4.7 ORIGINAL SET/ORIGINAL REVERSE SENSOR
4.8 ORIGINAL SIZE SENSOR
4.9 ORIGINAL FEED DRIVE
4.10 REGISTRATION SENSOR
4.11 STAMP SOLENOID AND ORIGINAL EXIT SENSOR

INTERCHANGE UNIT (B300/B416)
1 OVERALL MACHINE INFORMATION 
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 DRIVE LAYOUT

2 DETAILED DESCRIPTION
2.1 JUNCTION GATE MECHANISM

3 REPLACEMENT AND ADJUSTMENT
3.1 EXIT SENSOR REPLACEMENT

1-BIN TRAY UNIT (A898/B413)
1 OVERALL INFORMATION
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTION

2 DETAILED SECTION DESCRIPTIONS
2.1 BASIC OPERATION

3 REPLACEMENT AND ADJUSTMENT
3.1 PAPER SENSOR REMOVAL

SHIFT TRAY UNIT (B313/B459)
1 OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 COMPONENT LAYOUT

2 DETAILED SECTION DESCRIPTIONS
2.1 BASIC OPERATION
2.2 PRIMARY MECHANISMS

3 REPLACEMENT AND ADJUSTMENT
3.1 TRAY COVER REPLACEMENT
3.2 TRAY MOTOR AND HALF TURN SENSOR REPLACEMENT

BY-PASS (A899/B415)
1 OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTION

2 DETAILED DESCRIPTIONS
2.1 BASIC OPERATION
2.2 PAPER SIZE DETECTION

3 REPLACEMENT AND ADJUSTMENT
3.1 PAPER FEED ROLLER/FRICTION PAD/PAPER END SENSOR
3.2 PAPER SIZE SENSOR BOARD
3.3 PAPER FEED CLUTCH

DUPLEX (A896/B414)
1 OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTION
1.5 DRIVE LAYOUT

2 DETAILED DESCRIPTIONS
2.1 BASIC OPERATION
2.2 FEED IN AND EXIT MECHANISM

3 REPLACEMENT AND ADJUSTMENT
3.1 COVER REMOVAL
3.2 ENTRANCE SENSOR REPLACEMENT
3.3 EXIT SENSOR REPLACEMENT

BRIDGE UNIT (A897/B417)
1 OVERALL MACHINE INFORMATION 
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTION
1.5 DRIVE LAYOUT

2 DETAILED DESCRIPTION
2.1 JUNCTION GATE MECHANISM

3 REPLACEMENT AND ADJUSTMENT
3.1 BRIDGE UNIT DRIVE MOTOR REPLACEMENT
3.2 TRAY EXIT SENSOR REPLACEMENT
3.3 RELAY SENSOR REPLACEMENT

1,000-SHEET FINISHER (B408)
1 REPLACEMENT AND ADJUSTMENT
1.1 MAIN PCB
1.2 STAPLER UNIT
1.3 MOTORS
1.4 MOTORS AND SENSORS

2 TROUBLESHOOTING
2.1 JAM DETECTION

3 SERVICE TABLES
3.1 DIP SWITCH SETTINGS

4 DETAILED DESCRIPTIONS
4.1 GENERAL LAYOUT
4.2 ELECTRICAL COMPONENT LAYOUT
4.3 ELECTRICAL COMPONENT DESCRIPTION
4.4 DRIVE LAYOUT
4.5 JUNCTION GATES
4.6 UPPER TRAY
4.7 LOWER TRAY UP/DOWN MECHANISMS
4.8 PAPER SHIFT MECHANISM
4.9 JOGGER UNIT PAPER POSITIONING MECHANISM
4.10 EXIT GUIDE PLATE
4.11 STAPLER MECHANISM
4.12 STAPLER UNIT MOVEMENT MECHANISM
4.13 PAPER FEED-OUT MECHANISM

5 OVERALL MACHINE INFORMATION
5.1 SPECIFICATIONS

500-SHEET FINISHER (G302/B442)
1 REPLACEMENT AND ADJUSTMENT
1.1 EXTERIOR
1.2 ENTRANCE UPPER GUIDE / PAPER EXIT UNIT
1.3 ENTRANCE LOWER GUIDE
1.4 PAPER EXIT UNIT GEAR / PADDLE ROLLER SOLENOID
1.5 STAPLER UNIT
1.6 JOGGER TRAY UNIT
1.7 PAPER EXIT SENSOR FEELER
1.8 MAIN MOTOR
1.9 JOGGER MOTOR
1.10 CONTROL BOARD
1.11 OUTPUT TRAY UNIT

2 DETAILED DESCRIPTIONS
2.1 OVERALL MACHINE INFORMATION
2.2 DETAILED SECTION DESCRIPTIONS

3 OVERALL MACHINE INFORMATION
3.1 SPECIFICATIONS

B453/B461 TABLE OF CONTENTS

1 INSTALLATION
1.1 INSTALLATION REQUIREMENTS
1.2 PRINTER/SCANNER INSTALLATION
1.3 PRINTER OPTIONS
1.4 CHECKING THE CONNECTIONS

2 TROUBLESHOOTING
2.1 CONTROLLER ERRORS
2.2 LEDS AND TEST POINTS

3 SERVICE TABLES
3.1 SERVICE PROGRAM MODE
3.2 PRINTER SERVICE MODE
3.3 SCANNER SERVICE MODE
3.4 FIRMWARE UPDATE PROCEDURE
3.5 POWER-ON SELF TEST
3.6 SELF DIAGNOSTIC TEST
3.7 USER PROGRAM MODE

4 DETAILED SECTION DESCRIPTIONS
4.1 OVERVIEW
4.2 CONTROLLER FUNCTIONS
4.3 SCANNER FUNCTIONS
4.4 NIB
4.5 IEEE1394 INTERFACE

SPECIFICATIONS
1 GENERAL SPECIFICATIONS
2 SOFTWARE ACCESSORIES
3 MACHINE CONFIGURATION

1 INSTALLATION
1.1 FAX UNIT
1.2 FAX UNIT OPTIONS

2 TROUBLESHOOTING
2.1 ERROR CODES
2.2 ERROR CODES FOR THE ISDN OPTION
2.3 FAX SC CODES
2.4 ISDN TEST FUNCTION

3 SERVICE TABLES
3.1 SERVICE PROGRAM MODE
3.2 BIT SWITCHES
3.3 NCU PARAMETERS
3.4 DEDICATED TRANSMISSION PARAMETERS
3.5 SERVICE RAM ADDRESSES

4 DETAILED SECTION DESCRIPTIONS
4.1 OVERVIEW
4.2 BOARDS
4.3 VIDEO DATA PATH
4.4 FAX COMMUNICATION FEATURES

SPECIFICATIONS
1 GENERAL SPECIFICATIONS
2 CAPABILITIES OF PROGRAMMABLE ITEMS
3 MACHINE CONFIGURATION

PARTS MANUAL TABLE OF CONTENTS

B022/B027 PARTS LOCATION AND LIST
LOCATION AND LIST
1.EXTERIOR 1 (B022/B027)
2.EXTERIOR 2 (B022/B027)
3.OPERATION PANEL (B022/B027)
4.PLATEN COVER (OPTION B406)
5.OPTICS SECTION 1 (B022/B027)
6.OPTICS SECTION 2 (B022/B027)
7.OPTICS SECTION 3 (B022/B027)
8.LASER UNIT (B022/B027)
9.TRANSFER UNIT (B022/B027)
10.PAPER FEED SECTION 1 (B022/B027)
11.PAPER FEED SECTION 2 (B022/B027)
12.PAPER FEED SECTION 3 (B022/B027)
13.TONER HOPPER UNIT (B022/B027)
14.PAPER REGISTRATION (B022/B027)
15.PAPER TRAY (B022/B027)
16.FUSING UNIT 1 (B022/B027)
17.FUSING UNIT 2 (B022/B027)
18.PAPER EXIT (B022/B027)
19.DRIVE SECTION 1 (B022/B027)
20.DRIVE SECTION 2 (B022/B027)
21.DRIVE SECTION 3 (B022/B027)
22.DRIVE SECTION 4 (B022/B027)
23.ELECTRICAL SECTION 1 (B022/B027)
24.ELECTRICAL SECTION 2 (B022/B027)
25.FRAME SECTION (B022/B027)
26.SBCU BOARD (B022/B027)
27.CONTROLLER BOARD (B022/B027)
28.IPU BOARD (B022/B027)
29.DECAL AND DOCUMENT (B022/B027)
30.SPECIAL TOOLS (B022/B027)

B022/B027 PARTS INDEX
PARTS INDEX

PAPER TRAY UNIT PS490 B390 PARTS LOCATION AND LIST
1.EXTERIOR (B390)
2.PAPER TRAY (B390)
3.PAPER FEED/TRANSFER (B390)
4.ELECTRICAL SECTION1 1 (B390)
5.ELECTRICAL SECTION1 2 (B390)
6.ELECTRICAL SECTION1 3 (B390)
7.DECALS AND DOCUMENTS (B390)

PAPER TRAY UNIT PS490 B390 PARTS INDEX
PARTS INDEX

LARGE CAPACITY TRAY PS500 B391 PARTS LOCATION AND LIST
1.EXTERIOR (B391)
2.PAPER FEED SECTION (B391)
3.TANDEM TRAY 1 (B391)
4.TANDEM TRAY 2 (B391)
5.TANDEM TRAY 3 (B391)
6.DRIVE/ELECTRICAL SECTION (B391)
7.DECALS AND DOCUMENTS (B391)

LARGE CAPACITY TRAY PS500 B391 PARTS INDEX
PARTS INDEX

AUTO REVERSE DOCUMENT FEEDER DF75 B386 PARTS LOCATION AND LIST
1.ARDF 1 (B386)
2.ARDF 2 (B386)
3.ARDF 3 (B386)
4.ARDF 4 (B386)
5.ARDF 5 (B386)
6.ARDF 6 (B386)
7.ARDF 7 (B386)
8.DECALS AND DOCUMENTS (B386)

AUTO REVERSE DOCUMENT FEEDER DF75 B386 PARTS INDEX
PARTS INDEX

INTERCHANGE UNIT TYPE 1027 B416 PARTS LOCATION AND LIST
1.INTERCHANGE UNIT 1 (B416)
2.INTERCHANGE UNIT 2 (B416)

INTERCHANGE UNIT TYPE 1027 B416 PARTS INDEX
PARTS INDEX

1-BIN TRAY UNIT PT280 B413 PARTS LOCATION AND LIST
1.1 BIN TRAY (B413)

1-BIN TRAY UNIT PT280 B413 PARTS INDEX
PARTS INDEX

INTERNAL SHIFT SORT TRAY TYPE 1027 B459 PARTS LOCATION AND LIST
1.INTERNAL SHIFT SORT TRAY TYPE1027(B459)

INTERNAL SHIFT SORT TRAY TYPE 1027 B459 PARTS INDEX
PARTS INDEX

BYPASS TRAY TYPE 1027 B415 PARTS LOCATION AND LIST
1.BYPASS TRAY 1 (B415)
2.BYPASS TRAY 2 (B415)

BYPASS TRAY TYPE 1027 B415 PARTS INDEX
PARTS INDEX

DUPLEX AD420 B414 PARTS LOCATION AND LIST
1.DUPLEX UNIT 1 (B414)
2.DUPLEX UNIT 2 (B414)
3.DUPLEX UNIT 3 (B414)

DUPLEX AD420 B414 PARTS INDEX 
PARTS INDEX

BRIDGE UNIT TYPE 1027 B417 PARTS LOCATION AND LIST
1.BRIDGE UNIT 1 (B417)
2.BRIDGE UNIT 2 (B417)
3.BRIDGE UNIT 3 (B417)

BRIDGE UNIT TYPE 1027 B417 PARTS INDEX
PARTS INDEX

1,000 SHEET FINISHER SR790 B408 PARTS LOCATION AND LIST
1.EXTERIOR (B408)
2.TRANSPORT SECTION (B408)
3.PAPER EXIT SECTION 1 (B408)
4.PAPER EXIT SECTION 2 (B408)
5.VERTICAL TRANSPORT (B408)
6.STAPLE SECTION 1 (B408)
7.STAPLE SECTION 2 (B408)
8.STAPLE SECTION 3 (B408)
9.SHIFT TRAY DRIVE (B408)
10.DRIVE SECTION (B408)
11.ELECTRICAL SECTION (B408)
12.DECALS AND DOCUMENTS (B408)

1,000 SHEET FINISHER SR790 B408 PARTS INDEX
PARTS INDEX

500 SHEET FINISHER SR820 B442 PARTS LOCATION AND LIST
1.EXTERIOR (B442)
2.SHIFT TRAY (B442)
3.DRIVE SECTION (B442)
4.PAPER EXIT SECTION (B442)
5.PAPER FEED SECTION (B442)
6.FRAME/ELECTRICAL SECTION (B442)

500 SHEET FINISHER SR820 B442 PARTS INDEX
PARTS INDEX

PRINTER/SCANNER CONTROLLER TYPE 1027 B453/B461/G335/B420 PARTS LOCATION AND LIST
1.PRINTER OPTION (B461/G335/B453/B420/B462)

PRINTER/SCANNER CONTROLLER TYPE 1027 B453/B461/G335/B420 PARTS INDEX
PARTS INDEX

FAX OPTION/G3 B418/B448/B449 PARTS LOCATION AND LIST
1.FAX OPTION TYPE 1027 (B418)
2.G3 INTERFACE UNIT TYPE 1027 (B448)
3.ISDN OPTION TYPE 1027 (B449)
4.MBU BOARD (B418)
5.NCU BOARD (120V B418/B448)
6.NCU BOARD (230V B418/B448)
7.FCU BOARD (120V B418)
8.FCU BOARD (230V B418)

FAX OPTION/G3 B418/B448/B449 PARTS INDEX
PARTS INDEX