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GESTETNER 3502, 4502, 3502p, 4502p, RICOH Aficio 1035, 1045, 1035P, 1045P, SAVIN 2535, 2545, 2535p, 2545p Service Manual and Parts Manual

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SERVICE MANUAL TABLE OF CONTENTS

1. INSTALLATION PROCEDURE
1. INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS
1.2 INSTALLATION FLOW CHART
1.3 MAIN MACHINE INSTALLATION
1.4 PAPER TRAY UNIT INSTALLATION
1.5 1-BIN TRAY UNIT INSTALLATION
1.6 BRIDGE UNIT INSTALLATION
1.7 1000-SHEET FINISHER INSTALLATION
1.8 TWO-TRAY FINISHER INSTALLATION
1.9 PUNCH UNIT INSTALLATION
1.10 AUTO REVERSE DOCUMENT FEEDER INSTALLATION
1.11 LCT INSTALLATION
1.12 PLATEN COVER INSTALLATION
1.13 KEY COUNTER INSTALLATION
1.14 ANTI-CONDENSATION HEATER
1.15 TRAY HEATER
1.16 TRAY HEATER (OPTIONAL PAPER TRAY UNIT

2. PREVENTIVE MAINTENANCE SCHEDULE 
2.1 PM TABLE

3. REPLACEMENT AND ADJUSTMENT
3.1 GENERAL CAUTIONS
3.2 SPECIAL TOOLS AND LUBRICANTS
3.3 FRONT DOOR
3.4 DUPLEX UNIT
3.5 UPPER RIGHT COVER
3.6 BY-PASS TRAY
3.7 REAR COVERS
3.8 LEFT COVERS
3.9 SCANNER UNIT
3.10 LASER UNIT
3.11 PHOTOCONDUCTOR UNIT (PCU)
3.12 DEVELOPMENT
3.13 TRANSFER UNIT
3.14 PAPER FEED
3.15 FUSING
3.16 BY-PASS TRAY
3.17 DUPLEX UNIT
3.18 DRIVE AREA
3.19 PRINTED CIRCUIT BOARDS
3.20 HARD DISK/CONTROLLER BOARD
3.21 COPY ADJUSTMENTS: PRINTING/SCANNING

4. TROUBLESHOOTING 
4.1 SERVICE CALL CONDITIONS
4.2 ELECTRICAL COMPONENT DEFECTS
4.3 BLOWN FUSE CONDITIONS
4.4 LEDS
4.5 TEST POINTS

5. SERVICE TABLES
5.1 SERVICE PROGRAM MODE
5.2 SOFTWARE DOWNLOAD
5.3 UPLOADING/DOWNLOADING NVRAM DATA
5.4 SELF-DIAGNOSTIC MODE
5.5 USER PROGRAM MODE
5.6 DIP SWITCHES

6 DETAILED SECTION DESCRIPTIONS
6.1 OVERVIEW
6.2 BOARD STRUCTURE
6.3 COPY PROCESS OVERVIEW
6.4 SCANNING
6.5 IMAGE PROCESSING
6.6 LASER EXPOSURE
6.7 PHOTOCONDUCTOR UNIT (PCU)
6.8 DRUM CHARGE
6.9 DEVELOPMENT
6.10 DRUM CLEANING AND TONER RECYCLING
6.11 PAPER FEED
6.12 BY-PASS TRAY
6.13 DUPLEX UNIT
6.14 IMAGE TRANSFER AND PAPER SEPARATION
6.15 IMAGE FUSING AND PAPER EXIT
6.16 ENERGY SAVER MODES

7. SPECIFICATIONS
7.1 GENERAL SPECIFICATIONS
7.2 MACHINE CONFIGURATION
7.3 OPTIONAL EQUIPMENT

AUTO REVERSE DOCUMENT FEEDER B351
1. REPLACEMENT AND ADJUSTMENT
1.1 COVERS
1.2 ORIGINAL FEED UNIT
1.3 ORIGINAL PICK-UP ROLLER
1.4 ORIGINAL FEED BELT
1.5 SKEW CORRECTION/INTERVAL/ REGISTRATION/ORIGINAL WIDTH SENSORS
1.6 ORIGINAL LENGTH SENSORS
1.7 SEPARATION ROLLER
1.8 INVERTER /ORIGINAL SET SENSORS
1.9 PICK-UP MOTOR/ORIGINAL STOPPER HP SENSOR/PICK-UP HP SENSOR
1.10 SCANNER MOTOR AND INVERTER MOTOR
1.11 FEED MOTOR, SKEW CORRECTION ROLLER CLUTCH
1.12 EXIT SENSOR
1.13 STAMP SOLENOID
1.14 CONTROLLER BOARD

2 TROUBLESHOOTING
2.1 TIMING CHARTS
2.2 JAM DETECTION

3 SERVICE TABLES
3.1 DIP SWITCHES
3.2 TEST POINTS
3.3 FUSES

4 DETAILED DESCRIPTION
4.1 MAIN COMPONENTS
4.2 DRIVE LAYOUT
4.3 ORIGINAL SIZE DETECTION
4.4 ORIGINAL FEED-IN MECHANISM
4.5 ORIGINAL TRANSPORT AND EXIT
4.6 STAMP

LARGE CAPACITY TRAY A683
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS………………………………………………………………………….9-1
1.2 MECHANICAL COMPONENT LAYOUT ……………………………………………9-2
1.3 ELECTRICAL COMPONENT LAYOUT……………………………………………..9-3
1.4 ELECTRICAL COMPONENT DESCRIPTION…………………………………….9-4
1.5 DRIVE LAYOUT

2. DETAILED DESCRIPTIONS
2.1 PAPER FEED MECHANISM
2.2 TRAY LIFT AND PAPER HEIGHT DETECTION MECHANISM
2.3 TRAY UNIT SLIDE MECHANISM

3. SERVICE TABLES
3.1 DIP SWITCHES
3.2 TEST POINTS
3.3 SWITCHES
3.4 FUSES

4. REPLACEMENT AND ADJUSTMENT
4.1 COVER REPLACEMENT
4.2 ROLLER REPLACEMENT
4.3 TRAY LIFT AND PAPER END SENSOR REPLACEMENT
4.4 RELAY SENSOR REPLACEMENT
4.5 SIDE FENCE POSITION CHANGE

PAPER TRAY UNIT A682
1. REPLACEMENT AND ADJUSTMENT
1.1 COVER REPLACEMENT
1.2 ROLLER REPLACEMENT
1.3 TRAY MOTOR REPLACEMENT
1.4 PAPER FEED AND RELAY CLUTCH REPLACEMENT
1.5 PAPER FEED UNIT REPLACEMENT
1.6 PAPER END, TRAY LIFT, AND RELAY SENSOR REPLACEMENT

2. SERVICE TABLES
2.1 DIP SWITCHES
2.2 TEST POINTS
2.3 SWITCHES
2.4 FUSES

3. DETAILED DESCRIPTIONS
3.1 MECHANICAL COMPONENT LAYOUT
3.2 ELECTRICAL COMPONENT LAYOUT
3.3 ELECTRICAL COMPONENT DESCRIPTION
3.4 DRIVE LAYOUT
3.5 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM
3.6 PAPER LIFT MECHANISM
3.7 PAPER END DETECTION
3.8 PAPER HEIGHT DETECTION

4. SPECIFICATIONS

BRIDGE UNIT A688
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 EXIT SENSOR REPLACEMENT

1 BIN TRAY B376
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT AND DRIVE LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTION

2. DETAILED DESCRIPTIONS
2.1 BASIC OPERATION

3. REPLACEMENT AND ADJUSTMENT
3.1 COVER REMOVAL
3.2 PAPER SENSOR REPLACEMENT
3.3 ENTRANCE AND PAPER LIMIT SENSOR REPLACEMENT

1,000 SHEET FINISHER A681
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 MECHANICAL COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT LAYOUT
1.4 ELECTRICAL COMPONENT DESCRIPTIONS
1.5 DRIVE LAYOUT

2. DETAILED DESCRIPTIONS
2.1 JUNCTION GATE MECHANISM
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM
2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM
2.4 STAPLER
2.5 FEED OUT MECHANISM
2.6 SHIFT TRAY UP/DOWN MECHANISM
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM
2.8 JAM CONDITIONS
2.9 TIMING CHARTS

3. SERVICE TABLE
3.1 DIP SWITCH TABLE
3.2 TEST POINTS
3.3 FUSES

4. REPLACEMENT AND ADJUSTMENT
4.1 COVER REMOVAL
4.2 ENTRANCE SENSOR REPLACEMENT
4.3 EXIT SENSOR REPLACEMENT
4.4 STACK HEIGHT SENSOR REPLACEMENT
4.5 POSITIONING ROLLER REPLACEMENT
4.6 STAPLER REPLACEMENT

TWO TRAY FINISHER B352
1. REPLACEMENT AND ADJUSTMENT
1.1 COVERS
1.2 POSITIONING ROLLER
1.3 TRAY 1 EXIT SENSOR
1.4 ENTRANCE SENSOR/STAPLER TRAY ENTRANCE SENSOR
1.5 STAPLER TRAY
1.6 UPPER STACK HEIGHT SENSORS/TRAY 1 UPPER LIMIT SWITCH
1.7 EXIT GUIDE PLATE MOTOR
1.8 LIFT MOTORS
1.9 LOWER EXIT SENSOR
1.10 LOWER STACK HEIGHT SENSORS
1.11 TRAY 2 SHUNT POSITION SENSOR
1.12 STAPLER UNIT
1.13 STAPLER ROTATION HP SENSOR
1.14 TRAY 1 INTERIOR
1.15 FINISHER MAIN BOARD
1.16 PUNCH HOLE POSITION ADJUSTMENT

2. TROUBLESHOOTING
2.1 TIMING CHARTS
2.2 JAM DETECTION

3. SERVICE TABLES
3.1 DIP SWITCH SETTINGS
3.2 TEST POINTS
3.3 FUSES

4. DETAILED DESCRIPTIONS
4.1 GENERAL LAYOUT
4.2 DRIVE LAYOUT
4.3 JUNCTION GATES
4.4 TRAY SHIFTING
4.5 TRAY UP/DOWN MECHANISMS
4.6 JOGGER UNIT PAPER POSITIONING MECHANISM
4.7 STAPLER MECHANISM
4.8 PUNCH UNIT (OPTIONAL)

NINE-TRAY MAILBOX AND BRIDGE UNIT G909/G912
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.2 COMPONENT LAYOUT
1.3 ELECTRICAL COMPONENT DESCRIPTIONS

2. DETAILED DESCRIPTIONS
2.1 BASIC OPERATION
2.2 PROOF TRAY SENSORS
2.3 TRAY SENSORS
2.4 TIMING CHART AND MISFEED DETECTION

3. INSTALLATION PROCEDURE
3.1 MAILBOX (G909)
3.2 BRIDGE UNIT FOR MAILBOX (G912)

4. REPLACEMENT AND ADJUSTMENT
4.1 PROOF TRAY UNIT
4.2 TRAY UNIT

5. SERVICE TABLES
5.1 DIP SWITCHES/VRIABLE RESISTORS/LEDS

B361/B362 PRINTER/SCANNER CONTROLLERS
1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS
1.2 PRINTER INSTALLATION
1.3 POSTSCRIPT UNIT (G577)
1.4 MEMORY (G578/G579)
1.5 NIB (G574)
1.6 IEEE1394 INTERFACE (G590)
1.7 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 MEACHINE CONFIGURATION

FAX UNIT B360
1. INSTALLATION
1.1 FAX UNIT

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

B003/B004/B006/B007 PARTS LOCATION AND LIST LOCATION OF UNIT
1.EXTERIOR 1 (B003/B004/B006/B007)
2.EXTERIOR 2 (B003/B004/B006/B007)
3.EXTERIOR 3 (B003/B004/B006/B007)
4.PLATEN COVER (B003/B004/B006/B007)
5.OPERATION PANEL ASS’Y (B003/B004/B006/B007)
6.OPTICS UNIT 1 (B003/B004/B006/B007)
7.OPTICS UNIT 2 (B003/B004/B006/B007)
8.LASER UNIT (B003/B004/B006/B007)
9.BY-PASS FEED UNIT 1 (B003/B004/B006/B007)
10.BY-PASS FEED UNIT 2 (B003/B004/B006/B007)
11.PAPER TRAY UNIT (B003/B004/B006/B007)
12.PAPER FEED SECTION (B003/B004/B006/B007)
13.PAPER REGISTRATION (B003/B004/B006/B007)
14.TONER HOPPER UNIT (B003/B004/B006/B007)
15.PCU UNIT 1 (B003/B004/B006/B007)
16.PCU UNIT 2 (B003/B004/B006/B007)
17.TRANSFER UNIT 1 (B003/B004/B006/B007)
18.TRANSFER UNIT 2 (B003/B004/B006/B007)
19.DEVELOPMENT UNIT (B003/B004/B006/B007)
20.FUSING UNIT (B003/B004/B006/B007)
21.PAPER SEPARATION UNIT (B003/B004/B006/B007)
22.DUPLEX UNIT 1 (B003/B004/B006/B007)
23.DUPLEX UNIT 2 (B003/B004/B006/B007)
24.DUPLEX UNIT 3 (B003/B004/B006/B007)
25.DRIVE SECTION 1 (B003/B004/B006/B007)
26.DRIVE SECTION 2 (B003/B004/B006/B007)
27.ELECTRICAL SECTION 1 (B003/B004/B006/B007)
28.ELECTRICAL SECTION 2 (B003/B004/B006/B007)
29.FRAME SECTION 1 (B003/B004/B006/B007)
30.FRAME SECTION 2 (B003/B004/B006/B007)
31.EXPANSION BOX (B003/B004/B006/B007)
32.IOB BOARD (B003/B004/B006/B007)
33.BICU BOARD (B003/B004/B006/B007)
34.CONTROLLER BOARD (B003/B004/B006/B007)
35.DECAL AND DOCUMENT (B003/B004/B006/B007)
36.SPECIAL TOOLS (B003/B004/B006/B007)

B003/B004/B006/B007 PARTS INDEX
PARTS INDEX

AUTO REVERSE DOCUMENT FEEDER B351 PARTS LOCATION AND LIST LOCATION OF UNIT 
1.ARDF1 (B351)
2.ARDF2 (B351)
3.ARDF3 (B351)
4.ARDF4 (B351)
5.ARDF5 (B351)
6.ARDF6 (B351)
7.ARDF7 (B351)
8.ARDF8 (B351)
9.ARDF9 (B351)
10.MAIN CONTROL BOARD (B351)
11.DECAL AND DOCUMENTS

AUTO REVERSE DOCUMENT FEEDER B351 PARTS INDEX
PARTS INDEX

TWO TRAY FINISHER B352 PARTS LOCATION AND LIST LOCATION OF UNIT 
1.EXTERIOR 1 (B352)
2.EXTERIOR 2 (B352)
3.PUNCH FRAME (B352)
4.PAPER TRANSFER 1 (B352)
5.PAPER TRANSFER 2 (B352)
6.PAPER TRANSFER 3 (B352)
7.STAPLE TRAY 1 (B352)
8.STAPLE TRAY 2 (B352)
9.STAPLE UNIT (B352)
10.UPPER PAPER EXIT 1 (B352)
11.UPPER PAPER EXIT 2 (B352)
12.UPPER PAPER EXIT 3 (B352)
13.LOWER PAPER EXIT (B352)
14.SHIFT DRIVE 1 (B352)
15.SHIFT DRIVE 2 (B352)
16.DRIVE SECTION (B352)
17.ELECTRICAL SECTION (B352)
18.MAIN CONTROL BOARD (B352)
19.DECAL AND DOCUMENT (B352)

TWO TRAY FINISHER B352 PARTS INDEX
PARTS INDEX

1 BIN TRAY B376 PARTS LOCATION AND LIST
1.1 BIN TRAY 1 (B376)
2.1 BIN TRAY 2 (B376)

1 BIN TRAY B376 PARTS INDEX
PARTS INDEX

PUNCH KIT TYPE1045 B377 PARTS LOCATION AND LIST
1.PUNCH KIT TYPE1045 (B377)

PUNCH KIT TYPE1045 B377 PARTS INDEX
PARTS INDEX

BRIDGE UNIT TYPE 1045 B397 PARTS LOCATION AND LIST
1.BRIDGE UNIT 1 (B397)
2.BRIDGE UNIT 2 (B397)

BRIDGE UNIT TYPE 1045 B397 PARTS INDEX
PARTS INDEX

FAX/G3/ISDN UNIT TYPE 1045 PARTS LOCATION AND LIST
1.FAX OPTION (B360)
2.G3/G4 OPTION (B366/B367)
3.NCU BOARD (B360)
4.FCU BOARD (B360)
5.SIG4 Board (B367)
6.NCU Board (B366)

FAX/G3/ISDN UNIT TYPE 1045 PARTS INDEX
PARTS INDEX

PRINTER/SCANNER UNIT TYPE 1045 B362 PARTS LOCATION AND LIST
1.PRINTER/SCANNER UNIT TYPE 1045 (B362/B361)

PRINTER/SCANNER UNIT TYPE 1045 B362 PARTS INDEX
PARTS INDEX

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