Ricoh Aficio AP2700 User manual

Russian Printer
Aficio AP2700
SERVICE MANUAL
October 1st, 1999
Subject to change

IIMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the printer power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. Note that some components of the printer and the paper tray unit are
supplied with electrical voltage even if the main power switch is turned off.
4. 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.
5. The inside and the metal parts of the fusing unit become extremely hot while
the printer 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. Try to remove with eye
drops or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The printer and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on
those models.
2. The NVRAM on the system control board has a lithium battery which can
explode if replaced incorrectly. Replace the NVRAM only with an identical
one. The manufacturer recommends replacing the entire NVRAM. Do not
recharge or burn this battery. Used NVRAM must be handled in accordance
with local regulations.

1. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
Do not incinerate toner bottles or used toner. Toner dust may ignite
suddenly when exposed to an open flame.
2. Dispose of used toner, developer, and organic photoconductors 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.
øWARNING
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
øWARNING
WARNING: Turn off the main switch before attempting any of the
procedures in the Laser Unit section. Laser beams can seriously damage
your eyes.
CAUTION MARKING:

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.

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TABLE OF CONTENTS
1. OVERALL MACHINE INFORMATION........................................1-1
1.1 SPECIFICATIONS.................................................................................... 1-1
1.1.1 GENERAL SPECIFICATIONS......................................................... 1-1
1.1.2 SUPPORTED PAPER SIZES.......................................................... 1-3
1.2 SOFTWARE ACCESSORIES................................................................... 1-4
1.2.1 PRINTER DRIVERS........................................................................ 1-4
1.2.2 UTILITY SOFTWARE...................................................................... 1-4
1.2.3 SERVICE TOOLS............................................................................ 1-4
1.3 MACHINE CONFIGURATION.................................................................. 1-5
1.3.1 SYSTEM COMPONENTS ............................................................... 1-5
1.4 PAPER PATH........................................................................................... 1-7
1.5 MECHANICAL COMPONENT LAYOUT................................................... 1-8
1.6 ELECTRICAL COMPONENT DESCRIPTIONS........................................ 1-9
1.7 PRINTING PROCESS............................................................................ 1-11
1.8 BOARD STRUCTURE............................................................................ 1-13
1.8.1 OVERVIEW ................................................................................... 1-13
1.8.2 DESCRIPTIONS............................................................................ 1-14
2. DETAILED SECTION DESCRIPTIONS.......................................2-1
2.1 LASER EXPOSURE................................................................................. 2-1
2.1.1 OVERVIEW ..................................................................................... 2-1
2.1.2 AUTO POWER CONTROL (APC)................................................... 2-2
2.1.3 LD SAFETY SWITCH...................................................................... 2-3
2.2 PHOTOCONDUCTOR UNIT (PCU).......................................................... 2-4
2.2.1 OVERVIEW ..................................................................................... 2-4
2.2.2 DRIVE MECHANISM....................................................................... 2-5
2.2.3 NEW PCU DETECTION MECHANINSM......................................... 2-6
2.3 DRUM CHARGE....................................................................................... 2-7
2.3.1 OVERVIEW ..................................................................................... 2-7
2.3.2 CHARGE ROLLER VOLTAGE CORRECTION ............................... 2-8
2.3.3 ID SENSOR PATTERN PRODUCTION TIMING............................. 2-9
2.3.4 DRUM CHARGE ROLLER CLEANING......................................... 2-10
2.4 DEVELOPMENT..................................................................................... 2-11
2.4.1 OVERVIEW ................................................................................... 2-11
2.4.2 DRIVE MECHANISM..................................................................... 2-12
2.4.3 DEVELOPER MIXING................................................................... 2-13
2.4.4 DEVELOPMENT BIAS................................................................... 2-14
2.4.5 TONER SUPPLY........................................................................... 2-15
2.4.6 TONER DENSITY CONTROL ....................................................... 2-17
2.4.7 TONER NEAR END/END DETECTION AND RECOVERY........... 2-21
2.5 DRUM CLEANING AND TONER RECYCLING...................................... 2-22
2.5.1 DRUM CLEANING......................................................................... 2-22
2.5.2 TONER RECYCLING .................................................................... 2-23

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2.6 PAPER FEED......................................................................................... 2-24
2.6.1 OVERVIEW ................................................................................... 2-24
2.6.2 PAPER FEED DRIVE MECHANISM ............................................. 2-25
2.6.3 PAPER FEED AND SEPARATION MECHANISM......................... 2-26
2.6.4 PAPER LIFT MECHANISM............................................................ 2-27
2.6.5 PAPER END DETECTION............................................................. 2-28
2.6.6 PAPER HEIGHT DETECTION....................................................... 2-29
2.6.7 PAPER SIZE DETECTION............................................................ 2-30
2.6.8 SPECIAL PAPER SETTING.......................................................... 2-31
2.6.9 SIDE AND END FENCES.............................................................. 2-32
2.6.10 PAPER REGISTRATION............................................................. 2-33
2.7 IMAGE TRANSFER AND PAPER SEPARATION.................................. 2-34
2.7.1 OVERVIEW ................................................................................... 2-34
2.7.2 IMAGE TRANSFER MECHANISM................................................ 2-35
2.7.3 TRANSFER ROLLER CLEANING................................................. 2-36
2.7.4 PAPER SEPARATION MECHANISM............................................ 2-36
2.8 IMAGE FUSING AND PAPER EXIT....................................................... 2-37
2.8.1 OVERVIEW ................................................................................... 2-37
2.8.2 FUSING DRIVE AND RELEASE MECHANISM............................. 2-38
2.8.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM...................... 2-39
2.8.4 PRESSURE ROLLER.................................................................... 2-40
2.8.5 CLEANING MECHANISM.............................................................. 2-40
2.8.6 NEW FUSING UNIT DETECTION................................................. 2-41
2.8.7 FUSING TEMPERATURE CONTROL........................................... 2-42
2.8.8 OVERHEAT PROTECTION........................................................... 2-44
2.8.9 PAPER EXIT.................................................................................. 2-44
2.9 ENERGY SAVER MODES ..................................................................... 2-45
2.10 CONTROLLER FUNCTIONS ............................................................... 2-46
2.10.1 PAPER SIZE/TYPE DETECTION AND SELECTION.................. 2-46
2.10.2 PAPER SOURCE SELECTION................................................... 2-46
2.10.3 OUTPUT TRAY SELECTION ...................................................... 2-48
2.10.4 COLLATION (SORT)................................................................... 2-49
2.10.5 DUPLEX PRINTING .................................................................... 2-50
2.10.6 STAPLING................................................................................... 2-50
2.10.7 PROOF PRINT ............................................................................ 2-51
2.10.8 RESET OPERATIONS ................................................................ 2-52
2.10.9 HDD (OPTIONAL)........................................................................ 2-52
3. INSTALLATION...........................................................................3-1
3.1 INSTALLING THE MACHINE................................................................... 3-1
3.2 INSTALLING OPTIONAL UNITS.............................................................. 3-2
3.2.1 BRIDGE UNIT.................................................................................. 3-2
3.2.2 1,000-SHEET FINISHER................................................................. 3-4
3.2.3 HARD DISK (HDD).......................................................................... 3-6

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4. SERVICE TABLES......................................................................4-1
4.1 GENERAL CAUTION................................................................................ 4-1
4.1.1 PCU................................................................................................. 4-1
4.1.2 TRANSFER ROLLER UNIT............................................................. 4-1
4.1.3 LASER UNIT.................................................................................... 4-1
4.1.4 FUSING UNIT.................................................................................. 4-2
4.1.5 PAPER FEED.................................................................................. 4-2
4.1.6 OTHERS.......................................................................................... 4-2
4.2 SERVICE PROGRAM MODE................................................................... 4-3
4.2.1 ENABLING AND DISABLING SERVICE PROGRAM MODE .......... 4-3
4.2.2 SERVICE PROGRAM MODE MENU TREE.................................... 4-4
4.3 PRINTER CONTROLLER SERVICE MODE............................................ 4-5
4.3.1 BIT SWITCH PROGRAMMING ....................................................... 4-5
4.3.2 NVRAM RESET............................................................................... 4-6
4.3.3 POWER-ON DIAGNOSTICS ERROR DISPLAY............................. 4-7
4.3.4 VENDER MAKER............................................................................ 4-7
4.3.5 SERVICE SUMMARY...................................................................... 4-7
4.4 PRINTER ENGINE SERVICE MODE....................................................... 4-9
4.4.1 SERVICE MODE MENU.................................................................. 4-9
4.4.2 SERVICE MODE TABLES............................................................. 4-10
4.4.3 INPUT CHECK TABLE.................................................................. 4-16
4.4.4 OUTPUT CHECK TABLE.............................................................. 4-20
4.4.5 ENGINE BOARD PROGRAM DOWNLOAD.................................. 4-22
4.5 SERVICE TOOLS................................................................................... 4-23
4.5.1 SERVICE TOOL MENU................................................................. 4-23
4.5.2 HDD TEST..................................................................................... 4-23
4.5.3 HDD FORMAT............................................................................... 4-24
4.5.4 NIB NVRAM BACKUP AND RESTORE ........................................ 4-24
4.6 CONTROLLER FIRMWARE UPDATE ................................................... 4-26
4.6.1 FIRMWARE DOWNLOAD ............................................................. 4-26
4.6.2 ERROR RECOVERY..................................................................... 4-27
4.7 POWER-ON SELF TEST........................................................................ 4-28
4.7.1 PARALLEL LOOP-BACK TEST..................................................... 4-28
4.7.2 OTHER TESTS.............................................................................. 4-28
5. PREVENTIVE MAINTENANCE...................................................5-1
5.1 USER MAINTENANCE............................................................................. 5-1
5.2 SERVICE MAINTENANCE....................................................................... 5-2
5.2.1 PM TABLE....................................................................................... 5-2
6. REPLACEMENT AND ADJUSTMENT........................................6-1
6.1 LASER UNIT............................................................................................. 6-1
6.1.1 CAUTION DECAL LOCATIONS...................................................... 6-1
6.1.2 LASER UNIT.................................................................................... 6-2
6.1.3 POLYGONAL MIRROR MOTOR..................................................... 6-4
6.1.4 LASER DIODE (LD) UNIT ............................................................... 6-4
6.1.5 LASER SYNCHRONIZATION DETECTOR..................................... 6-5

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6.2 PHOTOCONDUCTOR UNIT (PCU)..........................................................6-6
6.2.1 PCU.................................................................................................6-6
6.3 TRANSFER UNIT.....................................................................................6-7
6.3.1 TRANSFER ROLLER UNIT.............................................................6-7
6.4 ID SENSOR..............................................................................................6-8
6.5 PAPER EXIT........................................................................................6-9
6.5.1 PAPER EXIT AND OVERFLOWSENSORS...................................6-9
6.6 PAPER FEED AND REGISTRATION.....................................................6-10
6.6.1 PAPER LIFT MOTORS..................................................................6-10
6.6.2 REGISTRATION CLUTCH.............................................................6-11
6.6.3 PAPER FEED CLUTCHES............................................................6-11
6.6.4 UPPER PAPER TRANSPORT CLUTCH.......................................6-12
6.6.5 LOWER PAPER TRANSPORT CLUTCH......................................6-12
6.6.6 REGISTRATION SENSOR............................................................6-13
6.6.7 UPPER RELAY SENSOR..............................................................6-14
6.6.8 LOWER RELAY SENSOR.............................................................6-15
6.6.9 UPPER PAPER SIZE SENSOR....................................................6-16
6.6.10 LOWER PAPER SIZE SENSOR/SPECIAL PAPER SENSOR....6-17
6.6.11 FEED ROLLERS..........................................................................6-18
6.6.12 PAPER END SENSOR (1ST AND 2ND PAPER FEED TRAYS).6-19
6.7 FUSING..................................................................................................6-20
6.7.1 FUSING UNIT................................................................................6-20
6.7.2 THERMISTOR...............................................................................6-20
6.7.3 THERMOFUSE..............................................................................6-21
6.7.4 HOT ROLLER AND FUSING LAMP..............................................6-22
6.7.5 PRESSURE ROLLER/CLEANING ROLLER.................................6-23
6.8 PCBS AND MOTORS.............................................................................6-24
6.8.1 PSU...............................................................................................6-24
6.8.2 ENGINE BOARD...........................................................................6-25
6.8.3 PRINTER CONTROLLER / NIB.....................................................6-26
6.8.4 HIGH VOLTAGE SUPPLY BOARD...............................................6-27
6.8.5 MAIN MOTOR................................................................................6-27
6.8.6 TONER BOTTLE MOTOR.............................................................6-28
7. TROUBLESHOOTING.................................................................7-1
7.1 SERVICE CALL CONDITIONS.................................................................7-1
7.1.1 PRINTER ENGINE SC CODES SUMMARY....................................7-1
7.1.2 PRINTER ENGINE SC CODES.......................................................7-2
7.2 PRINTER CONTROLLER ERROR.........................................................7-11
7.2.1 ERROR CODES............................................................................7-11
7.3 CONTROLLER LED DISPLAY...............................................................7-12
7.3.1 LOCATION.....................................................................................7-12
7.3.2 FATAL ERROR..............................................................................7-12
7.4 ELECTRICAL COMPONENT DEFECTS................................................7-15
7.4.1 SENSORS.....................................................................................7-15
7.4.2 SWITCHES....................................................................................7-17
7.5 BLOWNFUSE CONDITIONS.................................................................7-18

v
OPTIONS
PAPER TRAY UNIT (A860)
1. OVERALL MACHINE INFORMATION..................................A860-1
1.1 SPECIFICATIONS..............................................................................A860-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A860-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A860-3
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A860-4
1.5 DRIVE LAYOUT.................................................................................A860-5
2. DETAILED DESCRIPTIONS.................................................A860-6
2.1 PAPER FEED AND SEPARATION MECHANISM..............................A860-6
2.2 PAPER LIFT MECHANISM................................................................A860-7
2.3 PAPER END DETECTION.................................................................A860-9
2.4 PAPER HEIGHT DETECTION.........................................................A860-10
2.5 PAPER SIZE DETECTION...............................................................A860-12
2.6 SIDE AND END FENCES.................................................................A860-13
Side Fences.................................................................................A860-13
End Fence....................................................................................A860-13
3. REPLACEMENT AND ADJUSTMENT................................A860-14
3.1 FEED ROLLER REPLACEMENT.....................................................A860-14
3.2 TRAY MAIN BOARD REPLACEMENT.............................................A860-15
3.3 TRAY MOTOR REPLACEMENT......................................................A860-15
3.4 RELAY CLUTCH REPLACEMENT...................................................A860-16
3.5 UPPER PAPER FEED CLUTCH REPLACEMENT..........................A860-17
3.6 LOWER PAPER FEED CLUTCH REPLACEMENT..........................A860-18
3.7 LIFT MOTOR REPLACEMENT........................................................A860-19
3.8 PAPER END SENSOR REPLACEMENT.........................................A860-20
3.9 VERTICAL TRANSPORT SENSOR REPLACEMENT.....................A860-20
3.10 PAPER SIZE SWITCH REPLACEMENT........................................A860-21
PAPER TRAY UNIT (A861)
1. OVERALL MACHINE INFORMATION...........................................1
1.1 SPECIFICATIONS........................................................................................1
1.2 MECHANICAL COMPONENT LAYOUT.......................................................2
1.3 ELECTRICAL COMPONENT LAYOUT........................................................3
1.4 ELECTRICAL COMPONENT DESCRIPTION..............................................4
1.5 DRIVE LAYOUT...........................................................................................5
2. DETAILED DESCRIPTIONS..........................................................6
2.1 PAPER FEED AND SEPARATION..............................................................6
2.2 PAPER LIFT MECHANISM..........................................................................7
2.3 PAPER END DETECTION...........................................................................9

vi
2.4 PAPER HEIGHT DETECTION ...................................................................10
2.5 PAPER SIZE DETECTION.........................................................................12
2.6 SIDE AND END FENCES...........................................................................13
3. REPLACEMENT AND ADJUSTMENT......................................... 14
3.1 FEED ROLLER REPLACEMENT...............................................................14
3.2 TRAY MAIN BOARD REPLACEMENT.......................................................15
3.3 TRAY MOTOR REPLACEMENT................................................................15
3.4 TRAY MOTOR REPLACEMENT................................................................16
3.5 LIFT MOTOR REPLACEMENT..................................................................17
3.6 PAPER END SENSOR REPLACEMENT...................................................18
3.7 PAPER SIZE SWITCH REPLACEMENT....................................................18
LCT (A862)
1. OVERALL MACHINE INFORMATION..................................A862-1
1.1 SPECIFICATIONS..............................................................................A862-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A862-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A862-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS..................................A862-4
2. DETAILED SECTION DESCRIPTIONS.................................A862-5
2.1 PAPER FEED.....................................................................................A862-5
2.2 REVERSE ROLLER AND PICK-UP ROLLER RELEASE...................A862-6
2.3 TRAY LIFT..........................................................................................A862-7
2.4 NEAR END/END DETECTION...........................................................A862-8
2.5 RIGHT TRAY SIDE FENCE................................................................A862-9
2.6 LEFT TRAY REAR FENCE ................................................................A862-9
2.7 RIGHT TRAY PAPER END DETECTION.........................................A862-10
3. REPLACEMENT AND ADJUSTMENT................................A862-11
3.1 DETACHING THE TRAY FROM THE MAINFRAME........................A862-11
3.2 REAR FENCE HP SENSOR.............................................................A862-11
3.3 CHANGING THE TRAY PAPER SIZE..............................................A862-12
3.4 LEFT TRAY PAPER END SENSOR.................................................A862-12
3.5 TRAY LIFT MOTOR..........................................................................A862-13
3.6 TRAY MOTOR..................................................................................A862-14
3.7 PAPER FEED CLUTCH AND RELAY CLUTCH...............................A862-15
3.8 PAPER FEED UNIT..........................................................................A862-16
3.9 UPPER LIMIT, RIGHT TRAY PAPER END, AND
RELAY SENSORS...........................................................................A862-17
3.10 REAR FENCE MOTOR ..................................................................A862-18
3.11 PICK-UP/PAPER FEED/REVERSE ROLLERS..............................A862-19

vii
BY-PASS UNIT (A899)
1 OVERALL MACHINE INFORMATION...................................A899-1
1.1 SPECIFICATIONS..............................................................................A899-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A899-1
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A899-2
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A899-2
2 DETAILED DESCRIPTIONS ..................................................A899-3
2.1 BASIC OPERATION...........................................................................A899-3
2.2 PAPER SIZE DETECTION.................................................................A899-4
3 REPLACEMENT AND ADJUSTMENT...................................A899-5
3.1 PAPER FEED ROLLER/FRICTION PAD/PAPER END SENSOR......A899-5
3.2 PAPER SIZE SENSOR BOARD.........................................................A899-6
3.3 PAPER FEED CLUTCH......................................................................A899-7
INTERCHANGE UNIT (G531)
1. OVERALL MACHINE INFORMATION................................. G531-1
1.1 SPECIFICATIONS..............................................................................G531-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................G531-2
1.3 DRIVE LAYOUT .................................................................................G531-3
2. DETAILED DESCRIPTION................................................... G531-4
2.1 JUNCTION GATE MECHANISM........................................................G531-4
To the Exit Tray or Bridge Unit (for the Upper Tray on top of
the Bridge Unit, or the Finisher) .....................................................G531-4
To the 1-bin Tray............................................................................G531-4
To the Duplex Unit .........................................................................G531-4
3. REPLACEMENT AND ADJUSTMENT................................. G531-5
3.1 EXIT SENSOR REPLACEMENT........................................................G531-5
DUPLEX (G529)
1. OVERALL MACHINE INFORMATION................................. G529-1
1.1 SPECIFICATIONS..............................................................................G529-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................G529-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................G529-3
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................G529-4
1.5 DRIVE LAYOUT .................................................................................G529-5

viii
2. DETAILED DESCRIPTIONS ................................................ G529-6
2.1 BASIC OPERATION...........................................................................G529-6
Larger than A4 lengthwise/LT Lengthwise.....................................G529-6
Up to A4 Lengthwise/LT lengthwise...............................................G529-7
2.2 FEED IN AND EXIT MECHANISM.....................................................G529-8
When Paper is Fed Into Duplex Unit:.............................................G529-8
Inversion and Exit:..........................................................................G529-8
3. REPLACEMENT AND ADJUSTMENT................................. G529-9
3.1 COVER REMOVAL ............................................................................G529-9
3.2 ENTRANCE SENSOR REPLACEMENT..........................................G529-10
3.3 EXIT SENSOR REPLACEMENT......................................................G529-11
BRIDGE UNIT (A897)
1. OVERALL MACHINE INFORMATION..................................A897-1
1.1 SPECIFICATIONS..............................................................................A897-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A897-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A897-3
1.4 ELECTRICAL COMPONENT DESCRIPTION....................................A897-4
1.5 DRIVE LAYOUT .................................................................................A897-5
2. DETAILED DESCRIPTION....................................................A897-6
2.1 JUNCTION GATE MECHANISM........................................................A897-6
3. REPLACEMENT AND ADJUSTMENT..................................A897-7
3.1 BRIDGE UNIT DRIVE MOTOR REPLACEMENT...............................A897-7
3.2 TRAY EXIT SENSOR REPLACEMENT .............................................A897-8
3.3 RELAY SENSOR REPLACEMENT....................................................A897-8
FINISHER (A681)
1. OVERALL MACHINE INFORMATION..................................A681-1
1.1 SPECIFICATIONS..............................................................................A681-1
1.2 MECHANICAL COMPONENT LAYOUT.............................................A681-2
1.3 ELECTRICAL COMPONENT LAYOUT..............................................A681-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS..................................A681-4
1.5 DRIVE LAYOUT .................................................................................A681-6

ix
2. DETAILED DESCRIPTIONS .................................................A681-7
2.1 JUNCTION GATE MECHANISM........................................................A681-7
Staple Mode...................................................................................A681-7
No staple Mode..............................................................................A681-7
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM.......................A681-8
2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM............................A681-9
2.4 STAPLER .........................................................................................A681-10
2.5 FEED OUT MECHANISM.................................................................A681-11
2.6 SHIFT TRAY UP/DOWN MECHANISM............................................A681-12
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM.....................................A681-13
2.8 JAM CONDITIONS...........................................................................A681-14
2.9 TIMING CHARTS .............................................................................A681-15
2.9.1 NO STAPLE MODE (A4 SIDEWAYS, 3 SHEETS/2SETS)......A681-15
2.9.2 STAPLE MODE (A4 SIDEWAYS, 2 SHEETS/2 SETS)...........A681-16
3. SERVICE TABLE ................................................................A681-17
3.1 DIP SWITCH TABLE ........................................................................A681-17
3.2 TEST POINTS..................................................................................A681-17
3.3 FUSES..............................................................................................A681-17
4. REPLACEMENT AND ADJUSTMENT................................A681-18
4.1 COVER REMOVAL ..........................................................................A681-18
Front Door....................................................................................A681-18
Front Cover..................................................................................A681-18
Rear Cover...................................................................................A681-18
Upper Cover.................................................................................A681-18
Lower Left Cover..........................................................................A681-19
Front Shift Tray Cover..................................................................A681-19
Rear Shift Tray Cover ..................................................................A681-19
Shift Tray......................................................................................A681-19
4.2 ENTRANCE SENSOR REPLACEMENT..........................................A681-20
4.3 EXIT SENSOR REPLACEMENT......................................................A681-21
4.4 STACK HEIGHT SENSOR REPLACEMENT ...................................A681-22
4.5 POSITIONING ROLLER REPLACEMENT.......................................A681-23
4.6 STAPLER REPLACEMENT..............................................................A681-24

x
MAILBOX (G518)
1. OVERALL MACHINE INFORMATION................................. G518-1
1.1 SPECIFICATIONS..............................................................................G518-1
1.2 COMPONENT LAYOUT.....................................................................G518-2
1.2.1 MECHANICAL COMPONENT LAYOUT....................................G518-2
1.2.2 DRIVE LAYOUT.........................................................................G518-2
1.3 ELECTRICAL COMPONENT DESCRIPTIONS..................................G518-3
2. DETAILED DESCRIPTIONS ................................................ G518-5
2.1 BASIC OPERATION...........................................................................G518-5
2.2 PAPER OVERFLOW DETECTION ....................................................G518-6
2.2.1 OVERVIEW ...............................................................................G518-6
2.2.2 DETECTION TIMING.................................................................G518-6
2.3 PAPER MISFEED DETECTION TIMING............................................G518-7
3. REPLACEMENT AND ADJUSTMENT................................. G518-9
3.1 EXTERIOR COVER REMOVAL.........................................................G518-9
3.2 TRAY OVERFLOW AND VERTICAL TRANSPORT SENSOR
REPLACEMENT...............................................................................G518-10
3.3 MAIN MOTOR REPLACEMENT.......................................................G518-11

1 October, 1999 SPECIFICATIONS
1-1
Overall
Information
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
1.1.1 GENERAL SPECIFICATIONS
Printing Speed: Maximum 27 pages per minute (A4/LT LEF)
(22 pages: duplex printing)
Printer Language: PCL6/PCL5e
PostScript Level 3
TIFF (rev 6.0 compatible)
Resolution: 600 dpi (PCL 6/PCL5e/PS3)
300 dpi (PCL 5e/PS3)
Resident Fonts: PCL:
35 Intellifonts
10 True Type fonts
1 Bitmap font
PS3:
136 fonts (24 Type 2 fonts, 112 Type 14 fonts)
Host Interface: Bi-directional IEEE1284 parallel x 1 (Standard)
Ethernet (100 Base-TX/10 Base-T for TCP/IP, IPX/SPX,
NetBEUI, Apple Talk)
Printing Paper Size: Maximum: A3/11" x 17"
Minimum:
1st paper Tray: A5 SEF
2nd paper Tray: A6 SEF
By-pass: A6/ 90 x 148 mm SEF
(Refer to section 1.1.2, "Supported Paper Size".)
Printing Paper
Weight: 1st paper tray: 60 to 105 g/m2 (16 to 28 lb.) 2nd paper tray: 60 to 157 g/m2 (16 to 42 lb.)
By-pass Tray: 60 to 200 g/m2 (16 to 110 Index)
Print Paper
Capacity: 1st and 2nd paper tray: 500 sheets x 2 Optional paper tray unit:
500 sheets x 1/2
Optional LCT
1000 sheets x 2
Optional by-pass tray:
100 sheets
Output Paper
Capacity: Standard output tray: 500 sheets Optional finisher: 1,000 sheets
Optional 4-bin mailbox: 500 sheets total
First Print Speed: 5 s or less (A4/LT LEF, 1st tray)
Warm-up Time Less than 45 seconds

SPECIFICATIONS 1 October, 1999
1-2
Memory: Standard 16 MB, up to 80 MB with optional DIMM.
Power Source: 120 V, 60 Hz: More than 10 A (for North America)
220 V - 240 V, 50/60 Hz: More than 6.0 A (for Europe)
Power Consumption: 120V 230V
Maximum 900W or less 900W or less
Printing 550W or less 550W or less
Energy Saver 25 W or less 25 W or less
Noise Emission: Mainframe Only Full System
Sound Power Level
Printing 51 dB or less 58 dB or less
Stand-by 23 dB or less 23 dB or less
NOTE: The above measurements were made in accordance with ISO 9296 at
the operator position.
Dimensions (W x D x H): 550 x 520 x 516 mm
Weight: Less than 46 kg

1 October, 1999 SPECIFICATIONS
1-3
Overall
Information
1.1.2 SUPPORTED PAPER SIZES
Trays LCT Duplex
Paper Size (W x L) 1st 2nd OP By-pass/
Tray 2
Ledger 11 x 17” Y Y Y NYY#
Legal 8.5 x 14“ Y Y Y NYY#
Letter SEF 8.5 x 11” Y Y Y NYY#
Letter LEF 11 x 8.5” Y Y Y Y Y Y#
Half Letter
SEF 5.5 x 8.5” Y#Y#Y#N N Y#
Half Letter LEF 8.5 x 5.5” N N N N N N
Executive SEF 7.25 x 10.5” Y#Y#Y#NYY#
Executive LEF 10.5 x 7.25” Y#Y#Y#N Y Y#
A3 297 x 420 mm YYY N Y Y#
B4 257 x 364 mm Y#Y#Y#N Y Y#
A4 SEF 210 x 297 mm Y Y Y NYY#
A4 LEF 297 x 210 mm Y Y Y Y Y Y#
B5 SEF 182 x 257 mm Y#Y#Y#NYY#
B5 LEF 257 x 182 mm Y#Y#Y#NYY#
A5 SEF 148 x 210 mm Y#Y#Y#NYY#
A5 LEF 210 x 148 mm N N N N N Y#
A6 SEF 105 x 148 mm N Y#N N N Y#
Folio 8.25 x 13” Y#Y#Y#NYY#
Foolscap 8.5 x 13” Y#Y#Y#N Y Y#
F8x13”Y#Y#Y#N Y Y#
Com10 Env. 4.125 x 9.5” N Y#N N N Y#
Monarch Env. 3.875 x 7.5” N Y#N N N Y#
C6 Env. 114 x 162 mm N Y#N N N Y#
C5 Env. 162 x 229 mm N Y#N N N Y#
DL Env. 110 x 220 mm N Y#N N N Y#
8K 267 x 390 mm Y#Y#Y#N N Y#
16K SEF 195 x 267 mm Y#Y#Y#N N Y#
16K LEF 267 x 195 mm Y#Y#Y#N N Y#
Custom [Minimum]
90 x 148 mm
[Maximum]
297 x 432 mm
N N N N N YC
Remarks:
Y Supported. The paper size sensor detects the paper size.
Y#Supported. The user has to select the correct paper size for the tray.
YCSupported. The user has to enter the width and length of the paper.
N Not supported.

SOFTWARE ACCESSORIES 1 October, 1999
1-4
1.2 SOFTWARE ACCESSORIES
The printer drivers and utility software are provided on one CD-ROM. An auto-run
installer allows you to select which components to install. The service tools are not
provided on the CD-ROM.
1.2.1 PRINTER DRIVERS
Printer Language Windows 3.1x Windows 95/98 Windows NT4.0 Macintosh
PCL 6 Yes Yes Yes No
PCL 5e Yes Yes Yes No
PS3 Yes Yes Yes Yes
NOTE: 1) The printer drivers for Windows NT 4.0 are only for the Intel x86
platform. There is no Windows NT 4.0 printer driver for PowerPC, Alpha,
or MIPS platforms.
2) The PS3 drivers are all genuine AdobePS drivers. A PPD file for each
operating system is provided with the driver.
3) The PS3 drivers for Macintosh support Mac OS 7.1 or later versions.
4) The PS3 drivers for Windows 3.1x and Windows NT4.0 do not support
the “Proof Print” function.
1.2.2 UTILITY SOFTWARE
Software Description
Agfa Font Manager
(Win3.1x, 95/98, NT4) A font management utility with screen fonts for the printer.
Aficio Manager for Admin
(Win 95/98, NT4) A printer management utility for network administrators. NIB
setup utilities are also available.
Aficio Manager for Client
(Win95/98, NT4) A printer management utility for client users.
Multi-Direct Print
(Win95/98, NT4) A utility for peer-to-peer printing over a NetBEUI or TCP/IP
network.
Port Navi
(Win95/98, NT4) A peer to peer print utility over a TCP/IP network. This
provides parallel printing and recovery printing function.
1.2.3 SERVICE TOOLS
Software Description
NBTFTP NIB firmware update utility for use on a NetBEUI network.
This utility is not on the Driver and Utilities CD-ROM; it is
issued separately as a service tool

1 October, 1999 MACHINE CONFIGURATION
1-5
Overall
Information
1.3 MACHINE CONFIGURATION
1.3.1 SYSTEM COMPONENTS
G038V502.WMF
[A]
[B]
[C]
[D]
[E]
[F]
[G]
[H]
[I] [J]

MACHINE CONFIGURATION 1 October, 1999
1-6
ItemMachine
Code No. Remarks
Main Unit G038 IUser installable
Option
Paper Tray Unit - 1 tray A861 GUsed in commonwith
Stinger-C (See note 1)
User installable
Paper Tray Unit - 2 trays A860
F
Used in commonwith
Stinger-C/Russian-C
(See note1)
User installable
LCT A862 EUsed in commonwith
Russian-C (See note1)
User installable
By-pass Tray A899 DUsed in commonwith
Russian-C
User installable
Interchange Unit G531 BUser installable
Duplex Unit G529 C(See note 2, 3)
User installable
4-bin MailboxG518 A(See note2)
User installable
Bridge Unit A897 IUsed in commonwith
Russian-C
(See note4)
Service installation
1000-sheet Finisher A681 HUsed in commonwith
Russian-C/NAD
(See note4)
Service installation
Internal Option
HDD G690 Used in commonwith
Stinger-C/Russian-C
Service installation
Memory 32or 64 MBG688 Used in commonwith
Stinger-C/Russian-C
User installable
Others
Maintenance Kit G719
NOTE:1) Onlyone of these options can be installed on the machine.
2) Requires the Interchange unit to be installed.
3) Requires the memoryoption to be installed.
4) The Bridge unit must be installed together with the 1000 sheet Finisher.
Either the LCT or Paper TrayUnit (2 trays) mustalso be installed.