Minolta CF2002 Service Manual

SERVICE • When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. � Depending on the model, some of the precautions given in the following do not apply. • Different markings are used to denote specific meanings as detailed below. Used to call the service technician attention to what is graphically represented inside the marking (including a warning). Used to prohibit the service technician from doing what is graphically represented inside the marking. Used to instruct the service technician to do what is graphically represented inside the marking. 1-1. Warning WARNING • Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. CAUTION • The following graphic symbols are used to give instructions that need to be observed. WARNING 1. Always observe precautions. • Parts requiring special attention in this product will include a label containing the mark shown on the left plus precautionary notes. Be sure to observe the precautions. • Be sure to observe the “Safety Information” given in the Operator’s Manual. 2. Before starting the procedures, be sure to unplug the power cord. • This product contains a high-voltage unit and a circuit with a large current capacity that may cause an electric shock or burn. • The product also contains parts that can jerk suddenly and cause injury. • If this product uses a laser, laser beam leakage may cause eye damage or blindness.

• Do not throw toner or the Toner Bottle (Imaging Cartridge, Toner Cartridge) into a fire. Toner expelled from the fire may cause burns. 4. Use the specified parts. • For replacement parts, always use the genuine parts specified in the manufac- turer’s parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possi- ble electric shock or fire. • Replace a blown electrical fuse or thermal fuse with its corresponding genuine part specified in the manufacturer’s parts manual. Installing a fuse of a different make or rating could lead to a possible fire. If a thermal fuse blows frequently, the temperature control system may have a problem and action must be taken to eliminate the cause of the problem. 5. Handle the power cord with care and never use a multiple outlet. • Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock. • Do not use a multiple outlet to which any other appliance or machine is con- nected. • Be sure the power outlet meets or exceeds the specified capacity. 6. Be careful with the high-voltage parts. • A part marked with the symbol shown on the left carries a high voltage. Touch- ing it could result in an electric shock or burn. Be sure to unplug the power cord before servicing this part or the parts near it. 7. Do not work with wet hands. • Do not unplug or plug in the power cord, or perform any kind of service or inspection with wet hands. Doing so could result in an electric shock. 8. Do not touch a high-temperature part. • A part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is ener- gized. Touching them may result in a burn. • Wait until these parts have cooled down before replacing them or any sur- rounding parts.

• Connect the power cord to an electrical outlet that is equipped with a ground- ing terminal. 10. Do not remodel the product. • Modifying this product in a manner not authorized by the manufacturer may result in a fire or electric shock. If this product uses a laser, laser beam leakage may cause eye damage or blindness. 11. Restore all parts and harnesses to their original positions. • To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed. • To promote safety, make sure that all tubing and other insulating materials are returned to their original positions. Make sure that floating components mounted on the circuit boards are at their correct distance and position off the boards. CAUTION 1. Precautions for Service Jobs. • A star washer and spring washer, if used originally, must be reinstalled. Omit- ting them may result in contact failure which could cause an electric shock or fire. • When reassembling parts, make sure that the correct screws (size, type) are used in the correct places. Using the wrong screw could lead to stripped threads, poorly secured parts, poor insulating or grounding, and result in a mal- function, electric shock or injury. • Take great care to avoid personal injury from possible burrs and sharp edges on the parts, frames and chassis of the product. • When moving the product or removing an option, use care not to injure your back or allow your hands to be caught in mechanisms.

• Wherever feasible, keep all parts and covers mounted when energizing the product. • If energizing the product with a cover removed is absolutely unavoidable, do not touch any exposed live parts and use care not to allow your clothing to be caught in the moving parts. Never leave a product in this condition unattended. • Never place disassembled parts or a container of liquid on the product. Parts falling into, or the liquid spilling inside, the mechanism could result in an electric shock or fire. • Never use a flammable spray near the product. This could result in a fire. • Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors. • Always use the interlock switch actuating jig to actuate an interlock switch when a cover is opened or removed. The use of folded paper or some other object may damage the interlock switch mechanism, possibly resulting in an electric shock, injury or blindness. 3. Precautions for the Working Environment. • The product must be placed on a flat, level surface that is stable and secure. • Never place this product or its parts on an unsteady or tilting workbench when servicing. • Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time. • Avoid dusty locations and places exposed to oil or steam. • Avoid working positions that may block the ventilation ports of the product. 4. Precautions for Handling Batteries. (Lithium, Nickel-Cadmium, etc.) • Replace a rundown battery with the same type as specified in the manufac- turer’s parts manual. • Before installing a new battery, make sure of the correct polarity of the installa- tion or the battery could burst. • Dispose of used batteries according to the local regulations. Never dispose of them at the user’s premises or attempt to try to discharge one. 5. Precautions for the Laser Beam. (Only for Products Employing a Laser) • Removing the cover marked with the caution label could lead to possible expo- sure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover. • If removing this cover while the power is ON is unavoidable, be sure to wear protective laser goggles that meet specifications. • Make sure that no one enters the room when the machine is in this condition. • When handling the laser unit, observe the “Precautions for Handling Laser Equipment.” 6. Precautions for storing the toner or imaging cartridge. • Be sure to keep the toner or imaging cartridge out of the reach of children. Licking the imaging cartridge or ingesting its contents is harmful to your health.

ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ. Entsorgung gebrauchter Batterien nach Angaben des Herstellers. France ATTENTION Il y a danger d’explosion s’il y a remplacement incorrect de la batterie. Remplacer uniquement avec une batterie du même type ou d’un type équivalent recom- mandé par le constructeur. Mettre au rebut les batteries usagées conformément aux instructions du fabricant. Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med batteri af samme fabrikat og type. Levér det brugte batteri tilbage til leverandøren. Finland, Sweden VAROlTUS Paristo voi räjähtää, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä käytetty paristo valmistajan ohjeiden mukaisesti. VARNING Explosionsfara vid felaktigt batteribyte. Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat- tillverkaren. Kassera använt batteri enligt fabrikantens instruktion. Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri. Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten. Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

• The PC Drum is a very delicate component. Observe the precautions given in “HAN- DLING OF THE PC DRUM” because mishandling may result in serious image problems. • Note that replacement of a circuit board may call for readjustments or resetting of partic- ular items, or software installation. 1-5. Precautions for Service • When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. � Depending on the model, some of the precautions given in the following do not apply. 1. Precautions Before Service • When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to over- loads. • Never disturb the LAN by breaking or making a network connection, altering termination, installing or removing networking hardware or software, or shutting down networked devices without the knowledge and express permission of the network administrator or the shop supervisor. 2. How to Use this Book DIS/REASSEMBLY, ADJUSTMENT • To reassemble the product, reverse the order of disassembly unless otherwise specified. TROUBLESHOOTING • If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give trou- bleshooting procedures applicable within the defective unit. • All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions. • The procedures preclude possible malfunctions due to noise and other external causes. 3. Precautions for Service • Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged. • After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions. • Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged motor or locking mechanism. • If the product is to be run with the front door open, make sure that the toner hopper is in the locked position. • Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sen- sors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit.

• Be sure to unplug the copier from the outlet before attempting to service the copier. • The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears. • Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet. • Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed. • While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses. • Never use flammable sprays near the copier. • A used battery should be disposed of according to the local regulations and never be dis- carded casually or left unattended at the user’s premises. • When reassembling parts, make sure that the correct screws (size, type) and toothed washer are used in the correct places. 5. Precautions for Circuit Inspection • Never create a closed circuit across connector pins except those specified in the text and on the printed circuit. • When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the GND wire. 6. Handling of PWBs During Transportation/Storage • During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem- perature. • When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static elec- tricity. • Do not touch the pins of the ICs with your bare hands. • Protect the PWBs from any external force so that they are not bent or damaged. During Inspection/Replacement • Avoid checking the IC directly with a multimeter; use connectors on the Board. • Never create a closed circuit across IC pins with a metal tool. • Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet. • When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board. • When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch a metal part to dis- charge static electricity before touching the PWB. • Note that replacement of a PWB may call for readjustments or resetting of particular items. 7. Handling of Other Parts • The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.

� Only for Products Not Employing an Imaging Cartridge. During Transportation/Storage • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. • In summer, avoid leaving the PC Drum in a car for a long time. Handling • Ensure that the correct PC Drum is used. • Whenever the PC Drum has been removed from the copier, store it in its carton or protect it with a Drum Cloth. • The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. • Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger- prints, and other foreign matter. • Do not scratch the surface of the PC Drum. • Do not apply chemicals to the surface of the PC Drum. • Do not attempt to wipe clean the surface of the PC Drum. If, however, the surface is contaminated with fingerprints, clean it using the following proce- dure. A. Place the PC Drum into one half of its carton. 1076D001 B. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. • Turn the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum. • Turn the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thor- oughly cleaned. � At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping. 1076D002

• Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. • If dirt remains after cleaning, repeat the entire procedure from the beginning one more time. 9. Handling of the Imaging Cartridge � Only for Products Employing an Imaging Cartridge. During Transportation/Storage • The storage temperature is in the range between –20 °C and +40 °C. • In summer, avoid leaving the Imaging Cartridge in a car for a long time. Handling • Store the Imaging Cartridge in a place that is not exposed to direct sunlight. Precautionary Information on the PC Drum Inside the Imaging Cartridge • Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger- prints, and other foreign matter. • Do not scratch the surface of the PC Drum. • Do not attempt to wipe clean the surface of the PC Drum. C. Soak a small amount of either ethyl alcohol or iso- propyl alcohol into a clean, unused Dust-Free Cot- ton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one con- tinuous movement from its rear edge to its front edge and off its surface one to two times. � Never move the Pad back and forth. 1076D003 D. Using the SAME face of the Pad, repeat the proce- dure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropri- ate for cleaning. 1076D004

TECH. REP. SETTINGS TROUBLESHOOTING

2-1. Installation Site ........................................................................................G-4 2-2. Power Source ..........................................................................................G-4 2-3. Grounding ................................................................................................G-4 3. PRECAUTIONS FOR USE ..............................................................................G-5 3-1. To ensure that the copier is used in an optimum condition .....................G-5 3-2. Operating Environment ............................................................................G-5 3-3. Power Requirements ...............................................................................G-5 3-4. Note .........................................................................................................G-5 4. HANDLING OF CONSUMABLES ....................................................................G-6 5. OTHER PRECAUTIONS .................................................................................G-7 6. LED RADIATION SAFETY ..............................................................................G-7 7. SYSTEM OPTIONS .........................................................................................G-8 MAINTENANCE 1. MAINTENANCE SCHEDULE ..........................................................................E-1 1-1. Guideline for Life Specifications Values by Unit ......................................E-3 2. DISASSEMBLY/REASSEMBLY AND CLEANING ..........................................E-5 (1) Cleaning of the Paper Take-Up Roller .............................................E-5 (2) Replacing of the Paper Take-Up Roller ...........................................E-5 (3) Cleaning of the Paper Separator Roller ...........................................E-5 (4) Replacing of the Separator Roll Assy ..............................................E-6 (5) Cleaning of the Synchronizing Rollers .............................................E-7 (6) Cleaning of the Paper Dust Remover ..............................................E-7 (7) Replacing of the Paper Dust Remover ............................................E-8 (8) Cleaning of the Transport Roller ......................................................E-8 (9) Cleaning of the 2nd Image Transfer Entrance Upper Guide ...........E-8 (10) Cleaning of the Scanner Rails .........................................................E-9 (11) Cleaning of the Mirrors (1st/2nd/3rd) ...............................................E-10 (12) Cleaning of the Lens ........................................................................E-11 (13) Cleaning of the Original Glass .........................................................E-11 (14) Cleaning of the CCD Sensor ...........................................................E-12 (15) Replacing the Waste Toner Bottle ...................................................E-13 (16) Cleaning of the Area around the Waste Toner Collecting Port ........E-14 (17) Replacing Ozone Filter ....................................................................E-15 (18) Cleaning of the Comb Electrode ......................................................E-15 (19) Cleaning LPH Assy ..........................................................................E-16 (20) Cleaning of the Fusing Entrance Guide Plate .................................E-17 (21) Replacement of the Deodorant Filter ...............................................E-17 3. Replacing the Units ..........................................................................................E-18 (1) Replacing the Image Transfer Roller Unit .......................................E-18 (2) Replacing the Image Transfer Belt Unit ...........................................E-19 (3) Replacing the Imaging Unit (C, M, Y, Bk) ........................................E-22

DIS/REASSEMBLY, ADJUSTMENT 1. SERVICE INSTRUCTIONS .............................................................................D-1 1-1. IDENTIFICATION OF FUSES .................................................................D-1 1-2. PARTS WHICH MUST NOT BE TOUCHED ...........................................D-2 (1) Red painted Screws ........................................................................D-2 (2) Variable Resistors on Board ............................................................D-2 2. DISASSEMBLY/REASSEMBLY ......................................................................D-3 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES ...............................D-3 2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS .......................................................................................D-5 (1) Removal of the CCD Unit ................................................................D-8 (2) Removal of the Image Processing Board and Image Processing Interface Board ................................................................................D-10 (3) Removal of the Image Control Board ..............................................D-12 (4) Removal of the High Voltage Unit (PC Drum CH.), High Voltage Unit (Image Transfer, Neutralizing), High Voltage Unit (Developing Bias), and Paper Size Detecting Board .....................................................D-13 (5) Removal of DC Power Supply 1 ......................................................D-15 2-3. Removal of Units .....................................................................................D-16 (1) Removal of the Toner Hopper Unit ..................................................D-16 (2) Removal of the LPH Unit .................................................................D-17 2-4. Disassembly of the IR Unit ......................................................................D-19 (1) Removal of the Scanner Motor ........................................................D-19 (2) Remove of the Scanner Assy ..........................................................D-20 (3) Removal of the Scanner Drive Cables ............................................D-21 (4) Winding of the Scanner Drive Cables ..............................................D-23 2-5. CLEANING AND DISASSEMBLY OF THE ENGINE PARTS .................D-28 (1) Cleaning of the Transfer Belt Unit ...................................................D-28 (2) Removal of the Imaging Unit Motor C/M/Y/Bk .................................D-29 (3) Removal of the Main Motor .............................................................D-30 (4) Removal of the Fusing Drive Motor .................................................D-31 (5) Removal of the Fusing Pressure/Retraction Motor ..........................D-31 (6) Removal of the 1st Image Transfer Pressure/Retraction Motor ......D-33 (7) Removal of Toner Replenishing Motor C/Bk ...................................D-33 (8) Removal of Toner Replenishing Motor Y/M .....................................D-34 (9) Removal of the 2nd Image Transfer Pressure/Retraction Motor .....D-34 (10) Removal of the Transport Roller Motor ...........................................D-35 (11) Removal of AIDC/Registration Sensor 1/2 ......................................D-37 (12) Removal of the LPH Assy ................................................................D-38 (13) Removal of ATDC Sensor Y/M/C ....................................................D-40 (14) Removal of the LED Drive Board ....................................................D-41 3. ADJUSTMENTS ..............................................................................................D-42 3-1. ADJUSTMENT JIGS AND TOOLS USED ...............................................D-42

(1) Adjustment of the Scanner Motor Timing Belt .................................D-43 (2) Focus Positioning of the Scanner and 2nd/3rd Mirrors Carriage .....D-44 (3) Scanner Position Adjustment ..........................................................D-44 3-3. ELECTRICAL/IMAGE ADJUSTMENT .....................................................D-45 (1) Accessing the Tech. Rep. Mode ......................................................D-45 (2) Producing a Test Print .....................................................................D-45 (3) Top Margin ......................................................................................D-46 (4) Left Margin .......................................................................................D-48 (5) Dup. Left Margin ..............................................................................D-49 (6) Zoom for FD ....................................................................................D-50 (7) Color Shift Correction ......................................................................D-51 (8) Leading Edge Skew Adjustment ......................................................D-53 (9) LPH Chip Adjust ..............................................................................D-54 (10) Gradation Adjust ..............................................................................D-55 (11) PRT Max Density .............................................................................D-56 (12) PRT Highlight ..................................................................................D-57 (13) Background Voltage Margin ............................................................D-58 (14) ATDC Level Setting .........................................................................D-59 (15) AE Adjust .........................................................................................D-60 (16) 2nd Transfer Adjust .........................................................................D-61 (17) Fuser Temp. ....................................................................................D-62 (18) Fuser Speed ....................................................................................D-63 (19) Touch Panel Adj. .............................................................................D-64 (20) Left Image ........................................................................................D-65 (21) Top Image .......................................................................................D-66 (22) CD-Mag. ..........................................................................................D-67 (23) FD-Mag. ...........................................................................................D-68 (24) Org. Detect Sensor ..........................................................................D-69 4. OTHER ADJUSTMENTS .................................................................................D-70 4-1. INSTALLATION OF THE MECHANICAL COUNTER (OPTION) ............D-70 4-2. MOUNT THE OPTIONAL ORIGINAL SIZE DETECTING SENSORS .....D-71 4-3. FLASH MEMORY ....................................................................................D-72 4-4. REMOUNTING RAM IC (IC202) ..............................................................D-74 SWITCHES ON PWBs, TECH. REP. SETTINGS 1. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs ........................S-1 1-1. PWB Location ..........................................................................................S-1 1-2. PWB-S1 (Tech. Rep. Setting Switches Board) ........................................S-1 (1) Initialize Procedure ..........................................................................S-2 (2) Memory Clear Procedure ................................................................S-2 (3) Data/Conditions Cleared by Reset Switches/Pins ...........................S-3 2. UTILITY MODE ................................................................................................S-4 2-1. Utility Mode Function Setting Procedure .................................................S-4 2-2. Utility Mode Function Tree .......................................................................S-5 (1) Administrator Mode Function Tree ..................................................S-6 2-3. Setting in the Utility Mode ........................................................................S-7

3-1. Tech. Rep. Mode Function Setting Procedure .........................................S-16 3-2. Tech. Rep. Mode Function Tree ..............................................................S-17 3-3. Setting in the Tech. Rep. Mode ...............................................................S-20 4. SECURITY MODE ...........................................................................................S-42 4-1. Security Mode Function Setting Procedure .............................................S-42 4-2. Security Mode Function Tree ...................................................................S-42 4-3. Settings in the Security Mode ..................................................................S-43 TROUBLESHOOTING 1. INTRODUCTION .............................................................................................T-1 1-1. Checking the electrical components ........................................................T-1 (1) Sensor .............................................................................................T-1 (2) Switch .............................................................................................T-1 (3) Solenoid ...........................................................................................T-2 (4) Clutch .............................................................................................T-2 (5) Motor .............................................................................................T-3 1-2. I/O CHECK ..............................................................................................T-4 (1) Check Procedure .............................................................................T-4 (2) I/O Check List ..................................................................................T-5 1-3. System Control Block Diagram ................................................................T-11 2. PAPER MISFEED ............................................................................................T-12 2-1. Initial Check Items ...................................................................................T-12 2-2. Misfeed Display .......................................................................................T-13 2-3. Misfeed Detecting Sensor Layout ............................................................T-14 2-4. Misfeed Detection Timing/Troubleshooting Procedures ..........................T-16 (1) 1st Drawer Paper Take-Up Misfeed ................................................T-16 (2) 2nd Drawer Paper Take-Up Misfeed ...............................................T-17 (3) 3rd Drawer Paper Take-Up Misfeed (PF-118) .................................T-18 (4) LCC Paper Take-Up Misfeed (PF-121) ...........................................T-19 (5) 4th Drawer Paper Take-Up Misfeed (PF-118) .................................T-20 (6) LCC Lift 2 to 1 paper transport Misfeed (PF121) .............................T-21 (7) Manual Bypass Take-Up Misfeed ....................................................T-22 (8) Vertical Transport Misfeed ...............................................................T-23 (9) Duplex Paper Take-Up Misfeed (AD-14) .........................................T-26 (10) Duplex Paper Transport Misfeed (AD-14) .......................................T-27 (11) 2nd Image Transfer Misfeed ............................................................T-28 (12) Fusing/Exit Misfeed .........................................................................T-29 3. MALFUNCTIONS ............................................................................................T-30 3-1. Warning Detection Timing and Troubleshooting Procedure ....................T-31 (1) P-5: AIDC Sensor (Front) failure .....................................................T-31 (2) P-28 AIDC Sensor (Back) failure .....................................................T-31 (3) P-6: Cyan IU failure .........................................................................T-32 (4) P-7: Magenta IU failure ....................................................................T-32 (5) P-8: Yellow IU failure .......................................................................T-32 (6) P-9: Black IU failure .........................................................................T-32 (7) P-21: Color Shift Test Pattern failure ...............................................T-33

(9) P-23: ATVC(C) failure ......................................................................T-34 (10) P-24: ATVC(M) failure .....................................................................T-34 (11) P-25: ATVC(Y) failure ......................................................................T-34 (12) P-26: ATVC(Bk) failure ....................................................................T-34 (13) P-27: ATVC(2nd) failure ..................................................................T-34 3-2. Malfunction Detection Timing and Troubleshooting Procedure ...............T-35 (1) C0000: Main Motor’s failure to turn .................................................T-35 (2) C0001: Main Motor Turning at abnormal timing ..............................T-35 (3) C0010: Imaging Unit Motor C’s failure to turn .................................T-36 (4) C0011: Imaging Unit C turning at abnormal timing ..........................T-36 (5) C0012: Imaging Unit Motor M’s failure to turn .................................T-36 (6) C0013: Imaging Unit M turning at abnormal timing .........................T-36 (7) C0014: Imaging Unit Motor Y’s failure to turn ..................................T-36 (8) C0015: Imaging Unit Y turning at abnormal timing ..........................T-36 (9) C0016: Imaging Unit Motor Bk’s failure to turn ................................T-36 (10) C0017: Imaging Unit Bk turning at abnormal timing ........................T-36 (11) C0040: Suction Fan Motor’s failure to turn ......................................T-38 (12) C0043: Cooling Fan Motor 1’s failure to turn ...................................T-38 (13) C0044: Cooling Fan Motor 3’s failure to turn ...................................T-38 (14) C0045: Cooling Fan Motor 4/5’s failure to turn ................................T-38 (15) C0046: Fusing Cooling Fan Motor’s failure to turn ..........................T-38 (16) C004C: Ozone Ventilation Fan Motor’s failure to turn .....................T-38 (17) C004E: Power Supply Cooling Fan Motor’s failure to turn ..............T-38 (18) C004F: Cooling Fan Motor 2’s failure to turn ...................................T-38 (19) C0060: Fusing Drive Motor’s failure to turn .....................................T-42 (20) C0061: Fusing Drive Motor turning at abnormal timing ...................T-42 (21) C0094: 2nd Image Transfer Roller pressure/retraction failure ........T-43 (22) C0096: Image Transfer Belt pressure/retraction failure ...................T-44 (23) C0098: Fusing Pressure Roller pressure/retraction failure ..............T-45 (24) C0200: Cyan PC Drum Charge Corona malfunction .......................T-46 (25) C0202: Magenta PC Drum Charge Corona malfunction .................T-46 (26) C0204: Yellow PC Drum Charge Corona malfunction .....................T-46 (27) C0206: Black PC Drum Charge Corona malfunction ......................T-46 (28) C0208: PC Drum Charge Corona malfunction ................................T-46 (29) C0400: Exposure Lamp’s failure to turn ON ....................................T-47 (30) C0410: Exposure Lamp turning ON at abnormal timing ..................T-47 (31) C0500: Heating Roller warm-up failure ...........................................T-48 (32) C0501: Fusing Pressure Roller warm-up failure ..............................T-48 (33) C0510: Heating Roller abnormally low temperature ........................T-48 (34) C0511: Fusing Pressure Roller abnormally low temperature ..........T-48 (35) C0520: Heating Roller abnormally high temperature ......................T-48 (36) C0521: Fusing Pressure Roller abnormally high temperature .........T-48 (37) C0650: Scanner Home Sensor malfunction ....................................T-50 (38) C0660: Scanner overrun failure .......................................................T-50 (39) C0F30: Abnormally low toner density detected Cyan ATDC Sensor ..................................................................................T-51

ATDC Sensor ..................................................................................T-51 (41) C0F32: Abnormally low toner density detected Magenta ATDC Sensor ..................................................................................T-51 (42) C0F33: Abnormally high toner density detected Magenta ATDC Sensor ..................................................................................T-51 (43) C0F34: Abnormally low toner density detected Yellow ATDC Sensor ..................................................................................T-51 (44) C0F35: Abnormally high toner density detected Yellow ATDC Sensor ..................................................................................T-51 (45) C0F36: Abnormally low toner density detected Cyan ATDC Sensor ..................................................................................T-53 (46) C0F37: Abnormally high toner density detected Cyan ATDC Sensor ..................................................................................T-53 (47) C0F3A: Cyan ATDC Sensor adjustment failure ..............................T-54 (48) C0F3B: Magenta ATDC Sensor adjustment failure .........................T-54 (49) C0F3C: Yellow ATDC Sensor adjustment failure ............................T-54 (50) C0F3D: Black ATDC Sensor adjustment failure ..............................T-54 (51) C1200: Memory mounting failure ....................................................T-56 (52) C1203: Memory mounting failure ....................................................T-57 (53) C1204: Memory mounting failure ....................................................T-57 (54) C1220: Image Input Time Out .........................................................T-58 (55) C1229: Image Output Time Out ......................................................T-59 (56) C1240: JBIG Error ...........................................................................T-60 (57) C1241: JBIG Error ...........................................................................T-60 (58) C1242: JBIG Error ...........................................................................T-60 (59) C1243: JBIG Error ...........................................................................T-60 (60) C1261: Memory Board Time Out .....................................................T-61 (61) C1265: Memory Board Time Out .....................................................T-61 (62) C1279: Memory Board Time Out .....................................................T-61 (63) C1290: Compress/Expand Time Out ...............................................T-61 (64) C12C0: Hard Disk Error ...................................................................T-62 (65) C12CB: Hard Disk Error ..................................................................T-62 (66) C12CC: Hard Disk Error ..................................................................T-62 (67) C12C1: Hard Disk Error ...................................................................T-63 (68) C12C2: Hard Disk Error ...................................................................T-63 (69) C12C3: Hard Disk Error ...................................................................T-63 (70) C12C4: Hard Disk Error ...................................................................T-63 (71) C12C5: Hard Disk Error ...................................................................T-63 (72) C12C6: Hard Disk Error ...................................................................T-63 (73) C12C7: Hard Disk Error ...................................................................T-63 (74) C12C8: Hard Disk Error ...................................................................T-63 (75) C12C9: Hard Disk Error ...................................................................T-63 (76) C12CA: Hard Disk Error ..................................................................T-63 (77) C12CF: Hard Disk Error ..................................................................T-63 (78) C13C8: New Transfer Cleaner Unit resetting failure .......................T-64 (79) C13CA: New Fusing Unit resetting failure .......................................T-64

(81) C13D2: Magenta IU EEPROM access error ...................................T-65 (82) C13D3: Yellow IU EEPROM access error .......................................T-65 (83) C13D4: Black IU EEPROM access error .........................................T-65 (84) C13D5: Cyan LPH correction data download failure .......................T-66 (85) C13D6: Magenta LPH correction data download failure .................T-66 (86) C13D7: Yellow LPH correction data download failure .....................T-66 (87) C13D8: Black LPH correction data download failure .......................T-66 (88) C3310: CCD clamp/gain adjustment failure ....................................T-67 (89) C3700: IR Power Supply Cooling Fan Motor turning at abnormal timing ...............................................................................T-68 (90) C3710: IR Drive Board Cooling Fan Motor turning at abnormal timing ...............................................................................T-68 (91) C3FFF: ROM contents fault detected upon start .............................T-68 3-3. Power Supply-Related Malfunctions ........................................................T-69 (1) Copier is not energized at all. ..........................................................T-69 (2) Only the Power Supply Cooling Fan rotates. ...................................T-70 (3) Control panel indicators do not light. ...............................................T-70 4. IMAGE QUALITY PROBLEMS ........................................................................T-71 4-1. Descriptions of the “State Confirm” Function of Tech. Rep. Mode Concerning Image Quality Problems ..........................T-71 (1) Table # .............................................................................................T-71 (2) Level History 1 .................................................................................T-72 (3) Level History 2 .................................................................................T-72 4-2. Troubleshooting Image Quality Problems ................................................T-73 4-3. Initial Check Items ...................................................................................T-73 4-4. Troubleshooting Procedure by a Particular Image Quality Problem ........T-75 (1) IR System: white lines in FD, white bands in FD, colored lines in FD, and colored bands in FD .......................................................T-75 (2) IR System: white lines in CD, white bands in CD, colored lines in CD, and colored bands in CD ......................................................T-76 (3) IR System: color spots .....................................................................T-77 (4) IR System: fog .................................................................................T-78 (5) IR System: blurred image, blotchy image ........................................T-79 (6) IR System: incorrect color image registration, sync shift (lines in CD) .....................................................................................T-80 (7) IR System: moire .............................................................................T-81 (8) IR System: skewed image ...............................................................T-82 (9) IR System: distorted image .............................................................T-83 (10) IR System: low image density, rough image ...................................T-84 (11) IR System: defective ACS ...............................................................T-85 (12) IR System: blank copy, black copy ..................................................T-86 (13) IR System: abnormal image ............................................................T-87 (14) Printer Monocolor: white lines in FD, white bands in FD, colored lines in FD, colored bands in FD, white lines in CD, white bands in CD, colored lines in CD, colored bands in CD .........T-88 (15) Printer Monocolor: uneven density in FD ........................................T-89

(17) Printer Monocolor: low image density ..............................................T-91 (18) Printer Monocolor: gradation reproduction failure ...........................T-93 (19) Printer Monocolor: foggy background ..............................................T-95 (20) Printer Monocolor: void areas, white spots ......................................T-97 (21) Printer Monocolor: colored spots .....................................................T-98 (22) Printer Monocolor: blurred image ....................................................T-99 (23) Printer Monocolor: blank copy, black copy ......................................T-100 (24) Printer Monocolor: 0.5-mm-pitch uneven image ..............................T-101 (25) Printer Monocolor: 2-mm-pitch uneven image .................................T-102 (26) Printer Monocolor: 94-mm-pitch uneven image ...............................T-103 (27) Printer 4-Color: white lines in FD, white bands in FD, colored lines in FD, and colored bands in FD ..................................T-104 (28) Printer 4-Color: white lines in CD, white bands in CD, colored lines in CD, and colored bands in CD .................................T-105 (29) Printer 4-Color: uneven density in FD .............................................T-106 (30) Printer 4-Color: uneven density in CD .............................................T-107 (31) Printer 4-Color: low image density ...................................................T-108 (32) Printer 4-Color: poor color reproduction ..........................................T-110 (33) Printer 4-Color: incorrect color image registration ...........................T-112 (34) Printer 4-Color: void areas, white spots ...........................................T-114 (35) Printer 4-Color: colored spots ..........................................................T-115 (36) Printer 4-Color: poor fusing performance, offset .............................T-116 (37) Printer 4-Color: brush effect, blurred image ....................................T-117 (38) Printer 4-Color: back marking ..........................................................T-118 (39) Printer 4-Color: 204-mm-pitch uneven image ..................................T-119 (40) Printer 4-Color: 94-mm-pitch uneven image ....................................T-120

� : Reliably fed –: Feeding prohibited Type Original Scanning PC Drum Type Copying System Scanning Density Print Density Paper Feeding System (Standard) Printing Process Exposure System Developing System Charging System Ozone Removal System Image Transfer System Paper Separating System Transfer Belt Cleaning System Fusing System Paper Charge Neutralizing Max. Original Size : : : : : : : : : : : : : : : : : : Freestanding scanner and printer separated from each other Scanning in main scanning direction with a reduc- tion-type color CCD (One Scan Reading System) OPC (organic photoconductor) Electrostatic dry-powdered image transfer to plain paper Equivalent to 600 dpi Equivalent to 600 dpi in main scanning direction x 1800 dpi in sub-scanning direction Three-Way system Manual Bypass Table...Single 1st Drawer....................250 sheets 2nd Drawer...................500 sheets Tandem-type indirect electrostatic recording sysytem LED Unit exposure for each of Y, M, C, and Bk MTHG System DC comb electrobe Scorotron System Ozone Filter Intermediate Transfer Belt System Selecting either nonwoven fabric bias or ground + Separation Finger Blade Cleaning + Brush + Toner Patch Belt Fusing Charge Neutralizing Brush A3 or 11×17 Paper Source 1st Drawer 2nd Drawer Manual Bypass Table Copy paper type Plain paper (64 to 90 g/m²) � � � Translucent paper – – – OHP transparencies (dedicated) � – � Thick paper (91 to 150 g/m²) � 20 sheets or less – � Thick paper (151 to 209 g/m²) – � Thick paper (210 to 256 g/m²) – � Postcards – � Envelope – � Label Sheet – � Copy paper dimen- sions Max. (width × length) 311 × 457 mm 12-1/4 × 18 297 × 432 mm 11-3/4 × 17 311 × 457 mm 12-1/4 × 18 Min. (width × length) 86 × 140 mm 3-1/2 × 5-1/2 182 × 182 mm 7-1/4 × 7-1/4 86 × 140 mm 3-1/2 × 5-1/2

(1st Drawer, full size, A4C, Manual Exposure) Copying Speed for Multi-Copy Cycle (copies/min.) (Full Color / Mono Color fed from 2nd Drawer) Zoom Ratio Environmental Conditions Multiple Copies Warming-up Time : : 1 to 999 copies 5 min. or less (at ambient temperature of 20 °C, 68 ° F and rated source voltage) 31-cpm Copier 20-cpm copier Full Color 9.9 sec. 14.1 sec. Mono Color 7.9 sec. 7.9 sec. Size 31-cpm Copier 20-cpm copier Size 31-cpm Copier 20-cpm copier A3, 11 × 17 A4L, 8-1/2 × 11L A4C, 8-1/2 × 11C 15/15 21/21 31/31 10/15 14/21 20/31 B4L B5L B5C 18/18 21/21 31/31 12/18 14/21 20/31 Fixed Metric Area Inch Area Full size × 1.000 × 1.000 Reduction × 0.816 × 0.707 × 0.500 × 0.785 × 0.733 × 0.647 × 0.500 Enlargement × 1.154 × 1.414 × 2.000 × 1.214 × 1.294 × 1.545 × 2.000 Variable (in 0.001 increments) × 0.250 to × 4.000 Lens Light Source : : Through Lens White Fluorescent Lamp Max. Power Consumption (copier only) Power Requirements : : 1.5 kw 110 v, 120 v, 127 v, 220 to 240 v ; 50/60 Hz Temperature 10 to 30 °C, 50 to 86 ° F (with a fluctuation of 10 °C, 50 ° F or less per hour) Humidity 25 to 85 % (with a fluctuation of 20 % or less) Ambient Illumination 3,000 lux or less Levelness 1° (1.75/100 or less)

Depth..........792 mm, 31-1/4 Height.........1025 mm, 40-1/4 Engine + 2nd Drawer Width..........596 mm, 23-1/2 Depth..........730 mm, 28-3/4 Height.........571 mm, 22-1/2 Scanner Width..........589 mm, 23-1/4 Depth..........730 mm, 28-3/4 Height.........152 mm, 6 Engine+ 2nd Drawer.........85 kg, 187-1/2 lbs Scanner............................19.5 kg, 43 lbs Rack..................................18 kg, 39-3/4 lbs

2-1. Installation Site To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: • Where it will be subjected to extremely high or low temperature or humidity. • Where it will be subjected to sudden fluctuations in either temperature or humidity. • Which is exposed to direct sunlight. • Which is in the direct air stream of an air conditioner, heater, or ventilator. • Which has poor ventilation or is dusty. • Which does not have a stable, level floor or where it will receive undue vibration. • Which is near any kind of heating device. • Which is near volatile flammables (thinner, gasoline, etc.). • Where it may be splashed with water. • Which puts the operator in the direct stream of exhaust from the copier. • Where ammonia gas might be generated. 2-2. Power Source • If any other electrical equipment is sourced from the same power outlet, make sure that the capacity of the outlet is not exceeded. • Use a power source with little voltage fluctuation. • Never connect by means of a multiple socket any other appliances or machines to the outlet being used for the copier. • Ensure that the copier does not ride on the power cord or communication cable of other electrical equipment, and that it does not become wedged into or underneath the mecha- nism. • Make the following checks at frequent intervals: � Is the power plug abnormally hot? � Are there any cracks or scrapes in the cord? � Has the power plug been inserted fully into the outlet? � Does something, including the copier itself, ride on the power cord? Use an outlet with a capacity of 110/120/127 V, 15 A or more. 220/240 V, 10 A or more. 2-3. Grounding • Always ground the copier to prevent receiving electrical shocks in the case of electrical leakage. • Connect the ground wire to the ground terminal of the outlet or a grounding contact which complies with the local electrical standards. • Never connect the ground wire to a gas pipe, the ground wire for a telephone, lightning arrester, or a water pipe for fear of fire and electrical shock.

3-1. To ensure that the copier is used in an optimum condition • Never place a heavy object on the copier or subject the copier to shocks. • Insert the power plug all the way into the outlet. • Do not attempt to remove any panel or cover which is secured while the copier is making copies. • Do not turn OFF the copier while it is making copies. • Provide good ventilation when making a large number of copies continuously. • Never use flammable sprays near the copier. • If the copier becomes inordinately hot or produces abnormal noise, turn it OFF and unplug it. • Do not turn ON the power switch at the same time when you plug the power cord into the outlet. • When unplugging the power cord, do not pull on the cord; hold the plug and pull it out. • Do not bring any magnetized object near the copier. • Do not place a vase or vessel containing water on the copier. • Be sure to turn OFF the power switch at the end of the workday or upon power failure. • Use care not to drop paper clips, staples, or other small pieces of metal into the copier. 3-2. Operating Environment The operating environmental requirements of the copier are as follows. • Temperature: 10 to 30 °C, 50 to 86 ° F • Humidity: 25 to 85 % RH • Rate of temperature change: 10 °C/h, 50 ° F/h • Rate of humidity change: 20 % RH/h 3-3. Power Requirements The power source voltage requirements are as follows. • Voltage fluctuation: AC110, 120, 220, 240 V ±10 % (copying performance assured) (127 V areas only; between -10 % and +6 %) (paper feeding performance assured) • Frequency fluctuation: 50/60 Hz ±0.3 % 3-4. Note • It is prohibited to copy paper and hard currencies, government securities, and municipal bonds (even when they are stamped as “Sample”). • For fear of infringement of copyright, it is also prohibited to copy copyrighted works, including books, music, works of art, maps, drawings, motion pictures, and photos except when the copy is to be used only personally. +10 % -15 %

Before using any consumables, always read the label on its container carefully. • Paper can be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded in the drawer, in a sealed plastic bag in a cool, dark place. • Keep consumables out of the reach of children. • Do not touch the PC Drum with bare hands. • The same sized paper is of two kinds, short grain and long grain. Short grain paper should only be fed through the copier crosswise, long grain paper should only be fed lengthwise. • If your hands become soiled with toner, wash them with soap and water. • Do not throw away any used consumables (PC Drum, starter, toner, etc.). They are to be collected. • Do not burn, bury in the ground, or throw into the water any consumables (PC Drum, starter, toner, etc.). • Do not store consumables in a place which: � Is hot and humid. � Is subject to direct sunlight. � Has an open flame nearby. • Never store the Imaging Cartridge standing on end.

• This product is a copier which operates by means of a LED (light emitting diodes) expo- sure system. There is no possibility of danger from the LED optical radiation, because the LED optical radiation level does not exceed the acceptable radiation limit of class 1 under all conditions of operation, maintenance, service and failure. CAUTION Double pole / neutral fusing ATTENTION Double pôle / fusible sur le neutre.

2. Scanner SC-1 3. Copier printer section 4. Large Capacity Cabinet PF-121 5. Copy Desk CD-2M 6. Finisher FN-116 7. Option Tray JS-100 8. Original Cover OC-2 9. Duplex Unit AD-14 10. Paper Feed Unit PF-118 11. Copy Table CT-2 12. Finisher FN-8 13. Copier Stand CS-2 14. Data Terminal DT-105 ( U.S.A .and Canada only) 15. Memory M256-2* 16. Hard Disk Drive HDD-5* 17. Punch Kit PK-4* 18. Mechanical Counter* 19. Printer Controller CN3101e* 20. Printer Controller CN3102Pro* 21. Printer Controller CN3102e* *:The internal options are not shown.

mended that the maintenance jobs described in this schedule be carried out as instruced. PM Parts Maintenance Cycle Parts No. Ref. Page in This Manual Clean Replace Paper Take-Up Section Paper Take-Up Roll When paper take-up failure occurs 200 K 4021-3012-01(1st) 4128-3214-01(2nd) �� E-5 Separator Roll Assy When paper take-up failure occurs 200 K 4658-0151-01 �� E-5 �� E-6 Transfer Section Synchronizing Roller Upon each call (60 K) — — �� E-7 Paper Dust Remover Upon each call (60 K) 152 K 4588-611 �� E-7 �� E-8 Transport Roller Upon each call (60 K) — — �� E-8 2nd Image Transfer Entrance Upper Guide Upon each call (60 K) — — �� E-8 Image Transfer Roller Unit — 152 K 4588-411 �� E-18 IR Section Scanner Rail When image failure occurs — — �� E-9 Mirrors (1st, 2nd, 3rd) When image failure occurs — — �� E-10 Lens When image failure occurs — — �� E-11 Original Glass When image failure occurs — — �� E-11 CCD Sensor When image failure occurs — — �� E-12 Image Transfer Section Image Transfer Belt Unit — 160 K 4588-211 �� E-19 Waste Toner Bottle — 30 K 4697-101 �� E-13 Around waste toner collecting port Upon each call — — �� E-14

• Replace the Paper Dust Remover and Ozone Filter at the same time. • When the Black Imaging Unit is replaced, also replace the Deodorant Filter (packed with the Black Imaging Unit) at the same time. • When the Toner Cartridge is replaced, also clean the Comb electrode. • The numeric values in the Maintenance Cycle column represent the Life Counter values. • The contents of this maintenance schedule are subject to change without notice. PM Parts Maintenance Cycle Parts No. Ref. Page in This Manual Clean Replace Developing Section Imaging Unit C/M/Y — 52 K — �� E-22 Imaging Unit Bk — 82 K — Ozone Filter — 152 K 4025-0447-01 �� E-15 Comb electrode 10 K or When image failure occurs — — �� E-15 LPH Section LPH Assy Upon each call or replacement of IU — — �� E-16 Fusing Section Fusing Unit — 152 K 4588-510 (100 V) 4588-512 (230 V) 4588-513 (120 V) �� E-26 Fusing Entrance Guide Plate When malfunction occurs — — �� E-17 Deodorant Filter — 10 K 4588-711 �� E-17

M: minutes Description Life Value new copy/print cycle is inhibited Waste Toner Bottle A waste toner full condition is detected when about 3.5 K(31-cpm Copier) 6.9 K(20-cpm Copier) copies are made after a waste toner near-full condition has been detected. — 30 K Fusing Unit The number of copies made is counted. (The counter counts up 2 for paper whose FD exceeds 216 mm.) Once the number of copies has reached its life value (inhibit), copying is prohibited. 150 K 152 K Paper Dust Remover The number of copies made is counted. (The counter counts up 2 for paper whose FD exceeds 216 mm.) 150 K 152 K* Ozone Filter The number of copies made is counted. (The counter counts up 2 for paper whose FD exceeds 216 mm.) 150 K 152 K* Transfer Roller Unit The number of copies made is counted. (The counter counts up 2 for paper whose FD exceeds 216 mm.) 150 K 152 K* Transfer Belt Unit • The number of copies made is counted. (The counter counts up 2 for paper whose FD exceeds 216 mm.) • The number of copies made is compared with the value of the number of hours through which the belt has turned trans- lated to a corresponding value of the number of copies made and the value, whichever reaches the life specifications value, is detected. Once the number of copies has reached its life value (inhibit), copying is peohibited. 150 K 160 K Imaging Unit C/ M/Y (20-cpm copier) The number of hours through which the PC Drum has turned is compared with the num- ber of hours through which the Developing Roller has turned translated to a corre- sponding value of the number of hours through which the PC Drum has turned and the value, whichever reaches the life specifi- cations value, is detected. Once the number of copies has reached its life value (inhibit), copying is peohibited. 6929 M (50 K) 7206 M (52 K) Imaging Unit C/ M/Y (31-cpm copier) 3479 M (50 K) 3618 M (52 K) Imaging Unit Bk (20-cpm copier) 7627 M (80 K) 7818 M (82 K) Imaging Unit Bk (31-cpm copier) 5411 M (80 K) 5546 M (82 K)

cycle is inhibited if “User” is selected for “Unit Change” accessed from “System Input” available under “Tech. Rep. Mode” and the life warning display is given if “Service” is selected for the same function (“Unit Change”) • The life specifications values represent the number of copies made or figures equivalent to it when given conditions (see the Table given below) are met. They can be more or less depending on the copier operating conditions of each individual user. • Conditions for Life Specifications Values 31-cpm Copier 20-cpm Copier Job Type Making three copies per job Monochrome: Making three copies per job Color: Making three copies per job Paper Size A4C,Letter C Color Ratio Color to Black = 6.5 to 1.5 Color to Black = 1.5 to 4.5 CV/M 8 K 6 K Original Density B/W = 5 % for each color, 6 % for Monochrome No. of Operating Days per Month 20 days (Power Switch turned ON and OFF 20 times per month)

(1) Cleaning of the Paper Take-Up Roller (2) Replacing of the Paper Take-Up Roller (3) Cleaning of the Paper Separator Roller 1. Slide out the drawer. 2. Using a soft cloth dampened with alcohol, wipe the Paper Take-Up Roller clean of dirt. 4658D005AA 1. Slide out the drawer. 2. Lock the Paper Lifting Plate into position. 3. Snap off one C-clip from the Paper Take-Up Roller Assy. 4. Slide the Paper Take-Up Roller Assy to the rear and take its shaft off the front bushing. 4658D008AA 5. Snap off one C-clip and remove the Paper Take- Up Roller. 6. Remove the Paper Separator Roller Assy. [See (4) Replacement of the Paper Separator Roller Assy.] 7. To reinstall, reverse the order of removal. 8. Select “Tech. Rep. Mode” → “Counter” → “Life” and clear the count of “1st” or “2nd.” 4658D009AA 1. Slide out the drawer. 2. Remove two screws and the Paper Separator Roll mounting bracket assy. 4658D002AA

3. Using a soft cloth dampened with alcohol, wipe the Paper Separator Roll clean of dirt. 4658D006AA 1. Slide out the drawer. 2. Remove two screws and the Paper Separator Roll mounting bracket assy and reinforcement plate. NOTES • Receive by hand the reinforcement plate that will come off position when the screws are removed. • When reinstalling the reinforcement plate, make sure that it is doweled into position. 4025E001AA 3. Take off the rubber stopper, shaft, spring, and guide plate to remove the Paper Separator Roll fixing bracket assy. 4658D003AA 4. Snap off one E-ring and the Paper Separator Roll Assy. 5. Remove the Paper Take-Up Roll. [See (2) Replacement of the Paper Take-Up Roll.] 6. To reinstall, reverse the order of removal. 7. Select “Tech. Rep. Mode” → “Counter” → “Life” and clear the count of “1st.” 4658D004AA

(6) Cleaning of the Paper Dust Remover 1. Open the Right Door. 2. Remove the Paper Dust Remover. See (7) Replacing the Paper Dust Remover. 4004D206AB 3. Using a soft cloth dampened with alcohol, wipe the Synchronizing Rollers clean of dirt. 4004D205AC Synchronizing Rollers 1. Open the Right Door. 2. Remove the Paper Dust Remover. See (7) Replacing the Paper Dust Remover. 4004D206AB 3. Using a brush, whisk dust off the Paper Dust Remover. 4025E002AA

(8) Cleaning of the Transport Roller (9) Cleaning of the 2nd Image Transfer Entrance Upper Guide 1. Open the Right Door. 2. Pushing the hook with a blue label inward, remove the Paper Dust Remover. 3. Remove the Ozone Filter. [See (17) Replace- ment of the Ozone Filter.] 4. To reinstall, reverse the order of removal. 5. Select “Tech. Rep. Mode” →”Counter” →”Life” and clear the count of “Paper Powder Filter/ Ozone Filter.” 4004D206AB 1. Open the Right Door. 2. Using a soft cloth dampened with alcohol, wipe the Transport Roller clean of dirt. 4025E053AA 1. Open the Right Door. 2. Open the Left Door. 3. Remove the Waste Toner Bottle. 4. Slide the Transfer Belt Unit out halfway. 5. Wipe the 2nd Image Transfer Entrance Upper Guide clean of dirt using a soft cloth. NOTE • When cleaning, use care not to be hurt by the leading edge of the guide that is sharp. 4025E055AA

1. Remove three screws and the IR Right Cover. 4025E003AA 2. Remove one screw each and the Original Glass fixing bracket (at the front and rear). 3. Remove the Original Glass. 4025E004AA 4. Using a soft cloth dampened with alcohol, wipe the Scanner Rails clean of dirt. NOTE • Apply lubricant after cleaning. 4025E005AA

1. Remove three screws and the IR Right Cover. 4025E003AA 2. Remove one screw each and the Original Glass fixing bracket (at the front and rear). 3. Remove the Original Glass. 4025E004AA 4. Using a soft cloth dampened with alcohol, wipe mirrors clean of dirt. 40004D199AA 1st Mirror 2nd/3rd Mirror

(13) Cleaning of the Original Glass 1. Remove three screws and the IR Right Cover. 4025E003AA 2. Remove one screw each and the Original Glass fixing bracket (at the front and rear). 3. Remove the Original Glass. 4025E004AA 4. Remove fourteen screws and the optical cover. 4025E006AB 5. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt. 4004D200AB 1. Using a soft cloth dampened with alcohol, wipe the Original Glass clean of dirt. 4004D201AA

1. Remove three screws and the IR Right Cover. 4025E003AA 2. Remove one screw each and the Original Glass fixing bracket (at the front and rear). 3. Remove the Original Glass. 4025E004AA 4. Remove fourteen screws and the optical cover. 4025E006AB 5. .Remove two hooks and the lens cover. 4025E050AA 6. Using a soft lint free cloth dampened with alco- hol, wipe the CCD Sensor clean of dirt. 4025E051AA

NOTES • If a Finishing Option is installed, remove if from the Main Unit before trying to replace the Waste Toner Bottle. • When removing the Finishing Option, support the Horizontal Transport Unit with your hand to prevent if from dropping. 1. Turn OFF the main switch. 2. Open the Left Door. 3. Grasp the handle, and remove the waste toner bottle. NOTES • Raise the waste toner bottle gently before remov- ing it. • If scattered toner has accumulated in the vicinity of the toner collecting port, do not tilt the waste toner bottle when removing it. • Do not leave the waste toner bottle in a tilted condi- tion after removing it. 4004D221AA 4. Remove the seals from the two toner collecting ports. 4025E008AA 5. Peel off the seals for blocking the two toner col- lecting ports, and place them over the toner col- lecting ports. 4025E007AA 6. Clean the surface around the waste toner collect- ing port. [See (16) Cleaning of the Area around the Waste Toner Collecting Port.] 7. Remove the waste toner bottle from its box, and remove the packing material. 8. Grasp the handle, and set the waste toner bottle in place. 4025E009AA

9. Close the Left Door. 4025E010AA 1. Open the Rear Left Cover. 2. Remove the Waste Toner Bottle. 4004D221AA 3. Wipe the areas around the Waste Toner Collect- ing Port clean of spilled toner and dirt using a soft cloth dampened with water or alcohol. 4004D222AB

(18) Cleaning of the Comb Electrode 1. Holding onto the hook, remove the Ozone Filter. 2. Remove the Paper Dust Remover. [See (7) Replacement of the Paper Dust Remover.] 3. To reinstall, reverse the order of removal. 4. Select “Tech. Rep. Mode” → “Counter”→”Life” and clear the count of “Paper Powder Filter/ Ozone Filter.” 4025E011AA 1. Open the Front Door. 2. Clean the Comb Electrode by moving the Comb Electrode Cleaning Lever In and Out several times. NOTE • Move the Comb Electrode Cleaning Lever slowly forward and backward until it stops. 4025E012AA

NOTE • After the Imaging Unit has been removed from the main unit, be sure to place it in the aluminum package or wrap it in a light shielding cloth, and store it in a dark place. Do not leave the Imaging Unit exposed to light for a extended period of time, as it may become damaged. 1. Open the Front Door. 2. Slide out the IU (C/M/Y/Bk). �� E-22 3. Remove the LED Cleaning Jig and LED Cleaning Jig Pad. 4025E014AA 4. Affix a LED Cleaning Jig Pad to the LED Clean- ing Jig. 4025E015AA 5. Clean the LED of the LPH Assy by moving the LED Cleaning Jig three reciprocating motions. NOTE • Use only the specified jig (LED Cleaning Jig) for cleaning. 4025E013AA

(21) Replacement of the Deodorant Filter 1. Remove the Fusing Unit. �� E-26 2. Using a soft cloth or cotton swab dampened with alcohol, wipe clean the Fusing Entrance Guide Plate. NOTES • Use care when cleaning the Fusing Entrance Guide Plate as it is easy to damage. • Be careful the Fusing Unit can be HOT. • Do not place the Fusing Unit on a workbench with its terminal strip facing down as it can become damaged. 4025E016AA 1. Holding onto the hook, take out the Deodorant Filter. 4025E017AA

(1) Replacing the Image Transfer Roller Unit Removal Procedure NOTES • If a Finishing Option is installed, remove if from the main unit before trying to replace the Waste Toner Bottle. • When removing the Finishing Option, support the horizontal transport unit with your hand to prevent if from dropping. Reinstallation Procedure 1. Turn OFF the main switch. 2. Open the Right Door. 4025E018AA 3. Unlock the blue lock levers (at two places). 4. Holding onto the blue lock levers (at two places), remove the Image Transfer Roller Unit. 4025E019AB 1. Holding onto the blue lock levers (at two places), mount the Image Transfer Roller Unit. 2. Lock the blue lock levers (at two places). NOTE • Avoid touching the Transfer Roller surface as it may become damaged. 4025E020AB 3. Close the Right Door. NOTE • Make sure that the door is locked in position both at front and rear. 4. Turn ON the Power Switch. 5. Select “Tech. Rep. Mode” → “Counter” → “Life” and clear the count of “Transfer Roller Unit.” 4025E021AA

Removal Procedure NOTES • If a Finishing Option is installed, remove if from the main unit before trying to replace the Transfer Belt Assembly. • When removing the Finishing Option, support the horizontal transport unit with your hand to prevent if from dropping. 1. Turn OFF the main switch. 2. Open the Right Door. 4025E018AA 3. Open the Left Door. 4025E022AA 4. Grasp the handle, and remove the waste toner bottle. NOTES • Raise the waste toner bottle gently before remov- ing it. • If scattered toner has accumulated in the vicinity of the toner collecting port, do not tilt the waste toner bottle when removing it. • Do not leave the waste toner bottle in a tilted condi- tion after removing it. 4025E023AA 5. Pull out the Image Transfer Belt Unit. 4025E024AA

(Fingerprints on the Transfer Film result in image problems.) 1. Insert the Transfer Belt Unit halfway up to the point shown on the left. NOTES • Note the arrow label provided at the guide on the copier side when inserting the Transfer Belt Unit. • Insert the Transfer Belt Unit until its terminal is stopped at the cutout in the guide on the copier side. 4025E027AB Terminal 2. Supporting the Transfer Cleaner Assy with a hand, remove two screws. 3. Remove the Transfer Cleaner Assy. 4. Remove protective paper taped to the Transfer Cleaner Assy. 4025E028AA 5. Turn over the Transfer Cleaner Assy so that the brush faces upward. 4025E029AA Brush 6. Uniformly apply the enclosed toner along the brush and on the side seals. NOTE • Save a small amount of toner for use in the subse- quent step. • Apply toner directly to the top of the side seals. Otherwise, the side seals could be worn or a noise could be produced when the image transfer belt moves. 4025E030AA Side Seals Brush

tion in the Same direction as in step 8, and check the Blade for improper contact, or fail- ure to remove the toner completely, or for any noise or binding. NOTES • If any faulty symptom is evident, apply toner to the Transfer Belt again. • If the Blade fails to remove toner completely off the Transfer Belt, perform step 11 once again. 7. Place the remainder toner on the paper towel that comes with the Transfer Belt Unit and apply an even coat of toner on the Transfer Belt (up to 15 mm from both edges). NOTE • The toner, even if there is any remaining should NOT be used in the copier. It is different from the Toner that is used in the Copier. 4025E031AA 8. Holding onto both ends of the Transfer Belt, rotate the Transfer Belt until the Blade of the Transfer Cleaner Assy contacts the location on the belt, to which the toner has been applied. 4025E032AA 9. Fit bosses (at the front and rear) of the Transfer Cleaner Assy into the hooks (at the front and rear) of the Transfer Belt Unit. 10. Secure the Transfer Cleaner Assy to the Transfer Belt Unit using two screws. 4025E033AA 12. Insert the Image Transfer Belt Unit. • Failure to have the Right side door open may result in damage to the Transfer Belt or it Drive. 4025E052AA

Removal Procedure 1. Take out the “Imaging Unit Pull-out Tray” from the packing box. 2. Turn OFF the Power Switch. 3. Unplug the power cord. 4. Open the Front Door. 13. Hold the handle and install the Waste Toner Bot- tle in position. 4025E009AA 14. Close the Left Door. 4025E010AA 15. Close the Right Door. NOTE • Make sure that the door is locked in position both at front and rear. 16. Turn ON the Power Switch. 17. Select “Tech. Rep. Mode” → “Gradation Adjust” and carry out Gradation Adjust. 4025E021AA 5. Release the lock lever of the Imaging Unit. C4004U047AA

Imaging Unit from the Main unit. C4587U004AA 7. Set the removal jig of the Imaging Unit in place. 8. Slowly rotate the jig clock-wise until it is fixed. C4587U005AA 9. Position the Imaging Unit Pull-out Tray under the Imaging Unit and insert it all the way into position. C4587U007AA 10. Supporting the Imaging Unit Pull-out Tray with one hand and holding the “T” Handle with the other, carefully slide the Imaging Unit out of the Main Unit. After removing the Imaging Unit place it on a level surface and cover it with a light block- ing cloth. 11. Remove the Imaging Unit Pull-out Jig and return it to the copier. C4587U008AA

Imaging Unit is the same as the color of the label at the mounting position on the main unit. 1. Remove the Imaging Unit from its aluminum pack. 2. Tilt the Imaging Unit to the left and shake it a small stroke in the tilt direction twice. Then, tilt it to the right and shake it a small stroke in the tilt direction twice. NOTES • Since the Imaging Unit is highly susceptible to light, keep it shielded from light up to the time it is installed. • Carefully unseal the aluminum pack. • If the Imaging Unit is packed in the aluminum pack- age again, seal the package using tape or another means. 4025U024AA 3. Remove the protective tapes C4587U013AA protective tape 4. Remove the shipping cushion. CAUTION • Make sure that the protective sheet is rolled up into the Imaging Unit as shown in the . protective sheet C4587U015AA protective sheet 5. Keeping the Imaging Unit in a level position, insert the Imaging Unit into the mounting position all the way until it is stopped. NOTE • Do not allow the Imaging Unit to become tilted while installing them into the Main Unit, as damage to the PC Drum or the LED assembly can result. 4025U028AC

11. Place the empty Imaging Unit Cover on the floor. 12. Remove a pair of gloves from the packing box and wear them. 14. Place the Imaging Unit that has been inserted into the Imaging Unit Cover in the alumi- num pack and place the pack in the packing box. 15. Place the Imaging Unit Pull-out Tray, gloves, and packing material in the packing box. 16. Plug in the power cord. 17. Turn ON the Power Switch. 18. Select “Tech. Rep. Mode” → “Gradation Adjust” and carry out Gradation Adjust. 6. Holding the underside of the Imaging Unit with your left hand, gently insert the Imaging Unit with your right hand. NOTE • Insert the Imaging Unit until a click is heard. 4025U029AB 7. Remove the Imaging Unit Cover. 8. Check that the Imaging Unit has been inserted all the way in the copier. 4025U030AB 9. Close the Imaging Unit Locking Lever. NOTE • Place the IU Lock Lever into the locked position until a click is heard. 4025E040AA 13. Insert the old Imaging Unit into the Imaging Unit Cover. C4587U024AA

Removal Procedure NOTE • Before replacing the Fusing Unit, ensure that it has had time to cool down. 1. Turn OFF the main switch, then wait for about 20 minutes. 2. Open the Right Door. 4025E018AA 3. Open the Upper Right Door. NOTE • When opening the Upper Right Door, be sure to support it with your hand until it is in the fully open position. If you remove your hand from the Upper Right Door, it may drop, and the resulting impact may cause the hinges to bend. 4025E041AA 4. Hold the handles (at two places) and slide out the Fusing Unit. 4025E042AB 5. Hold the handles (at two places) and remove the Fusing Unit. NOTE • Please use care while Installing/Removing the Fusing Unit due to the close proximity of the Fus- ing Drive Gears. 4025E043AA

Fusing Unit in position. 4025E044AA 2. Hold the handles (at two places) and push the Fusing Unit into position. 4025E044AB 3. Close the Upper Right Door. 4025E046AA 4. Close the Right Door. NOTE • Ensure that both the front and rear sides are locked. 4025E021AA

4025D001AA 4025D002AB DC Power Supply 3 PU201 F1: 250 V 5 A F100: 250 V 3.15 A DC Power Supply 2 PU2 100 V Area F1: 125 V 4 A 200 V Area F1: 250 V 4 A DC Power Supply 1 PU1 100 V Area F1: 250 V 15 A F2: 250 V 15 A F3: 250 V 15 A F4: 250 V 15 A 200 V Area F1: 250 V 8 A F2: 250 V 8 A F3: 250 V 8 A F4: 250 V 8 A DC Power Supply 1 PU1 F101: 250 V 3.15 A F102: 250 V 3.15 A F103: 250 V 3.15 A F104: 250 V 3.15 A

(1) Red painted Screws Purpose of Application of Red Paint Red painted screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. Note that when two or more screws are used on the part in questions, only one representa- tive screw may be marked with red paint. (2) Variable Resistors on Board Do not turn the variable resistors on boards for which no adjusting instructions are given in “ADJUSTMENT.”

IDENTIFICATION AND REMOVAL PROCEDURES No. Name Removal Procedure 1 Original Glass Remove the IR Upper Right Cover. → Remove one screw and the Original Glass fixing brackets (front and rear). → Remove the Origi- nal Glass. 2 IR Upper Right Cover Remove three screws and the IR Upper Right Cover. 3 Control Panel Remove the four caps on both sides of the control panel. → Remove four screws and the flat cable. → Remove the control panel. 4 IR Front Cover Remove the IR Lower Front Cover. → Loosen three screws and remove the IR Front Cover. 5 IR Lower Front Cover Remove the pipe ends (left and right). → Remove two screws and the IR Lower Front Cover. 6 IR Left Cover Remove the IR Upper Cover. → Remove the IR Rear Cover. → Demount the IR Unit from the Copier Stand. → Remove four screws and the IR Left Cover. 7 IR Upper Cover Remove the Original Cover. → Remove six screws and the IR Upper Cover. 8 IR Rear Cover Disconnect the power cable and ADF cable. → Remove the IR Upper Cover. → Remove two screws and the IR Rear Cover. 9 IR Right Cover Remove the IR Upper Cover. → Remove the IR Rear Cover. → Demount the IR Unit from the Copier Stand. → Remove four screws and the IR Right Cover. 1 3 4 5 6 7 8 9 2 4025D003AA 4025D004AA

the Ozone Filter. → Remove two screws and the Rear Left Cover. 2 Panel Cover Open the Front Door. → Remove one screw and the Panel Cover. 3 Front Door Open the Front Door. → Lift the Front Door off the copier. 4 Hopper Left Cover Open the Front Door. → Remove one screw and lift the Hopper Left Cover upward to take it off. 5 Paper Output Cover Open the Upper Right Door. → Remove two screws and the Paper Output Cover. 6 Rear Upper Cover Remove the Paper Output Cover. → Remove the Rear Cover. → Remove the deodorant filter. → Remove three screws and the Rear Upper Cover. 7 Rear Cover Remove seven screws and the Rear Cover. 8 Rear Right Cover Open the Right Door. → Remove the Rear Upper Cover. → Remove one screw and the Rear Right Cover. 9 Front Right Cover Open the Right Door. → Open the Upper Right Door. → Remove the Panel Cover. → Remove one screw and the Front Right Cover. 1 2 3 4 5 6 7 8 9 4025D005AA 4025D006AA

COMPONENTS NOTES • When removing a circuit board or other electrical component, refer to “Handling of PWBs” and follow the corresponding removal procedures. • The removal procedures given in the following omit the removal of connectors and screws securing the circuit board support or circuit board. • Where it is absolutely necessary to touch the ICs and other electrical components on the board, be sure to ground your body. Symbol Name Removal Procedure - CCD Unit �� D-8 PWB-B Image Processing Interface Board �� D-10 PWB-C Image Processing Board �� D-10 � Upgrade the firmware after the replacement. PWB-IC Scanner Motor Drive Board Remove the IR Rear Cover. → Remove 11 screws and the reinforcement frame. → Remove the Scanner Motor Drive Board. UN201 Control Panel Remove the four rubber caps on the right and left and remove four screws. → Remove the control panel and then remove the flat cable from the control panel. PU201 DC Power Supply 3 Remove the IR Rear Cover.→ Remove 11 screws and the reinforcement frame. → Remove five screws and DC Power Supply 3. CCD Unit UN201 PWB-IC PU201 PWB-B PWB-C 4025D007AA

D-6 HV2 PWB-F PWB-LED PU1 PU2 PWB-S1 PWB-S PWB-I HV3 HV1 PWB-PIC PWB-G PWB-IO 4025D008AA 4025D009AB

Left Cover.→ Remove three screws and the upper rear left metal bracket. → Remove five screws and the IO Board. PWB-G Option Interface Board Remove the I/O Board. → Remove four screws and slide the Option Interface Board off the copier. PWB-PIC PIC Board Remove the I/O Board. → Remove five screws and the harness protective metal bracket. → Remove nine screws and the rear left metal bracket. → Remove PWB-F. → Remove eight screws and the PIC Board. � You MUST Upgrade the firmware after the replace- ment. PWB-F Image Control Board �� D-12 � Upgrade the firmware after the replacement. HV1 High Voltage Unit (PC DRUM CH.) �� D-13 HV2 High Voltage Unit (Image Transfer, Neu- tralizing) �� D-13 HV3 High Voltage Unit (Developing Bias) �� D-13 PU1 DC Power Supply 1 �� D-15 PU2 DC Power Supply 2 Remove the Paper Output Cover and Rear Upper Cover. → Remove four screws and the PWB cover. → Remove three screws and DC Power Supply 2. PWB-LED LED Drive Board �� D-41 PWB-I Paper Size Detecting Board �� D-13 PWB-S Paper Type Detection Board Open the Front Door. → Slide out the paper drawer. → Remove one screw and the Paper Type Detection Board cover.→ Remove one screw and the Paper Type Detection Board. � There are locking tabs inside the Paper Type Detection Board cover. Try to expand both sides of the cover when removing it. PWB-S1 Tech. Rep. Setting Switches Board Open the Front Door. → Remove the Panel Cover. → Remove two screws and the Right Front Cover. → Remove one screw and the Tech. Rep. Setting Switches Board.

1. Remove the Original Glass. 2. Remove 14 screws and optical cover. 4025E006AB 3. Remove the Image Processing Interface Board cable from the CCD Unit. 4025D113AA Image Processing Interface Board 4. Unplug connector 4025D114AA 5. Remove four screws and the CCD Unit. NOTE • Make doubly sure that you remove the correct screws. If any screw that should not be removed is removed, it results in the distance between the lens and the CCD sensor or tilt in these parts being varied. 4025D115AA

3. Turn ON the Power Switch. 4. Carry out the adjustment procedure for CD-Mag. (see D-67). If the specifications are not met, loosen the CCD Unit mounting screws and move the CCD Unit in the FD direc- tion as necessary. NOTE • Hold the CCD Unit by hand when moving it. NEVER use a screwdriver or similar tool to tap to move it, as a varied distance between the CCD sensor and lens results. • If the specified width on the copy is less than the specifications, move the CCD Unit to the left. • If the specified width on the copy is longer than the specifications, move the CCD Unit to the right. � Moving the CCD Unit over 1 mm results in the zoom ratio being varied about 2%. 5. Reversing the order of removal, reinstall all parts that have been removed. 1. Align the CCD Unit with the center of the gradua- tions as illustrated on the left and then tighten the four screws. 4025D116AA

1. Remove the Original Glass. 2. Remove 14 screws and optical cover. 4025E006AB 3. Unplug the connectors and remove the cord clamps of the Original Size Detecting Sensors. 4. Remove 12 screws and the Image Processing Board lid. 4025D010AC 5. Remove the Image Processing Interface Board cable. 4025D011AB 6. Unplug all connectors of the Image Processing Board. 4025D012AA 7. Remove the IR hookup cable. NOTES • Be sure to hold onto the connector when removing or installing the cable. NEVER pull on the cable. • At reinstallation, make sure that the Connector is not Tilted. 4004D010AA

4025D013AA 9. Remove eight screws and the Image processing Board. � Upgrade the firmware after the replacement. 4025D014AA

1. Remove the Rear Cover. 2. Remove eight screws at the I/F cable connection (five on the side face and three on the rear face of the copier). 4334O014AA 4334O015AA 3. Slide the Image Control Board to the left off the copier. � Remount IC202 and upgrade the firmware after the replacement. 4334O016AA

Transfer, Neutralizing), High Voltage Unit (Developing Bias), and Paper Size Detecting Board 1. Remove the Rear Upper Cover. 2. Remove the Rear Left Cover. 3. Remove the Rear Right Cover. 4. Remove five screws and the harness protective metal bracket. 4025D015AA 5. Remove three screws and unplug three connec- tors. Then, remove the rear left metal bracket. 4025D017AA 6. Unplug all connectors from the Main Board. 7. Unplug the two connectors from the Option Inter- face Board. 8. Unplug the two connectors from the PIC Board. 4025D016AA 9. Remove two screws and the 2nd Drawer power line mounting bracket. 4025D018AA

and off the copier. 4025D019AA 11. Disconnect connectors, terminals, and flat cable from the High Voltage Unit (Image Transfer, Neu- tralizing). 12. Remove six screws and the High Voltage Unit (Image Transfer, Neutralizing). 4025D020AA 13. Disconnect connectors, terminals, and flat cable from the High Voltage Unit (PC Drum CH.). 14. Remove two screws. Then, lift the High Voltage Unit (PC Drum CH.) and take it out to the front. 4025D021AA 15. Disconnect the connectors and flat cable from the High Voltage Unit (Developing Bias). 16. Remove two screws. Then, lift the High Voltage Unit (Developing Bias) and take it out to the front. 4025D022AA 17. Slide out the paper drawer. 18. Remove two screws, unplug the connector, and remove the Paper Size Detecting Board. 4025D023AA

1. Remove the Upper Cover (Exit Tray). Then renumber the remaining steps. 2. Remove six screws and the PWB cover. 4025D024AA 3. Remove four screws and the PWB cover. 4025D025AA 4. Unplug all connectors from DC Power Supply 1. 4025D026AA 5. Remove nine screws and slide DC Power Supply 1 to the right. 4025D027AC 6. Remove DC Power Supply 1. 4025D028AA

(1) Removal of the Toner Hopper Unit 1. Open the Front Door. 2. Remove the Toner Cartridge (C, M, Y, Bk). 3. Remove the IU (C, M, Y, Bk). NOTE • After the Imaging Unit has been removed from the main unit wrap it in the light shielding cloth and store it in a dark place. DO NOT leave the Imaging Unit exposed to light for a extended period of time as it will become damaged. 4. Remove the hopper left cover. 5. Remove the Front Right Cover. 6. Remove two screws and the Front Door Switch cover. 4025D029AA 7. Disconnect terminals. � Terminals (from top downward): blue, white, and green 4004D045AA 8. Disconnect five connectors. 9. Remove five screws and the Toner Hopper Unit. 4025D030AA

1. Open the Front Door. 2. Slide out the IU (C, M, Y, Bk). NOTES • After the IU has been pulled out, place the IU lock lever back into the locked position. • When installing the Imaging Unit into the main unit, make sure that the Toner supply shutter is opened if the Imaging Unit Lower Cover is not used. 3. Removed the Rear Left Cover. 4. Remove five screws and the harness protective metal bracket. 4004D229AA 5. Remove two screws and unplug one connector on the PIC Board. 4025D142AA 6. Unplug four connectors from the IO Board. 7. Disconnect two hookup connectors. 4025D031AB NOTE • When unplugging the connector, make sure that connector A (on the copier side) is disconnected. Connector B (on the LPH Unit side) should not be disconnected. 40004D232AA A B

the Waste Toner Bottle and Transfer Belt Unit. 9. Turning the IU (C, M, Y, Bk) drive hub, push it into the locked position (at four places). NOTES • During the locking procedure, use care not to touch the LED surface. • Should the LED surface be touched, clean it with the LED Cleaning Jig. 4004D024AA 10. Remove four screws and slide out the LPH Unit. NOTE • When the LPH Unit is to be replaced, remove the ATDC Sensor from the old LPH Unit and remount it on the new one. This step is not, however, neces- sary if the IU is replaced at the same time. 4025D032AA

(1) Removal of the Scanner Motor 1. Remove the IR Rear Cover. 2. Remove 11 screws and the reinforcement frame. 4025D033AA 3. Remove the tension spring for the Scanner Motor timing belt. 4025D034AA 4. Remove three screws and the Scanner Motor Assy. 4025D036AA 5. Remove two screws and the Scanner Motor. 4025D037AA 1. Temporarily secure the Scanner Motor Assy using three screws. 2. Hook the spring. 3. With the Scanner drive gear set screw located on the right-hand side as shown on the left, slide the Scanner Motor Assy to the left and check that it is returned to the original position by the tension of the spring. Perform this step three times. 4. Securely tighten the three screws to fix the Scan- ner Motor Assy into position. 4025D132AA screw

1. Remove the Original Glass. 2. Move the Scanner Assy to the location shown and remove one mounting screw each at the front and rear end. 4004D202AA NOTE • Do not remove the Scanner Positionng Screws. 4025D038AA Scanner mounting Screws Scanner positioning Screws 3. Take out the Scanner Assy by turning it in the direction of the arrow shown. 4004D017AB 4. Remove one screw and the holder. 5. Remove the flat cable. 6. Remove the Scanner Assy. 4025D039AA

1. Remove the IR RearCover. 2. Remove four screws and Control Panel. 4025D042AA 3. Remove the holding bracket and flat cable. 4025D041AB 4. Remove four screws and the control panel base. 4025D040AA 5. Remove the IR Front Cover. 6. Remove the Original Glass. 7. Remove 14 screws and the Optical Cover. 4025E006AB 8. Remove the Scanner Assy. �� D-20 9. Remove the IR Right Cover and the IR Left Cover. 10. Unhook the springs of the Scanner Drive Cables on the hook side, one each at the front and in the rear. 4002D110AB

�� D-19 12. Remove one screw and then slide the front pulley toward the front. 4002D112AA 13. Remove one screw and then slide the rear pulley toward the front. 4002D113AA 14. Remove one screw and the Scanner drive gear. 4025D043AA 15. Snap off the C-clip and remove the bushing (front). 4025D044AA 16. Slide the shaft toward the rear and lift it. Then, remove the front and rear pulleys. 17. Remove the Scanner Drive Cables. 4025D045AA

4025D045AA Pulley A Pulley D Pulley E Pulley B Pulley F Pulley C 1. Position the round bead of the Scanner Drive Cable in the pulley as shown. NOTE • Make sure that the bead snugly rests in the slit in the pulley. Front 4025D046AA

pulley five turns clockwise, from the rear toward the front side. 4025D047AA 3. Wind the hook end of the cable around the pulley five turns counterclockwise, from the front toward the rear side. NOTE • Make sure that no part of the cable rides on the other. 4025D048AA 4. Slip the Cable Holding Jig onto the pulley to secure the cable in position. 4025D049AA 5. Position the round bead of the Scanner Drive Cable in the pulley as shown. NOTE • Make sure that the bead snugly rests in the slit in the pulley. Rear 4025D051AA 6. Wind the fixed bead end of the cable around the pulley five turns clockwise, from the front toward the rear side. 4025D052AA

five turns counterclockwise, from the rear toward the front side. NOTE • Make sure that no part of the cable rides on the other. 4025D053AB 8. Slip the Cable Holding Jig onto the pulley to secure the cable in position. 4025D054AB 9. Install the front and rear pulleys and bushings onto the shaft and fit the C-clip. 4025D056AA 10. Mount the Scanner drive gear on the shaft and secure it using one screw. NOTE • Allow a clearance of about 0.1 mm between the Scanner drive gear and bushing. 4025D057AA 4025D059AA 0.1 mm

each. 4025D058AA 12. Mount the Scanner Motor Assy. �� D-19 4025D117AA 13. Wind the bead end of the cable around pulley C and pulley B, then hook the bead onto the Adjust- able Anchor. Front 4002D008AA Pulley C Pulley B 14. Wind the hook end of the cable around pulley A and pulley B. 4002D009AA Pulley B Pulley A 15. Fit the hook end of the cable to the spring and then hook the spring to the catch in the frame. NOTE • Select the appropriate catch in the frame (from among three) so that the spring measures 64.2 mm ±1 mm. 4002D119AB

20. Mount the Scanner Assy and Flat Cable. 21. Reinstall the optical cover. 22. Reinstall the Original Glass. 23. Reinstall all covers which have been removed. 24. Reinstall the Control Panel. 25. Adjust the position of the Scanner and 2nd/3rd Mirrors Carriage. �� D-44 NOTE • Whenever the Scanner Drive Cables have been removed, be sure to carry out the “FD- Mag” adjustment procedure. �� D-68 16. Wind the bead end of the cable around pulley F and pulley E, then hook the bead onto the Adjust- able Anchor. Rear 4002D010AA Pulley F Pulley E 17. Wind the hook end of the cable around pulley D and pulley E. 4002D011AA Pulley E Pulley D 18. Fit the hook end of the cable to the spring and then hook the spring to the catch in the frame. NOTE • Select the appropriate catch in the frame (from among three) so that the spring measures 64.2 mm ±1 mm. 4002D120AB

(1) Cleaning of the Transfer Belt Unit NOTES • If the dry cloth is not effective in removing dirt, dampen it with alcohol. • Do not use a cloth wet with water. • If any solvent is to be used, select one from among the following: IPA, ethyl alcohol, PPC Cleaner, and Solmix AP-7. • When the solvent has been used for cleaning, make 28 or more copies using A3 blank sheets of paper to remove image noise. 1. Remove the Transfer Belt Unit. �� Meintenance Schedule Section 2. Wipe the surface of the Transfer Belt with a dry cloth. 4004D228AA

1. Remove the Rear Upper Cover. 2. Remove the Rear Left Cover. 3. Remove the Rear Right Cover. 4. Remove five screws and the harness protective metal bracket. 4025D015AA 5. Remove three screws, unplug three connectors, and remove the rear left metal bracket. 4025D017AA 6. Unplug all connectors of the IO Board. 7. Unplug two connectors of the Option Interface Board. 8. Unplug two connectors of the PIC Board. 4025D016AA 9. Remove two screws and the power line mounting bracket for the 2nd Drawer. 4025D018AA 10. Remove 11 screws and lift the PWB box upward and off the copier. 4025D019AA

11. Remove the LPH Unit. �� D-17 12. Unplug two connectors. 13. Remove four screws and Imaging Unit Motor Y. 4025D135AA 14. Unplug two connectors each. 15. Remove four screws each and Imaging Unit Motor M/C/Bk. 4025D136AA 1. Remove the PWB Box. �� D-13 (steps 1 through 10) 2. Unplug one connector. 3. Remove four screws and the Main Motor. 4004D060AA

(5) Removal of the Fusing Pressure/Retraction Motor 1. Remove the PWB Box. �� D-13 (steps 1 through 10) 2. Remove four screws and the Cooling Fan Assy. 4025D060AA 3. Unplug one connector. 4. Remove four screws and the Fusing Drive Motor. 4004D062AB 1. Remove the PWB Box. �� D-13 (steps 1 through 10) 2. Remove four screws and the Cooling Fan Assy. 4025D060AA 3. Remove two screws and the harness holder. 4004D063AA 4. Unplug two connectors. 5. Remove three screws and the Fusing Pressure/ Retraction Motor Assy. 4004D064AA

NOTE • Use care not to lose the pin. 7. Snap off one E-ring and remove the bushing. 8. Remove two screws and the Fusing Retraction Position Sensor mounting bracket. 4004D125AA 9. Remove the gear (black). 4004D209AA 10. Remove two screws and the Fusing Pressure/ Retraction Motor. 4004D126AB Precaution for Reinstallation • When reinstalling the harness holder, make sure that the protrusion on the backside of the holder fits into the hole in the metal bracket. 4004D065AB

(7) Removal of Toner Replenishing Motor C/Bk 1. Remove the PWB Box. �� D-13 (steps 1 through 10) 2. Remove four screws and the Cooling Fan Assy. 4025D060AA 3. Disconnect connectors, terminals, and flat cable. 4. Remove six screws and slide the High Voltage Unit (Image Transfer, Neutralizing) to the left and off the copier. 4025D020AA 5. Unplug one connector. 6. Remove two screws and the 1st Image Transfer Pressure/Retraction Motor. 4004D069AA 1. Remove the Right Front Cover. 2. Unplug one connector. 3. Remove four screws and the Toner Replenishing Motor C/Bk Assy. 4004D071AB

(9) Removal of the 2nd Image Transfer Pressure/Retraction Motor 1. Remove the Toner Hopper. �� D-16 2. Unplug one connector. 3. Remove two screws and the Front Door Switch Assy. 4025D050AA 4. Remove one screw and the gear. 4025D055AA 5. Remove two screws. Then, turn the Toner Replenishing Motor Y/M counterclockwise and take it off the copier. 4025D061AA 1. Open the Right Door. 2. Unlock the tab and remove the Transport Unit Assy. 4025D062AA 3. Remove four screws, unplug one connector, and remove the gear assy and motor assy. 4025D063AA

4. Remove two screws and the 2nd Image Transfer Pressure/Retraction Motor. 4025D064AA 1. Open the Right Door. 2. Unlock the tab and remove the Transport Unit Assy. 4025D062AA 3. Remove one screw, ground wire, and ground plate. 4. Unplug five connectors and remove the Transport Unit Assy. 4025D065AA 5. Snap off the C-clip and remove the gear. 6. Unhook the spring. 4025D066AA 7. Remove three screws and the holder. 4025D093AA

4025D067AA 9. Remove three screws and the mounting bracket. 4025D068AA 10. Remove two screws and the Transport Roller Motor. 4025D069AA

1. Remove the Front Right Door. 2. Remove one screw and the Tech. Rep. Setting Switches Board Assy. 4025D070AA 3. Unplug three connectors 4025D071AA 4. Open the Right Door. 5. Remove four screws and the Synchronizing Roller entrance guide. 4025D072AA 6. Remove five screws and the cover. 4025D073AA 7. Remove three screws, unplug one connector, and remove AIDC/Registration Sensor 1. 4025D074AA

8. Remove two screws, unplug one connector, and remove AIDC/Registration Sensor 2. 4025D075AA 1. Remove the LPH Unit. �� D-17 2. Remove two screws, unplug one connector, and remove the Guide Assy. 4025D076AA 3. Remove two screws and, holding the LPH Assy with hands, unlock it. NOTES • Do not touch the LED by hand. Clean the LED, if touched by hand, using the LED cleaning jig. • Be careful about the spring that can spring off when the LPH Assy is unlocked. 4025D077AA 4. Peel off the seal, unlock the LPH Assy, and remove the flat cable. 5. Unhook the springs. 6. Perform the same procedure for each of different colors of LPH Assy. 4025D078AB Seal Flat Cable

4025D079AA 2. Unlock the LPH Assy and place the pivot tabs (at two places) at the upper position. 4025D081AA 3. Insert the flat cable into the LPH Assy and lock the LPH Assy. 4. Affix the seal that comes with the LPH Assy to the location shown on the left. NOTE • Failure to affix the seal could cause the flat cable to come off the LPH Assy. 4025D080AB Seal Seal Flat Cable Flat Cable Double-Sided Adhesive Tape 5. Holding onto both ends of the LPH Assy, align the portions shown on the left and then press it down into the locked position. 4025D082AA

6. Unlock the LPH Assy. 4025D084AA 7. Hook the springs and press the LPH Assy down into the locked position. 4025D085AA 8. Remove the LPH Assy mounting jigs. 9. Install the two screws. 4025D083AA 10. Install the two screws to secure the guide assy. 11. Connect the connector. 4025D087AA 1. Remove the LPH Unit. �� D-17 2. Remove two screws, unplug the connector, and remove the ATDC Sensor. 4025D088AA

1. Remove the LPH Unit. �� D-17 2. Remove two screws each, unplug one connector each, and remove each guide assy. 4025D089AA 3. Remove the flat cables (eight). 4025D090AB 4. Remove eight screws, unplug two connectors, and remove the LED Drive Board. 4025D092AA

3-1. ADJUSTMENT JIGS AND TOOLS USED Imaging Unit Removal Jig (“T” Handle) LED Cleaning Jig LED Cleaning Jig Pad Scanner Drive Cable Holding Jig LPH Assy Mounting Jigs 4025D118AA 4004D185AA 4004D186AA 4025D120AA 4025D121AA