Page 1
4
SERVICE
1 OUTLINE
2 ISW
3 SERVICE
4 SERVICE
Page 2
1 OUTLINE
2 ISW
Main Precautions for Maintenance
1. Points to be confirmed before maintenance
Before starting maintenance, ask a user
and collect information about troubles occurred on the machine before the maintenance and the conditions of the machine to
grasp key points for the maintenance.
2. Copy sample
3 SERVICE
4 SERVICE
Be sure to make copy samples at the start
and the end of maintenance for checking
images.
3. Drum
1) Never expose the drum to the sunlight.
2) When replacing a drum or a cleaning
Blank page
Be also careful not to expose a drum to
indoor light as far as possible.
When a drum unit or a drum is out of the
machine, never fail to cover it with a
drum cover.
blade, refer to item of mounting/dismounting of a cleaning blade for doing a
replacement work.
4. After replacing the drum or the developer,
refer to the list of adjustment items, and
carry out the necessary adjustments.
5. When maintenance is completed, be sure
to reset the PM counter (25 mode). Incidentally, a development counter is reset automatically in the course of L detection adjustment.
6. When replacing a toner bottle, wait until the
toner supply message on the operation
panel displays before the replacement.
Caution: Turn the main switch off and
pull out the power plug without fail before the work of
maintenance.
Page 3
SERVICE SCHEDULE
Number of copies (unit: 10,000)
Service item (cycles)
Maintenance
(Every 100,000 copies or prints)
Periodic check (I)
(Every 200,000 copies or prints)
Periodic check (II)
(Every 400,000 copies or prints)
Periodic check (III)
(Every 800,000 copies or prints)
Maintenance
(Every 100,000 copies or prints)
Periodic check
(Every 200,000 copies or prints)
Periodic check
(Every 100,000 copies or prints)
Periodic check
(Every 200,000 copies or prints)
Maintenance
(Every 200,000 copies or prints)
Maintenance
(Every 100,000 copies or prints)
MaintenanceMaintenance
(Every 100,000 copies or prints)
Maintenance
(Every 100,000 copies or prints)
Periodic check
(Every 300,000 copies or prints)
Classifica-
tion
Main body
RADF
(DF-315)
DB-608
(1 tray + LCT)
DB-208
(3 trays)
DB-208A
(1 tray)
FNS
(FS-109)
10 20 30 40 50 60 90 100 110
Service
times
11 times
5 times
2 times
1 time
11 times
5 times
11 times
11 times
5 times
11 times
5 times
11 times
3 times
Guarantee period (5 years or 1,200,000 copies)
SERVICE
[1] Service Schedule
1 OUTLINE
2 ISW
3 SERVICE
4-1
4 SERVICE
Page 4
SERVICE
[2] Maintenance Items
1 OUTLINE
1. Main body (Every 100,000 copies or prints)
Classification Service itemNo.
Preparation
1
Fixing unit
2
2 ISW
Drum unit
3
3 SERVICE
4 SERVICE
Developing
4
unit
Write unit
5
6
Transfer/
Separation
corona unit
(1) Image check
(2) External parts
(3) Check of adjustment value,
Dmax and correction error
(1) Fixing unit removing
(2) Upper cover removing
(1) Drum unit removing
(2) Drum unit check
(3) Charging corona unit removing
(4) Charging control plate
(5) Charging wire 55FA2501*
(6) Charging corona unit cleaning
(Back plate and its around, and PCL)
(7) Cleaner mount assembly
(8) Charging wire cleaning block (C)
(9) Charging wire cleaning block (D)
(10) Developing unit removing
(11) Drum removing
(12) Drum cartridge/Developing unit bot-
tom plate/Toner control sensor/Sepa-
rating claw/Developing bias intercept/
Clean with each
(13) Cleaning blade 55GA5601*
(14) Drum installing
(15) Charging corona unit installing
(1) Developing unit lower rib (inside &
outside)/upper cover (back side of
the urethane sheet)
(2) Developing unit installation
(3)
Toner supply opening and its around
(1)
Mirror
(2)
Dust-proof glass
(1) Transfer/Separation corona unit
cleaning (Front and rear block/Guide
rail/Separating bridge/Entrance guide
plate/Back plate) and include remov-
ing and installing
(2) Discharging wire 55GA2607*
55GA2507*
55GA-252*
55GA-253*
55GA-255*
Implementation classification
Cleaning
Lubrication
Replacement
Material used
SupplyCheck
Drum cleaner / Waste rag /
Blower brush
Blower brush / Cleaning pad /
Drum cleaner (Drum cleaner:
only when using the toner con-
trol sensor cleaning.)
Waste rag / Blower brush
(When cleaning the back
side of the urethane sheet,
the back side should be
cleaned, particularly the
urethane sheet section.)
Waste rag
Cleanig pad
Cleanig pad
Blower brush / Cleaning pad
Tools used
Remarks: ( ) and ( ) indicate the following in the classification of implementation.
( ) indicates items that must always be implemented.
( ) indicates items for checking whether they have reached the substantial resistance count listed in the fixed replacement part list and judge
whether to replace them or not.
4-2
Page 5
SERVICE
Classification Service itemNo.
Machine
7
inside
2nd paper
8
feed unit
By-pass unit
9
Paper feed
10
unit
ADU
11
Reversal
12
paper exit
section
Reading
13
section
(1) Conveyance unit 55GA4501*
Conveyance guide plate
(2)
Conveyance belt 55GA4506*
(3)
Registration guide plate (B) assembly
(1)
Registration unit 55GA4301*
(2)
Registration roller (lower)
(3)
Registration roller (upper)
(4)
Registration paper feed roller
(5)
P
aper conveyance roller
(6)
Photo sensors 55208551*
(7)
Paper feed door 55GA-408*
(8)
By-pass tray 55GA-428*
(1)
Double feed prevention roller
(2)
Separation roller 54004056*
(3)
Paper feed roller 25BA4032*
(4)
Double feed prevention plate
(5)
Photo sensor/2 55WA8552*
(6)
Photo sensor 55208551*
(7)
Paper feed unit removing
(1)
Paper feed roller 25BA4032*
(2)
Separation roller 54004056*
(3)
Double feed prevention roller
(4)
Gears
(5)
Paper feed unit installing
(6)
Registration roller (lower)
(1)
Conveyance roller (A) 55HA5025*
(2)
Conveyance roller (B) 55HA5026*
(3)
Conveyance roller (C) 55HA5087*
(4)
Photo sensor 25AA8551*
(5)
Photo sensor 55208551*
(6)
Paper exit reversal roller
(1)
Reversal roller 40BA4825*
(2)
Conveyance roller 55GA4806*
(3)
Paper exit roller 55GA4805*
(4)
Photo sensors 25AA8552*
(5)
Original glass 55YA6150*
(1)
Lens 55GA6001*
(2)
1st mirror 55GA6106*
(3)
2nd mirror 55GA6115*
(4)
Original glass (1) 55GA6139*
(5)
Optics drive wire (front)
(6)
Optics drive wire (rear)
(7)
Optics driven sheet 25BA6189*
(8)
Optics driven sheet (upper)
(9)
APS sensors 25SA8552*
(10)
Photo sensors 55208551*
(11)
Lamp power supply relay cord
(12)
55GA4502*
55GA-431*
55GA4311*
55GA4312*
55GA4322*
55GA4323*
54004056*
54004235*
54004056*
55GA6132*
55YA9012*
Implementation classification
Cleaning
Lubrication
Replacement
Material used
SupplyCheck
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Blower brush
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Blower brush
Blower brush
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Plus guard No. 2
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Blower brush
Blower brush
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Blower brush
Drum cleaner / Cleaning pad
Blower brush
Blower brush / Cleaning pad
Blower brush / Cleaning pad
Drum cleaner / Cleaning pad
Multi oil / Cotton tips
Multi oil / Cotton tips
Blower brush
Blower brush
Tools used
1 OUTLINE
2 ISW
3 SERVICE
4 SERVICE
4-3
Page 6
SERVICE
1 OUTLINE
Classification Service itemNo.
1415Fixing unit
2 ISW
3 SERVICE
Final check
4 SERVICE
(1) Fixing cleaning roller 55GA5312*
(2) Fixing roller (A) 55GA5311*
(3) Fixing cleaning pad 55GA5350*
(4) Fixing roller (upper) 55GA5303*
(5) Paper exit guide (lower) removing
(6) Fixing roller (lower) 55GA5304*
(7) Fixing claw (upper) 25SA5315*
(8) Fixing claw (lower) 54005310*
(9) Fixing paper exit roller (lower)
55GA5329*
(10) Paper exit pulley 54005322*
(11) Fixing entrance plate (lower)
55GA5320*
(12) Fixing entrance plate (upper)
55GA5337*
(13) Fixing temperature sensor 2
55GA8842*
(14) Photo sensor 55208551*
(15) Paper exit guide (lower) installing
(16) Fixing upper cover installing
(17) Fixing unit installing
(1) Toner cartridge supply
(2) W.U.T measure and check
(3) Image check after changing
consumables
(Necessary operation when replac-
ing the 200,000 copy materials).
(4) Copy sample check
(5) PM counter reset (25 mode)
(6) Leakage breaker reset
(7) Machine surroundings, Externals
Implementation classification
Cleaning
Lubrication
Replacement
SupplyCheck
()
Material used
Tools used
Roller cleaner / Cleaning pad
Roller cleaner / Cleaning pad
Roller cleaner / Cleaning pad
Roller cleaner / Cotton tips
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Roller cleaner / Cleaning pad
Roller cleaner / Cleaning pad
Roller cleaner / Cleaning pad
Blower brush
Drum cleaner / Cleaning pad
4-4
Page 7
SERVICE
2. RADF [DF-315] (Every 100,000 copies or prints)
Implementation classification
Classification Service itemNo.
Machine
1 (1) Registration sensor mirror
inside
(2) Registration sensor
(3) Read sensor reflection element
(4) Read sensor
(5) Switchback sensor mirror
(6) Switchback sensor
(7) Paper dust removing pad
(8) Paper feed roller
(9) Separation roller
(10) Double feed prevention roller
Cleaning
3. DB [DB-208/DB-208A/DB608] (Every 100,000 copies or prints)
Implementation classification
Classification Service itemNo.
Externals
1
Paper feed
2
section Note
Externals
3
(1) Externals
(1) Paper feed unit removing
(2) Paper feed roller 25BA4032*
(3) Separation roller 54004056*
Note
(4) Double feed prevention roller
Note
(5) Gears
(6) Paper feed unit installing
(1) Externals
54004056*
Cleaning
Lubrication
Replacement
SupplyCheck
Material used
Tools used
Blower brush
Blower brush
Blower brush
Blower brush
Blower brush
Blower brush
Blower brush
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
DB-208: Operational manhours of 1 unit X 3
DB-208A: Operational manhours of 1 unit X 1
DB-608: Operational manhours of 1 unit X 2
Lubrication
Replacement
( )
( )
( )
SupplyCheck
Material used
Tools used
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Plus guard No. 2
Drum cleaner / Cleaning pad
1 OUTLINE
2 ISW
3 SERVICE
Note : For the DB-208A alone, replace after 100,000 copies.
4. FNS [FS-109] (Every 100,000 copies or prints)
Classification Service itemNo.
Conveyance
1 (1) Conveyance drive roller (A)
section
(2) Paper exit drive roller
Implementation classification
Cleaning
Lubrication
Replacement
4 SERVICE
Material used
SupplyCheck
Drum cleaner / Cleaning pad
Drum cleaner / Cleaning pad
Tools used
4-5
Page 8
SERVICE
[3] Main Body Periodic Check
1 OUTLINE
1. Periodic check (I) (Every 200,000 copies or prints)
Classification Service itemNo.
(1) Fixing claw (upper) 25SA5315*
(2) Heat insulating sleeve 45405339*
(3) Fixing roller (upper) 55GA5303*
(1) Drum
(2) Separation claw 55GA-206*
(3) Drum counter reset (47 mode)
(1) Developer (include the developing
unit installing)
(2) L detection adjustment (36 mode)
(1) Separation roller
(2) Paper feed roller
Double feed prevention roller
(3)
(1) Ozone filter 55YA7350*
(2) Fixing filter 55GA7337*
54004056*
25BA4032*
54004056*
2 ISW
Fixing unit
1
Drum unit
2
Developing
3
unit
Paper feed4
unit
Ozone filter
5
Implementation classification
Cleaning
Lubrication
Replacement
Material used
SupplyCheck
Tri-flow
Setting powder
Tools used
3 SERVICE
2. Periodic check (II) (Every 400,000 copies or prints)
Classification Service itemNo.
By-pass
1
(paper feed
section)
Fixing unit
2
4 SERVICE
(1) Double feed prevention roller
54004056*
(2) Separation roller 54004056*
(3) Paper feed roller 25BA4032*
(1) Fixing claw (lower) 54005310*
(2) Fixing roller (lower) 55GA5304*
(3) Fixing bearing (upper) 55GA7502*
(4) Bearing 55GA7503*
(5) Fixing bearing (lower) 55GA7504*
3. Periodic check (III) (Every 800,000 copies or prints)
Classification Service itemNo.
Fixing unit1 (1) Fixing heater lamp 1 55HF8302*
(2) Fixing heater lamp 2 55HF8303*
Implementation classification
Cleaning
Implementation classification
Cleaning
Lubrication
Lubrication
Replacement
Replacement
Material used
SupplyCheck
SupplyCheck
Tools used
Material used
Tools used
4-6
Page 9
SERVICE
[4] RADF [DF-315]
1. Periodic check (Every 200,000 copies or prints)
Classification Service itemNo.
Paper feed
1 (1) Paper feed roller 120A4582*
section
(2) Separation roller 120A4582*
(3)
Double feed prevention pad
(4) Paper dust removing pad 129H-472*
120A-458*
Cleaning
[5] DB [DB-208]
1. Periodic check (Every 300,000 copies or prints)
Classification Service itemNo.
Paper feed
1 (1) Separation roller 54004056*
section
( three units)
(2) Paper feed roller 25BA4032*
(3) Double feed prevention roller
54004056*
Cleaning
[6] DB [DB-608]
Implementation classification
Lubrication
Implementation classification
Lubrication
Replacement
Replacement
1 OUTLINE
Material used
SupplyCheck
Tools used
2 ISW
Material used
SupplyCheck
Tools used
3 SERVICE
1. Periodic check (Every 200,000 copies or prints)
Classification Service itemNo.
Paper feed
1 (1) Separation roller 54004056*
section
( two units)
(2) Paper feed roller 25BA4032*
(3) Double feed prevention roller
54004056*
Cleaning
[7] FNS [FS-109]
1. Periodic check (Every 300,000 copies or prints)
Classification Service itemNo.
Paper exit
1 (1) Paper exit drive roller / A (Tray 2)
section
(2) Paper exit drive roller / A (Tray 3)
13LP-498*
13LP-498*
Cleaning
Implementation classification
Lubrication
Implementation classification
Lubrication
Replacement
Replacement
Material used
SupplyCheck
Tools used
4 SERVICE
Material used
SupplyCheck
Tools used
4-7
Page 10
SERVICE
[8] Actual Count Replacement Parts
1 OUTLINE
Classification
Drum cartridge
(include charging
corona unit)
2 ISW
Developing unit
Paper feed unit
3 SERVICE
By-pass paper feed
unit
4 SERVICE
Fixing unit
Parts name
Cleaning blade
Charging wire
Charging control plate
Cleaner mount assembly
Charging wire cleaning block (C)
Charging wire cleaning block (D)
Transfer/Separation charging wire
OPC drum
Separation claw
Developer
(Tray: 1) Separation rubber
(Tray: 1) Paper feed rubber
(Tray: 1) Double feed prevention rubber
(Tray: 2) Separation rubber
(Tray: 2) Paper feed rubber
(Tray: 2) Double feed prevention rubber
(Tray: 3) Separation rubber
(Tray: 3) Paper feed rubber
(Tray: 3) Double feed prevention rubber
(Tray: 4) Separation rubber
(Tray: 4) Paper feed rubber
(Tray: 4) Double feed prevention rubber
(By-pass) Separation rubber
(By-pass) Paper feed rubber
(By-pass) Double feed prevention rubber
Fixing cleaning roller
Fixing roller (A)
Fixing cleaning pad
Fixing roller (upper)
Fixing claw (upper)
Heat insulating sleeve
Fixing roller (lower)
Fixing claw (lower)
Fixing bearing (upper)
Bearing
Fixing bearing (lower)
Fixing heater lamp / 1
Fixing heater lamp / 2
Part number Actual count
55GA5601* 100,000
55FA2501* 100,000
55GA2507* 100,000
55GA-252* 100,000
55GA-253* 100,000
55GA-255* 100,000
55GA2607* 100,000
– 200,000
55GA-206* 200,000
– 200,000
54004056* 100,000
25BA4032* 100,000
54004056* 100,000
54004056* 100,000
25BA4032* 100,000
54004056* 100,000
54004056* 100,000
25BA4032* 100,000
54004056* 100,000
54004056* 100,000
25BA4032* 100,000
54004056* 100,000
54004056* 100,000
25BA4032* 100,000
54004056* 100,000
55GA5312* 100,000
55GA5311* 100,000
55GA5350* 100,000
55GA5303* 200,000
25SA5315* 200,000
45405339* 200,000
55GA5304* 400,000
54005310* 400,000
55GA7502* 400,000
55GA7503* 400,000
55GA7504* 400,000
55HF8302* 800,000
55HF8303* 800,000
4-8
Page 11
SERVICE
Classification
Rear of main body
DF-315
FS-109
Part number Actual count
55GA7337*
55YA7350*
200,000
200,000
120A4582* 90,000
120A4582*
120A-458*
129H-474*
129H-472*
90,000
90,000
450,000
90,000
13LP-498* 200,000
13LP-498* 200,000
120H5040* 500,000
120H5040* 500,000
Parts name
Fixing filter
Ozone filter
Paper feed roller
Separation roller
Double feed prevention pad
Pick-up clutch ass'y
Paper dust removal pad
(Tray 2) Paper exit drive roller / A
(Tray 3) Paper exit drive roller / A
* Staple unit (front)
* Staple unit (rear)
Note: Regarding usage frequency, 1 staple of the 3-sheets sort is the condition for assuming a main body count 1.5
million resistance when using the system.
1 OUTLINE
2 ISW
4-9
3 SERVICE
4 SERVICE
Page 12
SERVICE
COPY MATERIALS
[1] PM Parts Kit Composition
1 OUTLINE
1. Composition (100,000 copies/kit)
Cleaning blade
2 ISW
Fixing cleaning roller
Fixing cleaning pad
3 SERVICE
Name
Quantity
1
1
1
Name
Cleaner mount assembly
Charging wire cleaning block (C)
Charging wire cleaning block (D)
Charging corona wire
Quantity
1
1
1
1
Fixing roller / A
4 SERVICE
Charging control plate
1
Charging wire (Transfer/Separation corona)
1
Toner filter (Note)
Note: Unnecessary in the case of the 7045.
2
1
4-10
Page 13
SERVICE
Name
Cleaning pad (10 sheets)
Vanity bag for collection
Dust bag (rubber band)
Developer collecting sheet (rubber band)
Quantity
3
1
1
1
1 OUTLINE
2 ISW
3 SERVICE
Cotton tips (4 pcs.)
1
4 SERVICE
4-11
Page 14
SERVICE
SERVICE MATERIALS LIST
1 OUTLINE
Material No.
2 ISW
00GR00020
3 SERVICE
00GR00170
000V-16-0
000V-17-0
Description Shape
Drum cleaner
Roller cleaner
Plus guard No. 2
Multi-oil
Remark
200 ml
200 ml
25 g
000V-19-0
4 SERVICE
000V-18-1
200 ml
Setting powder
25 g
Cleaning pad
10 pcs
1 pack
4-12
Page 15
SPECIAL TOOLS LIST
SERVICE
Tool No. Description Shape
Temperature sensor
55GAJG01*
120A1052*
7050K002*
00M6-2-00
position adjusting jig
(for fixing)
RADF position adjusting jig
Optics position
adjusting jig
Door switch jig
Quantity
1
1 set
2
1
Remark
2 pieces/set
1 OUTLINE
2 ISW
3 SERVICE
00VD-5000
55GA2025*
120A9711*
120A9712*
Note: The 55GA2025* drum support tool is screwed to the inside of the main body (front panel/left).
Application: Makes it possible to rotate the drum with the drum cartridge removed from the main body.
New pyramid chart
Drum support tool
(Note)
ADJ chart
White chart
1
1
1
1
Instelled below
the total
counter in the
front door
4 SERVICE
4-13
Page 16
SERVICE
1 OUTLINE
2 ISW
3 SERVICE
Tool No.
00VC-2-00
00VD-1000
00VE-1004
Description Shape Remark
Drum cover
Blower brush
Tester
(00VE-1004)
Quantity
1
1
1
4 SERVICE
4-14
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