KONICA MINOLTA CF5001 Service Manual

Service Manual

[Field Service]

CF5001

Dual references may be used on the following:

Official Options name : Popular Options name

AFR-20 : RADF, DF

C-208 : LT

FN-120 : FNS

FN-9 : FNS

Cover Inserter D : PI

PK-5 : PU

TMG-3 TU

In-System Writer : ISW

CF5001 Field Service Ver.1.0 Sep 2003 CONTENTS

CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1

IMPORTANT NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1

SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-10

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-10

SAFETY CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-11

INDICATION OF WARNING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13

I DISASSEMBLY/ASSEMBLY

1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Replacing the dust filter /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Replacing the dust filter /1 and the ozone filter /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Replacing the toner collection box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.4 Angle adjustment of the operation board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.5 Removing and reinstalling the main board unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

2. SCANNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2.1 Screws that must not be removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2.2 Removing and reinstalling the platen glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2.3 Removing and reinstalling the CCD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2.4 Removing and reinstalling the exposure unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

2.5 Removing and reinstalling the exposure lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

2.6 Removing the scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

2.7 Reinstalling the scanner wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

3. WRITING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

3.1 Screw that must not be removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

3.2 Removing and reinstalling the write unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

4. PROCESS UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

4.1 Flow of the disassembly of the process unit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

4.2 Cleaning the charging corona unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

4.3 Cleaning/replacing, removing and reinstalling the charging wire assy

/the charging control plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

4.4 Pulling out the process unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

4.5 Removing and reinstalling the transfer belt unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

4.6 Replacing the belt cleaning brush unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

4.7 Replacing the belt cleaning blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

4.8 Replacing the toner collection sheet /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

4.9 Replacing the belt separation claw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

4.10 Replacing the transfer belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

4.11 Replacing the 1st transfer roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

4.12 Replacing the 2nd transfer roller /U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

4.13 Replacing the drum cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

I DIS./ASSEMBLYII ADJUSTMENTIII SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

i

CONTENTS CF5001 Field Service Ver.1.0 Sep 2003

4.14 Removing and reinstalling the drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

4.15 Replacing the developing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

4.16 Replacing the developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

4.17 Replacing the belt separation claw solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

4.18 Removing and reinstalling the process unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

4.19 Removing and reinstalling the image correction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

I DIS./ASSEMBLY

II ADJUSTMENT

III SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

5. TONER SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

5.1 Opening and closing the toner supply section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

5.2 Replacing the charging dust filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

6. PAPER FEED TRAYS /1 to /3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

6.1 Removing and reinstalling the paper feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

6.2 Removing and reinstalling the paper feed trays /1 to /3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

6.3 Replacing the paper feed roller and the feed rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

6.4 Replacing the double feed prevention rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60

6.5 Replacing the paper feed clutch and the pre-registration clutch . . . . . . . . . . . . . . . . . . . . . . . . . 1-61

6.6 Removing and reinstalling the tray up/down wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62

7. BY-PASS TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66

7.1 Replacing the paper feed roller and the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66

7.2 Replacing the double feed prevention roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68

7.3 Replacing the paper feed clutch /BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69

8. VERTICAL CONVEYANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71

8.1 Removing and reinstalling the vertical conveyance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71

8.2 Replacing the intermediate conveyance clutch /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74

9. FIXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75

9.1 Screws that must not be removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75

9.2 Removing and reinstalling the fixing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76

9.3 Replacing the fixing upper heater lamps /1 and /2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77

9.4 Replacing the fixing lower heater lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79

9.5 Replacing the fixing roller /U, ball bearing /U and the heat insulating sleeve /U . . . . . . . . . . . . . 1-82

9.6 Replacing the fixing roller /L, ball bearing /L and the heat insulating sleeve /L . . . . . . . . . . . . . . 1-84

9.7 Replacing the fixing temperature sensor /3, and removing and reinstalling

the fixing temperature sensor /1 and the thermostat /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86

9.8 Replacing the fixing temperature sensor /4, and removing and reinstalling

the fixing temperature sensor /2 and the thermostat /L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91

9.9 Replacing the fixing drive gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96

9.10 Replacing the fixing cleaning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98

9.11 Replacing the fixing torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100

10. REGISTRATION/ADU/REVERSE/PAPER EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102

10.1 Removing and reinstalling the ADU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102

10.2 Replacing the registration cleaning sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104

10.3 Replacing the separation discharging plate unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105

10.4 Replacing the transfer ground plate unit and the 2nd transfer roller /L . . . . . . . . . . . . . . . . . . . 1-106

10.5 Replacing the registration roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107

10.6 Replacing the intermediate conveyance clutches /2 and /3. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109

10.7 Replacing the ADU conveyance clutches /1 and /2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110

10.8 Replacing the ADU pre-registration clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111

10.9 Replacing the decurler roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112

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CF5001 Field Service Ver.1.0 Sep 2003 CONTENTS

11. OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114

11.1 Installation of the Key Counter Socket (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114

11.2 Installation / Remove of the Memory Unit (OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115

AFR-20 DISASSEMBLY/ASSEMBLY

1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-117

1.1 RADF hinge opening/closing angle adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-117

1.2 Removing and reinstalling the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-119

1.3 Removing and reinstalling the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-120

1.4 Removing and reinstalling the registration roller cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121

2. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122

2.1 Cleaning the no paper sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122

2.2 Removing and reinstalling the paper feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123

2.3 Replacing the paper feed roller and the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-125

2.4 Replacing the double feed prevention roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-127

3. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-129

3.1 Cleaning the registration roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-129

3.2 Cleaning the registration sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-130

3.3 Removing and reinstalling the conveyance belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131

4. REVERSE/PAPER EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-133

4.1 Cleaning the paper exit roller/the paper exit sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-133

4.2 Cleaning the reverse roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-133

5. REMOVING AND REINSTALLING RADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-134

C-208 DISASSEMBLY/ASSEMBLY

1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-135

1.1 Removing and reinstalling the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-135

1.2 Removing and reinstalling the clutch replacement cover and the rear cover . . . . . . . . . . . . . . 1-137

1.3 Removing and reinstalling the paper feed pick-up cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138

2. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-139

2.1 Cleaning the paper dust removing brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-139

2.2 Removing and reinstalling the paper feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-140

2.3 Replacing the paper feed roller and the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141

2.4 Replacing the double feed prevention roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142

2.5 Replacing the paper feed clutch and the pre-registration clutch . . . . . . . . . . . . . . . . . . . . . . . . 1-144

3. TRAY UP/DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-145

3.1 Removing and reinstalling the rear drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-145

3.2 Removing and reinstalling the up/down wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-150

I DIS./ASSEMBLYII ADJUSTMENTIII SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

FN-9/FN120 DISASSEMBLY/ASSEMBLY

1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-159

1.1 Removing and reinstalling of the booklet tray (FN-9 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-159

1.2 Removing and reinstalling of the top cover /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-160

1.3 Removing and reinstalling of the top cover /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-160

1.4 Removing and reinstalling of the side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-161

1.5 Removing and reinstalling of the finisher door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-161

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CONTENTS CF5001 Field Service Ver.1.0 Sep 2003

1.6 Removing and reinstalling of the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-162

1.7 Removing and reinstalling of the main tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-163

1.8 Removing and reinstalling of the main paper exit opening cover . . . . . . . . . . . . . . . . . . . . . . . 1-164

1.9 Removing and reinstalling of the booklet paper exit opening cover (FN-9 only) . . . . . . . . . . . . 1-164

2. CONVEYANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-165

2.1 Replacing the paper exit roller /A (sponge roller). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-165

I DIS./ASSEMBLY

II ADJUSTMENT

2.2 Replacing the intermediate conveyance roller (sponge roller). . . . . . . . . . . . . . . . . . . . . . . . . . 1-167

2.3 Removing and reinstalling of the paper exit opening unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-168

3. MAIN TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-170

3.1 Replacing the tray up/down motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-170

3.2 Removing and reinstalling of the up/down wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-171

4. STACKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-175

4.1 Replacing the stacking assist roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-175

4.2 Removing and reinstalling of the stacker unit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-175

4.3 Removing and reinstalling of the stacker unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-176

5. STAPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-179

5.1 Removing and reinstalling of the stapler unit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-179

5.2 Replacing the clincher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-180

5.3 Replacing the stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-182

PK-5 DISASSEMBLY/ASSEMBLY

1. PUNCH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-185

III SERVICE TOOL

1.1 Replacing the Punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-185

1.2 Cleaning the Punch Edges and Punch Scraps Full PS (PS802) . . . . . . . . . . . . . . . . . . . . . . . . 1-188

Cover Inserter D DISASSEMBLY/ASSEMBLY

1. External Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-189

1.1 Removing / Re-installing the External covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-189

2. Paper feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-191

IV SERVICEV CODE LISTVI DIAGRAMS

2.1 Replacing the Paper feed roller and Feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-191

2.2 Replacing the Double feed prevent roller and Torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-192

TMG-3 DISASSEMBLY/ASSEMBLY

1. TRIMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-193

1.1 Replacing the trimmer knife /U and trimmer knife /L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-193

II ADJUSTMENT

1. HOW TO USE THE ADJUSTMENT SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2. ADJUSTMENTS WHEN REPLACING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. LIST OF ADJUSTMENT ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

4. MODE CHANGE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

4.1 Setting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

4.2 Display transition of 36 modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

4.3 Display transition of 25 modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

4.4 Display transition of Key Operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

iv

CF5001 Field Service Ver.1.0 Sep 2003 CONTENTS

5. CHECKING BY THE P FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

5.1 Checking method of the P function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

6. 25 MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

6.1 List of adjustment items for 25 mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

6.2 Setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

6.3 Setting software DIPSW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

6.4 Paper size setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

6.4.1 Standard size setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

6.4.2 Non-standard size setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

6.4.3 Wide paper setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

6.5 PM count setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

6.5.1 Count reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

6.5.2 Change setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

6.6 Data collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

6.7 Parts counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

6.7.1 Count of special parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

6.7.2 Count of each parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

6.8 Password setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

6.9 Telephone number setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

6.10 M/C serial number setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

6.11 Indication of ROM version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

6.12 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

6.13 Setting date input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

6.14 Board change mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

7. 36 MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

7.1 Setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

7.2 Process adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

7.2.1 High voltage adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

7.2.2 Drum peculiarity adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

7.2.3 Sensor output check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

7.2.4 Exclusive paper setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

7.2.5 Recall standard data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

7.3 Image adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

7.3.1 Magnification adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

7.3.2 Timing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

7.3.3 RADF adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

7.3.4 Centring adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

7.3.5 Non-image area erase check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

7.3.6 Recall standard data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

7.4 Image quality adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

7.4.1 Scanner gamma adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

7.4.2 Printer gamma adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

7.4.3 Sharpness adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

7.4.4 Contrast adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

7.4.5 Image judge adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

7.4.6 ACS adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

7.4.7 Density adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

I DIS./ASSEMBLYII ADJUSTMENTIII SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

v

CONTENTS CF5001 Field Service Ver.1.0 Sep 2003

7.4.8 Tone adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

7.4.9 Recall standard data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

7.5 Running test mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

7.5.1 Setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

7.6 Test pattern output mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

7.7 Test pattern density setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

I DIS./ASSEMBLY

II ADJUSTMENT

III SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

7.8 Finisher adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

7.8.1 Stitch and fold stopper adjustment (FN-9 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

7.8.2 Fold stopper adjustment (FN-9 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

7.8.3 Cover sheet tray size adjustment (Cover Inserter D only) . . . . . . . . . . . . . . . . . . . . . . . . 2-102

7.8.4 Trimming stopper adjustment (TMG-3 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

7.8.5 Punch adjustment (PK-5 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

7.8.6 Three-folding adjustment (FN-9 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

7.8.7 2 positions staple pitch adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

7.9 List output mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

8. 47 MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107

8.1 47 mode/multi mode setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107

8.2 Adjustment data display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

8.3 Hard disk check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

8.4 Input check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

8.5 Output check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121

9. OTHER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131

9.1 Paper feed roller/BP pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131

9.2 Paper feed height (upper limit) adjustment (by-pass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132

9.3 Pick-up movement amount adjustment (by-pass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134

9.4 Paper feed tray /1 to /3 mis-centering adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135

9.5 Paper feed tray/1 to /3 sheet feed pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136

9.6 FNS adjustment of the by-pass conveyance guide plate magnet . . . . . . . . . . . . . . . . . . . . . . . 2-138

9.7 FNS adjustment of the by-pass gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-139

9.8 FNS adjustment of the shift position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141

9.9 FNS adjustment of the paper exit opening solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142

9.10 FNS adjustment of the position of paper exit arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144

9.11 FNS adjustment of the position of alignment plate/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-146

9.12 FNS adjustment of the position of alignment plate/L (only for FN-9) . . . . . . . . . . . . . . . . . . . . . 2-148

9.13 FNS adjustment of the stapling position (flat stapling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150

9.14 FNS adjustment of the stapling position in a vertical direction. . . . . . . . . . . . . . . . . . . . . . . . . . 2-152

9.15 FNS adjustment of the stapling position (flat stapling) (only for FN-9). . . . . . . . . . . . . . . . . . . . 2-156

9.16 FNS adjustment of the angle of the folding stopper (only for FN-9). . . . . . . . . . . . . . . . . . . . . . 2-158

9.17 FNS adjustment of the folding force (only for FN-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-160

9.18 FNS adjustment of the three-holding position (only for FN-9) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-161

9.19 FNS adjustment of the stapler drive belt position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-162

9.20 TU adjustment of the sheet cutting parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-166

9.21 LCT tray mis-centering adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-167

9.22 LCT skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-169

9.23 LCT paper feed roller pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-171

9.24 LCT up/down plate horizontal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-172

9.25 LCT sheet feed pressure adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-173

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9.26 LCT paper feed height (upper limit) adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-174

9.27 LCT pick-up release amount adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-176

9.28 PK Adjusting the tilt of the punch hole position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-178

9.29 Sensitivity adjustment for the PK paper edge sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-179

9.30 PI Centering Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-180

9.31 Adjusting the tilt of PI (when PK punch is used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-181

III SERVICE TOOL

1. ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 Description of the ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 Installing the USB driver for ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.3.1 Board used for the ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.3.2 Data flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.3.3 ISW transfer type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.3.4 Instances of ISW transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

1.3.5 Setup procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

2. UPDATING WITH ISW Trns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

2.1 Setting Up ISW Trns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

2.1.1 Installing the application program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

2.1.2 Setting up ISW Trns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

2.1.3 ISW Trns Main Window Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

2.1.4 Parallel port setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

2.2 Copying Transfer Data (Update Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

2.3 Connecting the CF5001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

2.4 Updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

2.4.1 Update operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

2.4.2 Checking the ROM version of the copier (before updating). . . . . . . . . . . . . . . . . . . . . . . . 3-16

2.4.3 Preparing the copier to transfer.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

2.4.4 Running ISW Trns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

2.4.5 Selecting transfer file (update data) conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

2.4.6 Selecting a version of transfer files (update data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

2.4.7 Verifying transfer files (update data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

2.4.8 Transmitting transfer files (update data). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

2.4.9 Exiting ISW Trns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

2.4.10 Verifying the ROM version of the copier (after updating) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

2.5 ISW Trns Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

2.6 Troubleshooting ISW Trns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

2.6.1 Unable to run ISW Trns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

2.6.2 Send file is not displayed when a combo box item is selected. . . . . . . . . . . . . . . . . . . . . . 3-22

2.6.3 NG produced by a file check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

2.6.4 “??” produced by a file check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

2.6.5 Unsuccessful file transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

2.7 Connecting to the ISW connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

2.7.1 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3 INTERNET ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.1 What is the Internet ISW? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

I DIS./ASSEMBLYII ADJUSTMENTIII SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

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CONTENTS CF5001 Field Service Ver.1.0 Sep 2003

3.2 Operating environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.3 Main features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.4 Initial setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.4.1 Setting on Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.4.2 Setting on Web browser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.5 Internet ISW using E-Mail remote notification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

I DIS./ASSEMBLY

II ADJUSTMENT

III SERVICE TOOL

3.5.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3.5.2 Transmitting E-Mail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.6 Internet ISW using Web utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.6.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.6.2 How to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.7 Precautions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.7.1 Prior announcement to administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.7.2 If power failure occurs during data rewriting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.7.3 ISW of multiple programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.7.4 If ISW fails in low power mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.8 Proxy server authentication in Internet ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.8.1 What is a proxy server? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.8.2 Authentication of proxy server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.8.3 Type and command list for authentication on proxy server . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.8.4 Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

4 MAIL REMOTE NOTIFICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

4.1 What is the Mail remote notification system?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

4.2 Operation environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

4.3 Initial setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

4.4 How to use the Mail remote notification system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

4.5 Disabling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

IV SERVICE

1. SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

IV SERVICEV CODE LISTVI DIAGRAMS

1.1 Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.2 Maintenance items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.3 Periodic check items (main body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

1.4 Periodic check items (AFR-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

1.5 Periodic check items (C-208). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

1.6 Periodic check items (FN-120/FN-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

1.7 Periodic check items (Cover Inserter D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

1.8 Periodic check items (TMG-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

1.9 Replacement parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

1.10 Important maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

2. COPY MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

2.1 Product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

2.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

2.3 PM parts kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

3. SERVICE MATERIAL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4. CE TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

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V CODE LIST

1. JAM CODE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2. ERROR CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

3. ABOUT ABNORMAL UNIT ISOLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

VI DIAGRAMS

1. PARTS LAYOUT DRAWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.1 CF5001 parts layout drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.2 AFR-20 parts layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

1.3 C-208 parts layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

1.4 FN-120/FN-9 parts layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

1.5 TMG-3 parts layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

2. CONNECTOR LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

2.1 Main Body connector layout drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

2.2 AFR-20 connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

2.3 C-208 connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

2.4 FN-120/FN-9 connector layout drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

2.5 TMG-3 connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

3. TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

3.1 Main Body timing chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

3.2 AFR-20 timing chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

3.3 C-208 timing chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

3.4 FN-120/FN-9 timing chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

3.5 TMG-3 timing chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

4. OVERALL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

4.1 AFR-20 Overall Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

4.2 C-208 Overall Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

4.3 FN-120/FN-9 Overall Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

4.4 TMG-3 Overall Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

4.5 Cover Inserter D Overall Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67

4.6 PK-5 Overall Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68

5. APPENDIX

5.1 CF5001 Overall Wiring Diagram (1/8)

5.2 CF5001 Overall Wiring Diagram (2/8)

5.3 CF5001 Overall Wiring Diagram (3/8)

5.4 CF5001 Overall Wiring Diagram (4/8)

5.5 CF5001 Overall Wiring Diagram (5/8)

5.6 CF5001 Overall Wiring Diagram (6/8)

5.7 CF5001 Overall Wiring Diagram (7/8)

5.8 CF5001 Overall Wiring Diagram (8/8)

I DIS./ASSEMBLYII ADJUSTMENTIII SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

ix

CONTENTS CF5001 Field Service Ver.1.0 Sep 2003

I DIS./ASSEMBLY

II ADJUSTMENT

III SERVICE TOOL

IV SERVICEV CODE LISTVI DIAGRAMS

Blank page

x

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the Safety and Important Warning Items described below to understand them before doing ser-

vice work.

IMPORTANT NOTICE

Because of possible hazards to an inexperienced person servicing this copier as well as the risk of damage to

the copier, Minolta Corporation strongly recommends that all servicing be performed only by Minolta-trained ser-

vice technicians.

Changes may have been made to this copier to improve its performance after this Service manual was printed.

Accordingly, Minolta Corporation does not warrant, either explicitly or implicitly, that the information contained in

this Service manual is complete and accurate.

The user of this Service manual must assume all risks of personal injury and/or damage to the copier while ser-

vicing the copier for which this Service manual is intended.

Therefore, this Service manual must be carefully read before doing service work both in the course of technical

training and even after that, for performing maintenance and control of the copier properly.

Keep this Service manual also for future service.

DESCRIPTION ITEMS FOR DANGER, WARNING AND

CAUTION

In this Service manual, each of three expressions “ DANGER”, “ WARNING”, and “ CAUTION” is defined

as follows together with a symbol mark to be used in a limited meaning.

When servicing the copier, the relevant works (disassembling, reassembling, adjustment, repair, maintenance,

etc.) need to be conducted with utmost care.

DANGER

WARNING

CAUTION

Symbols used for safety and important warning items are defined as follows:

:Precaution when using the copier.

:Prohibition when using the copier.

:Action having a high possibility of suffering death or serious injury

:Action having a possibility of suffering death or serious injury

:Action having a possibility of suffering a slight wound, medium trouble, and

property damage

General precaution Electric hazard High temperature

General prohibition Do not touch with wet hand Do not disassemble

:Direction when using the copier.

General instruction

S-1

Unplug

Ground/Earth

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY WARNINGS

1. MODIFICATIONS NOT AUTHORIZED BY MINOLTA

Minolta copiers are renowned for their high reliability. This reliability is achieved through high-quality design and

a solid service network.

Copier design is a highly complicated and delicate process where numerous mechanical, physical, and electrical

aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For

this reason, unauthorized modifications involve a high risk of degradation in performance and safety. Such mod-

ifications are therefore strictly prohibited. the points listed below are not exhaustive, but they illustrate the rea-

soning behind this policy.

DANGER : PROHIBITED ACTIONS

• Using any cables or power cord not specified by Minolta.

• Using any fuse or thermostat not specified by Minolta. Safety will not be

assured, leading to a risk of fire and injury.

• Disabling fuse functions or bridging fuse terminals with wire, metal clips, sol-

der or similar object.

• Disabling relay functions (such as wedging paper between relay contacts)

• Disabling safety functions (interlocks, safety circuits, etc.) Safety will not be

assured, leading to a risk of fire and injury.

• Making any modification to the copier unless instructed by Minolta.

• Using parts not specified by Minolta.

S-2

SAFETY AND IMPORTANT WARNING ITEMS

2. CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Minolta copiers are extensively tested before shipping, to ensure that all applicable safety standards are met, in

order to protect the customer and customer engineer (hereafter called the CE) from the risk of injury. However,

in daily use, any electrical equipment may be subject to parts wear and eventual failure. In order to maintain

safety and reliability, the CE must perform regular safety checks.

2.1 Power Supply

WARNING: Wall Outlet

• Check that mains voltage is as specified. Plug the power cord into the dedi-

cated wall outlet with a capacity greater than the maximum power consump-

tion.

If excessive current flows in the wall outlet, fire may result.

• If two or more power cords can be plugged into the wall outlet, the total load

must not exceed the rating of the wall outlet.

If excessive current flows in the wall outlet, fire may result.

kw

WARNING: Power Plug and Cord

• Make sure the power cord is plugged in the wall outlet securely.

Contact problems may lead to increased resistance, overheating, and the

risk of fire.

• Check whether the power cord is damaged. Check whether the sheath is

damaged.

If the power plug, cord, or sheath is damaged, replace with a new power

cord (with plugs on both ends) specified by Minolta. Using the damaged

power cord may result in fire or electric shock.

• When using the power cord (inlet type) that came with this copier, be sure to

observe the following precautions:

a. Make sure the copier-side power plug is securely inserted in the socket

on the rear panel of the copier.

Secure the cord with a fixture properly.

b. If the power cord or sheath is damaged, replace with a new power cord

(with plugs on both ends) specified by Minolta.

If the power cord (inlet type) is not connected to the copier securely, a

contact problem may lead to increased resistance, overheating, and risk

of fire.

• Check whether the power cord is not stepped on or pinched by a table and

so on.

Overheating may occur there, leading to a risk of fire.

S-3

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Power Plug and Cord

• Do not bundle or tie the power cord.

Overheating may occur there, leading to a risk of fire.

• Check whether dust is collected around the power plug and wall outlet.

Using the power plug and wall outlet without removing dust may result in

fire.

• Do not insert the power plug into the wall outlet with a wet hand.

The risk of electric shock exists.

• When unplugging the power cord, grasp the plug, not the cable.

The cable may be broken, leading to a risk of fire and electric shock.

WARNING: Wiring

• Never use multi-plug adapters to plug multiple power cords in the same out-

let.

If used, the risk of fire exists.

• When an extension cord is required, use a specified one.

Current that can flow in the extension cord is limited, so using a too long

extension cord may result in fire.

Do not use an extension cable reel with the cable taken up. Fire may

result.

WARNING: Ground Lead

• Check whether the copier is grounded properly.

If current leakage occurs in an ungrounded copier, you may suffer electric

shock while operating the copier. Connect the ground lead to one of the

following points:

a. Ground terminal of wall outlet

b. Ground terminal for which Class D work has been done

S-4

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Ground Lead

• Pay attention to the point to which the ground lead is connected.

Connecting the ground lead to an improper point such as the points listed

below results in a risk of explosion and electric shock:

a. Gas pipe (A risk of explosion or fire exists.)

b. Lightning rod (A risk of electric shock or fire exists.)

c. Telephone line ground (A risk of electric shock or fire exists in the case

of lightning.)

d. Water pipe or faucet (It may include a plastic portion.)

2.2. Installation Requirements

WARNING: Prohibited Installation Place

• Do not place the copier near flammable materials such as curtains or volatile

materials that may catch fire.

A risk of fire exists.

• Do not place the copier in a place exposed to water such as rain water.

A risk of fire and electric shock exists.

WARNING: Nonoperational Handling

• When the copier is not used over an extended period of time (holidays, etc.),

switch it off and unplug the power cord.

Dust collected around the power plug and outlet may cause fire.

CAUTION: Temperature and Humidity

• Do not place the copier in a place exposed to direct sunlight or near a heat

source such as a heater.

A risk of degradation in copier performance or deformation exists.

Do not place the copier in a place exposed to cool wind.

Recommended temperature and humidity are as follows:

Temperature: 10 °C to 30 °C

Humidity: 10 % to 80 % (no dew condensation)

Avoid other environments as much as possible.

CAUTION: Ventilation

• Do not place the copier in a place where there is much dust, cigarette smoke,

or ammonia gas.

Place the copier in a well ventilated place to prevent machine problems

and image faults.

S-5

SAFETY AND IMPORTANT WARNING ITEMS

CAUTION: Ventilation

• The copier generates ozone gas during operation, but it is not sufficient to be

harmful to the human body.

If a bad smell of ozone is present in the following cases, ventilate the room.

a. When the copier is used in a poorly ventilated room

b. When taking a lot of copies

c. When using multiple copiers at the same time

CAUTION: Vibration

• When installing the copier, read the Installation Guide thoroughly. Be sure to

install the copier in a level and sturdy place.

Constant vibration will cause problems.

• Be sure to lock the caster stoppers.

In the case of an earthquake and so on, the copier may slide, leading to a

injury.

CAUTION: Inspection before Servicing

• Before conducting an inspection, read all relevant documentation (Service

manual, technical notices, etc.) and proceed with the inspection following the

prescribed procedure in safety clothes, using only the prescribed tools. Do

not make any adjustment not described in the documentation.

If the prescribed procedure or tool is not used, the copier may break and a

risk of injury or fire exists.

• Before conducting an inspection, be sure to disconnect the power plugs from

the copier and options.

When the power plug is inserted in the wall outlet, some units are still pow-

ered even if the POWER switch is turned OFF. A risk of electric shock

exists.

• The area around the fixing unit is hot.

You may get burnt.

DANGER: Work Performed with the Copier Powered

• Take every care when making adjustments or performing an operation check

with the copier powered.

If you make adjustments or perform an operation check with the external

cover detached, you may touch live or high-voltage parts or you may be

caught in moving gears or the timing belt, leading to a risk of injury.

S-6

SAFETY AND IMPORTANT WARNING ITEMS

DANGER: Work Performed with the Copier Powered

• Take every care when servicing with the external cover detached.

High-voltage exists around the drum unit. A risk of electric shock exists.

WARNING: Safety Checkpoints

• Check the exterior and frame for edges, burrs, and other damages.

The user or CE may be injured.

• Do not allow any metal parts such as clips, staples, and screws to fall into the

copier.

They can short internal circuits and cause electric shock or fire.

• Check wiring for squeezing and any other damage.

Current can leak, leading to a risk of electric shock or fire.

• When disconnecting connectors, grasp the connector, not the cable.

(Specifically, connectors of the AC line and high-voltage parts)

Current can leak, leading to a risk of electric shock or fire.

• Carefully remove all toner remnants and dust from electrical parts and elec-

trode units such as a charging corona unit.

Current can leak, leading to a risk of copier trouble or fire.

• Check high-voltage cables and sheaths for any damage.

Current can leak, leading to a risk of electric shock or fire.

• Check electrode units such as a charging corona unit for deterioration and

sign of leakage.

Current can leak, leading to a risk of trouble or fire.

• Before disassembling or adjusting the write unit incorporating a laser, make

sure that the power cord has been disconnected.

The laser light can enter your eye, leading to a risk of loss of eyesight.

• Do not remove the cover of the write unit. Do not supply power with the write

unit shifted from the specified mounting position.

The laser light can enter your eye, leading to a risk of loss of eyesight.

• When replacing a lithium battery, replace it with a new lithium battery speci-

fied in the Parts Guide Manual. Dispose of the used lithium battery using the

method specified by local authority.

Improper replacement can cause explosion.

S-7

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Safety Checkpoints

• After replacing a part to which AC voltage is applied (e.g., optical lamp and

fixing lamp), be sure to check the installation state.

A risk of fire exists.

• Check the interlock switch and actuator for loosening and check whether the

interlock functions properly.

If the interlock does not function, you may receive an electric shock or be

injured when you insert your hand in the copier (e.g., for clearing paper

jam).

• Make sure the wiring cannot come into contact with sharp edges, burrs, or

other pointed parts.

Current can leak, leading to a risk of electric shock or fire.

• Make sure that all screws, components, wiring, connectors, etc. that were

removed for safety check and maintenance have been reinstalled in the orig-

inal location. (Pay special attention to forgotten connectors, pinched cables,

forgotten screws, etc.)

A risk of copier trouble, electric shock, and fire exists.

DANGER: HANDLING OF SERVICE MATERIALS

• Toner and developer are not harmful substances, but care must be taken not

to breathe excessive amounts or let the substances come into contact with

eyes, etc. It may be stimulative.

If the substances get in the eye, rinse with plenty of water immediately.

When symptoms are noticeable, consult a physician.

• Never throw the used cartridge and toner into fire.

You may be burned due to dust explosion.

DANGER : HANDLING OF SERVICE MATERIALS

• Unplug the power cord from the wall outlet.

Drum cleaner (isopropyl alcohol) and roller cleaner (acetone-based) are

highly flammable and must be handled with care. A risk of fire exists.

S-8

SAFETY AND IMPORTANT WARNING ITEMS

DANGER : HANDLING OF SERVICE MATERIALS

• Do not replace the cover or turn the copier ON before any solvent remnants

on the cleaned parts have fully evaporated.

A risk of fire exists.

• Use only a small amount of cleaner at a time and take care not to spill any

liquid. If this happens, immediately wipe it off.

A risk of fire exists.

• When using any solvent, ventilate the room well.

Breathing large quantities of organic solvents can lead to discomfort.

3. MEASURES TO TAKE IN CASE OF AN ACCIDENT

• If an accident has occurred, the distributor who has been notified first must immediately take emergency

measures to provide relief to affected persons and to prevent further damage.

• If a report of a serious accident has been received from a customer, an on-site evaluation must be carried

out quickly and Minolta Corporation must be notified.

• To determine the cause of the accident, conditions and materials must be recorded through direct on-site

checks, in accordance with instructions issued by Minolta Corporation.

• For reports and measures concerning serious accidents, follow the regulations given in “Serious Accident

Report/Follow-up Procedures”.

4. CONCLUSION

• Safety of users and customer engineers depends highly on accurate maintenance and administration.

Therefore, safety can be maintained by the appropriate daily service work conducted by the customer

engineer.

• When performing service, each copier on the site must be tested for safety. The customer engineer must

verify the safety of parts and ensure appropriate management of the equipment.

S-9

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY INFORMATION

IMPORTANT INFORMATION

The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration implemented

regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products mar-

keted in the United States.

This copier is certified as a “Class 1” laser product under the U.S.

Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation

Control for Health and Safety Act of 1968. Since radiation emitted inside this copier is completely confined within

protective housings and external covers, the laser beam cannot escape during any phase of normal user opera-

tion.

S-10

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY CIRCUITS

This machine is provided with the following safety circuits to prevent machine faults from resulting in serious

accidents.

•

Overall protection circuit

•

Fixing upper lamp /1 (L2), Fixing upper lamp /2 (L3), Fixing lower lamp (L4) overheating prevention circuit

These safety circuits are described below to provide

the service engineer with a renewed awareness of

them in order to prevent servicing errors that may

impair their functions.

1. Overall protection circuit

CBR1

NF

CBR2

1.1 Protection by circuit breaker /1 (CBR1) and circuit breaker /2 (CBR2)

CBR1 and CBR2 interrupt the AC line instantaneously when an excessive current flows due to a short in

the AC line.

CAUTION:

The CBR1 and CBR2 functions must not be deactivated under any circumstances.

8050sf001

S-11

SAFETY AND IMPORTANT WARNING ITEMS

2. Fixing upper lamp /1 (L2), Fixing upper lamp /2 (L3), Fixing lower lamp (L4) overheating

prevention circuit

PRCB ACDB

TH1

TH3

TH2

TH4

Control
section

AC driver

section

RL1

RL1

FHCB

L2

TS1

L3

TS2

L4

8050sf002e

2.1 Protection by software

The output voltage from fixing temperature sensor /1 (TH1) and fixing temperature sensor /2 (TH2) is read

by the CPU. If this voltage is abnormal, L2, L3, and L4 are turned OFF by opening main relay (RL1).

CAUTION:

• The clearance between the fixing upper roller and TH1 and the clearance between the fixing

lower roller and TH2 must not be changed. When replacing them, make sure to comply with the

specified clearances.

• The RL1 function must not be deactivated under any circumstances.

2.2 Protection by the hardware circuit

The output voltages from fixing temperature sensor /1 (TH1), fixing temperature sensor /2 (TH2), fixing

temperature sensor /3 (TH3), and fixing temperature sensor /4 (TH4) are compared with the abnormality

judgment reference value in the comparator circuit. If the output voltage from TH1, TH2, TH3, or TH4

exceeds the reference value, L2, L3, and L4 are turned OFF by opening RL1.

CAUTION:

• The clearance between the fixing upper roller and TH1 and the clearance between the fixing

lower roller and TH2 must not be changed. When replacing them, make sure to comply with the

specified clearances.

• Periodically check the contact between the fixing upper roller and TH3 and the contact

between the fixing lower roller and TH4, and replace them if any abnormality is detected.

• The RL1 function must not be deactivated under any circumstances.

2.3 Protection by thermostat /1 (TS1) and thermostat /2 (TS2)

When the temperature of the fixing upper roller exceeds the specified value, TS1 is turned OFF, thus inter-

rupting the power to L2 and L3 directly. When the temperature of the fixing lower roller exceeds the speci-

fied value, TS2 is turned OFF, thus interrupting the power to L4 directly.

CAUTION:

Do not use any other electrical conductor in place of TS1 and TS2.

S-12

SAFETY AND IMPORTANT WARNING ITEMS

INDICATION OF WARNING ON THE MACHINE

Caution labels shown below are attached in some areas on/in the machine.

When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid

burns and electric shock.

CAUTION

Please adhere to all caution labels to avoid burns or injury.

S-13

8050sf003e

SAFETY AND IMPORTANT WARNING ITEMS

CAUTION

-

Please adhere to all caution labels to avoid burns or injury.

S-14

8050sf004e

SAFETY AND IMPORTANT WARNING ITEMS

CAUTION

-

Please adhere to all caution labels to avoid burns or injury.

S-15

8050sf005e

SAFETY AND IMPORTANT WARNING ITEMS

CAUTION

-

Please adhere to all caution labels to avoid burns or injury.

S-16

8050sf006e

SAFETY AND IMPORTANT WARNING ITEMS

8050sf007e

CAUTION

-

Please adhere to all caution labels to avoid burns or injury..

S-17

SAFETY AND IMPORTANT WARNING ITEMS

Unplug the machine before removing platen glass.

Debrancher le copieur avant de retirer la vitre d'exposition.

Desenchufe la maquina antes de quitar el vidrio.

Desconecte a unidade da tomada antes de remover o vidro de exposicao.

PS

~

8050sf008e

CAUTION

-

Please adhere to all caution labels to avoid burns or injury.

S-18

CF5001 Field Service Ver.1.0 Sep 2003 EXTERIOR

I DISASSEMBLY/ASSEMBLY

Caution:

• Make sure the power cord of the copier is

unplugged from the power outlet before dis-

assembly or assembly.

1. EXTERIOR

1.1 Replacing the dust filter /2

A. Periodically replaced parts/cycle

• Dust filter /2: Every 100,000 copies

B. Procedure

1. Loosen 2 screws [1] and remove the filter cover

[2].

[1]

I DIS./ASSEMBLY

2. Pull out the dust filter /2 [2] from the filter cover

[1].

3. Reinstall the above parts following the removal

steps in reverse.

1-1

[1]

[2]

[2]

8050ma3001

8050ma3002

EXTERIOR CF5001 Field Service Ver.1.0 Sep 2003

1.2 Replacing the dust filter /1
and the ozone filter /1

A. Periodically replaced parts/cycle

• Dust filter /1: Every 100,000 copies

• Ozone filter /1: Every 100,000 copies

I DIS./ASSEMBLY

B. Procedure

1. Loosen 4 screws [1] and remove the side cover /

2 [2].

[1]

2. Pull out the filter replacement duct [1].

[1]

[1][2]

8050ma3004

8050ma3005

1-2

CF5001 Field Service Ver.1.0 Sep 2003 EXTERIOR

3. Remove the 2 dust filters /1 [2] and the ozone fil-

ter /3 [3] from the filter replacement duct [1].

[1] [3] [2]

4. Reinstall the above parts following the removal

steps in reverse.

Note:

• When reinstalling the ozone filter /1, be care-

ful not snap and fracture it.

• When reinstalling the dust filter /1, be sure to

press it against the stopper section [4] of the

filter replacement duct.

I DIS./ASSEMBLY

[4]

8050ma3006

1-3

EXTERIOR CF5001 Field Service Ver.1.0 Sep 2003

1.3 Replacing the toner collec­tion box

A. Periodically replaced parts/cycle

• Toner collection box: Every 50,000 copies (to be

replaced by the user)

I DIS./ASSEMBLY

B. Procedure

1. Open the toner collection door [1] and pull out

the toner collection box [2].

[1]

[2]

8050ma3007

1-4

CF5001 Field Service Ver.1.0 Sep 2003 EXTERIOR

2. Peel the label [2] off the toner collection box [1]

and plug the entrance of the toner collection box

[1].

3. Reinstall the above parts following the removal

steps in reverse.

I DIS./ASSEMBLY

[2]

[1]

[3]

[2]

8050ma3008

1-5

EXTERIOR CF5001 Field Service Ver.1.0 Sep 2003

1.4 Angle adjustment of the
operation board

Note:

• The operation board can be set at the two

steps of 7 and 18 degrees depending on the

I DIS./ASSEMBLY

front cover /2 provided or not provided.

When the front cover /2 provided: 7 degrees

When the front cover /2 not provided: 18

degrees

A. Procedure

1. Open the front door [1] and the toner supply

door [2].

2. Remove 2 screws [3] and release the fixing of

the operation board [4].

3. With the operation board raised up, remove the

front cover /2 [5] (when the angle is changed

from 7 to 18 degrees).

4. Fasten the operation board [4] with 2 screws [3].

5. Close the front door [1] and the toner supply

door [2].

[4][3] [5] [3]

Note:

• When changing the angle of the operation

board from 18 to 7 degrees, install the front

cover /2 by following Step 3.

[1]

[2]

8050ma3009

1-6

CF5001 Field Service Ver.1.0 Sep 2003 EXTERIOR

1.5 Removing and reinstalling the main board unit

A. Procedure

1. Remove the platen cover.

2. Remove the filter cover. (See "1.1 Replacing the

dust filter /2.")

3. Loosen 2 screws [1], remove 13 screws [2], and

then remove the rear cover [3].

4. Remove the side cover /2. (See "1.2 Replacing

the dust filter /1 and the ozone filter /1.")

5. Remove the screws [5], one for each, and then

remove the 2 original cover supports [6].

6. Remove 2 caps [4].

7. Remove 4 screws [7] and then remove the scan-

ner cover /R [8].

[8] [7] [6] [5] [4][6] [5]

[4]

[2]

[2]

I DIS./ASSEMBLY

8. Remove the special screw [1].

9. Remove 4 screws [2] and then remove the

board seal plate /2 [3].

[2]

[1][3]

[1][3]

8050ma3010

1-7

[2]

8050ma3011

EXTERIOR CF5001 Field Service Ver.1.0 Sep 2003

10. Remove 5 connectors [1].

11. With the lock lever [2] brought down this side,

[1] [3] [1]

release the lock and pull out the ribbon cable [3].

I DIS./ASSEMBLY

[3]

[2]

[1]

Note:

• Move the lock lever [1] forward, then insert the

ribbon cable [2] firmly into the connector

while ensuring that the conductive face of the

ribbon cable [3] is positioned on the opposite

side of the lock lever.

[2]

[1]

8050ma3012

[3]

1-8

CF5001 Field Service Ver.1.0 Sep 2003 EXTERIOR

• Then with the lock lever [1] brought back to its

original position, lock the ribbon cable [2].

[2]

[1]

I DIS./ASSEMBLY

12. Remove 2 screws [1] and then remove the

board seal plate /4 [2].

[2]

[1]

8050ma3013

1-9

EXTERIOR CF5001 Field Service Ver.1.0 Sep 2003

13. Remove a bracket cable clamp [1].

14. Remove 2 connectors [2].

[3][4]

15. Remove 4 screws [3] and then remove the main

board unit [4].

16. Reinstall the above parts following the removal

steps in reverse.

I DIS./ASSEMBLY

Note:

• When removing or reinstalling the main board

unit, be careful that the battery on the memory

board (MB) does not touch with the frame.

[2]

[3][1]

8050ma3014

1-10

CF5001 Field Service Ver.1.0 Sep 2003 SCANNER

2. SCANNER

2.1 Screws that must not be removed

Note:

Screws that have been paint-locked are not

allowed to be removed. So, be careful not to

remove them.

[1]

I DIS./ASSEMBLY

2.2 Removing and reinstalling the platen glass

A. Procedure

1. Remove 3 screws [1] and then remove the origi-

nal positioning plate /R [2].

2. Remove 2 screws [3] and then remove the origi-

nal positioning plate /L [4].

3. Remove 2 screws [5] and the remove the scan-

ner cover /M [6].

4. Remove the platen glass [7].

5. Reinstall the above parts following the removal

steps in reverse.

Note:

• Be sure to reinstall the platen glass with its

white reference plate [8] up.

[1][1][1]

8050ma3015

[5][1] [6][4] [2]

1-11

[7][3] [8]

8050ma3016

SCANNER CF5001 Field Service Ver.1.0 Sep 2003

2.3 Removing and reinstalling the CCD unit

A. Procedure for removal

1. Remove the platen glass. (See "2.2 Removing

and reinstalling the platen glass.")

I DIS./ASSEMBLY

2. Remove the connector [1].

3. Remove 9 screws [2] and then remove the CCD

cover [3].

4. Remove the screw [4] and then remove the rib-

bon cable cover [5].

[4] [5] [3]

5. With the lock lever [1] brought down, release the

lock and pull out the ribbon cable [2].

Note:

• Move the lock lever [1] downward, then insert

the ribbon cable [2] firmly into the connector

while ensuring that the conductive face of the

ribbon cable is positioned on the opposite

side of the lock lever.

• Then bring the lock lever back to its original

position, lock the ribbon cable.

1-12

[2][1]

[2][1]

8050ma3141

8050ma3142

CF5001 Field Service Ver.1.0 Sep 2003 SCANNER

6. Remove 4 screws [1] and then remove the CCD

unit [2].

[1] [2]

Note:

• Be careful not to remove screws other than

those mentioned above. Otherwise, it

becomes necessary to make all sort of optical

adjustments which cannot be handled in the

field.

• Be careful not to touch the lens. This may

result in poor images.

7. Reinstall the above parts following the removal

steps in reverse.

[1]

8050ma3143

I DIS./ASSEMBLY

1-13

SCANNER CF5001 Field Service Ver.1.0 Sep 2003

2.4 Removing and reinstalling the exposure unit

A. Procedure for removal

1. Remove the slit glass. (See "2.2 Removing and

reinstalling the slit glass.")

I DIS./ASSEMBLY

2. Open the toner supply section. (See "5.1 Open-

ing and closing of the toner supply section.")

3. Remove 2 caps [2].

4. Remove 6 screws [1].

5. After removing the relay connector [4] with the

scanner cover /F [3] shifted to the front side

once, remove the scanner cover /F [3].

[1][2] [2]

[3]

[4]

[1]

8050ma3017

1-14

CF5001 Field Service Ver.1.0 Sep 2003 SCANNER

6. Remove 2 screws [1] and release the fixing of

the exposure unit [2].

[2][5][1] [4]

7. Rotate the exposure unit [2] while holding it hor-

izontally, pull it up and place it upon the scanner

room [6].

[3]

8050ma3018

[6] [5]

[1]

I DIS./ASSEMBLY

8. Remove the connector [1].

9. Remove the screw [2] and release the cable [4]

from the cable holder [3].

10. Remove the exposure unit [5].

[4]

[5][1][2] [3]

8050ma3019

1-15

SCANNER CF5001 Field Service Ver.1.0 Sep 2003

B. Procedure for reinstallation

1. Set the exposure unit [1] into the main body.

2. Move the V-mirror unit [2] to the paper exit side,

[2] [1][4]

and pass an optical positioning jig [3] through

each of the exposure unit [1] and the V-mirror

unit [2] from the front side.

I DIS./ASSEMBLY

Note:

• When reinstalling the exposure unit, be sure

to use the optical positioning jig.

3. Fasten the exposure unit [1] with 2 screws [4].

4. Remove 2 optical positioning jigs [3].

5. For the subsequent steps, reinstall the parts fol-

lowing the removal steps in reverse.

[3]

[4]

8050ma3020

1-16

CF5001 Field Service Ver.1.0 Sep 2003 SCANNER

2.5 Removing and reinstalling the exposure lamp

A. Procedure

1. Remove the exposure unit. (See "2.4 Removing

and reinstalling the exposure unit.")

2. Cut the binding band [1] and release the fixing

of the cable [2].

3. Remove 2 screws [3] and then remove the HP

detection plate [4].

4. Remove 2 screws [5] and then remove L1 (expo-

sure lamp) [6].

5. Reinstall the above parts following the removal

steps in reverse.

[6][1] [3]

I DIS./ASSEMBLY

[2] [4] [5]

8050ma3021

1-17

SCANNER CF5001 Field Service Ver.1.0 Sep 2003

2.6 Removing the scanner wire

A. Procedure

1. Remove the exposure unit. (See "2.4 Removing

and reinstalling the exposure unit.")

2. Remove 2 caps [1].

I DIS./ASSEMBLY

3. Remove the screw [2] and remove the scanner

cover /R [3].

4. Remove the screw [4] and remove the scanner

cover /L [5].

[1] [4] [1][3] [2]

5. Loosen the screws [1], one for each, and

release the fixing of two spring fixing plates [2].

[5]

[2]

[1]

8050ma3022

8050ma3023

1-18

CF5001 Field Service Ver.1.0 Sep 2003 SCANNER

6. Remove the wire terminal [3] of the scanner wire

/R [2] from the spring fixing plate [1], and then

remove the scanner wire /R [2] in the order of

the pulley /3 [4], the outside of the V-mirror pul-

ley [5] and the pulley /2 [6].

7. Remove the metal bead [8] of the scanner wire /

R [2] from the wire stopper [7], and then remove

the scanner wire /R [2] in the order of the inside

of the V-mirror pulley [5] and the pulley /1 [9].

[5]

[3][6][4]

8. Remove the scanner wire /R [2] from the drive

pulley [10].

9. Remove the scanner wire /F [11] by following

Steps 5 to 7.

Note:

• The scanner wires /F and /R are installed sym-

metrically.

[9]

[10]

[2]

I DIS./ASSEMBLY

[2]

[3]

[1]
[11]

1-19

[2] [8][7]

8050ma3024

SCANNER CF5001 Field Service Ver.1.0 Sep 2003

2.7 Reinstalling the scanner wire

A. Procedure

1. Move the V-mirror unit [1] to the paper exit side,

and pass the optical positioning jig [2] through

the V-mirror unit [1] from the front side.

I DIS./ASSEMBLY

Note:

• Be careful not to damage the mirror with the

jig.

• When reinstalling the scanner wire, be sure to

fasten the V-mirror with the optical position-

ing jig.

[1]

2. Drop into the fitting hole of the drive pulley [4] a

metal bead [3] provided at the center of each of

the scanner wires /F [1] and /R [2], and starting

from this hole, wind the scanner wire 2.5 turns

[5] outwards and 3.5 turns [6] inwards.

Note:

• For the scanner wires /F and /R, common

wires are used.

• Be sure to wind each of scanner wires so that

the wire terminal is on the outside and the

metal bead [7] on the inside.

• Be sure to wind each of scanner wires so that

both ends of the wire come out under the

drive pulley.

• Be sure to wind each of the scanner wires

closely around the drive pully with no wire

running on another wire.

[8]

[2]

[4]

[3]

[7]

[6]

[5]

[5]

[6]

[7]

[3]

[1]

[4]

[2]

8050ma3025

[8]

[4]

8050ma3026

3. After winding the scanner wires /F and R/, be

sure to fasten each wire end with a tape [8] so

that it will not come off.

1-20

CF5001 Field Service Ver.1.0 Sep 2003 SCANNER

4. Pass the scanner wire /R [2] on the metal bead

[3] side (inside) which is wound around the drive

pulley [1] through the pulley /1 [4] and the V-mir-

ror pulley [5] in this order, and then hook the

metal bead [3] onto the wire stopper [6].

5. Pass the scanner wire /R [2] on the wire terminal

[7] side (outside) which is wound around the

drive pulley [1] through the pulley /2 [8] and the

outside of V-mirror pulley [5] and the pulley /3 [9]

in this order, and then hook the wire terminal [7]

onto the spring fixing plate [10].

[5]

6. Reinstall the scanner wire /F [11] by following

Steps 4 and 5.

I DIS./ASSEMBLY

[9]

[10]

[2]

[3][6][4]

FRONT

[2]

[3]

[1]
[11]

[2] [8][7]

8050ma3027

1-21

SCANNER CF5001 Field Service Ver.1.0 Sep 2003

7. Tighten the screws [1], one for each, and fasten

the 2 spring fixing plates [2].

[2]

8. For the subsequent steps, reinstall the parts fol-

lowing the removal steps in reverse.

I DIS./ASSEMBLY

[1]

8050ma3140

1-22

CF5001 Field Service Ver.1.0 Sep 2003 WRITING

3. WRITING

3.1 Screw that must not be removed

Note:

• The screws [1] of each unit of the YMCK are

not allowed to be removed. So, be careful not

to remove them.

I DIS./ASSEMBLY

[1]

8050ma3028

1-23

WRITING CF5001 Field Service Ver.1.0 Sep 2003

3.2 Removing and reinstalling the write unit

Warning:

• Be sure that the write unit should not be

I DIS./ASSEMBLY

powered with it slid from its normal instal-

lation position.

• Be sure not to remove the write unit cover

while being supplied with power. Otherwise,

laser beams get into your eyes and you may

lose your sight.

Note:

• Be sure not to remove the write unit cover. Do

not loosen the screws, either.

• When removing the write unit, be careful not

to touch the dust glass (to prevent the mirror

from being stained).

• Be sure not to remove the write unit for at

least two minutes after the main power switch

is turned off.

• When replacing the side cover /1, insert the

prong [1] on the side cover /1 into the notch

on the main body.

[1]

8050ma3175

A. Procedure

1. Open the by-pass tray [1].

2. Loosen 4 screws [2] and remove the side cover /

2 [3].

3. Loosen 5 screws [4] and remove the side cover /

1 [5].

[4] [2][5]

[1]

[3]

8050ma3029

1-24

CF5001 Field Service Ver.1.0 Sep 2003 WRITING

4. Remove 5 relay connectors [1].

5. Remove 10 screws [2] and then remove the fan

[2] [2]

holder /R [3].

I DIS./ASSEMBLY

Note:

• Check the direction where the fan is assem-

bled.

[1] Turn the label side inside.

[2] Turn the label side outside.

6. Remove 2 screws [1] and then remove the write

pressing board [2] while pressing it downward.

7. Remove 2 screws [3] and then remove 2 write

cooling ducts [4].

Note:

• Be sure to hold the upper half of the write

pressing board when removing it.

[4]

[3]

[1]

[1]

[2]

[2][1][2] [3]

8050ma3030

5001ma3030

1-25

[2][3]

8050ma3031

WRITING CF5001 Field Service Ver.1.0 Sep 2003

8. Remove the connectors [1], 2 each, and then

remove the write unit /Y [2], write unit /M [3],

write unit /C [4] and the write unit /K [5].

[2]

[1]

[1]

9. Reinstall the above parts following the removal

steps in reverse.

[3]

I DIS./ASSEMBLY

[4]

[5]

[1]

[1]

8050ma3032

Note:

• The write units /C, /M and /Y are all common.

• The bottom of the write units /C, /M and /Y is

provided with a wire tension spring [1] which

differentiates these three write units from the

write unit /K.

• Be careful not install any other write unit in

the installation place for the write unit /K.

[1]

8050ma3034

1-26

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4. PROCESS UNIT

4.1 Flow of the disassembly of
the process unit section

Open the toner supply section

Open the front fan cover

Pull out the process unit Remove the charging corona unit

Pull out the transfer belt unit

Remove the drum cartridge Remove the developing unit

Remove the process unit

Remove the image correction unit

I DIS./ASSEMBLY

1-27

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.2 Cleaning the charging corona unit

A. Procedure

Note:

I DIS./ASSEMBLY

• The charging corona units are provided for

the four colors of yellow, magenta, cyan and

black. These units are common. Do not reuse

a charging corona unit that was once used for

a color since it has been stuck with the toner

of the color.

1. Open the toner supply section. (See "5.1 Open-

ing and closing the toner supply section.")

2. With the lever [2] of the charging corona unit [1]

pressed down once to the lower right side, pull

out the charging corona unit this side for

removal.

[1]

[2]

8050ma3037

1-28

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

3. Remove a charging cleaning block [3] from the

charging suction assembly [2] provided on the

[3] [1]

outside of the toner supply unit [1].

Note:

• There are two charging cleaning blocks pro-

vided. Be sure to use either of these two

blocks when cleaning the charging corona.

I DIS./ASSEMBLY

4. Holding the charging corona unit [2] so that the

charging control plate [1] comes up, set the

charging cleaning block [3] to the notch and

insert it from under the bottom on the rear side,

and turn it about 45° clockwise.

Note:

• If the charging wire is cleaned with the charg-

ing control plate facing down, there is a risk

that dust that has stuck to the charging wire

sticks to the charging control plate. So, when

cleaning the charging wire, be sure to hold the

charging corona unit so that the charging

control plate comes upward.

5. Clean the charging wire [4] by sliding back and

forth the charging cleaning block [3].

6. Reinstall the above parts following the removal

steps in reverse.

[1]

[2]

[2]

[3]

8050ma3038

8050ma3039

1-29

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.3 Cleaning/replacing, remov­ing and reinstalling
the charging wire assy
/the charging control plate

A. Periodically replaced parts/cycle

I DIS./ASSEMBLY

• Charging wire assy: Every 100,000 copies

• Charging control plate: Every 200,000 copies

• Charging grid spring: Every 200,000 copies

Note:

• The charging corona unit is made up of a

charging wire assy, charging control plate and

a charging grid spring.

B. Procedure

1. Remove the charging corona unit. (See "4.2

Cleaning and replacing the charging corona

unit.")

2. Remove 2 charging control springs [1] and then

remove the charging control plate [2].

3. Clean the charging control plate by blowing off

dust with a blower brush.

4. Reinstall the above parts following the removal

steps in reverse.

Note:

• Be sure to install the charging control plate so

that the side on which the charging control

spring is hooked comes to the front of the

charging corona unit.

• Be sure to install each of the charging control

springs with its tips [3] of both ends point

toward the charging wire.

[2]

[1]

[2]

1-30

[3]

8050ma3040

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4.4 Pulling out the process unit

Note:

• In order to prevent the main body from falling

down, the process unit and the ADU are pro-

vided with a safety mechanism so that they

cannot be pulled out at the same time.

• If the ADU has been pulled out when pulling

out the process unit, be sure to push it back

into the main body.

A. Procedure

1. Open the toner supply section. (See "5.1 Open-

ing and closing the toner supply section.")

2. Loosen the screw [1] and open the front fan

cover [2].

[2]

I DIS./ASSEMBLY

3. Bring down the stand handle /L [1] and the

stand handle /R [2] to the inside at the same

time to release the fixing of the process unit [3].

Then, hold each of the stand handles to pull out

the process unit [3].

4. Reinstall the above parts following the removal

steps in reverse.

1-31

[1]

[1]

8050ma3035

[3]

[2]

8050ma3036

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.5 Removing and reinstalling the transfer belt unit

A. Procedure

1. Pull out the process unit. (See "4.4 Pulling out

the process unit.")

I DIS./ASSEMBLY

2. Loosen the screws [1], 2 each.

3. After turning once the belt positioning shaft [2]

counterclockwise, pull it out for removal.

[2]

[1]

4. Remove the supporting rod [3] from the charg-

ing corona suction assembly [2] provided on the

inside of the toner supply unit [1].

Note:

• The supporting rod is an auxiliary device to

allow a removed transfer belt unit to self

stand. When removing the transfer belt unit,

be sure to make necessary arrangements in

advance.

[1]

[2]

8050ma3043

[3] [1]

8050ma3044

1-32

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

5. With the handle [1] raised up, remove the trans-

fer belt unit [2].

[1]

[2]

Note:

• Be careful not to touch and damage the trans-

fer belt [3] with bare hands.

• Make sure to grab both ends of the handle of

the transfer belt with both hands.

[3]

Hold

Hold

[1]

I DIS./ASSEMBLY

6. Set the supporting rod [2] to the transfer belt unit

[1] to allow it to self stand.

7. Reinstall the above parts following the removal

steps in reverse.

Note:

• Make sure not to touch and damage the trans-

fer belt unit with the drum at installation.

[2]

5001ma3045

[1][2]

8050ma3046

1-33

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

Note:

• When reinstalling the transfer belt unit [1], be

sure to turn the cam [3] clockwise fully until it

[1]

will not turn any more before starting work.

• Be sure to install the transfer belt unit so that

2 transfer support blocks /F [4] and the 2

I DIS./ASSEMBLY

transfer support blocks /R [5] are accompa-

nied with the guide pins [2] provided at two

places each at front and rear.

[2]

• Be sure not to rotate the transfer belt when

the transfer belt unit self stand with a support-

ing rod.

[3]

[2]

[5]

[4]

8050ma3047

1-34

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4.6 Replacing the belt cleaning brush unit

A. Periodically replaced parts/cycle

• Belt cleaning brush unit: Every 600,000 copies

B. Procedure

1. Remove the transfer belt unit. (See "4.5 Remov-

ing and reinstalling the transfer belt unit.")

2. Remove 2 screws [2] while holding the belt

cleaning unit [1] by hand, and then remove the

belt cleaning unit.

3. Replace the belt cleaning brush unit with a new

one.

4. Reinstall the above parts following the removal

steps in reverse.

Note:

• The belt cleaning unit is made up of the belt

cleaning brush unit and the parts listed below.

(For details of these parts, see "4.7 Replacing

the belt cleaning blade" and "4.8 Replacing

the toner collection sheet /1.")

Belt cleaning blade : 1 piece

Blade spring : 2 pieces

Stop ring : 2 pieces

Blade fulcrum shaft : 1 piece

Toner collection sheet /1 : 1 piece

Toner collection sheet /2 : 1 piece

Screw : 3 pieces

• Before installing the belt cleaning unit, apply

the setting powder on the portion [3] on the

transfer belt.

• When reinstalling it, set the guide sections

provided on both sides below the belt clean-

ing unit to the pins of the transfer belt unit,

and then attach the screws.

I DIS./ASSEMBLY

[2][2]

[1]

[3]

8050ma3048

1-35

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.7 Replacing the belt cleaning blade

A. Periodically replaced parts/cycle

• Belt cleaning blade: Every 100,000 copies

I DIS./ASSEMBLY

B. Procedure

1. Remove the belt cleaning unit. (See "4.6

Replacing the belt cleaning unit.")

2. Remove 2 blade springs [1].

3. After removing the stop ring [2], pull out the

blade support shaft [3] and remove the belt

cleaning blade [4].

4. Reinstall the above parts following the removal

steps in reverse.

Note:

• Before installing the belt cleaning unit, coat

the entire surface on the side on the transfer

belt, on which the belt cleaning unit is to be

mounted, with the setting powder.

[2]

[3]

[3][4]

[1]

8050ma3049

1-36

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4.8 Replacing the toner collec­tion sheet /1

A. Periodically replaced parts/cycle

• Toner collection sheet /1: Every 200,000 copies

B. Procedure

1. Remove the belt cleaning unit.

2. After removing 3 screws [1], remove the toner

collection sheet /2 [2] and then remove the toner

collection sheet /1 [3].

3. Reinstall the above parts following the removal

steps in reverse.

Note:

• Be careful not to fold the PET sheet of the

toner collection sheet /1, or damage it by hit-

ting it on the edge.

I DIS./ASSEMBLY

[1]

1-37

[3][2]

8050ma3159

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.9 Replacing the belt separa­tion claw

A. Periodically replaced parts/cycle

• Belt separation claw: Every 600,000 copies

I DIS./ASSEMBLY

B. Procedure

1. Remove the transfer belt unit. (See "4.5 Remov-

ing and reinstalling the transfer belt unit.")

2. Remove the screw [1] and then remove the sep-

aration claw unit [2].

Note:

• Be careful not to touch and/or damage the

transfer belt [3] with bare hands.

• When reinstalling the separation claw unit, be

sure to apply setting powder to the semicircle

[4] of the transfer belt [3].

[1]

[3]

[4]

[2]

[2]

8050ma3050

3. Remove the screws [1], one each, and then

remove 3 transfer belt separation claws [2].

4. Reinstall the above parts following the removal

steps in reverse.

[1]

[2]

8050ma3051

1-38

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4.10 Replacing the transfer belt

A. Screw that must not be removed

Note:

• The screws [1] shown in the drawing below

are not allowed to be removed. Be careful not

to remove them.

B. Periodically replaced parts/cycle

• Transfer belt: Every 200,000 copies

[1]

C. Procedure

1. Remove the transfer belt unit. (See "4.5 Remov-

ing and reinstalling the transfer belt unit.")

2. Remove the belt cleaning unit. (See "4.6

Replacing the belt cleaning unit.")

3. Remove the separation claw unit. (See "4.9

Replacing the belt separation claw.")

4. Remove 2 tension springs [1].

8050ma3148

[1][1]

I DIS./ASSEMBLY

1-39

8050ma3053

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

5. Stand up the transfer belt unit [1] by using the

front side of the transfer belt unit [1] as the bot-

[3] [6][2]

tom.

6. Remove the screw [2] and release the fixing of

the handle [3].

7. Remove 2 screws [4] and then remove the shaft

I DIS./ASSEMBLY

stopper [5].

8. Remove the screw [6] and then remove the ten-

[4]

sion plate /R [7].

Note:

• When reinstalling the tension plate /R, knock

against the projection of the tension plate /R.

9. Remove 2 screws [8] and then remove the high

voltage supply curler /R [9].

10. Remove the stop ring [10] and then remove the

bearing [11].

[12] [1]

[7]

[5]

Note:

• When reinstalling the stop ring, be sure to

raise the shaft so that the stop ring is set in

the groove of the shaft.

11. Pull up the transfer belt [12] for removal.

Note:

• Be sure to reinstall the transfer belt so that

the rear side stamped with "UP SIDE" at the

edge of the belt comes up.

• When holding the transfer belt by hand, hold it

within 10mm from the upper end. Be careful

not touch any part other than this.

12. Reinstall the above parts following the removal

steps in reverse.

Note:

• Be careful not to touch and/or damage the

transfer belt with bare hands.

• Before installing the belt cleaning unit, coat

the entire surface on the side on the transfer

belt, on which the belt cleaning unit is to be

mounted, with the setting powder.

[11]

[8]

[9][10]

8050ma3054

8050ma3152

1-40

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4.11 Replacing the 1st transfer roller

A. Periodically replaced parts/cycle

• 1st transfer roller /Y, /M, /C, /K: Every 200,000

copies

B. Procedure

1. Remove the transfer belt. (See "4.10 Replacing

the transfer belt.")

2. Place the transfer belt unit as shown in the illus-

tration.

3. Remove the stop ring [1].

4. After removing 1 bearing [2], slide the stopper /4

[3] to open the tip end of the transfer release

arm [4].

5. Remove the 1st transfer roller /K [6] while sliding

it.

6. Remove 3 1st transfer rollers/Y, /M, /C [5].

Note:

• Be sure to reinstall the 1st transfer roller so

that a shallow groove near the groove of the

E-ring comes this side.

[7]

[4] [3]

[3] [4]

[7] [6]

[7][5]

[7]

I DIS./ASSEMBLY

7. Remove the E-rings [7], 2 each, from each of

the 1st transfer rollers.

8. Reinstall the above parts following the removal

steps in reverse.

[2][1]

8050ma3055

1-41

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.12 Replacing the 2nd transfer roller /U

A. Periodically replaced parts/cycle

• 2nd transfer roller /U: Every 200,000 copies

I DIS./ASSEMBLY

B. Procedure

1. Remove the transfer belt. (See "4.10 Replacing

the transfer belt.")

2. After raising the 2nd transfer roller /U [1] once,

remove it diagonally from the lower side.

Note:

• The fixing of the 2nd transfer roller /U was

released when the transfer belt was removed

at the time of the removal of the high voltage

supply curler.

• Be sure to reinstall the 2nd transfer roller /U

so that the shaft end with a dent comes to the

bottom.

3. Remove 2 bearings [2] from the 2nd transfer

roller /U [1].

4. Reinstall the above parts following the removal

steps in reverse.

[2]

[1]

1

2

1-42

[1][2]

8050ma3056

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4.13 Replacing the drum car­tridge

A. Periodically replaced parts/cycle

• Drum cartridge: Every 100,000 copies

B. Procedure

Note:

• The drum cartridges are provided for the four

colors of yellow, magenta, cyan and black,

and they are all common. However, be sure to

avoid reusing a drum cartridge that was once

used for a color since it has been stuck with

the toner of that color.

1. Remove the transfer belt unit. (See "4.5 Remov-

ing and reinstalling the transfer belt unit.")

2. After raising once both ends [2] of the drum stay

/U [1], hold them and remove the drum cartridge

/Y [3].

3. Remove the drum cartridge /M [4], drum car-

tridge /C [5] and the drum cartridge /K [6] in the

same manner as in Step 2.

4. Reinstall the above parts following the removal

steps in reverse.

Note:

• When reinstalling each drum cartridge, be

sure to check if both ends of the cartridge

have been dropped into the grooves of the

drum installation blocks /F [7] and /R [8]. (The

drum installation blocks /F [7] and /R [8] are

for yellow drum cartridges. Repeat the steps

for other cartridges in the same manner.)

• When reinstalling the drum cartridge /K [6], be

careful that the mylar [9] is not caught up.

• Be careful not touch and damage the photo-

sensitive material of the drum with bare

hands.

• When the drum cartridge is not used for a

long period of time, be sure to store it in the

dark place with a cover on it (to shield the

light).

[8]

[1]

[9]

I DIS./ASSEMBLY

[2]

[7]
[3]

[4]

[5]

[6]

8050ma3057

1-43

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.14 Removing and reinstalling the drum

A. Screw that must not be removed

Note:

I DIS./ASSEMBLY

• Screws that are paint locked are not allowed

to be removed. Be careful not to remove them

at all costs.

[1]

[1]

B. Procedure

1. Remove the drum cartridge. (See "4.13 Replac-

ing the drum cartridge.")

2. Remove 2 screws [1] and then remove the drum

stay /U [2].

[1]

[2]

8050ma3058

8050ma3059

1-44

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

3. Remove the coupling shaft /A [1] and then

remove the coupling /A [2].

4. Remove 2 screws [3].

5. Remove the position adjusting plate /R [8].

[6]

6. Remove the stop ring [4] and then remove the

screw idler gear [5].

7. Remove 3 screws [6] (be careful not to remove

black screw.).

8. Remove the position adjusting plate /F [7].

9. Hold both ends of the drum [9] and raise it up for

removal.

[7] [5] [4][9]

Note:

• Be sure to reinstall the drum so that the cou-

pling side of the drum flange comes to the

rear side of the drum cartridge.

10. Reinstall the above parts following the removal

steps in reverse.

I DIS./ASSEMBLY

[3]

[1] [8][2]

8050ma3060

1-45

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.15 Replacing the developing unit

A. Periodically replaced parts/cycle

• Developing unit: Every 600,000 copies

I DIS./ASSEMBLY

B. Procedure

Note:

• Be careful not to fold the Teflon sheet posted

at the developing sleeve side of the develop-

ing unit upper cover.

• When cleaning the developing unit, be sure to

use Hydro-Wipe which is specified as a CE

tool. Using paper or cloth other than Hydro-

Wipe will cause the developing regulation

plate in the developing unit to be stuck with

dust and lint of the paper or cloth, thus result-

ing in white streaks on the images.

• The developing units are provided for the four

colors of yellow, magenta, cyan and black,

and they are all common. However, be sure to

avoid reusing a developing unit that was once

used for a color since it has been stuck with

the toner of that color.

1. Open the toner supply section. (See "5.1 Open-

ing and closing the toner supply section.")

2. Remove 2 screws [1] and then remove 4 devel-

oping support legs [3] provided inside the toner

supply unit [2].

Note:

• When placing the developing unit by itself, be

sure to set the developing support legs to the

body of the developing unit as a seat to pre-

vent the toner bristles section from getting in

touch with other sections.

3. Pull out the process unit. (See "4.4 Pulling out

the process unit.")

[2]

[3]

[3]

[1]

8050ma3062

1-46

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4. Remove the screws [1], 3 each, and then

remove 2 developing pressing blocks [2] while

[1] [1]

sliding the upper side of the developing pressing

blocks.

I DIS./ASSEMBLY

5. Remove the relay connectors [1], 1 each, and

then remove 4 developing units [2] one at a time.

6. Reinstall the above parts following the removal

steps in reverse. Place an appropriate color

label supplied with the developing unit on the

new unit.

Note:

• Be careful not to open the developing unit

cover.

[1]

[2]

[2]

8050ma3063

8050ma3064

1-47

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.16 Replacing the developer

A. Periodically replaced parts/cycle

• Developer: Every 100,000 copies

B. Procedure

I DIS./ASSEMBLY

1. Remove the developing unit. (See "4.15 Replac-

ing the developing unit.")

2. Put the developing unit [1] on end and rotate its

upper end in drawing an arc to discharge devel-

oper. After discharging the developer, repeat

Steps 3 and 4 below to discharge all of the

developer.

8050ma3149

3. Install the rotating jig [1] provided inside the

toner supply unit to the coupling [2] on the agita-

tor screw side and turn it in the arrow-marked

direction.

[1] [2]

8050ma3150

1-48

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4. Install the rotating jig to the coupling [1] on the

developing sleeve side and turn it in the arrow-

[1]

marked direction.

Note:

• If the jig is turned in the reverse direction, it

sometimes occurs that the developer is not

discharged completely. Be careful not to turn

it in the reverse direction.

5. Charge a new developer. (See "7. 36 mode," "II .

Adjustment" in Field Service.)

8050ma3151

I DIS./ASSEMBLY

1-49

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.17 Replacing the belt separa­tion claw solenoid

A. Periodically replaced parts/cycle

• Developer: Every 1,500,000 copies

I DIS./ASSEMBLY

B. Procedure

1. Remove the transfer belt unit. (See "4.5 Remov-

ing and reinstalling the transfer belt unit.")

2. Remove the screw [1] and then remove the sole-

noid lever [2].

3. Remove the relay connector [3].

4. Remove the screw [4] and release the cable [6]

from the cable clamp [5].

5. Remove 2 screws [7] and then remove the SD1

(belt separation claw solenoid) [8].

6. Reinstall the above parts following the removal

steps in reverse.

Note:

• When having reinstalled the solenoid bar,

check to see if the shaft [9] of SD1 (belt sepa-

ration claw solenoid) moves smoothly while

sliding it.

[8]

[7]

1-50

[4] [5] [6] [3] [2] [1]

8050ma3069

CF5001 Field Service Ver.1.0 Sep 2003 PROCESS UNIT

4.18 Removing and reinstalling the process unit

A. Procedure

1. Remove the transfer belt unit. (See "4.5 Remov-

ing and reinstalling the transfer belt unit.")

2. Remove all of the drum cartridges. (See "4.13

Replacing the drum cartridge.")

3. Remove all of the developing units. (See "4.15

Replacing the developing unit.")

4. Remove the screws [1], 2 each.

Note:

• When removing the process unit, be sure to

remove in advance the transfer belt unit, drum

cartridge and the developing unit.

• Be careful not to remove black screws.

[8]

[6]

I DIS./ASSEMBLY

5. Push back the process unit [6] until it becomes

possible to see the screw [5] through each hole

[4] of the guide rails /L [2] and /R [3].

6. Remove the screws [5], 1 each.

Note:

• Be careful not to remove black screws.

7. Pull out the process unit [6] again. Then remove

it from the guide rails /L [2] and /R [3] as

explained below:

The projection [7] on the guide rail /L is set into

the notch [8] of the process unit. The notch [10]

of the process unit is placed on the projection [9]

on the guide rail /R. Accordingly, slide the guide

rail /L a little against the process unit to remove

it from the guide rail /L, and then remove it from

the guide rail /R by raising the process unit.

8. Reinstall the above parts following the removal

steps in reverse.

[4]

[2]

[5]

[1]

[1]

[7][6]

[4]

[5]

[3]

1-51

[10] [9]

8050ma3070

PROCESS UNIT CF5001 Field Service Ver.1.0 Sep 2003

4.19 Removing and reinstalling the image correction unit

A. Procedure

1. Remove the process unit. (See "4.18 Removing

and reinstalling the process unit.")

I DIS./ASSEMBLY

2. Remove a relay connector [1].

3. Remove 2 screws and then remove the image

correction unit [3].

4. Reinstall the above parts following the removal

steps in reverse.

Note:

• When removing the image correction unit, be

sure to remove in advance the process unit.

• When removing the image correction unit, be

careful not to touch the drum drive shaft [4] of

each color. Otherwise, this may cause stress

to it.

[4][3] [1]

8050ma3071

[4]

[2]

1-52

CF5001 Field Service Ver.1.0 Sep 2003 TONER SUPPLY

5. TONER SUPPLY

5.1 Opening and closing the toner supply section

A. Procedure

1. Open the front door [1].

2. Loosen the screw [2] and open the toner supply

section [3].

Note:

• With the toner supply section left open, be

sure not to apply force to the toner supply

sections such as the operation board. If

applied, the hinge of the toner supply section

may be deformed.

• When closing the toner supply section,

tighten the screw with a hand before using a

driver to prevent stripping the thread.

[1] [2] [3]

8050ma3072

I DIS./ASSEMBLY

3. Remove once the door lock [2] provided on the

inside of the toner supply section [1] and replace

it at a new position where it becomes a stopper.

4. Close the front door following the steps for

opening in reverse order.

Note:

• When the toner supply section is opened, be

sure to replace the door lock to a new position

where it becomes a stopper and prevent it

from getting in touch with the process unit

when being pulled out.

[2]

[1]

1-53

[2]

[1]

8050ma3073

TONER SUPPLY CF5001 Field Service Ver.1.0 Sep 2003

5.2 Replacing the charging dust filter

A. Periodically replaced parts/cycle

• Charging dust filter: Every 600,000 copies

I DIS./ASSEMBLY

B. Procedure

1. Open the toner supply section. (See "5.1 Open-

ing and closing the toner supply section.")

2. Remove the charging dust filter [3] from the

charging suction assembly [2] provided on the

inside of the toner supply section [1].

3. Reinstall the above parts following the removal

steps in reverse.

[3] [1]

[2]

8050ma3074

1-54

CF5001 Field Service Ver.1.0 Sep 2003 PAPER FEED TRAYS /1 to /3

6. PAPER FEED TRAYS /1 to /3

6.1 Removing and reinstalling the paper feed unit

A. Procedure

Note:

• Since the composition of the paper feed trays

/1 to /3 is the same, the explanation here is

made of the steps for the paper feed tray /1.

1. Pull out the paper feed tray /1 [1].

2. Remove 4 screws [2] and then remove the

paper feed unit cover [3].

[3]

I DIS./ASSEMBLY

[2]

[1]

[2]

8050ma3160

1-55

PAPER FEED TRAYS /1 to /3 CF5001 Field Service Ver.1.0 Sep 2003

3. Remove the connector [1].

4. Remove a screw [2] and loosen a hold-down

shaft screw [3].

5. After sliding the paper feed unit [4] to the rear

side, lift it up. Remove the connector [5] and

then remove the paper feed unit [4].

I DIS./ASSEMBLY

6. Reinstall the above parts following the removal

steps in reverse.

[3]

[5]

[4]

[2]

[1]

8050ma3161

1-56

CF5001 Field Service Ver.1.0 Sep 2003 PAPER FEED TRAYS /1 to /3

6.2 Removing and reinstalling the paper feed trays /1 to /3

A. Procedure

Note:

• Since the composition of the paper feed trays

/1 to /3 is the same, the explanation here is

made of the steps for the paper feed tray /1.

1. Pull out the paper feed tray /1.

2. Remove the paper feed unit.

3. Remove 4 screws [1] and lift up the paper feed

tray /1 [2] for removal.

4. Reinstall the above parts following the removal

steps in reverse.

[1]

I DIS./ASSEMBLY

[2][1]

8050ma3162

1-57

PAPER FEED TRAYS /1 to /3 CF5001 Field Service Ver.1.0 Sep 2003

6.3 Replacing the paper feed roller and the feed rubber

A. Periodically replaced parts/cycle

• Paper feed roller: Every 2,500,000 copies (Every

800,000 copies in actual replacement count)

I DIS./ASSEMBLY

• Feed rubber: Every 400,000 copies (Every

125,000 copies in actual replacement count)

B. Procedure

Note:

• Since the composition of the paper feed trays

/1 to /3 is the same, the explanation here is

made of the steps for the paper feed tray /1.

1. Pull out the paper feed tray /1.

2. Remove the paper feed unit.

3. Remove 2 stop rings [1], slide 2 bearings [2] to

the outside and then remove the paper feed

roller assembly [3].

[1]

1-58

[2] [3]

8050ma3163

CF5001 Field Service Ver.1.0 Sep 2003 PAPER FEED TRAYS /1 to /3

4. Remove a bearing [1].

5. Remove a stop ring [2] and then remove the

[7]

paper feed roller [3].

6. Remove a stop ring [4] and then remove the

feed roller [5].

7. Remove the feed rubber [6] from the feed roller

[5].

8. Reinstall the above parts following the removal

steps in reverse.

[6]

I DIS./ASSEMBLY

Note:

• Be sure to install the feed rubber [6] so that

the paint mark [7] turns in the arrow-marked

direction.

• Be sure to check that each roller is not stuck

with grease.

[5]

[4]

[1]

[2][3]

8050ma3164

1-59

PAPER FEED TRAYS /1 to /3 CF5001 Field Service Ver.1.0 Sep 2003

6.4 Replacing the double feed prevention rubber

A. Periodically replaced parts/cycle

• Double feed prevention rubber: Every 400,000

copies (Every 125,000 copies in actual replace-

I DIS./ASSEMBLY

ment count)

B. Procedure

Note:

• Since the composition of the paper feed trays

/1 to /3 is the same, the explanation here is

made of the steps for the paper feed tray /1.

1. Pull out the paper feed tray /1.

2. Remove the paper feed unit.

3. Remove the paper feed roller assembly.

4. Remove a stop ring [1] and then remove the

double feed prevention roller [2].

5. Remove the gear [3] from the double feed pre-

vention roller [2].

6. Remove the double feed prevention rubber [4]

from the double feed prevention roller [2].

7. Reinstall the above parts following the removal

steps in reverse.

[5]

Note:

• Be sure to install the double feed prevention

rubber [4] so that the paint mark [5] turns in

the arrow-marked direction.

• Be sure to check that the double feed preven-

tion roller is not stuck with grease.

[1]

[2][4][3]

8050ma3165

1-60

CF5001 Field Service Ver.1.0 Sep 2003 PAPER FEED TRAYS /1 to /3

6.5 Replacing the paper feed
clutch and the pre-registra­tion clutch

A. Periodically replaced parts/cycle

• Paper feed clutches /1 to /3 (MC7, MC9, MC11):

Every 4,000,000 copies (Every 2,000,000 copies

in actual replacement count)

• Pre-registration clutches /1 to /3 (MC8, MC10,

MC13): Every 4,000,000 copies (Every

2,000,000 copies in actual replacement count)

B. Procedure

Note:

• Since the composition of the paper feed trays

/1 to /3 is the same, the explanation here is

made of the steps for the paper feed tray /1.

I DIS./ASSEMBLY

1. Pull out the paper feed tray /1.

2. Remove the paper feed unit.

3. Remove 2 connectors [1].

4. Remove a stop ring [2] and then remove the

MC7 [3].

5. Remove a stop ring [4] and then remove the

MC8 [5].

6. Reinstall the above parts following the removal

steps in reverse.

Note:

• When reinstalling the clutches, be sure to

check that the stopper [6] of each clutch is in

the specified position.

[5] [4]

[6]

[3]

[2]

[1]

8050ma3166

1-61

PAPER FEED TRAYS /1 to /3 CF5001 Field Service Ver.1.0 Sep 2003

6.6 Removing and reinstalling the tray up/down wire

Wire length:

• Up/down wire /A and up/down wire /C: 531mm

• Up/down wire /B and up/down wire /D: 160mm

I DIS./ASSEMBLY

A. Removing the wire

Note:

• Since the composition of the paper feed trays

/1 to /3 is the same, the explanation here is

made of the steps for the paper feed tray /1.

1. Pull out the paper feed tray /1.

2. Remove the paper feed unit.

3. Remove the paper feed tray /1.

4. Remove 3 screws [1] and then remove the wire

cover /FR [2].

5. Remove 2 screws [3] and then remove the wire

cover /FL [4].

6. Remove 3 screws [5] and then remove the wire

cover /RR [6].

7. Remove 2 screws [7] and then remove the wire

cover /RL [8].

[5][7] [6] [2]

[1]

[3]

[4][8]

8050ma3167

1-62

CF5001 Field Service Ver.1.0 Sep 2003 PAPER FEED TRAYS /1 to /3

8. Remove an E-ring [1].

9. Slide the drive pulley [2] to the inside and

remove the wires /C [3] and /D [4].

10. After removing an E-ring [5], remove the pulley

[6] and release the wires /C [3] and /D [4] from

the wire restraining cover [7].

11. Remove a screw [8] from the bottom of the

paper feed tray /1 and then remove the wire /D

[4].

12. After removing an E-ring [9], remove the pulley

[10] and release the wire /C [3] from the wire

restraining cover [11].

13. Remove a screw [12] from the bottom of the

paper feed tray /1 and then remove the wire /C

[3].

[9]

[11]

[10]

14. Remove an E-ring [13].

15. Slide the drive pulley [14] to the inside and

remove the wires /A [15] and /B [16].

16. After removing an E-ring [17], remove the pulley

[18] and release the wires /A [15] and /B [16]

from the wire restraining cover [19].

17. Remove a screw [20] from the bottom of the

paper feed tray /1 and then remove the wire /B

[16].

18. After removing an E-ring [21], remove the pulley

[22] and release the wire /A [15] from the wire

restraining cover [23].

19. Remove a screw [24] from the bottom of the

paper feed tray /1 and then remove the wire /A

[15].

[7]

[6]

[3]

[5]

I DIS./ASSEMBLY

[21]

[3]

[8]

[4]

[1]

[2][12]

[19][22][23] [18]

[17]

[15]

[20]

[16]

1-63

[13][14][24][15]

8050ma3168

PAPER FEED TRAYS /1 to /3 CF5001 Field Service Ver.1.0 Sep 2003

B. Attaching the wire

4. After winding the wire /C [3] and the wire /D [10]

around the pulley [11], insert it into the shaft [13]

Note:

• Since the composition of the paper feed trays

together with the wire restraining cover [12] and

fasten it with an E-ring [14].

/1 to /3 is the same, the explanation here is

made of the steps for the paper feed tray /1.

I DIS./ASSEMBLY

1. Install the wire /C [3] to the wire holding shaft [2]

with a screw [1] from the bottom side of the

Note:

• Be sure to wind the wires around the pulley

[11] so that the wire /C [3] comes to the out-

side and the wire /D [10] to the inside.

paper feed tray.

2. After winding the wire /C [3] around the pulley

[4], insert it into the shaft [6] together with the

wire restraining cover [5] and fasten it with an E-

ring [7].

5. After sliding the drive pulley [15] to the outside

with the wire /C [3] and the wire /D [10] inserted

into the up/down drive shaft [14], fasten it with

an E-ring [16].

3. Install the wire /D [10] to the wire holding shaft

[9] with a screw [8] from the bottom side of the

paper feed tray.

[12]

[7]

[5]

[4]

[11]

[4]

[13]

[3]

[6]

[3]

[8]

[9]

[16]

[17]

[18]

[10]

[15][14][1][2]

[17]

8050ma3169

1-64

CF5001 Field Service Ver.1.0 Sep 2003 PAPER FEED TRAYS /1 to /3

Note:

• Be sure to wind the wires around the pulley

[14] so that the wire /C [3] comes to the out-

side and the wire /D [10] to the inside.

6. Install the wires /A [17] and /B [18] by following

Steps 1 to 5.

Note:

• After completion of attaching the wires, be

sure to rotate the up/down drive shaft by hand

to check to see if the up/down plate goes up

and down smoothly.

7. For the subsequent steps, reinstall the parts fol-

lowing the removal steps in reverse.

I DIS./ASSEMBLY

1-65

BY-PASS TRAY CF5001 Field Service Ver.1.0 Sep 2003

7. BY-PASS TRAY

7.1 Replacing the paper feed roller and the feed roller

A. Periodically replaced parts/cycle

I DIS./ASSEMBLY

• Paper feed roller: Every 800,000 copies in actual

replacement count

• Feed roller: Every 125,000 copies in actual

replacement count

B. Procedure

1. Pull out the ADU. (See "10.1 Removing and

reinstalling the ADU.")

2. Remove 6 screws [1] and then remove the

paper feed solenoid cover [2].

[1]

3. Remove the stop ring [1].

4. Remove the bearing [2] and then remove the

paper feed roller unit [3].

[3]

[1][2]

8050ma3075

[1][2]

8050ma3076

1-66

CF5001 Field Service Ver.1.0 Sep 2003 BY-PASS TRAY

5. After removing the stop ring [1], pull out the feed

shaft [2] and remove the paper feed gear

[3][2]

assembly [3].

6. Remove the paper feed roller [4] from the paper

feed gear assembly [3].

I DIS./ASSEMBLY

7. Remove the feed roller assembly [2] from the

by-pass drive shaft [1].

8. Remove the feed roller [3] from the feed roller

assembly [2].

Note:

• Be sure to install the feed roller [3] so that the

paint mark [4] turns in the direction shown in

the drawling.

9. Reinstall the above parts following the removal

steps in reverse.

Note:

• Be sure to install the paper feed roller unit [1]

so that the actuator section [2] coincides with

the detection section of the PS47 (no paper

sensor /BP) [3].

• Be sure to install the paper feed roller unit [1]

so that the tip end of the paper feed side of

the paper up/down lever comes into contact

with the inside of the top plate of the paper

feed roller unit [1].

[3] [2][4]

[4] [1]

[4]

[2] [1][3]

8050ma3077

8050ma3078

1-67

[1]

8050ma3079

BY-PASS TRAY CF5001 Field Service Ver.1.0 Sep 2003

7.2 Replacing the double feed prevention roller

A. Periodically replaced parts/cycle

• Double feed prevention roller: Every 125,000

copies in actual replacement count

I DIS./ASSEMBLY

B. Procedure

1. Remove the paper feed roller and the feed roller.

(See "Replacing the paper feed roller and the

feed roller.")

2. Remove 2 double feed pressure springs [1].

3. After removing the stop ring [2], pull out the dou-

ble feed prevention shaft [3] and remove the

flange [4] and the double feed prevention roller

assembly [5].

4. Remove the double feed prevention roller [6]

from the double feed prevention roller assembly

[5].

5. Reinstall the above parts following the removal

steps in reverse.

[7]

Note:

• Be sure to install the double feed prevention

roller [6] so that the paint mark [7] turns in the

direction shown in the drawing.

[1]

[2][3][1]

[6][4] [5]

8050ma3080

1-68

CF5001 Field Service Ver.1.0 Sep 2003 BY-PASS TRAY

7.3 Replacing the paper feed
clutch /BP

A. Periodically replaced parts/cycle

• Paper feed clutch /BP (MC6): Every 2,000,000

copies in actual replacement count

B. Procedure

1. Open the toner supply section. (See "5.1 Open-

ing and closing the toner supply section.")

2. Pull out the ADU. (See "10.1 Removing and

reinstalling the ADU.")

3. Remove the fixing unit. (See "9.2 Removing and

reinstalling the fixing unit.")

4. Remove 4 screws [1]. (One of the screws is

installed on the underside of the ADU cover/R

[2].)

5. After pulling out the ADU cover /R [2] halfway,

remove 2 relay connectors [3] and then remove

the ADU cover /R [2].

6. Remove the screw [4] and then remove the

stand pulling lever [5].

7. Remove 2 screws [6] and then remove the ADU

cover /L [7].

[1]

[1]

[2]

I DIS./ASSEMBLY

[7]

[4]

[3][5][6]

8050ma3081

1-69

BY-PASS TRAY CF5001 Field Service Ver.1.0 Sep 2003

8. Remove a relay connector [1].

9. Remove the stop ring [2] and then remove the

[2][3]

paper feed clutch /BP (MC6) [3].

10. Reinstall the above parts following the removal

steps in reverse.

I DIS./ASSEMBLY

Note:

• When reinstalling the paper feed clutch /BP

(MC6) [1], be sure to set the stopper in the

detente groove [2].

[1]

[2]

8050ma3082

[1]

8050ma3083

1-70