Kyocera KM-3035, KM-4035, KM-5035 Service Manual

Page 1
KM-3035 KM-4035 KM-5035
SERVICE
MANUAL
Published in April 2005
842FG112
Version 3.0
Page 2
CAUTION
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturers instructions.
CAUTION
Double-pole/neutral fusing.
Page 3
Version history
Version Date Replaced pages Remarks
1 19 October 2004 2-2-2
3.0 22 April 2005 Contents, 1-1-1, 1-1-2, 1-1-3, 1-1-4, 1-3-3, 1-3-4, 1-3-5, 1-3-6, 1-3-7, 1-3-7-1, 1-3-8, Chapter 1-4 (overall rerised), 1-6-29, 1-6-30, 1-6-37, 1-6-41, 1-6-42, 2-4-15
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This page is intentionally left blank.
Page 5

Safety precautions

This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.
Page 6
Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION:Bodily injury or damage to property may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.
Page 7
1. Installation Precautions
WARNING
Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. ............................................................................................
Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or electric shock. Connecting the earth wire to an object not approved for the purpose may cause explosion or electric shock. Never connect the ground cable to any of the following: gas pipes, lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. .............................................................................................................................
CAUTION:
Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .....
Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..............
Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. ..........................................................................................................................
Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........
Always handle the machine by the correct locations when moving it. ..............................................
Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may
cause the copier to move unexpectedly or topple, leading to injury..................................................
Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain
medical attention. ..............................................................................................................................
Advice customers that they must always follow the safety warnings and precautions in the copiers
instruction handbook. ........................................................................................................................
Page 8
2. Precautions for Maintenance
WARNING
Always remove the power plug from the wall outlet before starting machine disassembly...............
Always follow the procedures for maintenance described in the service manual and other related
brochures. .........................................................................................................................................
Under no circumstances attempt to bypass or disable safety features including safety
mechanisms and protective circuits. .................................................................................................
Always use parts having the correct specifications...........................................................................
Always use the thermostat or thermal fuse specified in the service manual or other related
brochure when replacing them. Using a piece of wire, for example, could lead to fire or other
serious accident. ...............................................................................................................................
When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ...............................................................
Always check that the copier is correctly connected to an outlet with a ground connection.............
Check that the power cable covering is free of damage. Check that the power plug is dust-free. If
it is dirty, clean it to remove the risk of fire or electric shock. ............................................................
Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ..............................................................................................................................
Handle the charger sections with care. They are charged to high potentials and may cause
electric shock if handled improperly. .................................................................................................
CAUTION
Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections...........................................................
Use utmost caution when working on a powered machine. Keep away from chains and belts........
Handle the fixing section with care to avoid burns as it can be extremely hot..................................
Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures...........................................................................................................
Do not remove the ozone filter, if any, from the copier except for routine replacement....................
Page 9
Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. ......................................................................................................
Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. ..............................................................................................
Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........
Remove toner completely from electronic components. ...................................................................
Run wire harnesses carefully so that wires will not be trapped or damaged. ...................................
After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten
connector, trapped wire and missing screws. ..................................................................................
Check that all the caution labels that should be present on the machine according to the
instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................
Handle greases and solvents with care by following the instructions below: ....................................
· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
· Ventilate the room well while using grease or solvents.
· Allow applied solvents to evaporate completely before refitting the covers or turning the main
switch on.
· Always wash hands afterwards.
Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc...........................................................................................................................
Should smoke be seen coming from the copier, remove the power plug from the wall outlet
immediately. ......................................................................................................................................
3. Miscellaneous
WARNING
Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than
the specified refiner; it may generate toxic gas. ................................................................................
Page 10
2FD/2FF/2FG-3.0

CONTENTS

1-1 Specifications
1-1-1 Specifications ....................................................................................................................................... 1-1-1
1-1-2 Parts names and their functions........................................................................................................... 1-1-3
(1) Copier ............................................................................................................................................. 1-1-3
(2) Operation panel .............................................................................................................................. 1-1-4
1-1-3 Machine cross section.......................................................................................................................... 1-1-5
1-1-4 Drive system ........................................................................................................................................ 1-1-6
(1) Drive system 1 (drive motor and eject motor drive trains).............................................................. 1-1-6
(2) Drive system 2 (paper feed motor drive train)................................................................................ 1-1-7
(3) Drive system 3 (duplex section) ..................................................................................................... 1-1-8
1-2 Handling Precautions
1-2-1 Drum .................................................................................................................................................... 1-2-1
1-2-2 Toner .................................................................................................................................................... 1-2-1
1-2-3 Installation environment ....................................................................................................................... 1-2-1
1-3 Installation
1-3-1 Unpacking and installation ................................................................................................................... 1-3-1
(1) Installation procedure ..................................................................................................................... 1-3-1
1-3-2 Setting initial copy modes..................................................................................................................... 1-3-8
1-3-3 Installing the key counter (option)........................................................................................................ 1-3-9
1-3-4 Installing the drawer heater (option)................................................................................................... 1-3-11
1-3-5 Installing the paper feeder (option) .................................................................................................... 1-3-13
1-3-6 Installing the large paper deck (option).............................................................................................. 1-3-17
1-3-7 Installing the booklet stitcher/switchback unit (option)....................................................................... 1-3-22
1-3-8 Installing the sheet-through document processor (option)................................................................. 1-3-33
1-3-9 Installing the Printing System (option)................................................................................................ 1-3-34
1-3-10 Installing the Scanning System (option)............................................................................................. 1-3-36
1-3-11 Installing the built-in finisher (option).................................................................................................. 1-3-39
1-3-12 Installing the job separator (option).................................................................................................... 1-3-45
1-3-13 Installing the Facsimile System (option)............................................................................................. 1-3-48
1-3-14 Installing the hard disk (option) .......................................................................................................... 1-3-56
1-3-15 Installing the 1000-sheet finisher (option).......................................................................................... 1-3-58
1-3-16 Installing the 3000-sheet finisher (option).......................................................................................... 1-3-63
1-4 Maintenance Mode
1-4-1 Copier management............................................................................................................................. 1-4-1
(1) Using the copier management mode.............................................................................................. 1-4-1
(2) Setting department management items.......................................................................................... 1-4-2
(3) Copy default ................................................................................................................................... 1-4-3
(4) Machine default .............................................................................................................................. 1-4-6
(5) Bypass setting ................................................................................................................................ 1-4-7
(6) Original size registration................................................................................................................. 1-4-7
(7) User adjustment ............................................................................................................................. 1-4-8
(8) Checking the total counter and printing out the counter report....................................................... 1-4-8
(9) Doucment management default setting.......................................................................................... 1-4-8
(10) Hard disk management .................................................................................................................. 1-4-8
(11) Status report print out..................................................................................................................... 1-4-8
(12) Language selection function........................................................................................................... 1-4-8
1-4-2 Maintenance mode............................................................................................................................... 1-4-9
(1) Executing a maintenance item ....................................................................................................... 1-4-9
(2) Maintenance mode item list.......................................................................................................... 1-4-10
(3) Contents of maintenance mode items.......................................................................................... 1-4-14
1-1-1
Page 11
2FD/2FF/2FG
1-5 Troubleshooting
1-5-1 Paper misfeed detection ...................................................................................................................... 1-5-1
(1) Paper misfeed indication ................................................................................................................ 1-5-1
(2) Paper misfeed detection conditions ................................................................................................ 1-5-2
(3) Paper misfeeds ............................................................................................................................... 1-5-9
1-5-2 Self-diagnosis ..................................................................................................................................... 1-5-20
(1) Self-diagnostic function ................................................................................................................ 1-5-20
(2) Self-diagnostic codes ................................................................................................................... 1-5-21
1-5-3 Image formation problems ................................................................................................................. 1-5-37
(1) No image appears (entirely white). ............................................................................................... 1-5-38
(2) No image appears (entirely black). ............................................................................................... 1-5-39
(3) Image is too light. ......................................................................................................................... 1-5-40
(4) Background is visible. ................................................................................................................... 1-5-40
(5) A white line appears longitudinally. .............................................................................................. 1-5-40
(6) A black line appears longitudinally. .............................................................................................. 1-5-41
(7) A black line appears laterally. ....................................................................................................... 1-5-41
(8) One side of the copy image is darker than the other. ................................................................... 1-5-41
(9) Black dots appear on the image. .................................................................................................. 1-5-42
(10) Image is blurred. ........................................................................................................................... 1-5-42
(11) The leading edge of the image is consistently misaligned with the original. ................................ 1-5-42
(12) The leading edge of the image is sporadically misaligned with the original. ................................ 1-5-43
(13) Paper creases. ............................................................................................................................. 1-5-43
(14) Offset occurs. ............................................................................................................................... 1-5-43
(15) Image is partly missing. ................................................................................................................ 1-5-44
(16) Fixing is poor. ............................................................................................................................... 1-5-44
(17) Image is out of focus. ................................................................................................................... 1-5-44
(18) Image center does not align with the original center. ................................................................... 1-5-45
(19) Image is not square. ..................................................................................................................... 1-5-45
1-5-4 Electrical problems ............................................................................................................................. 1-5-46
(1) The machine does not operate when the power switch is turned on. ........................................... 1-5-46
(2) The drive motor does not operate (C2000). ................................................................................. 1-5-46
(3) The paper feed motor does not operate (C2500). ........................................................................ 1-5-46
(4) The eject motor does not operate. ................................................................................................ 1-5-46
(5) The upper lift motor does not operate (C1010). ........................................................................... 1-5-47
(6) The lower lift motor does not operate (C1020). ............................................................................ 1-5-47
(7) The scanner motor does not operate. .......................................................................................... 1-5-47
(8) Cooling fan motor 1 does not operate. ......................................................................................... 1-5-47
(9) Cooling fan motor 2 does not operate. ......................................................................................... 1-5-47
(10) Cooling fan motor 3 does not operate. ......................................................................................... 1-5-47
(11) Cooling fan motor 4 does not operate. ......................................................................................... 1-5-47
(12) Cooling fan motor 5 does not operate. ......................................................................................... 1-5-48
(13) Cooling fan motor 6 does not operate. ......................................................................................... 1-5-48
(14) Cooling fan motor 7 does not operate. ......................................................................................... 1-5-48
(15) The upper paper feed clutch does not operate. ............................................................................ 1-5-48
(16) The lower paper feed clutch does not operate. ............................................................................ 1-5-48
(17) Feed clutch 1 does not operate. ................................................................................................... 1-5-48
(18) Feed clutch 2 does not operate. ................................................................................................... 1-5-48
(19) Feed clutch 3 does not operate. ................................................................................................... 1-5-49
(20) The bypass paper feed clutch does not operate. ......................................................................... 1-5-49
(21) The bypass feed clutch does not operate. .................................................................................... 1-5-49
(22) The registration clutch does not operate. ..................................................................................... 1-5-49
(23) The duplex feed clutch does not operate. .................................................................................... 1-5-49
(24) The feedshift solenoid does not operate. ..................................................................................... 1-5-49
(25) The toner feed solenoid does not operate. ................................................................................... 1-5-50
(26) The cleaning lamp does not turn on. ............................................................................................ 1-5-50
(27) The exposure lamp does not turn on. ........................................................................................... 1-5-50
(28) The exposure lamp does not turn off. ........................................................................................... 1-5-50
(29) The fixing heater does not turn on (C6000). ................................................................................. 1-5-50
1-1-2
Page 12
2FD/2FF/2FG
(30) The fixing heater does not turn off. ............................................................................................... 1-5-50
(31) Main charging is not performed. ................................................................................................... 1-5-50
(32) Transfer charging is not performed. ............................................................................................. 1-5-51
(33) No developing bias is output. ....................................................................................................... 1-5-51
(34) The original size is not detected. .................................................................................................. 1-5-51
(35) The original size is not detected correctly. ................................................................................... 1-5-51
(36) The touch panel keys do not work. ............................................................................................... 1-5-51
(37) The message requesting paper to be loaded is shown
when paper is present in the upper drawer. ................................................................................. 1-5-51
(38) The message requesting paper to be loaded is shown
when paper is present in the lower drawer. .................................................................................. 1-5-51
(39) The message requesting paper to be loaded is shown
when paper is present on the bypass tray. ................................................................................... 1-5-51
(40) The size of paper in the upper drawer is not displayed correctly. ................................................ 1-5-52
(41) The size of paper in the lower drawer is not displayed correctly. ................................................. 1-5-52
(42) The printing width of the paper on the bypass tray is not detected correctly. ............................... 1-5-52
(43) A paper jam in the paper feed, paper conveying or fixing section is indicated
when the power switch is turned on. ............................................................................................ 1-5-53
(44) The message requesting covers to be closed is displayed
when the front cover and conveying cover are closed. ................................................................ 1-5-53
(45) Others. .......................................................................................................................................... 1-5-53
1-5-5 Mechanical problems ......................................................................................................................... 1-5-54
(1) No primary paper feed. ................................................................................................................. 1-5-54
(2) No secondary paper feed. ............................................................................................................ 1-5-54
(3) Skewed paper feed. ...................................................................................................................... 1-5-54
(4) The scanner does not travel. ........................................................................................................ 1-5-54
(5) Multiple sheets of paper are fed at one time.................................................................................. 1-5-54
(6) Paper jams. .................................................................................................................................. 1-5-54
(7) Toner drops on the paper conveying path. ................................................................................... 1-5-55
(8) Abnormal noise is heard. .............................................................................................................. 1-5-55
1-6 Assembly and Disassembly
1-6-1 Precautions for assembly and disassembly ......................................................................................... 1-6-1
(1) Precautions ..................................................................................................................................... 1-6-1
(2) Running a maintenance item .......................................................................................................... 1-6-2
1-6-2 Paper feed section ............................................................................................................................... 1-6-3
(1) Detaching and refitting the forwarding, paper feed and separation pulleys .................................... 1-6-3
(2) Detaching and refitting the bypass separation, bypass papaer feed and
bypass forwarding pulleys .............................................................................................................. 1-6-5
(3) Adjustment after roller and clutch replacement ............................................................................ 1-6-10
(3-1) Adjusting the leading edge registration of image printing .................................................... 1-6-10
(3-2) Adjusting the leading edge registration for memory image printing ..................................... 1-6-11
(3-3) Adjusting the center line of image printing ........................................................................... 1-6-12
(3-4) Adjusting the margins for printing ........................................................................................ 1-6-13
(3-5) Adjusting the amount of slack in the paper .......................................................................... 1-6-14
1-6-3 Optical section .................................................................................................................................... 1-6-15
(1) Detaching and refitting the exposure lamp ................................................................................... 1-6-15
(2) Detaching and refitting the scanner wires .................................................................................... 1-6-16
(2-1) Detaching the scanner wires ............................................................................................... 1-6-16
(2-2) Refitting the scanner wires .................................................................................................. 1-6-17
(3) Detaching and refitting the laser scanner unit .............................................................................. 1-6-20
(4) Adjusting the skew of the laser scanner unit (reference) .............................................................. 1-6-22
(5) Detaching and refitting the ISU (reference) .................................................................................. 1-6-23
(6) Adjusting the position of the ISU (reference) ................................................................................ 1-6-25
(7) Adjusting the longitudinal squareness (reference) ....................................................................... 1-6-26
(8) Adjusting magnification of the scanner in the main scanning direction ........................................ 1-6-27
(9) Adjusting magnification of the scanner in the auxiliary scanning direction ................................... 1-6-28
(10) Adjusting the scanner leading edge registration ........................................................................... 1-6-29
(11) Adjusting the scanner center line ................................................................................................. 1-6-30
(12) Adjusting the margins for scanning an original on the contact glass ............................................ 1-6-31
1-1-3
Page 13
2FD/2FF/2FG-3.0
1-6-4 Drum section ...................................................................................................................................... 1-6-32
(1) Detaching and refitting the drum unit............................................................................................ 1-6-32
(2) Detaching and refitting the main charger unit............................................................................... 1-6-32
(3) Detaching and refitting the drum separation claw assemblies..................................................... 1-6-33
1-6-5 Developing section............................................................................................................................. 1-6-34
(1) Detaching and refitting the developing unit.................................................................................. 1-6-34
1-6-6 Transfer section ................................................................................................................................. 1-6-35
(1) Detaching and refitting the transfer roller assembly..................................................................... 1-6-35
1-6-7 Fixing section ..................................................................................................................................... 1-6-36
(1) Detaching and refitting the fixing unit ........................................................................................... 1-6-36
(2) Detaching and refitting the heat roller separation claws............................................................... 1-6-36
(3) Detaching and refitting the press roller......................................................................................... 1-6-37
(4) Detaching and refitting the fixing heater M and S......................................................................... 1-6-38
(5) Detaching and refitting the heat roller........................................................................................... 1-6-39
(6) Detaching and refitting the fixing unit thermistor 1 and 2............................................................. 1-6-40
(7) Adjusting front position of the fixing unit (adjusting lateral squareness)....................................... 1-6-41
1-6-8 Others ................................................................................................................................................ 1-6-42
(1) Detaching and refitting the ozone filters (only for 230 V specifications)....................................... 1-6-42
1-7 Requirements on PCB Replacement
1-7-1 Upgrading the firmware on the main PCB............................................................................................ 1-7-1
1-7-2 Adjustment-free variable resisters (VR)............................................................................................... 1-7-2
1-7-3 Remarks on main PCB replacement.................................................................................................... 1-7-2
1-7-4 Upgrading the the printer board firmware ............................................................................................ 1-7-3
2-1 Mechanical construction
2-1-1 Paper feed section ............................................................................................................................... 2-1-1
2-1-2 Main charging section .......................................................................................................................... 2-1-5
2-1-3 Optical section...................................................................................................................................... 2-1-7
(1) Original scanning............................................................................................................................ 2-1-8
(2) Image printing................................................................................................................................. 2-1-9
2-1-4 Developing section............................................................................................................................. 2-1-12
(1) Formation of magnetic brush........................................................................................................ 2-1-13
(2) Computing the absolute humidity................................................................................................. 2-1-14
(3) Single component developing system.......................................................................................... 2-1-15
2-1-5 Transfer and separation sections....................................................................................................... 2-1-17
2-1-6 Cleaning and charge erasing sections............................................................................................... 2-1-19
2-1-7 Fixing section ..................................................................................................................................... 2-1-20
2-1-8 Eject and switchback sections............................................................................................................ 2-1-22
2-1-9 Duplex section.................................................................................................................................... 2-1-24
(1) Paper conveying operation in duplex copying.............................................................................. 2-1-25
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1
(1) PCBs .............................................................................................................................................. 2-2-1
(2) Switches and sensors..................................................................................................................... 2-2-2
(3) Motors............................................................................................................................................. 2-2-4
(4) Other electrical components........................................................................................................... 2-2-5
2-3 Operation of the PCBs
2-3-1 Power source PCB............................................................................................................................... 2-3-1
2-3-2 Main PCB ............................................................................................................................................. 2-3-5
2-3-3 Operation unit PCB ............................................................................................................................ 2-3-17
2-3-4 Scanner drive PCB............................................................................................................................. 2-3-22
2-3-5 CCD PCB ........................................................................................................................................... 2-3-25
1-1-4
Page 14
2FD/2FF/2FG-3.0
2-4 Appendixes
Timing chart No. 1 .......................................................................................................................................... 2-4-1
Timing chart No. 2 .......................................................................................................................................... 2-4-2
Timing chart No. 3 .......................................................................................................................................... 2-4-3
Timing chart No. 4 .......................................................................................................................................... 2-4-4
Timing chart No. 5 .......................................................................................................................................... 2-4-5
Timing chart No. 6 .......................................................................................................................................... 2-4-6
Timing chart No. 7 .......................................................................................................................................... 2-4-7
Timing chart No. 8 .......................................................................................................................................... 2-4-8
Timing chart No. 9 .......................................................................................................................................... 2-4-9
Timing chart No. 10 ...................................................................................................................................... 2-4-10
Timing chart No. 11 ...................................................................................................................................... 2-4-11
Chart of image adjustment procedures........................................................................................................ 2-4-12
Maintenance parts list................................................................................................................................... 2-4-15
Periodic maintenance procedures................................................................................................................ 2-4-16
Optional devices supplied parts list.............................................................................................................. 2-4-18
General wiring diagram ................................................................................................................................ 2-4-20
1-1-5
Page 15

1-1-1 Specifications

Type ...............................................Desktop
Copying system .............................Indirect electrostatic system
Originals .........................................Sheets and books
Maximum size: A3/11" × 17"
Original feed system ......................Fixed
Copy paper ....................................Drawer: Plain paper (64 – 105 g/m
Bypass table: Plain paper (45 – 200 g/m
Special paper: Transparencies, tracing paper, colored paper, letterhead and
envelopes (when using the printer function only)
Note: Use the bypass table for special paper.
Copying sizes.................................Maximum: A3/11" × 17"
Minimum: A6R/5
1
/2" × 81/2" (When the bypass table is used)
Magnification ratios ........................Manual mode: 25 – 400%, 1% increments
Auto copy mode: fixed ratios
Metric
1:1 ± 1.0%, 1:4.00/1:2.00/1:1.41/1:1.22/1:1.15/1:0.86/1:0.81/1:0.70/1:0.50/1:0.25
Inch
1:1 ± 1.0%, 1:4.00/1:2.00/1:1.29/1:1.21/1:0.78/1:0.64/1:0.50/1:0.25
Copy speed....................................At 100% magnification in copy mode:
30 cpm copier
A3/11" × 17": 20 copies/min.
1
B4/8
/2" × 14": 20 copies/min. A4/11" × 8 A4R/8
1
/2": 30 copies/min.
1
/2" × 11": 22 copies/min. B5: 30 copies/min. B5R: 18 copies/min. 40 cpm copier A3/11" × 17": 23 copies/min.
1
B4/8
/2" × 14": 23 copies/min. A4/11" × 8 A4R/8
1
/2": 40 copies/min.
1
/2" × 11": 27 copies/min. B5: 40 copies/min. B5R: 22 copies/min. 50 cpm copier A3/11" × 17": 26 copies/min.
1
B4/8
" × 14": 26 copies/min.
/
2
A4/11" × 8 A4R/8
1
/2": 50 copies/min.
1
/2" × 11": 31 copies/min. B5: 50 copies/min. B5R: 24 copies/min.
First copy time................................From 3.9 s (A4/11" × 8
From 3.5 s (A4/11" × 8
1
/2") <30 cpm copier>
1
/2") <40 cpm copier/50 cpm copier>
Warm-up time.................................25 s or less (room temperature 23°C/73.4°F, 50% RH)
In preheat/energy saver mode: 12 s or less (room temperature 23°C/73.4°F, 50% RH) [priorty to power save]
Paper feed system .........................Automatic feed
Capacity: Drawers: 500 sheets Manual feed Capacity: Bypass: 200 sheets
Continuous copying .......................1 - 999 sheets
Photoconductor..............................a-Si (drum diameter 40 mm)
Charging system ............................Single positive corona charging (500 µA)
Exposure light source ....................Semiconductor laser
Exposure scanning system............Polygon mirror
Developing system.........................Dry, reverse developing (single component system)
Developer: 1-component, magnetism toner Developing bias: +1.72 kV AC Developing shift bias: 160 V Toner replenishing: automatic from a toner container
2
)
2
)
2FD/2FF/2FG-3.0
1-1-1
Page 16
2FD/2FF/2FG-3.0
Tr ansfer system .............................Transfer roller (100 µA)
Separation system .........................Separation electrode (60 or 10 µA depending on the paper)
Fixing system .................................Heat roller
Heat source: halogen heaters (120 V specifications:main 600 W, sub 500 W/220-240 V specifications:main 640 W, sub 534 W) Control temperature: 175°C/347°F (at normal ambient temperature, 50 cpm copier) 170°C/338°F (at normal ambient temperature, 40 cpm copier) 165°C/329°F (at normal ambient temperature, 30 cpm copier) Abnormally high temperature protection device: 170°C/338°F thermostat
Fixing pressure: 107.8 N
Charge erasing system..................Exposure by cleaning lamp
Cleaning system.............................Cleaning blade and roller
Scanning system............................Flat bed scanning by CCD image sensor
Bit map memory.............................27 MB (standard)
Image storage memory..................37 MB (standard)
Resolution ......................................600 × 600 dpi
Light source....................................Inert gas lamp
Dimensions ....................................585 (W) × 646 (D) × 745 (H) mm
23" (W) × 25
2
/5" (D) × 291/3" (H)
Weight ............................................Approx. 82 kg/165 lbs
Floor requirements.........................1512 (W) × 646 (D) mm
1
59
/2" (W) × 252/5" (D)
Functions........................................Auto paper selection mode, Image quality selection, Auto magnification selection
mode, Zoom mode, Preset zoom mode, XY zoom mode, 2-sided copy modes, Page separation/Split copy modes, Margin mode, Centering/Image shift mode, Memo mode, Border erase modes, Combine/Merge Copy modes, Print page numbers mode, Form overlay mode, Booklet/Stitching mode, Book to Booklet mode, Sort/ Finished mode, Auto rotation function, Cover mode, Transparency + backing sheet mode, Invert mode, Mirror image mode, Proof mode, Repeat copy mode*, Batch scanning mode, Eco print mode, Program function, Job build mode, Form registration*, Shared data box*, Synergy print boxes*, Copy management mode, Language selection function *Requires the optional hard disk
Power source .................................120 V AC, 60 Hz, 12 A Max.
220 – 240 V AC, 50/60 Hz, 6.5 A Max.
Power consumption........................Max. 1450 W
Options...........................................DP, paper feeder, large paper deck, job separator, 3000-sheet finisher, 1000-sheet
finisher, booklet stitcher, built-in finisher, key counter, fax board, printer board,
network printer board, network scanner board, hard disk
1-1-2
Page 17

1-1-2 Parts names and their functions

(1) Copier
2FD/2FF/2FG-3.0
1 Original cover 2 Operation panel 3 Conveying cover handle 4 Conveying cover 5 Bypass tray 6 Insert guides 7 Toner container 8 Toner container release lever 9 Toner disposal tank 0 Cleaning shaft ! Front cover @ Main power switch
Figure 1-1-1
# Copy store section $ Platen % Original size scales ^ Upper drawer & Lower drawer * Side cover ( Length adjustment plate ) Width adjustment lever Handles for transport ¤ Main power switch cover*
*: Only for metric specifications.
1-1-3
Page 18
2FD/2FF/2FG-3.0
(2) Operation panel
0
(* &^ % 7654
3
!
@
# $
1 Start key (Indicator lamp) 2 Stop/clear key 3 Reset key 4 Energy Saver (preheat) key 5 Interrupt key (Indicator lamp) 6 Management key 7 Default Setting/Counter key 8 Numeric key 9 Touch panel 0 Brightness adjustment control dial ! Copier key (Indicator lamp)
)
1289
Figure 1-1-2
@ Printer key (Indicator lamp) # Scanner key (Indicator lamp) $ Fax key (Indicator lamp) % Auto Selection key (Indicator lamp) ^ Job Build key (Indicator lamp) & Repeat Copy key (Indicator lamp) * Job Queue key (Indicator lamp) ( Document Management key (Indicator lamp) ) Power key (Indicator lamp)* Main power Indicator lamp*
*: Only for metric specifications.
1-1-4
Page 19

1-1-3 Machine cross section

2FD/2FF/2FG
Figure 1-1-3 Machine cross section
1 Paper feed section 2 Main charging section 3 Optical section 4 Developing section 5 Transfer and separation section 6 Cleaning and charge erasing section section 7 Fixing section 8 Eject and switchback section 9 Duplex section
Light path
Paper path
1-1-5
Page 20
2FD/2FF/2FG

1-1-4 Drive system

(1) Drive system 1 (drive motor and eject motor drive trains)
1-1-6
1 Drive motor gear 2 Drum gear Z76H/Z30H 3 Drum gear Z70H 4 Gear Z76H/Z35H 5 Gear Z50H 6 Gear Z36S/Z31H 7 Gear Z37H/28H 8 Gear Z34H
As viewed from machine rear
Figure 1-1-4
9 Registration clutch gear 0 Gear Z63H/Z45S ! Gear Z37S @ Gear Z24S # Joint gear Z32S $ Eject motor gear % Gear Z47S/Z28S ^ Eject gear Z30S
Page 21
(2) Drive system 2 (paper feed motor drive train)
2FD/2FF/2FG
1 Paper feed motor gear 2 Gear Z76H/Z35S 3 Feed gear Z25 4 Feed gear Z25 5 Feed gear Z25 6 Feed gear Z25 7 Gear Z41S/Z24S/P30 8 Upper paper feed clutch gear 9 Paper feed drive belt 0 Gear Z41S/Z24S
As viewed from machine rear
Figure 1-1-5
! Lower paper feed clutch gear @ Gear Z41S/P15 # Bypass drive belt $ Gear Z60S/P20 % Gear Z41S/P18 ^ Gear Z40S/Z32S & Container drive belt * Gear Z24S/P40 ( Gear Z40S/Z25S ) Container gear
1-1-7
Page 22
2FD/2FF/2FG
(3) Drive system 3 (duplex section)
Figure 1-1-6
1 Pulley T30 2 Duplex belt 3 Pulley T30 4 Duplex feed clutch gear 5 Gear 25 6 Idle gear 20 7 Gear 25
1-1-8
Page 23
2FD/2FF/2FG

1-2-1 Drum

Note the following when handling or storing the drum.
When removing the drum unit, never expose the drum surface to strong direct light.
Keep the drum at an ambient temperature between 0°C/32°F and 35°C/95°F and at a relative humidity not higher than
85% RH. Avoid abrupt changes in temperature and humidity.
Avoid exposure to any substance which is harmful to or may affect the quality of the drum.
Do not touch the drum surface with any object. Should it be touched by hands or stained with oil, clean it.

1-2-2 Toner

Store the toner in a cool, dark place. Avoid direct light and high humidity.

1-2-3 Installation environment

1. Temperature: 10 - 35°C/50 - 95°F
2. Humidity: 15 - 85%RH
3. Power supply: 120 V AC, 12 A
4. Power source frequency: 50 Hz ±0.3%/60 Hz ±0.3%
5. Installation location
Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams.
Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directed onto the machine.
Avoid dust and vibration.
Choose a surface capable of supporting the weight of the machine.
Place the machine on a level surface (maximum allowance inclination: 1° ).
Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor, such as
mercury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.
Select a room with good ventilation.
6. Allow sufficient access for proper operation and maintenance of the machine. Machine front: 1000 mm/39 Machine right: 300 mm/1113/16" Machine left: 300 mm/1113/16"
220 - 240 V AC, 5.7 A (Average)
3
/8" Machine rear: 300 mm/1113/16"
f
ec
b
5
3
13
/16"
/8"
7
/16"
/16"
a: 745 mm/29 b: 585 mm/23" c: 646 mm/25 d: 1510 mm/59
a
d
e: 1032 mm/405/8"
f: 961 mm/37
Figure 1-2-1 Installation dimensions
1-2-1
Page 24

1-3-1 Unpacking and installation

(1) Installation procedure
Start
Unpack.
Remove the tapes and pad.
2FD/2FF/2FG
Install the optional paper feeder or
large paper deck.
Remove the pins holding light source units 1 and 2.
Install the original cover or the DP.
Install other optional devices.
Install the toner container.
Install the toner disposal tank.
Connect the power cord.
Carry out initial developer setting
(maintenance item U130).
Load paper.
Output an own-status report
(maintenance item U000).
Exit maintenance mode.
Print out the user setting list.
Make test copies.
Completion of the machine installation.
1-3-1
Page 25
2FD/2FF/2FG
Moving the machine
When moving the machine, pull out the four handles for transport on the right and left sides and hold them. * For the left front handle for transport, open the door and push it into the machine before pulling out the handle.
Handle for transport
Handle for transport
Figure 1-3-1
Handle for transport
Handle for transport
1-3-2
Page 26
Unpack.
120 V specifications
2FD/2FF/2FG-3.0
Figure 1-3-2a Unpacking
1 Copier 2 Power cord 3 Upper pad 4 Sheet 5 Outer case 6 Inner frame 7 Eject spacer 8 Hinge joints 9 Bottom pad 0 Machine cover ! Front left pad
Caution: Place the machine on a level surface.
@ Front right pad # Rear left pad $ Rear right pad % Skid ^ Plastic bag & Bar code labels * Bottom spacer ( Plastic bag ) Operation guide Plastic bag ¤ M3 x 8 screws
1-3-3
Page 27
2FD/2FF/2FG-3.0
230 V specifications
1-3-4
Figure 1-3-2b Unpacking
1 Copier 2 Power cord 3 Upper left pad 4 Upper right pad 5 Outer case 6 Inner frame 7 Eject spacer 8 Belts 9 Bottom pad 0 Machine cover ! Front left pad @ Front right pad
Caution: Place the machine on a level surface.
# Rear left pad $ Rear right pad % Skid ^ Plastic bag & Bar code labels * Bottom spacer ( Plastic bag ) Operation guide Plastic bag ¤ M3 x 8 screws Spacer
Page 28
Remove the tapes and pad.
1. Remove the tapes holding the front cover,
bypass tray, drawers and original detection switch.
2. Remove the tape and then remove the pad at the
eject section.
3. Remove the tape holding the power cord.
Tape
2FD/2FF/2FG-3.0
Tape
Pad
Tape
Tape
4. Remove the three tapes holding the pins for light
source units 1 and 2.
5. Remove the tape holding the conveying cover.
Tapes
Figure 1-3-3
Tapes
Tape
Figure 1-3-4
1-3-5
Page 29
2FD/2FF/2FG-3.0
6. Pull upper and lower drawers out and remove the tape holding each of the drawer lift. *If necessary, please fix the cassette cursor with the screws included in the machine box.
Install the optional paper feeder or large paper deck.
1. Install the optional paper feeder or large paper deck as necessary (see page 1-3-13 to 1-3-21).
Tape
Figure 1-3-5
Remove the pins holding light source units 1 and 2.
1. Remove the two pins for light source unit 1 and the pin for light source unit 2.
Light source unit 1 pins
Light source unit 2 pin
Install the original cover or the DP.
1. Install the original cover or DP (see page 1-3-33 when installing the DP).
Figure 1-3-6
Install other optional devices.
1. Install the optional devices (job separator, finisher, fax board, and/or printer board etc.) as necessary.
1-3-6
Page 30
Install the toner container.
1. Open the front cover.
2. Tap the top of the toner container five to six times.
3. Shake the toner container approximately 10 times in the horizontal direction to stir toner.
2FD/2FF/2FG-3.0
Toner container
Figure 1-3-7
Toner container
4. Gently push the toner container into the copier along the rails.
*Push the container all the way into the copier until
it locks in place.
Figure 1-3-8
Toner container
Figure 1-3-9
1-3-7
Page 31
2FD/2FF/2FG-3.0
Install the toner disposal tank.
1. Install the toner disposal tank in the copier.
2. Close the front cover.
Connect the power cord.
1. Connect the power cord to the connector on the copier.
2. Insert the power plug into the wall outlet.
Toner disposal tank
Figure 1-3-10
Carry out initial developer setting (maintenance item U130).
1. Turn the main switch on and enter the maintenance mode by entering “10871087” using the numeric keys.
2. Enter “130” using the numeric keys and press the start key.
3. Press the start key to execute the maintenance item. The drive stops within approximately 5 minutes.
4. Press the stop/clear key.
Load paper.
1. Load paper in the drawer.
Output an own-status report (maintenance item U000).
1. Enter “000” using the numeric keys and press the start key.
2. Select “MAINTENANCE” and press the start key to output a list of the current settings of the maintenance items.
3. Press the stop/clear key.
Exit maintenance mode.
1. Enter "001" using the numeric keys and press the start key. The machine exits the maintenance mode.
Print out the user setting list.
1. Press the * key to enter default setting and press the [Print form] key. The counter report will be output.
Make test copies.
1. Place an original and make test copies.
Completion of the machine installation.
1-3-8
1-3-7-1
Page 32
This page is intentionally left blank.
2FD/2FF/2FG-3.0
1-3-9
Page 33
2FD/2FF/2FG-3.0

1-3-2 Setting initial copy modes

Factory settings are as follows:
Maintenance
item No.
U253 U254 U255 U258
U260 U264
U277 U331 U342 U343 U344
Contents
Switching between double and single counts Turning auto start function on/off Setting auto clear time Switching copy operation at toner empty detection Changing the copy count timing Setting the display order of the date
Setting auto application change time Switching the finisher eject section Setting the ejection restriction Switching between duplex/simplex copy mode Setting preheat/energy saver mode
Factory setting
Double count ON 90s SINGLE MODE, 70
After ejection Inch specifications: MONTH-DATE-YEAR Metric specifications: DATE-MONTH-YEAR 30s OFF ON OFF ENERGY STAR
1-3-10
1-3-8
Page 34

1-3-3 Installing the key counter (option)

Key counter installation requires the following parts: Key counter set (P/N 2A369703) Contents of the set:
Key counter cover (P/N 2A360010)
Key counter retainer (P/N 66060030)
Key counter cover retainer (P/N 66060022)
Key counter mount (P/N 66060040)
Key counter socket assembly (P/N 41529210)
Four (4) M4 × 6 bronze TP-A screws (P/N B4304060)
Two (2) M4 × 10 bronze TP-A screws (P/N B4304100)
One (1) M4 × 20 bronze TP-A screw (P/N B4304200)
One (1) M4 × 6 chrome TP-A screw (P/N B4104060)
One (1) M3 × 8 bronze binding screw (P/N B1303080)
One (1) M4 × 30 bronze binding screw (P/N B1304300)
Two (2) M3 × 6 bronze flat-head screws (P/N B2303060)
One (1) M3 bronze nut (P/N C2303000)
2FD/2FF/2FG
Procedure
1. Fit the key counter socket assembly to the key counter retainer using the two screws and nut.
2. Fit the key counter mount to the key counter cover using the two screws, and attach the key counter retainer to the mount using the two screws.
3. Remove the three screws holding the middle right cover and then the cover.
4. Cut out the aperture plate on the middle right cover using nippers.
5. Pass the connect inside the copier through the aperture and refit the middle right cover.
M4 × 6 screws (B4304060)
Key counter retainer (66060030)
M3 nut (C2303000)
M4 × 6 screws (B4304060)
Key counter socket assembly (41529210)
M3 × 6 flat-head screws (B2303060)
Figure 1-3-11
Middle right cover
Key counter mount (66060040)
Key counter cover (2A360010)
Aperture
Figure 1-3-12
Connector
1-3-9
Page 35
2FD/2FF/2FG
6. Pass the connector of the key counter through the aperture in the key counter retainer, and insert into the connector of the copier.
7. Seat the projection of the key counter cover retainer in the aperture in the middle right cover.
8. Fit the key counter cover with the key counter socket assembly inserted to the key counter cover retainer on the copier using the screw.
9. Insert the key counter into the key counter socket assembly.
Key counter cover retainer (66060022)
Key conuter cover
Connector
10. Turn the main switch on and enter the maintenance mode.
11. Run maintenance item U204 and select KEY-COUNTER.
12. Exit the maintenance mode.
13. Check that the message requesting the key counter to be inserted is displayed on the touch panel when the key counter is pulled out.
14. Check that the counter counts up as copies are made.
Connector
Projection
M4 × 30 screws (B1304300)
Figure 1-3-13
1-3-10
Page 36

1-3-4 Installing the drawer heater (option)

Drawer heater installation requires the following parts:
Drawer heater (P/N 34860030): for 120 V specifications
Drawer heater (P/N 33960020): for 220 - 240 V specifications
Band (P/N M2107120)
Procedure
1. Remove thirteen screws and then the rear cover.
2FD/2FF/2FG
Rear cover
2. Pull the upper and lower drawers out.
3. Fit the drawer heater to the bottom of the machine and bind the wire of the drawer heater with the band.
4. Put the wire of the drawer heater out of the machine through the aperture of the rear frame.
5. Remove the four screws and the two connectors and then remove the wires from the clamp. Remove the power source unit from the rear side of the machine.
Figure 1-3-14
Aperture
Drawer heater
Band
Figure 1-3-15
Clamp
Figure 1-3-16
Connectors
Power source unit
1-3-11
Page 37
2FD/2FF/2FG
6. Remove the two screws and pull out the wire of the drawer heater that has been put out of the rear frame while raising the power source PCB unit.
7. Insert the connector of the drawer heater into the connector of the machine.
8. Refit all the removed parts.
Power source PCB unit
Wire of the drawer heater
Connector
Figure 1-3-17
1-3-12
Page 38

1-3-5 Installing the paper feeder (option)

Preparation
1. Remove the lower drawer from the copier.
2. Place the copier on top of the paper feeder with the positioning pins at the front left and right of the paper feeder aligned with the holes in the base of the copier.
2FD/2FF/2FG
Lower drawer
Figure 1-3-18
3. Secure the copier to the paper feeder using the two pins.
4. Refit the lower drawer to the copier.
Pin
Holes
Pins
Paper feeder
Figure 1-3-19
Pin
Figure 1-3-20
Paper feeder
1-3-13
Page 39
2FD/2FF/2FG
5. Remove the screw and then the cover from the rear of the paper feeder.
6. Remove the screw from the copier.
7. Insert the 12-P connector of the paper feed desk into the connector on the copier.
Screw
Screw
Figure 1-3-21
Cover
8. Route the harness through the clamp on the retainer. Check that the harness and the motor do not contact.
9. Fit the retainer using the screw removed in step 6 and the two CVM4 × 06 cross-head chromate binding screws.
10. Refit the cover.
12-P connector
Figure 1-3-22
Harness
Motor
Retainer
Screw
Clamp
CVM4 × 06 cross-head chromate binding screws
1-3-14
Figure 1-3-23
Page 40
11. Turn the four leveling bolts until they reach the floor and adjust them to level the machine.
12. Fit the two stays to the left of the paper feeder (one toward the front and the other the rear) using the two M4 × 10 chrome TP screws such that they make contact with the floor. Note: Do not fit the stays if the finisher is to be installed.
13. Connect the copier power plug to the wall outlet and turn the copier power switch on.
14. Load paper into the drawer and make a test copy to check the operation.
2FD/2FF/2FG
Leveling bolts
Figure 1-3-24
Adjusting the center line
1. Run maintenance item U993. Select “PG1” and output a test pattern.
2. Check if the center of the paper and that of the test pattern output are aligned. If not, perform the following adjustment.
M4 × 10 chrome TP screws
Stays
Figure 1-3-25
Center of the paper
Center of the test pattern output
Figure 1-3-26
1-3-15
Page 41
2FD/2FF/2FG
3. Open the drawer of the paper feeder and loosen the three screws securing the adjuster.
A and B: test pattern output examples
4. If the test pattern output example looks like A, move the adjuster in the direction of the white arrow (e) and retighten the three screws. If the test pattern output example looks like B, move the adjuster in the direction of the black arrow (b) and retighten the three screws.
5. Output the test pattern again.
6. Repeat steps 3 to 5 until the centers of the paper and the test pattern are aligned.
Drawer
AB
Screws
Adjuster
*If necessary, please fix the cassette cursor
with the screws included in the machine box.
Figure 1-3-27
1-3-16
Page 42

1-3-6 Installing the large paper deck (option)

Preparation
1. Remove the lower drawer from the copier.
2. Place the copier on top of the large paper deck with the positioning pins at the front left and right of the large paper deck aligned with the holes in the base of the copier.
2FD/2FF/2FG
Lower drawer
Figure 1-3-28
3. Secure the copier to the large paper deck using the two pins.
4. Refit the lower drawer to the copier.
Hole
Large paper desk
Pin
Pin
Hole
Pin
Figure 1-3-29
Pin
Figure 1-3-30
Large paper desk
1-3-17
Page 43
2FD/2FF/2FG
5. Remove the screw and then the cover from the rear of the large paper deck.
6. Remove the screw from the rear of the copier.
Screw
Figure 1-3-31
7. Insert the 12-pin connector of the large paper deck into the connector on the copier.
Screw
Cover
12-pin connector
8. Fit the retainer using the screw removed in step 6 and the two CVM4 × 06 cross-head chromate binding screws.
9. Refit the cover using the screw (see step 5).
OK NG
Figure 1-3-32
Retainer
CVM4 × 06 cross-head chromate binding screw
CVM4 × 06 cross-head chromate binding screw
Screw
Figure 1-3-33
1-3-18
Page 44
10. Turn the four leveling bolts until they reach
the floor and adjust them to level the machine.
2FD/2FF/2FG
Leveling bolts
Figure 1-3-34
11. Fit the stay to the lower left of the large paper deck toward the rear using the two M4 × 16 chrome TP screws such that it makes contact with the floor. Note: Do not fit the stay if the finisher is to be installed.
Setting the paper size
1. Open the large paper deck.
2. Move the sliders at the machine front and rear inward (two at each point).
3. Remove the screw from each of the front and rear lateral size adjusters.
Stay
M4 × 16 chrome TP screws
Figure 1-3-35
Screw
Leteral size adjuster
Sliders
Leteral size adjuster
Sliders
Screw
Figure 1-3-36
1-3-19
Page 45
2FD/2FF/2FG
4. Insert the upper tabs and lower tabs of the front and rear lateral size adjusters into the upper slots and lower slots respectively such that the size indicators point to the size of paper to be used. Secure the lateral size adjusters using the screw for each.
5. Move the front and rear sliders (two at each point) outward until they make contact with the lateral size adjusters.
Lower tabs
Lower tabs
Lower slots
Lower slots
Upper tab
Upper slots
Upper slots
Upper tabs
Upper tab
Upper slots
Upper slots
Size indicator
A4 LT B5
B5 LT
A4
Size indicator
Figure 1-3-37
6. Remove the screw from each of the left and right longitudinal size adjusters.
7. Align the pin holes in the left and right longitudinal size adjusters with the A4 pins or B5 pins according to the size of paper to be used. Secure the adjusters using the screw for each.
Longitudinal size adjuster
B5 pins
B5
A4 pins
A4
Screw
Pin hole
Screw
Pin hole
Screw
Longitudinal size adjuster
Figure 1-3-38
8. Connect the copier power plug to the wall outlet and turn the copier power switch on.
9. Run maintenance item U208 and set the paper size for the large paper deck (B5/A4/ Letter).
10. Load paper into the drawer and make a test copy to check the operation.
1-3-20
Page 46
Adjusting the center line
1. Run maintenance item U993. Select “PG1” and output a test pattern.
2. Check if the center of the paper and that of the test pattern output are aligned. If not, perform the following adjustment.
3. Pull out the cassette of the paper feeder and loosen the two screws securing the adjuster.
2FD/2FF/2FG
Center of the test pattern output
Center of the paper
Figure 1-3-39
A and B: test pattern output examples
4. If the test pattern output looks like A, move
AB
the adjuster in the direction of the black arrow (b) and retighten the two screws. If the test pattern output looks like B, move the adjuster in the direction of the white arrow (e) and retighten the two screws.
5. Output a test pattern again.
6. Repeat steps 3 to 5 until the centers of the paper and the test pattern are aligned.
Screw
Adjuster
Screw
Figure 1-3-40
7. Loosen the five screws.
8. Adjust the position of the front cover so that the level indicating the position of the adjuster and the level indicating the position of the front cover are the same. If the positions of the adjuster and front cover are not aligned, the paper cassette cannot be closed properly.
9. Retighten the five screws.
Levels
Screws
Levels
Adjuster
Figure 1-3-41
Levels
Screw
Front cover
Levels
Screws
1-3-21
Page 47
2FD/2FF/2FG

1-3-7 Installing the booklet stitcher/switchback unit (option)

Preparation
1. Open the conveying cover of the copier.
2. Remove the two screws securing the feedshift guide assembly and then the assembly.
Feedshift guide assembly
Screws
Figure 1-3-42
Conveying cover
3. Fit the curl eliminator to the conveying cover such that the projections on the cover fit into the two ends of the curl eliminator.
4. Secure the curl eliminator using the two screws removed in step 2.
5. Close the conveying cover.
6. Fit the latch catch to the conveying cover using two M4 × 10 binding screws.
Projection
Curl eliminator
Screw
Figure 1-3-43
Conveying cover
Screw
Projection
1-3-22
Latch catch
M4 × 10 binding screws
Figure 1-3-44
Page 48
7. Remove 13 screws and take off the rear cover.
8. Remove 13 screws and take off the shield cover.
2FD/2FF/2FG
Rear cover
Figure 1-3-45
Shield cover
9. Insert the board supports into the three round holes of the IPC PCB. Detach the 10-pin connector (four wires) from YC4 on the main PCB and connect it to J2 on the IPC PCB.
Screws
Figure 1-3-46
Main PCB
YC15
YC4
IPC PCB
J2
10-Pin connector
Figure 1-3-47
1-3-23
Page 49
2FD/2FF/2FG
10. Connect J1 on the IPC PCB to YC15 on the main PCB.
11. Insert the board supports into the three round holes of the main PCB and secure the IPC PCB.
12. Refit the shield cover and rear cover.
Round holes
YC4
YC15
Round hole
Main PCB
IPC PCB
J2
Board supports
J1
13. Align the rail retainer with the groove of the guide rail and attach the rail retainer to the guide rail. Make sure that the plate spring of the rail retainer fits into the groove and the edge of the guide rail fits between the pulleys on the reverse side of the rail retainer.
Figure 1-3-48
Board support
Guide rail
Figure 1-3-49
Rail retainer
Plate spring
1-3-24
Page 50
When the switchback unit is not to be installed
14. Orient the guide rail such that its pulley is positioned toward the copier, and then fit a caster rail to each side of the rail retainer.
When the switchback unit is to be installed
15. Attach a spacer to each end of the rail retainer using two M4 × 6 binding screws for each.
16. Orient the guide rail such that its pulley is positioned toward the copier, and then fit the caster rails to the spacer.
Caster rail
Rail retainer
Rail retainer
M4 × 6 binding screws
Spacer
Rail retainer
2FD/2FF/2FG
Pulley
M4 × 6 binding screws
Guide rail
17. Secure the rail retainer to the copier using two M4 × 10 binding screws such that the front and rear gaps between the floor and rail retainer are approximately 10 mm.
Caster rail
Spacer
Caster railGuide rail
Caster rail
Figure 1-3-50
Rail retainer
10 mm 10 mm
Rail retainer
M4 × 10 binding screws
Figure 1-3-51
1-3-25
Page 51
2FD/2FF/2FG
18. Slightly lift the bottom of the finisher and insert the rail fixing plate into the finisher, and then join them by inserting two M4 × 6 binding screws loosely.
19. Insert the guide rail into the rail fixing plate and secure it using an M4 × 6 binding screw at the position where the screw hole in it and that in the rail fixing plate meet. Note: When installing the switchback unit, use screw hole a in the guide rail; when not installing the switchback unit, use screw hole b in the guide rail.
Finisher
Rail fixing plate
M4 × 6 binding screws
Rail fixing plate
Figure 1-3-52
M4 × 6 binding screw
Rail fixing plate
Guide rail
20. Adjust the position of the rail fixing plate so that the gap between the plate and the floor is approximately 8.0 mm, and then tighten the two loosely fitted M4 × 6 binding screws.
Screw hole a
Screw hole b
Figure 1-3-53
M4 × 6 binding screws
Rail fixing plate
8.0 mm
M4 × 6 binding screws
1-3-26
Figure 1-3-54
Page 52
2FD/2FF/2FG
21. Fit the eject tray to the finisher by hooking the two claws and secure it using two M4 × 6 binding screws.
Eject tray
M4 × 6 binding screws
Claw
Claw
Figure 1-3-55
22. Open the front panel and insert the stapler unit into the finisher. When inserting the stapler unit into the finisher, be sure to grasp the upper portion (shaft) of the stapler unit as shown in the illustration. If the plate in the middle portion (stay transport) is grasped, the unit may be deformed, resulting in paper jams.
23. Close the front panel.
Shaft
Stapler unit
Front panel
Installing the switchback unit
1. Remove the two support rubbers on the right of the finisher and loosely fit the two M3 × 8 binding screws in their places.
2. Remove the two screws.
Figure 1-3-56
Screw
Stay transport
Finisher
Screw
Support rubber
Support rubber
Figure 1-3-57
M3 × 8 binding screws
1-3-27
Page 53
2FD/2FF/2FG
3. Release the hook of the switchback unit by lifting the release lever.
4. Fit the switchback unit to the finisher by hanging the hook of the switchback unit on the loosely fitted M3 × 8 binding screws.
5. Tighten the loosely fitted M3 × 8 binding screws.
6. Secure the switchback unit using two M4 × 12 TP screws.
7. Close the switchback unit.
Switchback unit
Release lever
Hook
Figure 1-3-58
Finisher
Hook
Switchback unit
8. Remove the two screws from the cover of the finisher.
M4 × 12 TP screw
Figure 1-3-59
M4 × 12 TP screw
M3 × 8 binding screws
Finisher
Screws
1-3-28
Figure 1-3-60
Page 54
9. Insert the rib of the front cover into the groove in the top cover of the switchback unit, and then fit the front cover to the finisher.
10. Secure the front cover by fitting an M4 × 12 TP screw and M4 × 16 TP screw into the holes where screws were inserted (see step 8).
Rib
Groove
Front cover
2FD/2FF/2FG
Finisher
M4 × 12 TP screw
M4 × 16 TP screw
Figure 1-3-61
11. Fit the two support rubbers removed in step 1 to the switchback unit.
12. If the finisher and the copier do not engage securely, perform the following finisher height adjustment.
Adjusting the height of the finisher
1. Remove the two covers from the lower left part of the finisher by removing one screw each.
2. Remove the four caps from above the four casters of the finisher.
Support rubbers
Figure 1-3-62
Cap
Cover
Screws
Cap
Caster
Cover
Figure 1-3-63
1-3-29
Page 55
2FD/2FF/2FG
3. Loosen the two screws on each of the four casters.
4. Adjust the height of the rear right caster by turning its adjustment bolt using a cross­headed screwdriver so that the axis of the pin of the latch catch is aligned with the middle of the three markings on the right of the slot of the finisher or switchback unit when the finisher is joined to the copier (viewed from the machine front). Note: Turning the adjustment bolts clockwise lowers the finisher, while turning them counterclockwise lifts the finisher.
Pin
Adjustment bolt
Screws
5. Adjust the height of the front right caster in the same manner as in step 4 so that the axis of the pin of the latch catch is aligned with the marking above the slot and the center of the two hooks on the finisher align with the center of the holes on the latch catch when the finisher is joined to the copier (viewed from above).
Slot
Pin
Caster
Figure 1-3-64
Pin
1-3-30
Slot
HolesHooks
Pin
Figure 1-3-65
Page 56
2FD/2FF/2FG
When the switchback unit is installed
6. Adjust the height of the front right caster in the same manner as in step 4 so that the hook of the latch catch is aligned with the projection of the switchback unit when the finisher is joined to the copier (viewed from front).
When the switchback unit is not installed
6. Adjust the height of the front right caster in the same manner as in step 4 so that the center of the hook of the latch catch is aligned with the marking of the finisher when the finisher is joined to the copier (viewed from front).
Projection
Hook
7. Adjust the height of the left two casters in the same manner as in step 4 so that the top and bottom gaps (A) between the finisher and the copier are the same when the finisher is detached from the copier.
8. Retighten the two screws on each of the four casters.
9. Refut the two covers and four caps.
Marking
Hook
Figure 1-3-66
A
A
Figure 1-3-67
1-3-31
Page 57
2FD/2FF/2FG
Connecting the signal cable
1. Connect the signal cable of the finisher to the copier. If the switchback unit has been installed, connect the signal cable of the switchback unit, as well.
2. Insert the copier power plug to the wall outlet and turn the power switch on.
3. Make test copies and check that the finisher and the switchback unit operate correctly.
Setting the booklet stapling position
1. Enter the maintenance mode and run U246.
2. Select "Saddle finisher" and press the start key.
3. Select the size to be set. The selected item is displayed in reverse.
4. Change the setting using the cursor up/down keys. a: Decrease the preset value. b: Increase the preset value. *Setting range: –125 to +125 Initial setting: 0 Change in value per step: Approx. 0.25 mm
5. Press the start key. The value is set.
6. Press the stop/clear key twice.
7. Run U001 to exit the maintenance mode.
Signal cable of the finisher
Signal cable of the switchback unit
Figure 1-3-68
1-3-32
a
b
Figure 1-3-69
Page 58

1-3-8 Installing the sheet-through document processor (option)

2FD/2FF/2FG
Preparation
1. Insert the DP into the copier.
2. Connect the connector of the DP to the copier.
3. Insert the copier power plug to the wall outlet and turn the power switch on.
DP
Figure 1-3-70
DP
4. Place the original on the DP and make a test copy. Check the operation and the copy image.
5. If the copy image is different from the original, run the following adjustment.
Maintenance item U070 (sub-scan line
adjustment) (see page 1-4-25) Maintenance item U071 (leading edge
timing adjustment) (see page 1-4-26) Maintenance item U072 (center line
adjustment) (see page 1-4-27)
Connector
Figure 1-3-71
1-3-33
Page 59
2FD/2FF/2FG

1-3-9 Installing the Printing System (option)

Procedure
1. Remove 2 screws and take off the cover.
2. Push the printing system all the way in along the rails, and fasten it with 2 screws.
Cover
Screws
Figure 1-3-72
Printing system
Install the (optional) network printer board.
3. Remove 2 screws and take off the cover.
4. Push the network printer board all the way in along the rails, and fasten it with 2 screws.
Screws
Cover
Screws
Figure 1-3-73
Screws
Netwark
printer
board
1-3-34
Figure 1-3-74
Page 60
Install the (optional) hard disk.
5. Remove 2 screws and take off the cover.
6. Push the hard disk all the way in along the rails, and fasten it with 2 screws.
2FD/2FF/2FG
Installing the Optional Memory DIMM
7. Remove the printing system, and insert the optional memory DIMM firmly into either of the memory slots. Push the DIMM firmly into the slot so that the two hooks (one hook at each end of the slot) snap closed.
The board provides two DIMM slots, and can accept up to two optional DIMMs. If installing a single DIMM, you can use either slot.
Cover
Screws
Hooks
Hard desk
Screws
Figure 1-3-75
Option mermory DIMM
Hooks
Memory
slots
Figure 1-3-76
1-3-35
Page 61
2FD/2FF/2FG

1-3-10 Installing the Scanning System (option)

Procedure
1. Remove 13 screws and take off the rear cover.
Rear cover
Figure 1-3-77
If the printing system is installed
2. Remove the 2 screws holding the printer system in place, and pull the printing system out of the shield cover.
3. Remove 13 screws and take off the shield cover.
Printer system
Screws
Figure 1-3-78
Shield cover
1-3-36
Screws
Figure 1-3-79
Page 62
2FD/2FF/2FG
4. Remove 2 screws, and take off the cover.
5. Firmly push connector CN1 on the scanner board all the way into connector YC46 on the main PCB.
6. Fasten the scanner board with 2 screws.
Cover
Screws
Figure 1-3-80
Connector YC46
Connector CN1
Scanner board
7. Fasten the shield cover into place with 13 screws.
Screws
Figure 1-3-81
Shield cover
Screws
Figure 1-3-82
1-3-37
Page 63
2FD/2FF/2FG
If the printing system was installed
8. Reinstall the printing system into the shield cover, fastening it into place with 2 screws.
9. Reattach the rear cover with 13 screws.
Printing system
Screws
Figure 1-3-83
Rear cover
1-3-38
Figure 1-3-84
Page 64

1-3-11 Installing the built-in finisher (option)

Preparation Note: When placing the transfer unit on the floor
or the like, be sure to place it upside down. If not, the stapler mounting plate may be deformed, resulting in a malfunction.
2FD/2FF/2FG
Transfer unit
Figure 1-3-85
Procedure
1. Remove the screw and the pin to remove the upper left cover.
2. Open the conveying cover and the front cover.
3. Loosen the two screws on the left side and the screw on the front side, open the hook on the right side, and remove the left front cover.
Upper left cover
Pin
Screw
Figure 1-3-86
Left front cover
Screws
Hook
Screw
Figure 1-3-87
1-3-39
Page 65
2FD/2FF/2FG
4. Close the conveying cover and the front cover.
5. Remove the two screws and then remove the ejection cover with the mounting plate.
6. Remove the two screws and then remove the inner ejection cover.
Ejection cover
Screws
Figure 1-3-88
7. Remove the screw located at the front of the static charge eliminator of the copier, fit the flat spring ejection from the lower side, and secure it with the removed screw.
Screws
Figure 1-3-89
Flat spring ejection
Inner ejection
cover
Screw
1-3-40
Figure 1-3-90
Page 66
8. Remove the blue screw from the transfer unit and then remove the mounting plate.
9. Remove the securing tape from the 13-pin connector, pass the wire under the stapler motor, and connect the wire with the 13-pin connector.
Blue screw
2FD/2FF/2FG
Transfer unit
Mounting plate
Securing tape
10. Insert the transfer unit into the copier from the front side and slide it to the left. Secure the unit using two +TP-A bronze screws M3 × 05 and the pin that has been fitted to the transfer unit.
Transfer unit
13-pin connector
Figure 1-3-91
+TP-A bronze screw M3 × 05
11. Insert the metal hook of the transfer unit into the oblong hole of the frame of the copier and secure it using a +TP-A bronze screw M3 ×
05. * Insert the projection of the frame into the
hole of the metal hook to position the hook.
* Arrange the cable to position it under the
metal fittings.
+TP-A bronze screw M3 × 05
Figure 1-3-92
Metal fittings
+TP-A bronze screw M3 × 05
Pin
Hook
Oblong hole
Hole
Projection
Cable
Figure 1-3-93
1-3-41
Page 67
2FD/2FF/2FG
12. Remove a screw, turn the metal fittings upward, and fit the screw again to the lower hole.
13. Insert the intermediate tray and connect the connector (white) of the intermediate tray to the transfer unit. Connect the connectors (gray) to the connectors of the copier as shown in the illustration. Connect the gray connector with more pins to the upper connector and the gray connector with less pins to the lower connector.
Metal fittings
Screw
Screw
Figure 1-3-94
Connector (white)
Intermediate tray
Connector (gray)
14. Attach the intermediate tray to the copier as shown in the illustration so that the right and left pins of the intermediate tray are positioned to the recessed portions of the copier and the transfer unit.
Transfer unit
1-3-42
Recessed portion
Figure 1-3-95
Pin
Recessed porton
Intermediate tray
Figure 1-3-96
Page 68
15. Attach the large ejection cover using the two screws that have secured the upper left cover.
2FD/2FF/2FG
Large ejection
cover
Figure 1-3-97
16. Open the front cover and the conveying cover.
17. Attach the staple cover. * Tighten the two screws on the left side to
secure the cover with the copier, secure the front side using the screw that has been removed in step 3, and secure the right side using a +TP-A chrome screw M3 × 05.
18. Close the conveying cover and the front cover. Attach the front ejection cover and the rear ejection cover using a +TP-A chrome screw M3 × 05 each.
+TP-A chrome screw M3 × 05
Staple cover
Figure 1-3-98
+TP-A chrome screw M3 × 05
Front ejection cover
Rear ejection cover
+TP-A chrome screw M3 × 05
Figure 1-3-99
1-3-43
Page 69
2FD/2FF/2FG
19. Attach the copy tray.
Copy tray
Figure 1-3-100
20. Open the staple cover and insert the staple cartridge into the stapler.
21. Close the staple cover.
22. Insert the power plug of the copier into an outlet and turn the power switch on.
23. Select the staple mode and make a stapled copy to check that stapling is performed properly.
Staple cover
Staple cartridge
Figure 1-3-101
1-3-44
Page 70

1-3-12 Installing the job separator (option)

2FD/2FF/2FG
Preparation
1. Insert the LED PCB into the job separator and connect the 2-pin connector of the LED PCB into the 2-pin connector of the job separator.
* Arrange the wire into the two grooves of the
job separator.
2. Open the conveying cover and the front cover.
3. Loosen the two left screws on the left side, remove the screw on the front side, open the hook on the right side, and remove the left front cover.
4. Close the conveying cover and the front cover.
Job separator
Left front
cover
2-pin connector
Figure 1-3-102
2-pin connector
Grooves
LED PCB
5. Remove the two screws and remove the ejection cover with the mounting plate.
Screws
Hook
Screw
Figure 1-3-103
Ejection cover
Screws
Figure 1-3-104
1-3-45
Page 71
2FD/2FF/2FG
6. Remove the two screws and then remove the inner ejection cover.
7. Insert the job separator into the copier from the front side and slide it to the left. Secure the front side using a +TP-A bronze screw M3 × 05 and the rear side using a pin. * Check to see if the branch pressure lever on
the rear side of the job separator has lowered.
Screws
Inner ejection
cover
Figure 1-3-105
+TP-A bronze screw M3 × 05
Job separator
Pin
Figure 1-3-106
1-3-46
Page 72
8. Connect the connector of the job separator to the lower connector of the copier.
9. Attach the job separator tray to the rail of the job separator by sliding it from the front side. * Insert the fitting section on the right side of
the job separator tray into the recessed portion of the copier.
* Put the hook on the right side onto the pin.
10. Open the left transfer cover and the front cover. Fit the left front cover JS to the location to which the upper front cover that has been removed in step 3 was fitted.
2FD/2FF/2FG
Connector
Connector of the copier
Figure 1-3-107
left front cover JS
Rail
11. Insert the power plug of the copier into an outlet and turn the power switch on.
12. Set the “copy ejection location” of the machine default settings to job separator.
13. Make a test copy to check that a copy is ejected to the job separator tray.
Job separator tray
Figure 1-3-108
Fitting section
Pin
Recessed portion
Hook
1-3-47
Page 73
2FD/2FF/2FG

1-3-13 Installing the Facsimile System (option)

Procedure
1. Remove 13 screws and take off the rear
cover.
Rear cover
Figure 1-3-109
If the printing system is installed
2. Remove the 2 screws holding the printer
system in place, and pull the printing system out of the shield cover.
3. Remove 13 screws and take off the shield
cover.
Printer system
Screws
Figure 1-3-110
Shield cover
1-3-48
Screws
Figure 1-3-111
Page 74
2FD/2FF/2FG
4. Move the film out of the way to the left, and fasten the fax board into place using four M3 × 06 chrome binding screws.
5. Connect the NCU cable to connector CN1 on the NCU board assembly.
Film
Fax board
Figure 1-3-112
NCU cable
M3 × 06 chrome binding screws
6. Fasten the NCU board assembly into place from the bottom with two M3 × 06 chrome binding screws.
7. Connect the three connectors from the NCU board assembly to the corresponding connectors on the fax board, as follows:
Speaker 2-pin connector YC7
NCU board connector YC3
Battery connector YC6
NCU board assembly
YC7
CN1
Figure 1-3-113
NCU board connector
YC3
YC6
NCU board assembly
Speaker 2-pin connector
M3 × 06 chrome binding screws
Battery connector
Figure 1-3-114
1-3-49
Page 75
2FD/2FF/2FG
8. Remove the film that fixes the three positive connectors of the power source PCB from the optional interface mounting plate. Important: Dispose of the film that has been removed.
9. Connect the FAX-PCB-Power cable to connector CN1 on the auxiliary power source PCB assembly.
Figure 1-3-115
Auxiliary power source PCB assembly
Optional interface mounting plate
Film
FAX-PCB-Power cable
10. Connect the three positive connectors on the power board to the corresponding connectors on the auxiliary power source PCB assembly, as follows.
White positive connector TB1 (white)
Green positive connector TB2 (green)
Small white positive connector TB3
Figure 1-3-116
Green positive connector
White positive connector
CN1
CN1
Auxiliary power source PCB assembly
TB2
TB3
TB1
Small white positive connector
1-3-50
Figure 1-3-117
Page 76
11. Fit the catch on the auxiliary power unit into the mount hole in the copier, and fasten the auxiliary power unit into place with one M3 × 06 chrome binding screw.
2FD/2FF/2FG
M3 × 06 chrome binding screw
12. Through the opening of controller-box above the speaker, connect the FAX-PCB-Power cable on the auxiliary power source PCB assembly to connector YC8 on the fax board.
13. Connect the 2-pin connector to the 2-pin connector with green cable.
Catch
Fax board
YC8
FAX-PCB-Power cable
Mount hole
Figure 1-3-118
Opening
2-pin connector with green cable
2-pin connector
Auxiliary power source PCB assembly
Figure 1-3-119
14. Unlock YC1 on the fax board by pulling its connector housing.
15. Hold the fax cable with its conductive side facing up, insert it into connector YC1, then push the housing back in to lock the connector.
16. Hold the other end of the fax cable with its conductive side facing down, and connect it to connector YC44 on the main PCB. (Pull the YC44 housing out to release the connector lock, then insert the cable, and then push the housing back in.) Important: Be sure to push the fax cable all the way in, and be sure that the connection is straight. A poor connection may result in a variety of problems.
Fax cable
YC44
Fax board
Figure 1-3-120
YC44
YC1
YC1
1-3-51
Page 77
2FD/2FF/2FG
17. Fasten the shield cover into place with 13 screws.
18. Remove 1 screw and take off the modular cover.
Shield cover
Screws
Figure 1-3-121
19. Hang the modular cover onto the holes on the controller-box cover, and fasten it into place with 1 screw.
Screw
Modular cover
Figure 1-3-122
Screw
Holes
1-3-52
Modular cover
Figure 1-3-123
Page 78
2FD/2FF/2FG
If the printing system was installed
20. Reinstall the printing system into the shield cover, fastening it into place with 2 screws.
21. Reattach the rear cover with 13 screws.
Printing system
Screws
Figure 1-3-124
Rear cover
22. Adhere the certification labels to the rear cover at the locations indicated in the illustration (only 120 V Spac.).
Figure 1-3-125
Certification labels
Figure 1-3-126
1-3-53
Page 79
2FD/2FF/2FG
23. Take the power label from the fax-kit label sheet, and adhere it to the copier directly under the power switch.
Main switch
Power label
Figure 1-3-127
24. Take the alphabet labels from the fax-lit label sheet, and adhere them above the corresponding numeric keys on the operation panel.
In Asia, use the PQRS TUV WXYZ label, and do not use the PRS TUV WXZ and OPER labels.
25. Connect the L terminal to the phone circuit using a modular connector cable. Important: On 120 V systems, use the included modular connector cable to make the connection.
Alphabet labels
1
4756
PQRS TUV
Figure 1-3-128
Management
ABC DEF
23
MNOJKL
WXYZ
98
OPER
0
L terminal
Reset
Interrupt
S
Start
Stop/ Clear
Energy Sever
1-3-54
L
Figure 1-3-129
Modular connector cable
Page 80
Initialization procedure after installation of facsimile system
1. Insert the copier power plug to the wall outlet and turn the power switch on.
2. Run maintenance item U601.
3. Enter a destination code using the numeric keys (refer to the destination code list) and then press the start key.
* Enter a destination code with three digits.
2FD/2FF/2FG
Code
000 009 080 084 088 108 126 136 137 152 156
4. Enter the OEM code (000) and then press the start key.
5. Confirm that the display is changed as shown in the illustration.
* At the position of @, the version number of
the software is displayed.
Destination
Japan Australia Hong Kong Indonesia Israel Malaysia New Zealand Peru Philippines Middle East Singapore
Code Code
159
South Africa
169
Thailand
181
U.S.A.
242
South America
243
Saudi Arabia
253
CTR21 (European nations)
Netherlands
Destination Destination
253
Sweden
France Austria Switzerland Belgium Denmark
Italy Germany Spain U.K.
254
INI. KEEP DATA COMPLETED XXX 000
INI. KEEP DATA COMPLETED V@.@@
Finland Portugal Ireland Norway
Taiwan
6. Press the cursor key to change the display to maintenance item U602.
7. Press the start key and confirm that the display is changed as shown in the illustration.
* At the position of @, the version number of
the software is displayed.
8. After completing the installation, run a communications test to confirm that the fax system is working correctly.
SELECT THE MAINTENANCE NUMBER.
Initial keep data U601
Figure 1-3-130
INI. SHIP DATA COMPLETED XXX 000
INI. SHIP DATA COMPLETED V@.@@
SELECT THE MAINTENANCE NUMBER.
Initial ship data U602
Figure 1-3-131
1-3-55
Page 81
2FD/2FF/2FG

1-3-14 Installing the hard disk (option)

Procedure
1. Remove the screw and remove the cover for the rear cover.
2. Attach the core to the wire of the hard disk by winding it one turn around the core. Attach the core to the 4-pin wire of the machine by winding it one turn around the core.
Cover for
the rear cover
Screw
Figure 1-3-132
4-pin
wire
3. Connect the wire to the YC49 connector on the main PCB and to the connector on the hard disk. Caution: Connect the blue connector of the wire to the YC49 connector of the main PCB, and connect the black connector of the wire to the connector of the hard disk. Connect the 4-pin connector of the machine to the YC1 connector on the sub power supply PCB of the hard disk.
Core
YC49 connector
Blue onnecor
YC1 connector
Figure 1-3-133
Wire
Wire
Core
Black connector
1-3-56
Connector
4-Pin connector
Figure 1-3-134
Page 82
4. Insert the hard disk and secure it with the screw that has been removed in step 1.
5. Insert the power plug of the copier to the outlet and turn the power switch on.
6. Run maintenance item U024 to initialize the hard disk.
2FD/2FF/2FG
Hard disk
Screw
Figure 1-3-135
1-3-57
Page 83
2FD/2FF/2FG
8

1-3-15 Installing the 1000-sheet finisher (option)

Procedure
1. Open the left cover of the copier.
2. Remove the two screws securing the feedshift guide assembly and then the assembly.
3. Fit the curl eliminator to the left cover such that the projections on the cover fit into the two ends of the curl eliminator.
4. Secure the curl eliminator using the two screws removed in step 2.
Feedshift guide assembly
Projection
Screws
Figure 1-3-136
Screw
Left cover
Screw
Projection
Curl eliminator
Figure 1-3-137
5. Close the left cover.
Left cover
6. Fit the latch catch to the left cover using two M4 × 10 binding screws.
M4 × 10 binding screws
Latch catch
Figure 1-3-138
1-3-58
Page 84
7. Align the rail retainer with the groove of the guide rail and attach the rail retainer to the guide rail. Make sure that the plate spring of the rail retainer fits into the groove and the edge of the guide rail fits between the pulleys on the reverse side of the rail retainer.
8. Orient the guide rail such that its pulley is positioned toward the copier.
Guide rail
Figure 1-3-139
2FD/2FF/2FG
Rail retainer
Plate spring
9. Secure the rail retainer to the copier using two M4 × 10 binding screws such that the front and the rear gaps between the floor and the rail retainer are approximately 10 mm.
Pullery
Rail retainer
Guide rail
Figure 1-3-140
Rail retainer
10 mm 10 mm
Rail retainer
M4 × 10 binding screws
Figure 1-3-141
1-3-59
Page 85
2FD/2FF/2FG
10. Insert the rail fixing plate into the bottom of the finisher and join them by inserting two M4 × 6 binding screws loosely.
Finisher
Rail fixing plate
M4 × 6 binding screws
Rail fixing plate
Figure 1-3-142
11. Insert the guide rail into the rail fixing plate and secure it using two M4 × 6 binding screws at the positions where the screw holes in it and those in the rail fixing plate meet.
M4 × 6 binding screws
Rail fixing plate
Guide rail
12. Adjust the position of the rail fixing plate so that the gap between the plate and the floor is approximately 8.0 mm, and then tighten the two loosely fitted M4 × 6 binding screws. If the finisher and the copier do not engage securely, perform the following finisher height adjustment.
Screw holes
Figure 1-3-143
M4 × 6 binding screws
Rail fixing plate
8.0 mm
M4 × 6 binding screws
1-3-60
Figure 1-3-144
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2FD/2FF/2FG
Adjusting the height of the finisher
Screw
1. Remove the front and rear covers from the finisher by removing two screws each. *When removing the covers, open both ends
of the covers in the directions indicated by
Cover
Screw
the arrows and remove three inside ribs to remove the covers.
Screw
Cover
Screw
Figure 1-3-145
2. Loosen the two screws on the rear right caster of the finisher. Adjust the height of the rear right caster by turning its adjustment bolt using a cross-headed screwdriver so that the axis of the pin of the latch catch is aligned with the marking of the slot of the finisher when the finisher is joined to the copier (viewed from the machine front). Note: Turning the adjustment bolt clockwise lifts the finisher, while turning it counterclockwise lowers the finisher.
Slot
Adjustment bolt
Pin
Screws
Figure 1-3-146
3. Adjust the height of the front right caster in the same manner as in step 2 so that each center of the hooking portions of the latch catch is aligned with the center of the two hooks on the finisher when the finisher is joined to the copier (viewed from above).
Hook
Hook
Hooking portions
Hooking portions
Figure 1-3-147
1-3-61
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2FD/2FF/2FG
4. Adjust the height of the left two casters in the same manner as in step 2 so that the right and left gaps a between the finisher and the copier are the same at the top and bottom when the finisher is detached from the copier.
5. Reattach the removed parts to their original positions.
Connecting the signal cable
1. Connect the signal cable of the finisher to the copier.
a
a
Figure 1-3-148
Operation check
1. Insert the copier power plug to the wall outlet and turn the power switch on.
2. Make test copies and check that the finisher operates correctly.
Signal cable
Figure 1-3-149
1-3-62
Page 88

1-3-16 Installing the 3000-sheet finisher (option)

Procedure
[Mounting the curl eliminator ]
1. Open the copiers left cover.
2. Remove two screws and take off the feedshift guide assembly.
Feedshift guide
assembly
2FD/2FF/2FG
Screws
Left cover
Figure 1-3-150
3. Mount the curl eliminator onto the left cover so that the projections at each end fits into place.
4. Fasten the curl eliminator into place with the two screws removed at step 2.
5. Fasten the retainer to the left cover with the two M4 × 8 TP-A chrome screws. Fasten at the center of the oblong holes.
Projection
Curl eliminator
Retainer
Screw
Figure 1-3-151
Screw
Projection
Left cover
M4 × 8
TP-A chrome screws
Figure 1-3-152
1-3-63
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2FD/2FF/2FG
[Mounting the finisher]
1. Unscrew the two blue screws and remove the two metal fittings holding the rail unit to the finisher.
Metal fittings
Blue screws
2. Unscrew the transport fastening screw from the rail unit, move it into the front screw hole, and screw it in.
Finisher
Finisher
Figure 1-3-153
Transport fastening
screw
Figure 1-3-154
Screw
hole
Rail unit
Rail unit
3. Pull out the two fastening pins holding the waste punch box in place, and take the waste punch box out of the finisher.
1-3-64
Waste
punch box
Fastening
pins
Figure 1-3-155
Page 90
4. Remove the tape securing the solenoid, and the tape securing the shifting guide.
5. Set the waste punch box back into the finisher, and fasten it into place with the two fastening pins.
6. Pull the rail unit out of the finisher.
7. Loosely fasten the rail unit to the copier’s finisher-attachment area with the two M4 × 10 TP-A bronze screws.
2FD/2FF/2FG
Solenoid
Tape
Tape
Shifting guide
Figure 1-3-156
M4 × 10
TP-A bronze screws
Rail unit
Figure 1-3-157
8. Move the finisher next to the copier, and open the finishers front cover. Adjust the height-adjustment screw in the rail unit until the guideline marked on the retainer is aligned with the center of the height-adjustment plate.
Guideline
Height-adjustment
plate
Height-adjustment
screw
Rail unit
Figure 1-3-158
1-3-65
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2FD/2FF/2FG
9. Pull the finisher away, and tighten up the two M4 × 10 TP-A bronze screws.
10. Set the finisher against the copier.
11. Open the finishers front cover.
12. Remove the tape securing the internal tray unit.
M4 × 10
TP-A bronze screws
Figure 1-3-159
13. Remove the fastening pin holding the internal tray unit in place, and pull out the middle tray unit.
Internal tray
Front cover
Internal tray
Tape
unit
Figure 1-3-160
Fastening pin
unit
1-3-66
Figure 1-3-161
Page 92
14. Remove the tape securing the cushioning material for the stapler unit, and remove the cushioning material.
2FD/2FF/2FG
Cushioning material
Tape
Stapler unit
Figure 1-3-162
15. Remove the two fastening pins securing the stapler unit at the bottom of the intermediate tray unit.
16. Raise the stapler unit in the indicated direction, and load the two stapler cartridges into the unit.
Intermediate tray unit
Fastening pin
Figure 1-3-163
Fastening pin
Stapler
unit
Stapler cartridges
Stapler unit
Figure 1-3-164
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2FD/2FF/2FG
17. Lift the stapler unit further up, and then lower it.
18. Set the intermediate tray unit back into the finisher, and close the front cover.
19. Fasten the main tray to the finisher using the two fixing guide pins and the two hexagonal cap nuts.
Stapler unit
Figure 1-3-165
Hexagonal cap nuts
20. Hold the auxiliary tray vertically, attach it to the top of the finisher, and lower it toward the exit side.
Main tray
Fixing guide
pins
Figure 1-3-166
Auxiliary tray
1-3-68
Figure 1-3-167
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2FD/2FF/2FG
[Connecting the signal cable]
1. Connect the finishers signal cable to the connector on the rear of the copier.
2. Plug the copier into a wall outlet, and turn its power switch on.
Connector
Signal cable
Figure 1-3-168
[Adjust the punch-hole centering]
1. Set the machine into punch mode, and make a test copy using manual feed. Note: Perform this check after checking that the center position of each drawer in the copier is correct.
2. Check the centering of the punch-holes on the test copy.
3. Loosen the two screws securing the retainer, move the retainer as necessary to adjust, and then retighten the screws.
If holes are off-center toward the front of the copier (case [a] in illustration):
Move the retainer toward the rear of the machine (in the direction of the If holes are off-center toward the rear of the copier (case [b] in illustration):
Move the retainer toward the rear of the machine (in the direction of the in the illustration).
Retainer
ab
Figure 1-3-169
[Adjust the paper curl]
1. Run paper through the machine.
2. Check the curl on the paper ejected onto the finishers auxiliary tray.
in the illustration.)
Screws
cd
Figure 1-3-170
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2FD/2FF/2FG
If excessive downward curl (case [c] in illustration): (1) Open the document finishers front cover. (2) Move the lower lever one step to the left.
Note:The lever is initially set to position “1”, and can be adjusted to five positions (“1” to
5). (3) Run paper through the machine. (4) Check the downward curl on the ejected
paper. (5) Repeat steps 2 to 4 until there is no curl. (6) Close the finisher’s front cover.
Lower lever
If excessive upward curl (case [d] in illustration): (1) Loosen the four screws and remove the
finishers upper cover.
Front cover
Screws
Figure 1-3-171
5
4
Upper cover
Screws
1
23
(2) Move the upper lever one step to the right.
Note:The lever is initially set to position “1”,
and can be adjusted to five positions (“1” to
5). (3) Run paper through the machine. (4) Check the upward curl on the ejected paper. (5) Repeat steps 2 to 4 until there is no curl. (6) Reattach the finisher’s upper, and tighten the
four screws.
1-3-70
Screws
1
Upper lever
Figure 1-3-172
2
3
4
5
Figure 1-3-173
Upper cover
Screws
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2FD/2FF/2FG

1-4-1 Copier management

In addition to a maintenance function for service, the copier is equipped with a management function which can be operated by users (mainly by the copier administrator). In this copier management mode, settings such as default settings can be changed.
(1) Using the copier management mode
Start
Press the Default Setting/Counter key.
Press the Management key.
Enter the
management code.
Press the Copy default key.
Enter the
management code.
Press the Machine default key.
Enter the
management code.
Press the Bypass setting key.
Press the Register orig. size key.
Press the User adjustment key.
Enter the
management code.
Press the Counter check key.
Execute department manage­ment items (page 1-4-2).
Press the [Close] key.
Make copy default settings (page 1-4-3).
Press the [Close] key.
Make machine default settings (page 1-4-6).
Press the [Close] key.
Make bypass settings (page 1-4-7).
Press the [Close] key.
Execute original size registration (page 1-4-7).
Press the [Close] key.
Make user adjustment (page 1-4-8).
Press the [Close] key.
Press the Document Management key.
Enter the
management code.
Press the Box Management [Hard Disk Management key.
Enter the
management code.
Press the Print report key.
Press the Language key.
Check the total counter (page 1-4-8).
Press the [Close] key.
Make document management default settings (page 1-4-8).
Press the [Close] key.
Execute hard disk management items (page 1-4-8).
Press the [Close] key.
Output the report (page 1-4-8).
Press the [Close] key.
Set the language (page 1-4-8).
End
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2FD/2FF/2FG
(2) Setting department management items
Register new department ID-codes
Registers department ID-codes and the corresponding department name, and set certain restrictions for using the copier under that ID­code.
1. Press the “Management edit” key.
2. Press the “Register” key.
3. Select “ID-code” and then press the “Change # key.
4. Enter the department ID-code to register (up to 8 digits) using the numeric keys.
5. Select “Name to display” and then press the Change # key.
6. Enter the name for that department, and then press the “End” key.
7. Set the restrictions for using the copier under that department ID-code and then press the Registr.” key.
Delete department ID-codes
1. Press the “Management edit” key.
2. Select the department ID-code to delete, and then press the “Delete” key.
3. Verify that this is the ID-code to delete, and press the “Ye s ” key.
Change registered information
1. Press the “Management edit” key.
2. Select the department ID-code to change the registered information, and then press the Mgt. Inf. Correction” key.
3. Select “ID-code” and then press the “Change # key.
4. Press the “Clear” key to delete the old ID- code.
5. Enter the new ID-code (up to 8 digits) using the numeric keys.
6. Select “Name to display” and then press the Change # key.
7. Press the “AllDel.” key to delete the old department name, then enter the new name.
8. Press the “End” key.
Check all departments
Checks the total number of copies made under all department ID-codes as a whole, print out a copy management report and clear the copy counts for all of the registered department ID-codes.
1. Press the “Management total” key. The total number of copies made under all department ID-codes as a whole will be displayed.
2. Press the “Print report” key. The copy management report is printed out.
3. Press the “Counter clear” key to clear all of the copy counts,.
4. Press the “Ye s ” key.
Check individual departments
Checks the total number of copies made under each individual department ID-code and/or clears the copy counts for individual departments as well.
1. Press the Each Mgt. Total” key.
2. Select the department ID-code to check the copy counts, and then press the “Total key. The total number of copies made under that department ID-code will be displayed.
3. Press the “Counter clear” key to clear all of the copy counts for that ID-code.
4. Press the “Ye s ” key.
Turning the copy management function ON/OFF
1. Select “On” or “Off” key.
Copier function management ON/OFF
1. Press the “Management Def. Set.” key.
2. Select “Copy management” and then press the Change # key.
3. Press the “On” key.
Printer function management ON/OFF
Note:This setting is only available when the optional printer board or network printer board is installed in the copier.
Printer error report
Note:This setting is only available when the optional printer board or network printer board is installed in the copier.
Non-standard printer driver printout (printer)
Note:This setting is only available when the optional printer board or network printer board is installed in the copier.
Copy/Printer output management
1. Press the “Management Def. Set.” key.
2. Select “Copy/Printer output mgt.” and then press the Change # key.
3. Select “All” or “Each” key.
Scanner function management ON/OFF
Note: This setting is only available when the optional network scanner board is installed in the copier.
Fax function management ON/OFF
Note: This setting is only available when the optional fax kit is installed in the copier.
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Response to exceeded restriction
Determines whether further use of the machine will be canceled or an error message will be generated when a department ID-code has exceeded its set limit.
1. Press the “Management Def. Set.” key.
2. Select “Excess of limit Setting” and then press the Change # key.
3. Select “Is not permitted” or “Only warning” key.
Default copy limit
1. Press the “Management Def. Set.” key.
2. Select “Def. Val. of coun. limit” and then press the Change # key.
3. Enter the default copy limit using the numeric keys. The limit can be set to any 1-page increment up to 999,999.
Total count for specified paper size (1 to 5)
1. Press the “Management Def. Set.” key.
2. Select one of the Total size 1” through “Total size 5 settings and then press the “Change # key.
3. Press the “On” key.
4. Press the “Select size” key.
5. Press the key that corresponds to the desired paper size, and then press the “Close” key.
6. To specify a paper type as well, press the Select paper type key.
7. Press the key that corresponds to the desired paper type, and then press the “Close” key.
(3) Copy default
Exposure mode
Selects the exposure mode at power-on.
1. Select “Exposure mode” and then press the Change # key.
2. Select “Manual” or “Auto” key.
Exposure adjustment step
Sets the number of exposure steps for the manual exposure mode.
1. Select “Exposure steps” and then press the Change # key.
2. Select “1 step” or “0.5 step” key.
Original quality
Sets the default mode for the image quality.
1. Select “Original image quality” [“Image quality Original] and then press the Change # key.
2. Select “Text+Photo, Photo or Te xt key.
Eco print mode ON/OFF
Determines whether or not the eco print mode will be the default setting in the initial mode.
1. Select “Eco Print” and then press the Change # key.
2. Select “On” or “Off” key.
Background exposure adjustment
Adjust the ground color of the copied paper.
1. Select “Background exp. adj.” and then press the Change # key.
2. Adjust the exposure using the “Lighter” key or the Darker key. Setting range: -2 to 2
Paper selection
Sets whether the copier will automatically select the same size of copy paper as the original once an original is set, or whether the designated default drawer will be automatically selected.
1. Select “Select paper” and then press the Change # key.
2. Select “APS” or “Default drawer[cassette]” key.
Paper type (Auto paper selection mode)
Selects the types of paper that will be available for selection under the APS (Auto Paper Selection) mode.
1. Select “Select paper type(APS)” and then press the Change #” key.
2. Press the “On” key and then press the keys that correspond to the types of paper to allow to be used under the auto paper selection mode.
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Default drawer
Sets one drawer that will be selected automatically regardless of the size of paper loaded in that drawer.
1. Select “Default drawer[cassette]” and then press the Change # key.
2. Press the key that corresponds to the desired drawer[cassette]. Settings: 1st paper/2nd paper/3rd paper/4th paper
* The setting for drawer 3 and 4 will only be
available when the optional paper feeder is installed.
Cover drawer
Sets which drawer will be used to feed the cover sheets in the cover mode, the booklet/stitching mode and the book to booklet mode.
1. Select “Drawer for cover paper” [“Cassette for cover paper] and then press the Change # key.
2. Press the key that corresponds to the desired drawer Settings: 1st paper/2nd paper/3rd paper/4th paper/Bypass
* The setting for drawer 3 and 4 will only be
available when the optional paper feeder is installed.
Default magnification ratio
Sets whether or not the appropriate magnification ratio to be calculated automatically when selecting the size of copy paper.
1. Select “Default magnification” [“Default mode] and then press the Change # key.
2. Select “Manual” or “AMS” key.
Auto exposure adjustment
Adjusts the overall exposure level for the auto exposure mode when making color copies.
1. Select “Auto exposure adj.(Auto)” and then press the Change # key.
2. Adjust the exposure using the “Lighter” key or the Darker key. Setting range: -3 to 3
Auto exposure adjustment (OCR)
Adjusts the overall exposure level for scanning with OCR (Optical Character Recognition) software when using the optional scanner functions of this copier.
1. Select “Adjust auto exposure (OCR)” and then press the Change # key.
2. Adjust the exposure using the “Lighter” key or the Darker key. Setting range: -3 to 3
Manual exposure adjustment (text+photo mode)
Adjusts the median exposure value when the text+photo mode is selected for the image quality.
1. Select “Manual exp.adj. (Mixed)” and then press the Change # key.
2. Adjust the exposure using the “Lighter” key or the Darker key. Setting range: -3 to 3
Manual exposure adjustment (text mode)
Adjusts the median exposure value when the text mode is selected for the image quality.
1. Select “Manual exp.adj. (Text) and then press the Change # key.
2. Adjust the exposure using the “Lighter” key or the Darker key. Setting range: -3 to 3
Manual exposure adjustment (photo mode)
Adjusts the median exposure value when the photo mode is selected for the image quality.
1. Select “Manual exp.adj. (Photo)” and then press the Change # key.
2. Adjust the exposure using the “Lighter” key or the Darker key. Setting range: -3 to 3
Sort mode ON/OFF
Determines whether or not the Sort mode will be the default setting in the initial mode.
1. Select “Sort” and then press the “Change #” key.
2. Select “Sort:On” or “Sort:Off” key.
Auto Rotation mode ON/OFF
Determines whether or not the Auto Rotation mode will be the default setting in the initial mode.
1. Select “Auto Rotation” and then press the Change # key.
2. Select “Rotate” or “No Rotate” key.
Margin width
Determines the default value of the location and width of the margins in the margin mode.
1. Select “Default margin width” and then press the Change # key.
2. Press the cursor up/down and left/right keys, as desired, to change the default margins and margin widths to the desired setting.
3
Setting range: 0 to
/4 (inch specifications)
0 to 18 mm (metric specifications)
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2FD/2FF/2FG
Erased border width
Determines the default value for the width of the border to be erased in the two border erase modes.
1. Select “Default erase width” and then press the Change # key.
2. Press the +/- keys to change the displayed widths to those desired. Setting range (Inch specifications)
3
Outside border: 0 to Center area: 0 to 1
/4”
1
/2” (Metric specifications) Outside border: 0 to 18 mm Center area: 0 to 36 mm
Copy limit
Sets the limit for the number of copies (or copy sets) that can be made at a time.
1. Select “Preset limit” and then press the Change # key.
2. Press the +/- keys to change the copy limit to the desired setting. Setting range: 1 to 999
Repeat copying ON/OFF
Sets whether or not to prohibit repeat copying, as well as whether or not to make repeat copying the default setting in the initial mode. Note: This setting is only available when the optional hard disk is installed in the copier.
1. Select “Modify Copy” and then press the Change # key.
2. Select “On” or “Off” key.
Customize screen layout (Add functions)
Adds often-used functions and/or modes, or to change the order of their layout, in order to make the display more appropriate to the way use of the copier.
1. Select “Customize(Add function)” and then press the Change # key.
2. Press the cursor up/down keys and “” key to change the order of layout.
Registration keys ON/OFF
Sets whether or not to allow a “Register” key to be displayed in the screen for those function and modes which can be registered under the registration keys. Functions and/or modes can only be registered under registration keys through the Register key.
1. Select “Display register key” [“Display "Register" key] and then press the “Change # key.
2. Select “On” or “Off” key.
Customize screen layout (Main functions)
Changes the order of the main functions and modes that are displayed in the “Basic” and the User choice tabs in order to make the display more appropriate to the way you use the copier.
1. Select “Customize(Main function)” and then press the Change # key.
2. Press the cursor up/down keys, “Move Ahead key or the Move Behind [Move backward] key to change the order of the basic functions and modes.
1-4-5
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