Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent
type recommended by the manufacturer. Dispose of used batteries according to the
manufacturer’s instructions.
CAUTION
Double-pole/neutral fusing.
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.
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.
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
• 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 copier’s
• 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
1-1-4 Drive system ........................................................................................................................................ 1-1-7
(1) Drive system 1 (optical section) ...................................................................................................... 1-1-7
(2) Drive system 2 (paper feed motor drive train) ................................................................................ 1-1-8
(3) Drive system 3 (image forming motor drive train) ........................................................................... 1-1-9
(4) Drive system 4 (drive motor drive train) ........................................................................................ 1-1-10
(5) Drive system 5 (large paper deck) ................................................................................................ 1-1-11
(6) Drive system 6 (duplex section) ................................................................................................... 1-1-12
(7) Drive system 7 (SRDF) ................................................................................................................. 1-1-13
1-2-2 Developer and toner............................................................................................................................. 1-2-1
1-3 Installation
1-3-1 Unpacking and installation ................................................................................................................... 1-3-1
(6) Language ...................................................................................................................................... 1-3-20
1-3-4 Installing the finisher (option) ............................................................................................................. 1-3-21
1-3-5 Installing the booklet stitcher (option)................................................................................................. 1-3-26
1-3-6 Installing the side deck (option).......................................................................................................... 1-3-31
1-3-7 Installing the key counter (option) ...................................................................................................... 1-3-35
1-3-8 Installing the cassette heater (option) ................................................................................................ 1-3-37
1-3-9 Installing the MMD host monitoring system device (option) ............................................................... 1-3-38
(1) Executing a maintenance item ....................................................................................................... 1-4-1
(2) Maintenance mode item list ............................................................................................................ 1-4-3
(3) Contents of maintenance mode items ............................................................................................ 1-4-7
1-5 Troubleshooting
1-5-1 Paper misfeed detection ...................................................................................................................... 1-5-1
(1) Paper misfeed indication ................................................................................................................ 1-5-1
(2) Paper misfeed detection conditions ................................................................................................ 1-5-3
(3) Paper misfeeds ............................................................................................................................. 1-5-13
(1) No image appears (entirely white). ............................................................................................... 1-5-37
(2) No image appears (entirely black). ............................................................................................... 1-5-37
(3) Image is too light. ......................................................................................................................... 1-5-38
1-1-1
2A0
(4) Background is visible. ................................................................................................................... 1-5-38
(5) A white line appears longitudinally. .............................................................................................. 1-5-38
(6) A black line appears longitudinally. .............................................................................................. 1-5-39
(7) A black line appears laterally. ....................................................................................................... 1-5-39
(8) One side of the copy image is darker than the other. ................................................................... 1-5-39
(9) Black dots appear on the image. .................................................................................................. 1-5-40
(10) Image is blurred............................................................................................................................ 1-5-40
(11) The leading edge of the image is consistently misaligned with the original. ................................ 1-5-40
(12) The leading edge of the image is sporadically misaligned with the original. ................................ 1-5-41
(13) Paper creases. ............................................................................................................................. 1-5-41
(1) No primary paper feed. ................................................................................................................. 1-5-59
(2) No secondary paper feed. ............................................................................................................ 1-5-59
(3) Skewed paper feed. ...................................................................................................................... 1-5-59
(4) The scanner does not travel. ........................................................................................................ 1-5-59
(5) Multiple sheets of paper are fed at one time.................................................................................. 1-5-59
(6) No refeed. ..................................................................................................................................... 1-5-59
(7) Paper jams. .................................................................................................................................. 1-5-59
(8) Toner drops on the paper conveying path. ................................................................................... 1-5-60
(9) Abnormal noise is heard. .............................................................................................................. 1-5-60
1-1-3
2A0
• SRDF
(1) No primary original feed. .............................................................................................................. 1-5-61
(2) No secondary original feed........................................................................................................... 1-5-61
(1) Adjusting the position of the magnetic brush (developing roller) (reference) ............................... 1-6-45
(2) Checking the position of the doctor blade (reference).................................................................. 1-6-46
(3) Detaching and refitting the developing filter and the upper developing seal ................................ 1-6-47
(4) Detaching and refitting the lower developing shaft and developing blade assembly ................... 1-6-48
1-1-4
2A0
1-6-7 Transfer section ................................................................................................................................. 1-6-49
(1) Detaching and refitting the transfer charger belt .......................................................................... 1-6-49
(2) Detaching and refitting the transfer roller ..................................................................................... 1-6-50
(3) Detaching and refitting the belt cleaning brush ............................................................................ 1-6-51
(1) Detaching and refitting the drum grounding plate spring .............................................................. 1-6-75
1-7 Requirements on PCB Replacement
1-7-1 Replacing the main PCB ...................................................................................................................... 1-7-1
1-7-2 Replacing the main PCB ROMs ........................................................................................................... 1-7-2
(1) Original scanning .......................................................................................................................... 2-1-17
(8) SRDF clutches and solenoids ........................................................................................................ 2-2-9
2-3 Operation of the PCBs
2-3-1 Power source PCB ............................................................................................................................... 2-3-1
2-3-2 Main PCB ............................................................................................................................................. 2-3-5
Chart of image adjustment procedures ........................................................................................................ 2-4-11
Maintenance parts list................................................................................................................................... 2-4-14
General connection diagram ........................................................................................................................ 2-4-20
1-1-6
1-1-1 Specifications
2A0
Copier
Type ............................................... Console
Copying system..............................Indirect electrostatic system
Originals .........................................Sheets and books
Maximum size: A3/11" × 17"
Original feed system ......................Fixed
2
Copy paper ....................................Cassette and duplex unit: Plain paper (64 – 80 g/m
Bypass table: Plain paper (60 – 160 g/m
2
)
)
Special paper:
Transparencies, tracing paper, colored paper and envelopes (only when used as a
printer)
Developer: 2-component, ferrite carrier and N32T black toner
Density control: Developer density detection
Toner replenishing: Automatic from a toner hopper
Transfer system .............................Transfer belt, approximately 1.2 to 1.3 kV (rated current: 50 µA)
Separation system .........................Transfer belt and separation claws
1-1
1-1-1
1-1
2A0
Fixing system ................................. Heat roller
Heat source:
Halogen heaters (main 970 W for 120 V models/1350 W for 230 V models,
sub 270 W for 120V models/380 W for 230 V models)
Control temperature: 185°C/365°F (at normal ambient temperature)
Abnormally high temperature protection devices: 180°C/356°F thermostats
Fixing pressure: 80 N
Charge erasing system .................. Exposure by cleaning lamp
Cleaning system ............................Cleaning blade
Scanning system............................Flat bed scanning by CCD image sensor
220 – 240 V AC, 50 Hz, 6.5 A (ave.), 8.5 A (max.)
2040 W (max.) for 230/240 V models
stitcher, MMD host monitoring system, print/scan system and tandem copy kit.
1-1-2
SRDF
Original feed system ......................Automatic feed
Original weights .............................Single-sided original mode: 35 – 160 g/m
Double-sided original mode: 50 – 120 g/m
2
2
Original paper ................................Plain paper, thermal paper, art paper and colored paper
1
Original sizes..................................A3 – A5R, folio/11" × 17" – 5
No. of originals ............................... Up to 70 sheets (A3, B4, folio, 11" × 17", 8
Up to 100 sheets (up to A4/11" × 8
/2" × 81/2"
1
/2")
1
/2" × 14")
Up to 30 sheets in the auto selection mode
Art or thermal paper must be fed individually.
Power source ................................. Electrically connected to the copier
2A0
1-1
1-1-3
2A0
1-1-2 Parts names and their functions
1-1
(1) Copier
3
2
1
@
#
)
‹
¤
⁄
0
!
9
4
6
5
^
$
%
°
7
8
‚
·
°
Œ
„
Ø´Áˇ‰¨”ˆ
*
&
›
‡
1 Front cover
2 Operation panel
3 Original size indicator lines
4 Contact glass
5 Operation section right cover
6 Original tray
7 Upper right cover
8 Lower right cover
9 Large paper deck
0 Upper cassette
! Lower cassette
@ Width guide
# Length guide
1-1-4
(
flfi
$ Bypass table
% Support guide
^ Insert guides
& Paper feed section knob
* Paper conveying section
( Paper conveying section release lever
) Fixing unit
⁄ Fixing knob
¤ Total counter
‹ Scanner counter
› Instruction handbook holder
fi Duplex unit
fl Duplex cover
Figure 1-1-1
‡ Re-feeding section
— Handles for transport
· Ejection cover
‚ Main switch
Œ Waste toner tank cover
„ Waste toner tank
´ SRDF
‰ Original table
ˇ Original insert guides
Á Original set indicator
¨ DF opening/closing lever
ˆ Original ejection cover
Ø DF original reversing cover
” Ejection guide
· Oil roller gear
‚ Duplex gear 44
Œ Idle pulley 31/42
„ Developing gear 20
´ Motor idle gear 45
‰ Drive motor gear
ˇ Motor idle gear 56/25
Á Gear 38T
¨ Fixing eject joint gear
ˆ Eject joint gear
Ø Fixing eject joint gear
” Developing gear 20
Å Idle gear 28
Í Oil roller gear 16
Î Gear 30
Ï Gear 19
˝ Fixing eject joint gear
Ó Idle gear 40
Ô Idle gear 28
Æ Eject pulley 24
Ò Switchback drive belt
Ú Forwarding pulley
¸ Paper conveying belt pulley
˛ SB gear 19
Ç Feedshift pulley 22
– Pulley 16
ı Pulley 20
˜ Paper conveying belt pulley
 Pulley 24
¯ Duplex paper conveying belt
˘ Idle gear 40
¿ SB gear 24
¡ Gear 32
™ Gear 36
£ Idle gear 30
¢ Gear 31
∞ Cleaning drive belt
§ Pulley 36
¶ Idle pulley 21
1-1-10
(5) Drive system 5 (large paper deck)
2A0
7
8
3
1
5
2
1 Pulse gear
2 Gear 1.0-24
3 Lift pulley
4 Left lift belt assembly
5 Right lift belt assembly
6 Large paper deck lift motor gear
7 Large paper deck paper feed clutch 2 gear
8 Gear 18
9 Gear 24
0 Gear 18
! Idle gear 31
@ Gear 33
# Gear 18
!@#$%)⁄
9
6
^
0
&
6
Figure 1-1-9
$ Gear 28
% Idle gear 19
^ Gear 20
& Gear 18
* Gear 24
( Gear 18
) Gear 14
⁄ Gear 14
¤ Large paper deck paper feed clutch 1 gear
‹ Paper feed belt pulley
› Paper feed belt
fi Paper feed belt pulley
fl Large paper deck conveying clutch gear
¤
*(
2
3
4
1
‹
›
fi
1-1
fl
1-1-11
2A0
(6) Drive system 6 (duplex section)
1-1
1
3
2
^
9
0
&
!
@
5
8
#
6
7%$
Figure 1-1-10
1 Duplex joint gear
2 Clutch gear 26
3 Paper conveying pulley 40
4 Paper conveying drive belt
5 Paper conveying tension pulley
6 Paper conveying pulley 20
7 Paper conveying pulley 20
8 Duplex registration gear 20/30
9 Clutch gear 26
1 Original feed motor pulley
2 Pulley 35/22/22
3 Idle gear 26
4 Original feed clutch gear
5 DF original feed pulley 18
6 DF forwarding pulley 18
7 Tension pulley
8 Original feed drive belt
9 DF forwarding belt
9
7
5
43
#
@
!
0
8
2
$
&
As viewed from machine rear
0 DF registration pulley 28/18
! Idle gear 15
@ Idle gear 20
# Switchback gear 18
$ DF registration drive belt
% Gear 22/35
^ Original conveying motor pulley
& Gear 28
* Original conveying drive belt 1
1-1
^
*
%
8
7
6
5
9
0
1
4
!
Figure 1-1-12 SRDF (inside front of machine)
1 Lower original conveying pulley 25/18
2 Gear 18/25
3 Eject gear 18
4 Middle original conveying pulley 18
5 Upper original conveying pulley 18
6 JAM release gear 24
3
2
As viewed from machine front
7 Joint gear 14
8 JAM release gear 14
9 Tension pulley
0 Eject drive belt
! Conveying drive belt 2
1-1-13
1-2-1Drum
Note the following when handling or storing the drum.
• When removing the image formation unit, never expose the drum surface to strong direct light.
• Keep the drum at an ambient temperature between –20°C/–4°F and 40°C/104°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.
• If the machine is left open for more than 5 minutes for maintenance, remove the drum and store it in the drum storage
bag (Part No. 78369020).
1-2-2Developer and toner
Store the developer and toner in a cool, dark place. Avoid direct light and high humidity.
2A0
1-2
1-2-1
1-3-1 Unpacking and installation
(1) Installation procedure
Start
Unpack.
2A0
Remove the tapes.
Remove the pins holding light source units 1 and 2.
Remove the cleaning assembly retainers.
Set the cleaning assembly.
Load developer.
Install the upper developing seal.
Fitl the belt cleaning spacers.
Adjust the fixing pressure.
1-31-3
Carry out initial developer setting.
(maintenance item U130)
Apply toner to the cleaning blade.
(maintenance item U160)
Exit maintenance mode.
Set the cleaning blade.
Load toner.
Install the original tray*.
Make test copies.
Completion of the machine installation.
Connect the power cord.
*For inch models only.
1-3-1
2A0
Unpack.
$^&
*(
›fi
%
2
5
0
8
1-3
°
fl
‹
‡
6
@
!
#
3
)
4
·
⁄
1
3
Figure 1-3-1 Unpacking
9
¤
7
1-3-2
1 Copier
2 Waste toner tanks
3 Bottom pad
4 Right-top pad
5 Left-top pad
6 Skid
7 Inner frame
8 Top case
9 Outer case
0 Tank spacer
! Front transfer spacer
@ Rear transfer spacer
# Upper developing seal
$ Belt cleaning spacers
% Plastic bag
^ Paper labels
& Indication label
* Cassette size labels
( Screws (TP-A bronze, M4 × 10)
) Hinge joints
⁄ Machine cover
¤ Bar code labels
‹ Plastic bag
› Instruction handbook
fi Business reply mail*
fl Original tray*
‡ Plastic bag*
° Accessories case*
· Power code*
*1: Inch models only.
*2: Metric models only.
1
1
1
1
2
Remove the tapes.
1. Remove the tapes holding the SRDF.
2. Remove the tape holding the front cover.
3. Remove the tape holding the right cover.
4. Remove the tapes holding the large paper deck
and cassettes.
5. Remove the tape holding the bypass table.
6. Remove the tapes holding the power cord.*
*Inch models only.
2A0
1-3
Power cord
Figure 1-3-2
7. Draw out the upper cassette and remove the
tapes holding the cassette lift and pull out the
upper developing seal.
Remove the pins holding light source units 1 and 2.
1. Remove the tapes with the two pins holding light
source unit 1 and the one pin holding light source
unit 2 at the left side of the machine, and remove
the each pin.
Upper developing seal
Cassette lift
Figure 1-3-3
Light source
unit 2 pin
Figure 1-3-4
Light source
unit 1 pin
1-3-3
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