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
1-1-2 Parts names ......................................................................................................................................... 1-1-2
1-1-4 Drive system ........................................................................................................................................ 1-1-4
1-4-1 Paper misfeed detection ...................................................................................................................... 1-4-1
(1) Paper misfeed detection ................................................................................................................. 1-4-1
(2) Paper misfeed detection conditions ................................................................................................ 1-4-1
(3) Paper misfeeds ............................................................................................................................... 1-4-5
(1) No paper feed. .............................................................................................................................. 1-4-15
(2) No paper ejection to the sort or non-sort trays. ............................................................................ 1-4-15
(3) Paper jams. .................................................................................................................................. 1-4-15
(4) Abnormal noise is heard. .............................................................................................................. 1-4-15
1-1-1
3C1
3C1
1-5 Assembly and Disassembly
1-5-1 Precautions for assembly and disassembly ......................................................................................... 1-5-1
2-1-1 Construction of each section ................................................................................................................ 2-1-1
(1) Paper conveying section ................................................................................................................ 2-1-1
2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1
2-3 Operation of the PCB
2-3-1 Main PCB ............................................................................................................................................. 2-3-1
· Tension pulley
‚ Upper feedshift belt
Œ Coupling pulley 20
„ Gear 33
´ Gear 24SB
‰ Gear 24/33
ˇ Paper conveying belt clutch gear
Á Pulley 20S3M
¨ Paper conveying belt
ˆ Tension pulley 20S3M
Ø Middle tray idle pulley 22
” Tension pulley
Å Pulley 31
Í Feedshift drive belt
Î Coupling pulley 20
Ï Drive switching gear 27
˝ Coupling pulley 22
Ó Gear 27
Ô Sub-section interconnecting gear
Æ Sub-section interconnecting gear
Ò Feedshift gear 22
Ú Coupling pulley 20
¸ Lower feedshift belt
˛ Coupling pulley 20
Ç Tension pulley
◊ Coupling pulley 20
ı Forwarding drive belt
˜ Tension pulley
 Shutter pulley
¯ Gear Z29
˘ Shutter pulley
¿ Paper conveying clutch gear
¡ Gear 23
™ Paddle idle gear 20/22
£ Clutch gear 36
¢ Gear 16
∞ Decurler gear 34
§ Decurler gear 27
1-1-5
1-2-1Unpacking
3C1
(1) Unpacking
›
‡—
2
8
$
3
#
¤
⁄
4
^)
9
fi
!
@
‹
1
&
0
5
Important: When moving the finisher, hold
the center of the sort tray mount,
otherwise the elevation belt may
become dislocated.
Figure 1-2-1 Unpacking
1 Finisher
2 Tray set assembly
3 Retainer
4 Stapler cartridges
5 Outer case
6 Inner frame
7 Bottom case
8 Upper spacer
9 Top spacer
0 Spacer (casters)
! Rear right spacer
@ Front right spacer
# Lower left spacer
$ Upper left spacer
% Middle left spacer
^ Spacer (stapler)
& Spacer (conveyor)
* Hinge joints
( Bar code labels
) Air-padded bag
%
fl
6
(
7
*
⁄ Machine cover
¤ Air-padded bag
‹ Leaflet
› Plastic bag
fi Curl eliminator set
fl Code labels
‡ Installation guide
— Installation guide
1-2-1
3C1
(2) Removing tapes and metal fittings
When installing the machine, be sure to remove the following tapes and metal fittings.
Procedure
1. Remove the two tapes holding the upper cover.
2. Remove the tape holding the signal cable.
3. Remove the tape holding the front cover.
4. Remove the pin holding the rail unit.
Tape
Signal cable
Tape
Upper cover
Figure 1-2-2
Tape
5. Remove the scrap hole-punch tank and then the
tapes holding the rotating plate solenoid and the
retaining path guide.
Rotating plate solenoid
Front cover
Tape
Pin
Rail unit
Figure 1-2-3
Retaining path guide
Tape
Tape
1-2-2
Figure 1-2-4
6. Open the front cover and remove the tape
holding the internal tray.
7. Remove the tape and cushion sheet
8. Remove the tape and then the pin holding the
internal tray.
3C1
Tape
Internal tray
Cushion sheet
Tape
Figure 1-2-5
Internal tray
9. Pull the internal tray out. Remove the tape and
then the pin holding the stapler unit.
Pin
Pin
Figure 1-2-6
Internal tray
Stapler unit
Figure 1-2-7
1-2-3
3C1
10. Remove the tape and then the cushion sheet
holding the internal tray wheel sensor.
11. Remove the tape and then the pin holding the
stapler unit.
Stapler unit
Internal tray
Cushion sheet
Tape
Pin
Figure 1-2-8
1-2-4
1-2-2Installing the mailbox (option)
3C1
Procedure
1. Remove the front top cover and rear top cover at
the top of the finisher using a flat-blade
screwdriver or the like.
2. While inserting the pins located at the front and
rear of the bottom of the mailbox into the
notches located at the front and rear of the top of
the finisher, attach the mailbox to the finisher.
Notch
Rear top cober
Finisher
Front top cover
Figure 1-2-9
Mailbox
Notch
Pin
Notch
Pin
3. Secure the front and rear attachment points of
the mailbox and finisher using a TP-A chrome
screw M4 x 14 for each.
Note: Be sure to secure the front connection
portion together with the mounting plate
cover.
Pin
Notch
Pin
Finisher
Figure 1-2-10
Mailbox
TP-A chrome
screw M4 × 14
TP-A chrome
screw M4 × 14
Finisher
Mounting
plate cover
Figure 1-2-11
1-2-5
3C1
4. Fit the seven copy eject bins to the ejection
section of the mailbox from the lowest bin to the
highest.
Note: To fit a copy eject bin, hold it at an angle as
shown in the diagram, warp it lightly by
squeezing at both ends and then insert the
pins located at the front and rear into the
round holes located at the front and rear of
the mailbox.
5. Remove the two screws located as shown in the
illustration that secure the side cover of the
mailbox, and remove the blanking seal from the
finisher.
Mailbox
Round hole
Pin
Copy eject bin
Figure 1-2-12
Mailbox
Side cover
6. Attach the main body mounting plate to the
mailbox and finisher using the two TP-A chrome
screws M3 × 10 and the + bind chrome screw
M4 × 25.
Figure 1-2-13
Main body
mounting plate
Screws
Blanking seal
Finisher
Mailbox
TP-A chrome
screws M3 × 10
+Bind chrome
screw M4 × 25
1-2-6
Finisher
Figure 1-2-14
7. Connect the finisher to the copier and connect
the signal lines of the mailbox to the connector at
the rear part of the copier.
8. Only for 230V specifications
Insert the clamp, GNK-5N and shield to near the
base of the signal line of the mailbox.
Remove the screw fitted to the copier, and
secure the clamp, GNK-5N and shield to the
copier using the screw.
9. Insert the copier power plug to the outlet and
turn the copier main switch on to check the
operation.
Signal line
Screw
3C1
Clamp
Figure 1-2-15
1-2-7
1-3-1 Maintenance mode
3C1
Maintenance
item No.
U237Setting finisher stack quantity
Description
Sets the number of sheets of each stack on the main tray and on the intermediate tray in the optional
finisher.
Purpose
To change the setting when a stack malfunction has occurred.
Method
1. Press the start key. The screen for selecting an item is displayed.
2. Select the item to be set. The selected item is displayed in reverse.
DisplayDescription
MAIN TRAYNumber of sheets of stack on the main tray
MIDDLE TRAYNumber of sheets of stack on the intermediate tray for sort
Setting the number of sheets of stack on the main tray
1. Change the setting using the cursor up/down keys.
SettingDescription
01500 sheets
13000 sheets
Initial setting: 0
2. Press the start key. The setting is set.
Setting the number of sheets of stack on the intermediate tray for sort copying or staple copying
1. Change the setting using the cursor up/down keys.
SettingDescription
0For sort copying: 30 sheets, for staple copying: 50 sheets
1For sort copying: 50 sheets, for staple copying: 50 sheets
2For sort copying: 30 sheets, for staple copying: 30 sheets
Initial setting: 0
2. Press the start key. The setting is set.
Completion
Press the stop/clear key. The screen for selectiong a maintenance item No. is displayed.
Description
copying or staple copying
1-3-1
3C1
Maintenance
item No.
U240Checking the operation of the Finisher
Description
Turns the finisher cluches or solenoids.
Purpose
To check the operation of the finisher cluches and solenoids.
Start
1 Press the start key. The screen for selecting an item is displayed.
2 Select an item. The screen for executing each item is displayed.
Display
CL, SOL TEST
JOGGER TEST
Method to check the operation of cluches and motors
1 Select the item to be operated. The selected item is displayed in reverse, and the motor or solenoid turns on
for 0.5 s.
DisplayClutches and solenoids
HBCL
PYSL
PSL1
PSL2
PSL3
BSL1
BSL2
PCL
PNSL OFF
PNSL ON
PNCL
KYSL
Description
Checks operation of cluches and motors.
Checks jogging and stapling operations.
Paper conveying belt clutch (PCBCL)
Paper shift solenoid (PSSOL)
Paddle solenoid 1 (PDSOL1)
Paddle solenoid 2 (PDSOL2)
Paddle solenoid 3 (PDSOL3)
Feedshift solenoid 1 (FSSOL1)
Feedshift solenoid 2 (FSSOL2)
Paddle clutch (PDCL)
Paper shift solenoid (PSSOL) OFF
Paper shift solenoid (PSSOL) ON
Punch clutch (PCL)
Trailing edge press solenoid (TEPSOL)
Description
1-3-2
DisplayClutches and solenoids
PCSL
DCSL
PGSL
2 To turn each clutch or solenoid on while the motor is driving, press the interrupt key before selecting the
clutch or solenoid.
The drive motor turns on, and the selected clutch or solenoid remains on until the selected item is pressed
again.
3 To stop the motor drive, press the interrupt key.
4 To return to the screen for selecting an item, press the stop/clear key after the motor stops.
Method to check the jogging and the stapling
1 Select the item to be operated.
2 To turn each clutch or solenoid on while the motor is driving, press the interrupt key before selecting the
clutch or solenoid.
Display
JOGGER
STAPLE
Completion
Press the stop/clear key. The screen for selecting a maintenance item No. is displayed.
Displays the status of the respective switches on the finisher.
Purpose
To check if respective switches on the finisher operate correctly.
Start
1 Press the start key.
2 Turn the respective switches on manually. The on-status of a switch is displayed in reverse.
Display
KOS
PS 3
FJHS
PS 2
DS
SS
RJHS
FSES
FSPS
RSES
RSPS
US
Swithes
Trailing edge press detection sensor (TEPDS)
Eject switch (ESW)
Front jogger home position sensor (FJHPS)
Internal tray wheel sensor (ITWS)
Front cover switch (FCSW)
Joint switch (JSW)
Rear jogger home position sensor (RJHPS)
Front stapler empty sensor (STES)
Front stapler self-priming sensor (STSPS)
Rear stapler empty sensor (STES)
Rear stapler self-priming sensor (STSPS)
Upper cover switch (UCSW)
Description
Display
FSTHS
RSTHS
FCES
RCES
SKS 1
PS 1
HBH S
SKS 2
PS 4
SKS 4
PKS
SKS 3
Completion
Press the stop/clear key when operation stops. The screen for selecting a maintenance item No. is displayed.
Swithes
Front stapler home position sensor (STHPS)
Rear stapler home position sensor (STHPS)
Front stapler cortridge sensor (STCS)
Rear stapler cartridge sensor (STCS)
Tray stock sensor A (TSSA)
Paper entry sensor (PES)
Paper conveying belt home position sensor (PCBHPS)
Tray stock sensor B (TSSB)
Tray midpoint sensor (TMS)
Tray lower limit sensor (TLLS)
Scrap hole-punch sensor (PDTS)
Tray upper limit sensor (TULS)
1-3-3
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