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SERVICE MANUAL FIELD SERVICE

7115/7118

KONICA BUSINESS TECHNOLOGIES, INC.

CONTENTS
DIS/REASSEMBLY, ADJUSTMENT
1. SAFETY INFORMATION ................................................................................. D-1 1-1. LASER SAFETY ...................................................................................... D-1 1-2. INTERNAL LASER RADIATION .............................................................. D-1 1-3. LASER SAFETY LABEL .......................................................................... D-4 1-4. LASER CAUTION LABEL ........................................................................ D-4 1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ............... D-4 2. SERVICE INSTRUCTIONS ............................................................................. D-5 2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS .................... D-5 2-2. PARTS WHICH MUST NOT BE TOUCHED ........................................... D-6 (1) Red Painted Screws ........................................................................ D-6 (2) Variable Resistors on Board ............................................................ D-6 3. DISASSEMBLY/REASSEMBLY ...................................................................... D-7 3-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES ............................................................ D-7 3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS ....................................................................................... D-9 (1) Removal of the Master Board .......................................................... D-10 (2) Removal of the Control Board ......................................................... D-11 (3) Removal of the High Voltage Unit ................................................... D-11 (4) Removal of the DC Power Supply ................................................... D-13 3-3. MAINTENANCE SCHEDULE .................................................................. D-16 3-4. PAPER TAKE-UP/TRANSPORT SECTION ............................................ D-18 (1) Removal of the Paper Separator Roll Assy and Paper Take-Up Roll ......................................................................... D-18 (2) Cleaning of the Paper Separator Roll .............................................. D-18 (3) Cleaning of the Paper Take-Up Roll ................................................ D-18 (4) Cleaning of the Right and Left Synchronizing Rollers ..................... D-19 (5) Removal of the Cleaning Pad .......................................................... D-19 (6) Cleaning of the Cleaning Pad .......................................................... D-20 (7) Cleaning of the Bypass Transport Roller ......................................... D-20 3-5. OPTICAL SECTION ................................................................................ D-21 (1) Cleaning of the Original Glass and ADF Glass ............................... D-21 (2) Cleaning of Mirrors .......................................................................... D-21 (3) Cleaning of the Lens ........................................................................ D-21 (4) Cleaning of the CCD Sensor ........................................................... D-22 (5) Cleaning of the Scanner Rails/Bushings ......................................... D-22 (6) Removal of the CCD Unit ................................................................ D-23 (7) Removal of the Scanner, Exposure Lamp, and Inverter Board ....... D-23 (8) Removal of the Scanner Drive Cables ............................................ D-25 (9) Winding of the Scanner Drive Cables .............................................. D-27 3-6. PH ............................................................................................................ D-29 (1) Removal of the PH Unit ................................................................... D-29 (2) Cleaning of the PH Window ............................................................. D-29

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3-7. Imaging Unit (IU) ...................................................................................... D-30 (1) Removal of the IU ............................................................................ D-30 (2) Disassembly of the IU ...................................................................... D-30 (3) Application of Toner ......................................................................... D-34 (4) Replacement of the ATDC Sensor .................................................. D-35 3-8. IMAGE TRANSFER SECTION ................................................................ D-36 (1) Removal of the Image Transfer Roller Assy .................................... D-36 (2) Cleaning of the Pre-Image Transfer Lower Guide Plate .................. D-36 (3) Cleaning of the Charge Neutralizing Plate ...................................... D-36 3-9. FUSING SECTION .................................................................................. D-37 (1) Removal of the Fusing Unit ............................................................. D-37 (2) Disassembly of the Fusing Unit ....................................................... D-37 3-10.MULTIPLE BYPASS (MT-102): OPTION ................................................ D-42 (1) Removal of the Separator Roll Assy ................................................ D-42 (2) Removal of the Paper Take-Up Roll ................................................ D-42 (3) Cleaning of the Separator Roll/Paper Take-Up Roll ........................ D-45 (4) Cleaning of the Paper Take-Up Roll ................................................ D-45 3-11.JOB TRAY (IT-102): OPTION ................................................................. D-46 (1) Removal of the Main Board ............................................................. D-46 (2) Paper Detecting Board .................................................................... D-48 3-12.SHIFTING UNIT (IS-101): OPTION ......................................................... D-49 (1) Removal of the Main Board ............................................................. D-49 4. ADJUSTMENT ................................................................................................. D-51 4-1. ADJUSTMENT JIGS AND TOOLS USED ............................................... D-51 4-2. TIMING BELT TENSION ADJUSTMENT ................................................ D-51 4-3. ACCESSING THE FUNCTION, TECH. REP. CHOICE, AND ADJUST MODE ....................................................................................... D-52 (1) Function Mode ................................................................................. D-52 (2) Tech. Rep. Choice Mode ................................................................. D-52 (3) Adjust Mode ..................................................................................... D-52 4-4. ELECTRICAL/IMAGE ADJUSTMENT ..................................................... D-53 (1) Edge Erase Adjustment (Leading, Trailing, and Top/Bottom Edges) ............................................................................................. D-53 (2) Loop Length Adjustment (1st and 2nd Trays, Bypass Tray) ........... D-54 (3) Printer CD Registration Adjustment ................................................. D-55 (4) Printer FD Registration Adjustment ................................................. D-56 (5) Scanner CD Registration Adjustment .............................................. D-57 (6) Scanner FD Registration Adjustment .............................................. D-58 (7) Scanner CD Zoom Adjustment ........................................................ D-59 (8) Scanner FD Zoom Adjustment ........................................................ D-60 (9) ATDC Sensor Automatic Adjustment (F8) ....................................... D-61 (10) 2nd Mirrors Carriage Distortion Adjustment .................................... D-61 (11) Manual Bypass Registration Adjustment ......................................... D-62 (12) Multiple Bypass Registration Adjustment (MT-102): Option ............ D-63 4-5. OTHER ADJUSTMENTS ......................................................................... D-64 (1) Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage ........................................................................................... D-64

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CCD Unit Position Adjustment ......................................................... D-65 Adjustment of the Gap between the Doctor Blade and Sleeve Roller (Db Adjustment) .................................................................... D-66 4-6. MISCELLANEOUS .................................................................................. D-68 (1) Remounting the EEPROM (U29) ..................................................... D-68 (2) Installation of the Plug-In Counter Socket (Option) ......................... D-69 (3) Installation of the Total Counter (Option) ......................................... D-70

(2) (3)

SWITCHES ON PWBs, TECH. REP. SETTINGS
1. CONTROL PANEL KEYS AND TOUCH PANEL ............................................. S-1 1-1. Control Panel Keys .................................................................................. S-1 2. UTILITY MODE ................................................................................................ S-4 2-1. Settings in the Utility Mode ...................................................................... S-4 2-2. Utility Mode Setting Procedure ................................................................ S-4 (1) User's Choice Mode (Display: U-1) ................................................. S-4 (2) Drum Dehumidify Mode (Display: U-2) ............................................ S-9 (3) Toner Replenisher Mode (Display: U-3) .......................................... S-9 (4) Custom Size Input Mode (Display: U-4) .......................................... S-9 (5) Administrator Mode (Display: U-5) .................................................. S-10 3. TECH.REP.MODE ........................................................................................... S-13 3-1. Tech.Rep.Mode Menu Function Tree ...................................................... S-13 3-2. Tech.Rep.Mode Function Setting Procedure ........................................... S-14 3-3. Setting in the Tech.Rep.Mode ................................................................. S-15 (1) Control Panel LED Check (Display: - - 0) ........................................ S-15 (2) Function (Display: - - 1) ................................................................... S-15 (3) Tech.Rep.Choice (Display: - - 2) ..................................................... S-16 (4) Counter Mode (Display: - - 3) .......................................................... S-18 (5) ATDC Sensor Output (Display: - - 4) ............................................... S-21 (6) Level History (Display: - - 5) ............................................................ S-21 (7) ROM Version (Display: - - 6) ........................................................... S-21 (8) Administrator No. Input (Display: - - 7) ............................................ S-22 (9) Change Fixed Zoom (Display: - - 8) ................................................ S-22 (10) Marketing Area Setting (Display: - - 9) ............................................ S-22 (11) Memory Clear (Display: - 10) ........................................................... S-23 (12) Total Clear (Display: - 11) ................................................................ S-23 (13) ADF Document Passage Test (Display: - 12) .................................. S-23 (14) ADF Original Glass Check (Display: - 13) ....................................... S-24 (15) Scanner Move Check (Display: - 14) ............................................... S-24 (16) Serial No. Display (Display: - 20) ..................................................... S-24 4. SECURITY MODE ........................................................................................... S-25 4-1. Settings in the Security Mode .................................................................. S-25 4-2. Security Mode Setting Procedure ............................................................ S-25 4-3. Setting in the Security Mode .................................................................... S-26 5. ADJUST MODE ............................................................................................... S-27 5-1. Settings in the Adjust Mode ..................................................................... S-27 5-2. Adjust Mode Setting Procedure ............................................................... S-27 5-3. Setting in the Adjust Mode ....................................................................... S-28

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TROUBLESHOOTING
1. INTRODUCTION ............................................................................................. T-1 1-1. Reading the Text ..................................................................................... T-1 2. PAPER TRANSPORT FAILURE ..................................................................... T-2 2-1. Paper Misfeed Detection ......................................................................... T-2 (1) Outline ............................................................................................. T-2 2-2. Paper Misfeed .......................................................................................... T-2 2-3. Misfeed Detection Sensor Layout ............................................................ T-4 2-4. Types of Misfeed Detection and Detection Timings ................................ T-6 3. MISFEED TROUBLESHOOTING PROCEDURES ......................................... T-7 3-1. Misfeed at Copier Paper Take-Up J01 and Misfeed at Bypass Tray J06 ...................................................................................... T-7 3-2. Misfeed at Paper Feed Cabinet Paper Take-Up and Transport Section J02, J03, J04, J05, J1 (PF-121) ................................. T-11 3-3. Misfeed at PC Drum J2 ............................................................................ T-13 3-4. Misfeed at Fusing Unit J3 ........................................................................ T-16 4. MALFUNCTION ............................................................................................... T-18 4-1. Detection Timing by Malfunction Code .................................................... T-18 4-2. Resetting Procedure by Malfunction Code .............................................. T-22 4-3. Troubleshooting Procedures by Malfunction Code .................................. T-23 (1) C0000: Main Motor malfunction ....................................................... T-23 (2) C0045: Fusing Cooling Fan Motor malfunction ............................... T-24 (3) C004E: Power Supply Cooling Fan Motor malfunction ................... T-25 (4) C0070: Toner Replenishing Motor malfunction ............................... T-26 (5) C0210: Abnormal image transfer voltage ........................................ T-27 (6) C0500: Warm-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature ................................... T-28 (7) C0650: Faulty Scanner Home Position Sensor ............................... T-30 (8) C0B60: Bin Switching Motor malfunction ........................................ T-31 (9) C0B80 Shift Motor malfunction ........................................................ T-33 (10) C0F32: Faulty ATDC Sensor C0F33: Improperly adjusted ATDC Sensor ..................................... T-34 (11) C1038: Engine connection failure .................................................... T-35 (12) C1200: Faulty ASIC/memory ........................................................... T-35 (13) C1300: Polygon Motor malfunction (startup failure, Lock signal failure, faulty Lock signal) C13F0: Faulty HSYNC .................................................................... T-36 (14) C1468: Faulty EEPROM .................................................................. T-37 (15) C14A3: IR fluorescent lamp fault ..................................................... T-38 (16) The copier does not turn ON. .......................................................... T-40 5. IMAGE FAILURE ............................................................................................. T-42 5-1. Image Failure Troubleshooting ................................................................ T-42 5-2. Initial Checks ........................................................................................... T-42 5-3. Image Failure Samples ............................................................................ T-44 5-4. Troubleshooting Procedures by Image Failure ........................................ T-45 (1) Blank copy ....................................................................................... T-45

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(2) Black copy ....................................................................................... T-46 (3) Low image density ........................................................................... T-47 (4) Foggy background or rough image .................................................. T-49 (5) Black streaks or bands .................................................................... T-51 (6) Black spots ...................................................................................... T-52 (7) Blank streaks or bands .................................................................... T-53 (8) Void areas ....................................................................................... T-54 (9) Smear on back ................................................................................ T-55 (10) Uneven image density ..................................................................... T-56 (11) Gradation reproduction failure ......................................................... T-58 (12) Periodically uneven image ............................................................... T-59 6. OTHER ERROR CODES ................................................................................ T-60 WIRING/CIRCUIT DIAGRAMS SERVICE/ADJUSTMENT ITEM LIST ELECTRICAL PARTS LAYOUT CONNECTOR LAYOUT WIRING DIAGRAMS (1-2) CIRCUIT DIAGRAM (1-2) CIRCUIT DIAGRAM PWB-A (1-3) DF-217 WIRING DIAGRAM DF-217 CIRCUIT DAIGRAM PWB PF-121 WIRING DIAGRAM PF-121 CIRCUIT DIAGRAM PWB

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SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
Installation Environment
Safety considerations usually are directed toward machine design and the possibility of human error. In addition, the environment in which a machine is operated must not be overlooked as a potential safety hazard. Most electrical equipment is safe when installed in a normal environment. However, if the environment is different from what most people consider to be normal, it is conceivable that the combination of the machine and the room air could present a hazardous combination. This is because heat (such as from fusing units) and electrical arcs (which can occur inside switches) have the ability to ignite flammable substances, including air. When installing a machine, check to see if there is anything nearby which suggests that a potential hazard might exist. For example, a laboratory might use organic compounds which, when they evaporate, make the room air volatile. Potentially dangerous conditions might be seen or smelled. The presence of substances such as cleaners, paint thinners, gasoline, alcohol, solvents, explosives, or similar items should be cause for concern. If conditions such as these exist, take appropriate action, such as one of the following suggestions. know what effect may be caused by altering any aspect of the machine's design. Such changes have the potential of degrading product performance and reducing safety margins. For these reasons, installation of any modification not specifically authorized by Konica Business Machines U.S.A., Inc., is strictly prohibited. The following list of prohibited actions is not all-inclusive, but demonstrates the intent of this policy.

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Using an extension cord or any unauthorized power cord adapter. Installing any fuse whose rating and physical size differs from that originally installed. Using wire, paper clips, solder, etc., to replace or eliminate any fuse (including temperature fuses). Removing (except for replacement) any air filter. Defeating the operation of relays by any means (such as wedging paper between contacts). Causing the machine to operate in a fashion other than as it was designed. Making any change which might have a chance of defeating built-in safety features. Using any unspecified replacement parts.

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Determine that the environment is controlled (such as through the use of an exhaust hood) so that an offending substance or its fumes cannot reach the machine. Remove the offending substance. Install the machine in a different location.

General Safety Guidelines
This equipment has been examined in accordance with the laws pertaining to various product safety regulations prior to leaving the manufacturing facility to protect the operators and service personnel from injury. However, as with any operating device, components will break down through the wear-and-tear of everyday use, as will additional safety discrepancies be discovered. For this reason, it is important that the technician periodically performs safety checks on the equipment to maintain optimum reliability and safety. The following checks, not all-inclusive, should be made during each service call: CAUTION: Avoid injury. Ensure that the equipment is disconnected from its power source before continuing.

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The specific remedy will vary from site to site, but the principles remain the same. To avoid the risk of injury or damage, be alert for changes in the environment when performing subsequent service on any machine, and take appropriate action.

Unauthorized Modifications
Konica equipment has gained a reputation for being reliable products. This has been attained by a combination of outstanding design and a knowledgeable service force. The design of the equipment is extremely important. It is the design process that determines tolerances and safety margins for mechanical, electrical, and electronic aspects. It is not reasonable to expect individuals not involved in product engineering to

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Look for sharp edges, burrs, and damage on all external covers and copier frame. Inspect all cover hinges for wear (loose or broken). Inspect cables for wear, frays, or pinched areas.

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SAFETY PRECAUTIONS

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Ensure that the power cord insulation is not damaged (no exposed electrical conductors). Ensure that the power cord is properly mounted to the frame by cord clamps. Check the continuity from the round lug (GND) of the power cord to the frame of the copier -- ensure continuity. An improperly grounded machine can cause an electrically-charged machine frame.

Applying Isopropyl Alcohol
Care should be exercised when using isopropyl alcohol, due to its flammability. When using alcohol to clean parts, observe the following precautions:

� �

Remove power from the equipment. Use alcohol in small quantities to avoid spillage or puddling. Any spillage should be cleaned up with rags and disposed of properly. Be sure that there is adequate ventilation. Allow a surface which has been in contact with alcohol to dry for a few minutes to ensure that the alcohol has evaporated completely before applying power or installing covers.

Safeguards During Service Calls
Confirm that all screws, parts, and wiring which are removed during maintenance are installed in their original positions.

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When disconnecting connectors, do not pull the wiring, particularly on AC line wiring and high voltage parts. Do not route the power cord where it is likely to be stepped on or crushed. Carefully remove all toner and dirt adhering to any electrical units or electrodes. After part replacement or repair work, route the wiring in such a way that it does not contact any burrs or sharp edges. Do not make any adjustments outside of the specified range.

Summary
It is the responsibility of every technician to use professional skills when servicing Konica products. There are no short cuts to high-quality service. Each piece of equipment must be thoroughly inspected with respect to safety considerations as part of every routine service call. The operability of the copier, and more importantly, the safety of those who operate or service the equipment, are directly dependent upon the conscientious effort of each and every technician. Remember...when performing service calls, use good judgment (have a watchful eye) to identify safety hazards or potential safety hazards that may be present, and correct these problem areas as they are identified -- the safety of those who operate the equipment as well as those who service the copier depend on it!

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1.

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

� When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. V Depending on the model, some of the precautions given in the following do not apply. � Different markings are used to denote specific meanings as detailed below.

WARNING CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

� The following graphic symbols are used to give instructions that need to be observed. Used to call the service technician's attention to what is graphically represented inside the marking (including a warning). Used to prohibit the service technician's from doing what is graphically represented inside the marking. Used to instruct the service technician's to do what is graphically represented inside the marking.

1-1.

Warning WARNING

1. Always observe precautions. � Parts requiring special attention in this product will include a label containing the mark shown on the left plus precautionary notes. Be sure to observe the precautions. � Be sure to observe the "Safety Information" given in the Operator's Manual. 2. Before starting the procedures, be sure to unplug the power cord. � This product contains a high-voltage unit and a circuit with a large current capacity that may cause an electric shock or burn. � The product also contains parts that can jerk suddenly and cause injury. � If this product uses a laser, laser beam leakage may cause eye damage or blindness.

P-1

3. Do not throw toner or the toner bottle into a fir. � Do not throw toner or the toner bottle (Imaging Cartridge) into a fire. Toner expelled from the fire may cause burns. 4. Use the specified parts. � For replacement parts, always use the genuine parts specified in the manufacturer's parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possible electric shock or fire. � Replace a blown electrical fuse or thermal fuse with its corresponding genuine part specified in the manufacturer's parts manual. Installing a fuse of a different make or rating could lead to a possible fire. If a thermal fuse blows frequently, the temperature control system may have a problem and action must be taken to eliminate the cause of the problem. 5. Handle the power cord with care and never use a multiple outlet. � Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock. � Do not use a multiple outlet to which any other appliance or machine is connected. � Be sure the power outlet meets or exceeds the specified capacity. 6. Be careful with the high-voltage parts. � A part marked with the symbol shown on the left carries a high voltage. Touching it could result in an electric shock or burn. Be sure to unplug the power cord before servicing this part or the parts near it. 7. Do not work with wet hands. � Do not unplug or plug in the power cord, or perform any kind of service or inspection with wet hands. Doing so could result in an electric shock. 8. Do not touch a high-temperature part. � A part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is energized. Touching them may result in a burn. � Wait until these parts have cooled down before replacing them or any surrounding parts. 9. Maintain a grounded connection at all times. (This item may not apply in the USA.) � Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could result in an electric shock or fire. � Never connect the ground wire to a gas pipe, water pipe, telephone ground wire, or a lightning conductor. 10. Do not remodel the product. � Modifying this product in a manner not authorized by the manufacturer may result in a fire or electric shock. If this product uses a laser, laser beam leakage may cause eye damage or blindness.

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11. Restore all parts and harnesses to their original positions. � To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed. � To promote safety, make sure that all tubing and other insulating materials are returned to their original positions. Make sure that floating components mounted on the circuit boards are at their correct distance and position off the boards.

1-2.

Caution CAUTION

1. Precautions for Service Jobs. � A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire. � When reassembling parts, make sure that the correct screws (size, type) are used in the correct places. Using the wrong screw could lead to stripped threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury. � Take great care to avoid personal injury from possible burrs and sharp edges on the parts, frames and chassis of the product. � When moving the product or removing an option, use care not to injure your back or allow your hands to be caught in mechanisms. 2. Precautions for Servicing with Covers and Parts Removed. � Wherever feasible, keep all parts and covers mounted when energizing the product. � If energizing the product with a cover removed is absolutely unavoidable, do not touch any exposed live parts and use care not to allow your clothing to be caught in the moving parts. Never leave a product in this condition unattended. � Never place disassembled parts or a container of liquid on the product. Parts falling into, or the liquid spilling inside, the mechanism could result in an electric shock or fire. � Never use a flammable spray near the product. This could result in a fire. � Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors. � Always use the interlock switch actuating jig to actuate an interlock switch when a cover is opened or removed. The use of folded paper or some other object may damage the interlock switch mechanism, possibly resulting in an electric shock, injury or blindness.

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3. Precautions for the Working Environment. � The product must be placed on a flat, level surface that is stable and secure. � Never place this product or its parts on an unsteady or tilting workbench when servicing. � Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time. � Avoid dusty locations and places exposed to oil or steam. � Avoid working positions that may block the ventilation ports of the product. 4. Precautions for Handling Batteries. (Lithium, Nickel-Cadmium, etc.) � Replace a rundown battery with the same type as specified in the manufacturer's parts manual. � Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst. � Dispose of used batteries according to the local regulations. Never dispose of them at the user's premises or attempt to try to discharge one. 5. Precautions for the Laser Beam. (Only for Products Employing a Laser) � Removing the cover marked with the caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover. � If removing this cover while the power is ON is unavoidable, be sure to wear protective laser goggles that meet specifications. � Make sure that no one enters the room when the machine is in this condition. � When handling the laser unit, observe the "Precautions for Handling Laser Equipment." 6. Precautions for storage the toner or imaging cartridge. � Be sure to keep the toner or imaging cartridge out of the reach of children. Licking the imaging cartridge or ingesting its contents is harmful to your health.

1-3.

Other Precautions

� When handling circuit boards, observe the "HANDLING of PWBs". � The PC Drum is a very delicate component. Observe the precautions given in "HANDLING OF THE PC DRUM" because mishandling may result in serious image problems. � Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.

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1-4.

Used Batteries Precautions

ALL Areas 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 manufacturer's instructions. Germany VORSICHT! Explosionsgefahr bei unsachgem��em Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ. Entsorgung gebrauchter Batterien nach Angaben des Herstellers. France ATTENTION Il y a danger d'explosion s'il y a remplacement incorrect de la batterie. Remplacer uniquement avec une batterie du m�me type ou d'un type �quivalent recommand� par le constructeur. Mettre au rebut les batteries usag�es conform�ment aux instructions du fabricant. Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig h�ndtering. Udskiftning m� kun ske med batteri af samme fabrikat og type. Lev�r det brugte batteri tilbage til leverand�ren. Finland, Sweden VAROlTUS Paristo voi r�j�ht��, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. H�vit� k�ytetty paristo valmistajan ohjeiden mukaisesti. VARNING Explosionsfara vid felaktigt batteribyte. Anv�nd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera anv�nt batteri enligt fabrikantens instruktion. Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri. Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten. Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

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1-5.

Precautions for Service

� When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. V Depending on the model, some of the precautions given in the following do not apply. 1. Precautions Before Service � When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads. � Never disturb the LAN by breaking or making a network connection, altering termination, installing or removing networking hardware or software, or shutting down networked devices without the knowledge and express permission of the network administrator or the shop supervisor. 2. How to Use this Book < DIS/REASSEMBLY, ADJUSTMENT > � To reassemble the product, reverse the order of disassembly unless otherwise specified. < TROUBLESHOOTING > � If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit. � All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions. � The procedures preclude possible malfunctions due to noise and other external causes. 3. Precautions for Service � Check the area surrounding the service site for any signs of damage, wear or need of repair. � Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged. � After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions. � Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged motor or locking mechanism. � If the product is to be run with the front door open, make sure that the toner hopper is in the locked position. � Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit.

P-6

4. Precautions for Dis/Reassembly � Be sure to unplug the copier from the outlet before attempting to service the copier. � The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears. � Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet. � Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed. � While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses. � Never use flammable sprays near the copier. � A used battery should be disposed of according to the local regulations and never be discarded casually or left unattended at the user's premises. � When reassembling parts, make sure that the correct screws (size, type) and toothed washer are used in the correct places. 5. Precautions for Circuit Inspection � Never create a closed circuit across connector pins except those specified in the text and on the printed circuit. � When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the GND wire.

P-7

6. Handling of PWBs < During Transportation/Storage > � During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. � Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature. � When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity. � Do not touch the pins of the ICs with your bare hands. � Protect the PWBs from any external force so that they are not bent or damaged. < During Inspection/Replacement > � Avoid checking the IC directly with a multimeter; use connectors on the Board. � Never create a closed circuit across IC pins with a metal tool. � Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet. � When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board. � When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB. � Note that replacement of a PWB may call for readjustments or resetting of particular items. 7. Handling of Other Parts � The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.

P-8

8. Handling of the PC Drum V Only for Products Not Employing an Imaging Cartridge. < During Transportation/Storage > � Use the specified carton whenever moving or storing the PC Drum. � The storage temperature is in the range between �20�C and +40�C. � In summer, avoid leaving the PC Drum in a car for a long time. < Handling > � Ensure that the correct PC Drum is used. � Whenever the PC Drum has been removed from the copier, store it in its carton or protect it with a Drum Cloth. � The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. � Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. � Do not scratch the surface of the PC Drum. � Do not apply chemicals to the surface of the PC Drum. � Do not attempt to wipe clean the surface of the PC Drum. If, however, the surface is contaminated with fingerprints, clean it using the following procedure. A. Place the PC Drum into one half of its carton.

1076D001

1076D002

B. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. � Turn the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum. � Turn the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned. V At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping.

P-9

C. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times. V Never move the Pad back and forth.
1076D003

D. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropriate for cleaning.

1076D004

NOTES � Even when the PC Drum is only locally dirtied, wipe the entire surface. � Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. � If dirt remains after cleaning, repeat the entire procedure from the beginning one more time.

9. Handling of the Imaging Cartridge V Only for Products Employing an Imaging Cartridge. < During Transportation/Storage > � The storage temperature is in the range between �20�C and +40�C. � In summer, avoid leaving the Imaging Cartridge in a car for a long time. < Handling > � Store the Imaging Cartridge in a place that is not exposed to direct sunlight. < Precautionary Information on the PC Drum Inside the Imaging Cartridge > � Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. � Do not scratch the surface of the PC Drum. � Do not attempt to wipe clean the surface of the PC Drum.

P-10

DIS/REASSEMBLY, ADJUSTMENT

1.
1-1.

SAFETY INFORMATION
LASER SAFETY

� This is a digital machine certified as a class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.

1-2.

INTERNAL LASER RADIATION
Semiconductor laser

Maximum average radiation power(*) Wavelength *:Laser Aperture of the Print Head Unit

26.4 �W 770-795 nm

� This product employs a Class 3b laser diode that emits an invisible laser beam. The laser diode and the scanning polygon mirror are incorporated in the print head unit. � The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit should not be opened under any circumstances.

Laser Aperture of the Print Head Unit

This figure Shows the view inside the Right Door with the Imaging Unit removed.

D-1

the U.S.A., Canada (CDRH Regulation) � This machine is certified as a Class I Laser product under Radiation Performance Standard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of the U.S. Department of Health and Human Services (DHHS). This means that the device does not produce hazardous laser radiation. � The label shown to page D-4 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States. CAUTION Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. Semiconductor laser Maximum power of the laser diode Wavelength All Areas CAUTION Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. Semiconductor laser Maximum power of the laser diode Wavelength Denmark ADVARSEL Usynlig Laserstr�ling ved �bning, n�r sikkerhedsafbrydere er ude af funktion. Undg� uds�ttelse for str�ling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene. Halvlederlaser Laserdiodens h�jeste styrke B�lgel�ngden 5 mW 770-795 nm 5 mW 770-795 nm 5 mW 770-795 nm

D-2

Finland, Sweden VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina n�kym�tt�m�lle lasers�teilylle. �l� katso s�teeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! Laitteen K�ytt�minen muulla kuin t�ss� k�ytt�ohjeessa mainitulla tavalla saattaa altistaa k�ytt�j�n turvallisuusluokan 1 ylitt�v�lle n�kym�tt�m�lle lasers�teilylle. Puolijohdelaser Laserdiodin suurin teho Aallonpituus 5 mW 770-795 nm

VARNING! Om apparaten anv�nds p� annat s�tt �n i denna bruksanvisning specificerats, kan anv�ndaren uts�ttas f�r osynlig laserstr�lning, som �verskrider gr�nsen f�r laserklass 1. Halvledarlaser Den maximala effekten f�r laserdioden V�gl�ngden 5 mW 770-795 nm

VARNING! Osynlig laserstr�lning n�r denna del �r �ppnad och sp�rren �r urkopplad. Betrakta ej str�len. Norway ADVERSEL Dersom apparatet brukes p� annen m�te enn spesifisert i denne bruksanvisning, kan brukeren utsettes for unsynlig laserstr�ling som overskrider grensen for laser klass 1. Halvleder laser Maksimal effekt till laserdiode B�lgelengde 5 mW 770-795 nm

D-3

1-3.

LASER SAFETY LABEL

� A laser safety labels is attached to the outside of the machine as shown below.

Laser safety label

1-4.

LASER CAUTION LABEL

� A laser caution label is attached to the inside of the machine as shown below.

4022D501AA

1-5.

PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

� When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. � When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the copier OFF. � If the job requires that the copier be left ON, take off your watch and ring and wear laser protective goggles. � A highly reflective tool can be dangerous if it is brought into the laser beam path. Use utmost care when handling tools on the user's premises.

D-4

2.
2-1.

SERVICE INSTRUCTIONS
IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS

Control Board (PWB-C) 125 V 3 A

Thermoswitch 1 (TS1) 250 V 7.5 A/125 V 15 A

DC Power Supply (PU1) 100 V system 125 V 15 A (F2) 200 V system 250 V 6.3 A (F2)

4021D006AA

D-5

2-2.
(1)

PARTS WHICH MUST NOT BE TOUCHED
Red Painted Screws

Purpose of Application of Red Paint Red painted screws show that the assembly or unit secured can only be adjusted or set at the factory and shall not be readjusted, set, or removed in the field. If it becomes unavoidably necessary to disassemble any of these assemblies and units, disassembly may be done provided that the conditions permitting reassembly are met. Note also that when two or more screws are used on the part in question, only one representative screw may be marked with red paint. (2) Variable Resistors on Board

Do not turn the variable resistors on boards for which no adjusting instructions are given in "ADJUSTMENT." Other Screws not Marked with Red Paint PH Unit PH Unit base plate

Left side face Right side face

D-6

3.
3-1.

DISASSEMBLY/REASSEMBLY
DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES

1

2 11 3 4

10

9

5

6 8 7

18 12 17 13

16

14

15

D-7

No. 1 2

Part Name Original Cover Original Glass

Removal Procedure Pull the Original Cover straight up. Remove no. 18. Remove two holding brackets or no. 11 and the Original Glass. Remove two control panel mounting screws. Remove two ground wire mounting screws. Remove one flat cable and unplug one connector. Remove no. 5. Remove one Right Inside Cover mounting screw. Remove no. 3. Open the Front Door and remove six Front Cover mounting screws. Open the Front Door and remove one band mounting screw. Snap off one C-clip. Slide out the 1st Tray. Remove the fixing brackets on the right and left. Remove no. 3. Remove no. 5. Remove no. 14. Remove five Left Cover mounting screws. Remove no. 3. Remove no. 5. Remove no. 14. Remove no. 8. Remove two screws and two Upper Cover mounting screws.

3

Control Panel

4 5 6 7 8

Right Inside Cover Front Cover Front Door 1st Tray Left Cover

9

Upper Cover

Remove no. 3. Remove no. 5. Remove no. 14. Remove 10 Rear Inside Cover no. 8. Remove no. 9. Remove no. 4. Remove two Rear Inside Cover mounting screws. 11 ADF Glass 12 Left Hinge 13 Right Hinge 14 Rear Cover 15 Rear Right Cover Remove two ADF Glass mounting screws. Remove no. 14. Remove three Left Hinge mounting screws. Remove no. 14. Remove three Right Hinge mounting screws. Remove six Rear Cover mounting screws. Remove no. 14. Remove one Rear Right Cover mounting screw.

Multiple Bypass 16 Cover (when the Remove two Multiple Bypass Cover mounting screws. option is mounted) 17 Right Door 18 Right Cover Remove no. 14. Remove no. 15. Remove three Right Door mounting screws. Remove no. 3. Remove no. 5. Remove no. 14. Remove four Right Cover mounting screws.

D-8

3-2.

REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS

� When removing a circuit board or other electrical component, refer to "PRECAUTIONS FOR HANDLING THE PWBs" and follow the corresponding removal procedures. � The removal procedures given in the following omit the removal of connectors and screws securing the circuit board support or circuit board. � Where it is absolutely necessary to touch the ICs and other electrical components on the board, be sure to ground your body.

PWB-A Job Tray (IT-102): Option Shifting Unit (IS-101): Option PWB-R1 PWB-J PWB-C PU3

PU2

PWB-A

PWB-I

HV1 PWB-R2 PU1

4021D009AA

PWB-B Job Tray (IT-102): Option

D-9

Symbol PWB-A PWB-C PWB-I PWB-J

Part Name Master Board Control Board Paper Size Detecting Board CCD Board D-10 D-11

Removal Procedure

Remove the Rear Cover. Remove the PWB Assy. Remove two screws and the PWB-I Assy. PWB-I D-23 Remove the CCD Unit as a unit. Remove the Fusing Unit. PWB-R1 Open the Right Door. PWB-R2 D-13 D-23 Remove two control panel mounting screws. Remove two ground wire mounting screws. Remove one flat cable and unplug one connector. PU3 D-11

PWB-R1 Fusing Board Pre-Image Transfer PWB-R2 Board PU1 PU2 PU3 HV1 DC Power Supply Inverter Board Control Panel High Voltage Unit

Job Tray (IT-102): Option Symbol PWB-A PWB-B Part Name Main Board D-46 Paper Detecting Board D-48 Removal Procedure

Shifting Unit (IS-101): Option Symbol PWB-A (1) Part Name Main Board D-49 Removal Procedure

Removal of the Master Board

1. Remove the Rear Cover. 2. Remove 12 screws and the PWB Cover Assy.

D-10

3. Unplug all connectors (but PJ20) from the Master Board. 4. Remove four screws and the Master Board.

(2)

Removal of the Control Board

1. Remove the Rear Cover. 2. Remove the PWB Cover Assy. 3. Unplug all connectors from the Control Board. 4. Remove six screws and the Control Board.

(3)

Removal of the High Voltage Unit

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, Upper Cover, Right Inside Cover, and Rear Inside Cover. 2. Remove the PWB Cover Assy. 3. Unplug all connectors from the Master Board (except for PJ20) and from the Control Board. 4. Remove the harness from seven wiring saddles and two edge covers.

D-11

5. Unplug three connectors from the High Voltage Unit and remove the harness from one wiring saddle.

6. Remove the harness from one wiring saddle.

7. Remove ten screws and the PWB Assy.

8. Remove the harness from one wiring saddle of the High Voltage Unit cover.

D-12

9. Remove nine screws and the High Voltage Unit cover.

10. Unplug two connectors from the High Voltage Unit. 11. Remove two screws and the High Voltage Unit.

(4)

Removal of the DC Power Supply

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, and Upper Cover. 2. Unplug two connectors of the Hopper Assy. 3. Remove two Hopper mounting screws on the right.

4. Remove two Hopper mounting screws on the left and the Hopper Assy.

5. Remove three screws and the Power Supply Right Cover.

D-13

6. Remove four screws and the Power Supply Left Cover.

7. Unplug one connector and remove the harness from one edge cover.

8. Unplug one connector and remove the harness from one wiring saddle.

9. Unplug one connector and remove the harness from one wiring saddle.

10. Unplug three connectors and remove the harness from two wiring saddles.

D-14

11. Remove two screws.

12. Remove two screws.

13. Remove four screws and the DC Power Supply.

D-15

3-3.

PM Parts Clean Paper Take-Up Roll (1st Tray) 1st Tray Double feed Paper Separator Roll Assy Multi Bypass Paper Take-Up Roll (Multiple Bypass) 150 Bypass Tray 150 40 -- -- -- 80 80 80 When a malfunction occurs -- -- When a malfunction occurs 40 40 -- 40 40 -- -- 40 -- -- 40 -- 27AE2701 -- 27AE-250 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 27AE2702 1 111T-501 1 14AH4001 1 150 111T-501 1 150 27AE4301 1 Replace

Maintenance Cycle (K) Part No. Qty Ref. Page Counter (*3) Associated Problems

D-18 D-18 D-42 D-42 D-19
IU Life

Paper take-up failure, double feed Paper take-up failure, double feed Double feed Failure to remove toner off completely, filming Dirty image Dirty image Paper misfeed

Paper Take-Up/ Transport Section

Multi Bypass Separator Roll Assy When a malfunction (Multiple Bypass) occurs Cleaning Pad Right Synchronizing Roller Left Synchronizing Roller Bypass Transport Roller Mirrors and lens Scanner rails/bushings Original Glass PH window

D-19 D-19 D-20 D-21 D-22 D-21 D-29
-- IR --

MAINTENANCE SCHEDULE

D-16
PC Drum Cleaning Blade PC Drum Paper Separator Finger PC Drum Charge Corona Assy Developer (starter) Ds collar 1 1 -- 1 1 --

Optical Section

PH Section

Image noise (white lines)

D-30 D-32 D-32 D-32 D-33 D-33
IU Life

Image noise (white lines)

Imaging Unit (*2)

PM Parts Clean Developer Scattering Prevention Plate Charge Neutralizing Sheet Pre-Image Transfer Upper Guide Plate Ozone Filter (Europe) (Areas other than Europe) Image Transfer Roller Assy Pre-Image Transfer Lower Guide Plate Charge Neutralizing Plate Fusing Unit (100-V system) (200-V system) -- 150 27AF-530 1 -- 150 27AE-530 1 When a malfunction occurs -- -- -- -- -- -- -- 150 27AE-451 1 -- 300 27AE1062 1 150 40 -- -- -- -- 40 27AE1066 1 40 -- -- -- Replace

Maintenance Cycle (K) Part No. Qty Ref. Page Counter (*3) Associated Problems

D-33 D-32 D-34 D-31 D-31
Ozone Filter Image Transfer Roller/ Fusing Unit -- -- Dirty image Misfeed due to paper not properly separated from PC Drum IU Life

Imaging Unit (*2)

D-36 D-36 D-36 D-37 D-37

Image Transfer Section

D-17

Fusing Section

Image Transfer Roller/ Fusing Unit

*1: Replace at 40K for recommended plain paper. Clean when the Cleaning Pad is full of paper dust for paper of other types. *2: The life of the Imaging Unit (except for the Ozone Filter) is determined by the period of time through which the PC Drum has turned (as translated to an equivalent distance traveled). The maintenance cycle in the table represents the number of copies made in the standard copy mode (A4C, 2PJ) which may differ depending on conditions in which the copiers are used among different users. *3: For details, see SWITCHES ON PWBs, TECH. REP. SETTINGS.

NOTE � k = 1,000 copies � The contents of this maintenance schedule are subject to change without notice. � For part numbers, see Parts Manual and Parts Modification Notice.

3-4.
(1)

PAPER TAKE-UP/TRANSPORT SECTION
Removal of the Paper Separator Roll Assy and Paper Take-Up Roll 1. Slide out the 1st Tray. 2. Remove two screws and the Paper Separator Roll Assy.

3. Press down the Paper Lifting Plate. 4. Snap off one C-clip from the Paper Take-Up Roll Assy. 5. Slide the Paper Take-Up Roll Assy to the rear so that it can be pulled off the bushing at the front.

6. Snap off one C-clip and remove the Paper TakeUp Roll.

(2)

Cleaning of the Paper Separator Roll 1. Remove the Paper Separator Roll Assy. 2. Using a soft cloth dampened with alcohol, wipe the Paper Separator Roll clean of dirt.

(3)

Cleaning of the Paper Take-Up Roll 1. Slide out the 1st Tray. 2. Remove the Paper Separator Roll Assy. 3. Using a soft cloth dampened with alcohol, wipe the Paper Take-Up Roll clean of dirt.

D-18

(4)

Cleaning of the Right and Left Synchronizing Rollers

1. Remove the Imaging Unit. 2. Using a soft cloth dampened with alcohol, wipe the Right and Left Synchronizing Rollers clean of dirt.

(5)

Removal of the Cleaning Pad

1. Remove the Imaging Unit. 2. Remove two screws and the stopper. 3. Remove the 1stTray.

4. Remove one screw and the Synchronizing Roller Sensor Assy.

NOTE � Do not unplug the sensor harness connector.

5. Remove three screws and the Cleaning Pad.

D-19

(6)

Cleaning of the Cleaning Pad 1. Remove the Cleaning Pad. 2. Using a brush, whisk dust and dirt off the Cleaning Pad.

(7)

Cleaning of the Bypass Transport Roller

1. Remove the Imaging Unit. 2. Remove two screws, unplug one connector, and remove the Bypass Transport Roller Assy.

3. Using a soft cloth dampened with alcohol, wipe the Bypass Transport Roller clean of dirt.

4. Using a soft cloth dampened with alcohol, wipe the rolls clean of dirt.

D-20

3-5.
(1)

OPTICAL SECTION
Cleaning of the Original Glass and ADF Glass 1. Using a soft cloth dampened with alcohol, wipe the Original Glass and ADF Glass clean of dirt.

(2)

Cleaning of Mirrors 1. Remove the Original Glass. 2. Using a soft cloth dampened with alcohol, wipe the mirrors clean of dirt.

(3)

Cleaning of the Lens

1. Remove the Original Glass. 2. Remove 15 screws and the CCD Unit cover.

D-21

3. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt.

(4)

Cleaning of the CCD Sensor

1. Remove the Original Glass. 2. Remove 15 screws and the CCD Unit cover. 3. Remove the Lens cover.

4. Using a soft cloth dampened with alcohol, wipe the CCD Sensor clean of dirt.

(5)

Cleaning of the Scanner Rails/Bushings 1. Remove the Original Glass. 2. Using a soft cloth dampened with alcohol, wipe the Scanner rails/bushings clean of dirt.

NOTE � After the Scanner rails/bushings have been cleaned, apply oil (copier lubricant A or FLOIL 947P).

D-22

(6)

Removal of the CCD Unit

1. Remove the Original Glass. 2. Remove 15 screws and the CCD Unit cover. 3. Unplug one connector. 4. Remove three screws and the CCD Unit.

NOTE � NEVER attempt to loosen or remove screws that are not specified when removing the CCD Unit.

<> � Temporarily secure the CCD Unit with each of the screws at the center of each slot. � After the CCD Unit has been installed, adjust the position of the CCD Unit. D-65

(7)

Removal of the Scanner, Exposure Lamp, and Inverter Board

1. Remove the control panel, Front Cover, Rear Cover, and Original Glass. 2. Remove the foam seal and mylar, one each at the front and rear.

NOTE � Ready a new foam seal and mylar and affix them after the procedure.

Front Foam Seal Mylar

Mylar Foam Seal Rear

D-23

3. Remove two Scanner mounting screws (to which no red paint has been applied).

4. Remove one screw and the cable holder. 5. Remove the flat cable from the Inverter Board and then remove the Scanner.

6. Unplug one connector from the Inverter Board. 7. Remove two screws and the Inverter Board.

8. Remove two screws and the Exposure Lamp.

D-24

(8)

Removal of the Scanner Drive Cables

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, Right Cover, Original Glass, and ADF Glass. 2. Remove the Scanner.

NOTE � Remove the two red painted screws to remove the Scanner in this step.
3. Remove two screws and the Exposure Lamp.

4. Loosen three screws to free the Scanner Motor Assy.

5. Unhook the spring from the cable hooks at the front and rear.

6. Remove the front cable from the cable pulley.

D-25

7. Remove the rear cable from the cable pulley.

8. Snap off one C-ring from the front side of the pulley assy.

9. Snap off one C-ring from the rear side of the pulley assy.

10. Remove the belt and the pulley assy.

11. Remove two screws and the pulley. 12. Remove the rear cable.

D-26

(9)

Winding of the Scanner Drive Cables

Rear

Front
4022D003AA

1. Wind the cable around the rear cable pulley of the pulley assy from side B toward side A and then secure the cable with tape. 2. Wind the cable around the front cable pulley of the pulley assy from side A toward side B and then secure the cable with tape.

NOTE � Make sure that no part of the cable rides on the other.

Bead Position Rear

B

Winding Direction on Side A

A Winding Direction on Side B

Front
B Winding Direction on Side A

A Winding Direction on Side B

Bead Position 3. Secure the pulley to the rear cable pulley using two screws.

NOTE � Make sure that the pulley is doweled to the cable pulley.

4022D005AA

D-27

4. Mount the pulley assy using two C-rings.

4022D006AB

5. Wind the cable at the front. 6. Hook the spring onto the cable hook and hook the spring onto the frame.

4022D007AB

7. Wind the cable in the rear. 8. Secure the cables at the front and rear with a spring.

4022D008AB

9. Temporarily secure the Scanner to the front and rear cables. 10. Perform the Focus-Positioning of the Scanner and 2nd/3rd Mirrors Carriage. D-64

4022D009AA

D-28

3-6.
(1)

PH
Removal of the PH Unit

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, and Upper Cover. 2. Remove the PWB Cover Assy. 3. Remove one flexible harness and unplug one connector from the Master Board.

4. Remove the harness from one edge cover and one wiring saddle.

5. Remove one screw and the ground wire.

NOTE � To remove the ground wire, remove the screw installed on the copier side.
6. Remove three screws and the PH Unit.

(2)

Cleaning of the PH Window

1. Remove the Front Cover, Rear Cover, Left Cover, and Upper Cover. 2. Wipe the PH window clean of dirt using a soft cloth.

D-29

3-7.

Imaging Unit (IU)

NOTE � When loading developer as part of the IU replacement procedure or when changing the developer, remove the Toner Bottle and run "ATDC Sensor Automatic Adjustment" (F8) twice to allow toner in the Spent Toner Recycling Duct and Toner Conveying Duct into the Developer Mixing Chamber before removing the IU.
(1) Removal of the IU 1. Open the Right Door. 2. Open the Front Door. 3. Remove two screws and, holding onto the handle of the IU, take off the IU.

Handle

NOTE � Before installing the IU, be sure to fully open the Right Door. If the IU is installed with the Right Door left ajar, the PC Drum protective shutter will not open, interfering with the Image Transfer Roller gear, thus producing noise. � When inserting the IU, do that slowly and, when you are sure that the drum gear contacts its mating part, push the IU all the way into position. If this step is done all at once, the drum gear could be damaged.

(2)

Disassembly of the IU

1. Remove one screw in the rear of the IU and remove the harness cover.

2. Remove two screws in the rear of the IU.

D-30

3. Remove two screws at the front of the IU.

4. Widen flaps on both ends (marked with A in the illustration on the left) of the Cleaning Assy in the direction of arrow and turn to take off