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Model A-C2
(Machine Code: B003/B004/B006/B007) SERVICE MANUAL

January 26th, 2001 Subject to change

IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off. 4. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 5. If the Start key is pressed before the copier completes the warm-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed. 6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands. HEALTH SAFETY CONDITIONS 1. Never operate the copier without the ozone filters installed. 2. Always replace the ozone filters with the specified ones at the specified intervals. 3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention. OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. 2. The NVRAM on the system control board has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations.

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1. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations. 4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.

!WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

!WARNING
WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:

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TABLE OF CONTENTS
1 INSTALLATION PROCEDURE.................................................... 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................................1-1 1.1.1 ENVIRONMENT ...............................................................................1-2 1.1.2 MACHINE LEVEL .............................................................................1-2 1.1.3 MINIMUM SPACE REQUIREMENTS...............................................1-3 1.1.4 POWER REQUIREMENTS ..............................................................1-4 1.2 INSTALLATION FLOW CHART ................................................................1-5 1.3 MAIN MACHINE INSTALLATION..............................................................1-6 1.3.1 ACCESSORY CHECK......................................................................1-6 1.3.2 INSTALLATION PROCEDURE ........................................................1-7 Development Unit and PCU..................................................................1-8 Toner Bottle ........................................................................................1-11 Paper Trays ........................................................................................1-12 Initialize TD Sensor and Developer ....................................................1-14 Set Paper Size for Paper Trays ..........................................................1-15 Electrical Total Counter.......................................................................1-16 HDD Caution Decal (for only NA models) ...........................................1-16 1.4 PAPER TRAY UNIT INSTALLATION ......................................................1-17 1.4.1 ACCESSORY CHECK....................................................................1-17 1.4.2 INSTALLATION PROCEDURE ......................................................1-18 1.5 1-BIN TRAY UNIT INSTALLATION .........................................................1-22 1.5.1 ACCESSORY CHECK....................................................................1-22 1.5.2 INSTALLATION PROCEDURE ......................................................1-23 1.6 BRIDGE UNIT INSTALLATION ...............................................................1-29 1.6.1 ACCESSORY CHECK....................................................................1-29 1.6.2 INSTALLATION PROCEDURE ......................................................1-30 1.7 1000-SHEET FINISHER INSTALLATION ...............................................1-32 1.7.1 ACCESSORY CHECK....................................................................1-32 1.7.2 INSTALLATION PROCEDURE ......................................................1-33 1.8 TWO-TRAY FINISHER INSTALLATION .................................................1-36 1.8.1 ACCESSORY CHECK....................................................................1-36 1.8.2 INSTALLATION PROCEDURE ......................................................1-37 1.9 PUNCH UNIT INSTALLATION ................................................................1-40 1.9.1 ACCESSORY CHECK....................................................................1-40 1.9.2 INSTALLATION PROCEDURE ......................................................1-41 1.10 AUTO REVERSE DOCUMENT FEEDER INSTALLATION...................1-44 1.10.1 ACCESSORY CHECK..................................................................1-44 1.10.2 INSTALLATION PROCEDURE ....................................................1-45 1.11 LCT INSTALLATION .............................................................................1-47 1.11.1 ACCESSORY CHECK..................................................................1-47 1.11.2 INSTALLATION PROCEDURE ....................................................1-48 1.12 PLATEN COVER INSTALLATION ........................................................1-50 1.13 KEY COUNTER INSTALLATION ..........................................................1-51 1.14 ANTI-CONDENSATION HEATER.........................................................1-53 1.15 TRAY HEATER .....................................................................................1-55
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1.16 TRAY HEATER (OPTIONAL PAPER TRAY UNIT) ...............................1-56

2 PREVENTIVE MAINTENANCE SCHEDULE ............................... 2-1
2.1 PM TABLE.................................................................................................2-1

3 REPLACEMENT AND ADJUSTMENT......................................... 3-1
3.1 GENERAL CAUTIONS..............................................................................3-1 3.1.1 LASER UNIT ....................................................................................3-1 3.1.2 USED TONER ..................................................................................3-1 3.2 SPECIAL TOOLS AND LUBRICANTS ......................................................3-2 3.2.1 SPECIAL TOOLS .............................................................................3-2 3.2.2 LUBRICANTS ...................................................................................3-2 3.2.3 SYMBOLS USED IN TEXT...............................................................3-2 3.3 FRONT DOOR ..........................................................................................3-3 3.4 DUPLEX UNIT...........................................................................................3-3 3.5 UPPER RIGHT COVER ............................................................................3-4 3.6 BY-PASS TRAY ........................................................................................3-5 3.7 REAR COVERS ........................................................................................3-6 3.7.1 REAR UPPER COVER.....................................................................3-6 3.7.2 REAR LOWER COVER....................................................................3-6 3.8 LEFT COVERS..........................................................................................3-7 3.8.1 LEFT UPPER COVER......................................................................3-7 3.9 SCANNER UNIT........................................................................................3-8 3.9.1 ARDF................................................................................................3-8 3.9.2 EXPOSURE GLASS.........................................................................3-9 3.9.3 SCANNER EXTERIOR PANELS/OPERATION PANEL .................3-10 3.9.4 LENS BLOCK/SBU ASSEMBLY ....................................................3-11 3.9.5 ORIGINAL SIZE SENSORS ...........................................................3-12 3.9.6 EXPOSURE LAMP .........................................................................3-13 3.9.7 SCANNER HP SENSOR/PLATEN COVER SENSOR ...................3-14 3.9.8 SCANNER MOTOR........................................................................3-15 3.9.9 LAMP STABILIZER AND SCANNER MOTOR DRIVE BOARD .....3-16 3.9.10 SCANNER WIRE..........................................................................3-17 3.10 LASER UNIT .........................................................................................3-21 3.10.1 CAUTION DECAL LOCATIONS ...................................................3-21 3.10.2 LASER UNIT ................................................................................3-22 3.10.3 POLYGON MIRROR MOTOR ......................................................3-23 3.10.4 LASER SYNCHRONIZATION DETECTOR..................................3-24 3.10.5 LD UNIT........................................................................................3-24 Laser beam pitch adjustment..............................................................3-25 3.11 PHOTOCONDUCTOR UNIT (PCU) ......................................................3-26 3.11.1 PCU ..............................................................................................3-26 3.11.2 DRUM...........................................................................................3-27 3.11.3 PICK-OFF PAWLS .......................................................................3-28 3.11.4 CHARGE ROLLER/CHARGE ROLLER CLEANING PAD............3-29 3.11.5 DRUM CLEANING BLADE...........................................................3-30 3.11.6 ID SENSOR..................................................................................3-31 3.12 DEVELOPMENT ...................................................................................3-32 3.12.1 DEVELOPMENT UNIT .................................................................3-32
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3.12.2 DEVELOPMENT FILTER .............................................................3-33 3.12.3 DEVELOPMENT ROLLER ...........................................................3-33 3.12.4 DEVELOPER................................................................................3-34 3.12.5 TD SENSOR.................................................................................3-36 3.13 TRANSFER UNIT..................................................................................3-37 3.13.1 TRANSFER BELT UNIT ...............................................................3-37 3.13.2 TRANSFER BELT ........................................................................3-38 3.13.3 TRANSFER BELT CLEANING BLADE AND TONER OVERFLOW SENSOR.......................................................................................3-39 3.14 PAPER FEED........................................................................................3-40 3.14.1 PICK-UP, SEPARATION, AND FEED ROLLERS ........................3-40 3.14.2 LOWER RIGHT COVER...............................................................3-41 3.14.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED CLUTCHES ...................................................................................3-42 3.14.4 UPPER PAPER FEED UNIT FOR TRAY 1 ..................................3-43 3.14.5 LOWER PAPER FEED UNIT FOR TRAY 2 .................................3-44 3.14.6 PAPER END/PAPER HEIGHT/RELAY SENSORS ......................3-45 3.14.7 REGISTRATION SENSOR...........................................................3-46 3.14.8 TRAY LIFT MOTOR .....................................................................3-48 3.14.9 FEED/DEVELOPMENT MOTOR..................................................3-49 3.15 FUSING .................................................................................................3-50 3.15.1 FUSING UNIT...............................................................................3-50 3.15.2 FUSING UNIT EXIT GUIDE .........................................................3-51 3.15.3 HOT ROLLER STRIPPERS .........................................................3-51 3.15.4 FUSING LAMPS ...........................................................................3-52 3.15.5 THERMISTORS AND THERMOSTATS .......................................3-54 3.15.6 FUSING ROLLER/PRESSURE ROLLER.....................................3-55 3.16 BY-PASS TRAY ....................................................................................3-57 3.16.1 COVER REPLACEMENT .............................................................3-57 3.16.2 BY-PASS PAPER FEED AND PICK-UP ROLLER REPLACEMENT ...........................................................................3-58 3.16.3 BY-PASS SEPARATION ROLLER REPLACEMENT ...................3-59 3.16.4 PAPER END SENSOR AND PICK-UP SOLENOID REPLACEMENT ...........................................................................3-60 3.16.5 PAPER SIZE SENSOR BOARD REPLACEMENT .......................3-61 3.16.6 BY-PASS TABLE REMOVAL .......................................................3-62 3.16.7 PAPER FEED CLUTCH REPLACEMENT....................................3-63 3.17 DUPLEX UNIT.......................................................................................3-64 3.17.1 DUPLEX COVER REMOVAL .......................................................3-64 3.17.2 DUPLEX ENTRANCE SENSOR REPLACEMENT.......................3-65 3.17.3 DUPLEX EXIT SENSOR REPLACEMENT ..................................3-66 3.18 DRIVE AREA.........................................................................................3-67 3.18.1 REGISTRATION CLUTCH AND TRANSFER BELT CONTACT CLUTCH .....................................................................3-67 3.18.2 MAIN MOTOR ..............................................................................3-68 3.18.3 TONER SUPPLY MOTOR............................................................3-69 3.19 PRINTED CIRCUIT BOARDS ...............................................................3-70 3.19.1 HIGH VOLTAGE POWER SUPPLY .............................................3-70 3.19.2 I/O BOARD ...................................................................................3-71
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3.19.3 BICU BOARD ...............................................................................3-72 3.19.4 PSU ..............................................................................................3-72 3.20 HARD DISK/CONTROLLER BOARD....................................................3-73 3.21 COPY ADJUSTMENTS: PRINTING/SCANNING ..................................3-74 3.21.1 PRINTING ....................................................................................3-74 Registration - Leading Edge/Side-to-Side...........................................3-74 Blank Margin.......................................................................................3-75 Main Scan Magnification.....................................................................3-75 Parallelogram Image Adjustment........................................................3-76 3.21.2 SCANNING...................................................................................3-77 Registration: Platen Mode...................................................................3-77 Magnification.......................................................................................3-77 Sub Scan Magnification ......................................................................3-77 3.21.3 ADF IMAGE ADJUSTMENT.........................................................3-78 Registration.........................................................................................3-78 3.21.4 TOUCH SCREEN CALIBRATION ................................................3-79

4 TROUBLESHOOTING ................................................................. 4-1
4.1 SERVICE CALL CONDITIONS .................................................................4-1 4.1.1 SUMMARY .......................................................................................4-1 4.1.2 SC CODE DESCRIPTIONS .............................................................4-2 4.2 ELECTRICAL COMPONENT DEFECTS ................................................4-16 4.2.1 SENSORS ......................................................................................4-16 4.2.2 SWITCHES.....................................................................................4-17 4.3 BLOWN FUSE CONDITIONS .................................................................4-18 4.4 LEDS .......................................................................................................4-18 4.5 TEST POINTS .........................................................................................4-18

5 SERVICE TABLES....................................................................... 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1 5.1.1 SERVICE PROGRAM MODE OPERATION.....................................5-1 Entering and Exiting SP mode ..............................................................5-1 SP Mode Button Summary ...................................................................5-2 Switching Between SP Mode and Copy Mode for Test Printing ...........5-3 Selecting the Program Number.............................................................5-3 5.1.2 SERVICE PROGRAM MODE TABLES ............................................5-4 SP1-xxx: Feed ......................................................................................5-4 SP2-xxx: Drum......................................................................................5-7 SP3-xxx: Process................................................................................5-15 SP4-xxx: Scanner ...............................................................................5-16 SP5-xxx: Mode ...................................................................................5-29 SP6-xxx: Peripherals ..........................................................................5-36 SP7-xxx: Data Log ..............................................................................5-38 5.1.3 TEST PATTERN PRINTING: SP2-902...........................................5-47 Test Pattern Table (SP2-902-2: IPU Test Print)..................................5-47 Test Pattern Table: SP2-902-3 Printing Test Patterns........................5-48 5.1.4 INPUT CHECK ...............................................................................5-49 Main Machine Input Check: SP5-803 .................................................5-49 ARDF Input Check: SP6-007 ..............................................................5-53
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5.1.5 OUTPUT CHECK ...........................................................................5-54 Main Machine Output Check: SP5-804...............................................5-54 ARDF Output Check: SP6-008) ..........................................................5-56 5.1.6 SMC PRINT OUT LISTS: SP5-990.................................................5-56 5.1.7 NIP BAND WIDTH ADJUSTMENT: SP1-109 .................................5-60 5.1.8 MEMORY ALL CLEAR: SP5-801 ...................................................5-61 5.1.9 SOFTWARE RESET ......................................................................5-62 5.1.10 SYSTEM SETTINGS AND COPY SETTING RESET ...................5-62 System Setting Reset .........................................................................5-62 Copier Setting Reset...........................................................................5-63 5.2 SOFTWARE DOWNLOAD ......................................................................5-64 5.3 UPLOADING/DOWNLOADING NVRAM DATA.......................................5-65 5.3.1 UPLOADING NVRAM DATA (SP5-824).........................................5-65 5.3.2 DOWNLOADING NVRAM DATA (SP5-825) ..................................5-66 5.4 SELF-DIAGNOSTIC MODE ....................................................................5-67 5.4.1 SELF-DIAGNOSTIC MODE AT POWER ON .................................5-67 5.4.2 DETAILED SELF-DIAGNOSTIC MODE .........................................5-68 Executing Detailed Self-Diagnosis......................................................5-68 5.5 USER PROGRAM MODE .......................................................................5-70 5.5.1 HOW TO USE UP MODE...............................................................5-70 UP Mode Initial Screen: User Tools/Counter Display..........................5-70 System Settings ..................................................................................5-70 Copier/Document Server Features .....................................................5-71 Printer, Facsimile, Scanner Settings ...................................................5-71 Counter ...............................................................................................5-72 5.6 DIP SWITCHES.......................................................................................5-73

6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ...............................................................................................6-1 6.1.1 COMPONENT LAYOUT ...................................................................6-1 6.1.2 PAPER PATH...................................................................................6-3 6.1.3 DRIVE LAYOUT ...............................................................................6-4 6.2 BOARD STRUCTURE...............................................................................6-5 6.2.1 BLOCK DIAGRAM............................................................................6-5 6.2.2 CONTROLLER .................................................................................6-7 6.3 COPY PROCESS OVERVIEW .................................................................6-9 Exposure...............................................................................................6-9 Drum charge .........................................................................................6-9 Laser exposure .....................................................................................6-9 Development.........................................................................................6-9 Image transfer.....................................................................................6-10 Separation ..........................................................................................6-10 ID sensor ............................................................................................6-10 Cleaning..............................................................................................6-10 Quenching ..........................................................................................6-10 6.4. SCANNING..............................................................................................6-11

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6.4.1 OVERVIEW ....................................................................................6-11 SCANNER DRIVE ..............................................................................6-12 Book Mode..........................................................................................6-12 ADF mode...........................................................................................6-12 6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE.........................6-13 6.5 IMAGE PROCESSING ............................................................................6-15 6.5.1 OVERVIEW ....................................................................................6-15 6.5.2 SBU (SENSOR BOARD UNIT).......................................................6-16 6.5.3 AUTO IMAGE DENSITY (ADS) ......................................................6-17 6.5.4 IPU (IMAGE PROCESSING UNIT).................................................6-18 Overview.............................................................................................6-18 6.5.5 IMAGE PROCESSING MODES .....................................................6-19 6.5.6 SUMMARY OF IMAGE PROCESSING FUNCTIONS ....................6-21 6.5.7 IMAGE PROCESSING STEPS AND RELATED SP MODES.........6-22 Text Mode...........................................................................................6-22 Text/Photo Mode ................................................................................6-23 Photo Mode ........................................................................................6-24 Pale (Low-Density Mode)....................................................................6-25 Generation Copy Mode.......................................................................6-26 Auto shading (shading correction) ......................................................6-27 Background erase...............................................................................6-27 Independent dot erase ........................................................................6-28 Filtering ...............................................................................................6-29 Pre-Filter .............................................................................................6-29 Text Mode...........................................................................................6-30 Photo Mode ........................................................................................6-31 Text/Photo Mode ................................................................................6-32 Low Density Mode ..............................................................................6-33 Generation Mode ................................................................................6-33 Main scan magnification and reduction...............................................6-34 correction..........................................................................................6-34 Gradation processing..........................................................................6-34 Line width correction ...........................................................................6-35 6.6 LASER EXPOSURE................................................................................6-36 6.6.1 OVERVIEW ....................................................................................6-36 6.6.2 AUTO POWER CONTROL (APC) ..................................................6-37 6.6.3 DUAL BEAM WRITING ..................................................................6-38 6.6.4 LASER BEAM PITCH CHANGE MECHANISM..............................6-39 6.6.5 LD SAFETY SWITCHES ................................................................6-40 6.7 PHOTOCONDUCTOR UNIT (PCU) ........................................................6-41 6.7.1 OVERVIEW ....................................................................................6-41 6.7.2 DRIVE MECHANISM......................................................................6-42 6.7.3 DRUM PAWLS ...............................................................................6-42 6.7.4 DRUM TONER SEALS...................................................................6-42 6.8 DRUM CHARGE .....................................................................................6-43 6.8.1 OVERVIEW ....................................................................................6-43 6.8.2 CHARGE ROLLER VOLTAGE CORRECTION ..............................6-44 Correction for Environmental Conditions ............................................6-44 Correction for paper width and thickness (by-pass tray only) .............6-45
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6.8.3 ID SENSOR PATTERN PRODUCTION TIMING............................6-46 6.8.4 DRUM CHARGE ROLLER CLEANING ..........................................6-46 6.9 DEVELOPMENT .....................................................................................6-47 6.9.1 OVERVIEW ....................................................................................6-47 6.9.2 DRIVE MECHANISM......................................................................6-48 6.9.3 DEVELOPER MIXING ....................................................................6-48 6.9.4 DEVELOPMENT BIAS ...................................................................6-49 Mechanism .........................................................................................6-49 Correction for paper width and thickness (by-pass tray only) .............6-49 6.9.5 TONER SUPPLY ............................................................................6-50 Toner bottle replenishment mechanism ..............................................6-50 Toner supply mechanism....................................................................6-51 Sensor Control Mode ..........................................................................6-52 Image Pixel Count Mode.....................................................................6-53 6.9.6 TONER NEAR END/END DETECTION .........................................6-53 6.9.7 TONER END RECOVERY .............................................................6-54 6.9.8 TONER SUPPLY WITH ABNORMAL SENSORS ..........................6-54 DRUM CLEANING AND TONER RECYCLING ..................................6-55 6.10.1 DRUM CLEANING........................................................................6-55 6.10.2 TONER RECYCLING ...................................................................6-55 6.11 PAPER FEED........................................................................................6-56 6.11.1 OVERVIEW ..................................................................................6-56 6.11.2 PAPER FEED DRIVE ...................................................................6-57 6.11.3 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM6-57 6.11.4 PAPER LIFT .................................................................................6-58 6.11.5 PAPER END DETECTION ...........................................................6-59 6.11.6 PAPER REGISTRATION..............................................................6-59 6.11.7 PAPER SIZE DETECTION...........................................................6-60 6.12 BY-PASS TRAY ....................................................................................6-61 6.12.1 OVERVIEW ..................................................................................6-61 6.12.2 BY-PASS TRAY OPERATION .....................................................6-62 6.12.3 BY-PASS PAPER SIZE DETECTION ..........................................6-63 6.13 DUPLEX UNIT.......................................................................................6-64 6.13.1 OVERVIEW ..................................................................................6-64 6.13.2 DUPLEX DRIVE LAYOUT ............................................................6-65 6.13.3 DUPLEX BASIC OPERATION .....................................................6-66 Larger than A4 lengthwise/LT lengthwise ...........................................6-66 Up to A4 lengthwise/LT lengthwise .....................................................6-66 6.13.4 DUPLEX UNIT FEED IN AND EXIT MECHANISM.......................6-67 Feed-in................................................................................................6-67 Inversion and Exit ...............................................................................6-67 6.14 IMAGE TRANSFER AND PAPER SEPARATION .................................6-68 6.14.1 OVERVIEW ..................................................................................6-68 6.14.2 BELT DRIVE MECHANISM..........................................................6-69 6.14.3 TRANSFER BELT UNIT CONTACT MECHANISM ......................6-69 6.14.4 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM .6-70 6.14.5 TRANSFER BELT CHARGE ........................................................6-71 Mechanism .........................................................................................6-71 Correction for paper width and thickness............................................6-72
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Currents applied to leading edge and image areas, and for by-pass feed....................................................................................6-73 6.14.6 TRANSFER BELT CLEANING MECHANISM ..............................6-74 6.15 IMAGE FUSING AND PAPER EXIT......................................................6-75 6.15.1 OVERVIEW ..................................................................................6-75 6.15.2 FUSING DRIVE ............................................................................6-76 6.15.3 FUSING DRIVE RELEASE MECHANISM....................................6-76 6.15.4 FUSING ENTRANCE GUIDE SHIFT MECHANISM .....................6-77 6.15.5 EXIT GUIDE PLATE AND DE-CURLER ROLLERS .....................6-77 6.15.6 PRESSURE ROLLER...................................................................6-78 6.15.7 CLEANING MECHANISM ............................................................6-78 6.15.8 FUSING TEMPERATURE CONTROL..........................................6-79 Temperature Control...........................................................................6-79 Fusing Idling Temperature ..................................................................6-80 6.15.9 OVERHEAT PROTECTION .........................................................6-80 6.16 ENERGY SAVER MODES ....................................................................6-81 6.16.1 OVERVIEW ..................................................................................6-81 6.16.2 ENERGY SAVER MODE..............................................................6-82 Entering the energy saver mode.........................................................6-82 What happens in energy saver mode .................................................6-82 Return to stand-by mode ....................................................................6-82 6.16.3 AUTO OFF MODE........................................................................6-83 Entering off stand-by and off modes ...................................................6-83 Off Stand-by mode..............................................................................6-83 Off Mode .............................................................................................6-83 Returning to stand-by mode................................................................6-83

SPECIFICATIONS.....................................................................SPEC-1
1 GENERAL SPECIFICATIONS.............................................................. SPEC-1 2 MACHINE CONFIGURATION .............................................................. SPEC-3 3 OPTIONAL EQUIPMENT ..................................................................... SPEC-5

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PERIPHERALS
ARDF (B351) 1 REPLACEMENT AND ADJUSTMENT................................... B351-1
COVERS ............................................................................................ B351-1 ORIGINAL FEED UNIT ...................................................................... B351-2 ORIGINAL PICK-UP ROLLER............................................................ B351-2 ORIGINAL FEED BELT...................................................................... B351-3 SKEW CORRECTION/INTERVAL/ REGISTRATION/ORIGINAL WIDTH SENSORS.......................................................................................... B351-4 1.6 ORIGINAL LENGTH SENSORS ........................................................ B351-5 1.7 SEPARATION ROLLER ..................................................................... B351-5 1.8 INVERTER /ORIGINAL SET SENSORS............................................ B351-6 1.9 PICK-UP MOTOR/ORIGINAL STOPPER HP SENSOR/PICK-UP HP SENSOR ............................................................................................ B351-6 1.10 SCANNER MOTOR AND INVERTER MOTOR................................ B351-7 1.11 FEED MOTOR, SKEW CORRECTION ROLLER CLUTCH ............ B351-8 1.12 EXIT SENSOR ................................................................................. B351-9 1.13 STAMP SOLENOID.......................................................................... B351-9 1.14 CONTROLLER BOARD ................................................................... B351-9 1.1 1.2 1.3 1.4 1.5

2 TROUBLESHOOTING ......................................................... B351-10
2.1 TIMING CHARTS ............................................................................. B351-10 2.1.1 A4(S)/LT(S) SINGLE-SIDE ORIGINAL MODE ........................ B351-10 2.1.2 A4(S)/LT(S) DOUBLE-SIDED ORIGINAL MODE .................... B351-11 2.2 JAM DETECTION............................................................................. B351-12

3 SERVICE TABLES............................................................... B351-13
3.1 DIP SWITCHES................................................................................ B351-13 3.2 TEST POINTS .................................................................................. B351-13 3.3 FUSES ............................................................................................. B351-13

4 DETAILED DESCRIPTION .................................................. B351-14
4.1 MAIN COMPONENTS...................................................................... B351-14 DRIVE LAYOUT .......................................................................... B351-15 4.3 ORIGINAL SIZE DETECTION.......................................................... B351-16 4.3.1 BASIC MECHANISM ............................................................... B351-16 4.3.2 MIXED ORIGINAL SIZE MODE .............................................. B351-18 4.4 ORIGINAL FEED-IN MECHANISM .................................................. B351-19 4.4.1 PICK AND SEPARATION........................................................ B351-19 4.4.2 ORIGINAL SKEW CORRECTION ........................................... B351-20 4.4.3 REDUCING THE INTERVAL BETWEEN PAGES ................... B351-20 4.5 ORIGINAL TRANSPORT AND EXIT................................................ B351-21 4.5.1 SINGLE-SIDED ORIGINALS................................................... B351-21 4.5.2 DOUBLE-SIDED ORIGINALS ................................................. B351-22 4.6 STAMP ............................................................................................. B351-23
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LCT (A683) 1 OVERALL MACHINE INFORMATION ................................... A683-1
1.1 1.2 1.3 1.4 1.5 SPECIFICATIONS.............................................................................. A683-1 MECHANICAL COMPONENT LAYOUT ............................................ A683-2 ELECTRICAL COMPONENT LAYOUT.............................................. A683-3 ELECTRICAL COMPONENT DESCRIPTION.................................... A683-4 DRIVE LAYOUT ................................................................................. A683-5

2 DETAILED DESCRIPTIONS .................................................. A683-6
2.1 PAPER FEED MECHANISM .............................................................. A683-6 2.2 TRAY LIFT AND PAPER HEIGHT DETECTION MECHANISM ......... A683-7 Tray lifting conditions ..................................................................... A683-7 Tray lowering conditions ................................................................ A683-7 2.3 TRAY UNIT SLIDE MECHANISM ...................................................... A683-8

3 SERVICE TABLES................................................................. A683-9
3.1 3.2 3.3 3.4 DIP SWITCHES.................................................................................. A683-9 TEST POINTS .................................................................................... A683-9 SWITCHES......................................................................................... A683-9 FUSES ............................................................................................... A683-9

4 REPLACEMENT AND ADJUSTMENT................................. A683-10
4.1 COVER REPLACEMENT ................................................................. A683-10 Tray Cover ................................................................................... A683-10 Front Cover.................................................................................. A683-10 Rear Cover .................................................................................. A683-10 Right Lower Cover ....................................................................... A683-10 Upper Cover ................................................................................ A683-10 4.2 ROLLER REPLACEMENT ............................................................... A683-11 4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ...... A683-11 Pick-up Roller .............................................................................. A683-11 Paper Feed Roller........................................................................ A683-11 Separation Roller ......................................................................... A683-11 4.3 TRAY LIFT AND PAPER END SENSOR REPLACEMENT ............. A683-12 Tray Lift Sensor ........................................................................... A683-12 Paper End Sensor ....................................................................... A683-12 4.4 RELAY SENSOR REPLACEMENT.................................................. A683-13 4.5 SIDE FENCE POSITION CHANGE.................................................. A683-14

PTU (A682) 1 REPLACEMENT AND ADJUSTMENT................................... A682-1
1.1 COVER REPLACEMENT ................................................................... A682-1 Right Cover.................................................................................... A682-1 Rear Cover .................................................................................... A682-1 1.2 ROLLER REPLACEMENT ................................................................. A682-2
x

1.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ........ A682-2 Pick-up Roller ................................................................................ A682-2 Paper Feed Roller.......................................................................... A682-2 Separation Roller ........................................................................... A682-2 1.3 TRAY MOTOR REPLACEMENT........................................................ A682-3 1.4 PAPER FEED AND RELAY CLUTCH REPLACEMENT .................... A682-4 1.5 PAPER FEED UNIT REPLACEMENT................................................ A682-5 Upper Paper Feed Unit .................................................................. A682-6 Lower Paper Feed Unit .................................................................. A682-6 1.6 PAPER END, TRAY LIFT, AND RELAY SENSOR REPLACEMENT. A682-7 Paper End Sensor ......................................................................... A682-7 Tray Lift Sensor ............................................................................. A682-7 Relay Sensor ................................................................................. A682-7

2 SERVICE TABLES................................................................. A682-8
2.1 2.2 2.3 2.4 DIP SWITCHES.................................................................................. A682-8 TEST POINTS .................................................................................... A682-8 SWITCHES......................................................................................... A682-8 FUSES ............................................................................................... A682-8

3 DETAILED DESCRIPTIONS .................................................. A682-9
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 MECHANICAL COMPONENT LAYOUT ............................................ A682-9 ELECTRICAL COMPONENT LAYOUT............................................ A682-10 ELECTRICAL COMPONENT DESCRIPTION.................................. A682-11 DRIVE LAYOUT ............................................................................... A682-12 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM... A682-13 PAPER LIFT MECHANISM .............................................................. A682-14 PAPER END DETECTION ............................................................... A682-16 PAPER HEIGHT DETECTION ......................................................... A682-17

4 SPECIFICATIONS................................................................ A682-18

BRIDGE UNIT (B688) 1 OVERALL MACHINE INFORMATION ................................... A688-1
1.1 1.2 1.3 1.4 1.5 SPECIFICATIONS.............................................................................. A688-1 MECHANICAL COMPONENT LAYOUT ............................................ A688-2 ELECTRICAL COMPONENT LAYOUT.............................................. A688-3 ELECTRICAL COMPONENT DESCRIPTION.................................... A688-3 DRIVE LAYOUT ................................................................................. A688-4

2 DETAILED DESCRIPTION .................................................... A688-5
2.1 JUNCTION GATE MECHANISM........................................................ A688-5

3 REPLACEMENT AND ADJUSTMENT................................... A688-6
3.1 EXIT SENSOR REPLACEMENT........................................................ A688-6

xi

1 BIN TRAY (B376) 1 OVERALL MACHINE INFORMATION ................................... B376-1
1.1 1.2 1.3 1.4 SPECIFICATIONS.............................................................................. B376-1 MECHANICAL COMPONENT AND DRIVE LAYOUT ........................ B376-2 ELECTRICAL COMPONENT LAYOUT.............................................. B376-3 ELECTRICAL COMPONENT DESCRIPTION.................................... B376-3

2 DETAILED DESCRIPTIONS .................................................. B376-4
2.1 BASIC OPERATION........................................................................... B376-4

3 REPLACEMENT AND ADJUSTMENT................................... B376-5
3.1 COVER REMOVAL ............................................................................ B376-5 Front Cover.................................................................................... B376-5 Upper Cover .................................................................................. B376-5 Rear Cover .................................................................................... B376-5 3.2 PAPER SENSOR REPLACEMENT ................................................... B376-6 3.3 ENTRANCE AND PAPER LIMIT SENSOR REPLACEMENT ............ B376-7 Paper Limit Sensor ........................................................................ B376-7 Entrance Sensor ............................................................................ B376-7

1,000 SHEET FINISHER (A681) 1 OVERALL MACHINE INFORMATION ................................... A681-1
1.1 1.2 1.3 1.4 1.5 SPECIFICATIONS.............................................................................. A681-1 MECHANICAL COMPONENT LAYOUT ............................................ A681-2 ELECTRICAL COMPONENT LAYOUT.............................................. A681-3 ELECTRICAL COMPONENT DESCRIPTIONS ................................. A681-4 DRIVE LAYOUT ................................................................................. A681-6

2 DETAILED DESCRIPTIONS .................................................. A681-7
2.1 JUNCTION GATE MECHANISM........................................................ A681-7 Staple mode................................................................................... A681-7 No staple mode.............................................................................. A681-7 2.2 JOGGER UNIT PAPER POSITIONING MECHANISM....................... A681-8 2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM............................ A681-9 2.4 STAPLER ......................................................................................... A681-10 2.5 FEED OUT MECHANISM ................................................................ A681-11 2.6 SHIFT TRAY UP/DOWN MECHANISM ........................................... A681-12 2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM..................................... A681-13 2.8 JAM CONDITIONS........................................................................... A681-14 2.9 TIMING CHARTS ............................................................................. A681-15 2.9.1 NO STAPLE MODE (A4 SIDEWAYS, 3 SHEETS/2SETS)...... A681-15 2.9.2 STAPLE MODE (A4 SIDEWAYS, 2 SHEETS/2 SETS) ........... A681-16

xii

3 SERVICE TABLE ................................................................. A681-17
3.1 DIP SWITCH TABLE ........................................................................ A681-17 3.2 TEST POINTS .................................................................................. A681-17 3.3 FUSES ............................................................................................. A681-17

4 REPLACEMENT AND ADJUSTMENT................................. A681-18
4.1 COVER REMOVAL .......................................................................... A681-18 Front Door.................................................................................... A681-18 Front Cover.................................................................................. A681-18 Rear Cover .................................................................................. A681-18 Upper Cover ................................................................................ A681-18 Lower Left Cover ......................................................................... A681-19 Front Shift Tray Cover.................................................................. A681-19 Rear Shift Tray Cover .................................................................. A681-19 Shift Tray ..................................................................................... A681-19 4.2 ENTRANCE SENSOR REPLACEMENT.......................................... A681-20 4.3 EXIT SENSOR REPLACEMENT...................................................... A681-21 4.4 STACK HEIGHT SENSOR REPLACEMENT ................................... A681-22 4.5 POSITIONING ROLLER REPLACEMENT....................................... A681-23 4.6 STAPLER REPLACEMENT ............................................................. A681-24

TWO TRAY FINISHER (B352) 1 REPLACEMENT AND ADJUSTMENT................................... B352-1
1.1 COVERS ............................................................................................ B352-1 1.1.1 EXTERNAL COVERS................................................................ B352-1 1.1.2 INNER COVER.......................................................................... B352-1 1.2 POSITIONING ROLLER..................................................................... B352-2 1.3 TRAY 1 EXIT SENSOR...................................................................... B352-2 1.4 ENTRANCE SENSOR/STAPLER TRAY ENTRANCE SENSOR ....... B352-3 1.5 STAPLER TRAY................................................................................. B352-3 1.6 UPPER STACK HEIGHT SENSORS/TRAY 1 UPPER LIMIT SWITCHB352-4 1.7 EXIT GUIDE PLATE MOTOR............................................................. B352-5 1.8 LIFT MOTORS ................................................................................... B352-5 1.9 LOWER EXIT SENSOR ..................................................................... B352-7 1.10 LOWER STACK HEIGHT SENSORS .............................................. B352-8 1.11 TRAY 2 SHUNT POSITION SENSOR ............................................. B352-8 1.12 STAPLER UNIT................................................................................ B352-9 1.13 STAPLER ROTATION HP SENSOR................................................ B352-9 1.14 TRAY 1 INTERIOR......................................................................... B352-10 1.14.1 TRAY 1 COVERS .................................................................. B352-10 tray Shift Sensors and tray release sensor .................................. B352-11 1.14.3 TRAY 1 SHIFT MOTOR ........................................................ B352-11 1.14.4 BACK FENCE LOCK CLUTCH ............................................. B352-11 1.15 FINISHER MAIN BOARD ............................................................... B352-12 1.16 PUNCH HOLE POSITION ADJUSTMENT ..................................... B352-12
xiii

2 TROUBLESHOOTING ......................................................... B352-13
2.1 TIMING CHARTS ............................................................................. B352-13 2.1.1 A4(S)/LT(S) SHIFT MODE WITH PUNCH ­ TRAY 1 .............. B352-13 2.1.2 A4(S)/LT(S) SHIFT MODE WITH PUNCH ­ TRAY 2 .............. B352-14 2.1.3 A4(S)/LT(S) STAPLE MODE WITH PUNCH ........................... B352-15 2.2 JAM DETECTION............................................................................. B352-16

3 SERVICE TABLES............................................................... B352-17
3.1 DIP SWITCH SETTINGS ................................................................. B352-17 3.2 TEST POINTS .................................................................................. B352-17 3.3 FUSES ............................................................................................. B352-17

4 DETAILED DESCRIPTIONS ................................................ B352-18
4.1 4.2 4.3 4.4 GENERAL LAYOUT ......................................................................... B352-18 DRIVE LAYOUT ............................................................................... B352-19 JUNCTION GATES .......................................................................... B352-20 TRAY SHIFTING .............................................................................. B352-21 4.4.1 TRAY SHIFT MECHANISMS .................................................. B352-21 Tray 1 (Upper Tray) ..................................................................... B352-21 Tray 2 (Lower Tray) ..................................................................... B352-22 4.5 TRAY UP/DOWN MECHANISMS .................................................... B352-23 4.5.1 TRAY 1 .................................................................................... B352-23 Introduction .................................................................................. B352-23 Normal and sort/stack modes ...................................................... B352-23 Staple mode................................................................................. B352-24 Tray 1 release mechanism........................................................... B352-25 4.5.2 TRAY 2 .................................................................................... B352-27 4.5.3 PRE-STACK MECHANISM ..................................................... B352-28 4.6 JOGGER UNIT PAPER POSITIONING MECHANISM..................... B352-29 Vertical Paper Alignment ............................................................. B352-29 Horizontal Paper Alignment ......................................................... B352-29 4.7 STAPLER MECHANISM .................................................................. B352-30 4.7.1 STAPLER MOVEMENT........................................................... B352-30 Stapler Rotation ........................................................................... B352-30 Side-to-Side Movement ............................................................... B352-30 4.7.2 STAPLER ................................................................................ B352-31 4.7.3 FEED OUT AND TRANSPORT ............................................... B352-32 4.8 PUNCH UNIT (OPTIONAL) .............................................................. B352-33 4.8.1 PUNCH DRIVE MECHANISM ................................................. B352-33 4.8.2 PUNCH WASTE COLLECTION .............................................. B352-34

xiv

26 January, 2001

INSTALLATION REQUIREMENTS

!CAUTION
Never turn off the main power switch when the power LED is lit or flashing. To avoid damaging the hard disk or memory, press the operation power switch to switch the power off, wait for the power LED to go off, and then switch the main power switch off. NOTE: The main power LED ( ) lights or flashes while the platen cover or ARDF is open, while the main machine is communicating with a facsimile or the network server, or while the machine is accessing the hard disk or memory for reading or writing data.

1.1 INSTALLATION REQUIREMENTS !CAUTION
ARDF
"Rating Voltage of Output Connector, Max. DC24 V"

Scanner Unit
"Rating Voltage of Output Connector, Max. DC24 V"

Finisher
"Rating Voltage of Output Connector, Max. DC24 V"

B004I016.WMF

LCT
"Rating Voltage of Output Connector, Max. DC24 V"

1-1

Installation

1. INSTALLATION PROCEDURE

INSTALLATION REQUIREMENTS

26 January, 2001

1.1.1 ENVIRONMENT
1. Temperature Range: 2. Humidity Range: 3. Ambient Illumination: 4. Ventilation: 5. Ambient Dust: 10°C to 30°C (50°F to 86°F) 15% to 80% RH Less than 1,500 lux (do not expose to direct sunlight.) Room air should turn over at least 30 m3/hr/person Less than 0.10 mg/m3 (2.7 x 10/6 oz/yd3)

6. Avoid areas exposed to sudden temperature changes: 1) Areas directly exposed to cool air from an air conditioner. 2) Areas directly exposed to heat from a heater. 7. Do not place the machine where it will be exposed to corrosive gases. 8. Do not install the machine at any location over 2,000 m (6,500 ft.) above sea level. 9. Place the main machine on a strong and level base. Inclination on any side should be no more than 5 mm (0.2"). 10. Do not place the machine where it may be subjected to strong vibrations.

1.1.2 MACHINE LEVEL
Front to back: Right to left: Within 5 mm (0.2") of level Within 5 mm (0.2") of level

1-2

26 January, 2001

INSTALLATION REQUIREMENTS

1.1.3 MINIMUM SPACE REQUIREMENTS
Place the main machine near the power source, providing clearance as shown:
Installation

C

560 mm (22")

B D

A

670 mm (26.4")
B004I010.WMF

180 mm (7.1")
B004I012.WMF

726 mm (28.6") A: Front: >75 cm (29.,6 ") B: Left: > 10 cm (4") C: Rear: > 10 cm (4") D: Right > 10 cm (4")

B004I014.WMF

NOTE: The 75 cm (29.5") recommended for the space at the front is for pulling out the paper tray only. If the operator stands at the front of the main machine, more space is required.

1-3

INSTALLATION REQUIREMENTS

26 January, 2001

1.1.4 POWER REQUIREMENTS

!CAUTION
1. Make sure that the wall outlet is near the main machine and easily accessible. Make sure the plug is firmly inserted in the outlet. 2. Avoid multi-wiring. 3. Be sure to ground the machine. 1. Input voltage level: North America 120 V, 60 Hz: More than 12 A Europe/Asia 220V~240V, 50Hz/60Hz: more than 8A 2. Permissible voltage fluctuation: ±10 % 3. Never set anything on the power cord.

1-4

26 January, 2001

INSTALLATION FLOW CHART

The following flow chart shows how to install the optional units more efficiently.

Unpack Copier

Does the user require the Paper Tray Unit, LCT, or Finisher? Yes Place Copier on the paper tray unit Install the paper tray unit No

Install the copier

Install the bridge unit (if required)

If the customer requires the 1-bin tray: Remove the scanner unit Install the 1-bin tray Replace the scanner unit

Install the remaining options in any order
B004I510.WMF

Bridge Unit: Paper Tray Unit: Other requirements:

Needed for the finishers and external output tray. Needed for LCT and finishers. See Overall Machine Information ­ Installation Option Table.

1-5

Installation

1.2 INSTALLATION FLOW CHART

MAIN MACHINE INSTALLATION

26 January, 2001

1.3 MAIN MACHINE INSTALLATION
1.3.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following list: Description Q'ty

1. Operation Panel Decal (-22 machine).................................... 1 2. Paper Size Decal ................................................................... 1 3. Model Name Decal (-15, -22 machines) ................................ 1 4. NECR ­ English (-17, -57 machines)..................................... 1 5. NECR ­ Multi Language (-19, -21, -27, -29, -67 machines)... 1 6. Energy Star Sticker (-26, -66 machines)................................ 1 7. Operation Instructions ­ System Setting................................ 1 (-15, -17, -19, -21, -26, -29, -55, -57, -66 machines) 8. Operation Instructions ­ Copy Reference.............................. 1 (-14, -15, -17, -19, -21, -26, -29, -55, -57, -66 machines) 9. EU Safety Information (-22, -27, -26, -24).............................. 1

1-6

26 January, 2001

MAIN MACHINE INSTALLATION

1.3.2 INSTALLATION PROCEDURE
Installation

[A] [B]

[D]

[C]
B004I100.WMF B004I102.WMF

B004I103.WMF

[D]

[E]
B004I101.WMF

1. Remove the main machine from the box, and remove all shipping retainers and tapes. NOTE: Store all shipping retainers as you remove them. You will need them if the machine is moved to another location in the future. 2. Remove scanner cushion [A], and install the end fence [B]. 3. Pull out the paper trays and remove all tape and bottom plate stoppers [C]. 4. On the right side of the machine, open the by-pass tray, duplex unit, and transfer right cover, and then remove all the shipping retainers [D] NOTE: If the paper tray unit is to be installed, do this now. ( 1.4) 5. If the paper tray unit is not to be installed, install the middle front cover [E] (provided in the second paper tray).

1-7

MAIN MACHINE INSTALLATION

26 January, 2001

Development Unit and PCU

[C]

[A]
B004I104.WMF

[B]

A284I500.WMF

[D]

[E] [F]

B004I511.WMF

1. Open the front cover and remove the tape and retainers [A]. 2. Loosen [B] (! x1) and rotate the bracket [C]. 3. At [D]: Push down lever !. Pull the PCU out a small distance ", and then push the development unit to the left # so the development unit is away from the drum. 4. Slowly slide out the PCU [E] and place it on a clean flat surface. 5. Remove the three clamps and wire [F].

1-8

26 January, 2001

MAIN MACHINE INSTALLATION

[A]

B004I512.WMF

[C]

[B]

B004I105.WMF

6. Spread a large piece of paper on a flat surface. NOTE: Make sure the area is free of pins, paper clips, staples, etc. to avoid attraction to the magnetic development roller. 7. Slide the development unit [A] out and place it on the paper. 8. Remove the tape and tag [B] from the development unit 9. Remove the entrance seal plate [C] (" x2).

1-9

Installation

MAIN MACHINE INSTALLATION

26 January, 2001

[A]

[C]

[B]
B004I106.WMF

[D]
B004I513.WMF

B004R957.WMF

10. Remove the development roller unit [A], and set it on th