Copystar CS-6030 User manual

SERVICE
MANUAL
Published in Apr ’06
3FB70944
Revision 4
CS-6030/8030

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.
ATTENTION
IL Y A DANGER D’EXPLOSION S’IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE.
REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MÊME TYPE OU D’UN TYPE REC-
OMMANDÉ PAR LE CONSTRUCTEUR. METTRE AU RÉBUT LES BATTERIES USAGÉES CON-
FORMÉMENT AUX INSTRUCTIONS DU FABRICANT.

Revision history
Revision Date Replaced pages Remarks
2 June 24, 2005 Overall revised
3 December 2, 2005 Overall revised
4 March 20, 2006 Overall revised

This page is intentionally left blank.

Safety precautions
This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.

1.Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. .............................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. ............................................................................................................................
CAUTION:
• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .......
• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ................
• Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. .........................................................................................................................
• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ...........
• Always handle the machine by the correct locations when moving it. ...............................................
• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause
the copier to move unexpectedly or topple, leading to injury. ...........................................................
• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is acciden-
tally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immedi-
ately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical
attention. ......................................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. .....................................................................................................................

2.Precautions for Maintenance
WARNING
• Always remove the power plug from the wall outlet before starting machine disassembly. ...............
• Always follow the procedures for maintenance described in the service manual and other related
brochures. .......................................................................................................................................
• Under no circumstances attempt to bypass or disable safety features including safety mechanisms
and protective circuits. .....................................................................................................................
• Always use parts having the correct specifications. ..........................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related bro-
chure when replacing them. Using a piece of wire, for example, could lead to fire or other serious
accident. ..........................................................................................................................................
• When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ................................................................
• Always check that the copier is correctly connected to an outlet with a ground connection. .............
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it
is dirty, clean it to remove the risk of fire or electric shock. ..............................................................
• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ...........................................................................................................................
• Handle the charger sections with care. They are charged to high potentials and may cause electric
shock if handled improperly. ............................................................................................................
CAUTION
• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections. ..........................................................
• Use utmost caution when working on a powered machine. Keep away from chains and belts. ........
• Handle the fixing section with care to avoid burns as it can be extremely hot. ..................................
• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures. ........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement. ....................
• Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. .....................................................................................................
• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. .............................................................................................
• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ........
• Remove toner completely from electronic components. ...................................................................
• Run wire harnesses carefully so that wires will not be trapped or damaged. ....................................
• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten connector,
trapped wire and missing screws. ...................................................................................................
• Check that all the caution labels that should be present on the machine according to the instruction
handbook are clean and not peeling. Replace with new ones if necessary. ......................................
• Handle greases and solvents with care by following the instructions below: .....................................
· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
· Ventilate the room well while using grease or solvents.
· Allow applied solvents to evaporate completely before refitting the covers or turning the power
switch on.
· Always wash hands afterwards.
• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc. .......................................................................................................................
• Should smoke be seen coming from the copier, remove the power plug from the wall outlet imme-
diately. ............................................................................................................................................
3.Miscellaneous
WARNING
• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the
specified refiner; it may generate toxic gas. .....................................................................................

2FB/2FC
CONTENTS
1-1 Specifications
1-1-1 Specifications..........................................................................................................................................1-1-1
1-1-2 Parts names............................................................................................................................................1-1-3
(1) Copier................................................................................................................................................1-1-3
(2) Operation panel.................................................................................................................................1-1-5
1-1-3 Cross section view ..................................................................................................................................1-1-6
1-1-4 Drive system ...........................................................................................................................................1-1-7
(1) Drive system 1 (Optical section)........................................................................................................1-1-7
(2) Drive system 2 (Cassette paper feed)...............................................................................................1-1-8
(3) Drive system 3 (Deck paper feed).....................................................................................................1-1-9
(4) Drive system 4 (Deck lift) ..................................................................................................................1-1-9
(5) Drive system 5 (Vertical paper feed)...............................................................................................1-1-10
(6) Drive system 6 (MP tray paper feed)...............................................................................................1-1-11
(7) Drive system 7 (Paper conveying) ..................................................................................................1-1-12
(8) Drive system 8 (Drive motor and developing motor drive trains) ....................................................1-1-13
(9) Drive system 9 (Transfer motor, fuser motor drive train).................................................................1-1-14
(10) Drive system 10 (Toner motor drive train).......................................................................................1-1-16
(11) Drive system 11 (Document processor)..........................................................................................1-1-17
1-2 Handling Precautions
1-2-1 Drum .......................................................................................................................................................1-2-1
1-2-2 Toner container.......................................................................................................................................1-2-1
1-2-3 Installation environment ..........................................................................................................................1-2-1
1-3 Installation
1-3-1 Unpacking and installation ......................................................................................................................1-3-1
(1) Installation procedure........................................................................................................................1-3-1
1-3-2 Setting initial copy modes .....................................................................................................................1-3-12
1-3-3 Installing the key counter (option) .........................................................................................................1-3-13
1-3-4 Installing the document finisher (option) ...............................................................................................1-3-15
1-3-5 Installing the side feeder (option)..........................................................................................................1-3-24
1-3-6 Installing the printer kit (option).............................................................................................................1-3-28
1-3-7 Installing the scanner kit (option) ..........................................................................................................1-3-31
1-3-8 Installing the security kit (option)...........................................................................................................1-3-33
1-4 Maintenance Mode
1-4-1 Maintenance mode .................................................................................................................................1-4-1
(1) Executing a maintenance item ..........................................................................................................1-4-1
(2) Maintenance mode item list...............................................................................................................1-4-2
(3) Contents of the maintenance mode items.........................................................................................1-4-7
1-4-2 Copier management .............................................................................................................................1-4-76
(1) Using the copier management mode ..............................................................................................1-4-76
(2) Job accounting ................................................................................................................................1-4-77
(3) Default settings for copying.............................................................................................................1-4-78
(4) Common default settings.................................................................................................................1-4-80
(5) Weekly timer....................................................................................................................................1-4-82
(6) Configuring MP tray.........................................................................................................................1-4-82
(7) Registering non-standard sizes for originals ...................................................................................1-4-83
(8) Setting document management defaults.........................................................................................1-4-83
(9) Hard disk management ...................................................................................................................1-4-83
(10) Printing reports................................................................................................................................1-4-83
(11) Checking total copy count ...............................................................................................................1-4-84
(12) Refreshing the drum........................................................................................................................1-4-84
(13) Selecting the language....................................................................................................................1-4-84
1-5 Troubleshooting
1-5-1 Paper misfeed detection .........................................................................................................................1-5-1
(1) Paper misfeed indication...................................................................................................................1-5-1

2FB/2FC-4
(2) Paper misfeed detection conditions ..................................................................................................1-5-2
(3) Paper misfeeds ...............................................................................................................................1-5-10
1-5-2 Self-diagnosis .......................................................................................................................................1-5-24
(1) Self-diagnostic function ...................................................................................................................1-5-24
(2) Self diagnostic codes ......................................................................................................................1-5-26
1-5-3 Image formation problems ....................................................................................................................1-5-46
(1) No image appears(entirely white)....................................................................................................1-5-48
(2) No image appears(entirely black)....................................................................................................1-5-49
(3) Image is too light. ............................................................................................................................1-5-50
(4) Background is visible.......................................................................................................................1-5-51
(5) A white line appears longitudinally. .................................................................................................1-5-51
(6) A black line appears longitudinally. .................................................................................................1-5-51
(7) A black line appears laterally...........................................................................................................1-5-52
(8) One side of the copy image is darker than the other.......................................................................1-5-52
(9) Black dots appear on the image......................................................................................................1-5-52
(10) Image is blurred...............................................................................................................................1-5-53
(11) The leading edge of the image is consistently misaligned with the original. ...................................1-5-53
(12) The leading edge of the image is sporadically misaligned with the original. ...................................1-5-53
(13) Paper creases. ................................................................................................................................1-5-54
(14) Offset occurs. ..................................................................................................................................1-5-54
(15) Image is partly missing....................................................................................................................1-5-54
(16) Fusing is poor..................................................................................................................................1-5-55
(17) Image is out of focus. ......................................................................................................................1-5-55
(18) Image center does not align with the original center.......................................................................1-5-55
(19) Image is not square.........................................................................................................................1-5-55
(20) There is a regular error between the centers of the original and copy image
when the DP is used. ......................................................................................................................1-5-56
(21) There is a regular error between the leading edges of the original and copy image
when the DP is used. ......................................................................................................................1-5-56
(22) A line appears at the leading or trailing edge..................................................................................1-5-56
(23) A line appears periodically. .............................................................................................................1-5-56
1-5-4 Electric problems ..................................................................................................................................1-5-57
Copier
(1) The machine does not operate when the main power switch is turned on......................................1-5-57
(2) The developing motor does not operate(C2100).............................................................................1-5-57
(3) The drive motor does not operate(C2200). .....................................................................................1-5-57
(4) The fuser motor does not operate(C2300). .....................................................................................1-5-57
(5) The transfer motor does not operate(C2550)..................................................................................1-5-58
(6) Paper feed motor 1 does not operate..............................................................................................1-5-58
(7) Paper feed motor 2 does not operate..............................................................................................1-5-58
(8) Paper feed motor 3 does not operate..............................................................................................1-5-58
(9) Paper feed motor 4 does not operate..............................................................................................1-5-58
(10) The feed motor does not operate....................................................................................................1-5-59
(11) The MP feed motor does not operate..............................................................................................1-5-59
(12) The vertical feed motor does not operate........................................................................................1-5-59
(13) The registration motor does not operate. ........................................................................................1-5-59
(14) The toner motor does not operate...................................................................................................1-5-60
(15) The cleaning motor does not operate..............................................................................................1-5-60
(16) The PTC cleaning motor does not operate. ....................................................................................1-5-60
(17) The polygon motor does not operate (C4000). ...............................................................................1-5-60
(18) Lift motor 1 does not operate. .........................................................................................................1-5-60
(19) Lift motor 2 does not operate. .........................................................................................................1-5-60
(20) Lift motor 3 does not operate. .........................................................................................................1-5-60
(21) Lift motor 4 does not operate. .........................................................................................................1-5-60
(22) The scanner motor does not operate. .............................................................................................1-5-60
(23) The duplex side registration motor does not operate......................................................................1-5-61
(24) The duplex feed motor does not operate. .......................................................................................1-5-61
(25) The duplex switchback motor does not operate..............................................................................1-5-61
(26) Cooling fan motor 1 or 2 does not operate......................................................................................1-5-61
(27) Cooling fan motor 3 does not operate.............................................................................................1-5-62
(28) Cooling fan motor 4 does not operate.............................................................................................1-5-62
(29) The scanner fan motor does not operate. .......................................................................................1-5-62
(30) The lamp fan motor does not operate. ............................................................................................1-5-62

2FB/2FC-4
(31) The LSU fan motor does not operate..............................................................................................1-5-62
(32) Developing fan motor 1 or 2 does not operate................................................................................1-5-63
(33) The image formation fan motor does not operate. ..........................................................................1-5-63
(34) The developing duct fan motor does not operate............................................................................1-5-63
(35) PWB fan motor 1 or 2 does not operate..........................................................................................1-5-64
(36) The power source fan motor does not operate. ..............................................................................1-5-64
(37) The feedshift fan motor does not operate. ......................................................................................1-5-64
(38) The duplex fan motor does not operate. .........................................................................................1-5-64
(39) The shield box fan motor does not operate.....................................................................................1-5-64
(40) The MP solenoid does not operate. ................................................................................................1-5-65
(41) The feedshift solenoid does not operate. ........................................................................................1-5-65
(42) The fuser web solenoid does not operate. ......................................................................................1-5-65
(43) The duplex feedshift solenoid does not operate..............................................................................1-5-65
(44) The duplex switchback solenoid does not operate..........................................................................1-5-65
(45) The cleaning lamp does not turn on................................................................................................1-5-65
(46) The exposure lamp does not turn on...............................................................................................1-5-66
(47) The exposure lamp does not turn off...............................................................................................1-5-66
(48) The fuser heater lamp M, S or L does not turn on...........................................................................1-5-66
(49) The fuser heater lamp M, S or L does not turn off...........................................................................1-5-66
(50) No main charging. ...........................................................................................................................1-5-66
(51) No developing bias is output. ..........................................................................................................1-5-66
(52) No transfer bias is output. ...............................................................................................................1-5-67
(53) The original size is not detected......................................................................................................1-5-67
(54) The original size is not detected correctly. ......................................................................................1-5-67
(55) The touch panel keys do not work...................................................................................................1-5-67
(56) The message requesting paper to be loaded is shown when paper is present in cassette 1. ........1-5-67
(57) The message requesting paper to be loaded is shown when paper is present in cassette 2. ........1-5-67
(58) The message requesting paper to be loaded is shown when paper is present in cassette 3. ........1-5-67
(59) The message requesting paper to be loaded is shown when paper is present in cassette 4. ........1-5-68
(60) The message requesting paper to be loaded is shown when paper is present on the MP tray......1-5-68
(61) The size of paper in cassette 3 is not displayed correctly...............................................................1-5-68
(62) The size of paper in cassette 4 is not displayed correctly...............................................................1-5-68
(63) The size of paper on the MP tray is not displayed correctly............................................................1-5-69
(64) A paper jam in the paper feed, paper conveying or fuser section is indicated
when the main power switch is turned on. ......................................................................................1-5-69
(65) The message requesting cover to be closed is displayed when the front cover is closed. .............1-5-69
(66) Others..............................................................................................................................................1-5-69
DP
(1) The original feed motor does not operate. ......................................................................................1-5-70
(2) The original conveying motor does not operate. .............................................................................1-5-70
(3) The original registration motor does not operate.............................................................................1-5-70
(4) The DP lift motor does not operate. ................................................................................................1-5-70
(5) The DP fan motor does not operate................................................................................................1-5-70
(6) The CIS does not turn on. ...............................................................................................................1-5-71
(7) The CIS does not turn off. ...............................................................................................................1-5-71
(8) A message indication cover open is displayed when the DP is closed correctly. ...........................1-5-71
(9) The size of original is not displayed correctly..................................................................................1-5-71
(10) An original jams when the main power switch is turned on.............................................................1-5-71
1-5-5 Mechanical problems ............................................................................................................................1-5-72
Copier
(1) No primary paper feed.....................................................................................................................1-5-72
(2) No secondary paper feed. ...............................................................................................................1-5-72
(3) Skewed paper feed. ........................................................................................................................1-5-72
(4) The scanner does not travel............................................................................................................1-5-72
(5) Multiple sheets of paper are fed at one time. ..................................................................................1-5-72
(6) Paper jams. .....................................................................................................................................1-5-72
(7) Toner drops on the paper conveying path.......................................................................................1-5-72
(8) Abnormal noise is heard..................................................................................................................1-5-73
DP
(1) No primary original feed. .................................................................................................................1-5-74
(2) No secondary paper feed. ...............................................................................................................1-5-74
(3) Originals jam. ..................................................................................................................................1-5-74

2FB/2FC-3
1-6 Assembly and Disassembly
1-6-1 Precautions for assembly and disassembly............................................................................................1-6-1
(1) Precautions .......................................................................................................................................1-6-1
(2) Running a maintenance item.............................................................................................................1-6-2
1-6-2 Paper feed section ..................................................................................................................................1-6-3
(1) Detaching and refitting the paper feed pulley, forwarding pulley and
separation pulley of cassette 1 and 2................................................................................................1-6-3
(2) Detaching and refitting the paper feed pulley, forwarding pulley and
separation pulley of cassette 3 and 4..............................................................................................1-6-10
(3) Pressure adjustment of separation pulley (reference).....................................................................1-6-14
(4) Adjusting the center line for cassette 1 or 2 ....................................................................................1-6-15
(5) Detaching and refitting the MP unit .................................................................................................1-6-17
(6) Detaching and refitting the MP paper feed pulley, MP forwarding pulley and
MP separation pulley.......................................................................................................................1-6-19
(7) Pressure adjustment of MP separation pulley.................................................................................1-6-24
(8) Adjustment after roller and motor replacement ...............................................................................1-6-25
(8-1) Adjusting the leading edge registration of image printing.......................................................1-6-25
(8-2) Adjusting the leading edge registration for duplex switchback copying .................................1-6-26
(8-3) Adjusting the center line of image printing ..............................................................................1-6-27
(8-4) Adjusting the margins for printing...........................................................................................1-6-28
(8-5) Adjusting the amount of slack in the paper ............................................................................1-6-29
1-6-3 Main charging section ...........................................................................................................................1-6-31
(1) Detaching and refitting the main charger unit..................................................................................1-6-31
(2) Detaching and refitting the main charger grid .................................................................................1-6-32
(3) Detaching the main charger wire cleaning pad ...............................................................................1-6-32
(4) Detaching and refitting the main charger wire.................................................................................1-6-33
1-6-4 Optical section ......................................................................................................................................1-6-34
(1) Detaching and refitting the exposure lamp......................................................................................1-6-34
(2) Detaching and refitting the scanner wires .......................................................................................1-6-37
(2-1) Detaching the scanner wires...................................................................................................1-6-37
(2-2) Fitting the scanner wires .........................................................................................................1-6-39
(3) Detaching the laser scanner unit.....................................................................................................1-6-42
(4) Detaching and refitting the ISU (reference).....................................................................................1-6-46
(5) Adjusting the longitudinal squareness (reference) ..........................................................................1-6-48
(6) Adjusting scanner image lateral squareness (reference) ................................................................1-6-49
(6-1) Adjusting the position of the laser scanner unit.......................................................................1-6-49
(6-2) Adjusting the position of the ISU .............................................................................................1-6-50
(7) Adjusting magnification of the scanner in the main scanning direction...........................................1-6-51
(8) Adjusting magnification of the scanner in the auxiliary scanning direction......................................1-6-52
(9) Adjusting the scanner center line ...................................................................................................1-6-53
(10) Adjusting the scanner leading edge registration ............................................................................1-6-54
(11) Adjusting the margins for scanning an original on the contact glass..............................................1-6-55
1-6-5 Drum section.........................................................................................................................................1-6-56
(1) Detaching and refitting the drum .....................................................................................................1-6-56
(2) Detaching and refitting the drum heater..........................................................................................1-6-57
(3) Detaching and refitting the drum heater electrode ..........................................................................1-6-59
1-6-6 Developing section................................................................................................................................1-6-60
(1) Detaching and refitting the developing unit .....................................................................................1-6-60
1-6-7 Transfer section ....................................................................................................................................1-6-61
(1) Detaching and refitting the transfer unit ..........................................................................................1-6-61
(2) Detaching and refitting the transfer belt ..........................................................................................1-6-63
(3) Detaching and refitting the transfer roller ........................................................................................1-6-65
1-6-8 Cleaning section ...................................................................................................................................1-6-66
(1) Detaching and refitting the cleaning unit .........................................................................................1-6-66
(2) Detaching and refitting the cleaning blade ......................................................................................1-6-67
1-6-9 Charge erasing section .........................................................................................................................1-6-68
(1) Detaching and refitting the PTC unit ...............................................................................................1-6-68
(2) Detaching and refitting the PTC cleaning pad.................................................................................1-6-68
(3) Detaching and refitting the PTC wire...............................................................................................1-6-69
1-6-10 Fuser section ........................................................................................................................................1-6-70
(1) Detaching and refitting the fuser unit...............................................................................................1-6-70
(2) Detaching and refitting the lower cleaning roller .............................................................................1-6-71
(3) Detaching and refitting the press roller............................................................................................1-6-72

2FB/2FC-3
(4) Detaching and refitting the cleaning felt ..........................................................................................1-6-73
(5) Detaching and refitting the fuser thermostat ...................................................................................1-6-75
(6) Detaching and refitting the fuser thermistor ....................................................................................1-6-75
(7) Detaching and refitting the fuser heater M, S and L........................................................................1-6-76
(8) Detaching and refitting the heat roller .............................................................................................1-6-79
(9) Detaching and refitting the heat roller separation claws..................................................................1-6-80
(10) Detaching and refitting the fuser eject upper roller..........................................................................1-6-81
1-6-11 Document processor (DP) section ........................................................................................................1-6-82
(1) Detaching and refitting DP ..............................................................................................................1-6-82
(2) Detaching and refitting the DP original feed belt, DP forwarding pulley and DP separation roller ..1-6-83
(3) Detaching and refitting CIS .............................................................................................................1-6-87
(4) Adjusting the tension of original feed belt........................................................................................1-6-90
(5) Adjusting the DP magnification .......................................................................................................1-6-91
(6) Adjusting the DP center line............................................................................................................1-6-92
(7) Adjusting the scanning start position when the DP is used.............................................................1-6-93
(7-1) Adjusting the leading edge registration ...................................................................................1-6-93
(7-2) Adjusting the trailing edge registration ....................................................................................1-6-94
(8) Adjusting the margins for scanning the original from the DP ..........................................................1-6-95
1-6-12 Others ...................................................................................................................................................1-6-96
(1) Detaching and refitting the waste toner box....................................................................................1-6-96
(2) Detaching and refitting the developing rear fan filter.......................................................................1-6-97
(3) Detaching and refitting the developing front fan filters ....................................................................1-6-97
(4) Detaching and refitting the image formation fan filter......................................................................1-6-98
(5) Detaching and refitting the front cover filters...................................................................................1-6-99
(6) Detaching and refitting the ozone filters........................................................................................1-6-100
1-7 Requirements on PWB Replacement
1-7-1 Upgrading the firmware...........................................................................................................................1-7-1
1-7-2 Adjustment-free variable resistors (VR) ..................................................................................................1-7-2
1-7-3 Remarks on main PWB replacement......................................................................................................1-7-2
1-7-4 Remarks on engine PWB replacement...................................................................................................1-7-3
1-7-5 Remarks on scanner PWB replacement.................................................................................................1-7-3
1-7-6 Upgrading the printer board firmware .....................................................................................................1-7-4
1-7-7 Remarks on hard disk unit (HDD) replacement ......................................................................................1-7-4
2-1 Mechanical construction
2-1-1 Paper feed section ..................................................................................................................................2-1-1
(1) Paper feed section 1 (cassette 1 and 2)............................................................................................2-1-1
(2) Paper feed section 2 (cassette 3 and 4)............................................................................................2-1-3
(3) Paper feed section 3 .........................................................................................................................2-1-5
(4) MP tray and MP tray paper feed section...........................................................................................2-1-7
2-1-2 Main charger section...............................................................................................................................2-1-9
2-1-3 Optical section ......................................................................................................................................2-1-11
(1) Original scanning.............................................................................................................................2-1-12
(2) Image printing..................................................................................................................................2-1-13
2-1-4 Developing section................................................................................................................................2-1-15
(1) Single component developing system.............................................................................................2-1-17
2-1-5 Transfer section ....................................................................................................................................2-1-18
2-1-6 Cleaning section ...................................................................................................................................2-1-19
2-1-7 Fuser section ........................................................................................................................................2-1-20
2-1-8 PTC section ..........................................................................................................................................2-1-22
2-1-9 Eject and feedshift section....................................................................................................................2-1-24
2-1-10 Duplex section ......................................................................................................................................2-1-26
(1) Circulation system (4 sheets circulation).........................................................................................2-1-28
2-1-11 Document processor (DP) section ........................................................................................................2-1-29
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout..............................................................................................................................2-2-1
(1) PWBs ................................................................................................................................................2-2-1
(2) Switches and sensors .......................................................................................................................2-2-3
(3) Motors ...............................................................................................................................................2-2-5
(4) Others................................................................................................................................................2-2-7
(5) PWBs (DP)........................................................................................................................................2-2-8

2FB/2FC-2.0
(6) Switches and sensors (DP)...............................................................................................................2-2-9
(7) Others (DP) .....................................................................................................................................2-2-10
2-3 Operation of the PWBs
2-3-1 AC power source PWB ...........................................................................................................................2-3-1
2-3-2 DC power source PWB ...........................................................................................................................2-3-4
2-3-3 Main PWB ...............................................................................................................................................2-3-8
2-3-4 Engine PWB..........................................................................................................................................2-3-17
2-3-5 Scanner PWB .......................................................................................................................................2-3-25
2-3-6 CCD PWB .............................................................................................................................................2-3-29
2-3-7 Deck PWB.............................................................................................................................................2-3-32
2-3-8 Cassette PWB.......................................................................................................................................2-3-37
2-3-9 Duplex PWB..........................................................................................................................................2-3-40
2-3-10 Operation PWB .....................................................................................................................................2-3-45
2-3-11 DP main PWB .......................................................................................................................................2-3-49
2-4 Appendixes
Chart of image adjustment procedures...................................................................................................2-4-1
Image quality...........................................................................................................................................2-4-4
Maintenance parts list.............................................................................................................................2-4-5
Periodic maintenance procedures ..........................................................................................................2-4-7
Maintenance kits...................................................................................................................................2-4-13
Parts kits ...............................................................................................................................................2-4-14
Wiring diagram No.1 .............................................................................................................................2-4-15
Wiring diagram No.2 .............................................................................................................................2-4-16
Wiring diagram No.3 .............................................................................................................................2-4-17
Wiring diagram No.4 .............................................................................................................................2-4-18
Wiring diagram No.5 .............................................................................................................................2-4-19
Wiring diagram No.6 .............................................................................................................................2-4-20
Wiring diagram No.7 .............................................................................................................................2-4-21
Wiring diagram No.8 .............................................................................................................................2-4-22
Wiring diagram No.9 .............................................................................................................................2-4-23
Wiring diagram No.10 ...........................................................................................................................2-4-24

2FB/2FC
1-1-1
1-1 Specific ations
1-1-1 Specifications
Copier
Type ................................................Console
Copying system ..............................Indirect electrostatic system
Originals..........................................Sheets, books and three-dimensional objects
Maximum size: A3/11" x 17"
Original feed system .......................Fixed
Copy paper .....................................Weight
Cassette: 60 - 160 g/m2
MP tray: 45 - 200 g/m2
Types
Cassette: Plain paper, colored paper
MP tray: Plain paper, special paper (colored paper, transparencies, etc.) and enve-
lopes (when using the printer function only)
Copy sizes ......................................Cassette
Maximum: A3/11" x 17"
Minimum: A5R/5 1/2" x 8 1/2"
MP tray
Maximum: A3/11" x 17"
Minimum: A6R/5 1/2" x 8 1/2"
During duplex copying
Maximum: A3/11" x 17"
Minimum: A5R/5 1/2" x 8 1/2"
Magnification ratios.........................Manual mode: 25 - 400%, 1% increments
Auto copy mode: Fixed ratios
Copying speed................................At 100% magnification in memory copy mode:
80 cpm
A4/11" x 8 1/2": 80 sheets/min.
A4R/8 1/2" x 11": 54 sheets/min.
A3/11" x 17": 40 sheets/min.
B4 (257 x 364 mm)/8 1/2" x 14": 50 sheets/min.
B5: 80 sheets/min.
B5R: 58 sheets/min.
When the document processor is used (at 100% magnification):
A4/11" x 8 1/2": 80 sheets/min.
60 cpm
A4/11" x 8 1/2": 60 sheets/min.
A4R/8 1/2" x 11": 43 sheets/min.
A3/11" x 17": 31 sheets/min.
B4 (257 x 364 mm)/8 1/2" x 14": 37 sheets/min.
B5: 60 sheets/min.
B5R: 47 sheets/min.
When the document processor is used (at 100% magnification):
A4/11" x 8 1/2": 60 sheets/min.
First copy time ................................2.9 s or less (80 cpm)/3.6 s or less (60 cpm) (A4/11" x 8 1/2", 100% magnification,
cassette 1)
Warm-up time .................................30 s
Recovery from low power mode: 10 s
Recovery from sleep mode: 30 s
(room temperature 23 °C/73.4 °F, 50%RH)
Paper feed system..........................Automatic feed (four cassettes)
Capacity: 1500 sheets (80 g/m2) x 2
500 sheets (80 g/m2)/525 sheets (75 g/m2) x 2
Manual feed
Capacity:
MP tray: 100 sheets (80 g/m2)
Multiple copying..............................1 - 9999 sheets
Photoconductor...............................a-Si (drum diameter 84 mm)
Charging system.............................Double positive corona charging
Recording system ...........................Semiconductor laser

2FB/2FC
1-1-2
Developing system .........................Dry, reverse developing (single component system)
Developer: 1-component, magnetism toner
Toner replenishing: Automatic from a toner container
Transfer system ..............................Transfer belt, approximately 1.5 kV
Separation system ..........................Transfer belt and separation claws
Fusing system.................................Heat roller
Heat source: Halogen heaters
120 V specifications
Main 1080 W, sub 500 W, small size 1000 W
220 -240 V specifications
Main 1350 W, sub 500 W, small size 1100 W
Control temperature: 200 °C/392 °F (80 cpm)/195 °C/383 °F (60 cpm)
(at normal ambient temperature)
Control temperature: (at normal ambient temperature)
Abnormally high temperature protection devices: thermostats
Charge erasing system...................Exposure by cleaning lamp
Cleaning system .............................Blade and fur brush
Scanning system ............................Flat bed scanning by CCD image sensor
Bitmap memory...............................128 MB (standard)
Image storage memory...................40 GB (standard)
Resolution.......................................600 x 600 dpi
Light source ....................................Inert gas lamp (30 W)
Dimensions .....................................680 (W) x 783 (D) x 1190 (H) mm
26 3/4" (W) x 30 13/16" (D) x46 7/8" (H)
Weight.............................................Approx. 188 kg/Approx. 413.6 lbs
Floor requirements..........................1480 mm (W) x 783 (D) mm
58 1/4" (W) x 30 13/16" (D)
Functions ........................................Selecting image quality, Adjusting exposure, Auto zoom, Manual zoom, Preset zoom,
XY zoom, Duplex mode, Split mode, Sort mode, Auto paper selection, Offset mode,
Combine mode, Margin mode, Centering originals, Border erase, Page numbering,
Cover mode, Form overlay, Booklet from sheets, Booklets from booklets, Memo
mode, Batch scanning, Proof mode, Repeat copy, Backing sheets for transparencies,
Auto rotation, EcoPrint (economy printing) mode, Inverted copying, Mirror image, Auto
selection mode, Multi-page forms, Programmed copying, Programming multi-part
jobs, Form box, Shared data box, Synergy print box, Output management, Job
accounting mode, Weekly timer, Language setting
Power source..................................120 V AC, 60 Hz, 16.0 A/220 - 240 V AC, 50/60 Hz, 9.5 A
Power consumption ........................1920 W
Options ...........................................Side feeder, document finisher, key counter, printer kit, scanner kit, security kit and
output tray.
Document processor (DP)
Original feed system .......................Automatic feed
Scanning system ............................Contact Image Sensor (CIS)
Originals..........................................Sheets
Original weights ..............................45 - 160 g/m2
Original sizes ..................................A3 - A5R, folio/11" x 17" - 5 1/2" x 8 1/2"
No. of originals................................200 sheets <plain paper (80 g/m2), colored paper, recycled paper, high quality paper
(50 g/m2)>
145 sheets (110 g/m2)
1 sheet (coated paper)
Power source..................................Supplied via copier

2FB/2FC
1-1-3
1-1-2 Parts names
(1) Copier
Figure 1-1-1
12
5
4
6
7
8
9
10
11
12
3
13
14
15
16
17
18
19
20
21
1. Operation panel
2. Operation panel lock lever
3. Document processor (DP)
4. Cassette 1
5. Cassette 2
6. Cassette 3
7. Cassette 4
8. MP tray
9. Paper width guides
10. MP tray extension
11. Right cover
12. Handles
13. Main power switch
14. Main power switch cover
15. Document processor bottom cover
16. Original size indicator plates
17. Platen
18. Front cover
19. Output tray (option)
20. Handles
21. Power cord

2FB/2FC
1-1-4
Figure 1-1-2
2223
26
29
28
24 23
27
25
3031
32
33
34
35
36
37
38
39
41
40
22. Original table
23. Original width guides
24. Cleaning cloth compartment
25. Original loaded Indicator
26. Document processor top cover
27. Ejection guide
28. Document processor angle adjustment lever
29. Original eject table
30. Toner container
31. Toner container release lever
32. Paper conveyor
33. Knob A1
34. Lever A2
35. Knob A3
36. Duplex unit
37. Deck conveying unit
38. Paper width guides
39. Paper width adjusting tab
40. Paper length guide
41. Paper length adjusting tab