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8/11/2019 66804900-Di3510-Service-Manual
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Di2010/Di2510/
Di3010/Di3510
Di2010f/Di2510f/
Di3010f/Di3510f
Service Manual
Return to SubMenu
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1. SAFETY PRECAUTIONS FOR INSPECT
SERVICE
When performing inspection and service procedures, observe theto prevent accidents and ensure utmost safety.
Depending on the model, some of the precautions given in the foll
Different markings are used to denote specific meanings as detail
The following graphic symbols are used to give instructions that n
Used to call the service technician attention to what is grapinside the marking (including a warning).
Used to prohibit the service technician from doing what is ginside the marking.
Used to instruct the service technician to do what is graphinside the marking.
1-1. Warning
WARNING Indicates a potentially hazardous situation which, if not avoided, c
serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, m
moderate injury. It may also be used to alert against unsafe pract
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WARNING2. Before starting the procedures, be sure to unplug the power co
This product contains a high-voltage unit and a circuit with acapacity that may cause an electric shock or burn.
The product also contains parts that can jerk suddenly and c If this product uses a laser, laser beam leakage may cause e
blindness.
3. Do not throw toner or the toner bottle into a fire.
Do not throw toner or the Toner Bottle (Imaging Cartridge, Toa fire. Toner expelled from the fire may cause burns.
4. Use the specified parts.
For replacement parts, always use the genuine parts specifiturers parts manual. Installing a wrong or unauthorized part
dielectric breakdown, overload, or undermine safety devicesble electric shock or fire. Replace a blown electrical fuse or thermal fuse with its corre
part specified in the manufacturers parts manual. Installing amake or rating could lead to a possible fire. If a thermal fusethe temperature control system may have a problem and actto eliminate the cause of the problem.
5. Handle the power cord with care and never use a multiple outle Do not break, crush or otherwise damage the power cord. P
object on the power cord, or pulling or bending it may damagpossible fire or electric shock.
Do not use a multiple outlet to which any other appliance or nected.
Be sure the power outlet meets or exceeds the specified cap Use only the power cord supplied in the package. If a power
plied, only use the power cord and plug that is specified in PINSTRUCTION. Failure to use this cord could result in a fire
Use the power cord supplied in the package only for this mause it for any other product. Failure to observe this precautiofire or electrical shock.
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1-2. Caution
WARNING8. Do not touch a high-temperature part.
A part marked with the symbol shown on the left and othexposure lamp and fusing roller can be very hot while thgized. Touching them may result in a burn.
Wait until these parts have cooled down before replacingrounding parts.
9. Maintain a grounded connection at all times.
Connect the power cord to an electrical outlet that is equterminal.
10. Do not remodel the product.
Modifying this product in a manner not authorized by theresult in a fire or electric shock. If this product uses a lase
may cause eye damage or blindness.11. Restore all parts and harnesses to their original positions.
To promote safety and prevent product damage, make sreturned to their original positions and properly secured saddles in order to avoid hot parts, high-voltage parts, scrushed.
To promote safety, make sure that all tubing and other in
returned to their original positions. Make sure that floatinmounted on the circuit boards are at their correct distancboards.
CAUTION1. Precautions for Service Jobs.
A star washer and spring washer, if used originally, mus
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CAUTION2. Precautions for Servicing with Covers and Parts Removed.
Wherever feasible, keep all parts and covers mounted whenproduct.
If energizing the product with a cover removed is absolutely not touch any exposed live parts and use care not to allow ycaught in the moving parts. Never leave a product in this con
Never place disassembled parts or a container of liquid on th
falling into, or the liquid spilling inside, the mechanism could tric shock or fire.
Never use a flammable spray near the product. This could re Make sure the power cord is unplugged before removing or
boards or plugging in or unplugging connectors. Always use the interlock switch actuating jig to actuate an in
when a cover is opened or removed. The use of folded pape
object may damage the interlock switch mechanism, possiblelectric shock, injury or blindness.
3. Precautions for the Working Environment.
The product must be placed on a flat, level surface that is st Never place this product or its parts on an unsteady or tilting
servicing. Provide good ventilation at regular intervals if a service job m
confined space for a long period of time. Avoid dusty locations and places exposed to oil or steam. Avoid working positions that may block the ventilation ports o
4. Precautions for Handling Batteries. (Lithium, Nickel-Cadmium,
Replace a rundown battery with the same type as specified turers parts manual.
Before installing a new battery, make sure of the correct pola
tion or the battery could burst. Dispose of used batteries according to the local regulations.
them at the users premises or attempt to try to discharge on
5. Precautions for the Laser Beam. (Only for Products Employing
Removing the cover marked with the caution label could lea
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1-3. Used Batteries Precautions
ALL AreasCAUTION
Danger of explosion if battery is incorrectly replaced.Replace only with the same or equivalent type recommended by theDispose of used batteries according to the manufacturers instruction
GermanyVORSICHT!
Explosionsgefahr bei unsachgemem Austausch der Batterie.Ersatz nur durch denselben oder einen vom Hersteller empfohlenen
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
FranceATTENTION
Il y a danger dexplosion sil y a remplacement incorrect de la batteriRemplacer uniquement avec une batterie du mme type ou dun typmand par le constructeur.
Mettre au rebut les batteries usages conformment aux instruction
DenmarkADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering.Udskiftning m kun ske med batteri af samme fabrikat og type.Levr det brugte batteri tilbage til leverandren.
Finland, SwedenVAROlTUS
Paristo voi rjht, jos se on virheellisesti asennettu.Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.Hvit kytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.Anvnd samma batterityp eller en ekvivalent typ som rekommenderatillverkaren.Kassera anvnt batteri enligt fabrikantens instruktion.
Norway
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1-4. Other Precautions When handling circuit boards, observe the HANDLING of PWBs. The PC Drum is a very delicate component. Observe the precautions
DLING OF THE PC DRUM because mishandling may result in seriou
Note that replacement of a circuit board may call for readjustments or ular items, or software installation.
1-5. Precautions for Service
When performing inspection and service procedures, observe the folloto prevent mishandling of the machine and its parts.
Depending on the model, some of the precautions given in the followin
1. Precautions Before Service
When the user is using a word processor or personal computer from asame line, take necessary steps to prevent the circuit breaker from oploads.
Never disturb the LAN by breaking or making a network connection, alinstalling or removing networking hardware or software, or shutting do
devices without the knowledge and express permission of the networkthe shop supervisor.
2. How to Use this Book
DIS/REASSEMBLY, ADJUSTMENT To reassemble the product, reverse the order of disassembly unless o
TROUBLESHOOTING
If a component on a PWB or any other functional unit including a mototext only instructs you to replace the whole PWB or functional unit and bleshooting procedures applicable within the defective unit.
All troubleshooting procedures contained herein assume that there areharnesses and cords and all connectors are plugged into the right pos
The procedures preclude possible malfunctions due to noise and othe
3. Precautions for Service Keep all disassembled parts in good order and keep tools under contrbe lost or damaged.
After completing a service job, perform a safety check. Make sure thatand screws are returned to their original positions.
Do not pull out the toner hopper while the toner bottle is turning. This
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4. Precautions for Dis/Reassembly
Be sure to unplug the copier from the outlet before attempting to s The basic rule is not to operate the copier anytime during disasse
necessary to run the copier with its covers removed, use care not
to be caught in revolving parts such as the timing belt and gears. Before attempting to replace parts and unplug connectors, make scord of the copier has been unplugged from the wall outlet.
Be sure to use the Interlock Switch Actuating Jig whenever it is neInterlock Switch with the covers left open or removed.
While the product is energized, do not unplug or plug connectors ior harnesses.
Never use flammable sprays near the copier.
A used battery should be disposed of according to the local regulacarded casually or left unattended at the users premises.
When reassembling parts, make sure that the correct screws (sizewasher are used in the correct places.
5. Precautions for Circuit Inspection
Never create a closed circuit across connector pins except those son the printed circuit.
When creating a closed circuit and measuring a voltage across coin the text, be sure to use the GND wire.
6. Handling of PWBs
During Transportation/Storage During transportation or when in storage, new P.W. Boards must n
removed from their protective conductive bags.
Do not store or place P.W. Boards in a location exposed to direct sperature. When it becomes absolutely necessary to remove a Board from it
case, always place it on its conductive mat in an area as free as potricity.
Do not touch the pins of the ICs with your bare hands. Protect the PWBs from any external force so that they are not ben
During Inspection/Replacement Avoid checking the IC directly with a multimeter; use connectors o Never create a closed circuit across IC pins with a metal tool. Before unplugging connectors from the P.W. Boards, make sure th
been unplugged from the outlet. When removing a Board from its conductive bag or conductive cas
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8. Handling of the PC Drum
Only for Products Not Employing an Imaging Cartridge.
During Transportation/Storage Use the specified carton whenever moving or storing the PC Drum.
The storage temperature is in the range between 20C and +40C. In summer, avoid leaving the PC Drum in a car for a long time.
Handling Ensure that the correct PC Drum is used. Whenever the PC Drum has been removed from the copier, store it in it
it with a Drum Cloth.
The PC Drum exhibits greatest light fatigue after being exposed to stroextended period of time. Never, therefore, expose it to direct sunlight. Use care not to contaminate the surface of the PC Drum with oil-base
prints, and other foreign matter. Do not scratch the surface of the PC Drum. Do not apply chemicals to the surface of the PC Drum. Do not attempt to wipe clean the surface of the PC Drum.
If, however, the surface is contaminated with fingerprints, clean it using tdure.
A. Place the PC Drum into one half
1076D001
B. Gently wipe the residual toner ofPC Drum with a dry, Dust-Free C
Turn the PC Drum so that the are
which the line of toner left by the Cpresent is facing straight up. Wipecontinuous movement from the reDrum to the front edge and off theDrum.T th PC D li htl d i1076D002
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NOTES
Even when the PC Drum is only locally dirtied, wipe the entire sur
Do not expose the PC Drum to direct sunlight. Clean it as quickly a
interior illumination.
If dirt remains after cleaning, repeat the entire procedure from the
time.
9. Handling of the Imaging Cartridge and Print Unit
Only for Products Employing an Imaging Cartridge and Print Unit.
During Transportation/Storage The storage temperature is in the range between 20 C and +40 In summer, avoid leaving the Imaging Cartridge and Print Unit in a
Handling Store the Imaging Cartridge and Print Unit in a place that is not ex
light.
Precautionary Information on the PC Drum Inside the Imaging Cartr Use care not to contaminate the surface of the PC Drum with oil-b
C. Soak a small amount of eithpropyl alcohol into a clean, uton Pad which has been foldNow, wipe the surface of the
tinuous movement from its reedge and off its surface one
Never move the Pad back and
1076D003
D. Using the SAME face of the dure explained in the latter h
entire surface of the PC DruAlways OVERLAP the areascomplete turns of the PC Drate for cleaning.
1076D004
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INDEX
MAINTENANCE
GENERAL
SWITCHES ON PWBsTECH. REP. SETTING
DIS/REASSEMBLY,ADJUSTMENT
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CONTENTS
GENERAL1. Specifications .........................................................................
2. PRECAUTIONS FOR INSTALLATION ..................................2-1. Installation Site ...............................................................2-2. Power Source .................................................................2-3. Grounding ......................................................................
3. PRECAUTIONS FOR USE ....................................................3-1. To ensure that the copier is used in an optimum conditio3-2. Operating Environment ..................................................3-3. Power Requirements ......................................................3-4. CAUTION .......................................................................
4. Handling Consumables ..........................................................5. Other Precautions ..................................................................6. SYSTEM OPTIONS ...............................................................
MAINTENANCE1. Maintenance Schedule ...........................................................
1-1. Guidelines for Life-time Expected Values by Unit ..........2. Disassembly/Reassembly and Cleaning ................................
(1) Cleaning of the Manual Bypass Paper Take-Up Ro(2) Replacement of the Manual Bypass Paper Take-Up(3) Cleaning of the Manual Bypass Separator Roll Ass
(4) Replacement of the Manual Bypass Separator Roll(5) Cleaning of the 1st Pickup Roller ...........................(6) Replacement of the 1st Pickup Roller ....................(7) Cleaning of the 1st Paper Take-Up Roller .............(8) Replacement of the 1st Paper Take-Up Roller ......(9) Cleaning of the 1st Separator Roll .........................(10) Replacement of the 1st Separator Roll Assy .........
(11) Cleaning of the 2nd Pickup Roller ..........................(12) Replacing of the 2nd Pickup Roller ........................(13) Cleaning of the 2nd Paper Take-Up Roller ............(14) Replacement of the 2nd Paper Take-Up Roller .....(15) Cleaning of the 2nd Separator Roll ........................
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(27) Replacement of the Ozone Filter ...........................(28) Cleaning of the Charge Neutralizing Plate .............
3. Replacement of the Units .......................................................(1) Replacement of the Image Transfer Roller Unit .....
(2) Replacement of the PC Drum Unit .........................(3) Replacement of the Developer ..............................(4) Replacement of the Developing Unit .....................(5) Cleaning of the Ds Collar .......................................(6) Replacement of the Fusing Unit
(When the Switch Back Unit is Not Installed) .........(7) Replacement of the Fusing Unit
(When the Switch Back Unit is Installed) ...............
DIS/REASSEMBLY,ADJUSTMENT1. SAFETY INFORMATION .......................................................
1-1. LASER SAFETY ............................................................1-2. INTERNAL LASER RADIATION ....................................1-3. LASER SAFETY LABEL ................................................
1-4. LASER CAUTION LABEL ..............................................1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPM
2. Disassembly/Reassembly Instructions ...................................2-1. Identification of Fuses ....................................................2-2. Parts Which Must Not Be Touched ................................
(1) Red Painted Screws ..............................................(2) Variable Resistors on Board ..................................
3. Disassembly/Reassembly ......................................................3-1. Doors, Covers, and Exterior Parts Identification and
Removal Procedures ......................................................3-2. Removal of Circuit Boards and Other Electrical Compon
(1) Removal of the Control Panel ................................(2) Removal of the Master Board ................................
(3) Removal of Paper Size Detecting Board 1 ............(4) Removal of Paper Size Detecting Board 2 ............(5) Removal of the DC Power Supply .........................(6) Removal of the High Voltage Unit ..........................
3-3. Removal of Units ............................................................(1) R l f th M l B U it
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(6) Removal of the CCD Unit .......................................(7) Installation Adjustment to be Made when CCD Unit(8) Removal of the MFB3 Board ..................................(9) Removal of the ROM Board ...................................
3-5. Cleaning and Disassembly of Engine Parts ...................(1) Removal of the Transport Motor ............................(2) Removing the IU Motor ..........................................(3) Removal of the AIDC Sensor .................................
4. Adjustment .............................................................................4-1. Adjustment Jigs and Tools .............................................4-2. Mechanical Adjustment ..................................................
(1) Adjustment of the Manual Paper Size Detection Un(2) Manual Bypass Unit Installation Check ..................(3) Scanner Position Adjustment .................................
4-3. Electrical/Image Adjustment ...........................................(1) Accessing the Tech. Rep. Mode ............................(2) Registration CD ......................................................(3) Registration FD ......................................................(4) Book Center Erase .................................................(5) Loop Adjustment ....................................................(6) Edge Erase (Leading Edge Erase) ........................(7) Edge Erase (Trailing Edge Erase) .........................(8) Edge Erase (Right/Left Edge Erase) ......................(9) Image Density Setting ............................................
(10) ATDC Sensor Gain Adjustment .............................(11) VG Adjust ...............................................................(12) Fuser Temp. ...........................................................(13) Registration (IR) .....................................................(14) IR-Mag Adjustment ................................................(15) Touch Panel Adjustment ........................................
5. Miscellaneous ........................................................................
5-1. Installation of the Key Counter (Option) .........................5-2. Mounting of the Original Size Detecting Sensors (Option5-3. Firmware Upgrade (MSC) ..............................................5-4. Firmware Upgrade (Printer/Finisher) ..............................
(1) Composition of the Service Jigs .............................
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2-1. Utility Mode Function Setting Procedure ........................2-2. Utility Mode Function Tree .............................................2-3. Settings in the Utility Mode .............................................
(1) Users Choice Functions ........................................
(2) Meter Count ...........................................................(3) Copy Job Recall .....................................................(4) User Management .................................................(5) Admin. Management ..............................................
2-4. Tech. Rep. Mode Function Setting Procedure ...............(1) Tech. Rep. Mode Function Tree ............................(2) Settings in the Tech. Rep. Mode ............................
(3) System Input ..........................................................(4) Administrator # Input ..............................................(5) Counter ..................................................................(6) Function .................................................................(7) I/O CHECK .............................................................(8) Movement Check ...................................................(9) RD Mode ................................................................(10) ROM Version .........................................................(11) Level History ..........................................................(12) Software Switch Settings .......................................
3. Security Mode ........................................................................3-1. Security Mode Setting Procedure ..................................3-2. Security Mode Function Tree .........................................
3-3. Settings in the Security Mode ........................................(1) Total Counter Count ...............................................(2) Size Counter Count ................................................(3) Copy Kit Counter ....................................................(4) Copy Kit .................................................................(5) Plug-In Counter ......................................................(6) Key Counter ...........................................................
(7) Vendor Mode .........................................................4. Adjust Mode ...........................................................................
4-1. Adjust Mode Setting Procedure .....................................4-2. Adjust Mode Function Tree ............................................4-3. Settings in the Adjust Mode ...........................................
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(6) Date/Time ..............................................................(7) Trouble Reset ........................................................
TROUBLESHOOTING1. Introduction ............................................................................
1-1. Electrical Components Check Procedure ......................(1) Sensor ...................................................................(2) Switch ...................................................................(3) Solenoid .................................................................(4) Clutch ...................................................................(5) Motor ...................................................................
1-2. I/O CHECK .....................................................................(1) Check Procedure ...................................................(2) I/O Check List ........................................................
2. Misfeeds .................................................................................2-1. Initial Checks ..................................................................2-2. Misfeed Display ..............................................................2-3. Misfeed-Detecting Sensor Layout ..................................
2-4. Misfeed Detection Timing/Troubleshooting Procedures (1) 1st Drawer Paper Take-Up Section Misfeed ..........(2) Image Transfer Section Misfeed ............................(3) Fusing Section/Paper Exit Section Misfeed ...........(4) Turnover Unit/Duplex Unit Transport Section Misfe(5) Duplex Unit Take-Up Section Misfeed ...................(6) 2nd Drawer Take-Up Section/
Vertical Transport Section Misfeed T-20(7) Manual Bypass Take-Up Section Misfeed .............(8) 3rd Drawer Take-Up Section Misfeed (PF-210) .....(9) 4th Drawer Take-Up Section Misfeed (PF-210) .....(10) LCC Paper Take-Up Section Misfeed (PF-122) .....
3. Malfunctions ...........................................................................
3-1. Resetting a Malfunction ..................................................3-2. List of Malfunction Codes ...............................................3-3. Malfunction Detection Timing and Troubleshooting Proc
(1) C0000: Transport Motor Failure .............................(2) C0010: Imaging Unit Motor Failure ........................(3) C0045 C li F M t F il
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(15) C0920: 1st Drawer Lift-Up Motor Failure ...............(16) C0950: 4th Drawer Lift-Up Motor Failure ...............(17) C0960: Manual Bypass Paper-Lifting Failure ........(18) C0990: LCC Elevator Motor Failure .......................
(19) C0991: LCC Lift Failure .........................................(20) C0996: LCC Lock Release Failure ........................(21) C0997: LCC Shift Gate Operation Failure .............(22) C0998: LCC Shift Failure .......................................(23) C099C: LCC Shift Motor Failure ............................(24) C099D: LCC Communication Failure .....................(25) C0F32: ATDC Sensor Failure ................................
(26) C0F33: ATDC Adjustment Failure .........................(27) C12D0: MIO Device Failure ...................................(28) C1300: Polygon Motor Failure ...............................(29) Main Unit Communication Failure ..........................(30) C133A: Main Unit G/A Communication Failure ......(31) C133B: Exit Option Paper Transport Failure .........(32) C13D0: EEPROM Failure ......................................(33) C13E0: Flash ROM Failure ....................................(34) C13F0: HSYNC Detection Failure .........................
3-4. Power-Supply-Related Malfunctions ..............................(1) Copier is not receiving power. ................................(2) Only the Power Unit Cooling Fan Motor turns. ......
4. Image Quality Problems .........................................................
4-1. Image Failure Troubleshooting ......................................4-2. Initial Check Items ..........................................................4-3. Troubleshooting Procedures for Specific Image Quality P
(1) Image Reading Section: Blank copy or black copy (2) Image Reading Section: Low image density or roug(3) Image Reading Section: Foggy background ..........(4) Image Reading Section: Black streaks or bands ...
(5) Image Reading Section: Black spots .....................(6) Image Reading Section: White streaks or bands ...(7) Image Reading Section: Uneven pitch ...................(8) Printer Section: Blank copy or black copy ..............(9) Printer Section: Low image density or rough image
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GENERAL
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1. Specifications
Copy medium
TypeOriginal Scanning System
PhotoconductorCopying System
ResolutionPaper Take-Up System
Exposure SystemDeveloping SystemCharging SystemImage Transfer SystemPaper Separator SystemFusing SystemPaper Discharging SystemOriginal Size
::
::
::
::::::::
Desktop/Console (dedicated cabinet Scanning in main scanning direction
color CCDOPC (organic photoconductor)Electrostatic dry powdered image trawith a laser600x600 dpi2WayManual bypass tray. . . . . . .150 shee
1st drawer . . . . . . . . . . . . . 500 shee2nd drawer . . . . . . . . . . . . .500 sheeMirror scanning slit exposure systemMT-HGsystemComb electrode with scorotron systeRoller image transferPaper separator fingers and charge nHeat rollerCharge neutralizing brushA3
Paper Source1st Drawer2nd Drawer
Copy papertype
Plain paper (56 to 90 g/m2) Transparencies -
Special (91 to 210 g/m2) -
Postcards (190 g/m2) -
Recycled
Label -
Envelope -
Copy paperdimensions
Max. (width x length)297 x 420 mm11-3/4 x 16-1/2
Min (width x length)148 x 210 mm
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Continuous Copy Speed (copies/min)
Zoom Ratios
Operating Environment
Size Di3510 Di3010 Di2510
A4Y/LetterY 35 30 25
Full size x 1.000
Fixed RatioReduction x 0.866, x 0.816, x 0.707
Enlargement x 1.154, x 1.224, x 1.414
Variable 25% to 400% (0.1% increments)
LensSource of Light
::
Through lens (F = 5.0, f = 43.72 nm)Noble gas fluorescent lamp
Power/Current Consumption
Power Requirements
:
:
1340 W 10 % (120-127 V area)1365 W 10 % (220-240 V aria)110 V, 120 V, 127 V, 220 to 240 V: 50/6
Temperature 10 to 32 C (with a fluctuation of 10 C or less p
Humidity 15 to 85 % (with a fluctuation of 20 % or less)
Ambient Illumination 3000 1x or less
Levelness 1 C (1.75/100 or less)
Machine Dimensions
Machine Weight
:
:
677(W) x 718(H) x 710(D)26-3/4 x 28-1/4 x 2874 Kg (Duplex Unit, Switch Back Unit, and included)71 Kg (Di2010 Only)
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2. PRECAUTIONS FOR INSTALLATION
2-1. Installation Site
To ensure safety and utmost performance of the copier, the copier sh
place: Where it will be subjected to extremely high or low temperature or
Where it will be subjected to sudden fluctuations in either tempera
Is subject to direct sunlight.
Which is in the direct air stream of an air conditioner, heater, or ve
Which has poor ventilation or is dusty.
Which does not have a stable, level floor or where it will receive un
Which is near any kind of heating device.
Which is near volatile flammables (thinner, gasoline, etc.).
Where it may be splashed with water.
Which puts the operator in the direct stream of exhaust from the c
Where ammonia gas might be generated.
2-2. Power Source
If any other electrical equipment is sourced from the same power
the capacity of the outlet is not exceeded.
Use a power source with little voltage fluctuation.
Never connect by means of a multiple socket any other appliancesoutlet being used for the copier.
Ensure that the copier does not ride on the power cord or commu
electrical equipment, and that it does not become wedged into or u
nism.
Make the following checks at frequent intervals:
Is the power plug abnormally hot? Are there any cracks or scrapes in the cord?
Has the power plug been inserted fully into the outlet?
Does something, including the copier itself, ride on the power cord
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3. PRECAUTIONS FOR USE
3-1. To ensure that the copier is used in an optimu
Never place a heavy object on the copier or subject the copier to shoc
Insert the power plug all the way into the outlet. Do not attempt to remove any panel or cover which is secured while th
copies.
Do not turn OFF the copier while it is making copies.
Provide good ventilation when making a large number of copies contin
Never use flammable sprays near the copier.
If the copier becomes inordinately hot or produces abnormal noise, tu
unplug it.
Do not turn ON the power switch at the same time when you plug the p
outlet.
When unplugging the power cord, do not pull on the cord; hold the plu
Do not bring any magnetized object near the copier. Do not place a vase or vessel containing water on the copier.
Be sure to turn OFF the power switch at the end of the workday or upo
Use care not to drop paper clips, staples, or other small pieces of met
3-2. Operating Environment
The operating environmental requirements of the copier are as follows. Temperature: 10 to 32 C
Humidity: 15 to 85 %RH
Rate of temperature change: 10 C/h
Rate of humidity change: 20 % RH/h
3-3. Power RequirementsThe power source voltage requirements are as follows.
Voltage fluctuation AC 110, 120, 220, 240 V (copying performanc
(120V areas only: between -10 % and +6 %)
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4. Handling Consumables
Before using any consumables, always read the label on its containe
Paper can be easily damaged by dampness. To prevent absorptio
paper, which has been removed from its wrapper but not loaded insealed plastic bag in a cool, dark place.
Keep consumables out of the reach of children.
Do not touch the PC Drum with bare hands.
The same sized paper is of two kinds, short grain and long grain.
should only be fed through the copier crosswise, long grain paper
lengthwise. The packing material will be marked. If your hands become soiled with toner, wash them with soap and
Do not throw away any used consumables (PC Drum, starter, tone
collected.
Do not burn, bury in the ground, or throw into the water any consu
starter, toner, etc.).
Do not store consumables in a place which:
Is hot and humid.
Is subject to direct sunlight.
Has an open flame nearby.
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5. Other Precautions
Use the following precautions when performing service jobs for a copier
When a service job needs to be performed in the laser beam path, suc
around the printer head or PC Drum, be sure first to unplug the powerfrom the outlet.
If the job requires that the power cord be left plugged in, observe the f
tions.
1. Take off your watch, ring and any other reflective object and wear las
gles.
2. Keep users away from the job site.3. Do not bring a highly reflective tool into the laser beam path during t
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6. SYSTEM OPTIONS
1 2
1023
22
11
8
9
12
13
20
17
16
14
21
18
19
1. Mail Bin Kit (MK-1)
2. Duplexing Document Feeder (AFR-19)
3. Key Counter Kit 4
4. TX Marker STAMP UNIT 25. 32MB Memory/64MB Memory/128MB
Memory
6. Hard Disk Drive Kit (HDD-6)
7 Data Terminal (DT 105)
13. Paper Feed Cabi
14. Large Capacity C
15. Copy Desk (CD-4
16. Network Scan Ki17. Printer Controller
18. Printer Controller
19. Internet Fax & Ne
(SU 3)
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6. SYSTEM OPTIONS
1 2
1023
22
11
8
9
12
13
20
17
16
14
21
18
19
1. Mail Bin Kit (MK-1)
2. Duplexing Document Feeder (AFR-19)
3. Key Counter Kit 4
4. TX Marker STAMP UNIT 25. 32MB Memory/64MB Memory/128MB
Memory
6. Hard Disk Drive Kit (HDD-6)
7 Data Terminal (DT 105)
13. Paper Feed Cabi
14. Large Capacity C
15. Copy Desk (CD-4
16. Network Scan Ki17. Printer Controlle
18. Printer Controller
19. Internet Fax & Ne
(SU 3)
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MAINTENANC
1 M i S h d l
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1. Maintenance Schedule
To ensure that the copier produces good copies and to extend its
mended that the maintenance jobs described in this schedule be c
instructed.
PM PartsCycle (K=1,000)
Clean Rep
P
aperTake-Up/TransportSection
Manual Bypass PaperTake-Up Roller
When paper take-up failure occurs
3
Manual BypassSeparator Roll Assy
When paper take-up failure occurs 3
1st Pickup RollerWhen paper take-up failure occurs
3
1st Paper Take-Up RollerWhen paper take-up failure occurs
3
1st Separator Roll AssyWhen paper take-
up failure occurs3
2nd Pickup RollerWhen paper take-up failure occurs
3
2nd Paper Take-up RollerWhen paper take-up failure occurs
3
2nd Separator Roll AssyWhen paper take-up failure occurs
3
Synchronizing Roller Bushing 9
Synchronizing Roller Gear 9
Paper Dust Removal AssyWhen a problem
occurs1
Transport Roller Upon each call
OpticalSection Scanner rails/bushings When image failureoccurs
Mirrors and lensWhen image failure
occurs
Original GlassWhen image failure
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CAUTIONS
Replace the Pickup Roller, Paper Take-Up Roller, and Separator Roll A
time.
The numeric values in the Maintenance Cycle column represent the L
Develop
ingSection
PC Drum Unit
Di3510 100
Di3010 90
Di2510 80
Di2010 65
Developer
Di3510 100
Di3010 90
Di2510 80
Di2010 65
Developing Unit
Di3510 400
Di3010 360
Di2510 320
Di2010 260
Ds CollarWhen the Devel-
oper is replaced.
FusingSection
Fusing Unit 450
PM PartsCycle (K=1,000)
Clean Replace
1 1 Guidelines for Life time Expected Values by
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1-1. Guidelines for Life-time Expected Values by
1: On the Di3510 2: Inhibit possible on the software SW in the Service Mode
CAUTION
The life specifications values represent the number of copies mad
to it when given conditions (see the Table given below) are met. T
less depending on the copier operating conditions of each individu
DescriptionLif
Val
Drum Unit Convert the rotation speed of the PCDrum to the number of pages when A4Yis printed using 4P/J.
100
Developer 100
Developing Unit Drum Unit x 4 times 400
Fusing UnitCount the number of times paper is fedout. 450
Di3510 Di3010 Di2510
Job Type 4P/J 3P/J
Paper Size A4Y
Original Density B/W ratio: 6 %
2 Disassembly/Reassembly and Cleaning
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2. Disassembly/Reassembly and Cleaning
(1) Cleaning of the Manual Bypass Paper Take-Up Roller
1. Remove the Rear Right Cover.
2. Remove the Lower Right Rear Cover.
3. Remove the Front Manual Bypass Cover.
4. Remove the Rear Manual Bypass Cover.
5. Remove five screws and unplug
tors. Then, remove the Manual
NOTE
When the Manual Bypass Unit ha
be sure to perform the Manual B
lation Check procedures.
D-494030D032AA
6. Remove two screws and the MTransport Cover.
7. Remove two screws and the M
Separator Fixing Bracket Assy.
4030D033AA
8. Using a soft cloth dampened w
the Manual Bypass Paper Take
of dirt.
4030D034AA
(2) Replacement of the Manual Bypass Paper Take-Up Roller
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(2) Replacement of the Manual Bypass Paper Take Up Roller
1. Remove the Rear Right Cover.
2. Remove the Lower Right Rear Cover.
3. Remove the Front Manual Bypass Cover.
4. Remove the Rear Manual Bypass Cover.
5. Remove five screws and un
tors. Then, remove the Man
NOTE
When the Manual Bypass Un
be sure to perform the Manu
lation Check procedures.
D-494030D032AA
6. Remove the wiring from the
7. Remove two screws and th
4030D513AA
8. Remove five screws and th
Lower Frame.
4030D036AA
9. Remove one C clip and the
Paper Take-Up Clutch.
10. Snap off one C-clip of the P
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(3) Cleaning of the Manual Bypass Separator Roll Assy
1. Remove the Rear Right Cover.
2. Remove the Lower Right Rear Cover.
3. Remove the Front Manual Bypass Cover.
4. Remove the Rear Manual Bypass Cover.
11. Remove one C clips and the M
Paper Take-Up Roller.
12. To reinstall, reverse the order o
13. Select Tech. Rep. Mode
CouBypass and clear the counter.
4030D038AA
5. Remove five screws and unplug
tors. Then, remove the Manual
NOTE
When the Manual Bypass Unit ha
be sure to perform the Manual B
lation Check procedures.
D-494030D032AA
6. Remove two screws and the MTransport Cover.
7. Remove two screws and the M
Separator Fixing Bracket Assy.
4030D033AA
8. Using a soft cloth dampened w
the Manual Bypass Separator R
(4) Replacement of the Manual Bypass Separator Roll Assy
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( ) p yp p y
1. Remove the Rear Right Cover.
2. Remove the Lower Right Rear Cover.
3. Remove the Front Manual Bypass Cover.
4. Remove the Rear Manual Bypass Cover.
5. Remove five screws and un
tors. Then, remove the Man
NOTE
When the Manual Bypass Un
be sure to perform the Manu
lation Check procedures.
D-494030D032AA
6. Remove two screws and th
Transport Cover.
7. Remove two screws and thSeparator Fixing Bracket As
CAUTION
Install the Manual Bypass Se
Bracket while pressing down
the metal bracket of the copi
4030D033AA
8. Remove the C clip, spring, a
remove the Separator Roll A
9. To reinstall, reverse the ord
10. Select Tech. Rep. Mode
Bypass and clear the count
4030D039AA
(5) Cleaning of the 1st Pickup Roller
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g
1. Remove the 1st Drawer.
4030D040AA
2. Remove two screws and the co
4030D041AA
3. Remove the connector.
4. Remove two screws and the 1s
Roller.
4030D042AA
5. Using a soft cloth dampened w
the 1st Pickup Roller clean of d
4030D043AB
(6) Replacement of the 1st Pickup Roller
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1. Remove the 1st Drawer.
4030D040AA
2. Remove two screws and th
4030D041AA
3. Remove the connector.
4. Remove two screws and th
Roller.
4030D042AA
5. Remove four screws and th
Roller Assy Cover and the
Assy.
4030D044AA
7 Remove one C clip and the 1st
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(7) Cleaning of the 1st Paper Take-Up Roller
7. Remove one C clip and the 1st
8. To reinstall, reverse the order o
9. Select Tech. Rep. ModeCou
Drawer and clear the counter.
4030D049AA
1. Remove the 1st Drawer.
4030D040AA
2. Remove two screws and the co
4030D041AA
3. Remove the connector.
4. Remove two screws and the 1s
Roller.
(8) Replacement of the 1st Paper Take-Up Roller
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1. Remove the 1st Drawer.
4030D040AA
2. Remove two screws and th
4030D041AA
3. Remove the connector.
4. Remove two screws and th
Roller.
4030D042AA
5. Remove four screws and th
Roller Assy Cover and the
Assy.
4030D044AA
7. Remove two C rings, one bush
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(9) Cleaning of the 1st Separator Roll
7. Remove two C rings, one bush
spring. Then, remove the 1st Pa
Roller Assy.
4030D046AA
8. Remove one C clip and the 1st
Roller.
9. To reinstall, reverse the order o
10. Select Tech. Rep. Mode Cou
Drawer and clear the counter.
4030D047AA
1. Remove the 1st Drawer.
4030D040AA
2. Remove two screws and the co
5. Using a soft cloth dampene
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(10) Replacement of the 1st Separator Roll Assy
g p
the 1st Separator Roll clean
4030D051AB
1. Remove the 1st Drawer.
4030D040AA
2. Remove two screws and th
4030D041AA
3. Remove the connector.
4. Remove two screws and th
Roller Assy.
6. Remove two screws and the 1s
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Precaution for Reinstallation of the Separator Roll Assy
Install the 1st Separator Roll Mounting Bracket Assy while pressing the
it coheres to the metal bracket of the copier.
Mounting Bracket Assy.
4030D052AA
7. Remove two E rings and the 1s
Mounting Bracket.
4030D053AA
8. Remove one C clip and the 1stAssy.
9. To reinstall, reverse the order o
10. Select Tech. Rep. Mode Cou
Drawer and clear the counter.
4030D054AA
(11) Cleaning of the 2nd Pickup Roller
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1. Slide out the 2nd Drawer.
2. Remove the Manual Bypas
E-4
3. Remove the Lower Right C
4030D055AA
4. Unplug three connectors.
5. Remove three screws and t
Roller Assy.
4131D058AC
6. Using a soft cloth dampene
the 2nd Pickup Roller clean
4030D043AC
(12) Replacing of the 2nd Pickup Roller
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1. Remove the Manual Bypass Unit.
E-4
2. Slide out the 2nd Drawer.3. Unhook two tabs and remove th
Door.
4030D055AA
4. Remove two screws and the Tr
Cover.
4030D056AA
5. Remove two screws and the M
Cover.
4131D058AC
6. Unplug three connectors.7. Remove three screws and the 2
Roller Assy.
8. Remove four screws and on
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remove the 2nd Paper Take
2nd Separator Roll Assy, an
Take-Up Roller Clutch.
4030D058AA
9. Remove two C clips and tw
remove the 2nd Pickup Rol
4030D048AA
10. Remove one C clip and the11. To reinstall, reverse the ord
12. Select Tech. Rep. Mode
Drawer and clear the count
4030D049AA
(13) Cleaning of the 2nd Paper Take-Up Roller
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1. Slide out the 2nd Drawer.
2. Remove the Manual Bypass Un
E-4
3. Remove the Lower Right Cover
4030D055AA
4. Unplug three connectors.
5. Remove three screws and the 2
Roller Assy.
4131D058AC
6. Using a soft cloth dampened w
the 2nd Paper Take-Up Roller c
40030D050AC
(14) Replacement of the 2nd Paper Take-Up Roller
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1. Remove the Manual Bypass Unit.
E-4
2. Slide out the 2nd Drawer.3. Unhook two tabs and remo
Door.
4030D055AA
4. Remove two screws and th
Cover.
4030D056AA
5. Remove two screws and th
Cover.
4131D058AC
6. Unplug three connectors.7. Remove three screws and t
Roller Assy.
8. Remove four screws and one C
th 2 d P T k U
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remove the 2nd Paper Take-Up
2nd Separator Roll Assy, and th
Take-Up Roller Clutch.
4030D058AA
9. Remove two C-clips and one b
4030D059AA
10. Remove two C clips and one buremove the 2nd Paper Take-Up
4030D046AA
11. Remove one C clip and the 2nd
Roller Assy.
12. To reinstall, reverse the order o
13. Select Tech. Rep. Mode Cou
Drawer and clear the counter.
4030D047AA
(15) Cleaning of the 2nd Separator Roll
1. Remove the Manual Bypass Unit.
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E-4
2. Slide out the 2nd Drawer.
3. Unhook two tabs and remo
Door.
4030D055AA
4. Unplug three connectors.
5. Remove three screws and t
Roller Assy.
4131D058AC
6. Using a soft cloth dampene
the 2nd Separator Roll clea
4030D051AC
(16) Replacement of the 2nd Separator Roll Assy
1. Remove the Manual Bypass Unit.
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E-4
2. Slide out the 2nd Drawer.
3. Unhook two tabs and remove th
Door.
4030D055AA
4. Remove two screws and the Tr
Cover.
4030D056AA
5. Remove two screws and the M
Cover.
4131D058AC
6. Unplug three connectors.
7. Remove three screws and the 2Roller Assy.
9. Remove two screws and th
Mounting Bracket Assy
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Precaution for Reinstallation of the Separator Roll Assy
Install the 2nd Separator Roll Mounting Bracket Assy while pressin
that it coheres to the metal bracket of the copier.
Mounting Bracket Assy.
4030D061AA
10. Remove two E rings and th
Mounting Bracket.
4030D053AA
11. Remove one C clip and theAssy.
12. To reinstall, reverse the ord
13. Select Tech. Rep. Mode
Drawer and clear the count
4030D054AA
4030D561AA
(17) Cleaning of the Synchronizing Rollers
1. Open the Right Door.
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(18) Replacement of the Synchronizing Roller Bushings and Sync
Gears
1. Open the Right Door.
4346U016AA
2. Open the Right Door.
3. Remove the Paper Dust Remov
4030D063AA
4. Using a soft cloth dampened w
the Synchronizing Rollers clean
4030D064AA
1. Open the Right Door.
2. Remove two E rings and tw
Roller Gears.
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4011D012AA
3. Remove one screw and the
4011D013AA
CAUTION
When reinstalling the ground
the ground plate is in contac
the bushings.
4011D014AB
4. Remove one spring and two
Bushings.
CAUTION
When reinstalling the bushing
flanges of the bushings are o
4011D015AA
7. Remove one spring, two E ring
chronizing Roller Gears.
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(19) Cleaning of the Paper Dust Remover Assy
g
CAUTION
When reinstalling the bushings, mflanges of the bushings are on th
4011D017AA
1. Open the Right Door.
4346U016AA
2. Remove the Paper Dust Remov
4030D063AA
3. Using a brush, whisk dust and
Dust Remover Assy.
(21) Cleaning of the Scanner Rails
1. Remove the Original Scann
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(22) Cleaning the Bushings
1. Remove the Original Scanning Glass.
2. Remove the Front Holding Bracket.
3. Remove two reinforcement plates.
4. Remove the Original Glass.
2. Remove the Front Holding
3. Remove two reinforcement
4. Remove the Original Glass
5. Using a soft cloth dampene
the Scanner Rails clean of
4030D147AA
5. Move the Scanner Assy to
4030D123AA
6. Remove the wire from the S
7. Unplug one connector and
and the Scanner Assy.
4030D125AA
(23) Cleaning of the Mirrors
1. Remove the Original Scanning
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(24) Cleaning of the Lens
(25) Cleaning of the Original Scanning Glass
2. Remove the Front Holding Brac
3. Remove two reinforcement plat
4. Remove the Original Glass.
5. Using a soft cloth dampened w
mirrors clean of dirt.
1167D017AC
1. Remove the Original Scanning
2. Remove the Front Holding Brac
3. Remove two reinforcement plat
4. Remove the Original Glass.
5. Remove six screws and the CC
4030D149AA
6. Using a soft cloth dampened w
the Lens clean of dirt.
4030D018AB
1. Using a soft cloth dampened wthe Original Scanning Glass cle
(26) Cleaning of the Original Glass
1. Using a soft cloth dampene
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(27) Replacement of the Ozone Filter
(28) Cleaning of the Charge Neutralizing Plate
the Original Glass clean of
4030D151AA
1. Remove the IR Rear Cover
2. Remove the Rear Cover.
3. Remove the Ozone Filter.
4030D066AA
1. Open the Right Door.
2. Using a soft cloth dampene
the Charge Neutralizing Pla
4030D568AA
3. Replacement of the Units
(1) Replacement of the Image Transfer Roller Unit
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(2) Replacement of the PC Drum Unit
1. Select Tech. Rep. Mode Counter PM PC Life.
2. Press the Clear key to clear the counter value.
3. Turn OFF the power.
CAUTIONS
Clear the PC counter before removing the IU.
After clearing the PC counter, be sure to turn OFF the power.
1. Open the Right Door.
2. Pull down the knobs forward anTransfer Roller.
4030D067AA
4. Open the Right Door.
5. Remove the IU.
4030U006AB
6. Remove the IU.
7. Remove four screws (silver) andPC Drum Unit and the Develop
8. Replace the PC Drum Unit.
9 To reinstall reverse the order o
(3) Replacement of the Developer
1. Select Tech. Rep. Mode Counter PM PC Life.
2. Press the Clear key to clear the counter value.
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ess e C ea ey o c ea e cou e a ue
3. Turn OFF the power.
CAUTIONS
Clear the PC counter before removing the IU.
After clearing the PC counter, be sure to turn OFF the power.
4. Remove the IU.
5. Remove four screws (silver
PC Drum Unit and the Deve
4030U007AB
6. Remove three screws and ting Prevention Plate.
4030U010AA
7. Remove the Toner Supply
4030U011AA
Dump the developer on the Slee
i th i th di ti f th
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ing the gear in the direction of th
If you rotate the gear in reverse,
the ATDC Sensor.
Dump developer until almost no d
the Sleeve Roller.4030D175AA
9. Set the developer while rotating
direction of the arrow.
4030U013AB
10. Reinstall the Toner Supply Port
4030U014AB
11. Using three screws, secure the
tering Prevention Plate.
4030U015AC
12. Install the PC Drum Unit an
13. Install the IU in the copier.
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14. Turn ON the power.
15. Select Tech. Rep. Mode Function F8 and press the Start ke
CAUTIONS
After replacing the developer, be sure to execute F8 under Functio
When the power is turned ON, execute F8 quickly.
4030U016AC
(4) Replacement of the Developing Unit
1. Select Tech. Rep. Mode Counter PM Developer.
2 Press the Clear key to clear the counter value
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2. Press the Clear key to clear the counter value.
3. Turn OFF the power.
CAUTIONS
Clear the developer counter before removing the IU.
After clearing the developer counter, be sure to turn OFF the power.
4. Remove the IU.
5. Remove four screws (silver) andPC Drum Unit and the Develop
6. Replace the Developing Unit.
7. Replace the PC Drum Unit.
4030U007AB
8. Supply new developer to the ne
Unit.
E-31
4030U013AB
9. Install the new PC Drum Unit an
Unit.
10. Install the IU in the copier.
4030U016AC
(5) Cleaning of the Ds Collar
1. Select Tech. Rep. Mode Counter PM PC Life.
2. Press the Clear key to clear the counter value.
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3. Turn OFF the power.
CAUTIONS
Clear the PC counter before removing the IU.
After clearing the PC counter, be sure to turn OFF the power.
4. Remove the IU.
5. Remove four screws (silver
PC Drum Unit and the Deve
4030U007AB
6. Remove three screws and ting Prevention Plate.
4030U010AA
7. Remove the Toner Supply
4030U011AA
Dump the developer on the Slee
ing the gear in the direction of th
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ing the gear in the direction of th
If you rotate the gear in reverse,
the ATDC Sensor.
Dump developer until almost no d
the Sleeve Roller.4030D175AA
9. Using a soft cloth dampened w
the Ds Collar.
CAUTION
Make sure the alcohol does not t
oper Roller.
4030D176AA
10. Set the developer while rotating
direction of the arrow.
4030U013AB
11. Reinstall the Toner Supply Port
4030U014AB
13. Install the PC Drum Unit an
14. Install the IU in the copier.
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15. Turn ON the power.
16. Select Tech. Rep. Mode Function F8 and press the Start ke
CAUTIONS
After replacing the developer, be sure to execute F8 under Functio
When the power is turned ON, execute F8 quickly.
4030U016AC
(6) Replacement of the Fusing Unit (When the Switch Back Unit i
1. Open the Right Door.
2. Remove the Rear Right Cover.
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g
3. Remove one screw and the Fro
4625U007AA
4. Unplug three connectors.
5. Remove the harness from the c
4030U0008AA
6. Remove two screws and unplug
Then, remove the Fusing Unit.
4030D514AA
7. Remove one screw and the Fu
8. Remove two screws, and th
9. Remove the Fusing Cover.
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(7) Replacement of the Fusing Unit (When the Switch Back U
1. Open the Right Door.
2. Remove the Rear Right Cover.
4625D015AA
3. Remove one screw and the
4625U007AA
4. Unplug two connectors of t
4347U005AA
5. Remove two screws in fron6. Loosen the two screws in th
7. Remove the Switch Back Unit.
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4347U007AA
8. Remove two screws and unplug
tors. Then, remove the Fusing U
4030D515AA
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DIS/REASSEMB
ADJUSTMEN
1. SAFETY INFORMATION
1-1. LASER SAFETY
This is a digital machine certified as a class 1 laser product. There
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danger from a laser, provided the machine is serviced according to
manual.
1-2. INTERNAL LASER RADIATION
*:Laser Aperture of the Print Head Unit
This product employs a Class 3b laser diode that emits an invisiblediode and the scanning polygon mirror are incorporated in the prin
The print head unit is NOT A FIELD SERVICE ITEM. Therefore, thshould not be opened under any circumstances.
Semiconductor laser
Maximum average radiation power(*) 28.9 W
Wavelength 770-795 nm
Laser Aperture ofthe Print Head Unit
4021O096AA
the U.S.A., Canada (CDRH Regulation)
This machine is certified as a Class I Laser product under Radiation Pdard according to the Food, Drug and Cosmetic Act of 1990. Compliafor Laser products marketed in the United States and is reported to thDevices and Radiological Health (CDRH) of the U S Food and Drug A
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Devices and Radiological Health (CDRH) of the U.S. Food and Drug Athe U.S. Department of Health and Human Services (DHHS). This meadoes not produce hazardous laser radiation.
The label shown to page D-4 indicates compliance with the CDRH regbe attached to laser products marketed in the United States.
All Areas
Denmark
CAUTION
Use of controls, adjustments or performance of procedures other than th
this manual may result in hazardous radiation exposure.
Semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm
CAUTION
Use of controls, adjustments or performance of procedures other than ththis manual may result in hazardous radiation exposure.
Semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm
ADVARSEL
Usynlig Laserstrling ved bning, nr sikkerhedsafbrydere er ude af funudsttelse for strling. Klasse 1 laser produkt der opfylder IEC60825 sik
Halvlederlaser
Laserdiodens hjeste styrke 5 mW
Blgelngden 770-795 nm
Finland, Sweden
VARO!
Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttmlle katso steeseen.
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Norway
LOUKAN 1 LASERLAITEKLASS 1 LASER APPARAT
VAROITUS!
Laitteen Kyttminen muulla kuin tss kyttohjeessa mainitulla takyttjn turvallisuusluokan 1 ylittvlle nkymttmlle lasersteily
Puolijohdelaser
Laserdiodin suurin teho 5 mW
Aallonpituus 770-795 n
VARNING!
Om apparaten anvnds p annat stt n i denna bruksanvisning spe
daren utsttas fr osynlig laserstrlning, som verskrider grnsen f
Halvledarlaser
Den maximala effekten fr laserdioden 5 mW
Vglngden 770-795
VARNING!Osynlig laserstrlning nr denna del r ppnad och sprren r urkostrlen.
ADVERSEL
Dersom apparatet brukes p annen mte enn spesifisert i denne br
brukeren utsettes for unsynlig laserstrling som overskrider grensen
Halvleder laser
Maksimal effekt till laserdiode 5 mW
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2. Disassembly/Reassembly Instructions
2-1. Identification of Fuses
DC Power Supply (PU1)
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40
pp y ( )
100 V AreaF103: 125 V 12 AF104: 125 V 12 AF103: 125 V 3.15 A
200 V AreaF101: 250 V 1.6 AF103: 250 V 6.3 AF104: 250 V 6.3 A
2-2. Parts Which Must Not Be Touched
(1) Red Painted Screws
Purpose of Application of Red Paint
R d i t d h th t th bl it d l b
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Red painted screws show that the assembly or unit secured can only be
the factory and shall not be readjusted, set, or removed in the field.Red-painted screws must not be removed or loosened.
Note that when two or more screws are used on the part in questions, on
tive screw may be marked with red paint.
(2) Variable Resistors on Board
Do not turn the variable resistors on boards for which no adjusting instru
ADJUSTMENT.
3. Disassembly/Reassembly
3-1. Doors, Covers, and Exterior Parts Identifica
Removal Procedures
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1 2 4
5
6
7
9
10
11
13
1
125
8
14
12
3
4030D
No. Name Removal Procedure
1 Original Cover
2Original ScanningGlass
Remote 14. Remove the Original Scan
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Glass
3 Original Glass Remove the Original Scanning Glass.
Remove two screws and the Original Glas
4 Front Holding Bracket Remove two screws and the Front Holdin
5 Control Panel D-11
6 Front CoverRemove 7. Open the Right Door. Reand the Toner Hopper.Remove 8.R
and the Front Cover.7 Front Door Remove one screw, C clip, and the Front
8 Lower Front CoverRemove 7. Remove 10. Remove twConnector Cover. Remove six screws Front Cover.
9 Left CoverRemove 15. Remove 16. Remove sthe Left Cover.
10 Paper Output CoverRemove 5. Remove three screws and Cover.
11 Rear Left Cover Remove two points and the Rear Left Cov
12 Front Right Cover Remove one screw and the Front Right C
13 Left IR Cover Remove 15. Remove the Left IR Cover
14 Upper Left IR Cover Remove two screws and the Upper Left I
15 Upper Rear Cover Remove three screws and the Upper Rea
16 Rear Cover Remove 15. Remove 12 screws and th
17 Lower Rear CoverRemove 18. Remove 6 screws and theCover.
18 Drawer Rear Cover Remove four screws and the Drawer Rea
19 Rear Right CoverOpen the Right Door. Remove two screRight Cover.
20 Lower Right Rear CoverOpen the Right Door. Remove 18. Rscrews and the Lower Right Rear Cover.
3-2. Removal of Circuit Boards and Other Electr
NOTES
When removing a circuit board or other electrical component, refe
PWBs and follow the corresponding removal procedures.
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The removal procedures given in the following omit the removal ofscrews securing the circuit board support or circuit board.
Where it is absolutely necessary to touch the ICs and other electri
board, be sure to ground your body.
Symbol Name Removal Procedur
IRBCR CCD
MFB3
ROM
403
Printer Section
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Symbol Name Removal Proce
PWB-A Master Board Removal of the Master B
PWB-I1 Paper Size Detecting Board 1 Removal of Paper Size Don page 13
PWB-I2 Paper Size Detecting Board 2 Removal of Paper Size D
on page 14
PWB-R2Pre-Transfer Guide Plate Reg-ister Board
Open the Right Door. RemRemove one screw and the PRegister Board Assy.
4030D12
PWB-A
PWB-I1
PWB-I2
PU1
(1) Removal of the Control Panel
1. Remove six screw covers.
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4030D178AA
2. Remove the six screws on trol Panel.
4030D179AA
3. Unplug two connectors and
4030D180AA
(2) Removal of the Master Board
1. Remove the Upper Rear Cover.2. Remove the Rear Cover.
3. Remove five screws and the HD
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NOTE When the printer is mounted with
unplug the HDD connector and t
HDD cover.
4030D155AA
4. Unplug the all connectors.5. Remove five screws and the m
NOTE
When replacing the master boar
replace the EEPROM.
D-81
4030D105AA
(3) Removal of Paper Size Detecting Board 1
1. Remove one screw.
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4030D558AA
2. Release the stopper and sl
4030D160AA
3. Unplug two connectors from4. Remove two screws and th
4030D161AA
5. Remove four screws and thing Board Assy.
4030D162AA
(4) Removal of Paper Size Detecting Board 2
1. Remove one screw.
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4030D558AA
2. Release the stopper and slide odrawer.
4030D160AA
3. Unplug two connectors from the4. Remove two screws and the Lif
4030D163AA
5. Remove four screws and the Pa
ing Board Assy.
4030D162AA
(5) Removal of the DC Power Supply
1. Remove the Front Right Door.2. Open the Right Door.3. Remove the Exit Cover.
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6. Remove the Lower Front Cover.7. Remove the Left Cover.
9. Remove the Rear Left Cover.
4. Slide out the Toner Hopper
4030D527AA
5. Remove five screws and th
4030D072AA
8. Remove four screws and thCover.
4030D075AA
10 Remove four screws and th
11. Remove two screws and the PoMotor.
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4030D074AA
12. Unplug eight connectors and reand the DC Power Supply Assy
4030D076AA
(6) Removal of the High Voltage Unit
1. Remove the Imaging Unit.2. Remove the Front Right Door.3. Remove the Exit Cover.4. Open the Right Door.
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5. Remove the Front Cover.6. Remove the Lower Front Cover.
7. Remove five screws and thtive metal bracket.
4030D077AA
8. Remove one screw and the
4030D109AA
9. Close the right door and respring.
4030D078AA
10. Remove four screws and thtive metal bracket.
11. Unplug four connectors and remand the Toner Hopper Assy.
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4030D080AB
12. Unplug one connector and remand the High Voltage Unit Cove
4131D058AC
13. Remove two screws and the IUMotor.
4030D082AA
14. Unplug four connectors and remand the High Voltage Unit.
4030D083A
3-3. Removal of Units
(1) Removal of the Manual Bypass Unit
1. Remove the Lower Right Rear Cover.2. Remove the Front Manual Bypass Cover.
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3. Remove the Rear Manual Bypass Cover.
(2) Removal of the PH Unit
1. Remove the Upper Rear Cover.2. Remove the Rear Cover.3. Open the Front Door.4. Remove the Exit Cover.
4. Remove five screws and untors. Then, remove the Man
NOTE
When the Manual Bypass Un
be sure to perform the Manu
lation Check procedures. D-49
4030D032AA
5. Remove nine screws and thbracket.
4030D084AA
6. Remove nine screws and thmetal bracket.
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Precaution for PH Reinstallation
When replacing the PH, install spacers according to the color of th
PH.
Screw Hold Position
PH l b l l A B
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Spacers Used
Screw Hold Position and Installation Position
PH label color A BGreen label No spacer No spacer
Blue label No spacer 0.1 mm spacer
Yellow label 0.2 mm spacer 0.1 mm spacer
Part No.0.1 mm spacer 4030-2053-01
0.2 mm spacer 4030-2054-01
A
C
B
4030D50
(3) Removal of the Toner Hopper Unit
1. Open the Front Door.
2. Remove one screw and the Ton
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(4) Disassembly of the Fusing Unit
NOTE
When removing and reinstalling each of the different covers and elect
make sure that the correct type of screw is used.
4030D109AA
1. Remove one C clip and the Fus
Guide Plate.
4030D086AA
2. Remove the wiring from the co3. Remove one screw and the har
metal bracket.
4030D164AA
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12. Remove two screws and the Fumostat Assy.
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4030D092AB
13. Remove two screws and the Fu
4030D093AB
14. Remove three screws, one E-ri
gear.
4030D094AA
15. Remove the pressure spring.
4030D095AA
17. Remove one screw and theRoller Assy.
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4030D097AA
18. Remove two bearings, two the Fusing Pressure Roller
4030D098AA
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3-4. Disassembly of the IR Unit
(1) Removal of the Scanner Motor
1. Remove the Upper Rear Cover.2. Remove the Right IR Cover.
3 Remove one spring two screws
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(2) Removal of the Exposure Lamp
1. Remove the Original Scanning Glass.2. Remove the Front Holding Bracket.
3. Remove two reinforcement plates.4. Remove the Original Glass.
3. Remove one spring, two screwsmotor.
4030D120AA
5. Move the Scanner Assy to the
4030D123AA
6. Unplug one connector and remand the Scanner Assy.
NOTE
When installing the Scanner Ass
form scanner position adjustmen
D-50
7. Remove one screw, and the
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(3) Removal of the Scanner Assy
1. Remove the Original Scanning Glass.
2. Remove the Front Holding Bracket.3. Remove two reinforcement plates.4. Remove the Original Glass.
4030D124AA
5. Move the Scanner Assy to
4030D123AA
6. Remove the wire from the S
7. Unplug one connector and and the Scanner Assy.8. To reinstall, reverse the ord
NOTE
When installing the Scanner
form scanner position adjust
D-504030D125AA
(4) Removal of the Scanner Drive Cables
1. Remove the Original Scanning Glass.2. Remove the Front Holding Bracket.3. Remove two reinforcement plates.4. Remove the Original Glass.
5. Remove six screws and the MF
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Cover.
4030D114AA
6. Remove six screws and the MFCover.
4030D115AA
7. Unplug two connectors and remand the connector cover.
4030D116AA
8. Remove seven screws and the Cover.
9. Remove one screw and thefrom the shaft.
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4030D128AA
10. Remove two screws and thleys.
4030D129AA
11. Remove the bearing and sh
12. Remove the Scanner Drivehook.
4030D130AA
(5) Winding of the Scanner Drive Cables
Pulley E
Pulley G
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Pulley A Pulley B
Pulley C
y
Pulley F
Pulley H
Scanner Drive Cable 4
Scanne
Scanner Drive Cable 1
Scanner Drive Cable 3
Front1. Position the round bead of the
Cable in the pulley as shown.
NOTE
Make sure that the bead snugly
the pulley.
4030D131AA
Scanner DriveCable 1
ScannerDriveCable 2
2. Wind the Scanner Drive Cable pulley four turns clockwise, fromthe front side.
NOTE Make sure that no part of the cab
other.
Rear4. Position the round bead of
Cable in the pulley as show
NOTE
Make sure that the bead snu
the pulley.
Scanner DriveCable 3
ScannerDriveCable 4
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4030D134AA
5. Wind the Scanner Drive Capulley four turns clockwise,
the front side.
NOTE
Make sure that no part of the
other.
4030D135AA
6. Wind the Scanner Drive Caclockwise from the rear to ththe cable with tape.
NOTE
Make sure that no part of the
other.
4030D136AA
7. Install two pulleys (front anAttach two bushings to the
4030D137AA
9. Attach the Drive Gear using on
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10. Mount the Scanner Motor Assy.
4030D139AA
Front11. Wind the Scanner Drive Cable
around pulley D and pulley B, hthe fixed spring, and then hookcatch in the frame.
4030D140AA
12. Wind the Scanner Drive Cable around pulley A and pulley C anto the side of the Scanner Fram
4030D141AA
Rear13. Wind the Scanner Drive Cable
around pulley E and pulley G ato the side of the Scanner Fram
16. Mount the cable to the Sca
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(6) Removal of the CCD Unit
1. Remove the Original Scanning Glass.2. Remove the Front Holding Bracket.3. Remove two reinforcement plates.4. Remove the Original Glass.
4030D144AA
17. Readjust the position of the D-5018. Attach two guide plates usi
secure the Scanner.19. Attach all the parts that hav20. Perform a test copy and ch
image.
4030D152AA
5. Remove six screws and the
4030D149AA
6. Move the Scanner Assy antors of the CCD Unit.
7. Remove two screws and th
(7) Installation Adjustment to be Made when CCD Unit is Replace
NOTES
Make this adjustment only when the CCD Unit has been replaced with
Before attempting to make this adjustment, make sure that registration
ments for the printer have been completed.
Do not loosen or remove the screws shown below.
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4030D601AA
1. Screw the three adjusting screwUnit only to half the thread leng
4030D591AA
2. From the bottom side of the CCdimension of the screw thread pmm (at three places).
3. sing two screws and a flat spring, install the CCD Unit in position4. Fit two cables to the CCD Unit.5. Using six screws, install the CCD Unit cover.6. Install the Document Scanning Glass and Original Glass.
NOTE
There is no need of tightening the screws of the Document ScannGlass, since the CCD Unit is to be adjusted in later steps.
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Tilt and FD Deviation Adjustment Procedure Using Scr
If tilt or deviation in the FD direction is as sA: Using an Allen wrench (3 mm), turn screwB: Using an Allen wrench (3 mm) turn screw
7. Turn ON the printer.8. If the setting in IR Registrat
available from the Adjust mchanged, set the function to
(zoom ratio).9. Prepare a test chart as shomake a copy of it.
4030D587AA
10. Measure tilt and deviation ithe produced copy as comp
the reference line in the FDchart.
11. If there is any tilt or deviatiofollow the steps given belowment using screws A and B
4030D589AA
A
B
4030D594AA
If tilt d i ti i th FD di ti i h
Tilt and FD Deviation Adjustment Procedure Using Screws
A
B
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If tilt or deviation in the FD direction is as shownA: Using an Allen wrench (3 mm), turn screw A coB: Using an Allen wrench (3 mm), turn screw B cl
A 1/4 turn of the screw results in deviation of 1
CD Deviation Adjustment Procedure Using Adjustmen
If deviation in the CD direction is as shown on t
1. Using a flat-blade screwdriver, turn adjuscounterclockwise.
A
4030D593AA
A
B
4030D596AA
12. Measure deviation in the CD di
duced copy as compared with rreference line in the CD directio
13. If there is any deviation in the Cloosen screws C and D and follmake an adjustment using adju
4030D590AA
E
Adjustmentplate
If deviation in the CD direction is as shown
1. Using a flat-blade screwdriver, turn aclockwise.
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14. Remove the CCD Unit cover.15. Apply lock paint to adjusting screws A, B, C, and D.16. Reinstall the CCD Unit cover.17. Reinstall the Document Scanning Glass and Original Glass.
18. Reinstall all covers that have been removed.
2. Tighten screws C and D.
4030D598AA
(8) Removal of the MFB3 Board
1. Remove the Upper Rear Cover.2. Remove the Rear Cover.3. Remove the Right IR Cover.
4. Remove one screw and the OriDetecting Sensor.
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4030D114AA
5. Remove six screws and the MFCover.
4030D115AA
6. Unplug two connectors and remand the connector cover.
4030D116AA
7. Remove four screws and the M
Cover.8. Remove two screws and the gr
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3-5. Cleaning and Disassembly of Engine Parts
(1) Removal of the Transport Motor
1. Remove the Upper Rear Cover.2. Remove the Rear Cover.3. Remove the Rear Right Cover.
4. Remove the Rear Lower Right Cover.
5 Remove two screws and the Oz
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(2) Removing the IU Motor
1. Remove the Upper Rear Cover.2. Remove the Rear Cover.
5. Remove two screws and the Oz
4030D101AA
6. Remove four screws and the Tr
4030D102AA
3. Remove four screws and the IU
(3) Removal of the AIDC Sensor
1. Select Tech. Rep. Mode Counter PM Developer and cle2. Turn OFF the power.3. Remove the IU.
NOTES
Clear the counter before removing the IU.
After clearing the counter, be sure to turn OFF the power.
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4. Remove four screws (silverPC Drum Unit and the Deve
4030U007AB
5. Remove three screws and t
ing Prevention Plate.
4030U010AA
6. Remove the Toner Supply
4030U011AA
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12. Install the PC Drum Unit an13. Install the IU in the copier.
4030U016AC
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14. Turn ON the power.15. Select Tech. Rep. Mode Function F8 and press the Start ke
NOTES After replacing the developer, be sure to execute F8 under Functio
When the power is turned ON, execute F8 quickly.
4. Adjustment
4-1. Adjustment Jigs and Tools
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4030D576AA
4030D578AA
Converter Interface C
Connection Cable
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8. Install the Manual Bypass Unit Cover so that part A (edge) of the RaManual Paper Size Detection Unit and part B of the Manual Bypass aligned in a straight line.
Rack Gear for the Manual
Paper Size Detection Unit
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9. Install the Manual Bypass Unit in the copier.10. Select the Tech. Rep. Mode Function FD.11. Set paper with a width of 301 mm in the tray of the Manual Bypass U12. Select the maximum size key on the Control Panel and press the Sta
automatic adjustment.13. Place the paper of the minimum size 89 mm in the drawer.14. Select the minimum size key on the Control Panel and press the Sta
automatic adjustment.
Manual Paper Size
4030D
(2) Manual Bypass Unit Installation Check
1. Remove the Rear Right Cover.2. Remove the Rear Lower Right Cover.3. Remove the Manual Bypass Front Cover.4. Remove the Manual Bypass Rear Cover.5. Check the 2nd Drawer Paper Take-up Guide and Manual Bypass
operation.
NOTES
Pull open the 2nd Drawer Paper Take up Door in the direction of th
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Pull open the 2nd Drawer Paper Take-up Door in the direction of th
it opens smoothly without binding.
If the door binds, perform the installation procedures again for the
Take-up Roll Assy and Manual Bypass Unit.
4030D586
2nd Drawer Paper Take-up Guide
M
(3) Scanner Position Adjustment
NOTE
Make this adjustment after any of the following procedures has been per
After the Scanner Drive Cables have been replaced.
When the Scanner has been removed.
When the Scanner Drive Cables has become loose.
Requirement
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q
At a given distance from the side of the scanner with the Scanner Assy
ner Drive Cables.
Adjustment Procedure 1. Remove the Original Scanning 2. Remove the Front Holding Brac3. Remove the Original Glass.4. Remove two screws and the Sc
4030D125AA
5. Slide the 2nd/3rd Mirrors Carriashown on the left.
6. Left side of the IR to part A: 70
A
4030D584AA
7. Hook the Scanner Assy to the c8. Install the Scanner Assy at the the left.
9. Left side of the IR to the right si
4-3. Electrical/Image Adjustment
(1) Accessing the Tech. Rep. Mode
1. Press the Utility key.2. Press the Meter Count key.3. Press the following keys in this order.Stop 0 0 Stop 0 1
NOTE
Ensure appropriate security for Tech. Rep. mode function setting p
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should never be known to any unauthorized person not involved w
Printer(2) Registration CD
Requirement Width A on the test pattern produ
within the following range.
Width A
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This adjustment must be made in any of the following cases:
When the PH Unit has been replaced.
When the paper type has been changed.
When the image on the copy is offset in the CD direction. When a faint image occurs on the leading edge of the image.
Adjustment Procedure1. Load the 1st Drawer with A3L or A4C paper.2. Enter the Adjust Mode.3. Touch Printer Registration (CD).4. Touch Test Print.
5. Select the 1st Drawer and press the Start key.6. Check the dimension of width A on the test pattern.7. If width A falls outside the specified range, change the setting using
Adjustment Procedure
If width A on the test pattern is wider than specifications.
Longer than the actual scale: crease the setting value.
Shorter than the actual scale: decrease the setting value.
8. Touch Test Print and select the 1st Drawer.9. Press the Start key.
Specification Adjust Mode Settin10.3 mm 2.0 mm Registration (CD) -4.0
4348U054AA
(3) Registration FD
Requirement Width B on the test pattern p
within the following range.
Width B
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