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FS-1118MFP KM-1820

SERVICE MANUAL
Published in February 2005 842GM110

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.

CAUTION
Double-pole/neutral fusing.

Revision history
Revision Date Replaced pages Remarks

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 accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical attention. .............................................................................................................................. Advice customers that they must always follow the safety warnings and precautions in the copier's 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 brochure 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 main 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 immediately. ......................................................................................................................................

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. ................................................................................

2GM

CONTENTS
1-1 Specifications
1-1-1 Specifications ....................................................................................................................................... 1-1-2 Names of parts ..................................................................................................................................... (1) Main body ....................................................................................................................................... (2) Operation panel .............................................................................................................................. 1-1-1 1-1-3 1-1-3 1-1-4

1-2 Handling Precautions
1-2-1 Drum .................................................................................................................................................... 1-2-1 1-2-2 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 Connecting the cable ......................................................................................................................... 1-3-16 (1) Connecting the network cable ...................................................................................................... 1-3-16 (2) Connecting the printer cable ......................................................................................................... 1-3-17 1-3-3 Installing the document processor (option) ........................................................................................ 1-3-18 1-3-4 Installing the expanding memory (option) .......................................................................................... 1-3-21 1-3-5 Installing the fax system (option) ........................................................................................................ 1-3-22

1-4 Maintenance Mode
1-4-1 Maintenance mode ............................................................................................................................... 1-4-1 (1) Executing a maintenance item ....................................................................................................... 1-4-1 (2) Maintenance modes ....................................................................................................................... 1-4-2 (3) Contents of maintenance mode items ............................................................................................ 1-4-3 1-4-2 System settings .................................................................................................................................. 1-4-18 (1) Executing a system setting item ................................................................................................... 1-4-18 (2) System settings ............................................................................................................................ 1-4-19 1-4-3 Service settings .................................................................................................................................. 1-4-21 (1) Executing a service setting item ................................................................................................... 1-4-21 (2) Contents of service setting items .................................................................................................. 1-4-22

1-5 Troubleshooting
1-5-1 Paper misfeed detection ...................................................................................................................... 1-5-1 (1) Paper misfeed indication ................................................................................................................ 1-5-1 (2) Paper misfeed detection conditions ................................................................................................ 1-5-2 (3) Paper misfeeds ............................................................................................................................... 1-5-4 1-5-2 Self-diagnosis ....................................................................................................................................... 1-5-8 (1) Self-diagnostic function .................................................................................................................. 1-5-8 (2) Self-diagnostic codes ..................................................................................................................... 1-5-8 1-5-3 Image formation problems ................................................................................................................. 1-5-15 (1) No image appears (entirely white). ............................................................................................... 1-5-16 (2) No image appears (entirely black). ............................................................................................... 1-5-16 (3) Image is too light. ......................................................................................................................... 1-5-17 (4) Background is visible. ................................................................................................................... 1-5-17 (5) A white line appears longitudinally. .............................................................................................. 1-5-17 (6) A black line appears longitudinally. .............................................................................................. 1-5-18 (7) A black line appears laterally. ....................................................................................................... 1-5-18 (8) One side of the print image is darker than the other. 1-1-1 ................................................................... 1-5-18 (9) Black dots appear on the image. .................................................................................................. 1-5-19 (10) Image is blurred. ........................................................................................................................... 1-5-19 (11) The leading edge of the image is consistently misaligned with the original. ................................ 1-5-19 (12) Paper creases. ............................................................................................................................. 1-5-20 (13) Offset occurs. ............................................................................................................................... 1-5-20 (14) Image is partly missing. ................................................................................................................ 1-5-20

2GM (15) Fixing is poor. ............................................................................................................................... (16) Image center does not align with the original center. ................................................................... 1-5-4 Electrical problems ............................................................................................................................. (1) The machine does not operate when the power switch is turned on. ........................................... (2) The main motor does not operate. (C2000) ................................................................................. (3) The scanner motor does not operate. .......................................................................................... (4) Cooling fan does not operate. ...................................................................................................... (5) The feed clutch does not operate. ................................................................................................ (6) The MP feed clutch does not operate. .......................................................................................... (7) The registration clutch does not operate. ..................................................................................... (8) The eraser lamp does not turn on. ............................................................................................... (9) The exposure lamp does not turn on. ........................................................................................... (10) The exposure lamp does not turn off. ........................................................................................... (11) The heater lamp does not turn on. ............................................................................................... (12) The heater lamp does not turn off. ............................................................................................... (13) Main charging is not performed. ................................................................................................... (14) Transfer charging is not performed. ............................................................................................. (15) A paper jam in the paper feed or exit section is indicated when the power switch is turned on. ............................................................................................ (16) The message requesting cover to be closed is displayed when the front cover is closed. ..................................................................................................... (17) Others. .......................................................................................................................................... 1-5-5 Mechanical problems ......................................................................................................................... (1) No primary paper feed. ................................................................................................................. (2) No secondary paper feed. ............................................................................................................ (3) Skewed paper feed. ...................................................................................................................... (4) The scanner does not travel. ........................................................................................................ (5) Multiple sheets of paper are fed at one time. ................................................................................. (6) Paper jams. .................................................................................................................................. (7) Abnormal noise is heard. .............................................................................................................. 1-5-21 1-5-21 1-5-22 1-5-22 1-5-22 1-5-22 1-5-22 1-5-22 1-5-23 1-5-23 1-5-23 1-5-23 1-5-23 1-5-23 1-5-23 1-5-24 1-5-24 1-5-24 1-5-24 1-5-24 1-5-25 1-5-25 1-5-25 1-5-25 1-5-25 1-5-25 1-5-25 1-5-25

1-6 Assembly and Disassembly
1-6-1 Precautions for assembly and disassembly ......................................................................................... 1-6-1 (1) Precautions ..................................................................................................................................... 1-6-1 1-6-2 Removing the process unit ................................................................................................................... 1-6-2 1-6-3 Removing the principal outer covers .................................................................................................... 1-6-3 (1) Removing the front top cover/face-down output tray ...................................................................... 1-6-3 (2) Removing the right cover ................................................................................................................ 1-6-4 (3) Removing the left cover .................................................................................................................. 1-6-4 1-6-4 Removing the feed roller ...................................................................................................................... 1-6-5 1-6-5 Removing the MP feed roller ................................................................................................................ 1-6-6 1-6-6 Removing the transfer roller ................................................................................................................. 1-6-8 1-6-7 Removing the primary circuit PWBs ..................................................................................................... 1-6-9 (1) Removing the engine PWB ............................................................................................................ 1-6-9 (2) Removing the main PWB ............................................................................................................. 1-6-10 (3) Removing the power supply PWB and high voltage PWB ........................................................... 1-6-12 (4) Removing the bias PWB ............................................................................................................... 1-6-13 1-6-8 Removing the main motor and drive unit ........................................................................................... 1-6-14 1-6-9 Removing and splitting the fuser unit ................................................................................................. 1-6-18 (1) Removing the separation craws ................................................................................................... 1-6-20 (2) Removing the heater lamp ........................................................................................................... 1-6-21 (3) Removing the heat roller .............................................................................................................. 1-6-22 1-1-2 (4) Removing the thermistor .............................................................................................................. 1-6-24 (5) Removing the thermal cutout ........................................................................................................ 1-6-25 (6) Removing the press roller ............................................................................................................. 1-6-26 1-6-10 Removing and scanner unit ............................................................................................................... 1-6-27 1-6-11 Removing the laser scanner unit and the eraser lamp ....................................................................... 1-6-29 1-6-12 Removing the ISU unit ....................................................................................................................... 1-6-32

2GM 1-6-13 1-6-14 1-6-15 1-6-16 1-6-17 Removing the exposure lamp ............................................................................................................ Removing the scanner mirror A ......................................................................................................... Removing the scanner motor ............................................................................................................. Removing the main charger unit ........................................................................................................ Adjustment the maintenance mode .................................................................................................... (1) Adjusting the leading edge registration of image printing ............................................................. (2) Adjusting the center line of image printing .................................................................................... (3) Adjusting the amount of slack in the paper ................................................................................... (4) Adjusting magnification of the scanner in the main scanning direction ........................................ (5) Adjusting magnification of the scanner in the auxiliary scanning direction ................................... (6) Adjusting the scanner leading edge registration ........................................................................... (7) Adjusting the scanner center line ................................................................................................. (8) Adjusting the margins for scanning an original on the contact glass ............................................ (9) Adjusting the DP magnification ..................................................................................................... (10) Adjusting the DP leading edge registration .................................................................................. (11) Adjusting the DP trailing edge registration ................................................................................... (12) Adjusting the DP center line ......................................................................................................... (13) Adjusting the margins for scanning the original from the DP ........................................................ 1-6-34 1-6-36 1-6-37 1-6-40 1-6-41 1-6-41 1-6-42 1-6-43 1-6-44 1-6-45 1-6-46 1-6-47 1-6-48 1-6-49 1-6-50 1-6-51 1-6-52 1-6-53

1-7 Upgrading the firmware
1-7-1 Upgrading the firmware on the main PWB ........................................................................................... 1-7-1

2-1 Mechanical construction
2-1-1 Paper feeding system .......................................................................................................................... 2-1-1 (1) Paper feed control .......................................................................................................................... 2-1-2 (2) Paper feeding mechanism .............................................................................................................. 2-1-3 2-1-2 Original scanning system ..................................................................................................................... 2-1-4 (1) ISU unit ........................................................................................................................................... 2-1-6 2-1-3 Electrophotographic system ................................................................................................................. 2-1-7 (1) Electrophotographic cycle .............................................................................................................. 2-1-7 (1-1) Process unit mechanism ....................................................................................................... 2-1-8 (2) Main charging ................................................................................................................................. 2-1-9 (2-1) Photo conductive drum .......................................................................................................... 2-1-9 (2-2) Charging the drum ............................................................................................................... 2-1-10 (3) Exposure ...................................................................................................................................... 2-1-11 (3-1) Laser scanner unit ............................................................................................................... 2-1-12 (3-2) Drum surface potential ........................................................................................................ 2-1-13 (4) Development ................................................................................................................................ 2-1-14 (5) Transfer ........................................................................................................................................ 2-1-15 (6) Fusing ........................................................................................................................................... 2-1-16 (6-1) Fuser unit mechanism ......................................................................................................... 2-1-17 (7) Cleaning ....................................................................................................................................... 2-1-18

2-2 Electrical Parts Layout
2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1 (1) Main unit ......................................................................................................................................... 2-2-1 (2) Scanner unit ................................................................................................................................... 2-2-2

2-3 Operation of the PWBs
2-3-1 Main PWB ............................................................................................................................................ 2-3-1 2-3-2 Engine PWB ......................................................................................................................................... 2-3-7 (1) Eraser lamp control circuit .............................................................................................................. 2-3-9 1-1-3 (2) Heater lamp control circuit ............................................................................................................ 2-3-10 (3) Polygon motor control circuit ........................................................................................................ 2-3-13 2-3-3 Power supply PWB ............................................................................................................................ 2-3-17 2-3-4 Bias PWB ........................................................................................................................................... 2-3-19 2-3-5 High voltage PWB .............................................................................................................................. 2-3-20 (1) Interlock switch ............................................................................................................................. 2-3-21

2GM 2-3-6 CCD PWB .......................................................................................................................................... 2-3-22 2-3-7 Operation PWB .................................................................................................................................. 2-3-24 2-3-8 Scanner PWB ..................................................................................................................................... 2-3-26

2-4 Appendixes
Timing chart No. 1 .......................................................................................................................................... Timing chart No. 2 .......................................................................................................................................... Timing chart No. 3 .......................................................................................................................................... Wiring diagram ............................................................................................................................................... 2-4-1 2-4-2 2-4-3 2-4-4

1-1-4

2GM

1-1-1 Specifications
Type ............................................... Desktop Copying system .............................. Indirect electrostatic system Originals ......................................... Sheets of paper (Maximum original size: folio/81/2" 14" [legal]) Platen: Sheets of paper, books, 3-dimensional objects (Maximum original size: folio/ 81/2" 14" [legal]) Original feed system ...................... Contact glass: fixed Document processor (optional): sheet-through Copy paper ..................................... Cassette: Plain paper (60 - 105 g/m2) MP tray: Plain paper (60 - 163 g/m2) Special paper: Transparencies, letterhead, colored paper, recycled paper Note: Use the MP tray for special paper. Copying sizes ................................. Maximum: folio/81/2" 14" [legal] Minimum: A6R /51/2" 81/2" Magnification ratios ........................ Manual mode: 50 - 200%, 1% increments Copying speed ............................... At 100% magnification, platen: A4/81/2" 11": 18 copies/min. A5: 10 copies/min. 81/2" 14": 15 copies/min. At 100% magnification, document processor: A4/81/2" 11": 18 copies/min. First copy speed ............................. Apporox. 9.5 s (A4/81/2" 11", original placed on the platen) Warm-up time ................................. 20 s or less Recovery from the low power mode: 10 s or less Recovery from the sleep mode: 15 s or less (at room temperature 23 C/73.4 F, humidity 60% RH) Paper feed system ......................... Cassette: 250 sheets (80 g/m2) MP tray: 50 sheets (80 g/m2) 25 sheets (120 g/m2) 10 sheets (160 g/m2) 1 sheet (Transparency) Stacking capacity ........................... Output tray: Approx. 150 sheets (80 g/m2) Face-up tray: 30 sheets (80 g/m2) 1 sheet (Special paper) Standard memory .......................... 96 MB (64 MB of system memory and 32 MB of additional memory) (Approx. 70 pages of memory possible with letter size, 5%, Text+Photo mode) Additional memory ......................... 1 slot (64 MB, 128 MB or 256 MB) Continuous copying ........................ 1 - 999 sheets Scanning system ............................ Flat bed scanning by CCD image sensor Resolution ...................................... Reading (scanning) 600 600 dpi Writing (printing) 600 600 dpi Original quality mode ..................... Text+Photo, Photo and Text Light source ................................... Cold cathode lamp Photoconductor .............................. OPC (drum diameter 30 mm) Charging system ............................ Single positive corona charging Developing system ......................... Single element reversing process Transfer system .............................. Transfer roller Fusing system ................................ Heat roller Heat source: halogen heaters (750 W) Control temperature: 190 C/374 F (at normal ambient temperature) Abnormally high temperature protection device: thermal cutout Charge erasing system .................. Exposure by cleaning lamp Cleaning system ............................ Cleaning blade Dimensions .................................... 496 (W) 421 (D) 385 (H) mm 199/16" (W) 165/8" (D) 153/16" (H) Weight ............................................ Approx. 14.5 kg/32.0 lbs Floor requirements ......................... 496 (W) 740 (D) mm 199/16" (W) 293/16" (D) Functions ........................................ Auto exposure adjustment, Ecoprint mode, Zoom mode, Preset zoom mode, Off mode, Print override mode, Low power mode, Layout modes, Sort mode and Program function

1-1-1

2GM Power source ................................. 120 V AC, 60 Hz, 7.8 A 220 - 240 V AC, 50/60 Hz, 4.0 A Power consumption ........................ 854 W Options ........................................... Paper feeder, document processor (DP), additional memory and fax system Printing functions Printing speed ................................ A4/81/2" 11": 18 prints/min. A5: 10 prints/min. 81/2" 14": 15 prints/min. First print speed ............................. Apporox. 8 s (A4/81/2" 11") Resolution ...................................... 300, 600 dpi and Fast 1200 Compatible operation system ......... Microsoft Windows 95/98/Me/NT 4.0/2000/XP Apple Macintosh OS 9.x/OS X 10.x UNIX/Linux Host interface ................................. Parallel: 1 port (IEEE1284) USB: 1 port (Hi-speed USB 2.0) Ethernet: 1 port (10BASE-T/100BASE-TX) PDL ................................................ PRESCRIBE Emulation mode ............................. Line printer, IBM proprinter, DIABLO 630, EPSON LQ-850, PCL6 and KPDL

Scanning functions Scanning speed ............................. Monochrome: 18 spm Full color or Grayscale: 4.8 spm (1:1 - A4/81/2" 11", 200 dpi) Resolution ...................................... 200 100, 200 400, 200, 300, 400 and 600 dpi Color mode ..................................... Full color, Grayscale and Monochrome Halftone .......................................... Full color: 8 bit/dot: each color Grayscale: 8 bit/dot Monochrome: 1 bit/dot Original quality mode ..................... Text+Photo, Photo, Text and OCR File format ...................................... PDF (All modes), TIFF (only monochrome mode), JPEG (except monochrome mode) Host interface ................................. Ethernet: 1 port (10BASE-T/100BASE-TX) USB (TWAIN): 1 port (Hi-speed USB)

1-1-2

2GM

1-1-2 Names of parts
(1) Main body

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Figure 1-1-1 Names of parts 1 Original cover 2 Contact glass 3 Original size indicator plate 4 Operation panel 5 Front top cover 6 Front cover 7 Process unit 8 Toner container 9 Lock lever 0 Toner container release lever ! Main charger cleaner @ Cassette # Paper guide $ Paper stopper % Stopper extension lock ^ Face-down output tray & MP tray * Extension tray ( Paper width guides ) Power switch / Face-up output tray Power cord < DP interface connector > Memory cover fi Parallel interface connector fl USB interface connector Network interface connector

1-1-3

2GM (2) Operation panel

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Figure 1-1-2

1 Status/Job cancel key and indicator 2 Copy key and indicator 3 Send key and indicator 4 One-touch keys (1 to 8) 5 Scan color select key and indicator 6 Program key and indicator 7 Scan resolution key and indicator 8 Function key and indicator 9 Print indicator 0 Send/Receive indicator ! Memory indicator @ Error indicator # System menu/Counter key and indicator $ Log out key and indicator % Numeric keys ^ Reset/Power key

& Main power indicator * Original quality key and indicator ( Original size key and indicator ) Exposure key and indicator / Paper select key and indicator Message display < Left select key > Right select key fi Back key fl Left cursor key Up cursor key -- Down cursor key Right cursor key , Enter key OE Stop/Clear key ,, Start key and indicator

1-1-4

2GM

1-2-1 Drum
Note the following when handling or storing the drum. When removing the process unit, never expose the drum surface to strong direct light. Keep the drum at an ambient temperature between 10 C/50 F and 32.5 C/90.5 F and at a relative humidity not higher than 80% RH. Avoid abrupt changes in temperature and humidity. Avoid exposure to any substance which is harmful to or may affect the quality of the drum. Do not touch the drum surface with any object. Should it be touched by hands or stained with oil, clean it.

1-2-2 Installation environment
1. Temperature: 10 - 32.5 C/50 - 90.5 F 2. Humidity: 20 - 80%RH 3. Power supply: 120 V AC, 7.8 A 220 - 240 V AC, 4.0 A 4. Power source frequency: 50 Hz 0.3%/60 Hz 0.3% 5. Installation location Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams. Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directed onto the machine. Avoid dust and vibration. Choose a surface capable of supporting the weight of the machine. Place the machine on a level surface (maximum allowance inclination: 1 ). Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor, such as mercury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents. Select a room with good ventilation. 6. Allow sufficient access for proper operation and maintenance of the machine. Machine front: 1000 mm/393/8" Machine rear: 300 mm/1113/16" Machine right: 300 mm/1113/16" Machine left: 300 mm/1113/16"

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a: 385 mm/153/16" b: 460 mm/181/8" c: 496 mm/199/16" d: 421 mm/165/8" e: 665 mm/263/16" f: 740 mm/293/16"

Figure 1-2-1 Installation dimensions

1-2-1

2GM

1-3-1 Unpacking and installation
(1) Installation procedure

Start

Unpack.

Remove the tapes, pads and sheets.

Remove the pin holding scanner unit.

Install a toner container.

Connect the power cord.

Inisializing the machine.

Load paper.

Using the one-touch key sheet.

Make test copies.

End of installation.

1-3-1

2GM Unpack.

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Figure 1-3-1 Unpacking

1 Main body 2 Toner container 3 Power cord 4 Cleaning cloth 5 One-touch key sheet 6 CD ROM 7 Outer case 8 Bottom pad 9 Upper pad 0 Side pad

! Front spacer @ Front pad # Bottom spacer $ Cassette spacer % Left pad ^ Right pad & Corner supports * Products cover ( Plastic bag ) Plastic bag

/ Pocket spacer Paper tag < Top sheet > Output tray sheet fi Bar code labels fl Label Operation guide -- Installation guide Plastic bag

1-3-2

2GM CAUTIONS Be sure to hold both the front and rear sides of the machine when carrying it, as shown in the illustration. Be sure not to pull the cassette out when holding the front of the machine. Be sure that the original cover is closed whenever transporting the machine. Do not attempt to carry the machine by holding only the top portion. Doing so may result in you dropping the machine and thereby damaging the machine and/or its covers.

Figure 1-3-2

1-3-3

2GM Remove the tapes, pads and sheets. 1. Remove the sheet and the two tapes.
Tapes Sheet

Figure 1-3-3 2. Open the original cover.
Original cover

Figure 1-3-4

1-3-4

2GM 3. Remove the eight tapes, the two pads and the sheet.

Pad

Pad

Tapes

Sheet

Tapes

Tape

Tape

Figure 1-3-5

4. Pull the cassette out of the machine.

Cassette

Figure 1-3-6
Cassette spacer

5. Remove the cassette spacer from inside the cassette.

Figure 1-3-7

1-3-5

2GM Remove the pin holding scanner unit. 1. Remove the yellow pin for scanner unit and the paper tag from the left side of the machine.
Pin

Paper tag

Figure 1-3-8

Install a toner container. 1. Open the front top cover and front cover.
Front top cover

Front cover

Figure 1-3-9

2. Store the pin for scanner unit on the inside of the front cover as shown in the illustration. * Be sure to save this pin as it is essential that it be used whenever the machine is moved. The location for storing the pin is clearly marked on the right side of the inside portion of the front cover.

Pin

Figure 1-3-10

1-3-6

2GM 3. Remove the process unit from the machine. CAUTIONS Place the process unit on a clean, level surface. Never expose the process unit to any sort of impact or shock. The drum in the process unit is sensitive to light. Never expose the drum even to normal office lighting (500 lux) for more than five minutes.
Process unit

Figure 1-3-11 4. Remove the protective cardboard.

Protective cardboard

Figure 1-3-12

5. Move the lock lever until it is in its unlocked position (marked UNLOCK).

Lock lever

Figure 1-3-13

1-3-7

2GM 6. Shake the toner container horizontally back and forth five or six times so that the toner inside of it becomes evenly distributed.

Toner container

Figure 1-3-14 7. Remove the orange protective seal.

Seal

Figure 1-3-15 8. Align the knob on the left side of the container with the groove in the process unit and set the toner container into the process unit.
Knob Toner container

Process unit

Figure 1-3-16

1-3-8

2GM 9. Hold the process unit stable and push on the areas marked PUSH HERE on the toner container until the container clicks into place.

Toner container

Figure 1-3-17 10. Push the lock lever back into its locked position.

Lock lever

Figure 1-3-18

11. Set the process unit into the machine by aligning the pins on both sides of the process unit with the guides inside the machine, and then slide the process unit all the way back into the machine until it stops.

Pin

Pin

Figure 1-3-19

1-3-9

2GM 12. Close the front cover.

Front cover

Figure 1-3-20 13. Close the front top cover.
Front top cover

Figure 1-3-21

1-3-10

2GM Connect the power cord. 1. Connect the power cord.

Power cord

Figure 1-3-22 Initializing the machine. 1. Turn the power switch to the machine ON ( | ).

Power switch

Figure 1-3-23 The machine will begin replenishing the toner. Wait until it has completed that operation. (15 minutes) Once the toner has been replenished and the machine is once again in a ready-to-use state, Ready to copy will appear on the message display and the Start indicator will light green.

Figure 1-3-24

1-3-11

2GM Load paper. 1. Pull the cassette out of the machine.

Cassette

Figure 1-3-25 2. Adjust the paper stopper in the rear portion of the cassette to fit the size of the paper being loaded there by pressing in on the release buttons and sliding the paper stopper to the corresponding paper size. NOTES The paper sizes are marked on the bottom of the cassette. The default factory setting is for A4/Letter size paper.
Paper stopper

Figure 1-3-26 Adjusting the paper stopper for Folio or Oficio II size paper 1) Remove the stopper extension lock from the paper stopper. 2) Slide the paper stopper towards the rear of the cassette until the grooves that are cut into the paper stopper are aligned with the rear edge of the cassette. 3) Insert the stopper extension lock into the holes in the paper stopper, as shown in the illustration.
Stopper extension lock Paper stopper

Stopper extension lock

Figure 1-3-27

1-3-12

2GM 4) Press down on the stopper extension lock and slide the paper stopper towards the rear of the cassette to set the lock into place. The paper stopper is in position for Folio and Oficio II size paper.

Paper stopper

Stopper extension lock

Figure 1-3-28 3. Adjust the paper width guides by pressing in on the release buttons and sliding the guides to fit the width of the paper being loaded in the cassette. NOTES The paper sizes are marked on the bottom of the cassette. The default setting is for A4/Letter size paper.
Paper width guide

Paper width guide

Figure 1-3-29 4. Set the paper in the cassette so that the leading edge is aligned against the paper stopper, but making sure that none of the paper gets caught on the overhanging tabs.
Paper stopper

Figure 1-3-30

1-3-13

2GM NOTES Always adjust the paper stopper and paper width guides before loading paper into the cassette. Failure to do so may result in skewed paper feed and/or a paper jam. Make sure that the paper is set securely against the paper stopper and the paper width guides. If there is any gap between the paper and the stopper or guides, readjust the paper stopper and/or the paper width guides, as appropriate. When you are loading paper into the cassette, make sure that the side to be copied or printed onto is facing downward. Be sure to load paper so that it is not folded or curled, etc. Do not load more paper than indicated by the lines located on the width guides.

Paper width guide

Figure 1-3-31

5. Push the cassette securely all the way back into the machine until it stops.

Cassette

Figure 1-3-32

1-3-14

2GM Using the one-touch key sheet. 1. Remove the one-touch key sheet from bottom side of the operation panel.

One-touch key sheet

Figure 1-3-33

2. Enter the information for the registered destinations onto the one-touch key sheet. (There are 4 spare one-touch key sheets included with this machine.) 3. Insert the sheet back between the one-touch keys from the bottom side of the operation panel.

One-touch key sheet

A- - - -B- - - -C- - - -D- - - -E- - - -F- - - -G- - - -H- - - --

Figure 1-3-34

Make test copies.

End of installation.

1-3-15

2GM

1-3-2 Connecting the cables
(1) Connecting the network cable To connect the machine to a network, use an network cable (10Base-T or 100Base-TX). Procedure 1. Turn the power switch located on the rear side of the machine off (O), and remove the power cord from the outlet.
Power switch

Figure 1-3-35

2. Connect the network cable to the network connector at the rear side of the machine. 3. Connect the other end of the network cable to network device (hub). 4. Make network settings.
Network cable

Figure 1-3-36

1-3-16

2GM (2) Connecting the printer cable To connect the machine directly to your computer, use either a parallel cable or USB cable. Procedure 1. Turn the power switch located on the rear side of the machine off (O), remove the power cord from the outlet and turn the power off to computer.
Power switch

Figure 1-3-37

2. Connect the printer cable to the parallel interface connector or USB interface connector located at the rear side of the machine. 3. Connect the other end of the printer cable to the parallel interface connector or USB interface connector on computer.

Printer cable

USB interface connector

Figure 1-3-38

1-3-17

2GM

1-3-3 Installing the document processor (option)
Procedure 1. Remove all of the components to the document processor from the box. CAUTION Be sure to hold both sides of the document processor when carrying it, as shown in the illustration. Be particularly careful NOT to touch the guide film or the thin white surface indicated by the A in the illustration.

A Document processor

Figure 1-3-39 2. Turn the power switch located on the rear side of the machine off (O). Disconnect the power cord.

Power switch

Figure 1-3-40 3. Open the original cover and lift it upward to remove it from the machine.

Oringinal holder

Figure 1-3-41

1-3-18

2GM 4. Attach the document processor to the machine. CAUTION Be sure that the connection cable does not get caught between the document processor and the machine when attaching the document processor to the machine.

Connection cable

Figure 1-3-42

5. Gently close the document processor.

Document processor

Figure 1-3-43 6. Attached the open end of the connection cable to the connector on the machine.
Document processor

Connection cable

Figure 1-3-44

1-3-19

2GM CAUTION Be sure to tighten the pins securely when connecting the cable.

Pins

Figure 1-3-45 7.Connect the power cord and turn the power switch on ( | ). Warm up will begin. 1 will appear on the operation panel and the start indicator will light when the machine is in a ready state.
Power switch

Figure 1-3-46

1-3-20

2GM

1-3-4 Installing the expanding memory (option)
The main PWB of the machine is equipped with one socket for memory expansion. Expansion memory is available in the form of DIMM (Dual In-line Memory Module). CAUTION Take precautions that no foreign substances such as metal chips or liquid get inside the machine during the installation process. Operation of the machine during the presence of a foreign substance may lead to fire or electric shock. WARNING Turn the power switch off. Disconnect the power cord.

Procedure 1. Remove the screw and then remove the memory cover. 3. Open the clips on both ends of the DIMM socket. 4. Insert the DIMM into the DIMM socket so that the notches on the DIMM align with the corresponding protrusions in the slot. 5. Close the clips on the DIMM slot to secure the DIMM.

Memory socket Stopper

Memory Stopper

Memory cover

Screw

Figure 1-3-47 Inserting the DIMM

1-3-21

2GM

1-3-5 Installing the fax system (option)
Turn the machine's power switch to OFF and unplug the machine from the power supply before installing the fax system. Precautions for handling the FAX assembly The FAX assembly is delivered in an antistatic airpadded bag. To prevent any damage, briefly touch a large metal object to ensure discharge of static electricity before removing the FAX assembly from the bag. Hold the FAX assembly by the metal plate on front as shown. Do not touch the circuits or electronic components on the PWB.

Figure 1-3-48 Procedure 1. On the rear of the machine, remove two screws and then remove the plate.

Screw

Plate Screw

Figure 1-3-49

2. Insert the FAX assembly along the rail in the machine until it clicks in place. Attach the fax assembly using two screws from step 1. IMPORTANT: When inserting the FAX assembly, slide it slowly and firmly all the way in.

Screw

Plate

Screw

Figure 1-3-50

1-3-22

2GM 3. Connect the modular cord to the line jack. 120 V specifications: Connect the modular cord with the attached ferrite core to the machine.
Line jack

Figure 1-3-51

220-240 V specifications only 4. Attach the core to the power cord of the machine so that the stopper section is located near the power plug as shown in the illustration.

Core

Stopper section

Figure 1-3-52

5. Plug the power cord into the machine. Turn the machine on. NOTE (120 V specifications only) When connecting a separate phone to the machine, attach the ferrite core to the modular cord before connection. Loop the modular cord through the ferrite core.

20 mm

Ferrite core

Figure 1-3-53

1-3-23

2GM Initialization procedure after installation of fax system 1. Insert the machine power plug to the wall outlet and turn the power switch on. 2. Run maintenance item U601. 3. Enter a destination code using the numeric keys (refer to the destination code list) and then press the enter key. * Enter a destination code with three digits.

Code 000 009 080 084 088 108 126 136 137 152 156

Destination Japan Australia Hong Kong Indonesia Israel Malaysia New Zealand Peru Philippines Middle East Singapore

Code 159 169 181 242 243 253

Destination South Africa Thailand U.S.A. South America Saudi Arabia CTR21 (European nations) Italy Germany Spain U.K. Netherlands

Code 253

Destination Sweden France Austria Switzerland Belgium Denmark Finland Portugal Ireland Norway Taiwan

254

4. Enter the OEM code (000) and then press the enter key. 5. After data initialization, the entered destination, OEM codes and ROM version are displayed. A ROM version displays three kinds, application, IPL, and boot.

Ini. Keep data COMPLETED XXX 000 APLI:**************** BOOT:**************** IPL:****************

Figure 1-3-54 6. After completing the installation, run a communications test to confirm that the fax system is working correctly.

1-3-24

2GM

1-4-1 Maintenance mode

The machine is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item

Start

Press the system menu/counter key.

Select Service setting using the up/down cursor keys.

While pressing the start key and the # key, press the enter key.

Maintenance mode is entered.

Select Maintenance mode using the up/down cursor keys.

Press the enter key.

Enter the maintenance item number using the up/down keys.

The maintenance item is selected.

Press the enter key.

The selected maintenance item is run.

Press the back key.

Yes

Repeat the same maintenance item? No

Yes

Run another maintenance item? No Turning power switch off and back on Maintenance mode is exited.

End

* The test print mode cannot be stopped until the preset number of sheets is printed. To stop the operation, remove the cassette to cause a paper empty state. To terminate the test print mode in the middle of operation, you must turn off the power switch and then on again to exit the maintenance mode.

1-4-1

2GM (2) Maintenance modes Category General Initialization Drive, paper feed and paper conveying system Optical Item Maintenance No. U000 Outputting an own-status report U020 Initializing all data U034 Setting paper timing Adjusting the leading edge registration Adjusting the center line U051 Adjusting the amount of slack in the paper U060 Adjusting the scanner input properties U063 Adjusting the shading position U065 Adjusting the scanner magnification Main scanning direction auxiliary scanning direction U066 Adjusting the leading edge registration for scanning an original on the contact glass U067 Adjusting the center line for scanning an original on the contact glass U070 Adjusting the DP magnification U071 Adjusting the DP scanning timing Adjusting leading edge registration Adjusting trailing edge registration U072 Adjusting the DP center line U074 Adjusting the DP input light luminosity U087 Turning the DP scanning position adjust mode on/off U089 Outputting a MIP-PG pattern High voltage Developing U101 Setting the other high voltages U130 Initial setting for the developer U144 Setting toner loading operation U157 Checking/clearing the developing drive time Fusing and cleaning U161 Setting the fusing control temperature Primary stabilization fusing temperature Secondary stabilization fusing temperature Copying operation temperature 1 Copying operation temperature 2 Number of sheets for fusing control U163 Resetting the fusing problem data Operation panel and support equipment Mode setting Image processing U203 Operating DP separately U207 Checking the operation panel keys Initial setting* -- -- -- -- 0 12 0 0 0 6 7 2 11 0 -0.7 1 35 -- 26/55/48/ 43/24/60 OFF 1 -- 135 160 190 195 5 -- -- --

U260 Changing the copy count timing U403 Adjusting margins for scanning an original on the contact glass U404 Adjusting margins for scanning an original from the DP U411 Adjusting the scanner automatically U425 Setting the target

-- -- -- -- -- -- -- -- -- --

Others

U901 Checking/clearing print counts by paper feed locations U905 Checking/clearing counts by the DP U911 Checking/clearing print counts by paper size U927 Clearing accounting counter U928 Checking/clearing the machine life count

* Initial setting for executing maintenance item U020

1-4-2

2GM (3) Contents of maintenance mode items Maintenance item No. U000 Outputting an own-status report Description

Description Outputs lists of the current settings of the maintenance items, and paper jam and service call occurrences and event log report. Purpose To check the current setting of the maintenance items, or paper jam or service call occurrences. Before initializing the backup RAM, output a list of the current settings of the maintenance items to reenter the settings after initialization or replacement. Method 1. Press the enter key. A selection item appears. 2. Select the item to be output using the up/down cursor keys. Display Maintenance Event Log Output list Outputs the maintenance list Outputs the event log report

3. Press the enter key. The test print mode is entered and a list is output. Completion Press the back key while a selection item is displayed. The indication for selecting a maintenance item No. appears. Detail of event log

1-4-3

2GM Maintenance item No. Item 1 Paper Jam Log Description Description #: Log number 1 to 16 jams are recorded. (If the number of jams exceeds 16, the oldest log is deleted.) Count.: Number of pages Total page counter at the time of jam Event: Log code Six types of two-digit hexadecimal numbers are displayed. Cause of jam/jam position/paper feed location/paper size/media type /ejection location Descriptions: Indicates the description of error (a) Cause of jam 03: No paper feed [] 04: Cover open JAM [] 05: Secondary paper feed timeout [H] 10: No paper feed from the MP tray [B] 11: No paper feed from the cassette [C] 12: No paper feed from the optional cassette [D] 20: Multiple sheets in the MP tray [B] 21: Multiple sheets in the cassette [C] 22: Multiple sheets in the optional cassette [D] 40: Misfeed in the fusing section [H] 50: Misfeed in the exit section [G] 70: No original feed [P] 71: An original jam in the original conveying section [P] 7A: DP original cover or front top cover open JAM [P] 7B: DP open JAM [P] 7F: Original remaining JAM [P] (b) Jam position

42 [B]: MP tray 43 [C]: Cassette 44 [D]: Optional cassette 47 [G]: Face-up/down eject tray 48 [H]: MFP 50 [P]: DP (c) Paper feed location 00: MP tray 01: Cassette 02: Optional cassette

1-4-4

2GM Maintenance item No. Item Description Description (c) Paper size 01: Envelope Monarch 02: Envelope #10 03: Envelope DL 04: Envelope C5 05: Executive 06: Letter 07: Legal 08: A4 (d) Media type 01: Plain 02: Transparency 03: Preprinted 04: Label 05: Bond 06: Recycled 07: Vellum 08: Rough (e) Ejection location 01: Face-down output tray 2 Service Call Log #: Log number 1 to 8 service calls are recorded. (If the number of service calls exceeds 8, the oldest log is deleted.) Count.: Number of pages Total page counter at the time of service call Service code: Log code #: Log number 1 to 8 maintenance logs are recorded. (If the number of replacement times exceeds 8, the oldest log is deleted.) Count.: Number of pages Total page counter at the time of replacement Item: Log code Two units of 1-byte values indicate a log. First byte 01: Replacement of toner container Second byte 00 : black (fixed) Jam count Counter display by cause of jam Example J05: 001 Jam05 occurred one time. Call system log Counter display by service call Example C0180: 006 C0180 occurred six times. Replacement log Replacement log display by item Example M00: 001 The toner container was replaced one time. 09: B5 0D: A5 0E: A6 0F: B6 10: Envelope #9 11: Envelope #6 12: ISO B5 13: Custom 09: Letterhead 0A: Color 0B: Prepunched 0C: Envelope 0D: Cardstock 10: Thick 15: Custom 1 16: Custom 2 1F: Postcard 20: Reply-paid postcard 21: Officio II 28: 16K 32: Statement 33: Folio 34: Western 2 35: Western 4 17: Custom 3 18: Custom 4 19: Custom 5 1A: Custom 6 1B: Custom 7 1C: Custom 8

3 Maintenance Log

4 Counter Log

1-4-5

2GM Maintenance item No. U020 Initializing all data Description

Description Initializes all the backup RAM on the engine PWB to return to the original settings. Purpose Used when replacing backup RAM on the engine PWB. After initialization, run U157 "Changing the developing drive time" and U411 "Adjusting the scanner automatically." Method 1. Press the enter key. A selection item appears. 2. Select Execute using the up/down cursor keys. 3. Press the enter key. All data in the backup RAM is initialized. When initialization is complete, turn the power switch off and on. Completion To exit this maintenance item without executing initialization, press the back key. The indication for selecting a maintenance item No. appears. U034 Adjusting the print start timing Adjustment See pages 1-6-41 and 42. U051 Adjusting the amount of slack in the paper Adjustment See page 1-6-43. U060 Adjusting the scanner input properties Description Adjusts the image scanning density. Purpose Used when the entire image appears too dark or light. Method Press the enter key. Setting 1. Change the setting using the left/right cursor keys. Display Adj. (MONO) Description Image scanning density Setting range 0 to 23 Initial setting 12

Increasing the setting makes the density higher, and decreasing it makes the density lower. 2. Press the enter key. The value is set. Test print mode While this maintenance item is being performed, copying from an original can be made in test print mode. 1. Press the system menu/counter key. The machine enters the test print mode. 2. Set the original and press the start key. * The test printing, however, cannot be stopped until the preset number of sheets is printed. 3. To return to the indication for setting, press the system menu/counter key. Completion Press the back key. The indication for select