Manual de Servicio 2500

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It is the reader's responsibility when discussing the information containedwithin this document to maintain a level of confidentiality that is in the bestinterest of Ricoh Americas Corporation and its member companies.

NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANYFASHION AND DISTRIBUTED WITHOUT THE PRIORPERMISSION OF RICOH AMERICAS CORPORATION.

All product names, domain names or product illustrations, includingdesktop images, used in this document are trademarks, registeredtrademarks or the property of their respective companies.They are used throughout this book in an informational or editorial fashiononly and for the benefit of such companies. No such use, or the use of

any trade name, or web site is intended to convey endorsement or otheraffiliation with Ricoh products.

2007 RICOH Americas Corporation. All rights reserved.


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The Service Manual contains informationregarding service techniques, procedures,

processes and spare parts of office equipmentdistributed by Ricoh Americas Corporation.

Users of this manual should be either servicetrained or certified by successfully completing aRicoh Technical Training Program.

Untrained and uncertified users utilizinginformation contained in this service manual torepair or modify Ricoh equipment risk personalinjury, damage to property or loss of warranty

protection.

Ricoh Americas Corporation

WARNING


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LEGENDPRODUCT CODE COMPANY

GESTETNER LANIER RICOH SAVIN

D010 DSm625 LD125 Aficio MP 2500 7025

DOCUMENTATION HISTORYREV. NO. DATE COMMENTS

* 09/2007 Original Printing


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D010

TABLE OF CONTENTS

INSTALLATION

1. INSTALLATION............................................................................ 1-11.1INSTALLATION REQUIREMENTS ............................................................1-1

1.1.1ENVIRONMENT................................................................................1-11.1.2MACHINE LEVEL..............................................................................1-21.1.3MINIMUM SPACE REQUIREMENTS ...............................................1-21.1.4POWER REQUIREMENTS ...............................................................1-3

1.2COPIER INSTALLATION ...........................................................................1-41.2.1POWER SOCKETS FOR PERIPHERALS ........................................1-41.2.2ACCESSORY CHECK ......................................................................1-4

D010 .....................................................................................................1-4D043 .....................................................................................................1-5

1.2.3INSTALLATION PROCEDURE .........................................................1-51.3

PLATEN COVER INSTALLATION..............................................................1-9

1.3.1ACCESSORY CHECK ......................................................................1-91.3.2INSTALLATION PROCEDURE .........................................................1-9

1.4ARDF INSTALLATION .............................................................................1-101.4.1ACCESSORY CHECK ....................................................................1-101.4.2INSTALLATION PROCEDURE .......................................................1-11

1.5TWO-TRAY PAPER TRAY UNIT INSTALLATION...................................1-141.5.1ACCESSORY CHECK ....................................................................1-141.5.2INSTALLATION PROCEDURE .......................................................1-14

1.6ONE-BIN TRAY INSTALLATION..............................................................1-161.6.1ACCESSORY CHECK ....................................................................1-161.6.2INSTALLATION PROCEDURE .......................................................1-16

1.7BRIDGE UNIT INSTALLATION................................................................1-191.7.1COMPONENT CHECK....................................................................1-191.7.2INSTALLATION PROCEDURE .......................................................1-19

Installation for a machine WITHOUT the 1-bin tray unit......................1-20Installation for a machine WITH the 1-bin tray unit .............................1-22

1.8500-SHEET FINISHER (B792) .................................................................1-24


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D010 ii SM

1.8.1ACCESSORY CHECK ....................................................................1-241.8.2INSTALLATION PROCEDURE .......................................................1-25

Installation of the 500-Sheet Finisher..................................................1-251.9

ANTI-CONDENSATION HEATER INSTALLATION..................................1-27

1.10 TRAY HEATERS ................................................................................1-28

1.10.1 TRAY HEATER..........................................................................1-281.10.2 TRAY HEATERS FOR THE OPTIONAL PAPER FEED UNIT...1-29

1.11 KEY COUNTER INTERFACE INSTALLATION ..................................1-331.12 DDST EXPANSION ............................................................................1-35

1.12.1 ACCESSORY CHECK...............................................................1-351.12.2 INSTALLING EXPANSION COMPONENT................................1-35

Installing Panels and Keys..................................................................1-361.13 PCL OPTION ......................................................................................1-38

1.13.1 ACCESSORY CHECK...............................................................1-381.13.2 INSTALLING PCL OPTION .......................................................1-38

1.14 MECHANICAL COUNTER..................................................................1-411.14.1 COMPONENT CHECK..............................................................1-411.14.2 INSTALLING MECHANICAL COUNTER...................................1-41

When removing the mechanical counter.............................................1-43

1.15 KEY COUNTER INSTALLATION (4 PINS).........................................1-44

PREVENTIVE MAINTENANCE

2. PREVENTIVE MAINTENANCE.................................................... 2-12.1PM TABLES ...............................................................................................2-1

2.1.1OPTICS.............................................................................................2-12.1.2DRUM AREA.....................................................................................2-12.1.3PAPER FEED....................................................................................2-22.1.4FUSING UNIT....................................................................................2-32.1.5ARDF.................................................................................................2-32.1.6PAPER TRAY UNIT ..........................................................................2-4

2.2HOW TO RESET THE PM COUNTER.......................................................2-5

REPLACEMENT AND ADJUSTMENT

3. REPLACEMENT AND ADJUSTMENT ........................................ 3-13.1GENERAL CAUTIONS...............................................................................3-1

Rev. 01/2009


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3.1.1PCU (PHOTOCONDUCTOR UNIT) ..................................................3-13.1.2TRANSFER ROLLER........................................................................3-13.1.3SCANNER UNIT................................................................................3-13.1.4

LASER UNIT .....................................................................................3-2

3.1.5FUSING UNIT....................................................................................3-23.1.6PAPER FEED....................................................................................3-2

3.2SPECIAL TOOLS AND LUBRICANTS .......................................................3-33.3EXTERIOR COVERS AND OPERATION PANEL......................................3-4

3.3.1REAR COVER...................................................................................3-43.3.2TRAY HARNESS COVER.................................................................3-43.3.3COPY TRAY......................................................................................3-53.3.4INNER COVER..................................................................................3-53.3.5UPPER COVERS ..............................................................................3-63.3.6LEFT COVER....................................................................................3-63.3.7FRONT COVER ................................................................................3-73.3.8FRONT RIGHT COVER ....................................................................3-73.3.9RIGHT REAR COVER.......................................................................3-83.3.10 RIGHT DOOR (DUPLEX UNIT) ...................................................3-83.3.11 BY-PASS TRAY...........................................................................3-93.3.12 RIGHT LOWER COVER............................................................3-103.3.13 PLATEN COVER SENSOR .......................................................3-10

3.4SCANNER UNIT.......................................................................................3-113.4.1EXPOSURE GLASS/DF EXPOSURE GLASS ................................3-11

Exposure Glass...................................................................................3-11DF Exposure Glass.............................................................................3-11

3.4.2LENS BLOCK..................................................................................3-113.4.3LAMP STABILIZER BOARD AND EXPOSURE LAMP ...................3-123.4.4ORIGINAL WIDTH/LENGTH SENSOR...........................................3-13

Sensor Positions.................................................................................3-14Rearranging Sensor Positions for China Model (8K/16K) ...................3-14

3.4.5SCANNER MOTOR.........................................................................3-153.4.6SCANNER HOME POSITION SENSOR.........................................3-163.4.7ADJUSTING SCANNER POSITIONS .............................................3-16

Overview.............................................................................................3-17Adjusting the First Scanner Contact Points.........................................3-18Adjusting the Second Scanner Contact Points ...................................3-18

3.5LASER UNIT ............................................................................................3-20


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3.5.1LOCATION OF CAUTION DECAL ..................................................3-203.5.2TONER SHIELD GLASS .................................................................3-203.5.3LASER UNIT ...................................................................................3-213.5.4

LD UNIT ..........................................................................................3-21

3.5.5POLYGONAL MIRROR MOTOR.....................................................3-223.5.6LASER UNIT ALIGNMENT ADJUSTMENT.....................................3-23

3.6PCU SECTION .........................................................................................3-253.6.1PCU.................................................................................................3-253.6.2PICK-OFF PAWLS AND TONER DENSITY SENSOR....................3-253.6.3OPC DRUM.....................................................................................3-273.6.4CHARGE ROLLER AND CLEANING BRUSH.................................3-283.6.5CLEANING BLADE .........................................................................3-283.6.6DEVELOPER...................................................................................3-29 3.6.7AFTER REPLACEMENT OR ADJUSTMENT..................................3-30

3.7TONER SUPPLY MOTOR........................................................................3-313.8PAPER FEED SECTION..........................................................................3-32

3.8.1PAPER FEED ROLLER: TRAY 1 ....................................................3-323.8.2PAPER FEED ROLLER: TRAY 2 ....................................................3-323.8.3FRICTION PAD ...............................................................................3-333.8.4PAPER END SENSOR....................................................................3-333.8.5UPPER/LOWER PAPER LIFT MOTORS........................................3-343.8.6EXIT SENSOR ................................................................................3-343.8.7BY-PASS FEED ROLLER AND PAPER END SENSOR.................3-353.8.8REGISTRATION ROLLER ..............................................................3-363.8.9BY-PASS PAPER SIZE SWITCH....................................................3-373.8.10 REGISTRATION CLUTCH.........................................................3-383.8.11 REGISTRATION SENSOR........................................................3-383.8.12 UPPER PAPER FEED CLUTCH AND BY-PASS FEED CLUTCH3-393.8.13 RELAY CLUTCHES...................................................................3-393.8.14 UPPER RELAY SENSOR..........................................................3-403.8.15 LOWER RELAY SENSOR.........................................................3-403.8.16 LOWER PAPER FEED CLUTCH...............................................3-413.8.17 UPPER/LOWER PAPER SIZE SENSORS................................3-413.8.18 UPPER/LOWER PAPER LIFT SENSOR...................................3-423.8.19 UPPER/LOWER PAPER HEIGHT SENSORS ..........................3-43

When reassembling the sensor bracket..............................................3-443.9

IMAGE TRANSFER..................................................................................3-45


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3.9.1IMAGE TRANSFER ROLLER .........................................................3-453.9.2IMAGE DENSITY SENSOR ............................................................3-463.9.3DISCHARGE PLATE.......................................................................3-46

Reassembling the discharge plate......................................................3-47

3.10 FUSING ..............................................................................................3-493.10.1 FUSING UNIT............................................................................3-493.10.2 THERMISTOR...........................................................................3-493.10.3 FUSING LAMPS........................................................................3-503.10.4 HOT ROLLER STRIPPER PAWLS............................................3-513.10.5 HOT ROLLER............................................................................3-513.10.6 THERMOSTAT ..........................................................................3-523.10.7 PRESSURE ROLLER AND BUSHINGS....................................3-523.10.8 NIP BAND WIDTH ADJUSTMENT ............................................3-533.10.9 CLEANING ROLLER .................................................................3-54

3.11 DUPLEX UNIT ....................................................................................3-553.11.1 DUPLEX EXIT SENSOR............................................................3-553.11.2 DUPLEX ENTRANCE SENSOR................................................3-553.11.3 DUPLEX INVERTER SENSOR .................................................3-563.11.4 DUPLEX TRANSPORT MOTOR ...............................................3-563.11.5 DUPLEX INVERTER MOTOR...................................................3-57

3.12 OTHER REPLACEMENTS.................................................................3-583.12.1 QUENCHING LAMP ..................................................................3-583.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD.............................3-583.12.3 BICU (BASE-ENGINE IMAGE CONTROL UNIT) ......................3-593.12.4 MAIN MOTOR............................................................................3-593.12.5 DUPLEX FAN ............................................................................3-603.12.6 REAR EXHAUST FAN...............................................................3-60

Replacement Procedure .....................................................................3-603.12.7 PSU (POWER SUPPLY UNIT) ..................................................3-613.12.8 GEARBOX .................................................................................3-62

Gear Arrangement in the Gearbox......................................................3-633.13 COPY ADJUSTMENTS PRINTING/SCANNING ................................3-64

3.13.1 PRINTING..................................................................................3-64Registration - Leading Edge/Side-to-Side...........................................3-64Blank Margin.......................................................................................3-65Main Scan Magnification.....................................................................3-66

3.13.2

SCANNING................................................................................3-66


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Registration: Platen Mode...................................................................3-66Magnification.......................................................................................3-67 Main Scan Magnification.....................................................................3-67Sub-Scan Magnification ......................................................................3-67

Standard White Density Adjustment ...................................................3-68

3.13.3 ARDF IMAGE ADJUSTMENT....................................................3-68Sub-scan Magnification.......................................................................3-69

TROUBLESHOOTING

4. TROUBLESHOOTING ................................................................. 4-14.1SERVICE CALL CONDITIONS ..................................................................4-1

4.1.1SUMMARY ........................................................................................4-14.1.2SC CODE DESCRIPTIONS ..............................................................4-2

4.2ELECTRICAL COMPONENT DEFECTS..................................................4-194.2.1SENSORS.......................................................................................4-194.2.2SWITCHES......................................................................................4-22

4.3BLOWN FUSE CONDITIONS ..................................................................4-244.4LED DISPLAY ..........................................................................................4-25

4.4.1BICU................................................................................................4-25

SERVICE TABLES

5. SERVICE TABLES....................................................................... 5-15.1SERVICE PROGRAM MODE.....................................................................5-1

5.1.1HOW TO ENTER THE SP MODE.....................................................5-15.2COPIER SP MODE TABLES......................................................................5-3

5.2.1SP1-XXX (FEED) ..............................................................................5-35.2.2SP2-XXX (DRUM) .............................................................................5-85.2.3SP3-XXX (PROCESS) ....................................................................5-125.2.4SP4-XXX (SCANNER) ....................................................................5-185.2.5SP5-XXX (MODE) ...........................................................................5-275.2.6SP6-XXX (PERIPHERALS).............................................................5-325.2.7SP7-XXX (DATA LOG)....................................................................5-345.2.8SP8-XXX (DATA LOG 2).................................................................5-415.2.9SP9-XXX (ETC.)..............................................................................5-46


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5.3PRINTER/SCANNER SP MODE TABLES (DDST CONTROLLER ONLY)5-475.3.1PRINTER SERVICE MODE ............................................................5-475.3.2SCANNER SYSTEM AND OTHERS...............................................5-47

5.4USING SP MODES ..................................................................................5-48

5.4.1ADJUSTING REGISTRATION AND MAGNIFICATION ..................5-485.4.2ID SENSOR ERROR ANALYSIS (SP 3310) ...................................5-485.4.3DISPLAY APS DATA (SP 4301-1) ..................................................5-495.4.4MEMORY CLEAR ...........................................................................5-50

With Flash Memory Card ....................................................................5-51Without Flash Memory Card ...............................................................5-52

5.4.5INPUT CHECK ................................................................................5-52Conducting an Input Check.................................................................5-52Input Check Table for Mainframe (SP 5803).......................................5-52Input Check Table for Finisher (SP 6124)...........................................5-56

5.4.6OUTPUT CHECK............................................................................5-58Conducting an Output Check for Mainframe.......................................5-58Output Check Table for Mainframe (SP 5804)....................................5-58Output Check Table for Finisher (SP 6128) ........................................5-60

5.4.7SERIAL NUMBER INPUT (SP 5811) ..............................................5-61Specifying Characters.........................................................................5-61

5.4.8NVRAM DATA UPLOAD/DOWNLOAD (SP 5824/5825) .................5-61Overview.............................................................................................5-62NVRAM Upload (SP 5824-1) ..............................................................5-62NVRAM Download (SP 5825-1)..........................................................5-63

5.4.9FIRMWARE UPDATE PROCEDURE..............................................5-63Engine (BICU) Firmware Update Procedure.......................................5-64DDST (Printer Scanner) Update Procedure........................................5-65

5.4.10 TEST PATTERN PRINT (SP 5902-1) ........................................5-67Executing Test Pattern Printing...........................................................5-67Test Patterns.......................................................................................5-67

5.4.11 PAPER JAM COUNTERS (SP 7504) ........................................5-695.4.12 SMC PRINT (SP 5990) ..............................................................5-715.4.13 ORIGINAL JAM HISTORY DISPLAY (SP 7508)........................5-71

Viewing the Copy Jam History ............................................................5-71Jam History Codes..............................................................................5-72

5.4.14 ADF APS SENSOR OUTPUT DISPLAY (SP 6901)...................5-72Sensor Positions.................................................................................5-72


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Reading Data......................................................................................5-73

DETAILED SECTION DESCRIPTIONS

6. DETAILED SECTION DESCRIPTIONS....................................... 6-16.1OVERVIEW ................................................................................................6-1

6.1.1COMPONENT LAYOUT....................................................................6-16.1.2PAPER PATH....................................................................................6-26.1.3DRIVE LAYOUT ................................................................................6-3

6.2BOARD STRUCTURE................................................................................6-46.2.1BLOCK DIAGRAM.............................................................................6-46.2.2BICU (BASE ENGINE AND IMAGE CONTROL UNIT) .....................6-46.2.3SBU (SENSOR BOARD UNIT)..........................................................6-5

6.3COPY PROCESS OVERVIEW...................................................................6-66.4SCANNING.................................................................................................6-8

6.4.1OVERVIEW .......................................................................................6-86.4.2SCANNER DRIVE.............................................................................6-96.4.3ORIGINAL SIZE DETECTION IN PLATEN MODE..........................6-10

6.5IMAGE PROCESSING.............................................................................6-136.5.1OVERVIEW .....................................................................................6-136.5.2SBU (SENSOR BOARD UNIT)........................................................6-146.5.3IPU (IMAGE PROCESSING UNIT) .................................................6-15

Overview.............................................................................................6-15Image Processing Modes ...................................................................6-15Image Processing Path.......................................................................6-17Original Modes....................................................................................6-18SP Modes for Each Image Processing Step .......................................6-18Auto Shading ......................................................................................6-19White Line Erase.................................................................................6-20Black Line Erase.................................................................................6-21Auto Image Density (ADS)..................................................................6-21Scanner Gamma Correction ...............................................................6-21Main Scan Magnification.....................................................................6-22Mirroring for ADF Mode ......................................................................6-22Filtering ...............................................................................................6-23ID Gamma Correction.........................................................................6-24Gradation Processing .........................................................................6-24


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6.5.4VIDEO CONTROL UNIT (VCU).......................................................6-25Fine Character and Image (FCI) .........................................................6-25Printer Gamma Correction ..................................................................6-26

6.6LASER EXPOSURE.................................................................................6-27

6.6.1OVERVIEW .....................................................................................6-276.6.2AUTO POWER CONTROL (APC)...................................................6-286.6.3LD SAFETY SWITCH......................................................................6-29

6.7PHOTOCONDUCTOR UNIT (PCU) .........................................................6-306.7.1OVERVIEW .....................................................................................6-306.7.2DRIVE .............................................................................................6-31

6.8DRUM CHARGE.......................................................................................6-326.8.1OVERVIEW .....................................................................................6-326.8.2CHARGE ROLLER VOLTAGE CORRECTION...............................6-33

Correction for Environmental Conditions ............................................6-336.8.3ID SENSOR PATTERN PRODUCTION TIMING.............................6-346.8.4DRUM CHARGE ROLLER CLEANING...........................................6-34

6.9DEVELOPMENT ......................................................................................6-356.9.1OVERVIEW .....................................................................................6-356.9.2DRIVE .............................................................................................6-366.9.3DEVELOPER MIXING.....................................................................6-366.9.4DEVELOPMENT BIAS ....................................................................6-376.9.5TONER SUPPLY.............................................................................6-38

Toner Bottle Replenishment Mechanism ............................................6-386.9.6TONER SUPPLY MECHANISM......................................................6-396.9.7TONER DENSITY CONTROL.........................................................6-39

Overview.............................................................................................6-39Toner Density Sensor Initial Setting....................................................6-42Toner Concentration Measurement ....................................................6-42Vsp/Vsg Detection ..............................................................................6-42Toner Supply Reference Voltage (Vref) Determination.......................6-42Toner Supply Determination ...............................................................6-43Toner Supply Motor On Time Determinations.....................................6-43

6.9.8TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS............6-44ID Sensor............................................................................................6-44TD Sensor...........................................................................................6-44

6.9.9TONER NEAR END/END DETECTION AND RECOVERY.............6-45Toner Near End Detection ..................................................................6-45


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Toner Near End Recovery ..................................................................6-45Toner End Detection...........................................................................6-45Toner End Recovery...........................................................................6-45

6.10

DRUM CLEANING AND TONER RECYCLING..................................6-46

6.10.1 DRUM CLEANING.....................................................................6-466.10.2 TONER RECYCLING ................................................................6-47

6.11 PAPER FEED.....................................................................................6-486.11.1 OVERVIEW................................................................................6-48 6.11.2 PAPER FEED DRIVE MECHANISM .........................................6-496.11.3 PAPER FEED AND SEPARATION MECHANISM.....................6-496.11.4 PAPER LIFT MECHANISM........................................................6-506.11.5 PAPER END DETECTION.........................................................6-516.11.6 PAPER HEIGHT DETECTION...................................................6-526.11.7 PAPER SIZE DETECTION........................................................6-53

Paper Tray ..........................................................................................6-53By-pass Tray.......................................................................................6-54

6.11.8 SIDE FENCES...........................................................................6-56Side Fences........................................................................................6-56End Fence ..........................................................................................6-56

6.11.9 PAPER REGISTRATION...........................................................6-576.11.10 TRAY LOCK MECHANISM....................................................6-57

6.12 IMAGE TRANSFER AND PAPER SEPARATION ..............................6-596.12.1 OVERVIEW................................................................................6-59 6.12.2 IMAGE TRANSFER CURRENT TIMING ...................................6-606.12.3 TRANSFER ROLLER CLEANING.............................................6-616.12.4 PAPER SEPARATION MECHANISM........................................6-62

6.13 IMAGE FUSING AND PAPER EXIT ...................................................6-636.13.1 OVERVIEW................................................................................6-63 6.13.2 FUSING UNIT DRIVE AND RELEASE MECHANISM ...............6-64

Fusing Unit Drive ................................................................................6-64Drive Release Mechanism..................................................................6-64Contact/Release Control.....................................................................6-64Drive Release Solenoid ......................................................................6-65

6.13.3 FUSING ENTRANCE GUIDE SHIFT .........................................6-666.13.4 PRESSURE ROLLER................................................................6-666.13.5 FUSING TEMPERATURE CONTROL.......................................6-67

Overview.............................................................................................6-67


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Temperature Control...........................................................................6-676.13.6 OVERHEAT PROTECTION.......................................................6-69

6.14 DUPLEX UNIT ....................................................................................6-716.14.1

OVERALL ..................................................................................6-71

6.14.2 DRIVE MECHANISM.................................................................6-726.14.3 BASIC OPERATION..................................................................6-72

Larger than A4 Short-edge/LT Short-edge..........................................6-72Up to A4 Short-edge/LT Short-edge ...................................................6-73

6.14.4 FEED IN AND EXIT MECHANISM ............................................6-756.15 ENERGY SAVER MODES OF BASIC MACHINES............................6-76

6.15.1 OVERVIEW................................................................................6-76 6.15.2 AOF ...........................................................................................6-776.15.3 TIMERS .....................................................................................6-776.15.4 RECOVERY...............................................................................6-77

6.16 ENERGY SAVER MODES OF DDST MACHINES.............................6-786.16.1 OVERVIEW................................................................................6-78 6.16.2 AOF ...........................................................................................6-796.16.3 TIMERS .....................................................................................6-796.16.4 RECOVERY...............................................................................6-79

SPECIFICATIONS

7. SPECIFICATIONS........................................................................ 7-17.1GENERAL SPECIFICATIONS....................................................................7-17.2SUPPORTED PAPER SIZES.....................................................................7-5

7.2.1ORIGINAL SIZE DETECTION...........................................................7-5North America, Europe, Asia, Taiwan...................................................7-5China, Korea.........................................................................................7-6

7.2.2PAPER FEED AND EXIT ..................................................................7-8Main Frame, Duplex..............................................................................7-8

7.3MACHINE CONFIGURATION..................................................................7-127.4OPTIONAL EQUIPMENT .........................................................................7-13

7.4.1ARDF...............................................................................................7-137.4.2TWO-TRAY PAPER TRAY UNIT ....................................................7-137.4.3ONE-BIN TRAY...............................................................................7-147.4.4BRIDGE UNIT .................................................................................7-157.4.5500-SHEET FINISHER....................................................................7-15


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D010 xii SM

B792 FINISHER SR3000

SEE SECTION B792 FOR DETAILED TABLE OF CONTENTS

D330 AUTO REVERSE DOCUMENT FEEDER DF 3020

SEE SECTION D330 FOR DETAILED TABLE OF CONTENTS

D331 PAPER FEED UNIT PB 3030


D339 1 BIN TRAY BN 3020


D340 BRIDGE UNIT BU 3010


D345 FAX OPTION TYPE 2500


D359 PRINTER/SCANNER UNIT TYPE 2500



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Read This First

Safety Notices

Important Safety Notices

Prevention of Physical Injury

1. Before disassembling or assembling parts of the copier and peripherals, make sure

that the copier power cord is unplugged.

2. The wall outlet should be near the copier and easily accessible.

3. If any adjustment or operation check has to be made with exterior covers off or open

while the main switch is turned on, keep hands away from electrified or mechanically

driven components.

4. The copier drives some of its components when it completes the warm-up period. Be

careful to keep hands away from the mechanical and electrical components as the

copier starts operation.

5. The inside and the metal parts of the fusing unit become extremely hot while the copier

is operating. Be careful to avoid touching those components with your bare hands.

Health Safety Conditions

1. Toner and developer are non-toxic, but if you get either of them in your eyes by

accident, it may cause temporary eye discomfort. Immediately wash eyes with plenty

of water. If unsuccessful, get medical attention.

2. This machine, which uses a high voltage power source, can generate ozone gas. High

ozone density is harmful to human health. Therefore, the machine must be installed in

a well-ventilated room.

Observance of Electrical Safety Standards

This machine and its peripherals must be serviced by a customer service representative

who has completed the training course on those models.

Keep the machine away from flammable liquids, gases, and aerosols. A fire or an

explosion might occur.

Safety and Ecological Notes for Disposal

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when


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exposed to an open flame.

2. Dispose of used toner, the maintenance unit which includes developer or the organic

photoconductor in accordance with local regulations. (These are non-toxic supplies.)3. Dispose of replaced parts in accordance with local regulations.

Laser Safety

The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based

optical units in the field. The optical housing unit can only be repaired in a factory or at a

location with the requisite equipment. The laser subsystem is replaceable in the field by a

qualified Customer Engineer. The laser chassis is not repairable in the field. Customer

engineers are therefore directed to return all chassis and laser subsystems to the factory or

service depot when replacement of the optical subsystem is required.

Use of controls, or adjustment, or performance of procedures other than

those specified in this manual may result in hazardous radiation exposure.

WARNING: Turn off the main switch before attempting any of the procedures in

the Laser Optics Housing Unit section. Laser beams can seriously damage your

eyes.

CAUTION MARKING:

Symbols and Abbreviations

This manual uses several symbols and abbreviations. The meaning of those symbols and

abbreviations are as follows:

See or Refer to

Clip ring


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Screw

Connector

= Clamp

E-ring

SEF Short Edge Feed

LEF Long Edge Feed


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INSTALLATION

D330 AUTO REVERSE DOC FEEDER DF3020

D345 FAX OPTION TYPE 2500


D331 PAPER TRAY UNIT PB3030


TROUBLESHOOTING

B792 FINISHER SR3000

D359 PRINTER/SCANNER UNIT TYPE 2500

SERVICE TABLES

DETAILED DESCRIPTIONS

SPECIFICATIONS

D339 1-BIN TRAY BN3020

D340 BRIDGE UNIT BU3010

TAB

POSITION

2

TAB

P

OSITION

1

TA

B

POSIT

ION

3

TAB

POSITION

4

TAB

POSITION

6

TAB

POSITION

5

TAB

PO

SITION

8

TAB

POSITION

7


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INSTALLATION

R EVIS ION H IST OR Y

Page Date Added/Updated/New

44 ~ 46 01/08/2008 New Information Key Counter Installation


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Installation Requirements

SM 1-1 D010

Installation

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

When you install or move a main machine, first remove the optional units except

for the ARDF, bridge unit, duplex unit, 1-bin tray unit and controller box from a

main machine.

Before installing options, please do the following: If there is a printer option in the machine, print out all data in the printer buffer.

Turn off the main switch and disconnect the power cord, the telephone line,

and the network cable.

1.1.1 ENVIRONMENT

Temperature and Humidity Chart

Temperature Range: 10C to 32C (50F to 89.6F)

Humidity Range: 15% to 80% RH

Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight)

Ventilation: 3 times/hr/person or more


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D010 1-2 SM

Ambient Dust: Less than 0.1 mg/m3 (2.7 x 10-6 oz/yd3)

Avoid areas exposed to sudden temperature changes:

1) Areas directly exposed to cool air from an air conditioner.

2) Areas directly exposed to heat from a heater.

Do not place the machine in areas where it can be exposed to corrosive gases.

Do not install the machine at any location over 2,000 m (6,500 ft.) above sea level.

Place the machine on a strong and level base. (Inclination on any side should be no

more than 5 mm.)

Do not place the machine where it is subjected to strong vibrations.

1.1.2 MACHINE LEVEL

Front to back: Within 5 mm (0.2") of level

Right to left: Within 5 mm (0.2") of level

1.1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing clearance as shown:

A (front): 750 mm (30")

B (left): 150 mm (6")

C (rear): 50 mm (2")

D (right): 250 mm (10")

The recommended 750 mm front space is sufficient to allow the paper tray to be pulled out.

Additional front space is required to allow operators to stand at the front of the machine.


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SM 1-3 D010

Installation

1.1.4 POWER REQUIREMENTS

Make sure that the wall outlet is near the machine and easily accessible. After

completing installation, make sure the plug fits firmly into the outlet.

Avoid multi-wiring.

Make sure the wall outlet is properly grounded.

Input voltage:

North and South America, Taiwan: 110 120 V, 60 Hz, 12 A

Europe, Asia: 220 240 V, 50/60 Hz, 7 A


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Copier Installation

D010 1-4 SM

1.2 COPIER INSTALLATION

1.2.1 POWER SOCKETS FOR PERIPHERALS

Be sure to plug the cables into the correct sockets.

[A]: Socket for ARDF (Rated voltage output max. DC24 V)

[B]: Socket for paper tray unit (Rated voltage output max. DC24 V)

1.2.2 ACCESSORY CHECK

Check that you have the accessories in this list.

D010

No. Description Qty

1 NECR-English (-17) 1

2 EU Safety Sheet (-26, -27) 1

3 Operating Instructions - Book (-17, -19, -21, -29) 1

4 Operating Instructions - CD-ROM (-17, -19, -21, -29) 1

5 Language Kit (-26, -27) 1

6 Model Name Plate (-29) 1

7 Emblem Cover (-29) 1


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Copier Installation

SM 1-5 D010

Installation

D043

No. Description Qty

1 Operating Instructions - Book 1

2 Operating Instructions - CD-ROM 1

3 Model Name Plate (-29) 1

4 Emblem Cover (-29) 1

5 Caution Sheet - CD-Driver (-29) 1

6 Sheet -EULA 1

1.2.3 INSTALLATION PROCEDURE

Unplug the machine power cord before starting the following procedure.

1. Remove filament tape and other padding.


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ARDF Installation

D010 1-10 SM

1.4 ARDF INSTALLATION


Check the quantity and condition of the accessories against the following list.

No. Description Qty

1 Scale Guide 1

2 DF Exposure Glass 1

3 Stud Screw 2

4 Knob Screw 2

5 Original Size Decal 2

6 Screwdriver Tool 1

7 Attention Decal Top Cover 1

8 Attention Decal Scanner 1

9 Cloth Holder 1

10 Cloth 1

11 Spacer*1 2

*1: The spacers are used for adjusting the trapezoid image.


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ARDF Installation

SM 1-11 D010

Installation


Unplug the copier power cord before starting the following procedure.

1. Remove the strips of tape.

2. Remove the left scale [A] ( x 2).3. Peel off the backing [B] of the double-sided tape attached to the glass holder.

4. Place the DF exposure glass [C] on the glass holder.

When installing the DF exposure glass, make sure that the painted mark [D] is

placed downward, as shown.

5. Peel off the backing [E] of the double-sided tape attached to the rear side of the scale

guide [F], then install it ( x 2 removed in step 2).

6. Install the two stud screws [G].


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ARDF Installation

D010 1-12 SM

7. Mount the DF on the copier, then slide the DF to the front as shown.

8. Secure the DF unit with two screws [H].

9. Connect the cable [I] to the copier.

10. Peel off the platen sheet [J] and place it on the exposure glass.

11. Line up the rear left corner of the platen sheet flush against corner [K] on the exposure

glass.

12. Close the ARDF.

13. Attach the appropriate scale decal [L] as shown.


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ARDF Installation

SM 1-13 D010

Installation

14. Attach the decal [M] to the top cover of the ARDF as shown, choosing the language

most suitable for the machine installed.

15. Line up the arrow on the decal [N] with the center of the ADF exposure glass as shown,

and attach it to the cover. As with step 14, choose the language most suitable for the

machine installed.

16. Attach the cloth holder [O] to the left side of the scanner as shown.

17. Insert the cloth [P] in the cloth holder.

18. Turn the main power switch on. Then check if the document feeder works properly.

19. Make a full size copy. Then check to make sure the registrations (side-to-side and

leading edge) and image skew are correct. If they are not, adjust the registrations and

image skew (refer to section 3.13.3 ARDF Image Adjustment).


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One-Bin Tray Installation

D010 1-16 SM

1.6 ONE-BIN TRAY INSTALLATION


Check the quantity and condition of the accessories.

No. Description Qty

1 Installation procedure 1

2 One-bin sorter 1

3 Exit tray 1

4 Tapping screw M3 x 6 1



1. Remove the inverter tray [A].

2. Remove the rail [B] (2 knob screws).

3. Remove the sorter cap [C] (1 rivet).


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SM 1-17 D010

Installation

4. Open the front cover [D].

5. Remove the front right cover [E] ( x 1).

6. Disconnect the connector [F].

7. Using a small cutter, cut the front cover to make an opening [G] for the 1-bin sorter.

8. Install the 1-bin sorter [H] as shown.

Make sure the connector [I] is connected firmly.

9. Fasten the screw.

10. Reconnect the connector [J] you removed in step 6.

Make sure that the connector is secure.


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D010 1-18 SM

11. Reassemble the front right cover [K].

12. Close the front cover [L].

13. Install the exit tray [M] as follows:

Keep the front end higher than the rear end.

Push the left hook into the opening of the copier.

Push the right hook into the opening of the copier.

14. Pull the support [N] out of the left end of the exit tray.

15. Insert the support into the left end of the paper exit tray [O] (of the copier).

16. Turn the main switch on.

17. Check the operation.


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Bridge Unit Installation

SM 1-19 D010

Installation

1.7 BRIDGE UNIT INSTALLATION

1.7.1 COMPONENT CHECK

No. Description Qty

1 Bridge Unit 1

2 Tapping screw: M3 x 6 1

3 Tapping screw: M3 x 8 2

4 Holder bracket 1


Unplug the copier power cord before starting the following procedure.

If you install the 1-bin tray (D339) to the machine, install the 1-bin tray first, before

installing the bridge unit (D340).

If you install the finisher unit (B792) to the machine, install the finisher unit after

installing the bridge unit (D340).


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D010 1-20 SM

Installation for a machine WITHOUT the 1-bin tray unit

1. Remove the inverter tray [A].

2. Remove the rail [B] (knob screw x 2).

3. Remove the inner cover right [C] (rivet screw x 1).

4. Remove the inner cover left [D] ( x 2).

5. Remove the inner tray [E] ( x 1). Middle screw.


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SM 1-21 D010

Installation

6. Open the front door [F].

7. Remove the front right cover [G] ( x 1).

8. Cut off the cutouts (3 pieces) [H] with small cutters.

d340i103

[K]

[I]

[J]

[L]

9. Remove the left upper cover [I] ( x 2).

10. Install the bridge unit [J] to the machine (Front side: (M3x8) x 2, Rear side: (M3x6)

x 1).

11. Connect the cables [K] to the machine ( x 2).

12. Reinstall the left upper cover ( x 2).

13. Reinstall the inner cover right if 1-bin tray unit is not installed (rivet screw x 1).

14. Reinstall the inner cover left ( x 2).

15. Install the holder bracket [L]

The holder bracket [L] is necessary when the finisher is installed. Do not

tighten it with a screw at this time.


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Tray Heaters

D010 1-28 SM

1.10 TRAY HEATERS


1.10.1 TRAY HEATER

1. Remove the 1st and 2nd tray cassettes.

2. Remove the rear cover [A] ( x 8).

3. Place the tray heater on the bottom frame inside the machine and pass the heater

harness [B] through the opening [C] of the rear frame.

4. Attach the tray heater [D] to the bottom frame ( x 1) as shown.


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Tray Heaters

SM 1-29 D010

Installation

5. Remove the harness cap [E] of the machine.

6. Connect the harness [F] that was run through the opening in step 3 of the heater to the

harness [G] of the machine.

7. Reinstall the rear cover and all tray cassettes/

8. Attach the power decal to the left side of the machine's main switch.

1.10.2 TRAY HEATERS FOR THE OPTIONAL PAPER FEED

UNIT1. Remove the rear cover of the main machine.

2. Pull out all the tray cassettes from the paper tray unit.


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Key Counter Interface Installation

D010 1-34 SM

4. Connect one side [D] of the harness to CN140 (13 pins) on the BICU and the other

side [E] of the harness to CN3 on the bridge board.

5. Clamp the harness (= x 4).

6. Reassemble the rear cover.


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PCL Option

SM 1-39 D010

Installation

2. Remove the DDST box left cover [A] ( x 7).

3. Remove the DDST box cover [B] ( x 7).

4. Install the PCL dongle [C] in the DDST board socket as shown above.

5. Turn on the DipSW2 [D] switch (upper position).

6. Remove the cover of the IC card slot on the DDST controller board.

7. Install the PCL IC card in the IC card slot.


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Mechanical Counter

SM 1-43 D010

Installation

7. Reassemble the machine.

When removing the mechanical counter

When removing the mechanical counter, first release the hook [A], and then pull it out.


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Key Counter Installation (4 PINS)

D010 1-44 SM

1.15 KEY COUNTER INSTALLATION (4 PINS)


1. Remove the left cover.

2. Remove the rear cover.

3. Cut the cap [A] with nippers.

4. Punch out the small hole [B] using a screwdriver.

5. Hold the key counter plate nuts [C] on the inside of the key counter bracket [D] and

insert the key counter holder [E].

6. Secure the key counter holder to the bracket ( x 2).

7. Install the key counter cover [F] ( x 2).

Rev. 01/2009


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Key Counter Installation (4 PINS)

D010 1-46 SM

12. Pass the relay harness through the opening [M] and reinstall the left cover.

13. Install the stepped screw [N].

14. Join the connectors [O].

15. Pass the joined connectors through the opening of the key counter holder assembly [P],

and put the connectors inside the assembly.

16. Hook the key counter holder assembly onto the stepped screw [N]. Check that the

harness is not caught between the left cover and the key counter holder assembly.

17. Secure the key counter holder assembly with the screw [Q].

Rev. 01/2009


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None


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PM Tables

SM 2-1 D010

Preventive

Maintenance

2. PREVENTIVE MAINTENANCE

2.1 PM TABLES

After preventive maintenance work, reset the PM counter (SP 7804-1).

PM intervals (60k, 120K and 600K) indicate the number of prints.

Key: AN: As necessary, C: Clean, R: Replace, L: Lubricate, I: Inspect

2.1.1 OPTICS

EM 60k 120k AN NOTE

Reflector C Optics cloth

1st mirror C C Optics cloth

2nd mirror C C Optics cloth

3rd mirror C C Optics cloth

Scanner guide rails C Do not use alcohol.

Platen cover I C

Replace the platen sheet if

necessary.

Blower brush or alcohol

Exposure glass C C Blower brush or alcohol

Toner shield glass C Blower brush

APS sensors C Blower brush

2.1.2 DRUM AREA

EM 60k 120k 600k AN NOTE

PCU I R


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PM Tables

D010 2-2 SM

EM 60k 120k 600k AN NOTE

Drum R

Developer R

Charge roller R

Cleaning brush (charge roller) R

Cleaning blade (OPC drum) R

Pick-off pawls (OPC drum) R

Transfer roller R

Discharge Plate R

ID sensor C C Blower brush

2.1.3 PAPER FEED

EM 60k 120k AN NOTE

Paper feed roller (each tray) C R CClean with water or

alcohol.

Friction pad (each tray) C R CClean with water or

alcohol.

Bottom-plate pad (each tray) C CClean with water or

alcohol.

Paper feed roller (bypass tray) C CClean with water or

alcohol.

Friction pad (bypass tray) C CClean with water or

alcohol.

Bottom-plate pad (by-pass tray) C CClean with water or

alcohol.

Registration rollers C C Clean with water or


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PM Tables

SM 2-3 D010

Preventive

Maintenance

EM 60k 120k AN NOTE

alcohol.

Relay rollers C CClean with water or

alcohol.

Paper feed guides C CClean with water or

alcohol.

Paper-dust Mylar C CClean with water or

alcohol.

2.1.4 FUSING UNIT

EM 60k 120k AN NOTE

Hot roller R/L S552R

Pressure roller R

Pressure roller cleaning

rollerR A cleaner and alcohol

Hot roller bushings I/L C S552R

Pressure roller bushing R C

Hot roller stripper pawls R C Dry cloth

Thermistor R C Dry cloth

Fusing guide plate C A cleaner and alcohol

Cleaning roller bushing C C Dry cloth

2.1.5 ARDF

EM 80k AN NOTE

Feed belt R C Clean with water or alcohol.


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PM Tables

D010 2-4 SM

EM 80k AN NOTE

Separation roller R C Clean with water or alcohol.

Pick-up roller R C Clean with water or alcohol.

Stamp R Replace when necessary.

White plate C C Clean with water or alcohol.

DF exposure glass C C Clean with water or alcohol.

Platen cover I C Clean with water or alcohol.

2.1.6 PAPER TRAY UNIT

60k 120k AN NOTE

Paper feed rollers R C Dry or damp cloth

Bottom-plate pads C C Dry cloth

Paper-feed guides C C Clean with water or alcohol.

Friction pads R C Dry or damp cloth

Relay clutch I

Feed clutches I

Relay roller C C Dry cloth


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How to Reset the PM Counter

SM 2-5 D010

Preventive

Maintenance

2.2 HOW TO RESET THE PM COUNTER

After preventive maintenance work, reset the PM counter (SP 7804-1) as follows.

Activate the SP mode ( "Service Program Mode").

1. Select SP 7804-1 (ResetPM Counter).

2. Press the OK key [A]. The message "Execute" shows.

3. Press the button [B] below the message "Execute."

4. The messages "Execute?" followed by "Cancel" and "Execute" show.


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How to Reset the PM Counter

D010 2-6 SM

5. To reset the PM counter, press the button [C] below the message "Execute."

6. Wait until the message "Completed" shows.

7. Quit the SP mode.


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None


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General Cautions

SM 3-1 D010

Replac

ement

Adjus

tment

3. REPLACEMENT AND ADJUSTMENT

3.1 GENERAL CAUTIONS

Do not turn off the main switch while any of the electrical components are active. Doing so

may result in damage to units (such as the PCU) as they are pulled out or replaced.

3.1.1 PCU (PHOTOCONDUCTOR UNIT)

The PCU consists of the OPC drum, charge roller, development unit, and cleaning

components. Observe the following precautions when handling the PCU.

1. Never touch the drum surface with bare hands. If the drum surface is dirty or if you

have accidentally touched the surface, wipe it with a dry cloth, or clean it with wet

cotton and then wipe it dry with a cloth.

2. Never use alcohol to clean the drum. Alcohol will dissolve the drum surface.

3. Store the PCU in a cool dry place.

4. Do not expose the drum to corrosive gases (ammonia, etc.).

5. Do not shake a used PCU, as this may cause toner and developer to spill out.

6. Dispose of used PCU components in accordance with local regulations.

You must run SP 3016-1 to initialize the TD sensor after you install a new PCU.

After starting initialization, be sure to wait for it to reach completion (wait for the

motor to stop) before you re-open the front cover or turn off the main switch.

3.1.2 TRANSFER ROLLER

1. Never touch the surface of the transfer roller with bare hands.

2. Be careful not to scratch the transfer roller, as the surface is easily damaged.

3.1.3 SCANNER UNIT

1. Use alcohol or glass cleaner to clean the exposure and scanning glass. This will

reduce the static charge on the glass.

2. Use a blower brush or a water-moistened cotton pad to clean the mirrors and lenses.

3. Make sure to not bend or crease the exposure lamps ribbon cable.

4. Do not disassemble the lens unit. This will cause the lens and copy image to get out of

focus.

5. Do not turn any of the CCD positioning screws. This will knock the CCD out of position.


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General Cautions

D010 3-2 SM

3.1.4 LASER UNIT

1. Do not loosen or adjust the screws securing the LD drive board on the LD unit. This will

knock the LD unit out of adjustment.

2. Do not adjust the variable resistors on the LD unit. These are adjusted at the factory.

3. The polygonal mirror and F-theta lens are very sensitive to dust.

4. Do not touch the toner shield glass or the surface of the polygonal mirror with bare

hands.

3.1.5 FUSING UNIT

1. After installing the fusing thermistor, make sure that it is in contact with the hot roller

and that the roller can rotate freely.2. Be careful to avoid damage to the hot roller stripper pawls and their tension springs.

3. Do not touch the fusing lamp and rollers with bare hands.

4. Make sure that the fusing lamp is positioned correctly and that it does not touch the

inner surface of the hot roller.

3.1.6 PAPER FEED

1. Do not touch the surface of the paper feed rollers.

2. To avoid misfeeds, the side and end fences in each paper tray must be positioned

correctly so as to align with the actual paper size.

3. The paper trays have interchangeability as following.

Standard Option

1st tray 2nd tray 3rd tray 4th tray

1st tray Yes No No NoStandard

2nd tray No Yes No No

3rd tray No No Yes YesOption

4th tray No No Yes Yes

If the optional tray heater or optics anti-condensation heater is installed, keep the

machine's power cord plugged in while the main switch is off, to keep the heater(s)

energized.


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Special Tools and Lubricants

SM 3-3 D010

Replac

ement

Adjus

tment

3.2 SPECIAL TOOLS AND LUBRICANTS

Part Number Description Qty

A0069104 Scanner Positioning Pins (4 pins/set) 1 set

A2929500 Test Chart S5S (10 pcs/set) 1 set

VSSM9000 FLUKE 87 Digital Multimeter 1

N8036701 4MB Flash Memory Card 1

A2579300 Grease Barrierta S552R 1

52039502 Grease G-501 1


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Exterior Covers and Operation Panel

D010 3-4 SM

3.3 EXTERIOR COVERS AND OPERATION PANEL

3.3.1 REAR COVER

1. Unplug the DF cable (if installed).

2. Rear cover [A] ( x 8)

3.3.2 TRAY HARNESS COVER

1. Tray harness cover [A] (1 rivet)


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SM 3-5 D010

Replac

ement

Adjus

tment

3.3.3 COPY TRAY

1. Copy tray [A] ( x 1hook x 1)

3.3.4 INNER COVER

1. Copy tray ( "Copy Tray")

2. Inner cover [A] ( x 2)


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D010 3-6 SM

3.3.5 UPPER COVERS

1. Platen Cover, ARDF, or ADF (if installed)

2. Rear cover ( "Rear Cover")

3. Front upper left cover [A] ( x 3)

4. Left upper cover [B] ( x 2)

5. Operation panel [C] ( x 4, x 1)

6. Right upper cover [D] ( x 1, 3 hooks)

Push the cover to the rear to release the hooks.

7. Top rear cover [E] ( x 1)

3.3.6 LEFT COVER

1. Left cover [A] ( x 5)


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SM 3-7 D010

Replac

ement

Adjus

tment

3.3.7 FRONT COVER

1. Pull out the (top) paper tray.

2. Open the front door [A].

3. Front cover [B] ( x 3)

3.3.8 FRONT RIGHT COVER

1. Open the front door [A].

2. Front right cover [B] ( x 1)


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D010 3-8 SM

3.3.9 RIGHT REAR COVER

1. Right upper cover ( "Upper Covers")

2. Open the duplex unit.

3. Right rear cover [A] ( x 2)

3.3.10 RIGHT DOOR (DUPLEX UNIT)


2. Open the right door [A].

3. Release the spring and chain.

4. Open the clamps [B] and disconnect the three connectors [C].

5. Right door [A]


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SM 3-9 D010

Replac

ement

Adjus

tment

3.3.11 BY-PASS TRAY

1. Right rear cover ( "Right Rear Cover")

2. Open the right door.

3. Release the by-pass tray cable from the clamps (see [B] in the preceding procedure

"Right Door") and disconnect the connector (5-pin connector with colored wires).4. Cable holder [A]

5. Front-side clip ring [B]

6. Front-side pin [C] (You can push the pin from behind the right door.)

7. Front-side tray holder arm [D]

8. Remove the rear-side clip ring, pin, and tray holder arm in the same manner.

9. By-pass tray [E]


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D010 3-10 SM

3.3.12 RIGHT LOWER COVER

1. Right lower cover [A] (2 pin)

3.3.13 PLATEN COVER SENSOR

1. Top rear cover ( "Upper Covers")

2. Platen cover sensor [A] ( x 1)


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Scanner Unit

SM 3-11 D010

Replac

ement

Adjus

tment

3.4 SCANNER UNIT

3.4.1 EXPOSURE GLASS/DF EXPOSURE GLASS

Exposure Glass

1. Front upper left cover ( "Upper Covers")

2. Left scale [A] ( x 2)

3. Rear scale [B] ( x 3)

4. Exposure glass [C]

Make sure that the mark on the exposure glass is at the rear left corner, and

that the left edge is aligned to the support on the frame when you reinstall the

exposure glass.

DF Exposure Glass

1. Front upper left cover ( "Upper Covers")

2. Left scale [A]

3. DF exposure glass [D]

Make sure that the yellow mark [E] is on the bottom at the front end when you

reinstall the DF exposure glass.

3.4.2 LENS BLOCK

Do not touch the paint-locked screws on the lens block. The position of the lens


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Scanner Unit

D010 3-12 SM

assembly (black part) is adjusted before shipment.

Do not grasp the PCB or the lens assembly when you handle the lens block. The

lens assembly may slide out of position.

1. Exposure glass ( "Scanner Unit")

2. Lens cover [A] ( x 5)

3. Disconnect the flat cable [B].

4. Lens block [C] ( x 4)

Adjust the image quality ( "Copy Adjustments Printing/Scanning") after you

install a new lens block.

3.4.3 LAMP STABILIZER BOARD AND EXPOSURE LAMP


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Scanner Unit

SM 3-13 D010

Replac

ement

Adjus

tment

1. Operation panel ( "Upper Covers")

2. Exposure glass ( "Exposure Glass/DF Exposure Glass")

3. Slide the first scanner to a position where the front end of the lamp is visible.4. Place one hand under the lamp stabilizer board [A] and release the hook [B].

5. Lamp stabilizer board ( x 1, flat cable x 1)

6. Press the plastic latch [C] and push the front end of the lamp toward the rear.

7. Lamp [D] (with the cable)

3.4.4 ORIGINAL WIDTH/LENGTH SENSOR

1. Exposure glass ( "Scanner Unit")

2. Original width sensor [A] ( x 1, x 1)

3. Lens block ( "Scanner Unit")

4. Original length sensor [B] ( x 1, x 1)


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Scanner Unit

D010 3-14 SM

Sensor Positions

Sensor positions vary according to regions as shown above.

Rearranging Sensor Positions for China Model (8K/16K)

This procedure is for China models only. You must rearrange the positions of the original

width and length sensors for the copier to detect the following original sizes:

8K SEF (270 x 390 mm)

16K SEF (195 x 270 mm)

16K LEF (270 x 195 mm)

After you have rearranged the positions, the sensors work as listed in the table. Rearrange

the sensor positions as follows:

Original Size Length Sensors Width Sensors

8K-SEF L1 L2 W1 W2

16K-SEF X X X O

16K-LEF X O O O

16K-SEF O O X O


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Scanner Unit

SM 3-15 D010

Replac

ement

Adjus

tment

1. Specify SP mode settings:

2. Select SP 4305 1, and specify 2 (=Yes).The machine will detect 8K/16K rather than A3/A4/B4/B5 (A3-SEF/B4-SEF 8K-SEF;

B5-SEF/A4-SEF 16K-SEF; B5-LEF/A4-LEF 16K-LEF).

3. Turn off the main switch.

4. Exposure glass ( "Scanner Unit").

5. Original width/length sensors [A] [B]

6. Rearrange the sensor positions [C] [D].

7. Turn on the main switch and check the operations.

3.4.5 SCANNER MOTOR


2. Right upper cover ( "Right Upper Cover")3. Exposure glass ( "Exposure Glass/DF Exposure Glass")

4. Duplex fan [A] ( x 2, x 1)

5. Scanner motor [B] ( x 3, x 1, spring x 1, belt x 1)

Install the belt first, then set the spring when you reassemble. Fasten the left-most

screw (viewed from the rear), and fasten the other two screws.

Adjust the image quality after you install the motor.


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Scanner Unit

D010 3-16 SM

3.4.6 SCANNER HOME POSITION SENSOR

1. Left upper cover, front upper cover, top rear cover ( "Upper Covers")

2. Exposure glass, DF exposure glass (if installed) ( "Exposure Glass/DF Exposure

Glass")

3. Disconnect the connector [A].4. Scanner left lid [B] ( x 7)

5. Sensor tape [C].

6. Scanner home position sensor [D]

3.4.7 ADJUSTING SCANNER POSITIONS

Grasp the front and rear ends (not the middle) of the first scanner when you

manually move it. The first scanner may be damaged if you press, push, or

pull it from the middle part.


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Scanner Unit

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Overview

Adjust the scanner positions when the first scanner [C] and second scanner [B] are not

parallel with the side frames [A], or, when you have replaced one or more of the scanner

belts.

To adjust the scanner positions, do either of the following:

To adjust the belt contact points on the first scanner ( "Adjusting the First Scanner

Contact Points" below.)

To adjust the belt contact points on the scanner bracket ( "Adjusting the Second

Scanner Contact Points" below.)

The two procedures above have the same objectives--to align the following holes and

marks:

The adjustment holes [E] [G] in the first scanner

The adjustment holes [E] [G] in the second scanner

The alignment marks [D] [F] on the frames

The scanner positions are correct when these holes and marks are aligned.


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Scanner Unit

D010 3-18 SM

Adjusting the First Scanner Contact Points

1. A(R)DF or platen cover

2. Operation panel, top rear cover ( "Upper Covers").

3. Exposure glass ( "Exposure Glass/DF Exposure Glass")

4. Loosen the 2 screws [A] [F].

5. Slide the 1st and/or 2nd scanners to align the following holes and marks:

The adjustment holes in the first scanner

The adjustment holes in the second scanner

The alignment marks on the frames

6. Insert the positioning tools [D] [E] through the holes and marks.

7. Check that the scanner belts [B] [C] [G] [H] are properly set between the bracket and

the 1st scanner.

8. Tighten the screws [A] [F].

9. Remove the positioning tools.

10. Reassemble the machine and check the operation.

Adjusting the Second Scanner Contact Points

1. A(R)DF or platen cover

2. Operation panel, top rear cover ( "Upper Covers").


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Laser Unit

D010 3-20 SM

3.5 LASER UNIT

The laser beam can cause serious damage to your eyes. Be absolutely sure

that the main power switch is off and that the machine is unplugged before

you access the laser unit.

3.5.1 LOCATION OF CAUTION DECAL

3.5.2 TONER SHIELD GLASS

1. Open the front door.


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Laser Unit

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2. Lift the toner cartridge latch [A].

3. Push the toner shield glass cover [B] to the left and pull it out.

4. Pull out the toner shield glass [C].

3.5.3 LASER UNIT

1. Toner shield glass ( "Toner Shield Glass")

2. Inner cover ( "Inner Cover")

3. Pull out the (upper) paper tray.

4. Front cover

5. Laser unit [A] ( x 2, x 4)

The screw at the left front position [B] is longer than the other three.

3.5.4 LD UNIT

Do not touch the paint-locked screw [A]. The LD position is adjusted before

shipment.


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Laser Unit

D010 3-24 SM

9. When you rotate the lever clockwise or counterclockwise by one notch of the lever, the

corners of the pattern shift by 0.4 mm (from the leading and trailing edges). See the

trim pattern made in step 2, and find how much the corners should be shifted.

10. Tighten the screw [A].

11. Tighten the screws on the laser unit.

12. Reinstall the inner cover and copy tray.

13. Print the trim pattern and check the result. Do the procedure again if further adjustment

is required.


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PCU Section

SM 3-25 D010

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3.6 PCU SECTION

3.6.1 PCU

1. Toner bottle with the holder [A]


3. Pull out the PCU [B].

Do not touch the OPC drum surface with bare hands.

4. Load new developer ( "Developer").

5. Do SP 3016-1 to reinitialize the TD sensor when you reassemble.

3.6.2 PICK-OFF PAWLS AND TONER DENSITY SENSOR

Do not turn the PCU upside down. This causes toner and developer to spill out.


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PCU Section

D010 3-28 SM

3.6.4 CHARGE ROLLER AND CLEANING BRUSH

1. OPC Drum ( "OPC Drum"))

2. Holding pin [A]

3. Stepped screw [B]

4. Charge roller [C] and cleaning brush [D] (with the holders and springs)

Turn the gear [E] (as necessary) so that the rear holder [F] comes out.5. When reassembling, adjust the image quality ( "After "Replacement or Adjustment").

3.6.5 CLEANING BLADE

1. Drum charge roller ( "Charge Roller and Cleaning Brush")

2. Cleaning blade [B] ( x 2)

3. When reassembling, adjust the image quality ( "After Replacement or Adjustment").


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PCU Section

SM 3-29 D010

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Reassembling

Apply toner to the edge of the new cleaning blade when you replace the cleaningblade. This prevents possible damage to the OPC drum and blade.

1. After installing the cleaning blade, remove some of the toner from the old

blade with your finger.

2. Apply the toner to the edge [A] of the new cleaning blade. Make sure to apply

the toner evenly along full length of the new cleaning blade.

3.6.6 DEVELOPER

1. PCU ( "PCU")

2. To allow the toner to fall to the development section, gently tap about eight different

spots on the top of the PCU with a screwdriver. Each spot must be approximately at anequal distance from the next spot.

3. Reinstall the PCU in the copier.

4. Turn the main switch on.

5. Open and close the front door and wait for the machine to rotate the development roller

for about 10 seconds.

6. Repeat the previous step two more times.

7. PCU ( PCU)

8. Separate the developer section from the OPC drum section ( "OPC Drum").


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PCU Section

D010 3-30 SM

9. Top part [A] of the development unit ( x 5)

Release the hook [B].10. Set the coupling [C] back on the shaft.

11. Turn the coupling in the direction of the arrow [D] to remove developer from the roller.

12. Turn the bottom part [E] over and rotate the gears to remove the developer.

13. Load new developer.

14. When reassembling, execute SP 3016-1 to reinitialize the TD sensor.

Make sure no toner or developer stays on the gear. Clean the gears as

necessary with a blower brush, etc.

Be sure to replace the Mylar at the rear side in the correct position. (The Mylar

protects the gears at the rear side from toner).

3.6.7 AFTER REPLACEMENT OR ADJUSTMENT

Do the following procedure after you replace or adjust any of the PCU components.

This procedure is not necessary when you replaced the whole PCU with a new

one.

1. Take 5 sample copies.

2. If black dots (dropped toner) show on any of the copies, continue as follows. (If all

copies are clean, you don't need to do the following steps.)

3. Remove the PCU from the mainframe.

4. Tap the top of the PCU with a screwdriver at eight evenly spaced locations (two or

three taps at each spot), to knock the recycled toner down into the development

section.

5. Put the PCU back into the mainframe.

6. Turn the main power on. Then open and close the door and wait for the machine to

rotate the development roller for 10 seconds. Then open and close the door two more

times, so that total rotation time is 30 seconds.

7. Make several sky-shot copies (or solid black prints).

If using A4 or 81/2" x 11" paper, make 4 copies/prints.

If using A3 or 11" x 17" paper, make 2 copies/prints.

To make solid black prints, use SP 5902 pattern 8.

Step 7 is required only after parts replacement or adjustment. You do not need

to make sky-shot (or solid black) copies after you replace the developer.


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Paper Feed Section

D010 3-32 SM

3.8 PAPER FEED SECTION

3.8.1 PAPER FEED ROLLER: TRAY 1

1. Pull out the paper tray 1 [A].

2. Pull up the stopper [B].

3. Paper feed roller [C]

3.8.2 PAPER FEED ROLLER: TRAY 2

1. Pull out the paper tray 1 and 2 [A].

2. Pull up the stopper [B].

3. Paper feed roller [C]


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Paper Feed Section

SM 3-33 D010

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3.8.3 FRICTION PAD

1. Pull out the paper tray.

2. Friction pad [A] (spring x 1)

3.8.4 PAPER END SENSOR

1. Paper cassette

2. Bracket [A] ( x 1, x 1)

3. Paper end sensor [B] (hook)


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Paper Feed Section

D010 3-38 SM

3.8.10 REGISTRATION CLUTCH

1. Rear cover

2. High-voltage power supply board bracket [A] ( x 4,= x 3, all connectors)

3. Registration clutch [B] (= x 1, x 1)

3.8.11 REGISTRATION SENSOR


2. Registration sensor [A] ( x 1)


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Paper Feed Section

D010 3-40 SM


2. Upper relay clutch [A] ( x 1, x 1)

3. Lower relay clutch [B] ( x 1, x 1)

3.8.14 UPPER RELAY SENSOR

1. Right door ( "Right Door")

2. Paper guide plate [A]

3. Paper guide frame [B] ( x 2)

4. Upper relay sensor bracket [C] ( x 1, x 1)

5. Upper relay sensor [D] (hooks)

3.8.15 LOWER RELAY SENSOR

1. Open the right lower cover [A].

2. Paper guide plate [B]

3. Lower relay sensor bracket [C] ( x 1, x 1)


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Image Transfer

SM 3-45 D010

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3.9 IMAGE TRANSFER

3.9.1 IMAGE TRANSFER ROLLER

Do not touch the transfer roller surface with bare hands


2. Release the hooks [A] at the both sides of the image transfer roller.

3. Lift the plastic holders [B] with the image transfer roller [C].

Leave the springs under the holders. Make sure that the pe

Manual de Servicio 2500

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