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Make/Model Information:

  • Brand:   Copystar
  • Models included:
    • CopyStar CS-3035
    • CopyStar CS-4035
    • CopyStar CS-5035

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English
  • Number of pages:   655
  • File size:  ∼ 31.53  MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   BMCR-1006

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CONTENTS
1-1 Specifications
1-1-1 Specifications
1-1-2 Parts names and their functions
(1) Copier
(2) Operation panel
1-1-3 Machine cross section
1-1-4 Drive system
(1) Drive system 1 (drive motor and eject motor drive trains)
(2) Drive system 2 (paper feed motor drive train)
(3) Drive system 3 (duplex section)
1-2 Handling Precautions
1-2-1 Drum
1-2-2 Toner
1-2-3 Installation environment
1-3 Installation
1-3-1 Unpacking and installation
(1) Installation procedure
1-3-2 Setting initial copy modes
1-3-3 Installing the key counter (option)
1-3-4 Installing the drawer heater (option)
1-3-5 Installing the paper feeder (option)
1-3-6 Installing the large paper deck (option)
1-3-7 Installing the booklet stitcher/switchback unit (option)
1-3-8 Installing the sheet-through document processor (option)
1-3-9 Installing the Printing System (option)
1-3-10 Installing the Scanning System (option)
1-3-11 Installing the built-in finisher (option)
1-3-12 Installing the job separator (option)
1-3-13 Installing the Facsimile System (option)
1-3-14 Installing the hard disk (option)
1-3-15 Installing the 1000-sheet finisher (option)
1-3-16 Installing the 3000-sheet finisher (option)
1-4 Maintenance Mode
1-4-1 Copier management
(1) Using the copier management mode
(2) Setting department management items
(3) Copy default
(4) Machine default
(5) Bypass setting
(6) Original size registration
(7) User adjustment
(8) Checking the total counter and printing out the counter report
(9) Doucment management default setting
(10) Hard disk management
(11) Status report print out
(12) Language selection function
1-4-2 Maintenance mode
(1) Executing a maintenance item
(2) Maintenance mode item list
(3) Contents of maintenance mode items
2FD/2FF/2FG
1-5 Troubleshooting
1-5-1 Paper misfeed detection
(1) Paper misfeed indication
(2) Paper misfeed detection conditions
(3) Paper misfeeds
1-5-2 Self-diagnosis
(1) Self-diagnostic function
(2) Self-diagnostic codes
1-5-3 Image formation problems
(1) No image appears (entirely white).
(2) No image appears (entirely black).
(3) Image is too light.
(4) Background is visible.
(5) A white line appears longitudinally.
(6) A black line appears longitudinally.
(7) A black line appears laterally.
(8) One side of the copy image is darker than the other.
(9) Black dots appear on the image.
(10) Image is blurred.
(11) The leading edge of the image is consistently misaligned with the original.
(12) The leading edge of the image is sporadically misaligned with the original.
(13) Paper creases.
(14) Offset occurs.
(15) Image is partly missing.
(16) Fixing is poor.
(17) Image is out of focus.
(18) Image center does not align with the original center.
(19) Image is not square.
1-5-4 Electrical problems
(1) The machine does not operate when the power switch is turned on.
(2) The drive motor does not operate (C2000).
(3) The paper feed motor does not operate (C2500).
(4) The eject motor does not operate
(5) The upper lift motor does not operate (C1010).
(6) The lower lift motor does not operate (C1020).
(7) The scanner motor does not operate.
(8) Cooling fan motor 1 does not operate.
(9) Cooling fan motor 2 does not operate.
(10) Cooling fan motor 3 does not operate.
(11) Cooling fan motor 4 does not operate.
(12) Cooling fan motor 5 does not operate.
(13) Cooling fan motor 6 does not operate.
(14) Cooling fan motor 7 does not operate.
(15) The upper paper feed clutch does not operate.
(16) The lower paper feed clutch does not operate.
(17) Feed clutch 1 does not operate.
(18) Feed clutch 2 does not operate.
(19) Feed clutch 3 does not operate.
(20) The bypass paper feed clutch does not operate.
(21) The bypass feed clutch does not operate
(22) The registration clutch does not operate.
(23) The duplex feed clutch does not operate.
(24) The feedshift solenoid does not operate.
(25) The toner feed solenoid does not operate.
(26) The cleaning lamp does not turn on.
(27) The exposure lamp does not turn on.
(28) The exposure lamp does not turn off.
(29) The fixing heater does not turn on (C6000).
2FD/2FF/2FG
(30) The fixing heater does not turn off.
(31) Main charging is not performed.
(32) Transfer charging is not performed.
(33) No developing bias is output.
(34) The original size is not detected.
(35) The original size is not detected correctly.
(36) The touch panel keys do not work.
(37) The message requesting paper to be loaded is shown
when paper is present in the upper drawer.
(38) The message requesting paper to be loaded is shown
when paper is present in the lower drawer.
(39) The message requesting paper to be loaded is shown
when paper is present on the bypass tray.
(40) The size of paper in the upper drawer is not displayed correctly.
(41) The size of paper in the lower drawer is not displayed correctly.
(42) The printing width of the paper on the bypass tray is not detected correctly.
(43) A paper jam in the paper feed, paper conveying or fixing section is indicated
when the power switch is turned on.
(44) The message requesting covers to be closed is displayed
when the front cover and conveying cover are closed.
(45) 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) Toner drops on the paper conveying path.
(8) Abnormal noise is heard.
1-6 Assembly and Disassembly
1-6-1 Precautions for assembly and disassembly
(1) Precautions
(2) Running a maintenance item
1-6-2 Paper feed section
(1) Detaching and refitting the forwarding, paper feed and separation pulleys
(2) Detaching and refitting the bypass separation, bypass papaer feed and
bypass forwarding pulleys
(3) Adjustment after roller and clutch replacement
(3-1) Adjusting the leading edge registration of image printing
(3-2) Adjusting the leading edge registration for memory image printing
(3-3) Adjusting the center line of image printing
(3-4) Adjusting the margins for printing
(3-5) Adjusting the amount of slack in the paper
1-6-3 Optical section
(1) Detaching and refitting the exposure lamp
(2) Detaching and refitting the scanner wires
(2-1) Detaching the scanner wires
(2-2) Refitting the scanner wires
(3) Detaching and refitting the laser scanner unit
(4) Adjusting the skew of the laser scanner unit (reference)
(5) Detaching and refitting the ISU (reference)
(6) Adjusting the position of the ISU (reference)
(7) Adjusting the longitudinal squareness (reference)
(8) Adjusting magnification of the scanner in the main scanning direction
(9) Adjusting magnification of the scanner in the auxiliary scanning direction
(10) Adjusting the scanner leading edge registration
(11) Adjusting the scanner center line
(12) Adjusting the margins for scanning an original on the contact glass
2FD/2FF/2FG-3.0
1-6-4 Drum section
(1) Detaching and refitting the drum unit
(2) Detaching and refitting the main charger unit
(3) Detaching and refitting the drum separation claw assemblies
1-6-5 Developing section
(1) Detaching and refitting the developing unit
1-6-6 Transfer section
(1) Detaching and refitting the transfer roller assembly
1-6-7 Fixing section
(1) Detaching and refitting the fixing unit
(2) Detaching and refitting the heat roller separation claws
(3) Detaching and refitting the press roller
(4) Detaching and refitting the fixing heater M and S
(5) Detaching and refitting the heat roller
(6) Detaching and refitting the fixing unit thermistor 1 and 2
(7) Adjusting front position of the fixing unit (adjusting lateral squareness)
1-6-8 Others
(1) Detaching and refitting the ozone filters (only for 230 V specifications)
1-7 Requirements on PCB Replacement
1-7-1 Upgrading the firmware on the main PCB
1-7-2 Adjustment-free variable resisters (VR)
1-7-3 Remarks on main PCB replacement
1-7-4 Upgrading the the printer board firmware
2-1 Mechanical construction
2-1-1 Paper feed section
2-1-2 Main charging section
2-1-3 Optical section
(1) Original scanning
(2) Image printing
2-1-4 Developing section
(1) Formation of magnetic brush
(2) Computing the absolute humidity
(3) Single component developing system
2-1-5 Transfer and separation sections
2-1-6 Cleaning and charge erasing sections
2-1-7 Fixing section
2-1-8 Eject and switchback sections
2-1-9 Duplex section
(1) Paper conveying operation in duplex copying
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout
(1) PCBs
(2) Switches and sensors
(3) Motors
(4) Other electrical components
2-3 Operation of the PCBs
2-3-1 Power source PCB
2-3-2 Main PCB
2-3-3 Operation unit PCB
2-3-4 Scanner drive PCB
2-3-5 CCD PCB
2FD/2FF/2FG-3.0
2-4 Appendixes
Timing chart No. 1
Timing chart No. 2
Timing chart No. 3
Timing chart No. 4
Timing chart No. 5
Timing chart No. 6
Timing chart No. 7
Timing chart No. 8
Timing chart No. 9
Timing chart No. 10
Timing chart No. 11
Chart of image adjustment procedures
Maintenance parts list
Periodic maintenance procedures
Optional devices supplied parts list
General wiring diagram
2FD/2FF/2FG-3.0
1-1-1 Specifications
Copying system
Originals
Maximum size: A3/11" 17"
Original feed system
Copy paper
Bypass table: Plain paper (45 200 g/m 2)
Special paper: Transparencies, tracing paper, colored paper, letterhead and
envelopes (when using the printer function only)
Note: Use the bypass table for special paper.
Copying sizes
Minimum: A6R/51/2" 81/2" (When the bypass table is used)
Magnification ratios
Auto copy mode: fixed ratios
1:1 1.0%, 1:4.00/1:2.00/1:1.41/1:1.22/1:1.15/1:0.86/1:0.81/1:0.70/1:0.50/1:0.25
1:1 1.0%, 1:4.00/1:2.00/1:1.29/1:1.21/1:0.78/1:0.64/1:0.50/1:0.25
Copy speed
30 cpm copier
A3/11" 17": 20 copies/min.
B4/81/2" 14": 20 copies/min.
A4/11" 81/2": 30 copies/min.
A4R/81/2" 11": 22 copies/min.
B5: 30 copies/min.
B5R: 18 copies/min.
40 cpm copier
A3/11" 17": 23 copies/min.
B4/81/2" 14": 23 copies/min.
A4/11" 81/2": 40 copies/min.
A4R/81/2" 11": 27 copies/min.
B5: 40 copies/min.
B5R: 22 copies/min.
50 cpm copier
A3/11" 17": 26 copies/min.
B4/81/2" 14": 26 copies/min.
A4/11" 81/2": 50 copies/min.
A4R/81/2" 11": 31 copies/min.
B5: 50 copies/min.
B5R: 24 copies/min.
First copy time
From 3.5 s (A4/11" 81/2") <40 cpm copier/50 cpm copier>
Warm-up time
In preheat/energy saver mode: 12 s or less (room temperature 23C/73.4F, 50%
RH) [priorty to power save]
Paper feed system
Capacity:
Drawers: 500 sheets
Manual feed
Capacity:
Bypass: 200 sheets
Continuous copying
Photoconductor
Charging system
Exposure light source
Exposure scanning system
Developing system
Developer: 1-component, magnetism toner
Developing bias: +1.72 kV AC
Developing shift bias: 160 V
Toner replenishing: automatic from a toner container
2FD/2FF/2FG-3.0
Transfer system
Separation system
Fixing system
Heat source: halogen heaters (120 V specifications:main 600 W, sub 500 W/220-240
V specifications:main 640 W, sub 534 W)
Control temperature: 175C/347F (at normal ambient temperature, 50 cpm copier)
170C/338F (at normal ambient temperature, 40 cpm copier)
165C/329F (at normal ambient temperature, 30 cpm copier)
Abnormally high temperature protection device: 170C/338F thermostat
Fixing pressure: 107.8 N
Charge erasing system
Cleaning system
Scanning system
Bit map memory
Image storage memory
Resolution
Light source
Dimensions
23" (W) 252/5" (D) 291/3" (H)
Weight
Floor requirements
591/2" (W) 252/5" (D)
Functions
mode, Zoom mode, Preset zoom mode, XY zoom mode, 2-sided copy modes, Page
separation/Split copy modes, Margin mode, Centering/Image shift mode, Memo
mode, Border erase modes, Combine/Merge Copy modes, Print page numbers
mode, Form overlay mode, Booklet/Stitching mode, Book to Booklet mode, Sort/
Finished mode, Auto rotation function, Cover mode, Transparency + backing sheet
mode, Invert mode, Mirror image mode, Proof mode, Repeat copy mode*, Batch
scanning mode, Eco print mode, Program function, Job build mode, Form
registration*, Shared data box*, Synergy print boxes*, Copy management mode,
Language selection function
*Requires the optional hard disk
Power source
220 240 V AC, 50/60 Hz, 6.5 A Max.
Power consumption
Options
finisher, booklet stitcher, built-in finisher, key counter, fax board, printer board,
network printer board, network scanner board, hard disk
2FD/2FF/2FG
Section Jam code Description Conditions
No paper feed from the
upper drawer
No paper feed from the
lower drawer
No paper feed from large
paper deck
No paper feed from pa-
per feeder upper drawer
No paper feed from pa-
per feeder lower drawer
No paper feed from by-
Jam in large paper deck
horizontal paper convey-
ing section 1
Jam in large paper deck
horizontal paper convey-
ing section 2
Jam in large paper deck
horizontal paper convey-
ing section 3
Misfeed in copier vertical
paper conveying section
Misfeed in paper feed
desk vertical paper con-
veying section
Misfeed in bypass verti-
cal paper conveying sec-
Multiple sheets in copier
paper feed section
Feed switch 1 (FSW1) does not turn on within 841 ms of the
upper paper feed clutch (PFCL-U) turning on; the clutch is
then successively turned off for 1 s and turned back on, but
the switch again fails to turn on within 841 ms.
Feed switch 2 (FSW2) does not turn on within 882 ms of the
lower paper feed clutch (PFCL-L) turning on; the clutch is
then successively turned off for 1 s and turned back on, but
the switch again fails to turn on within 882 ms.
Feed switch 3 (FSW3) does not turn on within 650 ms of pa-
per feed clutch 1 (PFCL1) turning on.
Feed switch 3 (FSW3) does not turn on within 880 ms of the
desk upper paper feed clutch (DPFCL-U) turning on; the
clutch is then successively held off for 1 s and turned back
on, but the switch again fails to turn on within 880 ms.
Desk feed switch (DFSW) does not turn on within 880 ms of
the desk lower paper feed clutch (DPFCL-L) turning on; the
clutch is then successively held off for 1 s and turned back
on, but the switch again fails to turn on within 880 ms.
The bypass feed switch (BYPFSW) does not turn on within
1730 ms of the bypass paper feed clutch (BYPPFCL) turning
on; the clutch is then successively held off for 1 s and turned
back on, but the switch again fails to turn on within 1730 ms.
Paper path sensor 3 (PPSENS3) does not turn on within 290
ms of the paper feed clutch 2 (PFCL2) turning on.
Paper path sensor 2 (PPSENS2) does not turn on within 310
ms of the paper path sensor 3 (PPSENS3) turning on.
Paper path sensor 1 (PPSENS1) does not turn on within 190
ms of the paper path sensor 2 (PPSENS2) turning on.
The registration switch (RSW) does not turn on within 936
ms of feed switch 1 (FSW1) turning on.
Feed switch 1 (FSW1) does not turn on within 1079 ms of
feed switch 2 (FSW2) turning on.
Feed switch 2 (FSW2) does not turn on within 1203 ms of
feed switch 3 (FSW3) turning on.
Feed switch 3 (FSW3) does not turn on within 888 ms of the
desk feed switch (DFSW) turning on.
The registration switch (RSW) does not turn on within 3932
ms of the bypass feed switch (BYPFSW) turning on.
Feed switch 1 (FSW1) does not turn off within the time re-
quired to convey the length of the used paper size plus 1123
ms of turning on.
Feed switch 2 (FSW2) does not turn off within the time re-
quired to convey the length of the used paper size plus 1123
ms of turning on.
Paper feed
section
CONTENTS
1-1 Specifications
1-1-1 Specifications
1-1-2 Part names
1-1-3 Machine cross section
1-1-4 Drive system
1-2 Installation
1-2-1 Unpacking
1-3 Troubleshooting
1-3-1 Paper misfeed detection
(1) Paper misfeed indication
(2) Paper misfeed detection conditions
(3) Paper misfeeds
1-3-2 Electrical problems
(1) The duplex feed clutch does not operate.
1-3-3 Mechanical problems
(1) Paper jams.
(2) Abnormal noise is heard.
1-4 Assembly and Disassembly
1-4-1 Precautions for assembly and disassembly
(1) Precautions
1-4-2 Procedure for assembly and disassembly
(1) Adjusting the margin for printing
(2) Adjusting the amount of slack at the registration roller
(3) Adjusting the center line of image printing
2-1 Mechanical construction
2-1-1 Construction of each section
(1) Paper conveying operation in duplex copying
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout
2-3 Appendixes
Periodic maintenance procedures
PARTS LIST
Published in July ’05
2FG70954
Revision 4
CS-3035/4035/5035
Contains: AD-63
J-1402
Print/Scan System (U)
FaxSystem (J)
CONTENTS
FIG. 1 EXTERIOR COVERS
FIG. 2 FRAMES
FIG. 3 CASSETTE
FIG. 4 PAPER FEED-IN SECTION I
FIG. 5 PAPER FEED-IN SECTION II
FIG. 6 PAPER FEED-IN SECTION III
FIG. 7 PAPER CONVEYING SECTION
FIG. 8 PAPER EXIT SECTION
FIG. 9 OPTICAL SECTION
FIG. 10 BYPASS UNIT
FIG. 11 BYPASS FEED UNIT
FIG. 12 LASER SCANNER UNIT
FIG. 13 DEVELOPING SECTION
FIG. 14 FIXING SECTION
FIG. 15 CLEANING SECTION
FIG. 16 DRIVING, COOLING SECTION I
FIG. 17 DRIVING, COOLING SECTION II
FIG. 18 ELECTRICAL COMPONENTS
FIG. 19 OPERATION UNIT
FIG. 20 OPTION (ORIGINAL HOLDER)
FIG. 21 OPTION I
FIG. 22 OPTION II & TOOL
INDEX


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