Ir7105 Series Rm

Jun 20 2006

Replacement Manual for Durability Enhancement Parts

iR7105/7095/7086 Series

ApplicationThis manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair

of products. This manual covers all localities where the products are sold. For this reason, there may be information in this

manual that does not apply to your locality.

CorrectionsThis manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When

changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need

arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition

of this manual.

The following paragraph does not apply to any countries where such provisions are inconsistent with local law.

TrademarksThe product names and company names used in this manual are the registered trademarks of the individual companies.

CopyrightThis manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or

translated into another language, in whole or in part, without the written consent of Canon Inc.

COPYRIGHT 2001 CANON INC.Printed in Japan

CautionUse of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction

Symbols UsedThis documentation uses the following symbols to indicate special information:

Symbol Description

Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.

Indicates an item requiring care to avoid electric shocks.

Indicates an item requiring care to avoid combustion (fire).

Indicates an item prohibiting disassembly to avoid electric shocks or problems.

Indicates an item requiring disconnection of the power plug from the electric outlet.

Indicates an item intended to provide notes assisting the understanding of the topic in question.

Indicates an item of reference assisting the understanding of the topic in question.

Provides a description of a service mode.

Provides a description of the nature of an error indication.

Memo

REF.

Introduction

The following rules apply throughout this Service Manual:1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with refer-

ence to the timing of operation.In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol , the arrow indicates thedirection of the electric signal.The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results insupplying the machine with power.

2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to indicate "Low".(The voltage value, how-ever, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'.In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessorsused in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of theDC controller PCB to the loads.

The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be com-municated in the form of Service Information bulletins.All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and beable to identify and isolate faults in the machine."

ContentsContents

Chapter 1 Replacement Parts

1.1 Durability enhancement parts list (Single parts replacement case)............................................................ 1-11.2 Durability enhancement parts list (Assembly replacement case) ............................................................. 1-10

Chapter 2 Parts Replacement Procedure

2.1 Items to Be Replaced as Instructed in the Service Manual (every 6 million, 12 million, and 18 million prints). 2-1

2.2 Items to Be Replaced as Instructed in the Service Manual (every 6 million pick-up) ................................. 2-12.3 Photosensitive Drum and Power Supply Brush Unit (every 6 million, 12 million, and 18 million prints) ..... 2-12.4 Items at the Rear of the Machine (every 6 million, 12 million, and 18 million prints) .................................. 2-22.5 Pre-Registration Roller (lower; every 6 million, 12 million, and 18 million prints) ....................................... 2-82.6 Fixing Web Solenoid/One-Way Cam (1)/Claw Reciprocating Gear (every 6 million, 12 million, and 18 million

prints).......................................................................................................................................................... 2-132.7 Outside Delivery Roller, Flapper Solenoid, and Upper Delivery Assembly (every 6 million, 12 million, and 18

million prints) .............................................................................................................................................. 2-152.8 Registration Upper Roller/Registration Collar (every 6 million and 18 million prints) ............................... 2-172.9 160-Brush Motor (every 6 million and 18 million prints)............................................................................ 2-202.10 Reciprocating Arm (every 6 million and 18 million prints) ....................................................................... 2-212.11 Registration/Transfer-Related Items (every 12 million prints)................................................................. 2-212.12 Vertical Path Swing Guide (every 12,000,000 prints) ............................................................................. 2-272.13 Main Pickup Drive Assembly (delivery 12,000,000 prints)...................................................................... 2-282.14 Drum Drive Assembly (every 12,000,000 prints) .................................................................................... 2-322.15 Drum Shaft Gear (every 12,000 prints)................................................................................................... 2-332.16 Main Drive Assembly (every 12,000,000 prints) ..................................................................................... 2-332.17 Waste Toner Pipe Assembly (every 12,000,000 prints).......................................................................... 2-382.18 Drum Intake Fan (every 12,000,000 prints) ............................................................................................ 2-392.19 Cleaner Drive Assembly (every 12,000,000 prints) ................................................................................ 2-402.20 Drum Shaft (every 12,000,000 prints)..................................................................................................... 2-422.21 Curler Drive Roller (vertical; every 1,200,000 prints) .............................................................................. 2-432.22 Vertical Path Curling Unit (every 12,000,000 prints)............................................................................... 2-432.23 Pre-registration Vertical Path Guide (every 12,000,000 prints) .............................................................. 2-472.24 Process Unit (12,000,000 prints) ............................................................................................................ 2-492.25 Developing Drive Assembly (every 12,000,000 prints) ........................................................................... 2-552.26 Fixing/Feeding Assembly Base (For 1,200,000 pc of Paper) ................................................................. 2-592.27 Fixing/Feeding Kit (For 1,200,000 pc. of Paper) ..................................................................................... 2-682.28 Duplexing Assembly (For 3 and 9 million pc of Paper) ........................................................................... 2-702.29 Dulplexing Assembly (For 6,000,000 pc. of Paper) ................................................................................ 2-722.30 Left deck pickup assembly (every 3,000,000 pickup operations) ........................................................... 2-872.31 Left deck pickup kit (Every 3,000,000 pickup operations and exclude the DC motor)............................ 2-922.32 Vertical path drive assembly (every 3,000,000 pickup operations)......................................................... 2-942.33 Lifter Driver assembly (every 3,000,000 pickup operations)................................................................... 2-952.34 Cassette pickup drive assembly (every 3,000,000 pickup operations) ................................................... 2-962.35 Manual feed tray drive assembly (every 3,000,000 pickup operations).................................................. 2-982.36 Vertical path roller assembly and Relay path guide (every 3,000,000 pickup operations) ..................... 2-992.37 Right door (Lower) unit (every 3,000,000 pickup operations) ............................................................... 2-1012.38 105-ppm/95-ppm Model DF Unit (every 2,000,000 prints; stream reading + fixed reading)................. 2-102

Contents2.39 86-ppm Model ADF (every 1,000,000 prints; stream reading).............................................................. 2-1172.40 Reader DF Unit (every 2,000,000 prints; stream reading + fixed reading) ........................................... 2-1252.41 Reader DF Unit (every 1,000,000 prints; stream reading + fixed reading) ........................................... 2-1282.42 Reader Unit (every 2,000,000 prints; stream reading + fixed reading)................................................. 2-1312.43 Reader Unit (every 1,000,000 (Stream scan)+200,000 (Fixed)........................................................... 2-1492.44 Vertical path roller assembly and Relay path guide (every 3,000,000 pickup operations), Unit Replacement

2-1592.45 Right door (Lower) unit (every 3,000,000 pickup operations), Unit Replacement ................................ 2-160

Chapter 1 Replacement Parts

Contents

Contents

1.1 Durability enhancement parts list (Single parts replacement case) ...............................................................................1-11.2 Durability enhancement parts list (Assembly replacement case) ................................................................................1-10

1.1 Durability enhancement parts list (Single parts replacement case)0013-0593

iR7105 / iR7095 / iR7086 / iR7095P / / /

T-1-1

Main Function

Expected Life (total counter)Description Parts # 6000K 12000K 18000K Symptom

Single parts

Drum

F43-8401

* * *

Lines are printed in an output image. These lines are similar to those caused by dirt on the wire of the corona assembly. Replacing the corona assembly does not remove this fault.

BRUSH UNIT

FG6-2295* * *

A smeared image or a short in the contact point occurs caused by wear in the sliding part of the brush unit.

DEVELOPING ASSEMBLY

FM2-4872

* * *

Noise, uneven density at regular interval, or toner leakage occcurs due to wear in the teeth or internal diameter of the gear.

ROLLER ASSEMBLY

FG6-5396

* * *

-0109 is displayed. (Jam Code: COPIER > DISPLAY > JAM)-Misfeeding or a jam occurs due to wear on the roller surface or decreased repulsion elasticity.

BELT, DRIVE, PAPER PICK-UP FB4-1354 * * * A pickup jam occurs.BELT, TIMING

XF9-0533 * * *Uneven density occurs at regular interval.

Fixing Feeder Unit

ROLLER, INTERNAL DELIVERY FB5-6833 * * *

Misfeeding or a jam occurs due to wear or friction change on the surface.

ROLLER, DELIVERY, OUTER FB5-3407 * * *

ROLLER, REGISTRATION, UPPER FF5-7877

* * *

FIXING WEB SOLENOID FL2-3531

* * *A failure occurs in web feeding or thermistor reciprocating mechanism due to wear in the active solenoid.

SOLENOID UNIT,1

FG6-5397

* * *

-010C is displayed. (Jam Code: COPIER > DISPLAY > JAM)-A jam occurs in straight delivery due to wear in the active solenoid.

CAM, ONE-WAY, 1 FB4-2235 * * *A scratch on the roller or defective image occurs due to wear in the cam.

GEAR, 22T FS7-0002 * * *A scratch on the roller or defective image occurs due to wear in the gear.

DELIVERY UNIT, UPPER

FM1-0668

* * *

-020A, 020B, or 010F is displayed. (Jam Code: COPIER > DISPLAY > JAM)-Misfeeding or a jam occurs due to wear in the ear roller guide.

COLLAR, REGISTRATION, LOWER FB5-7676

* * *Misfeeding, a jam, uneven density at regular interval, or skew occurs due to wear in the collar.

GEAR, 32TFS6-0056

* * *A blurred image or registration misalignment occurs due to wear in the sliding part of the gear.

Hopper Assembly

HOPPER ASSEMBLYFM2-4063

*E020/E025 is displayed. White stripes are printed in an image due to a toner supply fault.

MOTOR, DC24VFK2-0015

* *E020 is displayed. White stripes are printed in an image due to a toner supply fault.

GUIDE, VERTICAL PATH SWING, U FF6-1531 * Misfeeding (0109/0188 jam) occurs.

Drive A

Cleaner drive unit

PULLEY FU5-3434 * -E013 is displayed.-Noise or clogging of waste toner occurs due to wear in the teeth or internal diameter of the gear.-Toner leaks from the cleaner.

GEAR, 29T FU6-0959 *GEAR, 24T/40T FS7-0021 *GEAR, 24T/48T FS7-0022 *GEAR, 18T FS7-0026 *GEAR, 28T/48T FU3-0414 *GEAR, 36T FU3-0415 *GEAR, 36T FU3-0416 *

Developer drive unit

GEAR, 32T FU6-0961 * * * -E010 is displayed.-Noise or uneven density at regular interval occurs due to wear in the teeth or internal diameter of the gear.

GEAR, 23T FU6-0962 * * *GEAR, 32T FS2-0485 *GEAR, 20T FS3-0046 *GEAR, 20T FS4-0157 *PULLEY FU5-3436 *SHAFT, DEVELOPING DRIVE, 3 FB5-7375 *

CLUTCH, ELECTROMAGNETIC FH6-5017 *

GEAR, 27T FS7-0072 *

Pick up main drive unit

GEAR, 25T FU6-0963 * * * -E015 is displayed.-Noise or a blurred image occurs due to wear in the teeth or internal diameter of the gear.-Uneven registration amount at the lead edge-A jam frequently occurs in pickup operation, registration, or operation in the double-sided unit.

COUPLING, REGISTRATION FB2-7841 *

BUSHING, PL FS1-1449 *PULLEY FU5-3435 *GEAR, 40T FS3-0165 *GEAR, 20T FU6-0964 *GEAR, 32T FU6-0961 *GEAR, 20T/32T FS6-0096 *GEAR, 68T FS7-0035 *GEAR, 50T FS7-0036 *MOTOR, BRUSHLESS FH6-1935 *

Drum drive unit

GEAR, 19T/63T FS7-0010 * -E012 is displayed.-Noise or uneven density at regular interval occurs due to wear in the teeth or internal diameter of the gear.

GEAR, 49T RS6-0057 *

MOTOR, BRUSHLESS FH6-1934 *

Drum Shaft FG6-7322 * Noise or uneven density at regular interval occurs due to wear in the shaft.Drum shaft gear GEAR, 90T FS7-0011 *

Main drive unit

BELT, TIMING FB4-1766 * -E010 is displayed.-A delivery jam (010B,020B,010C,020C) occurs.

COUPLING, INPUT FB2-1047 *GEAR, 38T/36T/PULLY, 22T FB5-6895 *

PULLEY, 22T FS5-3609 *PULLEY FS5-3612 *PULLEY, 18T FS5-3890 *GEAR, 50T/24T/18T FS7-0012 *GEAR, 24T FS7-0014 *GEAR, 20T FS7-0016 *GEAR, 18T/27T FS7-0017 *GEAR, 24T FS7-0018 *GEAR, 26T FS7-0019 *GEAR, 44T FS7-0896 *GEAR, 40T FS7-0897 *GEAR, 39T FS7-0898 *MOTOR, BRUSHLESS FH6-1935 *

Waste toner pipe unit GEAR, 26T FS7-0027 * Toner leaks from the cleaner.

Drum intake fan FAN, INTAKE

FH6-1550

*

-E820 is displayed.-Double transfer occurs.-010B jam occurs frequently. (Paper does not enter the fixing assembly.)

Main Function


Drive B

Vertical roller path unit

ROLLER, VERTICAL PATH FB4-1420 * * *

GEAR, 18T FS2-0566 *

Vertical path unitMOUNT, VERTICAL PATH FF6-1516 *

Misfeeding (0109/0118: delay jam, 0205: stationary jam) occurs.

ROLLER ASSEMBLY FG6-5396 *

Pre-registration vetical guide

GUIDE, VERTICAL PATH FB4-3811 *

Misfeeding (0109/0118: delay jam, 0205: stationary jam) occurs.

PAPER FEEDER SENSOR ASSEMBLY FG6-2311 *

Main Function


Fixing feeding

Fixing Feeder Unit

INNER DELIVERY SENSOR UNIT

FM2-4876

*

-020A/010F is displayed. (Jam Code: COPIER > DISPLAY > JAM)-Misfeeding or a jam occurs due to wear in the delivery sensor lever.

COUPLING, DRIVE FB2-1035 * -Misfeeding occurs in delivery operation. (010B/020B/020A/010C/020C/010F/020D, etc.)-Noise occurs.

DEFLECTOR, 1 FB4-2305 *DEFLECTOR, 2 FB4-2306 *DEFLECTOR, 3 FB4-2307 *DEFLECTOR, 4 FB4-2308 *BELT, TIMING FB4-2314 *FLAG, SENSOR FB6-2373 *EXTERNAL DELIVERY SENSOR ASS'Y FM2-5855

*

BUSHING FS5-1803 *PULLEY, 18T FS5-3615 *GEAR, 38T FS6-0899 *GEAR, 37T FS6-0991 *GEAR, 28T/45T FS6-0992 *GEAR, 39T/46T FS6-0993 *GEAR, 16T/26T FS6-0994 *GEAR, 21T FS6-0995 *GEAR, 20T/38T FS6-0996 *GEAR, 18T FS6-0997 *GEAR, 15T/32T FS6-0998 *GEAR, 30T FS6-0999 *GEAR, 22T FS7-0002 *SENSOR, REVERSE JAM FK2-0149 *

MOTOR, BRUSHLESS FK2-1002 *GUIDE, PRE-REGISTRATION, LOWER FL2-3520

*Variation in lead edge registration changes. Misfeeding (0109/0209/010C) occurs more frequently. Printing accuracy is worsened.GUIDE, PRE-

REGISTRATION, UPPER FL2-3471

*

GUIDE, PRE-TRANSFER, LOWER FF5-7878 *

GUIDE, PRE-TRANSFER, UPPER FF6-1053 *

ROLLER, REGISTRATION, LOWER FF6-1049

*

SENSOR UNIT, PAPER FEEDER FL2-3539 *

-Transportation jam (0209/010C) that relates to the registrationunit is generated. -Resist in the image point changes. (/that becomes small grows. )

CLUTCH, ELECTROMAGNETIC FH6-5013 *

GEAR, REGISTRATION DRIVE INPUT FS7-0901

*

GEAR, 20T FS6-0081 *

BUSHINGFS6-1149

*A distorted image (lack of parallel line accuracy, right angle accuracy) or noise occurs.

PLATE, POSITIONING, FIXING FF5-7658 * A distorted image (lack of parallel line accuracy, right angle accuracy) or noise occurs.

BUSHING FS5-1798 *BUSHING FS5-1804 *BUSHING QTY2 FS5-1468 *

Main Function


T-1-2

AP Kit

CAM FB4-1622 *Toner overflows from the post corona assembly.

AP kit

ARM, RECIPROCATING FB6-2400

* * *A defective image (defective cleaning) occurs due to wear in the sliding part of the reciprocating arm.

SUPPORT, DRUM SIDE FB4-1575

*A smeared image or a short in the contact point occurs due to wear in the electric supply assembly.

PAPER FEED CLAW ASS'Y FG1-3472

*A line scratch occurs on the drum, and the similar line is printed in a solid black image.

GEAR, 14T FS6-0121 * -Noise occurs.-Toner leaks from the cleaner.GEAR, 18T FS6-0136 *

GEAR, 30T FS6-0138 *GEAR, 14T FS6-0972 *GEAR, 14T/26T FS6-0973 *GEAR, 21T FS6-0975 *GEAR, 20T FS6-0976 *GEAR, 14T/26T FS6-0977 *GEAR, 14T FS6-0978 *GEAR, 26T FS7-0048 *GEAR, 23T/39T FS7-0050 *

Duplexing Function

Expected life (actual usage)Description Parts # 3000K 6000K 9000K Symptom

Single parts

SOLENOID UNIT,3

FG6-5399

* * *

-0110 is displayed. (Jam Code: COPIER > DISPLAY > JAM)-A jam occurs in reverse delivery/double-sided delivery due to wear in the active solenoid.

ROLLER, SPONGE, DUPLEXING FF6-1520 * * *-0109 is displayed. (Jam Code: COPIER > DISPLAY > JAM)

GUIDE, REVERSE, 2 FF9-1910 * * * -020F is displayed. (Jam Code: COPIER > DISPLAY > JAM)-Misfeeding or a jam occurs due to wear on the roller surface or friction change on the surface.

ROLLER, REVERSEFF6-1519

* * *

Main Function


Duplexing Duplexing unit

GUIDE, REVERSE DELIVERY FB4-2106 *

Misfeeding (various types of jam) occurs in the double-sided unit.(**07/**11/**12/**10: delay, stationary jam, 0105 jam, 020A/020D jam)

DEFLECTOR FB4-2135 *GUIDE, DUPLEXING OUTLET FB6-0625 *

GUIDE, LEFT FF5-8202 *GUIDE, LOWER FEEDER, UPPER FF5-8200 *

ROLLER, FEEDER FB5-6925 *ROLLER, FEEDER FB6-0560 *ROLLER, FEEDER FB6-0575 *GUIDE, REVERSING, UPPER FB4-2114 *

GUIDE, LEFT DECK, LOWER FF6-1536 *

GUIDE, LEFT DECK, UPPER FB6-0525 *

PLATE, SENSOR SUPPORT FF5-7737 *

SUPPORT, FEEDER SENSOR FF6-1843 *

SUPPORT, SENSOR, FEEDER, LEFT FF6-1844 *

SENSOR UNIT, DUPLEX REVERSE FL2-3540 *

FAN, COOLING FH6-1490 *MOTOR, STEPPING FH6-1939 *MOTOR, STEPPING FH6-1940 *CLUTCH, ELECTROMAGNETIC FH6-5014 *

BUSHING, PL FS1-1401 *GEAR, 16T FS5-0338 *GEAR, 20T FS5-0514 *GEAR, 16T FS5-0710 *GEAR, 20T FS5-0714 *PULLEY, 14T FS5-3314 *GEAR, 16T/24T FS5-3613 *PULLEY, 30T FS5-3617 *GEAR, 18T/16T FS5-3942 *PULLEY, 18T FS5-3943 *GEAR, 16T FS5-3945 *GEAR, 40T FS6-0070 *GEAR, 16T FS6-0145 *

Duplexing Function

Expected life (actual usage)Description Parts # 3000K 6000K 9000K Symptom

T-1-3

T-1-4

Righ deck pick up function

Expected life (actual usage)Description Parts # 3000k Symptom

Right deck pick up unit

Right deck pick up unit FG6-8018 *

-0102 is displayed. (Jam Code: COPIER > DISPLAY > JAM)-A fault occurs in pickup operation due to defective connection caused by wear in the clutch connecting assembly.-0101 is displayed. (Jam Code: COPIER > DISPLAY > JAM)-A fault occurs in pickup operation due to wear in the active solenoid.-Noise, misfeeding, jam, or skew occurs due to a chip in the one-way part of the roller shaft.-Misfeeding (0101/0102/0114/0214/0105 jam) occurs in pickup operation.

Lifter drive unitDC MOTOR

FK2-0017*

The lifting plate in the deck is not lifted up. (Paper cannot be picked up.)

Left deck pick up function


Single parts Left deck pick up unit

CLUTCH, ELECTROMAGNETIC

FH6-5043

*

-0102 is displayed. (Jam Code: COPIER > DISPLAY > JAM)-A fault occurs in pickup operation due to defective connection caused by wear in the clutch connecting assembly.

CLUTCH, ONE-WAY FB4-9043 *Noise occurs because the one-way clutch has reached the end of its life.

SHAFT, PAPER FEEDER ROLLER FC7-4553

*Noise, misfeeding, jam, or skew occurs due to a chip in the one-way part of the roller shaft.

GUIDE, PICK-UP, LOWER FB6-0524 *

Misfeeding (0102/0202/0113/0213/0112 jam) occurs in pickup operation.

UPPER GUIDE, PICKUP FF6-1535 *

LEVER, PAPER FB2-7720 *SOLENOID FK2-0126 *GEAR, 24T FS2-0544 *GEAR, 16T FS5-0338 *PULLEY, 16T FS5-3333 *GEAR, 20T FS6-0053 *

Left deck pick up unit

Lifter drive unit DC MOTOR FK2-0017 *The lifting plage in the deck is not lifted up. (Paper cannot be picked up.)

3K left pick up unitPULLEY, 39T FS2-3494 * Misfeeding (0102/0202/0113/0213/

0112 jam) occurs in pickup operation.GEAR, 20T FS5-0514 *GEAR, 32T FS6-0056 *

T-1-5

T-1-6

T-1-7

T-1-8

Cassette pick up function


Cassette pick up

Cassette pick up unitFG9-3888

*Misfeeding (**03/**04/**07/**08: delay, stationary jam, 0106) occurs in pickup operation.

Cassette pick up drive unit

PULLEY, 39T FS2-3494 * Misfeeding (**03/**04/**07/**08: delay, stationary jam) occurs in pickup operation.

GEAR, 36T FS4-0014 *GEAR, 20T FS4-0145 *GEAR, 76T FS6-0055 *GEAR, 32T FS6-0056 *

Vertical path drive unit

GEAR, 40T FS3-0165 * Misfeeding (0203/0204/0207/0208/0206: stationary jam, 0105: delay jam) occurs in pickup operation.GEAR, 40T FS5-0398 *

Vertical path roller unit

ROLLER, VERTICAL PATH FB4-1350 *

Misfeeding (0203/0204/0207/0208/0206: stationary jam, 0105: delay jam) occurs in pickup operation. GEAR, 18T FS2-0566 *

Middle path guide

GUIDE, VERTICAL PATH, MIDDLE FB6-6578 *

Misfeeding (0203/0204/0207/0208/0206: stationary jam, 0105: delay jam) occurs in pickup operation.MOUNT, PAPER

PATH SENSOR FF5-8194 *

Righ door unit (lower)

GUIDE, VERTICAL PATH FB2-7750 *

Misfeeding (0203/0204/0207/0208/0206: stationary jam, 0105: delay jam) occurs in pickup operation.GUIDE, VERTICAL

PATH SWING, L FF6-1532 *

Reader ADF Unit (In case of replacing Reader and ADF at same time)105PPM - 95PPM - 86PPM -AB FM2-4754 AB FM2-4754 AB FM2-4754A FM2-4755 A FM2-4755 A FM2-3197inch/A FM2-4756 inch/A FM2-4756 inch/A FM2-3196inch/AB FM2-4757 inch/AB FM2-4757 inch/AB FM2-3198

Reader Unit (If Replacing Reader separately from ADF)105PPM - 95PPM - 86PPM -AB FM2-4749 AB FM2-4749 AB FM2-4749A FM2-4750 A FM2-4750 A FM2-3193inch/A FM2-4751 inch/A FM2-4751 inch/A FM2-3192inch/AB FM2-4752 inch/AB FM2-4752 inch/AB FM2-3194


T-1-9

T-1-10

T-1-11

T-1-12

T-1-13

Label (prohibitted usage) (If Replacing Reader separately from ADF)105PPM - 95PPM - 86PPM -AB FC6-0983 AB FC6-0983 AB FC6-0983A FC6-0998 A FC6-0998 A FC5-3057inch/A FC6-0984 inch/A FC6-0984 inch/A FC5-3056inch/AB FC6-0984 inch/AB FC6-0984 inch/AB FC5-3056

Service label (If Replacing Reader separately from ADF)105PPM - 95PPM - 86PPM -AB FL2-3447 AB FL2-3447 AB FL2-3447A FL2-3447 A FL2-3447 A FL2-5188inch/A FL2-3447 inch/A FL2-3447 inch/A FL2-5188inch/AB FL2-3447 inch/AB FL2-3447 inch/AB FL2-5188

ADF Unit (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FM2-2440 AB FM2-2440 AB FM2-2440A FM2-2440 A FM2-2440 A FM2-0675inch/A FM2-2440 inch/A FM2-2440 inch/A FM2-0675inch/AB FM2-2440 inch/AB FM2-2440 inch/AB FM2-0675

Size label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FL2-3447 AB FL2-3447 AB FL2-3447A FB4-8044 A FB4-8044 A FC5-3052inch/A FB4-8043 inch/A FB4-8043 inch/A FC5-3051inch/AB FC6-0992 inch/AB FC6-0992 inch/AB FC5-3062

Original set label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FB4-8042 AB FB4-8042 AB FB4-8042A FC6-0994 A FC6-0994 A -inch/A FC6-0993 inch/A FC6-0993 inch/A -inch/AB FC6-0993 inch/AB FC6-0993 inch/AB -

T-1-14

T-1-15

1.2 Durability enhancement parts list (Assembly replacement case)0013-1839

iR7105 / iR7095 / iR7086 / iR7095P / / /

ADF Stack bypass size label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FB4-8048 AB FB4-8048 AB FB4-8048A FB4-8050 A FB4-8050 A -inch/A FB4-8049 inch/A FB4-8049 inch/A -inch/AB FC6-0995 inch/AB FC6-0995 inch/AB -

ADF Stack bypass set label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FB4-8046 AB FB4-8046 AB FB4-8046A - A - A -inch/A - inch/A - inch/A -inch/AB - inch/AB - inch/AB -

T-1-16

Main Function

Expected Life (total counter)Description Parts # 6000K 12000K 18000K Remarks

Single parts kit

DRUM F43-8401 * * *BRUSH UNIT FG6-2295 * * *DEVELOPING ASSEMBLY FM2-4872 * * *ROLLER ASSEMBLY, PREREGISTRATION

FG6-5396

*

* (Not necessary to replace when replacing vertical path unit FG6-8016 at 12000K)

*

BELT, DRIVE, PAPER PICK-UP FB4-1354 * * *BELT, TIMING XF9-0533 * * *

FIXING FEED UNIT

ROLLER, INTERNAL DELIVERY FB5-6833 * *

ROLLER, DELIVERY, OUTER FB5-3407 * *

ROLLER, REGISTRATION, UPPER FF5-7877

* *

FIXING WEB SOLENOID FL2-3531 * *

SOLENOID UNIT,1 FG6-5397 * *CAM, ONE-WAY, 1 FB4-2235 * *GEAR, 22T FS7-0002 * *DELIVERY UNIT, UPPER FM1-0668 * *

COLLAR, REGISTRATION, LOWER FB5-7676

* *

GEAR, 32T FS6-0056 * *

HOPPER ASSEMBLY

HOPPER ASSEMBLY FM2-4063 *MOTOR, DC24V FK2-0015 * *

GUIDE, VERTICAL PATH SWING, U FF6-1531 *

Drive kit A

CLEANER DRIVE ASSEMBLY FM2-4877 *

DEVELOPER DRIVE UNIT

DEV. DRIVE ASSEMBLY FM2-4109 *

GEAR, 32T FU6-0961 * *GEAR, 23T FU6-0962 * *

PICH UP MAIN DRIVE UNIT

PICK-UP MAIN DRIVE ASSEMBLY FM2-4878 *

GEAR, 25T FU6-0963 * *DRUM DRIVE ASSEMBLY FG6-8008 *DRUM SHAFT FG6-7322 *DRUM SHAFT GEAR FG6-7324 *MAIN DRIVE ASSEMBLY FM2-4089 *WASTE TONER PIPE ASSEMBLY FG6-2020 *DRUM INTAKE FAN ASSEMBLY FM2-4104 *

Drive Kit B

VERTICAL ROLLER PATH UNIT FG6-1976 *ROLLER, VERTICAL PATH FB4-1420 * *VERTICAL PATH UNIT FG6-8016 *PRE-REGISTRATION VERTICAL GUIDE FG6-2242 *

T-1-17

Fixing feeding kit

FIXING/FEEDER ASSEMBLY FM2-5875 * iR7086N 100V

FM2-5874 *iR7105i 200ViR7095i 200V

FM2-6146*

iR7105 208V ULiR7095 208V ULiR7095P 208V UL

FM2-6999 * iR7086 208V UL

FM2-5876

*

iR7105 230V A/BiR7095 230V A/BiR7095 220V CNiR7105 230V GBiR7095 230V GBiR7105 220V CNiR7105 230V AUiR7095 230V AUiR7105 230V EURiR7095 230V EUR

FM2-6123*

iR7086 230V GBiR7086 230V AUiR7086 230V EUR

FM2-6149 * iR7086BFM2-6148 * iR7105B 200V

FM2-6147*

iR7095P 230V GBiR7095P 230V AUiR7095P 230V EUR

PLATE, POSITIONING, FIXING FF5-7658 *BUSHING FS5-1798 *BUSHING FS5-1804 *BUSHING QTY' 2 FS5-1468 *

AP kit POST CAM FB4-1622 *AP KIT

FM2-5870

*

iR7086N 100ViR7105i 200ViR7095i 200ViR7105 230V A/BiR7095 230V A/BiR7095 220V CNiR7105 230V GBiR7095 230V GBiR7086 230V GBiR7105 220V CNiR7105 230V AUiR7095 230V AUiR7086 230V AUiR7105 230V EURiR7095 230V EURiR7086 230V EUR

FM2-6958

*

iR7105B 200ViR7086B 100ViR7105 208V ULiR7095 208V ULiR7086 208V ULiR7095P 208V ULiR7095P 230V GBiR7095P 230V AUiR7095P 230V EUR

ARM, RECIPROCATING FB6-2400 * *

Duplexing Function

Expected life (actual usage)Description Parts # 3000K 6000K 9000K Remarks

Single parts kit

SOLENOID UNIT,3 FG6-5399 * *ROLLER, SPONGE, DUPLEXING FF6-1520 * *GUIDE, REVERSE, 2 FF5-1910 * *ROLLER, REVERSE FF6-1519 * *

Duplexing kit DUPLEX ASSEMBLY FM2-5872 *

Main Function

Expected Life (total counter)Description Parts # 6000K 12000K 18000K Remarks

T-1-18

T-1-19

T-1-20

T-1-21

T-1-22

T-1-23

Righ deck pick up function

Expected life (actual usage)Description Parts # 3000k Remarks

Right deck pick up unit

RIGHT DECK PICK UP ASSEMBLY FG6-8018 *LIFTER DRIVE ASSEMBLY FG6-2243 *

Left deck pick up function


LEFT DECK PICK UP ASSEMBLY FG9-3890 *

Left deck pick up unit

LIFTER DRIVE ASSEMBLY FG6-2243 *LEFT PICK-UP DRIVE ASSEMBLY FG6-1996 *

Cassette pick up function


CASSETTE PICK-UP ASSEMBLY (2 sets) FG9-3888 *

Cassette pick up kit

PICK-UP DRIVE ASSEMBLY FG5-4449 *VERTICAL PATH DRIVE ASSEMBLY FG6-8577 *DEVELOPING SUPPORT PLATE FG6-1975 *MIDDLE PATH GUIDE FG6-2313 *RIGHT DOOR UNIT (LOWER) FM2-4874 *

Reader ADF Unit (In case of replacing Reader and ADF at same time)105PPM - 95PPM - 86PPM -

ABFM2-4754 AB FM2-4754 AB FM2-4754

AFM2-4755 A FM2-4755 A FM2-3197

inch/AFM2-4756 inch/A FM2-4756 inch/A FM2-3196

inch/ABFM2-4757 inch/AB FM2-4757 inch/AB FM2-3198


Reader Unit (If Replacing Reader separately from ADF)105PPM - 95PPM - 86PPM -AB FM2-4749 AB FM2-4749 AB FM2-4749

T-1-24

T-1-25

T-1-26

T-1-27

A FM2-4750 A FM2-4750 A FM2-3193inch/A FM2-4751 inch/A FM2-4751 inch/A FM2-3192inch/AB FM2-4752 inch/AB FM2-4752 inch/AB FM2-3194

Label (prohibitted usage) (If Replacing Reader separately from ADF)105PPM - 95PPM - 86PPM -AB FC6-0983 AB FC6-0983 AB FC6-0983A FC6-0998 A FC6-0998 A FC5-3057inch/A FC6-0984 inch/A FC6-0984 inch/A FC5-3056inch/AB FC6-0984 inch/AB FC6-0984 inch/AB FC5-3056

Service label (If Replacing Reader separately from ADF)105PPM - 95PPM - 86PPM -AB FL2-3447 AB FL2-3447 AB FL2-3447A FL2-3447 A FL2-3447 A FL2-5188inch/A FL2-3447 inch/A FL2-3447 inch/A FL2-5188inch/AB FL2-3447 inch/AB FL2-3447 inch/AB FL2-5188

ADF Unit (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FM2-2440 AB FM2-2440 AB FM2-2440A FM2-2440 A FM2-2440 A FM2-0675inch/A FM2-2440 inch/A FM2-2440 inch/A FM2-0675inch/AB FM2-2440 inch/AB FM2-2440 inch/AB FM2-0675

Size label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FL2-3447 AB FL2-3447 AB FL2-3447A FB4-8044 A FB4-8044 A FC5-3052inch/A FB4-8043 inch/A FB4-8043 inch/A FC5-3051inch/AB FC6-0992 inch/AB FC6-0992 inch/AB FC5-3062

Reader Unit (If Replacing Reader separately from ADF)105PPM - 95PPM - 86PPM -

T-1-28

T-1-29

T-1-30

Original set label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FB4-8042 AB FB4-8042 AB FB4-8042A FC6-0994 A FC6-0994 A -inch/A FC6-0993 inch/A FC6-0993 inch/A -inch/AB FC6-0993 inch/AB FC6-0993 inch/AB -

ADF Stack bypass size label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FB4-8048 AB FB4-8048 AB FB4-8048A FB4-8050 A FB4-8050 A -inch/A FB4-8049 inch/A FB4-8049 inch/A -inch/AB FC6-0995 inch/AB FC6-0995 inch/AB -

ADF Stack bypass set label (If Replacing ADF separately from Reader)105PPM - 95PPM - 86PPM -AB FB4-8046 AB FB4-8046 AB FB4-8046A - A - A -inch/A - inch/A - inch/A -inch/AB - inch/AB - inch/AB -

Chapter 2 Parts Replacement Procedure

Contents

Contents

2.1 Items to Be Replaced as Instructed in the Service Manual (every 6 million, 12 million, and 18 million prints)..........2-12.2 Items to Be Replaced as Instructed in the Service Manual (every 6 million pick-up) ..................................................2-12.3 Photosensitive Drum and Power Supply Brush Unit (every 6 million, 12 million, and 18 million prints) ...................2-12.4 Items at the Rear of the Machine (every 6 million, 12 million, and 18 million prints) .................................................2-22.5 Pre-Registration Roller (lower; every 6 million, 12 million, and 18 million prints) .....................................................2-82.6 Fixing Web Solenoid/One-Way Cam (1)/Claw Reciprocating Gear (every 6 million, 12 million, and 18 million prints)

2-132.7 Outside Delivery Roller, Flapper Solenoid, and Upper Delivery Assembly (every 6 million, 12 million, and 18 million

prints) .............................................................................................................................................................................2-152.8 Registration Upper Roller/Registration Collar (every 6 million and 18 million prints) ..............................................2-172.9 160-Brush Motor (every 6 million and 18 million prints) ...........................................................................................2-202.10 Reciprocating Arm (every 6 million and 18 million prints) ......................................................................................2-212.11 Registration/Transfer-Related Items (every 12 million prints)..................................................................................2-212.12 Vertical Path Swing Guide (every 12,000,000 prints) ...............................................................................................2-272.13 Main Pickup Drive Assembly (delivery 12,000,000 prints) ......................................................................................2-282.14 Drum Drive Assembly (every 12,000,000 prints)......................................................................................................2-322.15 Drum Shaft Gear (every 12,000 prints) .....................................................................................................................2-332.16 Main Drive Assembly (every 12,000,000 prints) ......................................................................................................2-332.17 Waste Toner Pipe Assembly (every 12,000,000 prints) ............................................................................................2-382.18 Drum Intake Fan (every 12,000,000 prints)...............................................................................................................2-392.19 Cleaner Drive Assembly (every 12,000,000 prints) ..................................................................................................2-402.20 Drum Shaft (every 12,000,000 prints) .......................................................................................................................2-422.21 Curler Drive Roller (vertical; every 1,200,000 prints)...............................................................................................2-432.22 Vertical Path Curling Unit (every 12,000,000 prints)................................................................................................2-432.23 Pre-registration Vertical Path Guide (every 12,000,000 prints) ................................................................................2-472.24 Process Unit (12,000,000 prints)................................................................................................................................2-492.25 Developing Drive Assembly (every 12,000,000 prints) ............................................................................................2-552.26 Fixing/Feeding Assembly Base (For 1,200,000 pc of Paper) ....................................................................................2-592.27 Fixing/Feeding Kit (For 1,200,000 pc. of Paper).......................................................................................................2-682.28 Duplexing Assembly (For 3 and 9 million pc of Paper) ............................................................................................2-702.29 Dulplexing Assembly (For 6,000,000 pc. of Paper) ..................................................................................................2-722.30 Left deck pickup assembly (every 3,000,000 pickup operations)..............................................................................2-872.31 Left deck pickup kit (Every 3,000,000 pickup operations and exclude the DC motor) ............................................2-922.32 Vertical path drive assembly (every 3,000,000 pickup operations)...........................................................................2-942.33 Lifter Driver assembly (every 3,000,000 pickup operations) ....................................................................................2-952.34 Cassette pickup drive assembly (every 3,000,000 pickup operations) ......................................................................2-962.35 Manual feed tray drive assembly (every 3,000,000 pickup operations) ....................................................................2-982.36 Vertical path roller assembly and Relay path guide (every 3,000,000 pickup operations) .......................................2-992.37 Right door (Lower) unit (every 3,000,000 pickup operations) ................................................................................2-1012.38 105-ppm/95-ppm Model DF Unit (every 2,000,000 prints; stream reading + fixed reading) .................................2-1022.39 86-ppm Model ADF (every 1,000,000 prints; stream reading) ...............................................................................2-1172.40 Reader DF Unit (every 2,000,000 prints; stream reading + fixed reading) .............................................................2-1252.41 Reader DF Unit (every 1,000,000 prints; stream reading + fixed reading) .............................................................2-1282.42 Reader Unit (every 2,000,000 prints; stream reading + fixed reading) ...................................................................2-1312.43 Reader Unit (every 1,000,000 (Stream scan)+200,000 (Fixed) ..............................................................................2-1492.44 Vertical path roller assembly and Relay path guide (every 3,000,000 pickup operations), Unit Replacement ......2-159

Contents

2.45 Right door (Lower) unit (every 3,000,000 pickup operations), Unit Replacement ................................................ 2-160

2.1 Items to Be Replaced as Instructed in the Service Manual (every 6 million, 12million, and 18 million prints)

0012-5061iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Be Replaced as Instructed in the Service Manual- developing assembly (FM2-4872)- inside delivery roller (FB5-6833)- registration roller (upper; FF5-7877)- registration clutch (FH6-5013)

2. Replacement ProcedureRefer the Service Manual.2.2 Items to Be Replaced as Instructed in the Service Manual (every 6 million pick-

up)0012-9792

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Be Replaced as Instructed in the Service Manual- Right deck pick-up assembly (FG6-8018)- Cassette pick-up assembly (FG9-3888)

2. Replacement ProcedureRefer the Service Manual.2.3 Photosensitive Drum and Power Supply Brush Unit (every 6 million, 12 million,

and 18 million prints)0012-5060

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- photosensitive drum (F43-6601)- power supply brush unit (FG6-2295)

2. Replacement Preparation

1) Replace the photosensitive drum unit.

3. Replacement Procedure

1) Remove the flange [2] found at the front. 2 mounting screws [1] 1 connector [3]

F-2-12) Remove the power supply unit [2] from the photosensitive drum. Pull off the flange [1] found at the rear.

[1]

[2]

[3]

F-2-23) Pull out the flat heater (drum heater) [1] found inside the photosensitive drum [2].

F-2-34) Remove the power supply brush unit [1]. 2 fastons [2] 2 screws [3]

F-2-4

2.4 Items at the Rear of the Machine (every 6 million, 12 million, and 18 millionprints)

0012-5163iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- pickup drive timing belt (FB4-1354)

[1]

[2]

[1]

[1]

[2]

[3]

- main drive timing belt (XF9-0533)- developing input gear (FU6-0962)- 32T gear (3 pc; FU6-0961)- limiter gear (FU6-0963)2. Replacement Preparation

Remove the rear cover.Remove the high-voltage unit.Remove the power supply cord mount.Open the controller box.


3-1 Pickup Drive Timing Belt (FB4-1354)/Main Drive Timing Belt (XF9-0533)

1) Remove the sub side plate [1]. 1 re-use band [2] 2 connectors [3] 4 screws [4]

F-2-52) Remove the waste toner case mount [1]. 5 connectors [2] 6 screws [3]

F-2-63) Remove the high-voltage unit mount [1]. 2 fastons [2] 2 cable clamps [3] 2 screws [4]

[1]

[2]

[4]

[4]

[3]

[1]

[2]

[2]

[2][3]

F-2-7

F-2-84) Detach the pickup drive timing belt [1].

F-2-95) Remove the fly wheel [1]. 2 screws [2]

F-2-106) Remove the main drive timing belt [1].

[1]

[2]

[1]

[2]

[1]

[1]

[2]

F-2-113-2 Developing Input Gear (FU6-0962)/32T Gear (FU6-0961) Refer to "the develop assembly drive assembly (12 million sheets)" at 12 million-sheet.

1) Remove the developing drive assembly. (See the Service Manual.)2) Remove the developing input gear [1]. 1 E-ring [2] 1 bearing [3]

F-2-123) Remove the clutch support plate [1]. 2 connectors [2] 1 wire saddle [3] 2 edge saddles [4] 5 screws [5]

F-2-134) Remove the developing cylinder clutch [1] and the developing cylinder deceleration clutch [2].

[1]

[1]

[2]

[3]

[1]

[2]

[2]

[3][4]

[4]

[5]

[5]

[5]

F-2-145) Remove 27T gear [1]. 1 E-ring [2]

F-2-156) Remove the 32T gear [1]. 1 E-ring [2] 1 bearing [3] 2 E-rings [4]

F-2-167) Remove the pulley [1]. 1 E-ring [2] 1 flange [3]

F-2-178) Remove the 32T gear [1].

[1][2]

[1][2]

[1]

[2]

[3][4]

[1]

[2]

[3]

F-2-189) Remove the gear support plate [1]. 6 screws [2]

F-2-1910) Remove the gear shaft [1].

F-2-2011) Remove the 32T gear [1]. 1 bearing [2] 2 E-rings [3]

F-2-213-3 Limiter Gear (FU6-0963)1) Remove the waste toner box mount [3]. 4 connectors [2] 5 screws [1]

[1]

[2]

[2]

[2]

[2][1]

[1]

[1]

[2]

[3]

[4]

[4]

[5]

F-2-222) Shift the cord guide [1]. 2 screws [2]

F-2-233) Remove the limiter gear [1]. A parallel pin is found behind the limiter gear. Take care not to drop it. 1 E-ring [2]

F-2-24

Go through the following steps to remove the curler drive roller before mounting the developing drive assembly.

2.5 Pre-Registration Roller (lower; every 6 million, 12 million, and 18 million prints)0012-5065

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to replace- pre-registration roller (lower; FG6-5396)- pre-registration roller (upper; FG6-5396)- curler drive roller(FB4-1420)


Remove the right pickup unit.


[1]

[2]

[2]

[2][3]

[1]

[2]

[1][2]

3-1 Removing the Pre-Registration Roller (lower)

1) Remove the cable cover [1].3 screws [2]

F-2-252) Free the cable [1]. 1 cord clamp (large) [2] 2 cord clamps (small) [3]

F-2-263) Remove the pre-registration roller unit (lower) [1]. 3 screws [2] 1 retaining plate (front) [3] 1 retaining plate (rear) [4] 1 connector [5] 2 mini-clamps [6] 1 edge saddle [7]

F-2-27

[1][2]

[1]

[2] [3]

[1]

[3] [4]

[2]

[2]

F-2-284) Remove the pre-registration roller (lower) [1] together with its attachments. 1 spring [2] each at front and rear 1 spring [3] 1 E-ring [4] 1 pin [5]

F-2-295) Remove the pre-registration roller [1]. 2 E-rings [2] 2 washers [3] 2 bearings [4]

F-2-303-2 Removing the Pre-Registration Roller (upper)1) Remove the retaining plate (rear) A [1].

[5][6][7]

[1]

[2] [3]

[4]

[5]

[1]

[2]

[3]

[4]

1 screw [2]

F-2-312) Remove the retaining plate (rear) B [1].

F-2-323) Remove the pre-registration roller unit [1].

F-2-334) Remove the pre-registration roller [1]. 2 E-rings [2] 2 washers [3] 2 bearings [4]

[1]

[2]

[1]

[1]

F-2-343-3 Removing the Curler Drive Roller1) Remove the curler drive roller [1] together with its attachments. Remove the E-ring [2], and shift the shaft in the direction of the hole [3].

F-2-352) Detach the following from the curler drive roller [1]. 4 E-rings [2] 1 gear [3] 1 parallel pin [4] 4 bearings [5]

[1]

[2]

[3]

[4]

[1]

[1] [2]

[3]

F-2-36

2.6 Fixing Web Solenoid/One-Way Cam (1)/Claw Reciprocating Gear (every 6million, 12 million, and 18 million prints)

0012-5193iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- web solenoid (FK2-0976)- one-way cam (1; FB4-2235)- claw reciprocating gear (FS7-0002)2. Replacement PreparationRemove the fixing feeding unit cover.

3. Replacement Procedure1) Remove the fixing motor unit [1]. 2 connectors [2] 2 edge saddles [3] 5 screws [4]

F-2-372) Remove the clutch support plate [1]. 2 connectors [2] 2 screws [3] 2 edge saddles [4]

[1]

[2]

[2]

[2][3]

[4]

[5]

[5]

[5][5]

[1]

[4] [2]

[4]

[4] [3]

[3]

F-2-383) Remove the fixing web solenoid assembly [1]. 2 screws

F-2-394) Remove the fixing web solenoid [1]. 2 screws [2]

F-2-405) Remove the one-way cam [1]. 1 one-way cam (2) [2] 1 spring [3]

F-2-416) Remove the clutch [1].

[2]

[3]

[1]

[3] [4]

[1]

[2]

[1]

[2]

[1]

[2]

[3]

F-2-427) Remove the claw reciprocating gear [1]. 2 E-rings [2] 2 gears [3]

F-2-43

2.7 Outside Delivery Roller, Flapper Solenoid, and Upper Delivery Assembly (every6 million, 12 million, and 18 million prints)

0012-5313iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- outside delivery roller (FB5-3407)- flapper solenoid (FG6-5397)- upper delivery assembly (FM1-0668)


Remove the fixing/transport unit cover.


1) Remove the E-ring [2].2) Open the upper delivery assembly [1].

F-2-443) Remove the upper delivery assembly [1]. 1 screw [2] 1 positioning pin [3]

[1]

[1]

[2]

[3]

[1]

[2]

F-2-454) Remove the delivery roller guide [1]. 3 screws [2]

F-2-465) Remove the flapper solenoid unit [1]. 1 connector [2] 2 screws [3]

F-2-476) Remove the flapper solenoid [1]. 1 re-use band [2] 1 connector [3] 2 screw [4]

F-2-487) Slide the bearing [1] in the direction of the gear. E-ring [2] at front

[1] [2][3]

[1]

[2]

[1]

[3]

[2]

[1]

[2]

[4][3]

F-2-498) Remove the outside delivery roller assembly [3]. Slide the E-ring [1] and the bearing [2] found at the rear toward the rear.

F-2-509) Remove the 6 outside rollers [5]. 1 E-ring [1] at rear of roller shaft one-way gear [2] bearing [3] 6 E-rings [4] of rollers

F-2-51

Take care not to lose the parallel pins of the rollers.

2.8 Registration Upper Roller/Registration Collar (every 6 million and 18 millionprints)

0012-5320iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- registration collar (front, rear; FB5-7676)- registration upper roller (FF5-7877)


Remove the fixing/transport unit cover.

3. Replacement Procedure3-1. Removing of the registration upper roller1) Remove the transfer / separation corona assembly.

[2] [1]

[2][1]

[3]

[5]

[5]

[4]

[4]

[3]

[2] [1]

2) Remove the registration clutch [1].1 connector [2]Loosen 2 hex nuts [3]

F-2-523) Remove the 32T gear [1].1 C-ring [2]

F-2-534) Remove the bushing [1].1 C-ring [2]1 spring [3]

F-2-545) Remove the clutch cover [1].1 screw [2]1 connector [3]

[1]

[2]

[3]

[1] [2]

[1] [2]

[3]

F-2-556) Remove the registration brake clutch [1].Loosen 2 hex nuts [2]


F-2-578) Remove the registration upper roller [1] and the transfer front guide (upper) together.

F-2-589) Detach the registration upper roller [2] from the transfer front guide (upper) [1].

[1] [2] [3]

[1]

[2]

[1] [2]

[3]

[1]

F-2-593-2. Removing the registration collar1) Remove the registration collar (front) [1].

F-2-603) Remove the registration collar (rear) [1].

F-2-61

2.9 160-Brush Motor (every 6 million and 18 million prints)0012-5465

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- 160-brush motor (FK2-0015)

2. Replacement PreparationRemove the sub hopper (snap-on).


1) Remove the upper frame [1] from the sub hopper. 9 screws [2]

[1]

[2]

[1]

[1][2]

F-2-622) Remove the 160-brush motor [1]. 1 connector [2] 3 screws [3]

F-2-63

2.10 Reciprocating Arm (every 6 million and 18 million prints)0012-5671

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- reciprocating arm (FB6-2400)

2. Replacement PreparationSlide out the process unit.

3. Replacement Procedure1) Remove the reciprocating arm [1]. 1 screw [2]

F-2-64

2.11 Registration/Transfer-Related Items (every 12 million prints)0012-5333

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Items to Replace- registration collar (front, rear; FB5-7676)- registration upper roller (FF5-7877)- pre-registration guide (upper; FL2-3471)- pre-registration guide (lower; FL2-3520)- pre-transfer guide (upper; FF6-1053)- pre-transfer guide (lower; FF5-7878)- registration lower roller (FF6-1049)

[1]

[2]

[2]

[1]

[2]

[3]

[1][2]

- registration clutch (FH6-5013)- transport sensor flag (FL2-3539)- clutch drive gear (32T gear; FS6-0056)- 8500 Registration Driving Input Gear (FS7-0901)

2. Replacement PreparationRemove the fixing/transport unit cover.

3. Replacement Procedure3-1. Removing of the registration upper roller, the clutch drive gear and the pre-transfer guide (upper)1) Remove the transfer / separation corona assembly.2) Remove the registration clutch [1].1 connector [2]Loosen 2 hex nuts [3]

F-2-653) Remove the clutch drive gaer (32T gear) [1].1 C-ring [2]


F-2-675) Remove the clutch cover [1].1 screw [2]1 connector [3]

[1]

[2]

[3]

[1] [2]

[1] [2]

[3]

F-2-686) Remove the registration brake clutch [1].Loosen 2 hex nuts [2]


F-2-708) Remove the registration upper roller [1] and the transfer front guide (upper) together.

F-2-719) Detach the registration upper roller [2] from the transfer front guide (upper) [1].

[1] [2] [3]

[1]

[2]

[1] [2]

[3]

[1]

F-2-723-2. Removing of the other parts1) Remove the registration collar (front) [1].

F-2-732) Remove the registration collar (rear) [1].

F-2-743) Remove the screw [1], the screw from the side [2], and the grounding screw [3].

F-2-754) Remove the registration/transfer unit [2]. Take the bushing [1] out of the groove. 1 E-ring [3]

[1]

[2]

[1]

[1][2]

[1]

[3]

[2]

1 bushing [4]

F-2-765) Remove the pre-registration guide (upper) [1]. 1 joint bar [3] by removing 2 screws [2]

F-2-776) Remove the transport sensor flag unit [1]. 2 screws [2]

F-2-787) Detach the transport sensor [1] connected to the transport sensor flag unit. 1 transport sensor flag [2]

[1]

[2]

[3][4]

[1]

[2]

[2]

[3]

[1]

[2]

F-2-798) Remove the 8500 Registration Driving Input Gear [1]. 1 E-ring [2]

F-2-809) Remove the pre-registration guide (lower) [1]. 4 position pins [3] by removing 4 screws [2]

F-2-8110) Remove the pre-transfer guide (lower) [1]. 2 position pins [3] by removing 2 screws [2]

[1]

[2]

[1][2]

[1]

[2]

[2][2]

[3]

[3]

[3][3]

F-2-8211) Remove the registration lower roller [1]. 2 E-rings [2] 2 washers [3] 2 bearings [4]

F-2-83

2.12 Vertical Path Swing Guide (every 12,000,000 prints)0012-6685

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- vertical path swing guide (upper; FF6-1531)


1) Open the vertical path guide door.

2) Remove the vertical path swing guide (upper) [1]. snapped in place

[1]

[2]

[2]

[3]

[3]

[1]

[2]

[3][4]

[2]

[3][4]

F-2-843) Remove the 2 springs [1] and the roll [2] from the vertical path swing guide (upper). snapped in place

F-2-85

2.13 Main Pickup Drive Assembly (delivery 12,000,000 prints)0012-6436

iR7105 / iR7095 / iR7086 / iR7095P / / /

Parts to Replace- limiter gear (FU6-0963)- registration coupling (FB2-7841)- bearing (FS1-1449)- S3M39T (6) pulley (FU5-3435)- 40T gear (FS3-0165)- swing gear (FU6-0964)- 32GT gear (FU6-0961)- 20-32T gear (FS6-0096)- 68T helical gear (FS7-0035)- 50T gear (FS7-0036)- DC brushless motor (FH6-1935)

2. Before Starting the WorkRemove the Main pickup drive assembly (refer the service manual).

3. Replacement Procedure3-1 Removing the DC Brushless Motor1) Remove the DC brushless motor [1]. 4 screws w/ washer [2]

F-2-863-2 Removing the S3M39T (6) Pulley1) Remove the S3M39T (6) pulley [1]. Take care not to drop the parallel pin.

[1]

[1]

[2]

[2]

[2][1]

[2]

[2]

1 E-ring [2]

F-2-873-3 Removing the Limiter Gear, 30-32T Gear1) Remove the limiter gear [1]. Take care not to drop the parallel pin. 1 E-ring [2]

F-2-882) Remove the gear retaining plate [1]. 2 screws [2]

F-2-893) Remove the 20-32T gear [1] 1 E-ring [2]

F-2-903-4 Removing the 68T Helical Gear, 50T Gear

[1]

[2]

[1]

[2]

[1]

[2]

[1]

[2]

1) Remove the motor support plate [1]. 4 screws [2]

F-2-912) Remove the 68T helical gear [1]. Take care not to drop the parallel pin. 1 E-ring [2] 2 hex screws [3]

F-2-923) Remove the 2 50T gears [1]. 1 E-ring [2] each

F-2-933-5 Removing the Swing Gear, Registration Coupling1) Remove the swing gear [1]. Take care not to drop the parallel pin. 1 E-ring [2]

F-2-942) Remove the E-ring [1] from the back of the unit.

[1][2]

[2]

[1]

[2]

[1]

[2]

[1]

[2]

F-2-953) Remove the registration coupling [1]. 1 E-ring [2]

F-2-963-6 Removing the Swing Gear, 50T Gear, 40T Gear1) Pull out the shaft [1] fitted with a coupling. 1 E-ring [2]

F-2-972) Remove the retaining plate [1]. 7 screws [2]

F-2-983) Remove the 7 50T gears [1] and the 40T gear [2]. 1 E-ring each

[1]

[1]

[1]

[1] [2]

[2]

[2]

[2]

F-2-994) Remove the swing gear [1]. 1 E-ring [2]

F-2-100

2.14 Drum Drive Assembly (every 12,000,000 prints)0012-6742

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- D1 gear (FS7-0010)- B sleeve drive gear 2 (RS6-0057)- DC brushless motor (FH6-1934)

2. Before Starting the WorkRemove the drum drive assembly. (Refer to the Service Manual.)

3. Replacement Procedure3-1 Removing the DC Brushless Motor1) Remove the DC brushless motor [1]. 2 connectors [2] 4 M3 screws [3]

F-2-1013-2 Removing the B Sleeve Drive Gear 2, and D1 Gear1) Remove the gear support plate [1]. 5 screws [2]

[1]

[1]

[1]

[1]

[2]

[3]

[2]

[3]

[1]

F-2-1022) Remove the D1 gear [1] and the B sleeve drive gear 2 [2]. 1 E-ring [3] each

F-2-103

2.15 Drum Shaft Gear (every 12,000 prints)0012-6744

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- 90T gear (FS7-0011)

2. Before Starting the Work

Remove the drum shaft gear (90T gear) together with its holder. (See the instructions under "Removing the Drum Drive Assembly" of the Service Manual.)

3. Replacement Procedure1) Remove the drum shaft gear (90T gear) [1]. 2 screws [2]

F-2-104

2.16 Main Drive Assembly (every 12,000,000 prints)0012-6746

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- fixing drive belt (FB4-1766)- input coupling (FB2-1047)- T1 gear pulley(8500) (FB5-6895)- pulley 22T (FS5-3609)- tension pulley (FS5-3612) 18T pulley (FS5-3890)- M1 gear (FS7-0012)- M3 gear (FS7-0014)- H1 gear (FS7-0016)

[1]

[2]

[2]

[2]

[1]

[2]

[3]

[1][2]

- H2 gear (FS7-0017)- H3 gear (FS7-0018)- H4 gear (FS7-0019)- F1 gear (FS7-0896)- 40T gear (FS7-0897)- 39T gear (FS7-0898)- DC brushless motor (FH6-1935)

2. Before Starting the Work1) Remove the waste toner drive assembly. (See the Service Manual.)2) Remove the main drive assembly [1]. 2 connectors [2] 2 wire saddles [3] 8 screws [4]

F-2-1053. Replacement Procedure3-1 Removing the DC brushless Motor, 18T Pulley, and H4 Gear1) Remove the DC brushless motor [1]. 4 screws w/ washer [2]

F-2-1062) Remove the 18T pulley [1]. 1 E-ring [2] 1 flange [3]


[4]

[4]

[4][4][4] [3]

[3]

[2][1]

[1]

[2]

[2]

[1]

[2]

[3]

F-2-1084) Remove the H4 gear [1] and the H3 gear [2]. 4 E-rings [3] 1 parallel pin [4]

F-2-1093-2 Removing the M3 Gear, H1 Gear, 40T Gear, M1 Gear, H2 Gear, and T1 Gear Pulley (8500)1) Remove the unit rear plate [1]. 4 screws [2]

F-2-1102) Remove the T1 gear pulley (8500) [1], 40T gear [2], and H1 gear [3]. 1 E-ring [4]

[2][1]

[1]

[2]

[3]

[3]

[4]

[2]

[2]

[1]

[2]

F-2-1113) Remove the M3 gear [1]. 2 E-rings [2]

F-2-1124) Remove the sub main drive assembly [1]. 3 screws [2]

F-2-1135) Remove the M1 gear [1] and the H2 gear [2]. 1 E-ring [3]

F-2-1143-3 Removing the Fixing Drive Belt, 22T Pulley, F1 Gear, 40T Gear, and Input Coupling1) Remove the gear support plate (right) [1].

[4]

[4]

[3]

[1]

[2]

[2]

[1]

[2]

[1]

[2]

[3]

[1]

[2]

2 screws [2]

F-2-1152) Remove the input coupling [1] and the 40T gear [2]. 2 E-rings [3]

F-2-1163) Remove the F1 gear [1]. 1 E-ring [2]

F-2-1174) Remove the gear support plate (left) [1]. 2 screws [2]

F-2-118

[1]

[2]

[2]

[1]

[3]

[2]

[1] [2]

[1]

[2]

5) Remove the fixing/feeding drive belt [1].

F-2-1196) Remove the 22T pulley [1]. 2 E-rings [2]

F-2-120

2.17 Waste Toner Pipe Assembly (every 12,000,000 prints)0012-6975

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- 26T gear (FS7-0027)

2. Before Starting the WorkRemove the waste toner pipe assembly. (See the instructions under "Removing the Drum Drive Assembly" of the Service Manual.)

3. Replacement Procedure1) Remove the 2 E-rings [1] and the bushing [2].

[1]

[2]

[1]

F-2-1212) Remove the 26T gear [1]. 1 parallel pin [2] 1 coupling [3]

F-2-122

2.18 Drum Intake Fan (every 12,000,000 prints)0013-2888

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- Drum intake fan (FH6-1550)

2. Before Starting the WorkRemove the HV-DC PCB. Refer to the service manual.

3. Replacement Procedure1) Remove the drum intake fan unit [3].Tow screws [1] Connector [2]

[1]

[2]

[2]

[1]

[3][2]

F-2-1231) Remove the drum intake fan [3].Three screws [2] Connector [1]

F-2-124

2.19 Cleaner Drive Assembly (every 12,000,000 prints)0012-6984

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- 18T pulley (FU5-3434)- C1 gear (FU6-0959)- C2 gear (FS7-0021)- C3 gear (FS7-0022)- C7 gear (FS7-0026)- C4A gear (FU3-0414)- C5A gear (FU3-0415)- C6A gear (FU3-0416)

2. Before Starting the WorkRemove the cleaner drive assembly. (See the Service Manual.)

3. Replacement Procedure3-1 Removing the 18T Pulley1) Remove the 18T pulley [1]. 1 E-ring [2] 1 flange [3]

[3] [1]

[1][2]

[1] [3] [2]

[2]

F-2-1253-2 Removing the C7 Gear1) Remove the C7 Gear.1 E-ring [2]. Remove also the parallel pin (behind the C7 gear), spring, and flange.

F-2-1263-3 Removing the C5A Gear, C3 Gear, C2 Gear, and C4A Gear1) Remove the gear support plate [1]. 3 screws [2]

F-2-1272) Remove the C5A gear [1], C3 gear [2], C2 gear [3], and C4A gear [4]. 1 E-ring [5]

[2]

[1]

[3]

[1]

[2]

[1]

[2]

[2]

[2]

F-2-1283-4 Removing the C1 Gear1) Remove the C1 gear [1]. Take care not to drop the parallel pin. 2 E-rings [2]

F-2-1293-5 Removing the C6A Gear1) Remove the C6A gear [1]. Take care not to drop the parallel pin. 1 E-ring [2]

F-2-130

2.20 Drum Shaft (every 12,000,000 prints)0012-7115

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- drum shaft (FG6-7322)

2. Before Starting the Work1) Slide out the process unit. (See the Service Manual.)2) Remove the developing drive assembly. (See the Service Manual.)

3. Replacement Procedure1) Remove the shaft retaining plate [1]. 6 screws [2]

F-2-1312) Pull out the drum shaft [1].

[2]

[2]

[1]

[3][4]

[5]

[2]

[1]

[2]

[1]

[2]

[1]

[2] [2]

F-2-132

2.21 Curler Drive Roller (vertical; every 1,200,000 prints)0012-7117

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- curler drive roller (vertical; FB4-1420)- 18T gear(FS2-0566)

2. Before Starting the Work1) Remove the manual feeder drive assembly. (See the Service Manual.)2) Remove the right pickup unit.

3. Replacement Procedure3-1 Replacing the Curler Drive Roller (vertical)Replace the curler driver roller by referring to the instructions in this manual for the pre-registration (lower; every 6,000,000, 12,000,000, 18,000,000prints).

3-2 18T Gear1) Remove the 2 18T gears [1]. Take care not to drop the parallel pin. 1 E-ring [2] each

F-2-133

2.22 Vertical Path Curling Unit (every 12,000,000 prints)0012-7221

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- evaluation sensor plate (FF6-1516)- pre-registration roller (FG6-5396)

2. Before Starting the WorkRemove the right pickup unit.

3. Replacement Procedure3-1 Removing the Pre-registration Roller (lower)1) Remove the cable cover [1]. 3 screws [2]

[1]

[1][2]

[1][2]


F-2-1353) Remove the pre-registration roller unit (lower) [1]. 3 screws [2] 1 retaining plate (front) ]3] 1 retaining plate (rear) ]4] 1 connector [5] 2 mini-clamps [6] 1 edge saddle [7]

F-2-136

[1][2]

[1]

[2] [3]

[1]

[3] [4]

[2]

[2]

F-2-1374) Remove the pre-registration roller (lower) [1] together with the attachments. 1 spring [2] each at front and rear 1 spring [3] 1 E-ring [4] 1 pin [5]

F-2-1385) Remove the pre-registration roller (lower) [1]. 2 E-rings [2] 2 washers [3] 2 bearings [4]

F-2-1393-2 Removing the Pre-registration Roller (upper)1) Remove the retaining plate (rear) A [1].

[5][6][7]

[1]

[2] [3]

[4]

[5]

[1]

[2]

[3]

[4]

1 screw [2]

F-2-1402) Remove the retaining plate B (rear) [1].

F-2-1413) Remove the pre-registration roller unit [1].

F-2-1424) Remove the pre-registration roller (upper) [1]. 2 E-rings [2] 2 washers [3] 2 bearings [4]

[1]

[2]

[1]

[1]

F-2-1433-3 Removing the Evaluation Sensor Plate1) Remove the evaluation sensor plate [1]. 2 screws [2]

F-2-1442) Remove the photointerrupter [1]. evaluation sensor plate [2]

F-2-145

2.23 Pre-registration Vertical Path Guide (every 12,000,000 prints)0012-7220

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- pre-registration path guide (FB4-3811)- feed sensor unit (FG6-2311)

2. Before Starting the WorkRemove the right deck pickup assembly. (See the Service Manual.)

3. Replacement Procedure1) Remove the cable cover [1]. 3 screws [2]

[1]

[2]

[3]

[4]

[1]

[2]

[2][1]


F-2-1473) Remove the pre-registration roller unit (lower) [1]. 3 screws [2] 1 retaining plate (front) [3] 1 retaining plate (rear) [4] 1 connector [5] 2 mini-clamps [6] 1 edge saddle [7]

F-2-148

[1][2]

[1]

[2] [3]

[1]

[3] [4]

[2]

[2]

F-2-1494) Remove the pre-registration vertical path guide assembly [1]. 1 connector [2] 2 screws [3]

F-2-1505) Remove the 3 cord clamps [2] and the feed sensor unit [3] connected to the pre-registration vertical path guide [1]. 2 screws [4] 1 connector [5]

F-2-151

2.24 Process Unit (12,000,000 prints)0012-7222

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- reciprocating arm (FB6-2400)- post-cam (FB4-1622)- slip ring (FB4-1575)- separation claw drive unit (FG1-3472)- gear-4(14Z) (FS6-0121)- cam gear (FS6-0136)- input gear (FS6-0138)- MG input gear (FS6-0972)- idler gear 1 (FS6-0973)- idler gear 2 (FS6-0975)- waste toner gear (FS6-0976)- reciprocating gear (FS6-0977)- reciprocating can gear (FS6-0978)- cleaner stirring gear (FS7-0048)- idler gear (FS7-0050)

2. Replacement Procedure1) Remove the process unit. (See the Service Manual.)2) Remove the photosensitive drum. (See the Service Manual.)

[5][6][7]

[1]

[2]

[4][5][3][4][1]

[2]

3. Replacement Procedure3-1 Removing the MG Input Gear1) Remove the MG input gear [1]. 1 E-ring [2]

F-2-1523-2 Removing the Stop Ring1) Remove the drum rear block [1]. 2 fastons [2] 3 screws [3]

F-2-1532) Remove the stop ring [1]. 3 clip rings [2]

F-2-1543-3 Removing the Separation Claw Drive Assembly1) Remove the separation claw drive assembly [1]. 2 screws [2]

[1]

[2]

[3]

[3]

[2]

[1]

[2]

[1]

F-2-1553-4 Removing the Input Gear, Waste Toner Gear, Gear 4 (14T), Idler Input Gear 1/2, Reciprocating Arm, Reciprocating Gear, and Reciprocating Cam Gear1) Remove the reciprocating arm [1]. 1 screw [2]

F-2-1562) Remove the reciprocating cam gear [1]. 1 E-ring [2]

F-2-1573) Remove the reciprocating arm. 1 E-ring [2] 1 spring [3]

[2][1]

[1]

[2]

[1]

[2]

F-2-1584) Remove the idler gear 1 [1] 1 E-ring [2]

F-2-159Remove the gear 4 (14T) [1]. 1 C-ring [2]

F-2-1606) Remove the 2 idler gears 2 [1]. 1 E-ring [2] each

[3] [1] [2]

[1] [2]

[1]

[2]

F-2-1617) Remove the waste toner gear [1].

F-2-1628) Remove the reciprocating gear [1]. 1 E-ring [2]

F-2-1633-5 Removing the Input Gear, Cam Gear, and Idler Gear1) Remove the developing fan [1]. 2 screws [2]

[2][1]

[1]

[2]

[1]

F-2-1642) Remove the cleaner front plate [1]. 2 screws [2] 2 self-tapping screws [3]

F-2-1653) Remove the cam gear [1] and the idler gear [2]. 1 E-ring [3] each

F-2-1664) Remove the 2 input gears [1].

F-2-1673-6 Removing the Cleaner Stirring Gear1) Remove the cleaner blade [1] together with the mounting plate. 5 screws [2]

[2]

[2]

[1]

[2]

[2]

[1][3]

[2]

[1][3]

[1]

F-2-1682) Remove the cleaner stirring gear [1]. 1 E-ring [2]

F-2-169

2.25 Developing Drive Assembly (every 12,000,000 prints)0012-7386

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace- 32T gear (FU6-0961)- developing input gear (FU6-0962)- 32T gear (FS2-0485)- feed pressure gear (20T; FS3-0046)- 20T pulley (FS4-0157)- 20T pulley (FU5-3436)- G3 shaft (8500; FB5-7375)- electromagnetic clutch (FH6-5017)- M gear (27T; FS7-0072)

2. Replacement ProcedureRemove the developing drive assembly. (Refer to the Service Manual.)

3. Replacement Procedure3-1 Removing the Developing Input Gear $1) Remove the developing input gear [1]. 1 E-right [2] 1 bearing [3]

F-2-170

[1]

[2]

[2][1]

[1]

[2]

[3]

3-2 Removing the 20T Gear $, 32T Gear $, Feed Pressure Gear (20T; FS3-0046), M Gear (27T; FS7-0072), and Electromagnetic Clutch (FH6-5017)1) Remove the clutch support plate [1]. 2 connectors [2] 1 wire saddle [3] 2 edge saddles [4] 5 screws [5]

F-2-1712) Remove the developing cylinder clutch [1] and the developing cylinder deceleration clutch [2].

F-2-1723) Remove the 20T gear [1]. 1 E-ring [2]

F-2-1734) Remove the 27T gear [1]. 1 E-ring [2]

F-2-1745) Remove the 32T gear (FU6-0961) [1]. 1 E-ring [2] 1 bearing [3] 2 E-rings [4]

[1]

[2]

[2]

[3][4]

[4]

[5]

[5]

[5]

[1][2]

[2][1]

[1] [2]

F-2-1756) Remove the 32T gear (FS2-0485) [1]. 1 E-ring [2]

F-2-1767) Remove the 20T gear [1]. 1 E-ring [2] 1 bearing [3] 2 E-rings [4] 1 parallel pin [5] 1 E-ring [6]

F-2-1778) Remove the E-ring [2] and the bearing [3] connected to the developing cylinder clutch (electromagnetic clutch) [1].

[1]

[2]

[3][4]

[1]

[2]

[2][5]

[3]

[4][1]

[6]

F-2-1783-3 Removing the 20T Pulley and 32Z Gear (FU6-0961)1) Remove the 20T pulley [1]. 1 E-ring [2] 1 flange [3]

F-2-1792) Remove the 32T gear [1].


F-2-1814) Remove the G3 shaft (8500) [1] together with the gears.

[2][3]

[1]

[1]

[2]

[3]

[1]

[2]

[2]

[2]

[2][1]

F-2-1825) Remove the 32T gear [1] from the G3 shaft (8500) [2]. 1 bearing [3] 3 E-rings [4] 1 parallel pin [5]

F-2-183

2.26 Fixing/Feeding Assembly Base (For 1,200,000 pc of Paper)0012-7651

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace-Inside Delivery Sensor Assembly(FM2-4876)-Driving Coupling (FB2-1035)-No. 2 Flapper (1) (FB4-2305)-No. 2 Flapper (2) (FB4-2306)-No. 2 Flapper (3) (FB4-2307)-No. 2 Flapper (4) (FB4-2308)-S2S Belt (88, FB4-2314)-Stationary Sensor Flag (FB6-2373)-Outside Delivery Sensor Unit (FM2-5855)-Bearing (FS5-1803)-S2M Pulley (18T, FS5-3615)-Driving Input Gear (FS6-0899)-Idler Gear 1 (37T, FS6-0991)-Idler Gear 2 (28-45T, FS6-0992)-Idler Gear 3 (39-46T, FS6-0993)-Idler Gear 4 (16-26T, FS6-0994)-Idler Gear 5 (21T, FS6-0995)-Idler Gear 6 (20-38T, FS6-0996)-Mickey Gear (Rear 18T, FS6-0997)-Mickey Gear (Front 15-32T, FS6-0998)-Outside Delivery Gear (Rear 30T, FS6-0999)-Claw Reciprocating Gear (22T, FS7-0002)-Reversal Jam Sensor Supporting Plate (FF5-7859)-DC Brush-less Motor (FK2-1002)-Feeding Sensor Flag Supporting Plate (FL2-3539)-Electro-magnetic Clutch (FH6-5013)-20T Gear (FS6-0081)-Fixing Web Solenoid (FK2-0976)-One-way Cam (1, FB4-2235)-Claw Reciprocating Gear (FS7-0002)

2. Replacement PreparationsRemove the Fix/Feed Base. See Service Manual.

3. Replacement Procedures3-1. Removing of the DC Brush-less motor. (FK2-1002)

[1]

[1]

[2]

[3]

[4]

[4]

[5]

1) Remove the DC Brush-less motor 1. 2 Connectors 2 4 Screws (w/washer) 3

F-2-1843-2. Removing of 20T Gear (FS6-0081), Idler Gear 5(21T, FS6-0995), Fixing Web Solenoid (FK2-0976), Claw Reciprocating Gear (22T, FS7-0002, Idler

Gear 5(21T, FS6-0995, Idler Gear 6(20-38T, FS6-0996), Mickey Gear (Front 15-32T, FS6-0998, One-way Cam (1, 1) (FB4-2235) and ClawReciprocating Gear (FS7-0002)

1) Remove the Motor Supporting Plate [1].2 Edge Saddles [2] 4 Screws [3]

F-2-1852) Remove the Fixing Web Solenoid Assembly [1].2 Screws [2]

F-2-1863) Remove the Fixing Web Solenoid [1].2 Screws [2]

[1] [3]

[2][3] [3]

[1]

[3]

[3]

[3] [2]

[2]

[1]

[2]

F-2-1874) Remove the One-way Cam (1) [1]1 One-way Cam (2) [2]1 Spring [3]

F-2-1885) Remove the Bearing from the One-way Cam Shaft [1].1 E-ring [2]

F-2-1896) Remove the Electro-magnetic Clutch [1].

F-2-1907) Remove 20T Gear [2] from the Electro-magnetic Clutch [1]. Do not drop the Parallel-pin.1 Bearing [3]1 Washer [4]1 E-ring [5]

[1]

[2]

[1]

[2]

[3]

[2]

[1]

[1]

F-2-1918) Remove the Claw Reciprocating Gear [1], Mickey Gear (Front 15-32T) [2], and Idler Gear 6 (20-38T) [3].2 E-rings [4]

F-2-1929) Remove the Feeding Fan [1].2 Screws [2]1 Connector [3]

F-2-19310) Remove the Idler Gear (21T) [1].1 E-ring [2]

F-2-1943-3. Removing of the Input Coupling

[5][4]

[2]

[1]

[3]

[1]

[4]

[2][3]

[2]

[3]

[1]

[2]

[2] [1]

1) Remove the Input Coupling [1]1 E-ring [2]

F-2-1953-4. Removing of the Driving Input Gear (FS6-0899), -Idler Gear 1 (37T, FS6-0991), Idler Gear 2 (28-45T, FS6-0992), Idler Gear 3 (39-46T, FS6-0993),

Mickey Gear (Rear 18T, FS6-0997), Idler Gear 4 (16-26T, FS6-0994), and Outside Delivery Gear (Rear 30T, FS6-0999)1) Remove the Driving Input Gear [1].2 E-rings [2]

F-2-1962) Remove the Idler Gear 2 (28-45T) [1].1 E-ring [2]

F-2-1973) Remove the Idler Gear 1 (37T) [1].1 E-ring [2]

F-2-1984) Remove the Idler Gear 3 [1].1 E-ring [2]

[1]

[2]

[2]

[1]

[2]

[1]

[2]

[1]

F-2-1995) Remove the Mickey Gear (Rear 18T) [1].1 E-ring [2]

F-2-2006) Remove the Outside Delivery Gear (Rear 30T) [1].1 E-ring [2]

F-2-2017) Remove the Idler Gear 4 (16-26T) [1].1 E-ring [2]

F-2-2023-5. Removing of the No. 2 Flapper (1, FB4-2305), No. 2 Flapper (2, FB4-2306), No. 2 Flapper (3, FB4-2307), No. 2 Flapper (4, FB4-2308), S2M Pulley

(18T, FS5-3615), Inside Delivery Sensor (FM2-4876), Feeding Sensor Flag Supporting Plate (FL2-3539), Stationary Sensor Flag (FB6-2373), OutsideSensor Unit (FM2-5855), and S2M Belt (88, FB4-2314).

3-5-1. Replacement Preparations1) Remove the Gear Plate [1].2 Screws [2]

[1] [2]

[1]

[2]

[1]

[2]

[1]

[2]

F-2-2032) Remove the Outside Delivery Roller [1].1 E-ring [2]1 Spacer [3]1 Bearing [4]

F-2-2043) Remove the Reversal Roller [1].1 E-ring [2]1 Spacer [3]1 Bearing [4]

F-2-2054) Remove the Inside Delivery Roller [1].1 E-ring [2]1 Spacer [3]1 Bearing [4]

F-2-2065) Remove the Reversal Path Unit B [1].

[2] [1]

[1] [2] [3]

[1] [2] [3]

[1][2] [3] [4]

1 Connector [2]4 Screws [3]

F-2-2076) Remove 2 Screws [1].

F-2-2087) Remove the Flapper Lever (1) [1].1 E-ring [2]

F-2-2098) Remove the E-ring [1], Spacer [2] and Bearing [3].

F-2-2109) Remove 2 E-rings [1], and 1 Bearing [2].

[1][2][3][3]

[1]

[1]

[2]

[1] [2] [3]

F-2-21110) Remove the Reversal Path Unit A [1].2 Screws [2]1 Connector [3]

F-2-2123-5-2 Replacement Procedures1) Remove the Feeding Sensor Flag Supporting Plate [1].1 Screw [2]

F-2-2132) Remove the No.2 Flapper (1) [1], No.2 Flapper (2) [2], No.2 Flapper (3) [3], and No.2 Flapper (4) [4].Snapped in Place3) Remove the M2S Pulley (18T) [1] and M2S Pulley (88) [2].

F-2-2144) Remove the Stationary Sensor Flag [1].1 E-ring [2]

[1]

[2]

[1][2] [3]

[1]

[2]

[5][6] [6]

[1] [1][3][4] [2]

F-2-2155) Remove the Outside Delivery Sensor Unit [1].2 Screws [2]

F-2-216

2.27 Fixing/Feeding Kit (For 1,200,000 pc. of Paper)0012-9787

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace-Fixing Positioning Plate (FF5-7658)-Bushing (FS5-1798)-Bushing (FS5-1804)-Bushing (3) (FS6-1149)-Bushing (2) (FS5-1468)

2. Replacement Procedures1) Remove the Fixing Positioning Plate [1].3 Screws [2]

F-2-2172) Remove the Bushing (FS5-1798) [1].2 Screws [2]

F-2-2183) Remove 2 Bushings (2) (FS5-1468) [1].2 Screws [2] each

[1][2]

[1] [2]

[1][2]

[2]

[1]

[2]

F-2-219

F-2-2204) Remove the Bushing (3) (FS6-1149) [1].2 Screws [2]

F-2-2215) Move the Harness Guide [1].2 Screws [2]

F-2-2226) Remove the Bushing (FS5-1804) [1].2 Screws [2]

[1]

[2]

[1]

[2]

[1]

[2]

[1] [2]

[2]

F-2-223

2.28 Duplexing Assembly (For 3 and 9 million pc of Paper)0012-8160

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace-Reversal Flapper Solenoid (FG6-5399)- Duplexing Sponge Roller (FF6-1520)-Reversal Guide (FF9-1910)-Reversal Roller (FF6-1519)

2. Replacement Preparations1) Remove the Duplexing Assembly. See the Service Manual.2) Remove the Duplexing Front Cover [1].Remove 3 Jam-removal Knobs [2] and 3 Screws [3], and Loosen 1 Screw [4].

F-2-2243. Replacement Procedures3-1. Removing of the Reversal Flapper Solenoid (FG6-5399)1) Remove the PCB Cover [1].3 Screws [2]

F-2-2252) Remove the Solenoid Unit [1].2 Screws [2]1 Connector [3]

[1] [2][2]

[1] [3] [4]

[2]

[1]

[2][2]

F-2-2263) Remove the Reversal Flapper Solenoid [1].1 Self-tapping Screw [2]2 Screws [2]

F-2-2273-2. Removing of Duplexing Sponge Roller (FF6-1520)1) Turn the Duplexing Unit upside down.2) Remove the Duplexing Sponge Roller 1.2 Screws [2]3 E-rings [3]2 Spacers [4]2 Bearing [5]2 Collars [6]

F-2-2283-3. Removing of the Reversal Guide (FF9-1910)1) Remove the Reversal Guide [1].1 Screw [2]1 Stop [3]2 Springs [4]

F-2-2293-4. Removing of the Reversal Roller (FF6-1519)1) Remove the Reversal Roller [1].

[1]

[2]

[3]

[1]

[2]

[3]

[6]

[6]

[1]

[2][5]

[4][3]

[2][5]

[4]

[3]

[1][4] [4] [3] [2]

5 E-rings [2]1 Screw [3]

F-2-230

2.29 Dulplexing Assembly (For 6,000,000 pc. of Paper)0012-8180

iR7105 / iR7095 / iR7086 / iR7095P / / /

1. Parts to Replace-Reversal Flapper Solenoid (FG6-5399)- Duplexing Sponge Roller (FF6-1520)-Reversal Guide (FF9-1910)-Reversal Roller (FF6-1519)-U-turn Outlet Guide (FB4-2106)-Flapper (FB4-2135)-Duplexing Outlet Guide (FB6-0625)-Left Guide (FF5-8202)-Lower Feeding Upper Guide (FF5-8200)-Feed Roller (Right, FB5-6925)-Feed Roller (Left, FB6-0560)-Feed Roller (Middle, FB6-0575)-U-turn Upper Guide (FB4-2114)-Left Deck Lower Guide (FF6-1536)-Left Deck Upper Guide (FB6-0525)-Sensor Supporting Plate (FF5-7737)-Feed Sensor Supporting Plate (FF6-1843)-Feed Sensor Supporting Plate (Left, FF6-1844)-Reversal Sensor Supporting Plate (FL2-3540)-Fan Motor (FH6-1490)-Stepping Motor (FH6-1939)-Stepping Motor (FH6-1940)-Electro-magnetic Clutch (FH6-5014)-Bearing (FS1-1401)-Roller Gear (FS5-0338)-20T Gear A (FS5-0514)-Gear 16T (FS5-0710)-Screw Gear (Y, FS5-0714)-Pulley (Circle 14, FS5-3314)-Pulley Gear 1 (FS5-3613)-P2M30T Pulley(FS5-3617)-Idler Stepped Gear (FS5-3942)-18T Pulley (FS5-3943)-16T Gear (FS5-3945)-40T Gear (FS6-0070)-16T Gear (FS6-0145)

2. Replacement Preparations1) Remove the Duplexing Assembly. See Service Manual.2) Remove the Duplexing Front Cover 1.Loosen 3 Jam-removal Knobs 2, 3 Screws 3, and 1 Screw 4.

[2][2]

[2]

[3]

[1]

F-2-2313-1. Removing of the Reversal Flapper Solenoid (FG6-5399)1) Remove the PCB Cover [1].3 Screws [2]

F-2-2322) Remove the Solenoid Unit [1].2 Screws [2] 1 Connector [3]

F-2-2333) Remove the Reversal Flapper Solenoid [1].1 Self-tapping Screw [2]2 Screws [1]

F-2-2343-2. Removing of the Duplexing Sponge Roller (FF6-1520)1) Turn the Duplexing Unit upside down.2) Remove the Duplexing Sponge Roller [1].2 Springs [2]3 E-rings [3]

[1] [3] [4]

[2]

[1]

[2][2]

[1]

[2]

[3]

[1]

[2]

[3]

2 Spacers [4]2 Bearings [5],2 Collars [6]

F-2-2353-3. Removing of the Reversal Guide (FF9-1910)1) Remove the Reversal Guide [1].1 Screw [2]1 Stop [3]2 Springs [4]

F-2-2363-4. Removing of the Reversal Roller (FF6-1519), 18T Pulley (FS5-3943) and Gear 16T (FS5-0710)1) Remove the Reversal Roller [1], 18T Pulley [4], and Gear 16T [5].5 E-rings [2]1 Screw [3]

F-2-2373-5 Removing the Fan motor (FH6-1490)1) Remove the fan base [1].3 screws [2]1 connector [3]

[6]

[6]

[1]

[2][5]

[4][3]

[2][5]

[4]

[3]

[1][4] [4] [3] [2]

[2]

[2]

[2][5][4]

[3]

[1]

F-2-2382) Remove the fan motor [1] from the base.2 screws [2]

F-2-2393-6 Removing the Roller gear (FS5-0338)1) Remove the roller gear [1]. Be sure not to drop the parallel pin.1 bearing [2]1 spacer [3]2 E-rings [4]

F-2-2403-7 Removing the Stepping motor3-7-1 Reversing motor (FH6-1939)1) Loosen the tension of the belt [3]. Unfasten the screw [1] and fasten the screw [1] again while pulling on the tension support plate [2] in the direction

of the arrow.2) Remove the reversing motor [6].1 connector [4]2 screws [5]

[2]

[2]

[3]

[1]

[1]

[2]

[4]

[1]

[3]

[2]

F-2-2413-7-2 Duplexing left feed motor (FH6-1940)1) Loosen the tension of the belt [3]. Unfasten the screw [1] and fasten the screw [1] again while pulling on the tension support plate [2] in the direction

of the arrow.2) Remove the duplexing left feed motor [6].1 connector [4]2 screws [5]

F-2-2423-7-2 Duplexing right feed motor (FH6-1940)1) Loosen the tension of the belt [3]. Unfasten the screw [1] and fasten the screw [1] again while pulling on the tension support plate [2] in the direction

of the arrow.2) Remove the duplexing right feed motor [6].1 connector [4]2 screws [5]

F-2-2433-8 Removing the Electromagnetic clutch (FH6-5014)3-8-1 Removing the deck (left) pull-off clutch and the lower feed middle clutch1) Remove each clutch [4].2 set screws [2] each1 connector [3] each

[2]

[1] [3] [6]

[5]

[5] [4]

[3] [1][6]

[5] [2] [4]

[1][6]

[5]

[5]

[2] [4]

[3]

F-2-2443-8-2 Removing the Lower feed right clutch1) Remove the clutch support plate [3].1 connector [1]2 screws [2]

F-2-2452) Remove the lower feed right clutch [3].1 bearing [1]1 spacer [2]1 E-ring [5]2 set screws [4]

F-2-2463-9 Removing the Idler stepped gear (FS5-3942), 16T gear (FS5-3945), 18T pulley (FS5-3943), and Pulley (round 14, FS5-3314)1) Remove the motor support plate [1].6 screws [2]

F-2-2472) Remove three pulleys (round 14) [1].1 E-ring [2] each

[2][2] [3][3]

[4]

[2] [1] [3] [2]

[1] [2] [3]

[2]

[2]

[1]

[2]

F-2-2483) Remove two 18T pulleys [1].1 screw w/ washer [2] each1 E-ring [3] each1 spacer [4] each

F-2-2494) Remove the idler stepped gear [1].1 E-ring [2]1 spacer [3]

F-2-2505) Remove the 16T gear [1].1 screw with washer [2]

F-2-2513-10 Removing the Screw gear (Y, FS5-0714), 20T gear A (FS5-0514), P2M30T pulley (FS5-3617), 16T gear (FS6-0145), Pulley gear 1 (FS5-3613), and40T gear (FS6-0070)1) Remove the clutch upper plate [1].4 connectors [2]3 screws [3]1 coil spring [4]

[2]

[1]

[2]

[1]

[2]

[1]

[2]

[1]

[4]

[3]

[2][1]

[4]

[3]

[2][3][1]

[2]

[1]

F-2-2522) Remove the screw gear (Y) [1].1 E-ring [2]

F-2-2533) Remove the 20T gear A [1] and P2M30T pulley [2]. Be sure not to drop the parallel pin.1 E-ring [3]1 spacer [4]

F-2-254 4) Remove the pulley gear 1 [1] and 16T gear [2].1 E-ring [3] each

F-2-2555) Remove the 40T gear [1].2 E-rings [2]

[1]

[2]

[3]

[3]

[4]

[2]

[1] [2]

[2] [4] [3] [1]

[2] [1]

[3]

F-2-2563-11 Removing the Left guide (FF5-8202), Bearing (FS1-1401), and Flapper (FB4-2135)1) Remove the left guide [1] along with the bearing and flapper.1 screw [2]1 guide pin [3]1 spring [4]

F-2-2572) Remove the bearing [2] and the flapper [3] from the left guide [1].1 self-tapping screw [4]1 side plate [5]1 spring [6]

F-2-2583-12 Removing the Upper U-turn guide (FB4-2114) and Reversing sensor support plate (FL2-3540)1) Remove the upper U-turn guide [1] along with the reversing sensor support plate.4 screws [2]2 springs [3]1 connector [4

F-2-2592) Remove the housing [2], two wire saddles [3], and reversing sensor flag [4] from the upper U-turn guide [1].2 screws [5]

[1][2]

[1]

[2

Ir7105 Series Rm

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