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KPOWERSCIENCE KP3828 Series Maintenance Manual

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KP3828 Series

Maintenance Manual

VER 2.6.4 9-2006
KPOWERSCIENCE CO.,LTD.
ISO 9001 CERTIFIED
TAIWAN BUSINESS DEPARTMENT:
8FL.,No. 276, Sec.1,Ta-Tung Rd., Hsi-Chih City, Taipei Hsien 221,Taiwan
TEL:886-2-2647-5855 FAX:886-2-2643-1151
CHINA BUSINESS DEPARTMENT:
No. 4, Lane 185, Huan-Ho St., Hsi-Chih City, Taipei Hsien 221,Taiwan
TEL:886-2-2694-8799 FAX:886-2-2694-6657
INTERNATIONAL BUSINESS DEPARTMENT:
No. 4, Lane 185, Huan-Ho St., Hsi-Chih City, Taipei Hsien 221,Taiwan
TEL:886-2-2694-8799 FAX:886-2-2694-6657

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  • Page 1: Maintenance Manual

    KP3828 Series Maintenance Manual VER 2.6.4 9-2006 KPOWERSCIENCE CO.,LTD. ISO 9001 CERTIFIED TAIWAN BUSINESS DEPARTMENT: 8FL.,No. 276, Sec.1,Ta-Tung Rd., Hsi-Chih City, Taipei Hsien 221,Taiwan TEL:886-2-2647-5855 FAX:886-2-2643-1151 CHINA BUSINESS DEPARTMENT: No. 4, Lane 185, Huan-Ho St., Hsi-Chih City, Taipei Hsien 221,Taiwan...

  • Page 2: Table Of Contents

    Contents Chapter1 Overview Chapter2 Principles Chapter3 Installation Chapter4 Electrical System Chapter5 Adjustments Chapter6 Periodic Maintenance Chapter7 Parts Replacement Chapter8 Troubleshooting Appendix I KMPU Circuit Diagram...
  • Page 3 Chapter1 Overview External View.................. 1-1 Specifications .................. 1-2 Features ..................1-4 Diagram ..................1-5 Configuration .................. 1-6 Operations and Adjustments ............1-11...

  • Page 4: Chapter1 Overview

    Chapter 1 Overview...

  • Page 5: External View

    External View External View...

  • Page 6: Specifications

    Specifications 1. General Scope Print speed ：3000/3500/4000 lines/min (6LPI) Print method ：Electrophotography process, LED array Resolution ：300 × 300 DPI Print width ：14.6 inch max. Photosensitive material ：OPC drum Interface ：Video interface Developing method ：Dry, two-component developer Cleaning system ：Blade-type cleaning system Fusing method ：Flash fusing with Xenon lamp Paper feed...
  • Page 7 3. Paper Type ：Fanfold paper (standard) Page length ：7 to 20 inches Page width ：6.5 to 16 inches (Fanfold paper) (When the power stacker unit is used, paper length range is 8 to 14 inches). Weight ：60~204 g/m 4. Environment Temperature ：Operating：10 to 30°C ：Non-operating：-10 to 35°C...

  • Page 8: Features

    Exposure LEDs are arranged widthwise at a density equivalent to the printing resolution of 300 dots per 1 inch (300dpi), and exposure is executed one line at a time. The KP3828 Series therefore achieves a higher accuracy of printing lineation.

  • Page 9: Diagram

    Diagram Host computer Printer Controller (Optional) Panel interface Video interface Operation panel KP3828 Series Power stacker KMPU...

  • Page 10: Configuration

    Configuration 1. Engine 1) OPC drum 2) Exposure section ˙ Main charger ˙ LED array ˙ LED for discharge 3) Developing section ˙ Developing unit 4) Transfer/separation section ˙ Transfer charger ˙ Separation charger 5) Cleaning section ˙ Blade ˙ Waste toner box 6) Fuser section ˙...
  • Page 11 COVER Top cover Rear cover Left side cover Front cover (upper) Right side cover Right side cover Front cover (lower) Fig.1-1...
  • Page 12 Fuser unit Cleaning unit Main charger Developing unit Transport unit Waste toner box DC power supply Fusing power supply Fig.1-2...
  • Page 13 LED array Varistor Air filter blower Developing motor Fuser exit blower Drum motor Paper out motor Elevator motor KMPU board Print controller Fig.1-3...
  • Page 14 Developing unit LED array Main charger Erase lamp unit OPC drum Transfer charger Pre-charger Fuser unit Cleaning unit Transport unit Fig.1-4 1-10...

  • Page 15: Operations And Adjustments

    Operations and Adjustments 1. Operations – provide the following operations to the controller (1) Mechanical initialization（reset operation） (2) Change length of fanfold paper (3) Automatic loading of fanfold paper (4) Page feeding of fanfold paper (5) Feeding of paper by 0.5 inch (line feed) (6) Printing on fanfold paper (7) Output of fanfold paper (8) Folding of fanfold paper...
  • Page 16 Chapter2 Principles Printing System Descriptions............2-1 2-1-1 Erase Lamp Unit ..............2-2 2-1-2 Main Charger ................2-3 2-1-3 LED Array................2-4 2-1-4 Developing Unit..............2-5 2-1-5 Transfer Charger ..............2-7 2-1-6 Pre-charger ................2-10 2-1-7 Cleaning Unit ................2-11 2-1-8 Fuser Unit................

  • Page 17: Chapter2 Principles

    Chapter 2 Principles...

  • Page 18: Printing System Descriptions

    Printing System Descriptions The printing mechanisms of KP3828 Series printer are located around the drum, which contain primary units as the followings: Erase lamp unit Main charger Led array Developing unit Transfer charger Pre-charger Blade cleaning unit Fuser unit Main charger...

  • Page 19: Erase Lamp Unit

    2-1-1 Erase Lamp Unit To ensure that the OPC drum is uniformly charged before exposure, exposing the drum surface to light from the erase lamp unit in the first printing step to neutralize residual charge. Erase lamp unit Residual charge OPC Drum Fig.2-2...

  • Page 20: Main Charger

    2-1-2 Main Charger After being electrically neutralized in the erase step, the OPC drum surface undergoes corona discharge so that it has uniform positive charges. The potential generated on the OPC drum surface is determined by the grid potential of the main charger that is grounded via a varistor. If the amount of corona discharge varies with the operation environment (temperature, humidity), soiling of the main charger, etc., the OPC drum surface potential cannot be kept constant.

  • Page 21: Led Array

    2-1-3 LED Array When the drum, which has been positively and uniformly charged in the main charging step, is exposed to light, the photosensitive film in an exposed area goes into conduction so that the charge in the exposed area is neutralized.

  • Page 22: Developing Unit

    2-1-4 Developing Unit In the developing unit section, toner is attracted to the electrostatic “latent image” formed in the exposure step, so that a “developed image” (visible image) is formed on the OPC drum surface. The developing roller consists of the inner-pole magnet roller and the sleeve roller.
  • Page 23 A developing bias is applied to the developing roller. The developing bias is obtained by a +350V DC bias (available setting range: +200V ~ +500V). Therefore, when the bias renders the developing roller surface potential positive, the strength of an electric field resulting from the difference between that potential and the OPC drum surface potential is greater than the magnetic force exerted between the toner and inner-pole magnet.

  • Page 24: Transfer Charger

    2-1-5 Transfer Charger 2-1-5-1 Transfer Wire The toner attracted to the OPC drum surface is positively charged due to the friction with the carrier in the developing unit. Therefore, when the paper supplied from the tractor is closely attached to the OPC drum surface on which the print image is developed and the back surface of the paper is negatively charged by transfer wire, the toner attracted to the OPC drum surface is transferred onto the paper.
  • Page 25 2-1-5-2 Separation Wire The drum surface areas to which no toner is attracted are positively charged. Therefore, the paper that is negatively charged in the transfer section has adhered to the drum and would not leave the drum if this situation were allowed to continue. Therefore, to separate the paper from the drum, separation wire eliminates the charge from the paper immediately after completion of toner image transfer, using DC bias.
  • Page 26 The transfer wire and separation wire are integrated into a single unit “transfer charger” together with the paper supply guide and paper transport section. An elevator motor vertically drives them. Transport unit OPC drum Transport belt Paper supply guide Transfer charger Fig.2-10...

  • Page 27: Pre-Charger

    2-1-6 Pre-charger After the paper is separated from the OPC drum, part of the toner, carrier, and paper dust remain on the drum surface without being transferred onto the paper. Such remaining toner should be positively charged due to the friction with the carrier in the developing unit.

  • Page 28: Cleaning Unit

    2-1-7 Cleaning Unit The remaining toner particles, which have been positively charged in the pre-charger section, are scraped away with a blade. The toner is finally carried by a screw conveyor and placed in a waste toner box. Blade Waste toner Screw conveyor OPC Drum Remaining toner...

  • Page 29: Fuser Unit

    2-1-8 Fuser Unit Xenon lamp Paper Melted and fixed Unfixed toner Fig.2-13 This printer uses a xenon lamp to provide flashlight on the paper to fix the toner. The toner is heated to a high temperature so that it is fixed by fusing onto the paper.

  • Page 30: Drive System Descriptions

    Drive System Descriptions The printer drive system is illustrated in Fig.2-14 below. Fuser unit Developing unit Splitter solenoid Toner supply clutch Developing motor Main body Drum motor Transport unit Splitter motor Elevator motor Paper out motor Paper in motor Fig.2-14 2-13...

  • Page 31: Paper In Drive

    2-2-1 Paper in Drive The paper in motor drives the tractor. Tractor Encoder Direction in which paper is conveyed Support shaft Gear (46) Support shaft Gear (44-23) Paper guide Gear (22) Paper in motor Fig.2-15 2-14...

  • Page 32: Opc Drum Drive

    2-2-2 OPC Drum Drive The drum motor drives the OPC drum and the cleaning unit. Cleaning unit driving shaft Drum driving shaft Outer diameter of the drum Gear Gear Gear Gear Drum motor Fig.2-16 2-15...

  • Page 33: Developing Drive

    2-2-3 Developing Drive The developing roller consists of the inner-pole magnet roller and the sleeve roller. The gearbox at the output shaft of the developing unit driving motor drives the shafts. One of these two shafts drives the inner-pole magnet roller and, at the same time, the other shaft drives the sleeve roller.

  • Page 34: Transport Unit Drive

    2-2-4 Transfer Unit Drive The transfer unit moves up and down when the cam installed on the elevator motor shaft rotates. Transfer charger Transfer unit Elevator motor Fig.2-18 2-17...

  • Page 35: Paper Out Drive

    2-2-5 Paper out Drive The rollers are driven along with the following rollers by the paper out motor. 1. Transport roller 2. Scuff roller Transport roller Scuff roller Gear Gear Gear Gear Gear Gear Feed motor Fig.2-19 2-18...

  • Page 36: Sensor System Descriptions

    Sensor System Descriptions The KP3828 Series printer sensor system is shown in Fig.2-20 below. Paper in section Paper out section Paper transport section Sensor PMS OPC Drum Scuff SW Sensor PTPS Sensor PTS Paper Splitter Transport roller Tractor Paper Transport belt...

  • Page 37: Paper In

    2-3-2 Paper in When the printing instruction (PRINT signal) is issued from the controller, the paper set on the tractor is automatically advanced upon OPC drum surface and the image on the OPC drum is transferred onto the paper while advancing.

  • Page 38: Transport

    2-3-3 Transport When the printer receives the print instruction (PRINT signal) from the controller and completes paper in, it sends the image data request signal (VSYNC signal) to the controller and, at the same time, begins to expose the OPC drum to the LED array light. The tractor advances the paper loaded to the transfer point when the drum- exposed surface reaches the toner transfer point.
  • Page 39 Chapter3 Installation Preparations..................3-1 Cautions................... 3-1 Carrying – in ................... 3-3 Unpacking ..................3-4 Setting OPC drum ................3-6 Setting Developing Unit..............3-9 Setting Toner Cartridge ..............3-12 Setting Others.................. 3-14 Setting-up of the AC Power Cable..........3-15 3-9-1 AC Power Cable Specification ..........3-15 3-9-2 Attach AC Power Cable in USA..........

  • Page 40: Chapter5

    Chapter 3 Installation...

  • Page 41: Preparations

    Preparations Prepare the below items 1) Maintenance tools 1. Phillips screwdriver (No.2 × 1) 2. Phillips screwdriver (No.1 × 1; for attaching AC cable, see Fig.3-19) 3. Wrench (20mm × 1; for adjusting level feet, see Fig.3-5) 4. Level × 1 5.
  • Page 42 Installation space： 1000 1000 1270 Stacker KP3828 Series Maintenance zone Operation zone △ Front (Dimensions in Fig.3-1...

  • Page 43: Carrying - In

    Carrying – in When carrying in the printer for installation, observe the following precautions： 1) As the weight of the printer is 240kg, move it with a forklift and avoid exposing it to vibration or shock. 2) The forks of a forklift truck must always be inserted in the prescribed direction.

  • Page 44: Unpacking

    Unpacking Step 1. Remove the binding bands. Step 2. Take off the top plate. Top plate Binding bands Fig.3-2 Step 3. Raise and remove the outer cover. Step 4. Remove the vinyl bag. Outer cover Vinyl bag Fig.3-3...
  • Page 45 Step 5. Remove the wrapping. Step 6. Remove the cushioning material. Step 7. Take out the inside box. Board Fig.3-4 Step 8. Use a forklift truck to lift the printer, and set the printer on a level floor. Step 9. Adjust up the level feet of the printer engine with a wrench by turning it until the lower surface of the base frame remains at 70 mm above the floor level.

  • Page 46: Setting Opc Drum

    Setting OPC Drum CAUTION 1) If a blade-type cleaning unit is installed, make sure the green lock lever of the cleaning unit is turned to the “open” position (horizontally to 3-o’clock direction) before setting OPC drum. 2) Never touch the drum surface. 3) Since the life of the drum will be shortened by exposure to ambient air, mount the drum as quickly as possible.
  • Page 47 Step 13. Remove the nut from the drum shaft. Fig.3-7...
  • Page 48 Step 14. Attach the drum support rod to the drum shaft. Drum support rod Drum shaft Fig.3-8 Step 15. Insert the drum through the shaft and when the drum contacts the inner end, turn the drum to fit the drum securely. OPC Drum Fig.3-9 Step 16.

  • Page 49: Setting Developing Unit

    Setting Developing Unit Step 17. Take out the developing unit. Step 18. Loosen the 3 screws and then remove the upper cover of the developer introduction section of the developing unit. Screws Developing unit Cover Fig.3-10 Step 19. Take out the developer and attach the nozzle to the developer bottle.
  • Page 50 Step 20. Move the developer bottle back and forth, and pour the developer uniformly into the developer introduction port. Developer Slit (Developer introduction port) Fig.3-12 Step 21. Rotate the developing roller a few times by turning the knob at the side with your hand, so that the developer will settle uniformly across the roll.
  • Page 51 Step 23. Insert the developing unit gently into the main body. Developing unit Fig.3-14 Step 24. Align the pinhole on the unit with the positioning pin on the main body. After the developing unit has been inserted all the way in, turn the lever downward by 120°...

  • Page 52: Setting Toner Cartridge

    Setting Toner Cartridge Wear vinyl gloves when handling the toner. Step 25. Hold the toner cartridge with the cover tape facing up and shake the cartridge 4 or 5 times as shown by the arrows. Cover tape Fig.3-16 Step 26. With the cover tape facing up, insert the cartridge into the toner hopper and slowly peel off the cover tape in the direction of the arrow on the tape.
  • Page 53 Step 27. After inserting the toner cartridge into the toner hopper, turn the toner cartridge clockwise by 180 ° to move the slit of the toner cartridge upward from the position of pin. Slit Fig.3-18 3-13...

  • Page 54: Setting Others

    Setting Others Step 28. Remove the rubber bands and tapes that are securing the transport unit. Step 29. Remove all other tapes attached to the interior of the engine. Step 30. Close the front cover (upper). 3-14...

  • Page 55: Setting-Up Of The Ac Power Cable

    Setting-up of the AC Power Cable Step 31. Open the rear cover. Step 32. Open the AC power terminal box. Step 33. Attach (screw on) the AC power cable with a No.1 Philips screwdriver. Step 34. Close the AC power terminal box. Step 35.

  • Page 56: Attach Ac Power Cable In Europe

    ˙ Clamp the terminals onto the wires in accordance with the manufacturer’s instructions. (2) Attach the AC power cable to the printer as follows: ˙ Connect the Green/Yellow wire to the printer terminal marked “FG”. ˙ Connect the White wire to the printer terminal marked “N”. ˙...

  • Page 57: Attach The Plug

    3-9-4 Attach the Plug (1) Select a plug that has the appropriate rating and agency approval as shown in the following table. Plug Type Reference Standards EURO CEE 7-7 250V AC BS 4343 240V AC IEC 309-2 More than 20A EN 60309-2 (INDUSTRIAL) CEE 17...

  • Page 58: Verify Grounding

    3-9-5 Verify Grounding Please verify that the grounding conductor in the AC power cable is connected to the printer terminal marked “FG” and to the plug terminal marked with “E” or “PE” or the safety earth symbol or green or green/yellow.
  • Page 59 KMPU board AC power terminal box AC power terminal box Breaker AC cable Turn on Fig.3-19 3-19...

  • Page 60: Setting The Paper

    3-10 Setting the Paper Step 37. Confirm the left tractor is set at the left end, and align the left side of the paper carton with the alignment mark as in Fig.3-21. Tractor Fig.3-20 Alignment mark Fig.3-21 3-20...
  • Page 61 Step 38. Supply the fanfold paper from between the paper empty sensor guide and the printer body. Paper empty sensor guide Fig.3-22 Step 39. Ensure the first perforation is at the peak (see Fig.3-24). Step 40. Open the paper holder levers on the tractors and set the leading end of the paper on the tractors.
  • Page 62 Step 41. Close the paper holder levers, and lock the green lock lever. Paper holder levers Green lock lever Fig.3-23 Perforation Fig.3-24 3-22...

  • Page 63: Power On

    Step 42. When the setting of the print engine has been completed, turn on the power and perform test printing. 3-12 Engine Self Test Printing KP3828 Series support pure engine self test without controller. Set Dip-switch SWA to self-test mode, then turn on the power, and perform engine self test printing.
  • Page 64 Chapter4 Electrical System Diagram ..................4-1 Electrical Configuration ..............4-2 Input / Output Signals ..............4-5...

  • Page 65: Chapter6

    Chapter 4 Electrical System...
  • Page 66 Diagram Host computer Printer Controller (Optional) Panel interface Video interface Operation panel KP3828 Series Power stacker KMPU Fig.4-1...
  • Page 67 Electrical Configuration The electrical system of this printer: LED array Power stacker High-voltage power supply KMPU board Sensor/Actuator 220V Controller 220V Fusing power DC power supply supply Operation panel Fig.4-2...
  • Page 68 Sensors and actuators Sensor POPS Sensor PMS Scuff SW Sensor PTPS Transport unit connector Suction fan Xenon lamp Fusing power supply Fuser unit connector Paper out motor Power stacker Fig.4-3...
  • Page 69 Toner empty sensor Toner supply clutch Toner density sensor Developing bias Main charger / Transfer charger / Pre-charger Cleaner bias LED array thermal sensor Drum surface potential sensor Cleaning unit set sensor Waste toner box set sensor Waste toner full sensor Erase lamp unit Page counter (8.5”) Drum encoder...
  • Page 70 Input / Output Signals I/O signal block diagram of the KMPU: Fig.4-5...
  • Page 71 Chapter5 Adjustments Operation Panel................5-1 KMPU Board .................. 5-3 Setting Dip-switches ..............5-4 Checking Individual Engine Status ..........5-5 Adjusting Toner Density ............... 5-9 Adjusting Fusing Power Supply ........... 5-10 Adjusting High Voltage Supply ............5-11...

  • Page 72: Adjustments

    Chapter 5 Adjustments...

  • Page 73: Operation Panel

    Operation Panel The operation panel contains ten function keys, one LCD screen, three status indicators, and five error indicators. Ready Data Error Line Split Menu Line Feed Form Form Test Save Length Feed Fig. 5-1 1. Function Keys: No error exists: Set the printer in the on-line or off-line state. ON LINE Error exists: Clear the error message.

  • Page 74: Status Indicators

    2. Status Indicators: READY (GREEN) Blinking: Printer is warming up. On: Printer is in the on-line state. Out: Printer is in the off-line state. DATA (GREEN) Blinking: Data is in buffer when printer is ready. On: Data is in buffer when printer stops. Out: No data is in buffer.

  • Page 75: Kmpu Board

    KMPU Board R9 R10 FPGA BOOT ROM D8 D10 D16 SWB SWA D9 D15 PROGRAM MAINTENANCE Fig.5-3 Variable Adjustment Test Point Voltage LED Definition Resistor Object Paper out Motor R24-up +1.91V D4 Toner enough Elevator Motor R30-up +2.56V D5 Toner low Drum Motor R42-left +1.80V...

  • Page 76: Setting Dip-Switches

    1 2 3 4 Fig.5-4 2. Engine self-test KP3828 Series support pure engine self-test without controller. Set Dip-switch SWA pin 1 “ON” to change the printer to self-test mode, and then turn on the power. The printer will perform engine self-test printing.

  • Page 77: Checking Individual Engine Status

    Checking Individual Engine Status Under engine checker mode, you can check individual engine status, such as the status of motor, fan, charger, sensor, etc., without connecting to a controller. 1. Power off engine. 2. Set Dip-switch SWA pin 1, 2, 3 “OFF” but pin 4 “ON” to change the printer to engine checker mode.
  • Page 78 When “SETTING” is selected: (1) Press “SAVE” key to enter sub menus. “DATA” indicator is off. (2) Press “︿” key or “﹀” key to select the item you want to check. The saved value of the selected item is indicated by a symbol of “＊”...
  • Page 79 MAINTENANCE menu: MAINTENANCE OPERATION 00: PI-MTR FOR 01: PI-MTR REV 02: TRANSPORT UP 03: TRANS-30UPDN 04: POMTR+PIMTR 05: PO-MOTOR 06: COUNTER UP 08: SPLIT-REAR 09: SPLIT-HOME 0A: DRUM MOTOR 0B: DEVELOP-MTR 12: SEPARAT-CLAW 14: SPLIT-SOLEN 16: TONER SUPPLY 18: SUCTION FAN 1C: VENTILAT FAN 1D: FUSER EX-FAN 1E: AIR FILTER...
  • Page 80 ALARM 01: COVER OPEN 02: PAPER EMPTY 07: SCUFF OPEN 08: NO CLEAN SET 09: W-TONER FULL 0E: NO W-TNR-BOX 0F: NO TONER 14: LED OVERHEAT 18: DRUM-MTR ERR 1D: FUSER TEM-HI 1E: FLASH PWR-ER SETTING 05: LED STROBE 07: IMAGE X0 08: IMAGE Y0 10: DSPS-SETUP 11: DEVELOP-BIAS...

  • Page 81: Adjusting Toner Density

    Adjusting Toner Density 1. Connect the minus terminal of the digital multimeter to the J7 (SGND) of KMPU board and the plus terminal to J2 (TDSCNT) of KMPU board. 2. Adjust R10 of KMPU board so that the reading on the digital multimeter shows the voltage: +4.8V is standard, plus is darker;...

  • Page 82: Adjusting Fusing Power Supply

    Adjusting Fusing Power Supply Turn V.ADJ of the fusing power supply and set to the desired voltage (normally set to 1850V). 1900 1950 1850 V.ADJ 1800 1700 1750 Fig.5-5 5-10...

  • Page 83: Adjusting High Voltage Supply

    Adjusting High Voltage Supply 1. +HV2 PRE CHARGE Use a digital multimeter and set to Ampere scale. Connect the meter’s red probe into the High Voltage Supply +HV2 transformer output terminal, and then connect the black probe into the High Voltage Supply +HV2 wire (See Fig.5-6).
  • Page 84 2. -HV TRANSFER CHARGE Use a digital multimeter and set to Ampere scale. Connect the meter’s red probe into the High Voltage Supply -HV transformer output terminal, and then connect the black probe into the High Voltage Supply -HV wire (See Fig.5-8). Turn on TRANSFER CHARGE under ENGINE CHECK selection, and then adjust High Voltage Supply VR401 (See Fig.5-9).
  • Page 85 3. -V1 CLEAN BIAS Use a digital multimeter and set to DC Voltage scale. Connect the meter’s red probe into the High Voltage Supply –V1, and then connect the black probe into the Case GND (See Fig.5-10). Turn on CLEAN BIAS under ENGINE CHECK selection, and then adjust High Voltage Supply VR601 (See Fig.5-11).
  • Page 86 4. -V2 CLEAN BIAS Use a digital multimeter and set to DC Voltage scale. Connect the meter’s red probe into the High Voltage Supply –V2, and then connect the black probe into the Case GND (See Fig.5-12). Turn on CLEAN BIAS under ENGINE CHECK selection, and then adjust High Voltage Supply VR701 (See Fig.5-13).
  • Page 87 5. TDSC Use a digital multimeter and set to DC Voltage scale. Connect the meter’s red probe into J2 (See Fig.5-14), and then connect the black probe into J7 (See Fig.5-15). The accomplishment of the task is shown in Fig.5-16. Adjust R10 of the KMPU board (See Fig.5-17).
  • Page 88 Fig.5-16 Fig.5-17 5-16...
  • Page 89 Chapter6 Periodic maintenance Introduction ..................6-1 Periodic Maintenance..............6-2 6-2-1 Periodic Maintenance by Operators........6-2 6-2-2 Periodic Maintenance by Service Engineers ......6-3 Cleaning ..................6-5 6-3-1 Tractor Unit ................6-5 6-3-2 Inside the Front Cover ............6-5 6-3-3 Developing Unit/Hopper Area..........6-6 6-3-4 Cleaning Unit Area ..............

  • Page 90: Chapter6 Periodic Maintenance

    Chapter 6 Periodic Maintenance...

  • Page 91: Introduction

    6-1 Introduction In order to maintain printing quality and printing accuracy of KP3828 Series at a level that will not be a problem in terms of practical use, it is important to perform periodic maintenance of consumable parts. The periods of cleaning...

  • Page 92: Periodic Maintenance

    Periodic Maintenance 6-2-1 Periodic Maintenance by Operators (Count by 8.5” size, B/W 5%) Every Every Every Every Every Item 20,000 50,000 100,000 200,000 300,000 Remarks pages pages pages pages pages Main charger Clean Replace Transfer Clean Replace charger Pre-charger Clean Replace Toner cartridge Replace...

  • Page 93: Periodic Maintenance By Service Engineers

    6-2-2 Periodic Maintenance by Service Engineers (Count by 8.5” size, B/W 5%) Every Every Every Every Remarks Item 200,000 300,000 500,000 600,000 Others pages pages pages pages Main charger Clean Replace Transfer Clean charger Replace Pre-charger Clean Replace OPC drum Replace Erase lamp unit Clean...
  • Page 94 Every Every Every Every Every Item 200,000 300,000 500,000 600,000 900,000 Others Remarks pages pages pages pages pages Paper empty Clean sensor area Tractor unit Clean Transfer guide Clean plate Transport unit Clean Transport belt Replace Capacitor Replace Every 2.4 million pages Xenon lamp Replace...

  • Page 95: Cleaning

    Cleaning 6-3-1 Tractor Unit Use a vacuum cleaner to remove the paper dust, etc. that are scattered across the tractor unit. Tractor Fig.6-1 6-3-2 Inside the Front Cover Open the front cover and use a vacuum cleaner to remove the scattered toner, paper dust, etc.

  • Page 96: Developing Unit/Hopper Area

    6-3-3 Developing Unit/Hopper Area Fig.6-3 6-3-4 Cleaning Unit Area Cleaning unit Fig.6-4...

  • Page 97: Fuser Unit Area

    6-3-5 Fuser Unit Area Fuser unit Fig.6-5 6-3-6 Waste Toner Box Unit Area Press down the opening lever to open the waste toner box unit. Waste toner box unit Opening lever Fig.6-6...

  • Page 98: Transport Unit

    6-3-7 Transport Unit 1. With the waste toner box unit being opened (see “6-3-6 Waste Toner Box Unit Area”), tilt the green lever of the transport unit to the left to lower the transport surface. Then pull out the transport unit and remove the scattered toner, paper dust, etc.

  • Page 99: Main Charger

    6-3-8 Main Charger CAUTION！！ Handle the chargers carefully to prevent damaging or cutting the charger wires. 1. Loosen the thumbscrew and pull the main charger out. Thumbscrew Main charger Fig.6-9 2. Use the brush to wipe off the dust on the main charger. Fig.6-10...
  • Page 100 3. Loosen the screw to detach the stainless mesh panel. Screw Stainless mesh panel Fig.6-11 4. Use the wire cleaner (applied with alcohol) to clean the wire of the main charger. Wire cleaner Fig.6-11a 6-10...
  • Page 101 5. Gently move the stainless spring plate to an exact 90° angle. Place the right side rectangle hole of the stainless mesh panel on top of the stainless spring plate. Stainless mesh panel Stainless spring plate Fig.6-11b 6. Align the phosphor copper plate with the screw below. Then tighten the screw.

  • Page 102: Pre-Charger And Transfer Charger

    6-3-9 Pre-charger and Transfer Charger 1. Open the waste toner box unit (see “6-3-6 Waste Toner Box Unit Area”). Loosen the thumbscrew and pull out the pre-charger (Fig.6-12a). Confirm that the transfer charger is at the “down” position. If the transfer charger is not at the “down”...
  • Page 103 3. Use the brush to wipe off the dust on the pre-charger and transfer charger. Clean the wires of the pre-charger (Fig.6-12c) and transfer charger (Fig.6-12d) with the wire cleaner. Pre-charger Fig.6-12c Transfer charger Fig.6-12d 5. After cleaning, insert the pre-charger and transfer charger to their original locations and tighten the thumbscrews.

  • Page 104: Opc Drum

    6-3-10 OPC Drum CAUTION！！ Be careful of the following 3 points when cleaning the OPC drum: a) Do not touch the drum surface. b) In order to avoid flawing of the drum surface, clean the drum at a location without dust. c) Parts of the drum with wiping stains may deteriorate if the drum is left in the main body for a long time with wiping stains on it.
  • Page 105 the drum surface with the special cloth. 2. Wipe Drum Special cloth Fig.6-14 6-15...

  • Page 106: Led Array

    6-3-11 LED Array Remove the developing unit and the OPC drum in advance (see “7-2-6 Developing Unit” and “7-2-9 OPC Drum”). Insert your hand from the OPC drum mounting section and clean the dirt on the LED array with “alcohol”. LED array Fig.6-15 6-3-12 Erase Lamp Unit...

  • Page 107: Fuser Unit Cover Glass

    6-3-13 Fuser Unit Cover Glass CAUTION！！ Be careful of the following 2 points when cleaning the fuser unit cover glass： a) Since the fuser unit will be hot immediately after operation, handle the unit after it has cooled fully. Do not make scratches on the cover glass or touch the cover glass directly with your hands.

  • Page 108: Developing Unit

    6-3-14 Developing Unit 1. Take out the developing unit (see “7-2-6 Developing Unit”). 2. Clean by sucking up the toner attached to the toner scatter prevention brush of the developing unit with a vacuum cleaner. Vacuum Toner scatter prevention brush Fig.6-18 6-18...
  • Page 109 6-3-15 emoving the Developer from the Developing Unit CAUTION！！ a) Be careful of not flawing the developing roller. b) Wear a mask and a pair of rubber gloves to perform this work. 1. Take out the developing unit (see “7-2-6 Developing Unit”). 2.
  • Page 110 5. Bring the developing unit back to the original condition, place it on another sheet, and then use a ground line to connect the developing unit to the main body of the engine. Connect the engine side of the ground line to the main body of the engine.
  • Page 111 Chapter 7 Parts Replacement Cover ..................... 7-1 Inside the Front Cover (Upper) ............. 7-2 7-2-1 Waste Toner Box Unit ............7-3 7-2-2 Waste Toner box..............7-3 7-2-3 Waste Toner Full Sensor ............7-4 7-2-4 Waste Toner Box Set Sensor........... 7-5 7-2-5 Waste Toner Box Unit.............
  • Page 112 7-3-3 Capacitor ................. 7-37 Inside the Rear Cover..............7-39 7-4-1 KMPU Board ................7-40 7-4-2 DCMTR DRV Board .............. 7-41 7-4-3 Surface Potential Measurement Board ........7-42 7-4-4 Drum Motor Unit ..............7-42 7-4-5 Developing Motor Unit............7-43 7-4-6 Paper out Motor Unit .............. 7-43 7-4-7 Paper in Motor Unit ..............

  • Page 113: Parts Replacement

    Chapter 7 Parts Replacement...

  • Page 114: Cover

    For safety, be sure to pull out the power plug when a part is to be detached. Do not operate the printer with parts removed except when performing inspection, adjustment, or other work that is specifically designated in this manual. Cover Top cover Rear cover...

  • Page 115: Inside The Front Cover (Upper)

    Inside the Front Cover (Upper) The units shown in Fig.7-2 are installed inside the front cover. Fuser unit Cleaning unit Main charger Air filter Toner cartridge Developing unit Transport unit Waste toner box DC power supply Fusing power supply Fig.7-2...

  • Page 116: Waste Toner Box Unit

    7-2-1 Waste Toner Box Unit This unit contains a box that collects waste toner carried from the cleaning unit. Attached to the right and left sides of the box’s neck are the light emitter and receptor of the waste toner box full sensor, which detects the full condition.

  • Page 117: Waste Toner Full Sensor

    2. Detach the cap from the waste toner box. Then use the cap to seal the waste toner box. Remove the waste toner box. Opening lever Waste toner box Fig.7-5 3. Install a new waste toner box. 7-2-3 Waste Toner Full Sensor Remove the waste toner box from the waste toner box unit and then remove the waste toner box full sensor by the following steps.

  • Page 118: Waste Toner Box Set Sensor

    2. Remove the screws that secure the boards for the light emitting and receiving, and then remove the boards. Screws Screws Fig.7-7 7-2-4 Waste Toner Box Set Sensor To remove the waste toner box set sensor, disconnect the connector and then remove the screws that secure the sensor bracket.

  • Page 119: Waste Toner Box Unit

    7-2-5 Waste Toner Box Unit To remove the waste toner box unit, remove the connector and waste toner box firstly. Then release the spring and remove the waste toner box unit by lifting it. Remove sensors and then replace with a new waste toner box unit.

  • Page 120: Developing Unit

    7-2-6 Developing Unit Follow the procedures below to remove the developing unit from the main body. 1. Turn the lever by 120° to the right to detach the developing roller from the OPC drum. Lever Fig.7-10 2. Hold the lever with one hand and pull out the unit partially. Fig.7-11...

  • Page 121: Setting The Developing Unit

    3. Hold the hanger with another hand and take out the unit from the main body. Hanger Fig.7-12 7-2-7 Setting the Developing Unit Be careful of the following three points when setting the developing unit. 1) Align the pinhole on the unit with the positioning pin on the main body. 2) After the developing unit has been inserted all the way in, turn the lever downwards by 120°...

  • Page 122: Toner Cartridge

    7-2-8 Toner Cartridge When the toner empty sensor detects the “toner empty” condition, follow the procedures below to replace the toner cartridge with the developing unit being set in the main body. • Turn the toner cartridge counterclockwise by 180 to align the slit of the toner cartridge with the pin of the developing unit and pull out the cartridge.
  • Page 123 3. With the cover tape facing up, insert the cartridge into the toner hopper and slowly peel off the cover tape in the direction of the arrow on the tape. Toner hopper Cover tape Fig.7-16 4. After inserting the toner cartridge into the toner hopper, turn the toner cartridge clockwise by 180°...

  • Page 124: Opc Drum

    7-2-9 OPC Drum CAUTION Be careful of the following points in installing or removing the OPC drum. 1) If a blade-type cleaning unit is installed, make sure the green lock lever of the cleaning unit is turned to the “open” position (horizontally to 3-o’clock direction) before removing or installing OPC drum.
  • Page 125 2. Open the waste toner box unit. Confirm that the transfer charger is at the “down” position. If the transfer charger is not at the “down” position, use a slotted screwdriver to turn the transfer elevator drive shaft counterclockwise to lower the transfer charger to the “down” position. Transfer charger Transfer elevator drive shaft Fig.7-19...
  • Page 126 4. Remove the nut from the drum shaft. Fig.7-21 5. Attach the drum support rod to the drum shaft. Drum support rod Drum shaft Fig.7-22 7-13...
  • Page 127 6. Pull out the drum. Be sure to hold the opposite side of the drum when taking out the drum. In other words, be sure to use both hands to take out the drum. However, be careful not to touch the drum surface with your hands. OPC Drum Fig.7-23 For installation of the OPC drum, please see “3-5 Setting OPC Drum.”...

  • Page 128: Drum Peripheral Equipment

    7-2-10 Drum Peripheral Equipment The following equipment is located around the OPC drum. 1) Main charger 2) Pre-charger 3) Transfer charger 4) Erase lamp unit 5) Cleaning unit 6) Drum support roller 7) LED array 8) Drum surface potential sensor Main charger Cleaning unit Pre-charger...

  • Page 129: Main Charger, Pre-Charger, Transfer Charger

    7-2-11 Main Charger, Pre-charger, Transfer Charger Any of these chargers can be removed by loosening thumbscrews (see “6-3-8 Main Charger” and “6-3-9 Pre-charger and Transfer Charger”) and pulled out along the guide rail. The transfer charger must be at the “down” position for removal. If it is not at the “down”...

  • Page 130: Drum Support Roller

    7-2-13 Drum Support Roller Drum support rollers are provided near part from which the drum is to be removed so that the drum surface will not come contact with the metal parts in the vicinity. The rollers are removed by removing screws securing the bracket.

  • Page 131: Air Filter

    7-2-14 Air Filter 1. Remove the screws at the front cover and then remove the air filter cover. Fig.7-27 2. Pull the air filter out. Fig.7-28 7-18...

  • Page 132: Transport Unit

    7-2-15 Transport Unit The transport unit is removed as follows: 1. Remove the waste toner box unit in advance. Turn the green lever to the left to lower the transport unit and pull out the unit. Fig.7-29 7-19...
  • Page 133 3. Remove the screws that are securing the right and left slide rails to the unit. For the screws at the rear, shift the unit so that the screws are matched in position with the holes of the rails (so that the screws can be seem through the holes) and then remove the screws.

  • Page 134: Transport Belt

    4. Lift the unit from the rails and remove the unit. Fig.7-32 The transport unit has the following replaceable parts: 1) Transport belt 2) Suction Fan 3) Connector block for the transfer charger The methods for removing the respective replacement parts are described in the following pages.
  • Page 135 7-2-16 Transport Belt When replacing the transport belt, the transport unit must be turned upside-down to remove the base conveyor. When turning the unit upside-down, be sure to put a rest underneath it to protect the protruding tips of the sensor levers. Also, be careful when handling the lever. 1.
  • Page 136 3. Remove the screw and then the stainless plate. Stainless plate Fig.7-35 4. Remove the E-rings securing the drive shaft to the unit frame and remove the bearing. Bearing E-ring Unit frame Fig.7-36 7-23...
  • Page 137 5. Remove the base conveyor from the unit frame. Remove the screw fastening the ground wire, and remove the wire. Ground Screw Fig.7-37 6. Remove the E-rings holding the drive shaft to the base conveyor, and then slide the bearing off the shaft. Bearing E-ring Drive shaft...
  • Page 138 7. Remove the drive shaft from the base conveyor, and remove the three transport belts. Transport belts Fig.7-39 8. When replacing the transport belt, be careful to distinguish the new belt’s front side from the backside. The surface of the front side is smooth, while the surface of the backside is rough.
  • Page 139 9. To adjust the belt tension, loosen the screws fastening the base conveyor, and adjust the tension of the belt by turning the setscrew with a hexagonal wrench. Screws Setscrew Fig.7-41 10. Adjust the height of the belt. Firmly tighten the screws to secure the adjustment.

  • Page 140: Fuser Unit

    7-2-17 Fuser Unit Loosening the thumbscrews on the holder plates at the right and left sides can pull out the fuser unit. Make sure to make room below the fuser unit by turning the green lever to the left to lower the transport surface. Fuser unit Thumbscrew on holder plate Green lever...

  • Page 141: Xenon Lamp

    7-2-18 Xenon lamp 1. Set the fuser unit that has been removed from the main body with the cover glass facing up. Fig.7-44 2. Remove the screws securing the paper guide on the entrance side of the unit and remove the paper guide. Paper guide Screws Fig.7-45...
  • Page 142 3. Remove the screws that secure the glass frame to the fuser box and remove the glass frame. Screws Glass frame Screws Fig.7-46 4. Remove the screws securing the lamp terminals. Screw Xenon lamp Screws Fig.7-47 7-29...
  • Page 143 5. Remove the screw from the front bracket and the rear bracket. Then remove the lamp. Screw Fig.7-48 7-30...

  • Page 144: Fuse Set

    7-2-19 Fuse Set 1. Remove the screw securing the fuse holder to the fuse box. Screw Fuse box Fuse holder Fig.7-49 2. Remove the screw securing the fuse holder cover. Screw Fuse holder Fig.7-50 7-31...
  • Page 145 3. Open the cover, remove the screws securing the fuse set and remove the fuse. Screws Fuse Set Fig.7-51 7-32...

  • Page 146: Inside The Front Cover (Lower)

    Inside the Front Cover (Lower) 7-3-1 DC Power Supply 1. Remove the front cover (lower) and the rear cover before the following steps. 2. Remove the connectors and screws from the rear side of the DC power supply. 3. Remove the screws from the front side, and then take out the DC power supply from the front side.

  • Page 147: Fusing Power Supply Unit

    7-3-2 Fusing Power Supply Unit WARNING It is dangerous to handle the power supply unit immediately after the main power (220V) is turned off. Wait at least 5 minutes before starting the work. 1. Remove the front cover (lower) and the rear cover before the following steps.
  • Page 148 5. Remove the screws of the high-voltage terminal, and disconnect the high-voltage cable (disconnect the red cable firstly then the black cable). Screws High-voltage cable (red) High-voltage cable (black) Fig.7-55 CAUTION Be aware that red cable connect to the〝+〞marked end, and the black cable connect to the〝－〞marked end.
  • Page 149 6. Remove the screws that secure the fusing power supply box. 7. Hold the handle and pull the fusing power supply box out. Screws Fig.7-56 8. Insert the new fusing power supply box. 9. Align the screw holes on the fusing power supply box with those on the printer base and then secure the fusing power supply box with the screws.

  • Page 150: Capacitor

    7-3-3 Capacitor WARNING It is dangerous to handle the power supply unit immediately after the main power (220V) is turned off. Wait at least 5 minutes before starting the work. There is one capacitor inside the fusing power supply unit. This capacitor is replaced in the following manner.
  • Page 151 4. Remove the nuts at the upper part of the capacitor and remove the respective cables. Nuts Fig.7-59 5. Remove the screws that secure the capacitor and remove the capacitor. Screws Fig.7-60 7-38...

  • Page 152: Inside The Rear Cover

    Inside the Rear Cover Surface potential measurement board LED array DCMTR DRV board Varistor Air filter blower Developing motor Fuser exit blower Drum motor Paper out motor Elevator motor KMPU board Print controller Fig.7-61 7-39...

  • Page 153: Kmpu Board

    7-4-1 KMPU Board 1. Remove the screws and remove the cover. 2. Remove the connectors. 3. Remove the screws that secure the KMPU board. Screws Fig.7-62 Screws Screws Fig.7-63 7-40...

  • Page 154: Dcmtr Drv Board

    7-4-2 DCMTR DRV Board 1. Remove the connectors. 2. Remove the screws that secure the DCMTR DRV board. Screws Fig.7-64 7-41...

  • Page 155: Surface Potential Measurement Board

    7-4-3 Surface Potential Measurement Board Remove the screws and the protective cover. Remove the connectors. Remove the screw pillars that secure the surface potential measurement board. Connectors Screw pillars Fig.7-65 7-4-4 Drum Motor Unit Disconnect the connector. Remove the screws and pull out the drum motor unit. Screws Connector Fig.7-66...

  • Page 156: Developing Motor Unit

    7-4-5 Developing Motor Unit Disconnect the connectors. Remove the screws and remove the developing motor unit. Connectors Screws Fig.7-67 7-4-6 Paper out Motor Unit Disconnect the connector. Remove the E-ring. Remove the screws and pull out the paper out motor unit. E-ring Screws Connector...

  • Page 157: Paper In Motor Unit

    7-4-7 Paper in Motor Unit 1. Remove the screws and remove the rear cover. 2. Disconnect the connector inside the cover. 3. Push out motor connector. 4. Remove the screws that secure the motor, and remove the motor. Screws Motor connector Fig.7-69 7-4-8 Elevator Motor Unit...

  • Page 158: Varistor Of The Main Charger

    7-4-9 Varistor of the Main Charger Remove the main charger varistor by removing the screws that secure the plate to the rear panel. Varistor Screws Fig.7-73 7-45...

  • Page 159: Inside The Left Side Cover

    Inside the Left Side Cover 7-5-1 Paper Output Unit Remove the screw in the front. Remove the screw in the rear, and then pull out the unit. Screws Fig.7-74 Screws Fig.7-75 7-46...

  • Page 160: Sensor Pops

    7-5-2 Sensor POPS Remove the connector (1 pc). Remove the screws of the sensor bracket, and remove the sensor POPS. POPS Connector Fig.7-76 7-47...

  • Page 161: Inside The Right Side Cover

    Inside the Right Side Cover 7-6-1 Tractor Unit 1. Remove the screws in the front side, and remove the screws in the rear side. 2. Disconnect the connectors. 3. Remove the screws of the right side cover (1) and (2), and then pull out the tractor unit.

  • Page 162: Sensor Pts

    7-6-2 Sensor PTS Disconnect the connector on the inner side. Remove the screws and remove the PTS. Screws Fig.7-79 Connector Screw Fig.7-80 7-49...

  • Page 163: Paper Empty Sensor

    7-6-3 Paper Empty Sensor Remove the screws. Remove the paper empty sensor from the bracket. Screws Screws Fig.7-81 7-50...

  • Page 164: Inside The Top Cover

    Inside the Top Cover Scuff switch Cleaning unit set sensor Sensor POPS LED array High voltage power supply Drum surface potential sensor Fig.7-82 7-51...

  • Page 165: High Voltage Power Supply

    7-7-1 High Voltage Power Supply Removing this unit by disconnecting the connectors and the high voltage wire terminal connected to the output terminal, and then removing the screws securing the high voltage power supply. Frame ground terminal Connectors Screws High voltage wire Screws Fig.7-83 CAUTION...

  • Page 166: Led Array

    7-7-2 LED Array It is necessary to remove the top cover and to take out the developing unit and the OPC drum beforehand in order to remove this unit (see “7-1 Cover”, “7-2-6 Developing Unit”, and “7-2-9 OPC Drum”). Disconnect the connectors from the LED array, and remove the screw on the LED array thermal sensor.
  • Page 167 Lift the LED array. Do not touch the surface of LED array during removal or attachment. Fig.7-86 When installing LED array, place the LED array on the left and right mounting brackets, and then insert the alignment pins into the holes of LED array mounting brackets.

  • Page 168: Cleaning Unit Set Sensor

    7-7-3 Cleaning Unit Set Sensor The cleaning unit set sensor is a limit switch that detects whether or not the cleaning unit is set. It is assembled to the inside of the rear panel so that the contacts close when the cleaning unit is set. Cleaning unit set sensor Fig.7-88...

  • Page 169: Drum Surface Potential Sensor

    7-7-4 Drum Surface Potential Sensor Remove the screws that secure the rear sensor bracket. Screws Fig.7-90 Remove the screws on the front side. Screws Fig.7-91 7-56...
  • Page 170 Remove the holders that secure the sensor to the bracket and remove the sensor. Drum surface potential Drum support roller Holders Fig.7-92 7-57...

  • Page 171: Troubleshooting

    Chapter8 Troubleshooting Troubleshooting of the Main Body Mechanism ......8-1 Remedies for Transport Failure ............8-22 Remedies for Developing Unit Errors ..........8-32 Causes of and Remedies for Errors..........8-37...

  • Page 172: Troubleshooting

    Chapter 8 Troubleshooting...

  • Page 173: Troubleshooting Of The Main Body Mechanism

    Troubleshooting of the Main Body Mechanism The procedures for dealing with the following errors are described in this section. Error code Error Front cover open No fanfold paper (PES, PTS) (also see “8-2 Remedies for Transport Failure ” Paper jam at fuser (PTPS)(see “8-2 Remedies for Transport Failure ”...

  • Page 174: Front Cover Open

    [01 Front cover open] Procedure Points to be checked Remedy Checking method Is the front cover If YES, go to 2. properly closed? If NO, close the front cover. Is the front cover sensor If YES, go to 3. Remove jack CN12 from the DC power normal? If NO, replace the supply, close the front cover properly,...
  • Page 175 (If the “No Fanfold Paper” error occurs during the start of printing or during loading.) Procedure Points to be checked Remedy Checking method Is the fanfold paper If YES, go to 2. engaged with the If NO, set the tractor? fanfold paper on the tractor.
  • Page 176 [07 Scuff lever open] Procedure Points to be checked Remedy Checking method Is the scuff lever in the If YES, go to 2. closed condition (knob If NO, set the scuff B is in “LOCK” lever to the closed position)? (Is the scuff condition (turn roller nipping)? knob B to “LOCK”...
  • Page 177 [0A/0B Splitter failure (front/rear)] Procedure Points to be checked Remedy Checking method Is the fuse 2 blown? If NO, go to 2. Measure the resistance across the ends If YES (fuse is of F2 (fuse 2) of the KMPU board with blown), replace the a digital multimeter.
  • Page 178 Procedure Points to be checked Remedy Checking method Is the KMPU board Is YES, go to 6. Disconnect jack J9 from connector normal? If NO, check the CN9 of the KMPU board and check the output of the DC following 2 points. power supply and Change to Engine Checker Mode (see then replace the...
  • Page 179 [0C/0D Transfer elevator motor failure (upper/lower limit position)] Procedure Points to be checked Remedy Checking method Does the transfer If YES, go to 5. If NO, go to 2. elevator motor operate at the proper timing during the power-on initialization process? Is the fuse 5 blown? If NO, go to 3.
  • Page 180 Bring the positive lead of a digital multimeter in contact with pin 31 of CN6 of the KMPU board and the negative lead in contact with SG (pin 32), and measure the voltage. If normal, the voltage will be approximately 0 V when upper sensor is blocked and will be approximately 5 V when upper sensor is not blocked.
  • Page 181 [16 Abnormal paper position] Procedure Points to be checked Remedy Checking method Is the paper top sensor If NO, go to 2. (PTS) blocked from If YES, remove light? whatever is blocking the light (paper, paper dust, etc.). Is PTS normal? If NO, replace PTS Bring the positive lead of a digital after checking the...
  • Page 182 [17 High voltage failure] Procedure Points to be checked Remedy Checking method Is the equipment to be If NO, set the Check the setting of the main charger, connected set properly? equipment transfer charger, separation charger, (The high-voltage properly. pre-charger, developing unit, and power supply will be in cleaning unit, and check whether or not the no-load condition if...
  • Page 183 [18 Drum motor failure] (Complete stop) Procedure Points to be checked Remedy Checking method Does the drum motor If YES, go to 4. start up at the proper If NO, go to 2. timing during power-on initialization? Is the fuse 4 blown? If NO, go to 3.
  • Page 184 [1E Fusing power supply failure] Procedure Points to be checked Remedy Checking method Is the fuser unit set If YES, go to 3. properly (is the If NO, set the fuser high-voltage unit properly. connection electrode normal)? Is the fusing power If NO, go to 3.
  • Page 185 [1F Flash failure] Procedure Points to be checked Remedy Checking method Is the fusing power If NO, go to 2. Bring the positive lead of a digital supply AC IN voltage multimeter in contact with the AC IN L abnormal? terminal of the fusing power supply and the negative lead in contact with the AC IN N terminal, and measure the...
  • Page 186 [20 Fuser unit overheat (Lamp housing)] Procedure Points to be checked Remedy Checking method Is the KMPU board If YES, go to 2. Bring the positive lead of a digital normal? If NO, go to 5. multimeter in contact with pin 2 of U37 (LM339MA) of the KMPU board, and the negative lead in contact with SG (J7), and then check whether or not the...
  • Page 187 Procedure Points to be checked Remedy Checking method Is the KMPU board If YES, replace the Disconnect connector CN6 from the normal? fuser exit blower. KMPU board, bring the positive lead of If NO, replace the a multimeter in contact with pin 32 of KMPU board.
  • Page 188 [22 Developing motor error] START Does the developing motor start up at the proper timing during power-on initialization? Measure the resistance across the ends of fuse of the DC board with a digital multimeter. The fuse is not blown if the resistance is approximately 0 Ω.
  • Page 189 Turn the POWER switch ON. If it’s normal, the developing motor operates at the proper timing during the power-on initialization process. Replace the Is the developing developing motor. motor normal? 8-17...
  • Page 190 [26 No cleaning unit] Procedure Points to be checked Remedy Checking method Is the cleaning unit set? If YES, go to 2. If NO, set the cleaning unit. Is the cleaning unit set If YES, go to 3. Remove connection jack J5 from sensor normal? If NO, replace connector CN5 of the KMPU board.
  • Page 191 [28 Waste toner box full] Procedure Points to be checked Remedy Checking method Has the waste toner in If YES, replace the the waste toner box waste toner box. reached the full level? If NO, go to 2. Is the waste toner box If YES, replace the Bring the positive lead of a digital full sensor (WTBF)
  • Page 192 [29 No waste toner box] Procedure Points to be checked Remedy Checking method Is the waste toner box If YES, go to 2. set? If NO, set the waste toner box. Is the waste toner box If YES, go to 3. Remove connection jack J5 from set sensor (WTBS) If NO, replace...
  • Page 193 [32 LED array overheat] Procedure Points to be checked Remedy Checking Method Is the output of the If YES, go to 2. Bring the positive lead of a digital LED array thermal If NO, replace the multimeter in contact with pin 1 of U37 sensor normal? KMPU board.

  • Page 194: Remedies For Transport Failure

    Remedies for Transport Failure The locations at which a transport failure may occur with this printer can largely be classified into the following： 1) Paper feed section 2) Transfer, separation, and fuser sections 3) Post-fusing and transport sections Paper output section The following jam detection sensors are positioned at the above sections.
  • Page 195 Transport Failure at the Paper Feed Section [02 No fanfold paper] (If the “No Fanfold Paper” error occurs when the power is turned on.) Procedure Points to be checked Remedy Checking method Is the fanfold paper If YES, go to 2. supplied from between If NO, supply the the paper empty sensor...
  • Page 196 [02 No fanfold paper] (If the “No Fanfold Paper” error occurs during the start of printing or during loading.) Procedure Points to be checked Remedy Checking method Is the fanfold paper If YES, go to 2. engaged with the If NO, set the tractor? fanfold paper on the tractor.
  • Page 197 [16 Abnormal paper position] Procedure Points to be checked Remedy Checking method Is the paper top sensor If NO, go to 2. (PTS) blocked from If YES, remove light? whatever is blocking the light (paper, paper dust, etc.) Is PTS normal? If NO, replace PTS Bring the positive lead of a digital after checking the...
  • Page 198 [03 Paper jam at fuser] Procedure Points to be checked Remedy Checking Method Is the driving of the If YES, go to 2. transport belt started If NO, replace the during power KMPU board. initialization? Is any paper dust or If NO, go to 3.
  • Page 199 PTPS Disassembly and Cleaning Procedures 1) Take out the conveyor block, remove the bracket suction fan, and then remove the PTPS block. 2) Remove one E-ring [1], pull out the shaft sensor [2], and remove the PTPS lever [4]. 3) Wipe the surface of the shaft sensor [2], the inner face of the hole of the PTPS lever [4], and the sensor spring [3] with alcohol.
  • Page 200 Transport Failure at the Post-fusing and Transport Sections [04 Paper jam after fusing] Procedure Points to be checked Remedy Checking method Is the transport belt If YES, go to 2. driven during power If NO, replace the initialization? KMPU board. Is the green lever of If YES, go to 3.
  • Page 201 [13 Paper remaining in paper output section] (In the case of straight output) Procedure Points to be checked Remedy Checking method Is there paper If NO, go to 2. remaining in the paper If YES, remove the output section (position remaining paper.
  • Page 202 Others (Mechanical factors, etc.) 1) Paper feed section 02 No fanfold paper (Applicable sensors: PES, PTS) 16 Abnormal paper position (Applicable sensor: PTS) “No Fanfold Paper” does not occur. Adjust the optical axis of PES. The “No Fanfold Paper” error occurs during loading. PTS position is wrong.
  • Page 203 4) Paper output section 13 Paper remaining in paper output section (Applicable sensor: POPS) 05 Paper jam at paper output section (Applicable sensor: POPS) Paper hits the paper guide. The output tray cannot contain paper. Paper hits the exit side of the top cover. The solenoid actuator is mounted poorly.

  • Page 204: Remedies For Developing Unit Errors

    Remedies for Developing Unit Errors Errors related to the developing unit can be largely classified into the following: 1) No toner 2) Toner density too low These errors occur under the following conditions. No Toner The empty condition is indicated by a signal from the toner empty sensor. To be more specific, the PIN2 output of U39 (LM339MA) of the KMPU board becomes 5 Toner density too low This error is determined by the toner supply rate and the toner density sensor output.
  • Page 205 [2A No toner] Procedure Points to be checked Remedy Checking method Is there enough toner in If YES, go to 2. When there is not enough in the the developing unit? If NO, replenish developing unit, an oscillation sound is toner with the emitted by the toner empty sensor.
  • Page 206 [2C Toner density too low] Procedure Points to be checked Remedy Checking method Is the KMPU board If YES, go to 2. Disconnect CN6 of the KMPU board normal? If NO, replace the and bring the positive lead of a digital KMPU board multimeter in contact with the collector (malfunction of the...
  • Page 207 Also, perform the following procedure to remove foreign matter that has entered inside the developing unit. Take out the developing unit from the main body (see “7-2-6 Developing Unit”). Remove the 3 screws that fix cover of the developing unit and remove the cover. Developing unit Screws Cover...
  • Page 208 Insert the scraper into the gap between the doctor blade and developing roller, and remove the foreign matter caught at the inner side of the doctor blade at the positions of the voids on the developing roller by pulling the scraper towards you.

  • Page 209: Causes Of And Remedies For Errors

    Causes of and Remedies for Errors 1. Toner odor 8-37...
  • Page 210 2. Breaking of the fuser cover glass 8-38...
  • Page 211 3. Fuser unit overheat (Error No.20) 8-39...
  • Page 212 4. Fusing is not performed 8-40...
  • Page 213 4. Fusing is not performed (continued) 8-41...
  • Page 214 5. Fusing power supply failure (Error Nos. 1E, 1F) 8-42...
  • Page 215 6. Paper jam 8-43...
  • Page 216 6. Paper jam (continued) 8-44...
  • Page 217 7. High voltage failure (Error No. 17) 8-45...
  • Page 218 8. Printing quality -To be continued- 8-46...
  • Page 219 8. Printing quality (continued) -To be continued- 8-47...
  • Page 220 8.Printing quality (continued) -To be continued- 8-48...
  • Page 221 8.Printing quality (continued) -To be continued- 8-49...
  • Page 222 8.Printing quality (continued) -To be continued- 8-50...
  • Page 223 8.Printing quality (continued) -To be continued- 8-51...
  • Page 224 9. Transfer motor failure 8-52...
  • Page 225 10. LED array overheat 8-53...
  • Page 226 11. Errors related to the feeder 8-54...
  • Page 227 12. Unusual noise 8-55...
  • Page 228 13. Overflow of developer 8-56...
  • Page 229 14. Discharge of toner 8-57...

  • Page 230: Kmpu Circuit Diagram

    Appendix I KMPU Circuit Diagram...

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