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Ricoh K-C3.5L Service Training

Ricoh K-C3.5L Service Training

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Model K-C3.5L
Model K-C3.5L
Service Training
Slide 1
K-C3.5L: Started 26 November, 2010
First draft: 2 December, 2010
Release 3 December, 2010
8 December, 2010: Several slides modified for easier Chinese translation. No
content changes.
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Summary of Contents for Ricoh K-C3.5L

  • Page 1 Model K-C3.5L Model K-C3.5L Service Training Slide 1 K-C3.5L: Started 26 November, 2010 First draft: 2 December, 2010 Release 3 December, 2010 8 December, 2010: Several slides modified for easier Chinese translation. No content changes.

  • Page 2: Table Of Contents

    Model K-C3.5L Contents 1. Product Outline 12. Transfer and Separation 2. Specifications 13. Paper Feed 3. Installation 14. Fusing 4. Machine Overview 15. Paper Exit 5. Scanner 16. Duplex 6. Image Processing 17. Peripherals ADF (DF2000) 7. Laser Exposure ARDF (DF2010) One-Tray Paper Tray (PS460) 8.

  • Page 3: Product Outline

    Model K-C3.5L Model K-C3.5L Service Training 1. Product Outline Slide 3 No additional notes.
  • Page 4 Model K-C3.5L Product Codes There are two versions of Model K-C3.5L – K-C3.5Lb (simplex) and K-C3.5Lcd (duplex). K-C3.5Lb Product Codes B268-50 (Asia-Pacific) B268-59 (Taiwan) B276-67 (Europe) K-C3.5Lcd Product Codes B269-49 (Asia-Pacific) B269-59 (Taiwan) B244-61 (China) B277-67 (Europe) Note: In this course we will refer to the two versions as K-C3.5Lb and K-C3.5Lcd.
  • Page 5 Model K-C3.5L The Machine This is the machine you will study in this training course. Note the following: Paper trays Bypass tray » On right side of machine – See next slide Operation panel ADF/ARDF (optional) Slide 5 No additional notes.
  • Page 6 Model K-C3.5L Bypass Tray By-pass Tray Slide 6 No additional notes.
  • Page 7 Model K-C3.5L Operation Panel Main Power Clear Indicator Modes Error Load Paper Operation User Tools/ Clear/ Display Selection Scroll Add Toner Switch Counter Stop Start Number # key Sort Lighter/ Escape Keys Darker Original Type Slide 7 No additional notes.
  • Page 8 Model K-C3.5L Main Power Indicator Platen Cover/ ADF (optional) Exposure Glass Operation Switch Internal Tray Operation Panel Front Cover Internal Tray Paper Tray External Part Names Main Power Switch Slide 8 "Operation Switch" refers to the Operation Panel Power Switch.
  • Page 9 Model K-C3.5L Standard Components K-C3.5Lb Mainframe K-C3.5Lcd Mainframe •Copy/Printer/Twain Scanner •Copy/Printer/Twain Scanner •16MB Memory •Duplex •16MB+32MB memory (w/o NIC model) •16MB Memory •250-sheet x1 tray •16MB+32MB memory (w/o NIC model) •100-sheet bypass tray •250-sheet x2 tray •250-sheet output tray •100-sheet bypass tray •USB 2.0...
  • Page 10 Model K-C3.5L Optional Units 1. Platen Cover The external optional units are shown to the 2. ADF right. Internal option: 3. ARDF: Only for K-C3Lcd NIC (Network 4. 1 Bin Tray: Only for K-C3Lcd interface card) 5. 1-tray paper bank 6.

  • Page 11: Specifications

    Model K-C3.5L Model K-C3.5L Service Training 2. Specifications Slide 11 No additional notes.
  • Page 12 Model K-C3.5L General Specifications Configuration Desktop Scanning system Flatbed with CCD sensing elements Printing process Laser beam exposure Dry, dual-component development system Zoom 50% to 200% in 1% steps Power Consumption Full system » Less than 1.28 kW Reduced Electrical Consumption via Lower Power mode »...

  • Page 13: Installation

    Model K-C3.5L Model K-C3.5L Service Training 3. Installation Slide 13 No additional notes.
  • Page 14 Model K-C3.5L Install the Copier Procedure: Copier Installation (see field service manual) Developer Initialization must be performed via SP-2214-1 After installing machine & all options, and making all test copies, record value of total counter. » This is very important, because this value will be used for billing with Meter Click contracts.
  • Page 15 Model K-C3.5L Putting in Developer Make only a small cut in top corner of bag for better control when pouring. Make sure not to spill developer on the gears. If you have to turn the gears to distribute developer evenly, make sure to do so very slowly and as little as possible.
  • Page 16 Model K-C3.5L Installation of Options Install the following options. See the FSM for all procedures. Platen Cover, ADF, or ARDF » Only one of these can be installed. Network Interface Board » This NIB is new with this pr oduct.

  • Page 17: Machine Overview

    Model K-C3.5L Model K-C3.5L Service Training 4. Machine Overview Slide 17 No additional notes.
  • Page 18 Model K-C3.5L Mechanical Component Layout Exposure 2nd Mirror Lamp Exposure Glass Scanner Motor 1st Mirror Hot Roller 3rd Mirror Exit Roller Exit Sensor Lens Block Scanner Pressure Roller HP Sensor OPC Drum Toner Supply Bottle Holder Image Density Sensor Laser Unit...
  • Page 19 Model K-C3.5L Paper Path ADF Original Feed Paper feed from By-pass Tray Paper feed from Tray 1 Slide 19 No additional notes.
  • Page 20 Model K-C3.5L Drive Layout Scanner Motor Hot Roller Main motor drives fusing unit, PCU and development unit. Fusing Unit OPC Drum Development roller Development Unit Slide 20 More on Drive Layout The top diagram shows the scanner. The scanner has one motor.
  • Page 21 Model K-C3.5L Copy Process Cleaning Paper separation Drum charge Image transfer Laser exposure Development Slide 21 More on the Copy Process The photoconductor unit (PCU) contains the drum, development roller, and charge roller. A charge roller gives the drum a negative charge.

  • Page 22: Scanner

    Model K-C3.5L Model K-C3.5L Service Training 5. Scanner Slide 22 No additional notes.
  • Page 23 Model K-C3.5L Scanner Unit 600 dpi CCD Exposure lamp: One xenon lamp The reflector reduces shadows on paste-up originals Slide 23 No additional notes.
  • Page 24 Model K-C3.5L Scanner Drive Scanner drive motor: Drives the scanner (100 mm/s) Timing belts are used in this model In ADF mode, scanner stays at home position. Original is scanned while ADF feeds sheet through. Slide 24 No additional notes.
  • Page 25 Model K-C3.5L Original Size Detection – Platen Mode (1) Reflective Platen cover sensor photosensors (APS sensors) detect the paper size. Original width sensors Original length sensors Slide 25 More on Original Size Detection in Platen Mode Overview Study the APS sensors. There are two length sensors and two width sensors.
  • Page 26 Model K-C3.5L Original Size Detection – Platen Mode (2) This table shows the outputs of the sensors for each original size. Original Size Length Sensors Width Sensors SP4301 Display A3/A4 LT/DLT Version Version 11"x17" 11110000 8.5"x11" 11010000 8.5"x13" – 11000000 A4 SEF 8.5"x13"...
  • Page 27 Model K-C3.5L SP Modes SP 4008: Sub scan magnification SP 4009: Main scan magnification SP 4010: Leading edge registration SP 4011: Side-to-side registration SP 4013: Scanner free run (exposure lamp off) SP 4305: Determines how machine interprets original size sensors for A4/LT widths.
  • Page 28 Model K-C3.5L Lab Work Practice the following replacement and adjustment procedures, referencing the FSM. Scanner Unit Copy adjustments Do any of the procedures that you think are in need of practicing. Pay attention to all notes, cautions, and warnings in the manual.

  • Page 29: Image Processing

    Model K-C3.5L Model K-C3.5L Service Training 6. Image Processing Slide 29 No additional notes.
  • Page 30 Model K-C3.5L Image Processing Circuit Memory Control DRAM Drum Driver GDI and Controller BICU Data comes to the BICU board from three sources. Scanner and SBU, Fax controller & Printer controller See the notes section below for more details. Slide 30 The CCD generates an analog video signal.
  • Page 31 Model K-C3.5L SBU Board BICU Digital Analog Processing 8-bit Data Processing 1 IPU VCU Analog Processing 2 The CCD converts the light reflected from the original into an analog signal. Each CCD line has 7,400 pixels, producing a resolution of 600 dpi (23.6 lines/mm).
  • Page 32 Model K-C3.5L Image Processing Unit BICU Memory Controller DRAM Slide 32 The image data from the SBU goes to the IPU (Image Processing Unit) on the BICU board, which carries out the following processes on the image data: 1. Auto shading 2.
  • Page 33 Model K-C3.5L Image Quality Adjustments - 1/3 Three basic original types Text Photo Special (can only be accessed through a user tool) Ten original types in total, selectable with a user tool Text modes: 2 Photo modes: 3 Special modes: 5...

  • Page 34: To Allocate An Original Type

    Model K-C3.5L Image Quality Adjustments - 2/3 The original mode key on the operation panel has two settings: Text Photo The default settings are: Text indicator lit: Normal Text (Text 1) Photo indicator lit: Photo Priority (Photo 1) To allocate an original type:...
  • Page 35 Model K-C3.5L Image Quality Adjustments - 3/3 SP 4922 to 4932: Image processing adjustments SP 4921: Selects one of the original modes; only one can be adjusted at any one time. First select a mode with SP 4921. Then adjust it with SP 4922 to 4932.
  • Page 36 Model K-C3.5L SP Modes SP 4015: Adjusts the area of the white plate used for auto shading SP 4903: ADS level SP 4904: Lower limit for ADS SP 4905: Determines how much of the image is used for ADS (the whole width or just a narrow...
  • Page 37 Model K-C3.5L Lab Work Study the scanning adjustments in the FSM. Replacement and Adjustment Copy Adjustments Printing/Scanning Scanning Do any of the procedures that you think that you need to practice. Pay attention to all notes, cautions, and warnings in the manual.

  • Page 38: Laser Exposure

    Model K-C3.5L Model K-C3.5L Service Training 7. Laser Exposure Slide 38 No additional notes.
  • Page 39 Model K-C3.5L Laser Optics One laser beam There is only one laser beam in this model. Slide 39 More on Laser Optics The LSD (laser synchronisation detector) is part of the laser diode unit, and cannot be replaced separately. Laser beam There is only one in this model.
  • Page 40 Model K-C3.5L Safety Switches Front/Right Cover Safety Switches LDD Drive Board +5VLD +24V BICU Laser beam Optical Path LD Driver IC Drum When the front or right-side cover is open, a switch cuts power to the laser diode. Both covers operate the same switch.
  • Page 41 Model K-C3.5L SP Modes SP 2915: Polygon mirror idling time SP 2998: Main scan magnification (printer) There is also a main scan adjustment for the scanner, which affects image processing algorithms. » SP 2998 affects laser on/off frequency in main scan direction.
  • Page 42 Model K-C3.5L Lab Work Before you start Go to the machine. Look for the front and right cover switches. See how the covers operate the switches. On the point-to-point diagram, look at the circuit from the power supply through to the laser diode.
  • Page 43 Model K-C3.5L Model K-C3.5L Service Training 8. PCU (Photo Conductor Unit) Slide 43 No additional notes.
  • Page 44 Model K-C3.5L Overview There is no new PCU detection in this machine. This is due to the PCU not being a user-replaceable part. Some of the PCU components are replaced individually at PM. When a new PCU is installed, new developer must also be installed and SP 2214 must be done to reinitialize the TD sensor.
  • Page 45 Model K-C3.5L PCU Components Cleaning blade Toner collection coil OPC Drum (30 Pick-off mm diameter) Quenching pawls lamp Charge Roller Charge With cleaning roller cleaning brush drum brush Pick-off Pawls Cleaning Unit Charge roller Counter blade mechanism Edge cleaning mechanism...
  • Page 46 Model K-C3.5L PCU Details The PCU contains the following. OPC drum Development unit (including development roller and TD sensor) Charge roller and charge roller cleaning brush Drum cleaning unit (blade, toner collection coil) Pick-off pawls The PCU does not contain the following.
  • Page 47 Model K-C3.5L Drive Main Motor The main motor drives the drum through a series of gears as shown above. Slide 47 No additional notes.

  • Page 48: Pcu

    Model K-C3.5L Lab Work Practice replacing PCU components. Replacement and Adjustment PCU Section Be sure to do the After Replacement or Adjustment procedure when you are finished practicing. (Also, see the notes section below.) Pay attention to all notes, cautions, and warnings in the manual.

  • Page 49: Drum Charge

    Model K-C3.5L Model K-C3.5L Service Training 9. Drum Charge Slide 49 No additional notes.
  • Page 50 Model K-C3.5L Drum Charge Roller Drum Charge Roller Roller is always in contact with drum. Drum charge roller is at -1700 V for printing. Drum surface voltage is - 950 V Slide 50 More on Drum Charge Roller The charge roller is part of the PCU unit.
  • Page 51 Model K-C3.5L Charge Roller Voltage Correction ID Sensor Pattern Sub-scan direction Charge Voltage Laser Diode Drum Potential Development Bias ID Sensor Output Details are in the notes section below. Slide 51 With a drum charge roller system, the voltage transferred from roller to drum varies with the temperature and humidity around the drum charge roller.
  • Page 52 Model K-C3.5L ID Sensor Pattern Production Timing The ID sensor pattern is made at the following times: During warm-up at power on When the machine starts warming up from energy saver mode and the temperature is less than the target temperature as set with SP Mode.
  • Page 53 Model K-C3.5L Charge Roller Cleaning Cam Gear Charge Roller Cleaning Brush Charge Roller Cleaning Brush is always in contact with drum charge roller A cam gear moves the charge roller from side to side to improve cleaning. This waste toner is not recycled.
  • Page 54 Model K-C3.5L SP Modes SP 2001: Charge roller voltage adjustment (for printing and for making an ID sensor pattern). Slide 54 No additional notes.

  • Page 55: Development & Toner Supply

    Model K-C3.5L Model K-C3.5L Service Training 10. Development and Toner Supply Slide 55 No additional notes.
  • Page 56 Model K-C3.5L Overview Single development roller Development Roller Two mixing augers Toner density control TD sensor ID sensor TD Sensor Slide 56 This machine uses a single-roller development system. Two mixing augers mix the developer. The toner density (TD) sensor and image density (ID) sensor (see the...
  • Page 57 Model K-C3.5L Main motor Drive Main motor: Drives development mechanism, via development drive shaft. Development drive shaft: Engages when PCU is pushed in. Development roller turns whenever main motor is on. No development clutch. Slide 57 No additional notes.
  • Page 58 Model K-C3.5L Developer Mixing Auger 1 Auger 2 Two mixing augers keep developer mixed. Auger 2 moves excess toner from development roller towards front. Auger 1 moves this excess toner, mixed with new toner, to rear and back to development roller.
  • Page 59 Model K-C3.5L Development Bias Bias terminal Development roller White areas: High negative charge (-950V) Black areas: Discharged by the laser (about -150V) Development bias (-650V): Forces the negatively-charged toner onto the discharged areas of the drum. Applied to development roller shaft through drive shaft.
  • Page 60 Model K-C3.5L Toner Bottle Replenishment When bottle is placed in bottle holder: Shutter moves against side of PCU, and it opens. When lever is returned Lever Cap is pulled away so that toner can come out. Shutter Side of PCU...
  • Page 61 Model K-C3.5L Toner Supply - Bottle Drive Toner Supply Motor Toner supply motor turns the bottle To supply fresh toner to development unit, toner supply motor turns on. Spiral grooves help toner to move towards bottle exit. Slide 61 No additional notes.
  • Page 62 Model K-C3.5L Toner Supply - Input to Development Unit Mylar tabs in bottle unit push toner towards development unit entrance. Recycled toner from drum also arrives at this entrance. New toner enters here Recycled toner enters here Slide 62 More on Toner Supply Input to the Development Unit Toner enters the development unit through the shutter.
  • Page 63 Model K-C3.5L Toner Density Control – 1 Overview Toner Supply Motor On Time Calculation Controlled by TD and ID sensors. TD Sensor Output (Vt) There are four modes but only Vt Reference two can be used. Voltage (Vref) (See notes below New Vref for details.)
  • Page 64 Model K-C3.5L Toner Density Control – 2 Toner Density Sensor Initial Setting The TD sensor initial setting (SP 2214: Developer Initialize) procedure must be done after replacing the developer. During TD sensor initial setting, the TD sensor is set so that the TD sensor output is the value of SP 2926 (default: 2.4 V).
  • Page 65 Model K-C3.5L Toner Density Control – 3 Vsp/Vsg Detection The ID sensor detects the following voltages. Vsg: The ID sensor output when checking the drum surface Vsp: The ID sensor output when checking the ID sensor pattern In this way, the reflectivity of both the drum surface and the...
  • Page 66 Model K-C3.5L Toner Density Control – 4 Toner Supply Reference Voltage (Vref) Determination The toner supply reference voltage (Vref) is used for toner supply determination (see below). Vref is determined using the following data: » ID sensor output (Vsp/Vsg) » (Vts or the current Vref) – Vt...
  • Page 67 Model K-C3.5L Abnormal Sensor Conditions ID sensor If ID sensor output is out of spec, machine disregards output from sensor, and uses a Vref of 2.5 V. After replacing ID sensor, reset error counter with SP 7-992. TD sensor If TD sensor output is out of spec, machine changes to fixed supply mode 2.
  • Page 68 Model K-C3.5L Toner Near-end/End Detection No near-end or end sensors Toner near-end/end are determined by TD sensor output (current and reference voltages). If near-end is detected, toner is added for a short period (adjustable with SP 2 923). If the toner level does not recover, toner end is after 50 more copies (the number of copies is adjustable with SP 2 213).
  • Page 69 Model K-C3.5L Toner Near-end/End Detection - Details If Vt level 6 is detected 5 consecutive times, near-end is detected. Toner is added after the copy job: If supply recovers to Vt level 5, near-end is cancelled. Otherwise, toner end occurs after 50 copies If Vt level 7 is detected 3 consecutive times, toner end is detected immediately.
  • Page 70 Model K-C3.5L SP Modes - Development SP 2201: Development bias (printing, ID sensor pattern creation) SP 2802: Forced developer agitation Slide 70 No additional notes.
  • Page 71 Model K-C3.5L SP Modes - Toner Supply SP 2221: ID sensor error display (Vsg, Vsp, Vt, etc if an ID sensor error occurred) SP 2908: Forced toner supply SP 2921: Toner supply mode (sensor control, fixed control) SP 2922: Toner supply motor on time (sensor control mode)
  • Page 72 Model K-C3.5L SP Modes - Toner Near-end/End SP 2213: Number of copies between near-end and end (20 or 50 - default: 50) SP 2923: Toner supply motor on time during recovery from end/near-end SP 2928: Clears the toner end condition Normally, do not use this, for the reasons explained in the SP table.
  • Page 73 Model K-C3.5L Lab Work Remove the ID sensor. Replacement and Adjustment Image Transfer Image Density Sensor Slide 73 No additional notes.

  • Page 74: Drum Cleaning & Toner Recycling

    Model K-C3.5L Model K-C3.5L Service Training 11. Drum Cleaning & Toner Recycling Slide 74 No additional notes.
  • Page 75 Model K-C3.5L Drum Cleaning Counter blade system, no brush Drum reverse rotation to clean blade’s edge Slide 75 More on Drum Cleaning This machine uses a counter blade, but no brush. The blade scrapes toner off the drum, and a toner collection coil picks up toner from the top of the pile and carries it back to the development unit.
  • Page 76 Model K-C3.5L Toner Recycling Toner collection coil Toner collection coil: Moves toner towards Toner collection coil the opening in the PCU (Photo Drum Conductor Unit) Opening Opening Mixing augur 1 Slide 76 More on Toner Recycling The slider with the two comb-like appendages on it is always vibrating.

  • Page 77: Transfer And Separation

    Model K-C3.5L Model K-C3.5L Service Training 12. Transfer and Separation Slide 77 No additional notes.
  • Page 78 Model K-C3.5L Overview Discharge Plate Pick-off Pawl Drum Transfer Roller Transfer Roller Transfer Roller Terminal Transfer roller is always in contact with drum. Drum curvature, pick-off pawl, and discharge plate separate paper from drum. Slide 78 The discharge plate is grounded.
  • Page 79 Model K-C3.5L Main Motor Drive Drum Transfer roller Drum drives Transfer Roller through gear. Transfer Roller always contacts drum There is no touch and release mechanism. Slide 79 No additional notes.
  • Page 80 Model K-C3.5L Transfer Current First, a low current (10 μA) is supplied at leading edge (before print area). Prevents positively charged toner remaining on drum from transferring to roller. Then high current is supplied (amount depends on paper size and type).
  • Page 81 Model K-C3.5L Transfer Roller Cleaning Negative cleaning current is applied, followed by positive current. Negatively and positively charged toner particles are both transferred back to drum. Current for negative-charge phase can be adjusted with SP 2301-4. Three conditions for entering cleaning mode: Before starting a job »...
  • Page 82 Model K-C3.5L Separation Discharge Plate Drum curvature and Discharge Plate separate paper from drum. There is no adjustment for discharge voltage in this machine, because discharge plate is grounded. Slide 82 No additional notes.
  • Page 83 Model K-C3.5L SP Modes SP 2301: Transfer current SP 2301 1: Paper tray » 'Normal’ paper SP 2301-2: By-pass tray » For special/thick paper SP 2301-4: During transfer roller cleaning SP 2906: Image writing position shift SP 2996: Transfer roller cleaning before each job,...

  • Page 84: Paper Feed

    Model K-C3.5L Model K-C3.5L Service Training 13. Paper Feed Slide 84 No additional notes.
  • Page 85 Model K-C3.5L Overview Built-in paper trays: 250 sheets each Friction pad and feed roller system By-pass tray: Up to 100 sheets Slide 85 More on Overview Note that the paper feed roller and shaft come out with the tray when the user pulls the tray out.
  • Page 86 Model K-C3.5L Paper Feed Drive Main Motor Main motor drives pick-up and feed mechanism. Paper feed Paper feed clutch clutches transfer main motor drive to Registration sensor paper feed roller. When paper feed clutch turns on, feed roller starts to feed paper.
  • Page 87 Model K-C3.5L Feed and Separation Paper feed roller Friction Feed roller and friction pad system. Pressure of friction pad not adjustable. Slide 87 No additional notes.
  • Page 88 Model K-C3.5L Tray Lift Hook Slider Projection When the tray is closed, projection on copier frame pushes slider off bottom plate hook. Slider is on bottom part of tray. After slider comes off, compressed springs lift bottom plate. Slide 88...
  • Page 89 Model K-C3.5L Paper End Detection Paper end sensor feeler falls through slot in bottom plate when there is no paper. Slide 89 No additional notes.
  • Page 90 Model K-C3.5L Paper Size Detection - Paper Tray Dial and microswitch mechanism. Paper size sensor detects position of dial selected by user User must set dial to correct size. (Size table is in the notes below.) Slide 90 More on Paper Size Detection...
  • Page 91 Model K-C3.5L Paper Size Detection - By-pass Tray Bypass paper size switch monitors paper width. Side fences turn a gear wheel that contains sensor terminals. Slide 91 More on Paper Size Detection The side guides contain ratchets that turn a gear wheel at the center of the sensor.
  • Page 92 Model K-C3.5L Side Fences Side fences have stoppers to prevent them from bending when a full tray is pushed in too strongly Slide 92 More on Side Fences If the tray is full of paper and it is pushed in strongly, the fences may deform or bend.
  • Page 93 Model K-C3.5L Registration Registration clutch transfers drive from main motor to registration roller. SP 1003 adjusts amount of buckle at registration roller to prevent skew. SP 1903: Adjusts Registration Clutch the amount of feed from the feed roller to help get paper...
  • Page 94 Model K-C3.5L SP Modes SP 1001: Leading edge registration for various paper feed stations SP 1002: Side-to-side registration for various paper feed stations SP 4010 - 11: Scanner registration SP 6006: ADF registration SP 1003: Paper feed timing. (Adjusts buckle at the registration roller to prevent skew.)
  • Page 95 Model K-C3.5L Lab Work Practice the removal procedures for the paper feed section. Replacement and Adjustment Paper Feed Section Slide 95 No additional notes.

  • Page 96: Fusing

    Model K-C3.5L Model K-C3.5L Service Training 14. Fusing Slide 96 No additional notes.
  • Page 97 Model K-C3.5L Overview Two fusing lamps Not identical Pressure Roller has a Cleaning Roller Thin-walled hot roller No oil supply mechanism Slide 97 Components 1. Paper exit roller 2. Exit sensor 3. Hot roller strippers 4. Pressure roller 5. Cleaning roller 6.
  • Page 98 Model K-C3.5L Drive Main motor Exit rollers Fusing unit is driven by main motor through gears. Paper exit rollers are driven by main motor through a timing belt. Slide 98 No additional notes.
  • Page 99 Model K-C3.5L Automatic Pressure Release Solenoid Cover Drive Gear Fusing unit drive gear disengages when cover is open for easier jam removal Fusing drive release solenoid cuts drive to fusing unit during warm-up. Slide 99 More on Automatic Release Pressure release when the cover is open The drive gear releases when the cover is open, so that jams can be removed.
  • Page 100 Model K-C3.5L Fusing Entrance Guide Shaft If paper creases in fusing unit, move guide to right. Slide 100 More on Entrance Guide Shaft The entrance guide can be moved to prevent creasing. Moving the guide to the right feeds the paper more directly to the gap between...
  • Page 101 Model K-C3.5L Pressure Roller The springs apply pressure between hot roller and pressure roller. The springs can be moved. Default position is at end. Slide 101 No additional notes.
  • Page 102 Model K-C3.5L Cleaning Roller Cleaning Roller Pressure Roller Cleaning Roller is always in contact with Pressure Roller. It removes toner and paper dust. Slide 102 No additional notes.
  • Page 103 Model K-C3.5L Fusing Temperature Control Machine checks thermistors once every 1.5 seconds. Machine compares current and previous readings, and the target, and then decides how long to keep lamp on during next second. Slide 103 More on Fusing Temperature Control The cpu switches the fusing lamp on/off depending on the thermistor output.
  • Page 104 Model K-C3.5L Fusing Lamp Power Supply Soft Start: Full power is applied to the fusing lamp gradually, not all at once Machine gradually allows more power to fusing lamp over a number of zero-cross cycles of ac supply. Slide 104...
  • Page 105 Model K-C3.5L Room Lighting Affects Caused by starting and stopping fusing lamp power every second SP 1108: Reduce flicker by inputting a larger value BICU may be unable to detect fusing lamp errors if the cycle is more than 2 seconds.
  • Page 106 Model K-C3.5L Poor Fusing on the First Few Copies If the room is cold, the hot roller may not stay hot for very long after reaching the print ready temperature. To solve this problem, set SP 1103 to 'on'. Slide 106...
  • Page 107 Model K-C3.5L Offset when Making Many Copies on Narrow Paper Target fusing temperature lowered by 10°C If the smallest copy paper width detected during a 40-second interval is less than 220 mm. Target fusing temperature lowered by another 5°C If, during the next 80 seconds, the smallest width detected is again less than 220 mm.
  • Page 108 Model K-C3.5L Reduced Copy Speed - Narrow Paper To ensure that images are properly fused onto paper 220 mm or less in width, machine automatically reduces copy speed under following conditions: After 180 seconds of continuous copying. When Thick or Special paper mode is used.
  • Page 109 Model K-C3.5L Overheat Protection Three levels of overheat protection Normally, the primary level can fully protect the hardware. The second works as the fail-safe feature for the first one. The third works as the fail-safe feature for the second one.
  • Page 110 Model K-C3.5L SP Modes SP 1103: Fusing idling on/off SP 1105: Fusing unit temperatures SP 1106: Displays the current fusing unit temperature SP 1107: Soft start adjustment SP 1108: Fusing temperature control cycle (1, 1.5, or 2 seconds) SP 1109: Nip band width adjustment...
  • Page 111 Model K-C3.5L Lab Work Practice the removal procedures for the fusing section. Replacement and Adjustment Fusing Slide 111 No additional notes.

  • Page 112: Paper Exit

    Model K-C3.5L Model K-C3.5L Service Training 15. Paper Exit Slide 112 No additional notes.
  • Page 113 Model K-C3.5L Drive Main motor Exit rollers Paper exit rollers are driven by main motor through a timing belt. Slide 113 No additional notes.
  • Page 114 Model K-C3.5L Model K-C3.5L Service Training 16. Duplex Slide 114 This section is for the K-C3.5Lcd only. The K-C3.5Lb is a simplex machine.
  • Page 115 Model K-C3.5L Overview Duplex inverter rollers After fusing, the junction gate directs Junction gate Duplex entrance the paper either: Exit rollers sensor Out through the exit rollers Upper transport Up to the duplex roller inverter rollers If paper goes to the...
  • Page 116 Model K-C3.5L Drive Duplex inverter roller Duplex inverter Duplex inverter motor motor drives the inverter roller Upper transport roller At the entrance to the inverter table Duplex transport Duplex transport motor drives the motor rollers in the duplex unit Lower transport...
  • Page 117 Model K-C3.5L Duplex Entrance Inverter gate solenoid Switches on to send paper to the inverter table Stays off to feed paper out of the machine Slide 117 No additional notes.
  • Page 118 Model K-C3.5L Duplex Feed Path Duplex inverter rollers and inverter The junction gate sensor directs the paper up to the duplex inverter rollers, instead of out to the exit rollers. When the paper trailing edge reaches the duplex inverter sensor:...
  • Page 119 Model K-C3.5L Paper Feed Time – Interleaving Longer than A4/LT SEF: Only one page can pass through at a time (that is, no interleaving is done). A4/LT SEF or shorter: Two pages can go through the duplex unit at once (this is known as ‘interleaving’).

  • Page 120: Duplex

    Model K-C3.5L Lab Work Practice the removal procedures for the duplex unit. Replacement and Adjustment Duplex Unit Slide 120 No additional notes.

  • Page 121: Peripherals

    Model K-C3.5L Model K-C3.5L Service Training 17. Peripheral Devices Slide 121 No additional notes.

  • Page 122: Adf (Df2000)

    Model K-C3.5L DF2000 Slide 122 No additional notes.
  • Page 123 Model K-C3.5L Overview Feeds originals past the DF exposure glass while scanning No inverter unit The DF exposure glass is a narrow glass to the left of the exposure glass. The ADF does not use the main exposure glass, unless the user selects book mode and places the originals on the glass (in which case, the ADF mechanism isn’t used - just the cover).
  • Page 124 Model K-C3.5L Original Size Detection Two width sensors, and two length sensors. All sensors are reflective photosensors. Supported Paper Sizes under Specifications in the FSM. Original Size Detection in the DF2000 service manual. Slide 124 No additional notes.
  • Page 125 Model K-C3.5L Pick-up Mechanism Original set sensor detects when original has been placed in feeder. Pick-up solenoid drops pick-up roller onto top sheet of originals. For details see Pick-up and Separation in the DF2000 service manual. Slide 125 No additional notes.
  • Page 126 Model K-C3.5L Separation Mechanism Transport motor drives all rollers. Feed clutch drives pick-up roller and feed belt. For details see Pick-up and Separation in the DF2000 service manual. Slide 126 No additional notes.
  • Page 127 Model K-C3.5L Transport and Feed-out Transport motor feeds original through scanner. Motor speed depends on reproduction ratio. For details see in the DF2000 Original Transport and Exit Mechanism service manual. Slide 127 No additional notes.
  • Page 128 Model K-C3.5L ADF Sensors ADF Sensors Note: Do not cover above sensors with your hands, or place objects on them. Doing so could cause: Paper size to be detected incorrectly Paper misfeed error message to appear. Slide 128 No additional notes.
  • Page 129 Model K-C3.5L SP Modes SP 6006: Registration SP 6009: ADF free run SP 6901: APS sensor display for the ADF Slide 129 No additional notes.

  • Page 130: Ardf (Df2010)

    Model K-C3.5L ARDF DF2010 Slide 130 No additional notes.
  • Page 131 Model K-C3.5L Overview Feeds originals past the DF exposure glass while scanning Inverter unit allows duplex copying and stacking in the correct order after scanning The DF exposure glass is a narrow glass to the left of the exposure glass.
  • Page 132 Model K-C3.5L Mechanical Components Look at the component layout diagrams. Mechanical component layout Drive layout Go to your machine and find the components on the diagrams. Note the two motors (DF Feed, DF Transport) and the clutch (DF Feed). Their functions will be explained during this section of the course.
  • Page 133 Model K-C3.5L Electrical Components For details regarding component layout, the functions of the components, and overall operation of the document feeder, refer to the ARDF DF2010 Service Manual. Go to your machine and find the components in the diagrams. Slide 133...
  • Page 134 Model K-C3.5L Original Size Detection One width sensor, and two length sensors Width sensor: Output depends on the guide position Slide 134 More on Original Size Detection The width sensor has four possible outputs, as shown in the diagram in the manual.
  • Page 135 Model K-C3.5L Pick-up and Separation Pick-up solenoid: Lifts the entrance guide, to lift the originals to the pick-up roller Transport motor: Drives all the rollers Feed clutch: Drives the pick-up roller and feed belt Slide 135 No additional notes.
  • Page 136 Model K-C3.5L Original Transport and Exit Single-sided Originals Transport motor: Feeds the original through the scanner Motor speed depends on the reproduction ratio Slide 136 More on Original Transport and Exit Single-sided Originals Study the path of paper through the DF.
  • Page 137 Model K-C3.5L Original Transport and Exit Double-sided Originals 1 Original exit sensor When the original exit sensor detects the leading edge, the junction gate opens and the original goes to the reverse tray. Slide 137 No additional notes.
  • Page 138 Model K-C3.5L Original Transport and Exit Double-sided Originals 2 When the paper is in the reverse tray, the DF feed motor reverses and the reverse roller feeds the original back into the ARDF. Slide 138 No additional notes.
  • Page 139 Model K-C3.5L Original Transport and Exit Double-sided Originals 3 The reverse side is scanned The original is fed to the reverse tray again The ARDF will reverse the page once more so that the pages of the original are stacked in the correct order.
  • Page 140 Model K-C3.5L Original Transport and Exit Double-sided Originals 4 The page is fed in from the reverse tray and out to the exit tray. Slide 140 No additional notes.
  • Page 141 Model K-C3.5L SP Modes SP 6006: Registration SP 6009: ARDF free run SP 6010: Stamp position adjustment (in the sub- scan direction only) Sp 6901: APS sensor display for the ARDF Slide 141 No additional notes.
  • Page 142 Model K-C3.5L Lab Work Practice removal and replacement procedures (see Replacement and Adjustment in the DF2010 Service Manual): Do any of the procedures that you think that you need to practice. Pay attention to all notes, cautions, and warnings in the manual.

  • Page 143: One-Tray Paper Tray (Ps450)

    Model K-C3.5L One-Tray Paper Tray Unit PS460 Slide 143 No additional notes.
  • Page 144 Model K-C3.5L Mechanical Components Study the mechanical and drive component layout diagrams in the Paper Tray 1 (PS460) service manual. Overall layout Drive layout Go to your machine and find the components on the diagrams. Slide 144 More on Mechanical Components The feed roller is part of the tray.
  • Page 145 Model K-C3.5L Electrical Components Study the electrical component layout diagram in the Paper Tray 1 (PS460) Service Manual. Go to your machine and find the components in the diagram. Slide 145 More on Electrical Components There are two motors, one to lift the tray and one to drive the rollers.
  • Page 146 Model K-C3.5L Paper Feed and Separation Feed roller and Feed roller friction pad feed system Paper feed motor drives the feed roller. There is no clutch. Friction pad Spring Slide 146 The paper tray holds 500 sheets. The paper feed roller drives the top sheet of paper from the paper tray to the copier/printer.
  • Page 147 Model K-C3.5L Paper Lift - Engaging the Shafts Paper size switch: Detects when the tray is pushed in The two shafts engage when the tray is pushed into the machine. One shaft lifts the stack The other shaft controls the paper feed pressure...
  • Page 148 Model K-C3.5L Paper Lift - Pressure Application Study the mechanism on your machine. Refer to the Paper Tray 1 (PS460) Service Manual. Study the description while referring to the diagram. Slide 148 No additional notes.
  • Page 149 Model K-C3.5L Paper Lift - Pressure Application Main pressure spring Lift sensor Secondary pressure spring Lift motor Bottom plate pressure lever When the lift sensor is activated, the lift motor reverses briefly to reduce the feed pressure Slide 149 More on Paper Lift – Pressure Application This slide shows how the tray is lifted.
  • Page 150 Model K-C3.5L Paper End Detection Paper end sensor feeler: Falls through a slot in the bottom plate when there is no paper. Slide 150 No additional notes.
  • Page 151 Model K-C3.5L Paper Height Detection Bottom plate pressure lever Paper height sensors Bottom plate pressure lever Moves as paper is used up Slide 151 More on Paper Height Detection Note that these sensors are not used unless the optional printer controller has been installed.
  • Page 152 Model K-C3.5L Paper Size Detection Paper size switch detects the position of the dial selected by the user ‘ ’ position: Use to select a non- standard paper size Input the size with User Tools - System Settings – Tray Paper Settings –...
  • Page 153 Model K-C3.5L Side Fences The side fences have stoppers to prevent them bending when a full tray is pushed in too strongly Slide 153 More on Side Fences If the tray is full of paper and it is pushed in strongly, the fences may deform or bend.
  • Page 154 Model K-C3.5L End Fences End fence The bottom plate lifts as the paper is used up The fence is connected to the bottom plate, and it moves forward when the bottom plate lifts. This keeps the edges of the paper in the stack tidy.
  • Page 155 Model K-C3.5L SP Modes SP 1908: Paper lift adjustment Slide 155 No additional notes.
  • Page 156 Model K-C3.5L Lab Work Practice replacement procedures. Refer to the Paper Tray 1 (PS460) Service Manual. Do any of the procedures that you think that you need to practice. Pay attention to all notes, cautions, and warnings in the manual.
  • Page 157 Model K-C3.5L Two-Tray Paper Tray Unit PS450 Slide 157 No additional notes.
  • Page 158 Model K-C3.5L Mechanical Components Study the component layout diagrams in the Two-Tray Paper Tray Unit (PS450) Service Manual. Mechanical component layout Drive layout Go to your machine and find the components in the diagrams. Slide 158 More on Mechanical Components The feed roller is part of the tray.
  • Page 159 Model K-C3.5L Electrical Components See the component layout diagram and details regarding component functionality in the Two- Tray Paper Tray Unit (PS460) Service Manual. Go to your machine and find the components on the diagram. Slide 159 More on Electrical Components There are three motors, one lift motor for each tray and one to drive the rollers in both the trays.
  • Page 160 Model K-C3.5L Paper Feed and Separation Feed roller and friction Feed roller pad system Paper feed motor drives the feed roller The appropriate paper feed clutch turns on to transfer drive from the motor to the rollers in the required tray.
  • Page 161 Model K-C3.5L Mechanisms The following are the same as for the one-tray unit. Paper Lift » The only difference is that there are adjustment SPs for both trays. Paper End Detection Paper Height Detection Paper Size Detection End and Side Fences Slide 161 No additional notes.
  • Page 162 Model K-C3.5L SP Modes SP 1908: Paper lift adjustment Slide 162 No additional notes.
  • Page 163 Model K-C3.5L Lab Work Practice the replacement procedures in the Two- Tray Paper Tray Unit (PS460) Service Manual. Do any of the procedures that you think that you need to practice. Pay attention to all notes, cautions, and warnings in the manual.

  • Page 164: One-Bin Tray (Pt340)

    Model K-C3.5L One-Bin Tray PT340 Slide 164 No additional notes.
  • Page 165 Model K-C3.5L Overview This tray can only be used on the B269 and B244 models. This is an optional extra output tray. It isn't a sorter. The tray does not move from side to side. Tray capacity: 100 sheets With more than one output tray, the user can (for example) direct copy mode output to the standard output tray, and fax mode output to the 1-bin tray.
  • Page 166 Model K-C3.5L Components See the component layout diagrams in the One Bin Tray (PT340) Service Manual. Go to your machine and find the components on the diagrams. Note The tray motor drives the components of the one- bin tray. The paper sensor checks if there is any paper in the tray.
  • Page 167 Model K-C3.5L Feed Mechanism Exit rollers At a fixed time after the first sheet of paper passes the copier’s registration sensor: The tray motor turns on to drive the exit rollers The junction gate solenoid turns on to open the junction gate.
  • Page 168 Model K-C3.5L Paper Detection The LED lights whenever the paper sensor detects that there is paper in the tray. Tray capacity: 100 sheets Paper cannot be fed from the bypass tray to the one-bin tray. Slide 168 More on Paper Detection If the paper source is the bypass tray, the output will not go to the one-bin tray, even if the user specified that this type output should go to that tray.
  • Page 169 Model K-C3.5L Tray Open Switch This switch detects when the tray has been moved Tray open switch away from the main body to remove a paper jam. A ‘cover open’ message appears. This message also appears if the one-bin tray becomes disconnected from the copier.
  • Page 170 Model K-C3.5L Lab Work Practice removal procedures (see One Bin Tray (PT340) service manual). Do any of the procedures that you think that you need to practice. Pay attention to all notes, cautions, and warnings in the manual. Slide 170...

  • Page 171: Maintenance

    Model K-C3.5L Model K-C3.5L Service Training 18. Maintenance Slide 171 No additional notes.
  • Page 172 Model K-C3.5L Service PM The machine has PM intervals of 60 K, and 120 K. Reset the PM counter after finishing PM SP 7804 1. How to Reset the PM Counter in the FSM. SP Modes SP 5501 1: PM alarm (0: No alarm)
  • Page 173 Firmware Update In previous models of this series all firmware updates were done by flash memory card. Model K-C3.5L memory updating is done by: Flash memory card for BICU firmware update. SD card for GDI controller update. Refer to the FSM for update procedure details.
  • Page 174 Model K-C3.5L Model K-C3.5L Service Training 19. Troubleshooting Slide 174 No additional notes.
  • Page 175 Model K-C3.5L Memory All Clear Before memory all clear, either: SP 5990: Print lists of settings (SMC lists) SP 5824: Upload NV-RAM contents » From NV-RAM to flash memory Memory All Clear SP 5801 Slide 175 More on Memory Clear This is only done after replacing the NVRAM or recovering from NVRAM problems.
  • Page 176 Model K-C3.5L Self Diagnostics The self-diagnostics procedure is automatically done just after power has been switched on. SP 7832: Result of diagnostics Slide 176 No additional notes.
  • Page 177 Model K-C3.5L Printing SMC Reports SP 5990 - Engine Slide 177 No additional notes.

  • Page 178: Troubleshooting

    Model K-C3.5L Defective Electrical Component Troubleshooting Electrical component defect table: See Electrical Component Defects in the Field Service Manual. Blown fuse table: See Blown Fuse Conditions in the Field Service Manual. If a problem concerns electrical circuit boards, first disconnect then reconnect the connectors before replacing the PCBs.
  • Page 179 Model K-C3.5L SC Codes Study the Service Call Conditions section of the Field Service Manual. (FSM Appendices Service Call Conditions) There are four levels of SC codes. Reset ‘Level A’ codes by first entering SP mode and then switching the machine off and on.
  • Page 180 Model K-C3.5L SP Modes - Symptom Troubleshooting - 1/3 SP 1103: Fusing idling enable/disable Enable if fusing on the first two copies is incomplete SP 1108: Fusing temperature control cycle Increase if the user complains about flickering room lights. However, fusing lamp errors may not be detected.
  • Page 181 Model K-C3.5L SP Modes - Symptom Troubleshooting - 2/3 SP 2301: Transfer current SP 2301 1-2: Increase if thicker paper than normal is used in the paper trays SP 2301 4: Increase if there is dirty background on the rear side »...
  • Page 182 Model K-C3.5L SP Modes - Symptom Troubleshooting - 3/3 SP 2906: 'Tailing' correction Adjust this if there are ghosts of thin vertical lines further down page from where vertical lines on image stop. SP 6910: ADF shading interval Reduce setting if white level is drifting during copy jobs using ADF.
  • Page 183 Model K-C3.5L SP Modes - Tests SP 1007: By-pass paper size sensor output display SP 4902: Exposure lamp on SP 5001: Operation panel indicators on SP 5803: Input tests SP 5804: Output tests SP 5902: Test pattern printout SP 6901: APS sensor output test (ADF) Slide 183 No additional notes.
  • Page 184 Model K-C3.5L SP Modes - Free Runs SP 4013: Scanner (with lamp on) SP 5802: Scanner and printer SP 5901: Printer SP 6009: ADF/ARDF Slide 184 No additional notes.

  • Page 185: Environmental Conservation

    Model K-C3.5L Model K-C3.5L Service Training 20. Environmental Conservation Slide 185 No additional notes.
  • Page 186 Model K-C3.5L Promote Use of Energy Saving Features Energy Saver Mode Proper use of energy saver modes saves energy and is environmentally friendly. Slide 186 No additional notes.
  • Page 187 Model K-C3.5L Energy Saver Modes - 1/3 Power Consumption Warm-up Operation Mode Ready Mode Energy Saving Off Mode Plug In Time Energy Saver Timer Timer Starts After 240 min Auto Off Timer from last job 1 – 240 min Energy saver mode should be utilized to save energy & protect environment.
  • Page 188 Model K-C3.5L Energy Saver Modes - 2/3 User can set these timers with User Tools System settings > Timer setting Energy saver timer (1–240 min) Energy Saver Mode » Default setting: 1minute Auto off timer (1–240 min) Off Mode » Default setting: 1 minute Example Energy saver timer: 1 min.
  • Page 189 Model K-C3.5L Energy Saver Modes - 3/3 Recommendation We recommend that default settings be used. If customer requests settings change, please explain: » Energy costs could increase » The environment could be impacted. Slide 189 No additional notes.
  • Page 190 Model K-C3.5L Energy Save Effectiveness - 1/3 With SP 8941: Machine Status data and power consumption values from the specifications, amount of energy used by machine can be estimated. 8941-001: Operating mode 8941-002: Standby mode 8941-003: Panel off mode 8941-005: Off/sleep mode...
  • Page 191 Model K-C3.5L Energy Save Effectiveness - 2/3 (1) At start of measurement period, read values of SP 8941:001-005 (Machine Status). (2) At end of measurement period, read values of SP 8941:001-005 (Machine Status). (3) Find amount of time spent in each mode.
  • Page 192 Model K-C3.5L Energy Save Effectiveness - 3/3 (5) Multiply this by power consumption spec for each mode and convert result to kWh (kilowatt hours) (6) This is a simulated value for power consumed. Example calculations: Mode/condition SP8941: Time at Time at...
  • Page 193 Model K-C3.5L End of Course Slide 193...

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