Kyocera mita KM-1525 Service Manual
  1. Manuals
  2. Brands
  3. Kyocera Manuals
  4. Printer
  5. mita KM-1525
  6. Service manual
Kyocera mita KM-1525 Service Manual

Kyocera mita KM-1525 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

SERVICE
MANUAL
Published in Mar.'01
842BV110

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the mita KM-1525 and is the answer not in the manual?

Questions and answers

Related Manuals for Kyocera mita KM-1525

Summary of Contents for Kyocera mita KM-1525

  • Page 1 SERVICE MANUAL Published in Mar.’01 842BV110...
  • Page 2 CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. CAUTION Double-pole/neutral fusing.
  • Page 3 Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.
  • Page 4 Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.
  • Page 5 1. Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current..................... •...
  • Page 6 2. Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 7 • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself....................... • Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item.
  • Page 8 CONTENTS 1-1 Specifications 1-1-1 Specifications ............................1-1-1 1-1-2 Parts names and their functions ......................1-1-2 (1) Copier ............................. 1-1-2 (2) Operation panel ..........................1-1-3 1-1-3 Machine cross section .......................... 1-1-4 1-1-4 Drive system ............................1-1-5 (1) Drive system 1 (optical section) ...................... 1-1-5 (2) Drive system 2 (drive motor drive train) ..................

  • Page 9: Table Of Contents

    (17) Image is out of focus........................1-5-17 (18) Image center does not align with the original center..............1-5-17 (19) Image is not square........................1-5-18 (20) Image contrast is low (carrier scattering)..................1-5-18 1-5-4 Electrical problems ..........................1-5-19 (1) The machine does not operate when the main switch is turned on.
  • Page 10 (2) Detaching and refitting the scanner wires ..................1-6-14 (2-1) Detaching the scanner wires ....................1-6-14 (2-2) Fitting the scanner wires ...................... 1-6-15 (3) Detaching and refitting the laser scanner unit ................1-6-18 (4) Adjusting the skew and vertical shifting of the laser scanner unit ..........1-6-20 (4-1) Adjusting the skew of the laser scanner unit ...............
  • Page 11 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout ........................... 2-2-1 (1) PCBs .............................. 2-2-1 (2) Switches and sensors ........................2-2-2 (3) Motors ............................. 2-2-3 (4) Other electrical components ......................2-2-4 2-3 Operation of the PCBs 2-3-1 Power source PCB ..........................2-3-1 2-3-2 Main PCB .............................
  • Page 12 1-1-1 Specifications Type ..........Desktop Copying system ......Indirect electrostatic system Originals ......... Sheets and books Maximum size: A3 Original feed system ...... Fixed Copy paper ........Drawer: Plain paper (64 – 80 g/m Bypass table: Plain paper (60 – 160 g/m Special paper: Transparencies, tracing paper and letterhead Note: Use the bypass table for special paper.
  • Page 13 1-1-2 Parts names and their functions (1) Copier & ¤ ⁄ ¤ Figure 1-1-1 1 Original cover 2 Operation panel 3 Paper conveying unit 4 Multi-Bypass 5 Insert guides 6 Support tray 7 Toner cartridge 8 Toner cartridge release lever 9 Waste toner tank 0 Waste toner tank release lever ! Cleaning shaft...
  • Page 14 (2) Operation panel 6 54 ‹ ¤⁄ fl › fi * & $ # !0 Figure 1-1-2 1 Start key (Indicator) % Misfeed location indicators 2 Stop/Clear key ^ Paper size indicators 3 Numeric keys & Original key 4 Reset key * Original size indicators 5 Interrupt key (Indicator) ( Misfeed indicator...
  • Page 15 1-1-3 Machine cross section Light path Paper path Figure 1-1-3 Machine cross section 1 Paper feed section 2 Main charging section 3 Optical section 4 Developing section 5 Transfer and paper conveying section 6 Cleaning section 7 Charge erasing section 8 Fixing section 1-1-4...
  • Page 16 1-1-4 Drive system (1) Drive system 1 (optical section) As viewed from machine front Figure 1-1-4 1 Scanner motor gear 5 Scanner wire 2 Gear 44/16 6 Scanner wire pulley 3 Gear 26 7 Scanner wire pulley 4 Scanner wire drum 8 Scanner wire pulley 1-1-5...
  • Page 17 (2) Drive system 2 (drive motor drive train) ˆ ¨ Á — ‰ ‡ ˇ fi fl › & Œ · ‹ „ ´ ⁄ ¤ ‚ As viewed from machine rear Figure 1-1-5 1 Drive motor gear $ Bypass paper feed clutch gear ‡...
  • Page 18 1-2-1 Drum Note the following when handling or storing the drum. • When removing the image formation unit, never expose the drum surface to strong direct light. • Keep the drum at an ambient temperature between –20°C/–4°F and 40°C/104°F and at a relative humidity not higher than 85% RH.
  • Page 19 1-3-1 Unpacking and installation (1) Installation procedure Start Unpack. Remove the tapes. Adjust the fixing pressure. Remove the pins holding light source units 1 and 2. Connect the power cord. Install the optional devices. Carry out initial developer setting (maintenance item U130). Remove the image formation unit.
  • Page 20 Light source unit 1 pins Light source unit 2 pin Figure 1-3-1 1-3-2...
  • Page 21 Unpack %&⁄ Figure 1-3-2 Unpacking 1 Copier # Bar code labels 2 Outer case $ Hinge joint 3 Inner frame % Drawer size sheet 4 Upper pads ^ Plastic bag 5 Bottom pads & Error code label* 6 Bottom case * Drawer spacers 7 Skid ( Drawer claw spacers...
  • Page 22 Remove the tapes. 1. Remove the tape holding the front cover and the power cord, and remove the tape binding the power cord. 2. Remove the tape holding the drawer. 3. Remove the two tapes holding the paper conveying unit and bypass tray. 4.
  • Page 23 7. Remove the tape holding each of the front and rear cursors. Rear cursor Front cursor Figure 1-3-5 8. Remove the tape holding each of the drawer claw spacers and then the spacers. 9. Refit the drawer. Drawer claw spacers Figure 1-3-6 1-3-5...
  • Page 24 Remove the pins holding light source units 1 and 2. 1. Remove the two pins for light source unit 1 and the pin for light source unit 2. Light source unit 1 pins Light source unit 2 pin Figure 1-3-7 Remove the image formation unit.
  • Page 25 Load developer. 1. Remove the developing unit upper cover by pushing and lifting it in the direction of the arrow Developing unit upper cover in the diagram. Caution: Be sure to place the image formation unit on a level surface when loading developer. Figure 1-3-9 2.
  • Page 26 2. Check that the cleaning shaft is inserted as far as 12-pin connector it will go. 3. Refit the image formation unit using the two screws. 4. Connect the 12-pin connector. Figure 1-3-12 Waste toner tank Install a waste toner tank. release lever 1.While holding the waste toner tank release lever up, fit the waste toner tank in the copier.
  • Page 27 Connect the power cord. 1. Connect the power cord to the connector on the copier. 2. Insert the power plug into the wall outlet. Carry out initial developer setting (maintenance item U130). 1. Turn the main switch on and enter the maintenance mode by entering “10871087” using the numeric keys. 2.
  • Page 28 Install a toner cartridge. 1. Open the front cover. 2. Shift the toner cartridge release lever to the right until it stops. Toner cartridge release lever Figure 1-3-15 3. Tap the toner cartridge on the top five or six times and shake it horizontally eight to ten times to agitate the toner.
  • Page 29 Make test copies. 1. Place an original and make test copies. Check if the center lines of the bypass tray and drawer are correct. If not, adjust the center lines. Completion of machine installation. 1-3-11...
  • Page 30 1-3-2 Setting initial copy modes Factory settings are as follows: Factory setting Maintenance item Contents Metric Inch U253 Switching between double and single counts Double count Double count U254 Turning auto start function on/off U255 Setting auto clear time 90 s 90 s U256 Turning auto preheat/energy saver function on/off On...
  • Page 31 1-3-3 Copier management In addition to a maintenance function for service, the copier is equipped with a management function which can be operated by users (mainly by the copier administrator). In this copier management mode, settings such as default settings can be changed.
  • Page 32 (2) Copy default User status report Paper selection Prints the details of the default settings. Sets whether the same sized paper as the original 1. Select “F01” and press the enter key. to be copied is automatically selected. If A4 paper is present, the list is automatically 1.
  • Page 33 Silent mode Selects whether or not to enter silent mode after copying. 1. Select “F14” and press the enter key. 2. Select “on” or “off” and press the enter key. Setting range: 1 (on)/2 (off) Auto shutoff Sets whether the auto shutoff function is available. 1.
  • Page 34 1-3-4 Installing the total counter (option) Procedure 1. Remove the right cover and eject tray. 2. Remove the Lumirror (polyester film) from the right side of the copier. 2-pin connector 3. Check the vertical orientation of the total Cutout counter and then insert it into the opening in 2-pin connector the copier.
  • Page 35 1-4-1 Maintenance mode The copier is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item Start Enter 10871087. · · · · · · · Entering the maintenance mode Enter the number of the maintenance item to be executed using the zoom +/- ·...
  • Page 36 (2) Maintenance mode item list Item Initial Section Maintenance item contents setting* General U000 Outputting an own-status report — U001 Exiting the maintenance mode — U004 Setting the machine number — U005 Copying without paper — Initialization U020 Initializing all data —...
  • Page 37 Item Initial Section Maintenance item contents setting* Developing U156 Changing the toner control level • Toner feed start level • Toner empty level U157 Checking/clearing the developing drive time — U158 Checking/clearing the developing count — Fixing and U161 Setting the fixing control temperature cleaning •...
  • Page 38 (3) Contents of maintenance mode items Maintenance Description item No. U000 Outputting an own-status report Description Outputs lists of the current settings of the maintenance items, and paper jam and service call occurrences. Purpose To check the current setting of the maintenance items, or paper jam or service call occurrences. Before initializing the backup RAM, output a list of the current settings of the maintenance items to reenter the settings after initialization or replacement.
  • Page 39 Maintenance Description item No. U005 Copying without paper Description Simulates the copy operation without paper feed. Purpose To check the overall operation of the machine. Method 1. Press the start key. A selection item appears. 2. Select the item to be operated using the copy exposure adjustment keys. Display Operation Only the copier operates.
  • Page 40 Maintenance Description item No. U021 Initializing memories Description Initializes the setting data other than that for adjustments due to variations between respective machines, i.e., settings for counters, service call history and mode settings. As a result, initializes the backup RAM according to the specifications depending on the destination selected in U252.
  • Page 41 Maintenance Description item No. U031 Checking switches for paper conveying Description Displays the on-off status of each paper detection switch on the paper path. Purpose To check if the switches for paper conveying operate correctly. Method 1. Press the start key. 2.
  • Page 42 Maintenance Description item No. U033 Checking solenoid operation Description Turns the solenoid on. Purpose To check the operation of the solenoid. Method 1. Press the start key. A selection item appears. 2. Select the desired operation using the copy exposure adjustment keys. 3.
  • Page 43 Maintenance Description item No. U053 Performing fine adjustment of the motor speed Description Performs fine adjustment of the speeds of the motors. Purpose Used to adjust the speed of the respective motors when the magnification is not correct. Method Press the start key. Setting 1.
  • Page 44 Maintenance Description item No. U060 Adjusting the scanner input properties Description Adjusts the image scanning density. Purpose Used when the entire image appears too dark or light. Method Press the start key. Setting 1. Change the setting using the zoom +/– keys. Description Setting range Initial setting...
  • Page 45 Maintenance Description item No. U065 Adjusting the scanner magnification Adjustment See pages 1-6-26 and 27. U066 Adjusting the leading edge registration for scanning an original on the contact glass Adjustment See page 1-6-28. U067 Adjusting the center line for scanning an original on the contact glass Adjustment See page 1-6-29.
  • Page 46 Maintenance Description item No. U088 Setting the input filter (moiré reduction mode) Description Turns moiré reduction mode on and off by switching the input filter on and off. Purpose Used to prevent regular density unevenness (moiré) on halftone image areas of the copy image in text mode and text and photo mode.
  • Page 47 Maintenance Description item No. U091 Checking shading Description Performs scanning under the same conditions as before and after shading is performed, displaying the original scanning values at nine points of the contact glass. Purpose To check the change in original scanning values before and after shading. The results may be used to decide the causes for fixing unevenness (uneven density) of the gray area of an image: either due to optical (shading or CCD) or other problems.
  • Page 48 Maintenance Description item No. When scanning is performed before shading, the scan value at the machine center should be slightly U091 different from those at the machine front and rear. When scanning is performed after shading, there should (cont.) be no difference between respective values. Any differences between the values at machine front and rear indicates that scanner problem causes the fixing unevenness.
  • Page 49 Maintenance Description item No. U093 Setting the exposure density gradient Description Changes the exposure density gradient in manual density mode, depending on respective image modes (text, text and photo, photo). Purpose To set how the image density is altered by a change of one step in the manual density adjustment. Also used to make copy image darker or lighter.
  • Page 50 Maintenance Description item No. U093 Setting (cont.) 1. Select the item to be adjusted by lighting a copy exposure indicator using the copy exposure adjustment keys. 2. Adjust the setting using the zoom +/– keys. Copy exposure Description Setting range Initial setting indicator Exp.
  • Page 51 Maintenance Description item No. U100 Setting the surface potential Description Changes the surface potential by changing the grid control voltage. Also performs main charging. Purpose To set the surface potential or check main charging. Also used when reentering data after initializing the set data.
  • Page 52 Maintenance Description item No. U101 Setting high voltages Description Changes the developing bias voltage and transfer voltage by changing the developing bias control voltage and transfer control voltage. Also checks the transfer output voltage. Purpose To check and change high voltages other than the main charger voltage. Start 1.
  • Page 53 Maintenance Description item No. U109 Setting the drum type Description Sets the type of the drum installed in the copier. Purpose To prevent variations in halftone due to differences in drum sensitivity. Method Press the start key. Setting 1. Select the drum type using the zoom +/– keys. Display Description Type G...
  • Page 54 Maintenance Description item No. U111 Checking/clearing the drum drive time Description Displays the drum drive time for checking, clearing or changing a figure, which is used as a reference when correcting the high voltage based on time. Purpose To check the drum status. Also used to clear the drive time after replacing the drum. Method 1.
  • Page 55 Maintenance Description item No. U131 Setting the toner sensor control voltage Description Displays or changes the toner sensor control voltage automatically set in maintenance item U130. Purpose To check the automatically set toner sensor control voltage. Also to change the toner density if an image is too dark or light.
  • Page 56 Maintenance Description item No. U155 Displaying the toner sensor output Description Displays the toner sensor output value, and related data. Purpose To check the toner sensor output value. Method 1. Press the start key. 2. Press the start key. Sampling starts. 3.
  • Page 57 Maintenance Description item No. U157 Checking/clearing the developing drive time Description Displays the developing drive time for checking, clearing or changing a figure, which is used as a reference when correcting the toner control. It is automatically cleared when U130 is executed. Purpose To check the developing drive time after replacing the developer.
  • Page 58 Maintenance Description item No. U161 Setting the fixing control temperature Description Changes the fixing control temperature. Purpose Normally no change is necessary. However, can be used to prevent curling or creasing of paper, or solve a fixing problem on thick paper. Method Press the start key.
  • Page 59 Maintenance Description item No. U196 Turning the fixing heater on Description Turns the fixing heater on. Purpose To check fixing heater. Method 1. Press the start key. “on” appears. 2. Press the start key. The fixing heater turns on for 1 s and then turns off. Completion Press the stop/clear key when fixing heater is off.
  • Page 60 Maintenance Description item No. U204 Setting the presence or absence of a total counter Description Sets the presence or absence of the optional total counter. Purpose Perform after installing the total counter. Method Press the start key. Setting 1. Select the installation status of the total counter using the zoom +/- keys. Display Description None...
  • Page 61 Maintenance Description item No. U250 Setting the maintenance cycle Description Displays and changes the maintenance cycle. Purpose To check and change the maintenance cycle. Method Press the start key. The current setting is displayed as follows: Maintenance cycle (number of copies) = setting × 1000 Setting 1.
  • Page 62 Maintenance Description item No. U251 Checking/clearing the maintenance count Description Displays, clears and changes the maintenance count. Purpose To check the maintenance count. Also to clear the count during maintenance service. Method 1. Press the start key. 2. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys. Copy exposure indicator Description Setting range Initial setting...
  • Page 63 Maintenance Description item No. U253 Switching between double and single counts Description Switches the count system for the total counter and other counters. Purpose According to user (copy service provider) request, select if A3/11" × 17" paper is to be counted as one sheet (single count) or two sheets (double count).
  • Page 64 Maintenance Description item No. U255 Setting auto clear time Description Sets the time to return to initial settings after copying is complete. Purpose To be set according to frequency of use. Set to a comparatively long time for continuous copying at the same settings, and a comparatively short time for frequent copying at various settings.
  • Page 65 Maintenance Description item No. U258 Switching copy operation at toner empty detection Description Selects if continuous copying is enabled after toner empty is detected, and sets the number of copies that can be made after the detection. Method Press the start key. The current setting is displayed. Start 1.
  • Page 66 Maintenance Description item No. U260 Changing the copy count timing Description Changes the copy count timing for the total counter and other counters. Purpose To be set according to user (copy service provider) request. If a paper jam occurs frequently in the eject section when the number of copies is counted at the time of paper ejection, copies are provided without copy counts.
  • Page 67 Maintenance Description item No. U332 Setting the size conversion factor Description Sets the factor for converting each paper size into A4/11" × 8 ". The black ratio is converted for the A4/ 11" × 8 " size using the factor set in this maintenance item. Values set are displayed in the user simulation. Purpose To set the factor to convert the black ratio of each paper size for A4/11"...
  • Page 68 Maintenance Description item No. U344 Setting preheat/energy saver mode Description Changes the control for preheat/energy saver mode. Purpose According to user request, selects which has priority, the recovery time from preheat or energy saver. Method Press the start key. Setting 1.
  • Page 69 Maintenance Description item No. U348 Setting the copy density adjustment range Description Selects the adjustment range for copy density from NORMAL and SPECIAL AREA (for wider range). Purpose To change the setting according to user request. When especially dark or light density is requested, set to SPECIAL AREA. Method Press the start key.
  • Page 70 Maintenance Description item No. U901 Checking/clearing copy counts by paper feed locations Description Displays or clears copy counts by paper feed locations. Purpose To check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts. Method 1.
  • Page 71 Maintenance Description item No. U903 Checking/clearing the paper jam counts Description Displays or clears the jam counts by jam locations. Purpose To check the paper jam status. Also to clear the jam counts after replacing consumable parts. Method 1. Press the start key. 2.
  • Page 72 Maintenance Description item No. U906 Resetting partial operation control Description Resets the service call code for partial operation control. Purpose To be reset after partial operation is performed due to problems in the drawers or other sections, and the related parts are serviced. Method 1.
  • Page 73 Maintenance Description item No. U910 Clearing the black ratio data Description Clears the accumulated black ratio data for A4/11" × 8 " sheets. Purpose To clear data as required at times such as during maintenance service. Method 1. Press the start key. 2.
  • Page 74 Maintenance Description item No. U990 Checking/clearing the time for the exposure lamp to light Description Displays or clears the accumulated time for the exposure lamp to light. Purpose To check duration of use of the exposure lamp. Also to clear the accumulated time for the lamp after replacement.
  • Page 75 Maintenance Description item No. U993 Outputting a VTC-PG pattern Description Selects and outputs a VTC-PG pattern created in the copier. Purpose When performing respective image printing adjustments, used to check the machine status apart from that of the scanner with a non-scanned output VTC-PG pattern. Method 1.
  • Page 76 Maintenance Description item No. U998 Outputting the memory list Description Outputs the list of memory. Purpose To output the list as required. Method Press the start key. Entering the address 1. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys. Copy exposure indicator Description Setting range...
  • Page 77 1-5-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the copier immediately stops copying and displays the jam location on the operation panel. Paper misfeed counts sorted by the detection condition can be checked in maintenance item U903. To remove paper jammed in the copier, open the front cover, paper conveying unit or drawer.
  • Page 78 (2) Paper misfeed detection conditions Figure 1-5-2 1-5-2...
  • Page 79 1. Jam at power-on • One or more of the switches in the paper feed conveying system is on when the main switch is turned on (jam code 00). 2. Paper feed section • No paper feed from drawer (jam code 10) The registration switch (RSW) does not turn on within 980 ms of the paper feed clutch (PFCL) turning on.
  • Page 80 4. Fixing section • Misfeed in fixing section (jam code 40) The eject switch (ESW) does not turn off within 2475 ms of the registration clutch (RCL) turning on. 2475 ms Timing chart 1-5-6 5. Eject section • Misfeed in eject section (jam code 50) The eject switch (ESW) does not turn off within 2475 ms of the registration switch (RSW) turning off.
  • Page 81 (3) Paper misfeeds Problem Causes/check procedures Corrective measures A piece of paper torn from Check visually and remove any found. A paper jam in the copy paper is caught paper feed, around the registration conveying, fixing or switch or the eject switch. eject section is Defective registration With 5 V DC present at CN3-6 on the main PCB, check if CN3-7...
  • Page 82 Problem Causes/check procedures Corrective measures Broken registration switch Check visually and replace the registration switch if its actuator A paper jam in the actuator. is broken. paper feed section With 5 V DC present at CN3-6 on the main PCB, check if CN3-7 Defective registration is indicated during switch.
  • Page 83 1-5-2 Self-diagnosis (1) Self-diagnostic function This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled. "C" and a number between 011 and 740 altenates, indicating the nature of the problem. After removing the problem, the self-diagnostic function can be reset by turning safety switch 1or 2 off and back on. (2) Self diagnostic codes Remarks Code...
  • Page 84 Remarks Code Contents Causes Check procedures/corrective measures C200 Drive motor problem Defective drive Replace the drive motor. • LOCK ALM signal remains high for 1 motor rotation s, 1 s after the drive motor has turned control circuit. Defective drive Check if the rollers and gears rotate transmission smoothly.
  • Page 85 Remarks Code Contents Causes Check procedures/corrective measures C510 Main charger problem Deformed high- Replace the spring. • MC ALM signal is detected voltage continuously for 800 ms when MC transformer PCB REM signal is turned on. terminal spring. C610 Broken fixing heater wire Fixing heater Check and reinstall if necessary.
  • Page 86 Remarks Code Contents Causes Check procedures/corrective measures C710 Toner sensor problem Defective toner Replace the toner sensor. • The sensor output voltage is outside sensor. the range of 0.5 to 4.5 V during toner Poor contact of Reinsert the connector. Also check for control.

  • Page 87: Image Is Out Of Focus

    1-5-3 Image formation problems (1) No image appears (2) No image appears (3) Image is too light. (4) Background is visible. (entirely white). (entirely black). See page 1-5-12 See page 1-5-12 See page 1-5-13 See page 1-5-13 (8) One side of the copy (5) A white line appears (7) A black line appears (6) A black line appears...
  • Page 88 (1) No image appears Causes (entirely white). 1. No transfer charging. Causes Check procedures/corrective measures 1. No transfer charging. A. Broken transfer wire. Replace or repair the wire. B. The connector terminals of the high-voltage Reinsert the connector. Also check for continuity within the transformer PCB make poor contact.
  • Page 89 (3) Image is too Causes light. 1. Insufficient toner. 2. Deteriorated developer. 3. Dirty or deteriorated drum. Causes Check procedures/corrective measures 1. Insufficient toner. If the display shows the message requesting toner replenishment, replace the cartridge. 2. Deteriorated developer. Check the number of copies made with the current developer. If it has reached the specified limit, replace the developer.
  • Page 90 (6) A black line appears Causes longitudinally. 1. Dirty contact glass. 2. Dirty or flawed drum. 3. Deformed or worn cleaning blade. 4. Dirty scanner mirror. Causes Check procedures/corrective measures 1. Dirty contact glass. Clean the contact glass. 2. Dirty or flawed drum. Clean the drum or, if it is flawed, replace it (see page 1-6-34).
  • Page 91 (9) Black dots appear Causes on the image. 1. Dirty or flawed drum. 2. Dirty contact glass. 3. Deformed or worn cleaning blade. Causes Check procedures/corrective measures 1. Dirty or flawed drum. Clean the drum or, if it is flawed, replace it (see page 1-6-34). 2.
  • Page 92 (12) The leading edge of Causes the image is sporadi- 1. Registration clutch, bypass paper feed clutch cally misaligned with or paper feed clutch installed or operating the original. incorrectly. Causes Check procedures/corrective measures 1. Registration clutch, bypass paper feed clutch Check the installation position and operation of the registration or paper feed clutch installed or operating clutch, bypass paper feed clutch and paper feed clutches.
  • Page 93 Causes (15) Image is partly miss- 1. Paper damp. ing. 2. Paper creased. 3. Drum condensation. 4. Flawed drum. Causes Check procedures/corrective measures 1. Paper damp. Check the paper storage conditions. 2. Paper creased. Replace the paper. 3. Drum condensation. Clean the drum.
  • Page 94 (19) Image is not Causes square. 1. Laser scanner unit positioned incorrectly. 2. Image scanning unit positioned incorrectly. Causes Check procedures/corrective measures 1. Laser scanner unit positioned incorrectly. Adjust the installation position of the laser scanner unit (see page 1-6-20). 2.

  • Page 95: Electrical Problems

    1-5-4 Electrical problems Problem Causes Check procedures/corrective measures No electricity at the power Measure the input voltage. The machine does outlet. not operate when The power cord is not Check the contact between the power plug and the outlet. the main switch is plugged in properly.

  • Page 96: The Registration Clutch Does Not Operate

    Problem Causes Check procedures/corrective measures Broken cooling fan motor 3 Check for continuity across the coil. If none, replace cooling fan Cooling fan motor 3 coil. motor 3. does not operate. Reinsert the connector. Also check for continuity within the Poor contact in the cooling fan motor 3 connector connector cable.

  • Page 97: Main Charging Is Not Performed (C510)

    Problem Causes Check procedures/corrective measures (16) Broken main charger wire. See page 1-5-12. Main charging is not Leaking main charger performed (C510). housing. Poor contact in the high- voltage transformer PCB connector terminals. Defective main PCB. Defective high- voltage transformer PCB . (17) Poor contact in the high- See page 1-5-12.

  • Page 98: Paper Conveying Unit Are Closed

    Problem Causes Check procedures/corrective measures (21) Poor contact in the Reinsert the connector. Also check for continuity within the The message connector terminals of connector cable. If none, remedy or replace the cable. requesting covers to safety switch 1 or 2. be closed is Defective safety switch 1 Check for continuity across the contacts of each switch.

  • Page 99: Mechanical Problems

    1-5-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following pulleys Clean with isopropyl alcohol. No primary paper feed. are dirty with paper powder: paper feed pulleys and bypass paper feed pulleys. Check if the paper feed pulleys are Check visually and replace any deformed deformed.

  • Page 100: Precautions For Assembly And Disassembly

    1-6-1 Precautions for assembly and disassembly (1) Precautions • Be sure to turn the main switch off and disconnect the power plug before starting disassembly. • When handling PCBs, do not touch connectors with bare hands or damage the board. •...

  • Page 101: Running A Maintenance Item

    (2) Running a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the zoom +/– keys The maintenance item is or numeric keys. selected. Press the start key. The selected maintenance item is run. Press the stop/clear key.

  • Page 102: Paper Feed Section

    1-6-2 Paper feed section (1) Detaching and refitting the paper feed pulleys Follow the procedure below to replace the paper feed pulleys. Procedure 1. Open the bypass tray and paper conveying unit and then remove the rear and rear left covers.
  • Page 103 6. Open the front cover and remove the image Stop ring formation unit (see page 1-6-31). 7. Remove the stop ring from the paper feed shaft unit (machine front). Figure 1-6-4 8. Push the paper feed shaft unit toward the machine rear (in the direction of 1) and remove the unit from the lower front side (in the direction of 2).

  • Page 104: Detaching And Refitting The Bypass Paper Feed Pulley

    (2) Detaching and refitting the bypass paper feed pulley Follow the procedure below to replace the bypass paper feed pulley. Procedure 1. Open the bypass tray, paper conveying unit and front cover and then remove the image formation unit (see page 1-6-31). 2.
  • Page 105 5. Remove the rear screw of the bypass paper feed pulley and then the pulley. Bypass paper feed pulley Figure 1-6-10 6. Replace the bypass paper feed pulley and refit all the removed parts. • When refitting, check that the cam on the rear of the shaft is correctly positioned (see figure 1-6-11).

  • Page 106: Detaching And Refitting The Left Registration Cleaner Assembly

    (3) Detaching and refitting the left registration cleaner assembly Follow the procedure below to replace the left registration cleaner assembley. Procedure Left registration roller 1. Open the bypass tray and paper conveying unit. 2. Remove the transfer roller unit (see page 1-6- 36).

  • Page 107: Detaching And Refitting The Bypass Paper Width Switch

    (5) Detaching and refitting the bypass paper width switch Follow the procedure below to replace the bypass paper width switch. Procedure 1. Remove the paper conveying unit and lower left cover (see page 1-6-5). 2. Remove the bypass tray assembly. 3.

  • Page 108: Adjustment After Roller And Clutch Replacement

    (6) Adjustment after roller and clutch replacement Perform the following adjustment after refitting rollers and clutches. (6-1) Adjusting the leading edge registration of image printing Make the following adjustment if there is a regular error between the leading edges of the copy image and original. U066 U034 (P.

  • Page 109: Adjusting The Center Line Of Image Printing

    (6-2) Adjusting the center line of image printing Make the following adjustment if there is a regular error between the center lines of the copy image and original when paper is fed from the drawer. U067 U034 (P. 1-6-29) Caution: Check the copy image after the adjustment.

  • Page 110: Adjusting The Margins For Printing

    (6-3) Adjusting the margins for printing Make the following adjustment if the margins are not correct. U403 U402 (P. 1-6-30) Caution: Check the copy image after the adjustment. If the margins are still incorrect, perform the above adjustments in maintenance mode. Procedure Start Enter maintenance mode.

  • Page 111: Adjusting The Amount Of Slack In The Paper

    (6-4) Adjusting the amount of slack in the paper Make the following adjustment if the leading edge of the copy image is missing or varies randomly, or if the copy paper is Z-folded. Procedure Start Original Copy Copy Enter maintenance mode. example 1 example 2 Figure 1-6-20...

  • Page 112: Optical Section

    1-6-3 Optical section (1) Detaching and refitting the exposure lamp Replace the exposure lamp as follows. Procedure 1. Remove the original cover. Contact glass 2. Remove the five screws holding the right cover. While sliding the right cover in the direction of the arrow in the diagram, remove the contact glass.

  • Page 113: Detaching And Refitting The Scanner Wires

    (2) Detaching and refitting the scanner wires Take the following procedure when the scanner wires are broken or to be replaced. Caution: After replacing the scanner wires, After replacing the scanner wires, make a test copy and check the copy image. If adjustment is required, perform (6) to (12) of the scanner adjustments (see pages 1-6-24 to 30).

  • Page 114: Fitting The Scanner Wires

    (2-2) Fitting the scanner wires Caution: When fitting the wires, be sure to use those specified below. Machine front: P/N 2AV1219 (black) Machine rear: P/N 2AV1220 (gray) Fitting requires the following tools: Two frame securing tools (P/N 2AV6808) Two scanner wire stoppers (P/N 3596811) Procedure 1.
  • Page 115 4. Loop the inner ends of the scanner wires around the grooves in the pulleys at the right of the scanner unit, winding from below to above.......................... 1 5. Loop the scanner wires around the inner grooves in the pulleys on the mirror 2 frame, winding from above to below.
  • Page 116 14. Mount the mirror 1 frame on the scanner rails and shift it toward the machine left. Frame securing tools 15. Insert the frame securing tools into the positioning holes (leftmost holes) at the front and rear of the scanner unit to secure the mirror 1 frame and mirror 2 frame, and then lock the mirror 1 frame down by screw.

  • Page 117: Detaching And Refitting The Laser Scanner Unit

    (3) Detaching and refitting the laser scanner unit Take the following procedure when the laser scanner unit is to be checked or replaced. Procedure 1. Open the front cover. 2. Remove the two screws holding the eject tray and then the tray. Eject tray Figure 1-6-32 3.
  • Page 118 5. Check or replace the laser scanner unit and LSU front spacer refit all the removed parts. Caution: Before fitting the new laser scanner unit, fit the LSU front spacer and LSU right spacer by orienting the markings correctly and using the correct layer as specified on the label on the laser scanner unit cover.

  • Page 119: Adjusting The Skew And Vertical Shifting Of The Laser Scanner Unit

    (4) Adjusting the skew and vertical shifting of the laser scanner unit (4-1) Adjusting the skew of the laser scanner unit Perform the following adjustment if the leading and trailing edges of the copy image are laterally skewed (lateral squareness not obtained). Caution: •...

  • Page 120: Adjusting The Vertical Shifting Of The Laser Scanner Unit

    (4-2) Adjusting the vertical shifting of the laser scanner unit Perform the following adjustment if the copy image shifts vertically due to vertical shifting of the position of the laser scanner unit. Vertical shifting : X (mm) Start Enter maintenance mode. Copy Copy Correct image...

  • Page 121: Detaching And Refitting The Isu (Reference)

    (5) Detaching and refitting the ISU (reference) Take the following procedure when the ISU is to be checked or replaced. Caution: After replacing the scanner wires, After replacing the scanner wires, make a test copy and check the copy image. If adjustment is required, perform (6) to (12) of the scanner adjustments (see pages 1-6-24 to 30).
  • Page 122 • Refitting the ISU 1. Fit the ISU using the two positioning pins. Positioning pins 2. Secure the ISU using the four screws. 3. Remove the two positioning pins and refit all the removed parts. Figure 1-6-41 1-6-23...

  • Page 123: Adjusting The Position Of The Isu (Reference)

    (6) Adjusting the position of the ISU (reference) Perform the following adjustment if the leading and trailing edges of the copy image are laterally skewed (lateral squareness not obtained). Caution: • Be sure to perform “(4-1) Adjusting the skew of the laser scanner unit” (page 1-6-20) first. •...

  • Page 124: Adjusting The Longitudinal Squareness (Reference)

    (7) Adjusting the longitudinal squareness (reference) Perform the following adjustment if the copy image is longitudinally skewed (longitudinal squareness not obtained). Caution: • Adjust the amount of slack in the paper (page 1-6-12) first. Check for the longitudinal squareness of the copy image, and if it is not obtained, perform the longitudinal squareness adjustment.

  • Page 125: Adjusting Magnification Of The Scanner In The Main Scanning Direction

    (8) Adjusting magnification of the scanner in the main scanning direction Perform the following adjustment if the magnification in the main scanning direction is not correct. U065 U065 U053 U067 (auxiliary scanning (main scanning (P. 1-4-9) (P. 1-6-29) direction) (P. 1-6-27) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 126: Adjusting Magnification Of The Scanner In The Auxiliary Scanning Direction

    (9) Adjusting magnification of the scanner in the auxiliary scanning direction Perform the following adjustment if the magnification in the auxiliary scanning direction is not correct. U065 U065 U053 (main scanning (auxiliary scanning (P. 1-4-9) direction) (P. 1-6-26) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 127: Adjusting The Scanner Leading Edge Registration

    (10) Adjusting the scanner leading edge registration Perform the following adjustment if there is regular error between the leading edges of the copy image and original. U034 U066 (P. 1-6-9) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner leading edge registration Start...

  • Page 128: Adjusting The Scanner Center Line

    (11)Adjusting the scanner center line Perform the following adjustment if there is a regular error between the center lines of the copy image and original. U034 U067 (P. 1-6-10) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner center line Start...

  • Page 129: Adjusting The Margins For Scanning An Original On The Contact Glass

    (12) Adjusting the margins for scanning an original on the contact glass Perform the following adjustment if the margins are not correct. U402 U403 (P. 1-6-11) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Start Enter maintenance mode.

  • Page 130: Main Charging Section

    1-6-4 Main charging section (1) Detaching and refitting the charger assembly Follow the procedure below to replace the charger assembly. Prucedure 1. Open the bypass tray, paper conveying unit Connector and front cover, and then remove the toner cartridge and waste toner tank. Hook 2.

  • Page 131: Replacing The Tungsten Wire (Reference)

    (2) Replacing the tungsten wire (reference) Take the following procedure when the tungsten wire is broken or to be replaced. Precautions • Use the specified tungsten wire (P/N: 2AR1016). • The part of the wire wrapped around the charger spring must not protrude over the L-shaped hook in the main charger rear housing.
  • Page 132 6. Wind the new tungsten wire six turns around one end of the charger spring and trim the end. • The width of the coiled tungsten wire and the cut end must be less than 2 mm. 7. Hook the other end of the charger spring onto the charger terminal of the main charger rear housing. 8.

  • Page 133: Drum Section

    1-6-5 Drum section (1) Detaching and refitting the drum Follow the procedure below to replace the drum. Cautions: • Avoid direct sunlight or strong light when detaching and fitting the drum. • Hold the drum at the ends and never touch the drum surface. •...

  • Page 134: Developing Section

    1-6-6 Developing section (1) Adjusting the position of the doctor blade (reference) Perform the following adjustment if carrier or background appears on the copy image. Procedure 1. Remove the image formation unit (see page MC rail 1-6-31). 2. Remove the charger assembly (see page 1- 6-31).

  • Page 135: Transfer Section

    1-6-7 Transfer section (1) Detaching and refitting the transfer roller assembly Follow the procedure below to replace the transfer roller assembly. Procedure 1. Open the bypass tray and paper conveying unit. 2. Remove the transfer roller assembly. Caution: Remove the transfer roller assembly carefully to prevent the residual toner in the transfer roller assembly from spilling.

  • Page 136: Cleaning Section

    1-6-8 Cleaning section (1) Detaching and refitting the cleaning blade Follow the procedure below to replace the cleaning blade. Procedure 1. Remove the image formation unit and the charger assembly (see page 1-6-31). Cleaning blade 2. Remove the MC rail (see page 1-6-35). 3.

  • Page 137: Detaching And Refitting The Drum Separation Claw Assemblies

    (2) Detaching and refitting the drum separation claw assemblies Follow the procedure to replace the drum separation claw assemblies. Procedure 1. Remove the image formation unit (see page Drum separation claw assemblies 1-6-31). 2. Remove the screw holding each of the drum separation claw assemblies and then the assemblies.

  • Page 138: Fixing Section

    1-6-9 Fixing section (1) Detaching and refitting the fixing unit Follow the procedure below to check or replace the fixing unit. Procedure 1. Open the bypass tray, paper conveying unit Connector (blue) and front cover, and then remove the rear cover, left front cover and left rear cover.

  • Page 139: Detaching And Refitting The Fixing Unit Thermistor

    (2) Detaching and refitting the fixing unit thermistor Follow the procedure below to replace the fixing unit thermistor. Procedure 1. Remove the fixing unit (see page 1-6-39). Fixing unit thermister 2. Remove the screw and detach the connector, and then remove the fixing unit thermistor. 3.

  • Page 140: Detaching And Refitting The Fixing Heater

    (4) Detaching and refitting the fixing heater Follow the procedure below to replace the fixing heater. Procedure 1. Remove the fixing unit (see page 1-6-39). 2. Detach the fixing heater connector. Connector Figure 1-6-70 3. Remove the screw holding each of the fixing heater front and rear retainers and then the retainers.

  • Page 141: Detaching And Refitting The Heat Roller

    (5) Detaching and refitting the heat roller Follow the procedure below to replace the heat roller. Procedure 1. Remove the fixing unit (see page 1-6-39). 2. Remove the fixing unit thermistor, fixing heater and heat roller separation claw assemblies (see pages 1-6-40 and 41). 3.
  • Page 142 6. Remove the four screws holding the fixing housing and then the housing. Fixing housing Figure 1-6-76 7. Remove the pressure spring from each of the front and rear ends of the fixing unit. Press springs Figure 1-6-77 8. Remove the C ring, gear and bushing on the C ring rear and the C ring and bushing on the front of the heat roller, and then remove the heat...

  • Page 143: Detaching And Refitting The Press Roller

    (6) Detaching and refitting the press roller Follow the procedure below to replace the press roller. Procedure 1. Remove the fixing unit (see page 1-6-39). 2. Remove the heat roller (see page 1-6-42). 3. Remove the screw holding the fixing guide plate and then the plate.

  • Page 144: Replacing The Main Pcb

    1-7-1 Replacing the main PCB Main PCB replacement requires the following tools: Memory tool PCB (P/N 2AV68030) NVRAM (P/N NAS09010) Procedure • Before replacing the main PCB (backing up the machine data) 1. Turn the main switch off and disconnect the shield cover power plug.
  • Page 145 5. Insert the power plug and turn the main switch on. LED1 (green) on the memory tool PCB flashes (on for 1 s → off for 1 s) for approximately 10 seconds and the machine data on the SRAM of the main PCB will be backed up on the NVRAM. 6.

  • Page 146: Upgrading The Firmware On The Main Pcb

    1-7-2 Upgrading the firmware on the main PCB Firmware upgrading requires the following tools: Flash tool assembly (P/N 35968010) Memory tool PCB (P/N 2AV68030) Master ROM Main ROM 1 IC (P/N 2BV68010) Procedure 1. Turn the main switch off and disconnect the power plug.

  • Page 147: Adjustment-Free Variable Resistors (Vr)

    1-7-3 Adjustment-free variable resistors (VR) The variable resistors listed below are set at the factory prior to shipping and cannot be adjusted in the field. • High-voltage transformer PCB: VR101, VR102, VR201, VR301, VR302 • Inverter PCB: VR1, VR2 1-7-4...

  • Page 148: Paper Feed Section

    2-1-1 Paper feed section The paper feed section consists of the primary feed and secondary feed subsections. Primary feed conveys paper from the drawer or bypass tray to the left and right registration rollers, at which point secondary feed takes place and the paper travels to the transfer section in sync with the printing timing.
  • Page 149 MPCB CN4-10 CN3-7 PFCL CN4-14 CN3-10 BYPPFCL CN4-12 BYPPSW CN6-2 Figure 2-1-2 Paper feed section block diagram Start key 263 ms 300 ms 300 ms 263 ms 100 ms 100 ms PFCL 3871 ms Copy paper: A4/11" × 8 ", magnification ratio 100%, two copies Timing chart 2-1-1 Paper feed from the drawer a: When the start key is pressed, the drive motor (DM) and the paper feed clutch (PFCL) turn on and paper feed pulleys rotate to start primary paper feed.
  • Page 150 Start key 263 ms 300 ms 100 ms BYPPFCL 3000 ms Original: A5R, copy paper: A3/11" × 17", magnification ratio 200% Timing chart 2-1-2 Paper feed from the bypass tray a: When the start key is pressed, the drive motor (DM) turns on. b: 3000 ms after the drive motor (DM) turns on, the bypass paper feed clutch (BYPPFCL) turns on and the bypass paper feed pulleys rotate to start primary paper feed.

  • Page 151: Main Charging Section

    2-1-2 Main charging section The main charging section consists of the drum and main charger assembly. The drum is electrically charged by means of a grid to form a latent image on the surface. The shield grid ensures that the charge is applied uniformly. Tungsten wire Main charger assembly Drum...
  • Page 152 HVTPCB MPCB 24 V DC CN1-9 CN4-1 MC REM CN1-7 CN4-3 GRID GRID CONT CN1-4 CN4-6 MC ALM Drum CN1-1 CN4-9 Figure 2-1-5 Main charging section block diagram Start key 840 ms 500 ms MC REM Timing chart 2-1-3 Main charging a: 500 ms after the start key is pressed, main charging (MC REM) starts.

  • Page 153: Optical Section

    2-1-3 Optical section The optical section consists of the scanner, mirror frames and the image scanning unit for scanning and the laser scanner unit for printing. Figure 2-1-6 Optical section 1 Mirror 1 frame 2 Mirror 2 frame 3 Exposure lamp (EL) 4 Mirror 1 5 Mirror 2 6 Mirror 3...

  • Page 154: Original Scanning

    (1) Original scanning The original image is illuminated by the exposure lamp (EL) and scanned by the CCD PCB (CCDPCB) in the image scanning unit via the three mirrors, the reflected light being converted to an electrical signal. The scanner and mirror frames travel to scan on the optical rails on the front and rear of the machine to scan from side to side.

  • Page 155: Image Printing

    (2) Image printing The image data scanned by the CCD PCB (CCDPCB) is processed on the main PCB (MPCB) and transmitted as image printing data to the laser scanner unit (LSU). By repeatedly turning the laser on and off, the laser scanner unit forms a latent image on the drum surface.
  • Page 156 Drum Figure 2-1-9 Laser scanner unit (2) 1 Laser diode: Generates the laser beam which forms a latent image on the drum. 2 Collimator lens: Collimates the diffused laser beam emitted from the laser diode to convert it into a cylindrical beam. 3 Cylindrical lens: Shapes the collimated laser beam to suit the printing resolution.

  • Page 157: Developing Section

    2-1-4 Developing section The developing section consists of the developing unit and the toner cartridge. The developing unit consists of the developing roller where a magnetic brush is formed, the doctor blade and the developing spirals that agitate the developer. Toner from the toner cartridge and residual toner collected in the cleaning section are conveyed to the waste toner tank.

  • Page 158: Formation Of Magnetic Brush

    (1) Formation of magnetic brush The developing roller consists of a magnet roller with five poles and a sleeve roller. Rotation of the sleeve roller around the magnet roller entrains developer, which in turn forms a magnetic brush at pole N1 on the magnet roller. The height of the magnetic brush is regulated by the doctor blade;...

  • Page 159: Toner Density Detection By The Toner Sensor

    (2) Toner density detection by the toner sensor The toner sensor (TNS) detects the toner density. As the developer passes by the sensor section of the toner sensor, the toner sensor detects the ratio of toner to carrier in the developer and converts it into a voltage. When more toner is used, the ratio of toner to carrier decreases and the toner sensor output voltage increases.

  • Page 160: Correcting The Toner Sensor Control Voltage

    (4) Correcting the toner sensor control voltage The toner sensor control voltage is corrected based on the absolute humidity and the total drive motor time so that the toner density is kept constant regardless of the changes in humidity and the total drive motor time. Toner sensor control voltage after correction = A + B + C A: Toner sensor control voltage before correction (value set by maintenance item U131) B: Correction data based on the absolute humidity...

  • Page 161: Correcting Toner Sensor Output Voltage

    • Correction based on the total drive motor time The toner sensor control voltage is also corrected based on the total time the drive motor (DM) has been on from execution of maintenance item U130, so that the toner sensor output voltage is regulated properly. Correction data X-10 X-20...

  • Page 162: Transfer And Separation Section

    2-1-5 Transfer and separation section The transfer and separation section consists mainly of the transfer roller and drum separation claws. A high voltage generated by the high-voltage transformer PCB (HVTPCB) is applied to the transfer roller for transfer charging. Toner adhered to the transfer roller is removed by the transfer cleaner. Separation claw pulleys Drum separation claws Transfer roller...
  • Page 163 Start key 418 ms TC REM 474 ms Timing chart 2-1-5 Operation of transfer a: 418 ms after the registration clutch (RCL) turns on to start secondary paper feed, transfer charging (TC REM) starts. b: 474 ms after the trailing edge of the paper turns the registration switch (RSW) off, transfer charging (TC REM) ends. 2-1-16...

  • Page 164: Cleaning Section

    2-1-6 Cleaning section The cleaning section consists of the cleaning blade that removes residual toner from the drum surface after the transfer process, and the cleaning spiral that carries the residual toner back to the waste toner tank. Cleaning spiral Lower cleaning seal Cleaning blade Drum...

  • Page 165: Charge Erasing Section

    2-1-7 Charge erasing section The cleaning lamp (CL) consists of LEDs which remove residual charge from the drum surface. Cleaning lamp (CL) Light-blocking lumirror Figure 2-1-23 Charge erasing section MPCB CL REM CN12-2 Drum Figure 2-1-24 Charge erasing section block diagram Start key MC REM 1316 ms...

  • Page 166: Fixing Section

    2-1-8 Fixing section The fixing section consists of the parts shown in Figure 2-1-25. When paper reaches the fixing section after the transfer process, it passes between the press roller and heat roller, which is heated by the fixing heater (FH). Pressure is applied by the fixing unit pressure springs so that the toner on the paper is melted, fused and fixed onto the paper.
  • Page 167 1500 ms 1000 ms 20 s 30 s DB REM Half speed Full speed Half speed CFM1, 2, 3 Timing chart 2-1-7 Operation of fixing section a: 1500 ms after the main switch (MSW) is turned on, the fixing heater (FH) turns on to heat the heat roller. At the same time, cooling fan motors 1, 2 and 3 (CFM1, 2 and 3) rotate at half speed.

  • Page 168: Electrical Parts Layout

    2-2-1 Electrical parts layout (1) PCBs Machine front Machine inside Machine rear Figure 2-2-1 PCBs 1. Main PCB (MPCB) ........Controls the other PCBs and electrical components. 2. Power source PCB (PSPCB) ....... Generates 24 V DC, +12 V DC, 5V DC and 3.3 V DC; controls the fixing heater.

  • Page 169: Switches And Sensors

    (2) Switches and sensors Machine front Machine inside Machine rear Figure 2-2-2 Switches and sensors 1. Main switch (MSW) ........Turns the AC power on and off. 2. Safety switch 1 (SSW1) ....... Breaks the safety circuit when the front cover is opened. 3.

  • Page 170: Motors

    (3) Motors Machine front Machine inside Machine rear Figure 2-2-3 Motors 1. Drive motor (DM) ......... Drives the machine. 2. Scanner motor (SM) ........Drives the optical system. 3. Toner feed motor (TFM) ....... Replenishes toner. 4. Cooling fan motor 1 (CFM1) ......Cools the fixing section. 5.

  • Page 171: Other Electrical Components

    (4) Other electrical components Machine front Machine inside Machine rear Figure 2-2-4 Other electrical components 1. Paper feed clutch (PFCL) ......Primary paper feed from the drawer. 2. Bypass paper feed clutch (BYPPFCL) ..Primary paper feed from the bypass tray. 3.

  • Page 172: Power Source Pcb

    2-3-1 Power source PCB Power source PCB AC input Noise Rectifier circuit 24 V DC filter 24 V DC output C29,30 circuit circuit 12 V DC 12 V DC output circuit 5.1 V DC 5.1 V DC output C37,91 circuit IC4 Switching Zero-cross regulator...
  • Page 173 LUG1 L5 D13 LUG2 Figure 2-3-2 Power source PCB silk-screen diagram Terminals (CN) Voltage Remarks TB-1 TB-2 220-240 V AC 220-240 V AC supply, input TB-4 TB-5 220-240 V AC 220-240 V AC supply for MSW, output 220-240 V AC AC supply for FH, output 3-1, 2 3-3, 4...

  • Page 174: Main Pcb

    2-3-2 Main PCB Main PCB Clock signal Analog image data CCD PCB Even Print data FEEPROM IC11 Address bus Writing tool Data bus IC16 Control signal output SRAM Driver Operation unit PCB IC15 IC19,25 Detection signal input Drive unit Scanner unit Developing unit Paper feed unit Control signal output...
  • Page 175 CN28 CN31 CN26 IC26 IC23 IC21 IC31 IC27 CN30 IC14 IC13 IC28 IC22 IC20 IC24 IC17 CN15 CN11 CN13 CN16 CN10 CN32 CN12 CN14...
  • Page 176 Terminals (CN) Voltage Remarks 3.3 V DC 3.3 V DC supply from PSPCB, input 1-5, 6 1-3, 4 5 V DC 5 V DC supply from PSPCB, input 1-9, 10 1-7, 8 24 V DC 24 V DC supply from PSPCB, input 12 V DC 12 V DC supply from PSPCB, input 0/5 V DC...
  • Page 177 Terminals (CN) Voltage Remarks 12-16 12-12 0/5 V DC DM on/off, output 12-17 12-12 0/5 V DC (pulse) DM drive clock pulse, output 12-18 12-12 0/5 V DC DM LOCK signal, input 13-1 13-4 24 V DC 24 V DC supply for TNS, output 13-2 13-4 TNS detection voltage, input...
  • Page 178 Terminals (CN) Voltage Remarks 28-1 24-5 0/24 V DC (pulse) SM coil energization pulse, output (_A) 28-2 24-5 24 V DC 24 V DC supply for SM, output 28-3 24-5 0/24 V DC (pulse) SM coil energization pulse, output (A) 28-4 24-5 0/24 V DC (pulse)

  • Page 179: Ccd Pcb

    2-3-3 CCD PCB CCD PCB Main PCB Logic IC1 Clock signal generator ASIC SHIFT SHIFT Transistor TR2 Analog signal processing circuit Even Even Transistor TR1 Figure 2-3-5 CCD PCB block diagram The CCD PCB (CCDPCB) is equipped with a CCD sensor IC2 for original scanning. The CCD sensor IC2 is controlled by the clock signals φ1, φ2, RS, CLP and SHIFT for CCD drive from the main PCB (MPCB) via logic IC1.

  • Page 180: Laser Diode Pcb

    2-3-4 Laser diode PCB Main PCB Laser diode PCB /ADJUST Laser driver Photo /ENABLE Driver sensor /VIDEO Figure 2-3-6 Laser diode PCB block diagram The laser diode PCB (LDPCB) consists of the laser diode LD1 and laser driver IC1. The laser driver IC1 on the laser diode PCB (LDPCB) turns the laser diode LD1 on and off according to the image data received from the main PCB (MPCB).
  • Page 181 2-4-1...
  • Page 182 2-4-2...

  • Page 183: Timing Chart No. 3

    Timing chart No. 3 Copying an A5R original onto a sheet of A3 copy paper from the bypass tray, magnification ratio 200% Start key Any key Fwd. rotation CN28-1,3,4,6 Rev. rotation 1078 P 34 P 472 P 2834 P 2834 P 2834 P 2362 P 5136 P...

  • Page 184: Timing Chart No. 4

    Timing chart No. 4 Continuous copying of an A4 original onto two sheets of A4 copy paper from the drawer, magnification ratio 100% Start key Any key Fwd. rotation CN28-1,3,4,6 Rev. rotation 1078 P 472 P 2834 P 2834 P 2834 P 2362 P 5294 P...

  • Page 185: Maintenance Parts List

    Maintenance parts list Maintenance part name Part No. Fig. No. Ref. No. Name used in service manual Name used in parts list Right registration roller RIGHT ROLLER, REGISTRATION 2AV06060 Left registration roller LEFT ROLLER, REGISTRATION 2AV06070 Paper feed pulley PULLEY, PAPER FEED 2AV06010 Bypass paper feed pulley PULLEY, PAPER FEED...

  • Page 186: Periodic Maintenance Procedures

    Periodic maintenance procedures Maintenance Section Method Maintenance cycle Points and cautions Page part/location Test copy and Perform at the maximum Test copy Every service test print copy size Maintenance Section Method Maintenance cycle Points and cautions Page part/location Paper feed Right registration roller Clean Every service...
  • Page 187 Maintenance Section Method Maintenance cycle Points and cautions Page part/location Developing Developer Replace Every service 1-3-7 section Drum unit Replace Every service Apply GE-334C conductive 1-6-34 grease (P/N A0199040) between the drum shaft and grounding plate. Charger assembly Replace Every service 1-6-31 Cleaning lamp Clean...
  • Page 188 Maintenance Section Method Maintenance cycle Points and cautions Page part/location Fixing/Eject Heat roller Clean or replace Clean after 100,000 Clean with alcohol. 1-6-42 section counts; check and replace after 200,000 counts Press roller Clean or replace Clean after 100,000 Clean with alcohol. 1-6-44 counts;...

  • Page 189: General Wiring Diagram

    General wiring diagram BIAS DRUM GRID 12-7 12-6 12-5 SSW2 WTDSW INLET LIVE CN2-1 Heater Noise filter control HVTPCB circuit CN2-3 910W 200V Phase 12-9 control PSPCB (Option) 12-8 32-1 24VR1 32-3 24VR1 10-7 SSW1 24VR2 10-3 12-3 MPCB 12-4 28-6 28-5 11-3...
  • Page 190 Siktgatan 2, 162 50 Vällingby, Sweden 2-28, 1-chome, Tamatsukuri, Chuo-ku Osaka 540-8585, Japan Phone: (08) 4719999 Phone: (06) 6764-3555 ©2001 KYOCERA MITA CORPORATION is a trademark of Kyocera Corporation is a registered trademark of KYOCERA MITA CORPORATION Printed in Holland...

Table of Contents