Kyocera Mita KM-1810 Service Manual
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Kyocera Mita KM-1810 Service Manual

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KM-1510/1810
SERVICE
MANUAL
Published in July '01
2A170762
Revision 2

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Summary of Contents for Kyocera Mita KM-1810

  • Page 1 KM-1510/1810 SERVICE MANUAL Published in July ’01 2A170762 Revision 2...
  • 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. ATTENTION IL Y A DANGER D’EXPLOSION S’IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE. REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MÊME TYPE OU D’UN TYPE REC- OMMANDÉ...

  • Page 3: Safety Precautions

    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: Installation Precautions

    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: Specifications 1

    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: Table Of Contents

    2A1/2 CONTENTS 1-1 Specifications 1-1-1 Specifications ............................1-1-1 1-1-2 Parts names ............................1-1-3 (1) Copier ............................. 1-1-3 (2) Operation panel ..........................1-1-4 1-1-3 Machine cross section .......................... 1-1-5 1-1-4 Drive system ............................1-1-6 (1) Drive system 1 (drive motor drive train) ..................1-1-6 (2) Drive system 2 (scanner motor drive train) ..................

  • Page 9: Assembly And Disassembly

    2A1/2 (13) Paper creases..........................1-5-20 (14) Offset occurs..........................1-5-20 (15) Image is partly missing......................... 1-5-21 (16) Fixing is poor..........................1-5-21 (17) Image is out of focus........................1-5-21 (18) Image center does not align with the original center..............1-5-22 (19) Image contrast is low (carrier scattering).
  • Page 10 2A1/2 1-6-3 Optical section ............................ 1-6-17 (1) Detaching and refitting the exposure lamp ................... 1-6-17 (2) Detaching and refitting the scanner wires ..................1-6-19 (2-1) Detaching the scanner wires ....................1-6-19 (2-2) Fitting the scanner wires ...................... 1-6-20 (3) Detaching and refitting the laser scanner unit ................1-6-23 (4) Detaching and refitting the ISU (reference) ..................
  • Page 11 2A1/2 2-1-8 Fixing section ............................. 2-1-20 2-1-9 DF section ............................2-1-22 (1) SDF (15 cpm copier) ........................2-1-22 (2) ADF (18 cpm copier) ........................2-1-23 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 .............................

  • Page 12: Specifications

    2A1/2 1-1-1 Specifications Type ..........Desktop Copying system ......Indirect electrostatic system Originals ......... DF (18 cpm copier): Sheets of paper (Maximum original size: folio/8 " 14") DF (15 cpm copier): Sheets of paper (A4R, folio/8 " 11"R, 8 " 14") Platen: Sheets of paper, books, 3-dimensional objects (Maximum original size: folio/ "...
  • Page 13 2A1/2 Floor requirements ......691 (W) 497 (D) mm " (W) " (D) Functions ........Self-diagnostics, preheat, automatic copy density control, enlargement/reduction copy and photo mode Power source ......... 120 V AC, 60 Hz, 9 A 220 - 240 V AC, 50/60 Hz, 4.8 A (average 2.5 A) Power consumption .......

  • Page 14: Parts Names

    2A1/2 1-1-2 Parts names (1) Copier • 15 cpm Copier • 18 cpm Copier ° ¤ ¤ fi fi fl ‹ › fl ‹ › ⁄ & ‡ Figure 1-1-1 1 DF % Cleaning shaft 2 Original table ^ Front cover 3 Original insertion guides &...

  • Page 15: Operation Panel

    2A1/2 (2) Operation panel Metric ⁄ % & Inch ⁄ % & Figure 1-1-2 1 Start key (Indicator) @ Paper Select key 2 Stop/Reset key # Drawer indicator 3 Size Select keys $ Optional drawer indicator 4 Data/On-line Indicator % Multi-bypass indicator 5 Printer key ^ DF indicator 6 Number of Copies/Zoom (+) key...

  • Page 16: Machine Cross Section

    2A1/2 1-1-3 Machine cross section 6 7 2 Light path Original 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 sparation section 6 Cleaning section 7 Charge erasing section 8 Fixing section 9 ADF (18 cpm copier)

  • Page 17: Drive System

    2A1/2 1-1-4 Drive system (1) Drive system 1 (drive motor drive train) & As viewed from machine rear Figure 1-1-4 1 Drive motor gear 0 Gear 97/25 2 Gear 67/30 ! Drum drive gear 53 3 Gear 23/16 @ Gear 40/45 4 Gear 37/21 # Gear 41 5 Gear 23...

  • Page 18: Drive System 2 (Scanner Motor Drive Train)

    2A1/2 (2) Drive system 2 (scanner motor drive train) As viewed from machine rear @, #, $ and % are parts of machine front Figure 1-1-5 1 Scanner motor gear 9 Drive change gear 25* 2 Scanner drive gear 27/13 0 Gear 25/19* 3 Scanner belt ! Conveying gear 20*...

  • Page 19: Drive System 3 (Original Feed Motor (18 Cpm Copier Only) Drive Train)

    2A1/2 (3) Drive system 3 (original feed motor (18 cpm copier only) drive train) As viewed from machine rear Figure 1-1-6 1 Original feed motor gear 2 Feed gear 42/20 3 Feed drive gear 20 4 Feed pulley 20 5 Idle gear 20 6 Feed drive gear 20 7 Lift gear 38 (4) Drive system 4 (ST feed motor (optional) drive train)

  • Page 20: Developer And Toner

    2A1/2 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 10 C/50 F and 32.5 C/90.5 F and at a relative humidity not higher than 85% RH.

  • Page 21: Installation Environment

    2A1/2 1-2-3 Installation environment 1. Temperature: 10 - 32.5 C/50 - 90.5 F 2. Humidity: 20 - 85%RH 3. Power supply: 120 V AC, 9 A 220 - 240 V AC, 4.8 A (average 2.5 A) 4. Power source frequency: 50 Hz 0.3%/60 Hz 0.3% 5.

  • Page 22: Unpacking And Installation

    2A1/2 1-3-1 Unpacking and installation (1) Installation procedure Start Unpack. Remove the tapes. Adjust the fixing pressure. Remove the tapes, pads and sheet inside the drawer. Remove the pins holding light source units 1 and 2. Remove the pad inside the machine. Install a toner container.
  • Page 23 2A1/2 Unpack • 15 cpm copier &*( ⁄ Figure 1-3-1 Unpacking 1 Copier @ Original holder 2 Power cord # Bar code labels 3 Upper pads $ Drawer spacer 4 Stay % Front drawer spacer 5 Outer case ^ Sheet 6 Bottom pads &...
  • Page 24 2A1/2 • 18 cpm copier &*( Figure 1-3-2 Unpacking 1 Copier ! Plastic bag 2 Power cord @ Pad 3 Upper pads # Bar code labels 4 Stay $ Drawer spacer 5 Outer case % Front drawer spacer 6 Bottom pads ^ Sheet 7 Tray spacer &...
  • Page 25 2A1/2 Remove the tapes. 1. Remove the tapes. 15 cpm: 12 pieces/18 cpm: 8 pieces • 18 cpm copier • 15 cpm copier Figure 1-3-3 2. Open the bypass tray and paper conveying cover and then remove the two tapes. Tapes Figure 1-3-4 1-3-4...
  • Page 26 2A1/2 Adjust the fixing pressure. 3. Lift the fixing section release levers and close the paper conveying cover. Fixing section release levers Figure 1-3-5 Remove the tapes, pads and sheet inside the drawer. 4. Pull the drawer out and remove the tapes and two pads.
  • Page 27 2A1/2 Remove the pins holding light source units 1 and 2. 6. Remove the tapes and two pins for light source unit 1 and 2. Tapes Pins Figure 1-3-8 7. Open the front cover and store the removed pins by securing them on the inside of the cover. The storing locations of the pins are marked inside the front cover.
  • Page 28 2A1/2 9. Pull out the tape from the developing section gently. Tape Figure 1-3-11 Install a toner container. 10. Hold the toner container vertically and tap the top 15 times. Turn the container upside-down and tap the top 15 times. Then, hold the container horizontally and shake it from side to side 10 times.
  • Page 29 2A1/2 Install a waste toner tank. 12. Install the waste toner tank and close all the covers and drawers. Waste toner tank Figure 1-3-14 Attach the original holder (15 cpm copier only). 13. Install the original holder to the left side of the copier.
  • Page 30 2A1/2 Load paper. 15. Pull the drawer out as far as it will go. When the optional drawer is installed, do not pull more than one drawer out at a time. 16. Press the drawer bottom plate down and lock it there.
  • Page 31 2A1/2 19. Set the paper flush against the left-hand wall of the drawer. * Load paper so that it is kept under the claw of the drawer. * When loading paper into the drawer, make sure that the copy side is facing upward (the copy side is the side facing upward when the package is opened.) * Check that the length and width guides securely...

  • Page 32: Setting Initial Copy Modes

    2A1/2 1-3-2 Setting initial copy modes Factory settings are as follows: Maintenance Contents Factory setting item No. Turning auto start function on/off U254 Setting auto clear time 90 s U255 Turning auto preheat/energy saver U256 function on/off U258 Switching copy operation at toner Single mode, 70 empty detectionempty detection Changing the copy count timing...

  • Page 33: Copier Management

    2A1/2 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, default settings can be changed.

  • Page 34: Default Settings

    2A1/2 (2) Default settings User status report Default drawer Outputs the details of the default settings. Sets the drawer to be selected in case such as after 1. Select “F01” and press the enter key. the stop/reset key is pressed. User status report is printed out.
  • Page 35 2A1/2 Copy limit Auto preheat time Sets the limit of the number of copies that can be Sets the auto preheat time. made at a time. 1. Select “F20” and press the enter key. 1. Select “F14” and press the enter key. 2.
  • Page 36 2A1/2 Paper feed shifting adjustment (drawer) Adjusts displacement of the copy image. 1. Select “F26” and press the enter key. 2. Select the setting and press the enter key. Setting range: -3.0 to +3.0 (1 steps moves 0.1) Paper feed shifting adjustment (optional drawer) Adjusts displacement of the copy image.

  • Page 37: Installing The Optional Drawer

    2A1/2 1-3-4 Installing the optional drawer Procedure 1. Remove the tapes, pad and plastic bag from the optional drawer. Tapes Tape Tapes Tape Figure 1-3-21 2. Place the copier on top of the optional drawer such that the right and left covers of the copier become flush with the drawer cover.
  • Page 38 2A1/2 4. If installing on a copier set for metric specifications, pull the optional drawer out as far as it will go and fit the rear paper stops for the metric specifications to the optional drawer. Note: If the rear paper stops for the metric specifications are not installed, problems such as a paper misfeed may occur.

  • Page 39: Installing The Printer Board/Network Board (Option)

    2A1/2 1-3-5 Installing the printer board/network board (option) Procedure 1. Remove the tape keeping the cover of the printer Printer board board from rotating. Tape Figure 1-3-26 2. Remove the printer cover from the copier by firmly pressing the part marked with a triangle. Printer cover Figure 1-3-27 3.
  • Page 40 2A1/2 4. Insert the printer board as far as it will go. 5. Secure the printer board to the copier using the two pins removed in step 3. Printer board Pins Figure 1-3-29 6. Remove the knock-out portion of the printer cover by firmly pressing with a tool, such as a screwdriver, and refit the printer cover to the copier.
  • Page 41 2A1/2 Installing the optional network board 1. Remove the two pins securing the option plate on the printer board and then remove the plate. Option plate Pins Figure 1-3-31 2. Insert the network board along the rails as far as it will go.

  • Page 42: Installing The Memory Board (Standard For 18 Cpm/Optional For 15 Cpm)

    2A1/2 1-3-6 Installing the memory board (standard for 18 cpm/optional for 15 cpm) Note: Make sure that the DIMM is securely inserted on the memory board before starting installation. Procedure 1. Remove the printer cover from the copier by firmly pressing the part marked with a triangle. Printer cover Figure 1-3-34 2.
  • Page 43 2A1/2 3. Insert the memory board as far as it will go. 4. Secure the memory board using the two pins removed in step 2. Memory board Pins Figure 1-3-36 5. Refit the printer cover to the copier. Printer cover Figure 1-3-37 1-3-22...

  • Page 44: Maintenance Mode

    2A1/2 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 Press the stop/reset key, start key and the left copy exposure adjustment key in the order presented and hold them down.

  • Page 45: Maintenance Mode Item List

    2A1/2 (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 46 2A1/2 Item Initial Section Maintenance item contents setting* High voltage U100 Setting the surface potential U101 Setting high voltages • Developing bias 200/34 • Transfer voltage • Transfer voltage output timing 256/544 U109 Setting the drum type U110 Checking/clearing the drum count —...
  • Page 47 2A1/2 Item Initial Section Maintenance item contents setting* Others U901 Checking/clearing copy counts by paper feed locations — U903 Checking/clearing the paper jam counts — U904 Checking/clearing the service call counts — U905 Checking/clearing counts by the DF — U910 Clearing the black ratio data —...

  • Page 48: Contents Of Maintenance Mode Items

    2A1/2 (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 49 2A1/2 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 50 2A1/2 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 51 2A1/2 Maintenance Description item No. U030 Checking motor operation Description Drives each motor. Purpose To check the operation of each motor. Method 1. Press the start key. A selection item appears. 2. Select the motor to be operated using the copy exposure adjustment keys. Display Motor Drive motor (DM)
  • Page 52 2A1/2 Maintenance Description item No. U033 Checking main switch operation Description Turns the main switch on by energizing the main switch off solenoid. Purpose To check the operation of the main switch off solenoid in auto shutoff mode. Method 1. Press the start key. "A" appears. 2.
  • Page 53 2A1/2 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.
  • Page 54 2A1/2 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 55 2A1/2 Maintenance Description item No. U065 Adjusting the scanner magnification Adjustment See pages 1-6-27 and 28. U066 Adjusting the leading edge registration for scanning an original on the contact glass Adjustment See page 1-6-29. U067 Adjusting the center line for scanning an original on the contact glass Adjustment See page 1-6-30.
  • Page 56 2A1/2 Maintenance Description item No. U071 Adjusting the DF scanning timing Adjustment See pages 1-6-50 and 51. U072 Adjusting the DF center line Adjustment See page 1-6-52. U073 Checking scanner operation Description Simulates the scanner operation under arbitrary conditions. Purpose To check scanner operation.
  • Page 57 2A1/2 Maintenance Description item No. U074 Adjusting the DF input light luminosity Description Adjusts the luminosity of the exposure lamp for scanning originals from the DF. Purpose Used if the exposure amount differs significantly between when scanning an original on the contact glass and when scanning an original from the DF.
  • Page 58 2A1/2 Maintenance Description item No. U087 Turning the DF scanning position adjust mode on/off Description Turns on or off the DF scanning position adjust mode, in which the DF original scanning position is adjusted automatically by determining the presence or absence of dust on the slit glass. Also changes the reference data for identifying dust.
  • Page 59 2A1/2 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 60 2A1/2 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 61 2A1/2 Maintenance Description item No. U091 When scanning is performed before shading, the scan value at the machine center should be slightly (cont.) different from those at the machine front and rear. When scanning is performed after shading, there should be no difference between respective values.
  • Page 62 2A1/2 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 63 2A1/2 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 64 2A1/2 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 65 2A1/2 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 66 2A1/2 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 A...
  • Page 67 2A1/2 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 68 2A1/2 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 69 2A1/2 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 70 2A1/2 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 71 2A1/2 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 72 2A1/2 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/reset key when fixing heater is off.
  • Page 73 2A1/2 Maintenance Description item No. U207 Checking the operation panel keys Description Checks operation of the operation panel keys. Purpose To check operation of all the keys and LEDs on the operation panel. Method 1. Press the start key. 2. “1” appears on the copy quantity display and the leftmost LED on the operation panel lights. 3.
  • Page 74 2A1/2 Maintenance Description item No. U244 Checking the DF switches Description Displays the status of the switches in the DF. Purpose To check if switches in the DF operate correctly. Method 1. Press the start key. "-5-" appears. 2. Manually turn on and off each switch to check the status. When the on-status of a switch is detected, the image mode LED corresponding to the operated switch lights.
  • Page 75 2A1/2 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 76 2A1/2 Maintenance Description item No. U254 Turning auto start function on/off Description Selects if the auto start function is turned on. Purpose Normally no change is necessary. If incorrect operation occurs, turn the function off: this may solve the problem. Method Press the start key.
  • Page 77 2A1/2 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 78 2A1/2 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 79 2A1/2 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 80 2A1/2 Maintenance Description item No. U332 Setting the size conversion factor Description Sets the factor for converting each paper size into A4/11" ". The black ratio is converted for the A4/ 11" " 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 81 2A1/2 Maintenance Description item No. U342 Setting the ejection restriction Description Sets or cancels the restriction on the number of sheets to be ejected continuously. When the restriction is set, the number of sheets that can be ejected continuously to the internal eject tray will be limited to 100.
  • Page 82 2A1/2 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 83 2A1/2 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 84 2A1/2 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 85 2A1/2 Maintenance Description item No. U905 Checking/clearing counts by the DF Description Displays or clears the counts of the DF. Purpose To check the use of the DF. Also to clear the counts after replacing consumable parts. Method 1. Press the start key. 2.
  • Page 86 2A1/2 Maintenance Description item No. U910 Clearing the black ratio data Description Clears the accumulated black ratio data for A4/11" " sheets. Purpose To clear data as required at times such as during maintenance service. Method 1. Press the start key. 2.
  • Page 87 2A1/2 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 88 2A1/2 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 89 2A1/2 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 90: Paper Misfeed Detection

    2A1/2 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 paper conveying cover or pull the drawer out.

  • Page 91: Paper Misfeed Detection Conditions

    2A1/2 (2) Paper misfeed detection conditions • SDF (15 cpm copier) DFTSW • ADF (18 cpm copier) DFTSW STFSW Figure 1-5-2 1-5-2...
  • Page 92 2A1/2 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 (“PF” appears on the copy quantity display.) The registration switch (RSW) does not turn on within 1255 ms of the paper feed clutch (PFCL) turning on.
  • Page 93 2A1/2 The ST feed switch* (STFSW) does not turn off within the time required to convey the length of the used paper size plus 2273 ms of turning on (when paper is fed from the optional drawer). STFSW * Paper size + 2273 ms Timing chart 1-5-6 •...
  • Page 94 2A1/2 6. DF • No original feed (jam code 70) During the primary feed of the second or subsequent originals, the DF timing switch (DFTSW) does not turn on within the specified number of original feed motor (OFM) pulses after the original feed motor (OFM) turns on. The DF timing switch (DFTSW) still fails to turn on after up to 5 retries (ADF)/3 retries (SDF) of the original feed operation.

  • Page 95: Paper Misfeeds

    2A1/2 (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, the ST feed switch*, eject section is eject switch or the DF timing indicated as soon as...
  • Page 96 2A1/2 Problem Causes/check procedures Corrective measures Paper in the bypass tray is Change the paper. A paper jam in the extremely curled. paper feed section Check if the bypass paper Check visually and replace the pulleys if deformed (see page 1- is indicated during feed pulleys are deformed.
  • Page 97 2A1/2 Problem Causes/check procedures Corrective measures Check if the registration Check and remedy if necessary. A paper jam in the clutch malfunctions. paper conveying Electrical problem with the Check (see page 1-5-24). section is indicated registration clutch. during copying (jam in registration/ Broken registration switch Check visually and replace the registration switch if its actuator...
  • Page 98 2A1/2 Problem Causes/check procedures Corrective measures (12) Broken DF timing switch Check visually and replace the DF timing switch if its actuator is An original jam in actuator. broken. the DF is indicated Defective DF timing With 5 V DC present at CN11-11 on the main PCB, check if during copying (An switch.

  • Page 99: Self-Diagnosis

    2A1/2 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 731 altenates, indicating the nature of the problem. After removing the problem, the self-diagnostic function can be reset by turning safety switch off and back on. (2) Self diagnostic codes Remarks Code...
  • Page 100 2A1/2 Remarks Code Contents Causes Check procedures/corrective measures C100 Exposure lamp problem Poor contact of Check the connection of connector CN12 • Check the CCD input value for the the connector on the main PCB, and the continuity across lighting status of the exposure lamp terminals.
  • Page 101 2A1/2 Remarks Code Contents Causes Check procedures/corrective measures C400 Polygon motor synchronization Defective power Check if 24 V DC is present at CN1-2 on problem source PCB. the power source PCB. If not, replace the • The polygon motor does not reach a power source PCB.
  • Page 102 2A1/2 Remarks Code Contents Causes Check procedures/corrective measures C610 Broken fixing heater wire Fixing unit Check and reinstall if necessary. • It takes 15 s or more for the fixing thermistor temperature to reach 50 C/122 F installed after the power is turned on or the incorrectly.
  • Page 103 2A1/2 Remarks Code Contents Causes Check procedures/corrective measures C730 Broken external temperature Poor contact of Reinsert the connector. Also check for thermistor wire the humidity continuity within the connector cable. If • The input voltage is above 4.5 V. sensor PCB none, repair or replace the cable.

  • Page 104: Image Formation Problems

    2A1/2 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 1-5-16 See page 1-5-16 See page 1-5-17 See page 1-5-17 (5) A white line appears (8) One side of the copy (7) A black line appears (6) A black line appears...
  • Page 105 2A1/2 (1) No image appears Causes (entirely white). 1. No transfer charging. Causes Check procedures/corrective measures 1. No transfer charging. A. The connector terminals of the high-voltage Reinsert the connector. Also check for continuity within the transformer PCB make poor contact. connector cable.

  • Page 106: Image Is Too Light

    2A1/2 (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 add toner indicator lights, replace the container. 2. Deteriorated developer. Check the number of copies made with the current developer. If it has reached the specified limit, replace the developer.

  • Page 107: A Black Line Appears Longitudinally

    2A1/2 (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 108: Black Dots Appear On The Image

    2A1/2 (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 109: The Leading Edge Of The Image Is Sporadically Misaligned With The Original

    2A1/2 (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 110: Image Is Partly Missing

    2A1/2 (15) Image is partly miss- Causes ing. 1. Paper damp. 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 111 2A1/2 (18) Image center does not Causes align with the original 1. Misadjusted center line of image printing. center. 2. Misadjusted scanner center line. 3. Original placed incorrectly. Causes Check procedures/corrective measures 1. Misadjusted center line of image printing. Readjust the center line of image printing (see pages 1-6-14). 2.

  • Page 112: Electrical Problems

    2A1/2 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 113: St Feed Motor Does Not Operate

    2A1/2 Problem Causes Check procedures/corrective measures Broken Original feed motor Check for continuity across the coil. If none, replace Original Original feed motor coil. feed motor. does not operate. Poor contact in the Reinsert the connector. Also check for continuity within the Original feed motor connector cable.

  • Page 114: The Fixing Heater Does Not Turn Off

    2A1/2 Problem Causes Check procedures/corrective measures (15) Broken fixing unit Measure the resistance. If it is , replace the fixing unit The fixing heater thermistor wire. thermistor. does not turn on (C610). (16) Dirty sensor part of the Check visually and clean the thermistor sensor parts. The fixing heater fixing unit thermistor.

  • Page 115: When The Main Switch Is Turned On

    2A1/2 Problem Causes Check procedures/corrective measures (21) Defective ST feed switch*. With 5 V DC present at CN5-9 on the main PCB, check if CN5-2 A paper jam in the on the main PCB remains low when the ST feed switch* is paper feed, paper turned on and off.

  • Page 116: Mechanical Problems

    2A1/2 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, ST paper feed pulleys* and bypass paper feed pulleys. Check if the paper feed pulleys are Check visually and replace any deformed deformed.

  • Page 117: Precautions For Assembly And Disassembly

    2A1/2 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 118: Running A Maintenance Item

    2A1/2 (2) Running a maintenance item Start Press the stop/reset key, start key and the left copy exposure adjustment key in the order presented and hold them down. · · · · · · · Entering the maintenance mode Press the stop/reset key. Enter the number of the maintenance item to be executed using the copy ·...

  • Page 119: Paper Feed Section

    2A1/2 1-6-2 Paper feed section (1) Detaching and refitting the paper feed pulleys High-voltage transfer PCB Follow the procedure below to replace the paper feed pulleys. Procedure 1. Remove the printer cover and rear cover. Pull out the drawer. 2. Remove the four screws and then detach the high-voltage transfer PCB.
  • Page 120 2A1/2 5. Remove the paper feed shaft unit from the lower front side of the machine. Paper feed shaft unit Figure 1-6-4 6. Remove the screw holding each of the paper feed pulleys and then the pulleys. Paper feed pulleys 7.
  • Page 121 2A1/2 (2) Detaching and refitting the ST paper feed pulleys and ST paper conveying roller (option) Follow the procedure below to replace the ST paper feed pulleys or ST paper conveying roller. (2-1) Detaching and refitting the ST paper feed pulleys Procedure 1.
  • Page 122 2A1/2 5. Open the left cover of the optional drawer. ST paper feed unit 6. Remove the screw holding ST drive motor PCB. 7. Remove the four screws holding the ST ST drive motor PCB paper feed unit and then the unit. Left cover Figure 1-6-9 8.
  • Page 123 2A1/2 10. Remove the bushing from the front side of the ST paper feed unit and detach the ST paper feed shaft unit. ST paper feed unit Bushing Figure 1-6-12 11. Remove the screw holding each of the ST paper feed pulleys and then the pulleys. ST paper feed pulleys 12.

  • Page 124: St Paper Conveying Roller (Option)

    2A1/2 (2-2) Detaching and refitting the ST paper conveying roller Procedure 1. Remove the ST paper feed unit (see page 1- 6-5). 2. Remove the stop ring and two gears toward the rear side of the ST paper feed unit. Gear Gear Stop ring...

  • Page 125: Detaching And Refitting The Bypass Paper Feed Pulley

    2A1/2 (3) Detaching and refitting the bypass paper feed pulley Follow the procedure below to replace the bypass paper feed pulley. Procedure 1. Remove the printer cover, rear cover and left cover. 2. Remove the image formation unit (see page 1-6-32).
  • Page 126 2A1/2 7. Remove the stop ring and then the bypass paper feed clutch. Stop ring Bypass paper feed clutch Figure 1-6-20 Bypass paper feed shaft unit 8. Remove the stop ring and bushing holding the bypass paper feed shaft unit and then the unit.
  • Page 127 2A1/2 10. Replace the bypass paper feed pulley and refit all the removed parts. • Refit the bypass paper feed pulley so that Ground plate the one-way clutch is machine rear. • When refitting the bypass paper feed shaft unit, check that the hole in the grounding plate is inserted over the projection under the bypass lift plate.

  • Page 128: Adjustment After Roller And Clutch Replacement

    2A1/2 (4) Adjustment after roller and clutch replacement Perform the following adjustment after refitting rollers and clutches. (4-1) 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 U071 U034...

  • Page 129: Adjusting The Leading Edge Registration For Memory Image Printing

    2A1/2 (4-2) Adjusting the leading edge registration for memory image printing Make the following adjustment if there is a regular error between the leading edge of the copy image and the leading edge of the original during memory copying. U066 U034 U407 (P.

  • Page 130: Adjusting The Center Line Of Image Printing

    2A1/2 (4-3) 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 U072 U034 (P. 1-6-30) (P.

  • Page 131: Adjusting The Margins For Printing

    2A1/2 (4-4) Adjusting the margins for printing Make the following adjustment if the margins are not correct. U403 U404 U402 (P. 1-6-31) (P. 1-6-53) Caution: Check the copy image after the adjustment. If the margins are still incorrect, perform the above adjustments in maintenance mode.

  • Page 132: Adjusting The Amount Of Slack In The Paper

    2A1/2 (4-5) 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 Enter maintenance mode. Enter “051” using the copy exposure Original Copy Copy...

  • Page 133: Optical Section

    2A1/2 1-6-3 Optical section (1) Detaching and refitting the exposure lamp Replace the exposure lamp as follows. Contact glass Procedure 1. Remove the printer cover and right cover and then the contact glass. Right cover Figure 1-6-29 2. Move the mirror 1 frame to the cutouts of the machine.
  • Page 134 2A1/2 4. Remove the two screws holding the exposure lamp and then the lamp. Exposure lamp 5. Replace the exposure lamp and refit all the removed parts. Figure 1-6-31 1-6-18...

  • Page 135: Detaching And Refitting The Scanner Wires

    2A1/2 (2) Detaching and refitting the scanner wires Take the following procedure when the scanner wires are broken or to be replaced. (2-1) Detaching the scanner wires Procedure 1. Remove the right cover, left cover, rear cover, upper front cover and contact glass. 2.

  • Page 136: Fitting The Scanner Wires

    2A1/2 (2-2) Fitting the scanner wires Caution: When fitting the wires, be sure to use those specified below. Machine front: P/N 2A11208 (gray) Machine rear: P/N 2A11209 (black) Fitting requires the following tools: Scanner motor unit Two frame securing tools (P/N 2A168080) Procedure 1.
  • Page 137 2A1/2 4. Insert the locating ball on each of the scanner wires into the hole in the respective scanner wire drum and wind the scanner wire two turns inward and eight turns outward. • Use the gray wire at the machine front and the black wire at the machine rear.
  • Page 138 2A1/2 7. Loop the scanner wires around the outer grooves in the pulleys on the mirror 2 frame, winding from above to below................................1 8. Hook the round terminals onto the catches inside the scanner unit............... 2 Figure 1-6-40 9.

  • Page 139: Detaching And Refitting The Laser Scanner Unit

    2A1/2 (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 and remove the waste toner tank and toner container. Connectors 2.
  • Page 140 2A1/2 6. Detach the two connector and remove the laser scanner unit. Sponge • When removing the connector that is covered with a sponge, remove the sponge first. 7. Replace the laser scanner unit and refit all the removed parts. Fit the sponge packing with the new scanner unit.

  • Page 141: Detaching And Refitting The Isu (Reference)

    2A1/2 (4) Detaching and refitting the ISU (reference) Take the following procedure when the ISU is to be checked or replaced. Procedure 1. Remove the printer cover, right cover and contact glass. 2. Remove the rear cover and the shield cover. 3.

  • Page 142: Adjusting The Longitudinal Squareness (Reference)

    2A1/2 (5) 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 1-6-16) first. Check for the longitudinal squareness of the copy image, and if it is not obtained, perform the longitudinal squareness adjustment.

  • Page 143: Adjusting Magnification Of The Scanner In The Main Scanning Direction

    2A1/2 (6) 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. 1-4-10) (P. 1-6-30) direction) (P. 1-6-28) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 144: Adjusting Magnification Of The Scanner In The Auxiliary Scanning Direction

    2A1/2 (7) 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 U070 (main scanning (auxiliary scanning (P. 1-4-10) (P. 1-6-49) direction) (P. 1-6-27) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 145: Adjusting The Scanner Leading Edge Registration

    2A1/2 (8) 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 U071 U066 (P. 1-6-12) (P. 1-6-50) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Start Enter maintenance mode.

  • Page 146: Adjusting The Scanner Center Line

    2A1/2 (9) 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 U072 U067 (P. 1-6-14) (P. 1-6-52) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner center line Start...

  • Page 147: Adjusting The Margins For Scanning An Original On The Contact Glass

    2A1/2 (10) Adjusting the margins for scanning an original on the contact glass Perform the following adjustment if the margins are not correct. U402 U404 U403 (P. 1-6-15) (P. 1-6-53) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner leading edge margin (3 2.5 mm)

  • Page 148: Image Formation Section

    2A1/2 1-6-4 Image formation section (1) Detaching and refitting the image formation unit Follow the procedure below to replace or check the image formation unit. Prucedure 1. Pull the drawer out and open the front cover, Waste toner tank bypass tray and paper conveying unit. 2.

  • Page 149: Detaching And Refitting The Main Charger Unit

    2A1/2 (2) Detaching and refitting the main charger unit Follow the procedure below to replace the charger assembly. Prucedure 1. Remove the image formation unit (see page Main charger unit 1-6-32). 2. Remove the screw holding the main charger assemby and then the assembly. 3.

  • Page 150: Detaching And Refitting The Drum

    2A1/2 (3) 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. • When removing the drum, spread paper underneath as there is a possibility of toner spill. Toner spill can be reduced by inserting an approximately 20-mm thick pad under the image formation unit toward the developing section and removing the drum with the unit slightly tilted.
  • Page 151 2A1/2 6. Remove the screw holding the upper developing seal and then the seal. Upper developing seal Figure 1-6-61 7. Pull the drum shaft out and remove the drum. • Detach the drum horizontally. 8. Replace the drum and refit all the removed parts.

  • Page 152: Detaching And Refitting The Cleaning Blade

    2A1/2 (4) Detaching and refitting the cleaning blade Follow the procedure below to replace the cleaning blade. Prucedure 1. Remove the image formation unit (see page Cleaning blade 1-6-32). 2. Remove the main charger unit (see page 1-6- 33). 3. Remove the drum (see page 1-6-34). 4.

  • Page 153: Replace The Developer

    2A1/2 (5) Replace the developer Follow the procedure below to replace the developer. Prucedure 1. Remove the image formation unit (see page Developing section cover 1-6-32). 2. Remove the screw and washer. While lifting the hooks upward, slide the developing section cover until removed.

  • Page 154: Transfer Section

    2A1/2 1-6-5 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 155: Fixing Section

    2A1/2 1-6-6 Fixing section (1) Detaching and refitting the fixing unit Follow the procedure below to check or replace the fixing unit. Procedure 1. Open the paper conveying unit and remove the left cover. 2. Remove the two screws and detach the three connector and then remove the fixing unit.

  • Page 156: Detaching And Refitting The Fixing Heater

    2A1/2 (3) 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. Remove the screw holding the fixing unit front cover and then the cover. Fixing unit front cover Figure 1-6-69 Fixing heater wire...
  • Page 157 2A1/2 5. Pull out the fixing heater from the fixing unit. 6. Replace the fixing heater and refit all the removed parts. • Do not touch the glass surfaces of the fixing heater with bare hands. Fixing heater Figure 1-6-72 1-6-41...

  • Page 158: Detaching And Refitting The Heat Roller Separation Claws

    2A1/2 (4) Detaching and refitting the heat roller separation claws Follow the procedure below to replace the heat roller separation claws. Procedure 1. Remove the fixing unit (see page 1-6-39). 2. Remove the fixing heater (see page 1-6-40). 3. Remove the screw holding the fixing heater Fixing heater rear retainer rear retainer and then the retainer.

  • Page 159: Detaching And Refitting The Heat Roller

    2A1/2 (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 four heat roller separation claws (see page 1-6-42). 3. Remove the two C rings, gear and two bushings and then remove the heat roller.
  • Page 160 2A1/2 4. Move the fixing pressure release lever to the the release position (in the direction of 1). 5. While holding the fixing pressure release levers outward, push the fixing pressure release levers further. Fixing pressure Fixing pressure release lever release lever Figure 1-6-78 6.

  • Page 161: Df Section

    2A1/2 1-6-7 DF section (1) Detaching and refitting the DF forwarding pulley and DF feed pulley (18 cpm copier only) Follow the procedure below to clean or replace the DF forwarding pulley or DF feed pulley. Procedure 1. Remove the two screws holding the DF lower left cover and theb the cover.

  • Page 162: Df Feed Pulley (18 Cpm Copier Only)

    2A1/2 • Detaching the DF feed pulley 5. Remove the stop ring and bushing and pull DF feed shaft unit the DF feed shaft unit out. Stop ring Bushing Figure 1-6-83 6. Remove the stop ring, and then remove the Stop ring DF feed pulley.

  • Page 163: Detaching And Refitting The Df Separation Pulley (18 Cpm Copier Only)

    2A1/2 (2) Detaching and refitting the DF separation pulley (18 cpm copier only) Follow the procedure below to clean or replace the DF separation pulley. Procedure 1. Remove the DF original switchback cover (see page 1-6-45). Original feed guide 2. Remove the screw holding the original feed guide and then the guide.

  • Page 164: Adjusting The Df Lateral Squareness

    2A1/2 (3) Adjusting the DF lateral squareness Perform the following adjustment if the copy image is laterally skewed (lateral squareness not obtained) when the DF is used. Procedure Start Place an original on the DF Retighten the screw and and make a test copy. close the DF.

  • Page 165: Adjusting The Df Magnification

    2A1/2 (4) Adjusting the DF magnification Adjust magnification in the auxiliary scanning direction if magnification is incorrect when the DF is used. U053 U065 U070 (P. 1-4-10) (P. 1-6-28) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Main scanning direction...

  • Page 166: Adjusting The Df Leading Edge Registration

    2A1/2 (5) Adjusting the DF leading edge registration Perform the following adjustment if there is a regular error between the leading edge of the original and the copy image. U034 U066 U071 (P. 1-6-12) (P. 1-6-29) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Start Enter maintenance mode.

  • Page 167: Adjusting The Df Trailing Edge Registration

    2A1/2 (6) Adjusting the DF trailing edge registration Perform the following adjustment if the original scanning end position is not correct when the DF is used. Caution: If the copy image looks like copy example 2, clean the DF original scanning section. Procedure Start Enter maintenance mode.

  • Page 168: Adjusting The Df Center Line

    2A1/2 (7) Adjusting the DF center line Perform the following adjustment if there is a regular error between the centers of the original and the copy image. U034 U067 U072 (P. 1-6-14) (P. 1-6-30) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Reference Start...

  • Page 169: Adjusting The Margins For Scanning The Original From The Df

    2A1/2 (8) Adjusting the margins for scanning the original from the DF Perform the following adjustment if margins are not correct. U402 U403 U404 (P. 1-6-15) (P. 1-6-31) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure DF leading edge margin (3 2.5 mm)

  • Page 170: Replacing The Main Pcb

    2A1/2-1 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 Upper shield cover power plug.
  • Page 171 2A1/2 6. 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. 7.

  • Page 172: Upgrading The Firmware On The Main Pcb

    2A1/2 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 IC (P/N 2A168050) Procedure 1. Turn the main switch off and disconnect the power plug.

  • Page 173: Adjustment-Free Variable Resistors (Vr)

    2A1/2 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 • Inverter PCB: VR1 1-7-4...

  • Page 174: Paper Feed Section

    2A1/2 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 upper drawer, lower 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 175 2A1/2 Start key PVSYNC PFCL 150 ms 150 ms 160 ms 300 ms Timing chart 2-1-1 Paper feed from the drawer a: When the drive motor (DM) turns on, the paper feed clutch (PFCL) turns on for 150 ms to start primary paper feed. b: 160 ms after the leading edge of the paper turns the registration switch (RSW) on, the registration clutch (RCL) turns on for 300 ms.
  • Page 176 2A1/2 Start key PVSYNC STFM 50 ms STPFCL 150 ms STFSW 150 ms 160 ms 300 ms Timing chart 2-1-3 Paper feed from the optional drawer a: When the drive motor (DM) turns on, the ST feed motor (STFM) turns on. b: 50 ms after the ST feed motor (STFM) turns on, the ST paper feed clutch (STPFCL) turns on for 150 ms to start primary paper feed.

  • Page 177: Figure 1

    2A1/2 2-1-2 Main charging section The main charging section consists of the drum and main charger unit. The drum is electrically charged plus by means of a grid to form a latent image on the surface. The shield grid ensures that the charge is applied uniformly. Main charger unit Tungsten wire Drum...
  • Page 178 2A1/2 Start key Video 95 ms MC REM 95 ms 95 ms 100 ms GRID CNT 95 ms Timing chart 2-1-4 Main charging a: When the Video signal is received from the optical section, main charging (MC REM) starts. b: 95 ms after main charging (MC REM) starts, the grid control voltage (GRID CNT) increases in stages. c: 100 ms after the trailing edge of the paper turns the eject switch (ESW) off, the grid control voltage (GRID CNT) decreases in stages.

  • Page 179: Optical Section

    2A1/2 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 2-1-5 Optical section 1 Mirror 1 frame 2 Exposure lamp (EL) 3 Mirror 1 4 Inveter PCB (INPCB) 5 Mirror 2 frame 6 Mirror 2...

  • Page 180: Original Scanning

    2A1/2 (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 181 2A1/2 DFCHSOL Lamp-on confirmation, AGC, and shading 412 P 600 P Fwd.rotation Rev.rotation 160 P 35 ms 35 ms 400 P 400 P SHPSW • When the scanner home position switch (SHPSW) is on at power-on Timing chart 2-1-6 Scanner operation (2) a: When the main switch (MSW) turns on, the scanner motor (SM) rotates forward, which turns off 400 scanner motor pulses after the scanner home position switch (SHPSW) turns off.

  • Page 182: Image Printing

    2A1/2 (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 183 2A1/2 Drum Figure 2-1-8 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 184: Developing Section

    2A1/2 2-1-4 Developing section The developing section consists of the developing unit and the toner container. 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 container Toner feed motor (TFM) Developing unit...

  • Page 185: Formation Of Magnetic Brush

    2A1/2 (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 186: Toner Density Detection By The Toner Sensor

    2A1/2 (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 187: Correcting The Toner Sensor Control Voltage

    2A1/2 (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 188: Correcting Toner Output Voltage

    2A1/2 • 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-15...

  • Page 189: Transfer And Separation Section

    2A1/2 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 minus. Toner adhered to the transfer roller is removed by the transfer cleaner. Drum separation claws Drum Transfer roller...
  • Page 190 2A1/2 Start key 150 ms 550 ms TC REM 215 ms TC CNT Timing chart 2-1-7 Operation of transfer a: 215 ms after the registration clutch (RCL) turns on to start secondary paper feed, transfer charging (TC REM) starts. b: 550 ms after the trailing edge of the paper turns the registration switch (RSW) off, transfer charging (TC REM) ends. 2-1-17...

  • Page 191: Cleaning Section

    2A1/2 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. The cleaning blade is equipped with a thrust mechanism to protect the blade and drum from scratches. Cleaning spiral Cleaning blade Drum...

  • Page 192: Charge Erasing Section

    2A1/2 2-1-7 Charge erasing section The cleaning lamp (CL) consists of LEDs which remove residual charge from the drum surface. Cleaning lamp (CL) Drum Figure 2-1-22 Charge erasing section MPCB CL REM CN3-6 Drum Figure 2-1-23 Charge erasing section block diagram 2-1-19...

  • Page 193: Fixing Section

    2A1/2 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 194 2A1/2 Secondary stabilization fixing temperature 180 C/356 F Primary stabilization fixing temperature 125 C/257 F Fixing temperature 70 ms 20 s DB REM 100 ms Half speed Timing chart 2-1-8 Operation of fixing section a: When the fixing temperature reaches 125 C/257 F after the main switch (MSW) is turned on, the copier enters primary stabilization.

  • Page 195: Df Section

    2A1/2 2-1-9 DF section (1) SDF (15 cpm copier) The DF consists of the components shown in Figure. It conveys the original across the DF contact glass in synchronization with the copier scanning operation. When an original is placed on the original table and the DF original detection switch turns on, the scanner motor (SM) turns on to drive the DF to feed the original.

  • Page 196: Adf (18 Cpm Copier)

    2A1/2 (2) ADF (18 cpm copier) The DF consists of the components shown in Figure. It conveys the original across the DF contact glass in synchronization with the copier scanning operation. During primary original feed, the original feed motor (OFM) turns on and the DF forwarding pulley and DF original conveying roller feed originals one by one.
  • Page 197 2A1/2 Start key 2000 ms 170 ms DFTSW 3000 ms 1700 ms 300 ms 100 ms 200 ms Timing chart 2-1-9 Operation of ADF a: Simultaneous to when the start key is turned on, the original feed motor (OFM) turns on to start primary original feed. b: 170 ms after the leading edge of the original turns the DF timing switch (DFTSW) on, the original feed motor (OFM) turns off.

  • Page 198: Electrical Parts Layout

    2A1/2 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, electrical components and optional devices. 2. Power source PCB (PSPCB) ....... Generates 24 V DC, 12 V DC and 5 V DC; controls the fixing heater. 3.

  • Page 199: Switches And Sensors

    2A1/2 (2) Switches and sensors • SDF (15 cpm) 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 (SSW) ........Breaks the safety circuit when the front cover or paper conveying cover is opened;...

  • Page 200: Motors

    2A1/2 (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 (CFM) ......Cools the machine interior. 5.

  • Page 201: Other Electrical Components

    2A1/2 (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 202: Power Source Pcb

    2A1/2 2-3-1 Power source PCB Power source PCB Main Rectifier switch 24 V DC Noise circuit filter Overvoltage 24 V DC circuit detection circuit C22, 24 output circuit AC input 12 V DC 12 V DC output circuit 5.1 V DC 5.1 V DC output circuit Switching...
  • Page 203 2A1/2 SF24 J2001 J2009 J1001A J2501A J1004 J1501A J1002A J1002 J7502 J1503 J7501 J2002 J1501 J1201 J1504A LUG1 J1503A J1502A AC250V T6.3AL AC250V COIL COIL24 SF24V SF24V Figure 2-3-2 Power source PCB silk-screen diagram 2-3-2...
  • Page 204 2A1/2 Terminals (CN) Voltage Remarks TB-1 TB-2 120 V AC 120 V AC supply, input TB-1 TB-2 220-240 V AC 220-240 V AC supply, input TB-3 TB-4 120 V AC 120 V AC supply for FH, output TB-3 TB-4 220-240 V AC 220-240 V AC supply for FH, output 24 V DC SF 24 V DC supply for MPCB, output (when SSW is on)

  • Page 205: Main Pcb

    2A1/2 2-3-2 Main PCB Main PCB Clock signal Analog image data CCD PCB S/H IC EVEN (IC43) (IC41) Print data (IC21) Printer data FEEPROM Printer controller* (IC55) Memory image data Address bus Memory PCB** Data bus (IC11) SDF (15 cpm) Control signal output ADF (18 cpm)
  • Page 206 2A1/2 CN18 CN17 CN16 CN12 TP42 R445 R516 R176 C518 C121 C512 C430 L416 IC57 L421 TP41 R175 C524 IC42 C823 R7121 R174 R7120 R446 R7119 C120 R410 C413 R172 R6109 C422 C824 C410 R6110 R6134 C411 R6111 C412 C611 C522 IC43 CN14...
  • Page 207 2A1/2 Terminals (CN) Voltage Remarks 24 V DC SF 24 V DC supply from PSPCB, input (when SSW is on) 24 V DC 24 V DC supply from PSPCB, input 5.1 V DC 5.1 V DC supply from PSPCB, input 12 V DC 12 V DC supply from PSPCB, input 0/5 V DC...
  • Page 208 2A1/2 Terminals (CN) Voltage Remarks 6-10 6-14 0/5 V DC Developing bias on/off, output 6-11 6-14 0/5 V DC Main charging ALM signal, input 6-12 0 - 5 V DC GRID control voltage, output 6-13 6-14 0/5 V DC Main charging on/off, output 6-15 6-14 24 V DC SF...
  • Page 209 2A1/2 Terminals (CN) Voltage Remarks 18-1 18-2 0/5 V DC LDPCB BD signal, input 18-3 18-2 5 V DC SF 5 V DC supply for LDPCB, output 18-5 18-2 0/5 V DC LDPCB ENABLE signal, input 18-6 18-2 0/5 V DC LDPCB VIDEO signal, input 18-7 18-2...

  • Page 210: Operation Pcb

    2A1/2 2-3-3 Operation PCB key_sen[0] CN2-2 key_sen[1] CN2-1 _SCAN[0] CN1-3 _SCAN[1] CN1-2 _SCAN[2] CN1-1 _SCAN[3] CN2-7 _SCAN[4] CN2-6 _SCAN[5] CN2-5 _SCAN[6] CN2-4 _SCAN[7] CN2-3 _LEDON[0] CN1-9 _LEDON[1] CN1-8 _LEDON[2] CN1-7 _LEDON[3] CN1-6 L14-1 _LEDON[4] CN1-5 L14-3 _LEDON[5] CN1-4 Figure 2-3-5 Operation unit PCB block diagram The operation unit PCB (OPCB) consists of key switches and LEDs.
  • Page 211 2A1/2 2A1/2-2 JP20 JP21 JP26 2A12807 REV:2 Figure 2-3-6 Operation unit PCB silk-screen diagram Terminals (CN) Voltage Remarks 4-18 0/5 V DC OPCB KEY1 signal, output 4-18 0/5 V DC OPCB KEY0 signal, output 4-18 0/5 V DC (pulse) OPCB DIG7 signal, input 4-18 0/5 V DC (pulse) OPCB DIG6 signal, input...

  • Page 212: Ccd Pcb

    2A1/2 2-3-4 CCD PCB CCD PCB Main PCB Logic IC1 Clock signal generator RESET RESET ASIC SHIFT SHIFT Transistor TR2 Analog signal processing circuit EVEN EVEN Transistor TR1 Figure 2-3-7 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 1, 2, RESET, CLP and SHIFT for CCD drive from the main PCB (MPCB) via logic IC1.

  • Page 213: Laser Diode Pcb

    2A1/2 2-3-5 Laser diode PCB Figure 2-3-8 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 214 2A1/2 Timing chart No. 1 From the main switch turned on to machine stabilization MSW On Secondary stabilization fixing temperature 180 C/356 F Primary stabilization fixing temperature 125 C/257 F Fixing temperature 70 ms CN13-5 DB REM CN6-10 MC REM CN6-13 DB CNT CN6-9...

  • Page 215: Timing Chart No. 2

    2A1/2 Timing chart No. 2 Copying an A4R/8 " 11"R original onto a sheet of A4R/8 " 11"R copy paper from the drawer, magnification ratio 100% Start key On 50 ms 4 ms CN3-3 MSYNC CN3-4 1000 ms VIDEO CN18-6 70 ms CN13-5 80 ms...

  • Page 216: Timing Chart No. 3

    2A1/2 Timing chart No. 3 Continuous copying of an A4R/8 " 11"R original onto two sheets of A4R/8 " 11"R copy paper from the drawer, magnification ratio 100% Start key On 50 ms 4 ms CN3-3 MSYNC CN3-4 1000 ms VIDEO CN18-6 70 ms...
  • Page 217 2A1/2 Timing chart No. 4 Copying an A4R/8 " 11"R original from the SDF onto a sheet of A4R/8 " 11"R copy paper from the optional drawer, magnification ratio 100% (15 cpm copier) DFODSW CN11-13 50 ms 4 ms CN3-3 MSYNC CN3-4 1000 ms...

  • Page 218: Timing Chart No. 5

    2A1/2 Timing chart No. 5 Continuous copying of an A4R/8 " 11"R original from the ADF onto two sheets of A4R/8 " 11"R copy paper from the bypass table, magnification ratio 100% (18 cpm copier) Start key On 50 ms 4 ms CN3-3 MSYNC...
  • Page 219 2A1/2 2-4-6...
  • Page 220 2A1/2 2-4-7...
  • Page 221 2A1/2 • Image quality Item Specifications Copier: ±1.0% or less 100% magnification Using DF: ±1.5% or less Copier: ±1.5% or less Enlargement/reduction Using DF: ±2.0% or less Copier: ±1.5 mm/200 mm or less Lateral squareness (copier mode) Using DF: ±2.0 mm/200 mm or less A: 3.0 ±...

  • Page 222: Wiring Diagram

    2A1/2-2 Wiring diagram HEATER-LIVE HEATER-COM (CN2) FEEDER (OPTION) STFM LIVE NOISE STPFCL FILTER HEATER CIRCUIT NEUTRAL L L STFSW (CN3) STSSW OPCB PSPCB DDSW DFOCSW (CN1) HUMS (CN9) MPCB (CN11) (CN16) (CN17) (CN2) (CN7) (CN12) (CN19) (CN20) PRINTER BOAD (OPTION) MEMPCB SHPSW (15 cpm: OPTION)
  • Page 223 Av. 16 de Septiembre #407 Col. Santa Inés, Delegación Azcapotzalco México, D.F. C.P. 02130 TEL : 3-83-27-41 FAX : 3-83-78-04 ©2000 KYOCERA MITA CORPORATION is a trademark of Kyocera Corporation is a registered trademark of KYOCERA MITA CORPORATION Printed in U.S.A.

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