Kyocera Mita DC-1560 Service Manual
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Kyocera Mita DC-1560 Service Manual

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DC-1560/2050
SERVICE
MANUAL
Published in Oct. '99
841AF110
DC-1560/2050 (KME) S/M

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Summary of Contents for Kyocera Mita DC-1560

  • Page 1 DC-1560/2050 SERVICE MANUAL Published in Oct. ’99 841AF110 DC-1560/2050 (KME) S/M...
  • 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 SERVICE MANUAL DC-1560/2050...

  • Page 4: 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 5 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 6: Installation Precautions

    indicates that action is required. The specific action required is shown inside the symbol. General action required. Remove the power plug from the wall outlet. Always ground the copier. 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.
  • Page 7 • Always handle the machine by the correct locations when moving it..• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause the copier to move unexpectedly or topple, leading to injury................•...
  • Page 8 • Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it is dirty, clean it to remove the risk of fire or electric shock..................• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may damage eyesight.
  • Page 9 • After maintenance, always check that all the parts, screws, connectors and wires that were removed, have been refitted correctly. Special attention should be paid to any forgotten connector, trapped wire and missing screws..................• Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling.

  • Page 10: Table Of Contents

    CONTENTS THEORY AND CONSTRUCTION SECTION 1-1 Specifications 1-1-1 Specifications DC-2050 ..............1-1-1 1-1-2 Specifications DC-1560 ..............1-1-3 1-2 Handling Precautions 1-2-1 Drum ..................... 1-2-1 1-2-2 Developer and toner ..............1-2-1 1-3 Mechanical Construction 1-3-1 Part names and their functions ............. 1-3-1 1-3-2 Machine cross section ..............
  • Page 11 3-5 Self Diagnostics 3-5-1 Self-diagnostic function ..............3-5-1 3-6 Troubleshooting 3-6-1 Image formation problems ............3-6-1 3-6-2 Paper misfeeds ................3-6-16 3-6-3 PCB terminal voltages ..............3-6-19 3-6-4 Electrical problems ..............3-6-30 3-6-5 Mechanical problems ..............3-6-38 3-7 Appendixes Timing chart No. 1 ..................3-7-1 Timing chart No.
  • Page 12 CONTENTS 1-1 Specifications 1-1-1 Specifications DC-2050 ..............1-1-1 1-1-2 Specifications DC-1560 ..............1-1-3 1-1-5...
  • Page 13 CONTENTS 1-2 Handling Precautions 1-2-1 Drum ....................1-2-1 1-2-2 Developer and toner ................1-2-1 1-1-7...
  • Page 14 CONTENTS 1-3 Mechanical Construction 1-3-1 Part names and their functions ............1-3-1 1-3-2 Machine cross section ................ 1-3-3 1-3-3 Drive system ..................1-3-4 1-3-4 Mechanical construction ..............1-3-6 (1) Paper feed section ..............1-3-6 (1-1) Paper feed from the paper drawer ........1-3-8 (1-2) Paper feed from the bypass table ........
  • Page 15 CONTENTS 2-1 Electrical Parts Layout 2-1-1 Electrical parts layout ................2-1-1 1-1-11...
  • Page 16 CONTENTS 2-2 Detection of Paper Misfeed 2-2-1 Paper misfeed detection ..............2-2-1 2-2-2 Paper misfeed detection conditions ............ 2-2-2 1-1-13...
  • Page 17 CONTENTS 2-3 Operation of the PCBs 2-3-1 Composite PCB .................. 2-3-1 2-3-2 Main PCB .................... 2-3-3 (1) Fixing unit abnormally high temperature/shorted thermistor detection circuit ....................2-3-4 (2) Toner feed motor drive circuit .............. 2-3-5 (3) Scanner motor drive circuit ..............2-3-6 (4) Reset circuit ..................
  • Page 18 CONTENTS 3-1 Installation 3-1-1 Unpacking and installation ..............3-1-1 (1) Installation environment .............. 3-1-1 (2) Installation procedure ..............3-1-2 3-1-2 Setting initial copy modes ..............3-1-16 3-1-3 Installing the key counter (option) ............. 3-1-17 3-1-4 Installing the dehumidifier (service part) ........... 3-1-19 1-1-17...
  • Page 19 CONTENTS 3-2 Simulation 3-2-1 Simulations ..................3-2-1 (1) Running a simulation ..............3-2-1 (2) Simulation list ................3-2-3 (3) Contents of simulations ............... 3-2-6 1-1-19...
  • Page 20 CONTENTS 3-3 Assembly and Disassembly 3-3-1 Precautions for assembly and disassembly ........3-3-1 (1) Precautions ................. 3-3-1 (2) Running a simulation ..............3-3-2 3-3-2 Paper feed section ................3-3-3 (1) Detaching and refitting paper feed pulleys A and B ....3-3-3 (2) Detaching and refitting the bypass lower pulley ......
  • Page 21 3-3-6 Developing section ................3-3-46 (1) Adjusting the position of the magnetic brush (developing roller) (reference) ................. 3-3-46 (2) Adjusting the position of the doctor blade (reference) ....3-3-47 (3) Adjusting developing bias voltage (reference) ......3-3-48 3-3-7 Transfer and separation section ............3-3-49 (1) Replacing the charger wires ............
  • Page 22 CONTENTS 3-4 PCB Initial Settings 3-4-1 Replacing the main PCB ..............3-4-1 3-4-2 Adjustment-free variable resistors (VR) ..........3-4-4 1-1-25...

  • Page 23: Self Diagnostics

    CONTENTS 3-5 Self Diagnostics 3-5-1 Self-diagnostic function ............... 3-5-1 (1) Self-diagnostic display ..............3-5-1 1-1-27...
  • Page 24 CONTENTS 3-6 Troubleshooting 3-6-1 Image formation problems ..............3-6-1 (1) No image (entirely white)............. 3-6-4 (2) No image (entirely black)............. 3-6-5 (3) Image is too light................. 3-6-6 (4) Background is visible..............3-6-6 (5) A white line appears longitudinally..........3-6-7 (6) A black line appears longitudinally.
  • Page 25 3-6-4 Electrical problems ................3-6-30 (1) The machine does not operate when the main switch is turned on................... 3-6-30 (2) The drive motor does not operate (C20)........3-6-30 (3) The scanner motor does not operate (C30)......3-6-30 (4) The lens motor does not operate (C40).
  • Page 26 CONTENTS 3-7 Appendixes Timing chart No. 1 ..................3-7-1 Timing chart No. 2 ..................3-7-2 Timing chart No. 3 ..................3-7-3 Composite PCB 1/3 ..................3-7-4 Composite PCB 2/3 ..................3-7-5 Composite PCB 3/3 ..................3-7-6 Operation unit PCB ..................3-7-7 Main PCB ......................
  • Page 27 THEORY AND CONSTRUCTION SECTION DC-1560/2050 (KME) S/M...

  • Page 28: Specifications

    CONTENTS 1-1 Specifications 1-1-1 Specifications DC-2050 ..............1-1-1 1-1-2 Specifications DC-1560 ..............1-1-3 1-1-5...
  • Page 29 1-1-1 Specifications DC-2050 Type …………………………… Desktop Copying system ……………… Dry, indirect electrostatic system Originals ……………………… Sheets, books and 3-dimensional Maximum size: A3/11" × 17" Original feed system ………… Fixed Copy paper …………………… Plain paper: 60 – 80 g/m for drawer feed 60 –...
  • Page 30 Fixing system ………………… Heat roller Heat source: halogen heater (980 W) Control temperature: 175°C/347°F (at normal ambient temperature) Abnormally high temperature protection devices: 140°C/284°F and 150°C/302°F thermostats Fixing pressure: 127.4 N Charge erasing system ……… Exposure by cleaning lamp Cleaning system ……………… Cleaning blade Functions ………………………...
  • Page 31 1-1-2 Specifications DC-1560 Type …………………………… Desktop Copying system ……………… Dry, indirect electrostatic system Originals ……………………… Sheets and books Maximum size: A3/11" × 17" Original feed system ………… Fixed Copy paper …………………… Plain paper: 60 – 80 g/m for drawer feed 60 –...
  • Page 32 Fixing system ………………… Heat roller Heat source: halogen heater (850 W with 120 V input, 980 W with 240 V input) Control temperature: 175°C/347°F (at normal ambient temperature) Abnormally high temperature protection devices: 140°C/284°F and 150°C/302°F thermostats Fixing pressure: 127.4 N Charge erasing system ………...

  • Page 33: Handling Precautions

    CONTENTS 1-2 Handling Precautions 1-2-1 Drum ....................1-2-1 1-2-2 Developer and toner ................1-2-1 1-1-7...

  • Page 34: Developer And Toner

    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 35 CONTENTS 1-3 Mechanical Construction 1-3-1 Part names and their functions ............1-3-1 1-3-2 Machine cross section ................ 1-3-3 1-3-3 Drive system ..................1-3-4 1-3-4 Mechanical construction ..............1-3-6 (1) Paper feed section ..............1-3-6 (1-1) Paper feed from the paper drawer ........1-3-8 (1-2) Paper feed from the bypass table ........

  • Page 36: Part Names And Their Functions

    11. Image formation unit 18. Drawer bottom plate 5. Bypass table 12. Front cover 19. Width guide tab 6. Auxiliary table 13. Bypass cover 20. Width guide 7. Insertion guides 14. Total counter 21. Length guide 1-3-1 DC-1560/2050 (KME) S/M...
  • Page 37 28. Original size indicator Reset Check Paper Size / Add Toner Maintenance Direction 11 15 Manual Zoom ( ) Zoom ( ) Print Auto Stop/ Paper Photo Clear Original Select Original Dark Light Figure 1-3-2 Operation panel 1-3-2 DC-1560/2050 (KME) S/M...

  • Page 38: Machine Cross Section

    1-3-2 Machine cross section Light path Paper path Figure 1-3-3 Machine cross section 1. Paper feed section (page 1-3-6) 2. Main charging section (page 1-3-10) 3. Exposure section (page 1-3-15) 4. Developing section (page 1-3-21) 5. Transfer and separation section (page 1-3-31) 6.

  • Page 39: Drive System

    1-3-3 Drive system As viewed from machine rear Figure 1-3-4 Drive system – copier main body 1. Drive motor gear 27. Gear 30/18 2. Gear 60/40 28. Gear 25 3. Gear 60/24 29. Idle gear 4. Gear 64/20 30. Idle gear 38 5.

  • Page 40: Toner Recycle Gear

    As viewed from machine rear Figure 1-3-5 Drive system – image formation unit 1. Blade thrust gear 31 5. Left spiral gear (machine rear) 2. Toner recycle gear 19 6. Developing gear 28 (machine front) 3. Magnet roller gear 17 7.

  • Page 41: Pulley

    1-3-4 Mechanical construction (1) Paper feed section Figure 1-3-6 Paper feed section 1 Bypass table @ Upper pre-transfer roller 2 Bypass lift # Lower pre-transfer roller 3 Bypass upper pulley $ Registration guide 4 Bypass lower pulley % Upper pre-transfer guide 5 Bypass lower guide ^ Bypass solenoid (BYPSOL) 6 Drawer bottom plate...
  • Page 42 The paper feed section consists of the primary feed and secondary feed subsections. Primary feed conveys paper from the paper drawer or the bypass table to the upper and lower registration rollers, at which point secondary paper feed takes place and the paper travels to the transfer section in sync with the exposure timing.
  • Page 43 (1-1) Paper feed from the paper drawer The paper drawer consists of the drawer bottom plate, drawer springs and other components and can hold up to 250 sheets of copy paper. Paper is fed out of the drawer by the rotation of paper feed pulleys A and B. Prescan start Print key HPSW...
  • Page 44 (1-2) Paper feed from the bypass table The bypass table can hold up to 50 sheets of paper at one time. When the print key is pressed, the bypass solenoid (BYPSOL) turns on, rotating the bypass upper pulley, while the bypass lift is raised until the paper comes into contact with the bypass upper pulley.
  • Page 45 (2) Main charging section The main charging section consists of the drum and main charger. The drum is electrically charged uniformly by means of a grid to form a latent image on the surface. Tungsten wire Main charger Main charger grid Figure 1-3-8 Main charging section 1-3-10...
  • Page 46 Figure 1-3-9 Main charger 1 Main charger front housing 7 Main charger front lid 2 Main charger rear housing 8 Main charger rear lid 3 Main charger shield 9 Charger spring 4 Tungsten wire 0 Charger terminal 5 Main charger grid ! Charger wire retainer pin 6 Grid tension plate @ Film...
  • Page 47 Scanner return start Print key Forward Reverse 300 ms All on 50 ms MC REM Timing chart 1-3-3 Main charging A 300 ms after the print key is pressed, all the blank lamps (BL) turn on. B 50 ms after the all blank lamps (BL) have turned on, main charging starts. C As soon as the scanner starts to return, main charging ends.
  • Page 48 Surface potential correction control The drum surface potential is corrected for the external temperature and humidity. If the external temperature is 24°C/75.2°F or less and the absolute humidity exceeds 25.0 g/m the drum surface potential is corrected as in the table bellow. The external temperature and relative humidity are detected by the external temperature thermistor (ETTH) and humidity sensor (HUMSENS) and the absolute humidity is calculated from these values.
  • Page 49 100% ( ° C) ( ° F) Temperature ( ° C/ ° F) Figure1-3-11 Absolute humidity vs. relative humidity Table 1-3-2 Surface potential correction value vs. external temperature Temperature Correction Temperature Correction Temperature Correction (°C/°F) value (V) (°C/°F) value (V) (°C/°F) value (V) 0/32...
  • Page 50 (3) Exposure section Figure 1-3-12 Exposure section 1 Mirror 1 ! Light source unit 2 2 Mirror 2 @ Main reflector 3 Mirror 3 # Auxiliary reflector 4 Mirror 4 $ Scanner motor (SM) 5 Mirror 5 % Optical section fan motor (OPFM) 6 Mirror 6 ^ AE sensor (AES) 7 Halogen lamp (HL)
  • Page 51 This copier employs a slit exposure system with a fixed original table, and a halogen lamp (HL) as the light source. The optical section consists of light source units 1 and 2. Light source unit 1 carries the halogen lamp and the main and auxiliary reflectors. Each unit travels from one side of the machine to the other along scanner rails at machine front and rear.
  • Page 52 Scan start Prescan start Scanner return start Print key 10 P 10 P HPSW 480 ms 480 ms 1687 P 1232 P Reverse Forward Reverse Forward Auto exposure mode, A4/11" × 8 " original Timing chart 1-3-4 Scanner travel A When the print key is pressed, the halogen lamp (HL) lights at the intensity for prescan. B 480 ms after the halogen lamp (HL) has turned on, the scanner motor (SM) rotates forward for prescan.
  • Page 53 Exposure control for manual exposure and photo modes The halogen lamp light intensity for manual exposure and photo modes is calculated from the data obtained by running simulation 24. Light intensity value Manual exposure mode Photo mode Drum potential 850 V DC Drum potential 680 V DC Drum potential...
  • Page 54 Exposure control for auto exposure mode In auto exposure mode, the halogen lamp lights at the intensity set for mode 1 in simulation 22 to perform prescan. The exposure level to copy that particular original is determined by using the value read in by the AE sensor. AE detection (prescan) Original leading edge Exposure...
  • Page 55 Light intensity correction for enlargement and reduction modes The halogen lamp light intensity for enlargement and reduction modes is determined by the value for copying at 100% magnification and the correction values set by simulation 29. Light intensity correction value Mode 1, sim.
  • Page 56 (4) Developing section The developing section consists of the developing assembly and toner hopper. Developing assembly Figure 1-3-19 Developing section The developing assembly consists of the developing roller where a magnetic brush is formed, doctor blade and the developing spirals that agitate the developer. In the toner hopper new toner from the toner cartridge is mixed with residual toner recovered from the cleaning section, and the mixture is conveyed to the developing assembly.
  • Page 57 Cleaning assembly Cleaning spiral Hopper paddle A Hopper spiral Developing assembly Right developing spiral Toner hopper Left developing spiral Toner feed motor Toner level sensor Hopper paddle B Toner flow Figure 1-3-20 Toner recycling 1-3-22...
  • Page 58 Formation of the 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 59 CN11-5 CN11-6 CN11-9 CN11-10 TLDS Developing bias TNS SIG CN11-3 TNS CONT CN11-1 DB REM CN1-20 CN1-8 MPCB HVTPCB Figure 1-3-22 Developing unit block diagram Toner density is detected by the toner sensor (TNS). The sensor section of the toner sensor detects the ratio of toner to carrier in the developer near it and converts it into a voltage.
  • Page 60 Toner density control Toner density is controlled by switching the toner feed motor on/off using as the reference the toner sensor output based on the toner sensor initial output value set when simulation 60 was executed when the developer was set. The toner sensor output is also used for toner empty detection in the toner hopper.
  • Page 61 D If the toner sensor output voltage falls to the toner empty end level within the toner feed motor forced feed operation time (3 minutes max.), the copier returns to the ready state and intermittent feed operations (3 minutes max.) are carried out until the toner sensor output voltage drops to the toner feed motor off level.
  • Page 62 Correcting toner sensor output voltage The toner density is subject to humidity changes and the developing unit drive time. To maintain the toner density constant, the toner sensor output voltage (TNS SIG) is corrected by the toner sensor control voltage (TNS CONT). TNS CONT = A + B –...
  • Page 63 Computing the absolute humidity The humidity sensor (HUMSENS) and external temperature thermistor (ETTH) are located on the humidity sensor PCB (HUMPCB). The humidity sensor (HUMSENS) converts the relative humidity detected by the humidity sensing element into a voltage and sends it to the main PCB (MPCB).
  • Page 64 • Correction based on the drive time The toner sensor control voltage (TNS CONT) is decreased as the developing unit drive time [the total time the drive motor (DM) has been on] increases from execution of simulation 0.19 –0.29 –0.50 Drive time (h) Figure 1-3-27 Correction based on the drive time 1-3-29...
  • Page 65 Toner level detection The toner level in the toner hopper is monitored by the toner level sensor (TLDS). Vibration shaft Hopper paddle B Toner level sensor (TLDS) Magnet Hopper housing Figure 1-3-28 Toner level detection The toner level sensor (TLDS) is a magnetic proximity sensor which is turned on by the magnet on hopper paddle B moving close to it.
  • Page 66 (5) Transfer and separation section Separation guide Separation pulley Drum separation claws Tungsten wires Transfer charger assembly Figure 1-3-29 Transfer and separation section The transfer and separation section consists of the transfer charger assembly and drum separation claws. The transfer charger assembly consists of the transfer charger, which applies a high voltage to transfer the toner image from the drum surface onto the paper, and the separation charger that helps the paper separate from the drum surface.
  • Page 67 Figure 1-3-30 Transfer charger assembly 1 Transfer charger front housing 7 Tungsten wire for transfer 2 Transfer charger rear housing 8 Tungsten wire for separation 3 Transfer charger front lid 9 Charger springs 4 Transfer charger rear lid 0 Charger terminals 5 Transfer charger shield ! Charger wire retainer pins 6 Separation guide...
  • Page 68 Secondary paper feed start Print key HPSW PFSOL 147 P+140 ms * 100 ms RSOL 220 ms TC REM 200 ms SC REM *1 Varies depending on the setting by simulation 27. Timing chart 1-3-5 Transfer and separation A 147 pulses + 140 ms after the scanner has started scanning and the home position switch (HPSW) has turned off, transfer and separation charging starts and the registration solenoid (RSOL) turns on to start secondary paper feed.
  • Page 69 (6) Cleaning section The cleaning section consists of the cleaning blade which removes residual toner from the drum surface after transfer, and the cleaning spiral that carries the residual toner back to the toner hopper. The cleaning unit employs the blade cleaning method. Figure 1-3-32 Cleaning section 1 Drum 3 Cleaning spiral...
  • Page 70 (7) Charge erasing section Blank lamps Cleaning lamp Figure 1-3-33 Charge erasing section The charge erasing section consists of the blank lamps and the cleaning lamp. The blank lamps (BL) are 44 LEDs. All the LEDs light to create leading edge and trailing edge blank cut margins.
  • Page 71 Scan start Secondary paper feed Print key HPSW 147 P+140 ms * RSOL 1500 ms 75 ms * 1000 ms 300 ms 1103 ms * All on Side erasure All on Manual exposure mode, A4/11" × 8 " copy paper, magnification ratio 100% *1 Varies depending on the setting by simulation 27.
  • Page 72 (8) Fixing and eject section Figure 1-3-35 Fixing and eject section 1 Fixing unit cover 0 Fixing pressure springs 2 Fixing unit blade ! Upper eject pulley 3 Fixing unit front guide @ Lower eject roller 4 Fixing unit upper guide # Fixing heater (H) 5 Heat roller $ Fixing unit thermostat 1 (TH1)
  • Page 73 The fixing and eject section consists of the parts shown in Figure 1-3-35. When the paper reaches the fixing section after the transfer process, it passes through the gap between the press roller and heat roller, which is heated by the fixing heater (H), where pressure is applied by the pressure springs so that toner on the paper is melted and fused onto the paper.
  • Page 74 Heating the heat roller and detecting temperature Figure 1-3-37 Heating the heat roller and detecting temperature 1 Heat roller 4 Fixing unit thermostat 2 (TH2) 2 Fixing heater (H) 5 Fixing unit thermistor (FTH) 3 Fixing unit thermostat 1 (TH1) 6 Fixing unit blade The heat roller is heated by the fixing heater (H) inside it;...
  • Page 75 Fixing temperature control 210 ms 300 ms 1000 ms Half ICFM Full speed speed 200 ms Dev. bias Timing chart 1-3-7 Fixing temperature control A 210 ms after the main switch (MSW) has been turned on, the fixing heater (H) turns on to heat the heat roller.
  • Page 76 • Fixing temperature control in environmental mode The fixing control temperature is changed as follows during environmental mode or depending on the status of the copier. • Environmental mode 1. Low temperature mode: The external temperature is below 20°C/68°F. 2. Normal temperature mode: The external temperature is 20°C/68°F or above. •...
  • Page 77 Paper separation Paper is separated in the fixing section by the separation claws as shown in Figure 1-3-38. Heat roller Press roller Heat roller separation claws Press roller separation claws Figure 1-3-38 Paper separation 1-3-42...
  • Page 78 ELECTRICAL SECTION DC-1560/2050 (KME) S/M...
  • Page 79 CONTENTS 2-1 Electrical Parts Layout 2-1-1 Electrical parts layout ................2-1-1 1-1-11...
  • Page 80 2-1-1 Electrical parts layout Machine front Machine inside Machine rear Figure 2-1-1 Layout of electrical parts: PCBs 1. Main PCB (MPCB) ..........Controls the other PCBs and electrical components. 2. Composite PCB (CPCB) ........Contains safety switch 1 and noise filter; generates 24 V and 5 V DC;...
  • Page 81 12 10 Machine front Machine inside Machine rear Figure 2-1-2 Layout of electrical parts: 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, and resets paper jam detection.
  • Page 82 14. Toner cartridge detection switch 2 (TCDSW2) ............Detects the presence or absence of the toner cartridge. 15. Toner sensor (TNS) ........... Detects the toner density in the developing unit. 16. Toner level sensor (TLDS) ......... Detects the toner level in the toner hopper.
  • Page 83 Machine front Machine inside Machine rear Figure 2-1-3 Layout of electrical parts: motors and solenoids 1. Drive motor (DM) ..........Drives the machine. 2. Scanner motor (SM) .......... Drives the optical system. 3. Lens motor (LM) ..........Drives the lens and mirrors 4 & 5. 4.
  • Page 84 Machine front Machine inside Machine rear Figure 2-1-4 Layout of electrical parts: other electrical parts 1. Halogen lamp (HL) ..........Performs exposure. 2. Cleaning lamp (CL) ..........Removes residual charge from the drum surface. 3. Blank lamps (BL) ..........Remove charge from non-image forming areas of the drum surface.
  • Page 85 CONTENTS 2-2 Detection of Paper Misfeed 2-2-1 Paper misfeed detection ..............2-2-1 2-2-2 Paper misfeed detection conditions ............ 2-2-2 1-1-13...

  • Page 86: Paper Misfeed Detection

    2-2-1 Paper misfeed detection When a paper jam occurs, the copier immediately stops copying and the copy quantity/ magnification display on the operation unit shows PF, J30, J40 or J50 indicating the location of the jam. Paper jam counts sorted by the detecting conditions can be checked by jam code in simulation 74.

  • Page 87: Paper Misfeed Detection Conditions

    2-2-2 Paper misfeed detection conditions No paper feed (PF) • The registration switch (RSW) does not turn on within 1500 ms after the paper feed solenoid (PFSOL) has turned on during drawer paper feed. PFSOL 1500 ms Timing chart 2-2-1 •...
  • Page 88 Paper jam in the paper conveying or fixing section (J40) • The eject switch (ESW) does not turn on within 1650 ms after the registration solenoid (RSOL) has turned on [except for the 1200 ms from the registration switch (RSW) turning off when the drive does not stop].
  • Page 89 CONTENTS 2-3 Operation of the PCBs 2-3-1 Composite PCB .................. 2-3-1 2-3-2 Main PCB .................... 2-3-3 (1) Fixing unit abnormally high temperature/shorted thermistor detection circuit ....................2-3-4 (2) Toner feed motor drive circuit .............. 2-3-5 (3) Scanner motor drive circuit ..............2-3-6 (4) Reset circuit ..................

  • Page 90: Composite Pcb

    2-3-1 Composite PCB CPCB SSW1 TRNS Noise Noise Rectify- filter filter C101 circuit input circuit circuit section L001 D001 Q101 Power source circuit section Switching circuit IC1 PC1 PC2 24 V DC Output smooth- ing/ feed- Halogen 24 V DC output back lamp...
  • Page 91 capacitor C101 in the rectifying circuit. The switching circuit turns FET Q101 on and off via switching control IC1, turning current to the primary coil of switching transformer TRNS on and off. The 24 V DC smoothing/output circuit converts the current induced in the secondary coil of TRNS into a stable 24 V DC output via diode D201 and smoothing capacitors C201 and C207.

  • Page 92: Main Pcb

    2-3-2 Main PCB MPCB Fixing unit Address bus abnor- Toner Data bus mally feed high motor tempera- drive EPROM ture/ circuit (IC9) shorted H REM ther- (IC11) (IC6) mistor CPCB NVRAM detec- OPCB tion (IC3) circuit Switches Address decoder sensors circuit Motors Chip Select...
  • Page 93 (1) Fixing unit abnormally high temperature/shorted thermistor detection circuit CN11-25 CN11-26 (IC11) IC20 – CPCB (IC6) H REM CN4-6 Figure 2-3-3 Fixing unit abnormally high temperature/shorted thermistor detection circuit The fixing unit abnormally high temperature/shorted thermistor detection circuit forces the fixing heater control signal H REM off if the fixing temperature reaches an abnormally high level.
  • Page 94 (2) Toner feed motor drive circuit _RESET INH1 MONI (IC11) CN11-5 OUT1 OUT2 CN11-6 IC14 +24 V Pin 2 (IN1) Pin 3 –24 V (IN2) Output voltage waveform IC14 input voltage waveform across CN11-5 and CN11-6 Figure 2-3-4 Toner feed motor drive circuit The toner feed motor drive circuit generates a pseudo-AC supply to run the toner feed motor (TFM), an AC motor.
  • Page 95 (3) Scanner motor drive circuit VrefA 24 V DC VrefB CN8-2 CN8-5 S.GND N.C. (IC11) CN8-1 CN8-3 CN8-4 CN8-6 P.GND Figure 2-3-5 Scanner motor drive circuit The scanner motor drive circuit controls the scanner motor (SM), a stepping motor. Driver IC2 turns the output current to the scanner motor coil on and off depending on the pulse signal from the main PCB.
  • Page 96 (4) Reset circuit (IC6) _RESET _RES2 _RES1 (IC11) IC17 _RESET _RESET Driver (IC14) Figure 2-3-6 Reset circuit Whenever there is a drop in the 5 V DC and until the 5 V DC supply stabilizes when the power is turned on, reset IC17 emits a reset signal to the CPU (IC11) to prevent IC11 from behaving erroneously.

  • Page 97: Operation Unit Pcb

    2-3-3 Operation unit PCB MPCB OPCB 24 V DC LEDs and 7-seg LEDs SEG a SEG b Source driver SEG c SEG d SEG e SEG f SEG g SEG h DEG 0 DEG 1 DEG 2 DEG 3 Sink driver DEG 4 DEG 5 DEG 6...
  • Page 98 SET UP AND ADJUSTMENT SECTION DC-1560/2050 (KME) S/M...
  • Page 99 CONTENTS 3-1 Installation 3-1-1 Unpacking and installation ..............3-1-1 (1) Installation environment .............. 3-1-1 (2) Installation procedure ..............3-1-2 3-1-2 Setting initial copy modes ..............3-1-16 3-1-3 Installing the key counter (option) ............. 3-1-17 3-1-4 Installing the dehumidifier (service part) ........... 3-1-19 1-1-17...

  • Page 100: Unpacking And Installation

    3-1-1 Unpacking and installation (1) Installation environment 1. Temperature: 10 – 35°C/50 – 95°F 2. Humidity: 15 – 85%RH 3. Power supply: 220 – 240 V AC, 6.3 A 4. Power source frequency: 50/60 Hz ± 0.3% 5. Installation location •...
  • Page 101 (2) Installation procedure Start Unpack. Remove the pins. Remove the fixing unit spacers. Remove the tapes and spacers. Load developer. Unlock the cleaning blade. Connect the power plug. Carry out initial developer setting (simulation 60). Exit simulation mode. Install a toner cartridge. Adjust the levelling bolts.
  • Page 102 Lens unit pins Light source unit 2 pin Light source unit 1 pins Bypass cover Fixing unit spacers Table stopper Figure 3-1-2 3-1-3...
  • Page 103 Unpack. Figure 3-1-3 Unpacking 1 Copier @ Top plate ⁄ Copy tray 2 Bottom pads # Accessories case ¤ Power cord 3 Hinge joints $ Plastic bag ‹ Right spacer 4 Skid % Instruction handbook › Inner spacer 5 Machine bottom cover ^ Bypass cover case fi...
  • Page 104 Remove the pins. 1. Remove the tapes holding the two light source unit 1 pins and the one light source unit 2 pin on the upper right cover, and then remove these pins. Light source unit 1 pins Light source unit 2 pin Figure 3-1-4 2.
  • Page 105 Remove the fixing unit spacers. 1. Open the eject cover and remove the two fixing unit spacers holding both ends of the press roller. Press roller Fixing unit spacers Figure 3-1-6 2. Close the eject cover. 3-1-6...
  • Page 106 Remove the tapes and spacers. 1. Detach the original holder and remove the paper from the contact glass. 2. Remove the tape on the top rear of the machine. 3. Refit the original holder. 4. Remove the tapes holding the insertion guides of the bypass table. 5.
  • Page 107 7. Remove the 12-pin plug of the image formation unit. 8. Remove the tape and turn the paper conveying section lever down. 12-pin plug Image formation unit Tape Paper conveying section lever Figure 3-1-9 9. Slide the image formation unit lever toward the left and, holding the front part of the unit and the unit’s handle, pull the unit level out of the machine.
  • Page 108 10. Remove the tape holding the fixing unit front guide inside the machine. Tape Fixing unit front guide Figure 3-1-11 Load developer. Caution: Place the image formation unit on a level surface when loading developer. 1. Slide the developing unit top lid toward the machine front off the image formation unit.
  • Page 109 2. Shake the developer bottle well. 3. Pour developer into the developing unit so that it covers the entire developing roller uniformly. Developer Figure 3-1-13 Loading developer 4. Refit the developing unit top lid to the image formation unit. Unlock the cleaning blade. 1.
  • Page 110 Connect the power plug. 1. Insert the power plug into the wall outlet. Carry out initial developer setting (simulation 60). 1. Turn the main switch on and enter 10871087 with the numeric keys to enter simulation mode. 2. Enter 60 with the numeric keys and press the print key. 3.
  • Page 111 Install a toner cartridge. 1. Open the front cover. 2. Shake the new toner cartridge up and down four or five times to agitate the toner. Figure 3-1-15 3. Insert the toner cartridge into the developing unit along the rails. Figure 3-1-16 3-1-12...
  • Page 112 4. Holding the toner cartridge with hand, pull off the film. Figure 3-1-17 5. Close the front cover. Adjust the levelling bolts. 1. Remove the tapes and turn the two levelling bolts below the right side of the machine until the machine is level. Levelling bolts Figure 3-1-18 Adjusting the levelling bolts 3-1-13...
  • Page 113 Install the table stopper. 1. Pull out the bypass table. 2. Insert the table stopper under the bypass table. Bypass table Table stopper Figure 3-1-19 Install the bypass cover. 1. Fit the bypass cover to the bypass table. Bypass cover Figure 3-1-20 3-1-14...
  • Page 114 Make test copies. 1. Place paper in the paper drawer and make test copies. Completion of machine installation. 3-1-15...

  • Page 115: Setting Initial Copy Modes

    3-1-2 Setting initial copy modes Factory settings are as follows: Sim. No. Contents Factory setting Selecting between double/single counts Double Setting initial exposure mode Inch: manual, Exp. 4 Metric: auto Selecting between manual/auto modes Auto Selecting the exposure scale 19 steps Setting the auto clear time 90 s Setting the auto preheat time...

  • Page 116: Installing The Key Counter (Option)

    3-1-3 Installing the key counter (option) Key counter installation requires the following part: Key counter socket assembly (P/N 41529210) Procedure 1. Detach the left cover. 2. Cut out the indicated area in the left cover using nippers. Left cover Key counter entrance Figure 3-1-21 3.
  • Page 117 8. Using the two screws removed in step 5, fit the key counter socket to the copier. 4-pin connector Screws Key counter socket 4-pin plug Figure 3-1-23 9. Refit the upper and lower right covers, front right cover, front inner cover and left cover. 10.

  • Page 118: Installing The Dehumidifier (Service Part)

    3-1-4 Installing the dehumidifier (service part) Dehumidifier installation requires the following parts: Dehumidifier assembly (P/N 66027021) Dehumidifier junction wire (P/N 34968010) ON label (P/N 34860010) OFF label (P/N 34860020) Two bronze binding screws M3 × 5 (P/N B1303050) *1 Only where required by regulations. Procedure 1.
  • Page 119 8. Fit the dehumidifier to the base center reinforcement with the two bronze binding screws M3 × 5. M3 × 5 Dehumidifier Base center reinforcement Figure 3-1-25 9. Insert the 2-pin connector of the dehumidifier into the opening at the rear of the copier and refit the base center reinforcement.
  • Page 120 10. Place the copier on its base. 11. Pull the dehumidifier 2-pin connector out of the rear of the copier and connect it to the 2-pin plug of the dehumidifier junction wire. 12. Run the dehumidifier junction wire through the six wire retainers. 13.
  • Page 121 15. Refit the bypass, rear, right upper and right front covers. 16. Attach the ON and OFF labels above the main switch. Note: These labels are necessary only where required by regulations. ON label OFF label Main switch Figure 3-1-28 17.
  • Page 122 CONTENTS 3-2 Simulation 3-2-1 Simulations ..................3-2-1 (1) Running a simulation ..............3-2-1 (2) Simulation list ................3-2-3 (3) Contents of simulations ............... 3-2-6 1-1-19...
  • Page 123 3-2-1 Simulations The copier is equipped with a simulation function which can be used to check and adjust the operation of electrical components. (1) Running a simulation Start Enter 10871087 with the numeric - - - - - - Entering simulation mode keys.
  • Page 124 • Selecting a mode Use the paper select key to select a mode during simulation. The paper size indicator corresponding to the selected mode lights up. Paper size indicators (indicate the selected mode) A3/11 × 17 Mode 1 × 14 Mode 2 A4R/8 ×...
  • Page 125 (2) Simulation list Sim. Section Simulation contents Default Exiting simulation mode Copying without paper Enabling ADF operation without originals Checking ADF operation Numeric key Operation Feeding originals continuously Feeding a single original Ejecting originals Setting shipping defaults Paper feed/ Turning the drive motor on conveying Checking switch operation Paper size indicator...
  • Page 126 Sim. Section Simulation contents Default Paper feed/ Setting the folio size 330 mm conveying Checking for skewed paper feed with test copies (cont.) Adjusting leading edge registration timing Adjusting ADF leading edge registration timing Adjusting the leading edge margin Adjusting the side erasure Adjusting the trailing edge blank cut Optical Turning the halogen lamp on...
  • Page 127 Sim. Section Simulation contents Default Copy Selecting between double/single counts Double modes count Setting initial exposure mode Inch: 1 Metric: 0 Selecting between manual/auto modes 0 (auto mode) Selecting the exposure scale 19 steps Setting the auto clear time 90 s Setting the auto preheat time 15 min.
  • Page 128 (3) Contents of simulations Sim. Description Remarks Exiting simulation mode 1. Enter 01 with the numeric keys. 2. Press the print key. The copier returns to the nor- mal mode. Copying without paper Check machine operation. 1. Remove the connector from CN1 on the high-volt- age transformer PCB.
  • Page 129 Sim. Description Remarks 4. Press the print key. The new setting is stored. (cont.) 5. Press the stop/clear key. Checking ADF operation Check ADF op- eration with or 1. Enter 06 with the numeric keys. without originals. 2. Press the print key. 3.
  • Page 130 Sim. Description Remarks Checking switch operation Check operations of switches on 1. Enter 11 with the numeric keys. the paper con- 2. Press the print key. veying and opti- cal systems. 3. Press the all clear/reset key. Test copy mode is entered.
  • Page 131 Sim. Description Remarks Setting the folio size 1. Enter 14 with the numeric keys. 2. Press the print key. The current setting appears on the copy quantity display. 3. Change the setting with the zoom-up/down keys. Contents Setting range Initial value Folio length 330 to 356 (mm) 330 mm...
  • Page 132 Sim. Description Remarks Turning the halogen lamp on Check halogen lamp operation. 1. Enter 20 with the numeric keys. 2. Press the print key. 3. Select manual or photo mode and set the copy den- sity (Exp.). 4. Press the print key. The halogen lamp lights at the selected intensity for 10 s at maximum and the opti- cal section fan motor operates at the same time.
  • Page 133 Sim. Description Remarks Turning the lens motor on 1. Enter 23 with the numeric keys. 2. Press the print key. 3. Select the magnification ratio with the zoom-up/ down keys. 4. Press the print key. The lens and mirrors 4 & 5 move to the positions for the selected magnification ratio.
  • Page 134 Sim. Description Remarks Setting transfer voltage See page 3-3-48. 1. Enter 31 with the numeric keys. 2. Press the print key. 3. Change the setting with the zoom-up/down keys. Contents Setting range Reference Transfer voltage 0 to 7 control value 4.
  • Page 135 Sim. Description Remarks Setting the drum potential See page 3-3-44. 1. Enter 32 with the numeric keys. 2. Press the print key. 3. Select a mode with the paper select key. 4. Change the setting with the zoom-up/down keys. Mode Contents Setting range Reference...
  • Page 136 Sim. Description Remarks Making a blank lamp test copy Check blank lamp operation. 1. Enter 42 with the numeric keys. 2. Press the print key. Test copy mode is entered. • Test copy mode can be exited by pressing the all clear/reset key.
  • Page 137 Sim. Description Remarks Setting the fixing temperature Set the fixing control tempera- 1. Enter 46 with the numeric keys. ture during 2. Press the print key. The current setting appears on standby and the copy quantity display. copying. 3. Select a mode with the paper select key. 4.
  • Page 138 Sim. Description Remarks Lighting all the indicators on the operation panel Check the indica- tors on the op- 1. Enter 50 with the numeric keys. eration panel. 2. Press the print key. All the indicators on the opera- tion panel light. 3.
  • Page 139 Sim. Description Remarks Adjusting the trailing edge blank cut See page 3-3-15, 16. Initializing the toner control level To be run during machine setup or 1. Enter 60 with the numeric keys. when developer 2. Press the print key. is replaced. 3.
  • Page 140 Sim. Description Remarks Initializing the backup memory To be run after replacing the 1. Enter 70 with the numeric keys. NVRAM on the 2. Press the print key. main PCB or if backup data has 3. Press the all clear/reset key. The following data in been erased due memory is initialized.
  • Page 141 Sim. Description Remarks Sim. Contents Initial data (cont.) Drum potential Normal mode Grid control value Main charging control value Photo mode Grid control value Main charging control value Fixing temperature Standby (normal temp.) Standby (low temp.) Copying (normal temp.) Copying (low temp.) Start of copying (normal temp.) Start of copying (low temp.) Fixing preheat temperature...
  • Page 142 Sim. Description Remarks Sim. Contents Initial data (cont.) Auto preheat time Auto shutoff time Paper size Maximum preset No. of copies Operation under the toner empty condition No. of copies 0 (unlimited) Copy mode 0 (single copies) Auto start Destination 1 (metric) Optical section fan motor control 0 (normal)
  • Page 143 Sim. Description Remarks Setting the maintenance cycle Check and change the main- 1. Enter 71 with the numeric keys. tenance cycle. 2. Press the print key. 3. Select a mode with the paper select key. The main- tenance cycle appears on the copy quantity display. Mode Contents Setting range...
  • Page 144 Sim. Description Remarks Checking/clearing the maintenance count 1. Enter 72 with the numeric keys. 2. Press the print key. 3. Select a mode with the paper select key. The main- tenance count appears on the copy quantity dis- play. Mode Contents Setting range Initial value...
  • Page 145 Sim. Description Remarks Checking/clearing service call records Display the codes and main- 1. Enter 73 with the numeric keys. tenance counts 2. Press the print key. of the last ten service call de- Mode Copy quantity display tections. Service call detection records (–1 to –10) Service call code Maintenance count, 100,000s and 10,000s digits (0 to 99)
  • Page 146 Sim. Description Remarks Checking/clearing jam counts 1. Enter 74 with the numeric keys. 2. Press the print key. The current count appears on the copy quantity display. 3. Select the mode to be displayed with the paper se- lect key. Mode Jam code Jam location Setting range...
  • Page 147 Sim. Description Remarks Checking/clearing the service call counts 1. Enter 76 with the numeric keys. 2. Press the print key. A service call code and its count appear alternately on the copy quantity dis- play. 3. Press the paper select key to check the counts of other service call codes.
  • Page 148 Sim. Description Remarks Checking/clearing the paper feed counts 1. Enter 77 with the numeric keys. 2. Press the print key. The current count appears on the copy quantity display. 3. Select the mode to be displayed with the paper se- lect key.
  • Page 149 Sim. Description Remarks Selecting between double/single counts Switch the count- ing method for 1. Enter 80 with the numeric keys. the total and 2. Press the print key. The current setting appears on maintenance the copy quantity display. counters be- tween double 3.
  • Page 150 Sim. Description Remarks Selecting between manual/auto modes Select the initial copy mode. 1. Enter 82 with the numeric keys. 2. Press the print key. The current setting appears on the copy quantity display. 3. Select the initial copy mode with the zoom-up/down keys.
  • Page 151 Sim. Description Remarks Setting the auto clear time 1. Enter 84 with the numeric keys. 2. Press the print key. The current setting appears on the copy quantity display. 3. Change the setting with the zoom-up/down keys. Contents Setting range Initial value Auto clear time 0 (cancelled),...
  • Page 152 Sim. Description Remarks Setting the auto shutoff time 1. Enter 86 with the numeric keys. 2. Press the print key. The current setting appears on the copy quantity display. 3. Change the setting with the zoom-up/down keys. Contents Setting range Initial value Auto shutoff time 0 (cancelled),...
  • Page 153 Sim. Description Remarks Setting the maximum preset number of copies Set the maximum number of copies 1. Enter 89 with the numeric keys. preset by the 2. Press the print key. The current setting appears on numeric keys. the copy quantity display. 3.
  • Page 154 Sim. Description Remarks Selecting between auto start on/off 1. Enter 92 with the numeric keys. 2. Press the print key. The current setting appears on the copy quantity display. 3. Select the auto start setting with the zoom-up/down keys. Setting Contents Auto start function off Auto start function on...
  • Page 155 CONTENTS 3-3 Assembly and Disassembly 3-3-1 Precautions for assembly and disassembly ........3-3-1 (1) Precautions ................. 3-3-1 (2) Running a simulation ..............3-3-2 3-3-2 Paper feed section ................3-3-3 (1) Detaching and refitting paper feed pulleys A and B ....3-3-3 (2) Detaching and refitting the bypass lower pulley ......
  • Page 156 3-3-6 Developing section ................3-3-46 (1) Adjusting the position of the magnetic brush (developing roller) (reference) ................. 3-3-46 (2) Adjusting the position of the doctor blade (reference) ....3-3-47 (3) Adjusting developing bias voltage (reference) ......3-3-48 3-3-7 Transfer and separation section ............3-3-49 (1) Replacing the charger wires ............

  • Page 157: Precautions For Assembly And Disassembly

    3-3-1 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 158 (2) Running a simulation Start Enter 10871087 with the numeric Simulation mode is entered... keys. Enter the number of the simulation The simulation is selected... to be run with the numeric keys.

  • Page 159: Paper Feed Section

    3-3-2 Paper feed section (1) Detaching and refitting paper feed pulleys A and B Clean or replace paper feed pulley A or B as follows. Procedure 1. Detach the rear cover. 2. Insert a straight screwdriver through the gap below the right side of the composite PCB and hold the paper feed solenoid on.
  • Page 160 Removing paper feed pulley A 7. Remove the screw and paper feed pulley A from drawer paper feed shaft A. Removing paper feed pulley B 8. Remove the screw and paper feed pulley B from drawer paper feed shaft A. 9.
  • Page 161 (2) Detaching and refitting the bypass lower pulley Clean or replace the bypass lower pulley as follows. Procedure 1. Detach the original holder. 2. Pull out the paper drawer. 3. Remove the bypass cover. 4. Open the front cover and take the image formation unit out of the copier. 5.
  • Page 162 (3) Detaching and refitting the bypass upper pulley Clean or replace the bypass upper pulley as follows. Procedure 1. Remove the right lower cover. 2. Disengage the stopper hook from the opening in the bypass paper feed shaft by lifting the shaft slightly, and remove the stopper and bushing from the shaft.
  • Page 163 (4) Replacing the bypass paper width switch Replace the bypass paper width switch as follows. Important: After replacing the bypass paper width switch, be sure to perform (7) Adjusting the position of the bypass table adjuster. Procedure 1. Remove the bypass, right lower and rear covers. 2.
  • Page 164 8. Reverse the bypass table assembly and remove the 5-pin connector of the bypass paper width switch. 9. Remove the two screws and bypass paper width switch. Bypass paper width switch Screws 5-pin connector Bypass table assembly Figure 3-3-8 Detaching the bypass paper width switch 10.
  • Page 165 (5) Adjusting the position of the original size indicator Perform the following adjustment if there is a regular error between the centers of the original and the copy image. Procedure Start Make a test copy at 100% with Original Copy Copy example 1 example 2...
  • Page 166 (6) Adjusting the position of the drawer cover Perform the following adjustment if there is a regular error between the centers of the original and the copy image on the paper fed from the drawer. Important: Before starting this adjustment, ensure (5) Adjusting the position of the original size indicator has been completed.
  • Page 167 (7) Adjusting the position of the bypass table adjuster Perform the following adjustment if there is a regular error between the centers of the original and the copy image on the paper fed from the bypass. Important: Before starting this adjustment, ensure (5) Adjusting the position of the original size indicator has been completed.
  • Page 168 (8) Adjustments after installing rollers and solenoids Perform the following adjustments after detaching and refitting the rollers and solenoids. (8-1) Adjusting leading edge registration timing Adjust the registration timing if there is a regular error between the leading edges of the original and the copy image.
  • Page 169 Adjust for another mode? Press the stop/clear key. Exit simulation mode. 3-3-13...
  • Page 170 (8-2) Adjusting the leading edge margin Adjust the leading edge margin as follows if it is not within the specified range. Important: Before starting this adjustment, ensure (8-1) Adjusting the leading edge registration timing has been completed. Procedure Contact glass Start A3/11"...
  • Page 171 (8-3) Adjusting the trailing edge blank cut for 100% copy Make the following adjustment if the trailing edge margin on a 100% copy image is not 0 mm. Important: Before starting this adjustment, ensure (8-1) Adjusting the leading edge registration timing has been completed. Procedure A3/11"...
  • Page 172 (8-4) Adjusting the trailing edge blank cut for reduction copy Make the following adjustment if dirt on the original mat shows on the trailing edge of the reduction copy image. Procedure A3/11" × 17" copy paper Contact glass Start Enter simulation mode. Enter 59 with the numeric keys.

  • Page 173: Main Charging Section

    3-3-3 Main charging section (1) Replacing the charger wire Take the following procedure when the charger wire is broken or to be replaced. Precautions • Use the specified tungsten wire for the charger wire. • The part of the wire wrapped around the charger spring must not protrude from the charger housing.
  • Page 174 3. Remove the screw and grid tension plate, then the main charger grid. 4. Remove the main charger front and rear lids. 5. Remove the charger wire retainer pin and charger spring, then the charger wire. Main charger grid Main charger rear lid Charger spring Charger wire Charger terminal...
  • Page 175 Wind. Charger spring Charger wire retainer pin Trim. Between 2 and 4 mm Charger terminal Notch Spring Less than 2 mm Less than 2 mm Main charger front housing Main charger rear housing Figure 3-3-22 Replacing the charger wire 11. Refit the front and rear lids to the main charger. 12.

  • Page 176: Exposure Section

    3-3-4 Exposure section (1) Detaching and refitting the halogen lamp Clean or replace the halogen lamp as follows. Procedure 1. Remove the contact glass. 2. Move light source unit 1 to the cutout in the upper rear frame. 3. Remove the halogen lamp by pressing its terminals at the front and rear of light source unit 1 outward.
  • Page 177 (2) Detaching and refitting the optical section thermostat Caution: Use the specified thermostat for replacement. Do not substitute a simple wire or similar; otherwise, the copier will be seriously damaged. Procedure 1. Remove the left cover. 2. Unplug the two 1-pin connectors of the optical section thermostat. 3.
  • Page 178 (3) Adjusting the positions of the light adjusters Perform the following adjustment after refitting or replacing the light adjusters, or if the copy image is abnormally light or dark on one side. Before starting this adjustment, be sure that the main and transfer chargers, mirrors and dust filter are not stained with toner.
  • Page 179 (4) Detaching and refitting the scanner wire Take the following steps when a scanner wire is broken or to be replaced. Important: After replacing a scanner wire, proceed to (5) Adjusting focus (lens unit). (4-1) Detaching the scanner wires Procedure 1.
  • Page 180 (4-2) Installing the scanner wires Required installation jig • Scanner wire drum clips (P/N 34968130) Procedure The procedure is similar for both front and rear wires. The fitting of the rear wire is described here. Numbers in circles correspond with those in Figures 3-3-28 to 3-3-30. 1.
  • Page 181 6. Run the end with the spring through the scanner wire holder on light source unit 1..........................5 7. Loop that end of the wire around the inner groove in the scanner wire pulley on light source unit 2 from bottom to top................6 8.
  • Page 182 (5) Adjusting focus (lens unit) Make the following adjustment when the scanner wires are replaced, or if the entire copy image is out of focus. Procedure Start Make a test copy at 100% with the maximum size of copy paper. Loosen the screw holding the mirrors 4 &...
  • Page 183 (6) Adjusting lateral image squareness (height of the mirrors 4 & 5 frame) Make the following adjustment if the copy image is laterally skewed (lateral squareness is not obtained). Procedure Start Original Copy Copy example 1 example 2 Make a test copy at 100% Figure 3-3-32 with the maximum size of copy paper.
  • Page 184 (7) Adjusting longitudinal image squareness (height of mirror 2) Make the following adjustment after replacing the scanner wires, or if the copy image is longitudinally skewed (longitudinal squareness is not obtained). Important: To adjust longitudinal image squareness, first adjust the levelling bolts and, if the problem persists, only then adjust the height of mirror 2.
  • Page 185 • Adjusting the height of mirror 2 Start Make a test copy at 100% with the maximum size of copy paper. Is the copy image correct? Original Copy Copy example 1 example 2 Figure 3-3-35 Mirror 2 Adjustment screw Figure 3-3-36 Adjusting the height of mirror 2 3-3-29...
  • Page 186 (8) Setting the exposure amount Perform the following adjustment when the drum is replaced. Reference: This procedure adjusts the exposure gradient for both normal and photo modes. Precautions • Check that the developer density is correct. • Check that the halogen lamp has not deteriorated. •...
  • Page 187 Select mode 1 with the paper - - - - - - Exp. 1 is selected. select key. Change the value to the mode 2 setting minus 15 with the zoom- up/down keys. Setting range: 102 to 243 Press the print key. The new setting is stored.
  • Page 188 Select mode 3 with the paper - - - - - - Exp. 7 is selected. select key. Change the value to the mode 4 setting plus 10 with the zoom-up/ down keys. Setting range: 102 to 243 Press the print key. The new setting is stored.
  • Page 189 (8-2) Setting the photo-mode exposure amount Procedure Start Enter simulation mode. Enter 24 with the numeric keys. Press the print key. Place the NTC on the contact glass and select mode 5 with - - - - - - Photo-mode Exp. 4 is selected. the paper select key.
  • Page 190 (9) Adjusting the auto exposure (AE sensor) reference value Procedure Start Select mode 2 with the paper select key. Check that exposure is correctly set in (8) Setting the exposure Place the NTC on the contact amount. glass. Enter simulation mode. Press the all clear/reset key (to start prescanning).
  • Page 191 (10) Adjusting lateral magnification (correcting the lens position) Make the following adjustment after replacing the lens unit, or if the lateral magnification is not correct. Procedure Start Enter simulation mode. Enter 25 with the numeric keys. Press the print key. Place the NTC on the contact glass and ensure A3/11"...
  • Page 192 (11) Adjusting longitudinal magnification (scanning speed) Procedure Start Enter simulation mode. Enter 26 with the numeric keys. Press the print key. Place the NTC on the contact glass and ensure A3/11" × 17" paper is present. Press the all clear/reset key. Press the print key.
  • Page 193 (12) Adjusting exposure amount for enlargement/reduction mode Make the following adjustment after (8) Setting the exposure amount has been completed. Procedure Start Enter simulation mode. Enter 29 with the numeric keys. Press the print key. Place the NTC on the contact glass and ensure A3/11"...
  • Page 194 (13) Setting the lens unit rank Make the following adjustment after replacing the main PCB or the lens unit. The lens unit is classified into seven ranks according to the focal distance of the lens unit. The adjustment is necessary to obtain correct enlargement and reduction ratios. Procedure Start Enter simulation mode.
  • Page 195 (14) Setting the optical section fan motor control Make the following adjustment when the mirrors and other optical components are unusually prone to dust due to environmental reasons, causing a background to appear on the copy image. Procedure Start Enter simulation mode. Enter 98 with the numeric keys.

  • Page 196: Drum Section

    3-3-5 Drum section (1) Replacing the drum Perform the following steps when cleaning or replacing the drum. Precautions • Avoid direct sunlight and strong light when detaching and refitting the drum. • Hold the drum at the ends and never touch the drum surface. •...
  • Page 197 4. Slide the image formation unit lever toward the left and, holding the front part of the unit and the unit’s handle, pull the unit level out of the machine. • Do not touch the drum separation claws when holding the image formation unit. Image formation unit handle Image formation unit lever...
  • Page 198 6. Detach the main charger from the image formation unit. 7. Pull the drum shaft out of the rear of the drum. 8. Holding both ends, detach the drum from the image formation unit. 1 mm Rear Front Drum Drum shaft E ring Drum rear bushing Drum shaft...
  • Page 199 (2) Cleaning the drum Clean the drum as follows when an image problem occurs, or if the drum is dirty. Precautions • Avoid direct sunlight and strong light when cleaning the drum. • Dust in the air and from the cleaning pad may damage the drum during operation. Avoid working in dusty place.
  • Page 200 (3) Adjusting the copy image after drum replacement (reference) Perform the following adjustment if the copy image density is still incorrect after making other adjustments. Caution: Do not change the settings for modes 2 and 4 in simulation 32. Procedure Start Make a test copy.
  • Page 201 Adjust for another mode? Press the stop/clear key. Exit simulation mode. 3-3-45...

  • Page 202: Developing Section

    3-3-6 Developing section (1) Adjusting the position of the magnetic brush (developing roller) (reference) Check or adjust the position of the magnetic brush if the image is abnormally light. Important: Before starting this adjustment, ensure that the doctor blade is installed correctly and that the correct amount of developer is present.
  • Page 203 (2) Adjusting the position of the doctor blade (reference) Make the following adjustment if carrier or background appears on the copy image. Procedure 1. Take the image formation unit out of the copier. 2. Remove the two screws and the developing unit upper cover. Screws Developing unit upper cover...
  • Page 204 (3) Adjusting developing bias voltage (reference) The developing bias voltage is factory-adjusted. Only perform the following adjustment when carrier or background appears on the copy image after control VR202 on the high- voltage transformer PCB has been turned accidentally. Required adjustment tool •...

  • Page 205: Transfer And Separation Section

    3-3-7 Transfer and separation section (1) Replacing the charger wires Take the following steps when the transfer or separation charger wire is broken or is to be replaced. Precautions • Use the specified tungsten wire for the charger wire. • The part of the wire wrapped around the charger spring must not protrude from the charger housing.
  • Page 206 5. Remove the separation guide and transfer charger front and rear lids. 6. Remove the charger wire retainer pins, charger springs and then the charger wires. Transfer charger rear lid Charger terminals Separation guide Transfer charger front lid Charger springs Charger wires Charger wire retainer pins Figure 3-3-48 Removing the charger wires...
  • Page 207 7. Wind the new tungsten wires at least five turns around one end of the charger springs, and trim the end of each wire. • The length of the twists and the cut wire must be less than 2 mm. 8.
  • Page 208 (2) Setting transfer voltage (reference) Perform the following steps after replacing the high-voltage transformer PCB or main PCB, or if a transfer error occurs at extremely high or low humidity. Procedure Start Enter simulation mode. Enter 31 with the numeric keys. Press the print key.
  • Page 209 (3) Setting separation shift bias voltage (reference) Perform the following steps if paper jams frequently in the separation section due to a separation error, or thin paper fails to separate or creases. Required adjustment tool • Tester Procedure High-voltage transformer PCB Start Apply the tester's positive terminal to jumper J401 of...

  • Page 210: Cleaning Section

    3-3-8 Cleaning section (1) Detaching and refitting the cleaning blade Check or replace the cleaning blade as follows. Procedure 1. Open the front cover and take the image formation unit out of the copier. 2. Detach the main charger and drum. 3.
  • Page 211 4. Remove the three screws and the cleaning blade. Screws Cleaning blade Boss Blade mount Figure 3-3-52 Removing the cleaning blade 5. Fit the new cleaning blade. • Ensure the cleaning blade is not riding over the boss of the blade mount. 6.
  • Page 212 (2) Detaching and refitting the drum separation claws Replace the drum separation claws as follows. Procedure 1. Open the front cover and take the image formation unit out of the copier. 2. Detach the main charger and drum. 3. Remove the two screws and separation claw mount. •...

  • Page 213: Fixing And Eject Section

    3-3-9 Fixing and eject section (1) Replacing the fixing heater Replace the fixing heater as follows. Procedure 1. Detach the left cover. 2. Remove the white 1-pin connector of the fixing heater, red 1-pin connector of the fixing heater relay wire, 2-pin connector of the fixing unit thermistor and 3-pin connector of the eject switch.
  • Page 214 5. Open the eject cover and slide the fixing unit toward the machine front to free the unit from the pins holding it at the machine rear, and take out the unit. Fixing unit pins Fixing unit Eject cover Figure 3-3-57 Removing the fixing unit 6.
  • Page 215 (2) Replacing the fixing unit thermistor Replace the fixing unit thermistor as follows. Procedure 1. Remove the fixing unit cover. 2. Remove the screw and fixing unit thermistor. 3. Fit the new fixing unit thermistor, with its projection seated into the upper hole in the fixing unit housing.
  • Page 216 (3) Detaching and refitting the fixing unit blade Clean or replace the fixing unit blade as follows. Procedure 1. Remove the fixing unit cover. 2. Remove the two screws, fixing unit thermistor partition and the fixing unit blade. 3. Clean or replace the fixing unit blade. 4.
  • Page 217 (4) Replacing fixing unit thermostats 1 and 2 Replace fixing unit thermostats 1 and/or 2 as follows. Caution: Use the specified thermostat for replacement. Do not substitute a simple wire or similar; otherwise, the copier will be seriously damaged. Procedure 1.
  • Page 218 (5) Detaching and refitting the press roller and its separation claws Clean or replace the press roller and/or its separation claws as follows. Procedure 1. Unlock the fixing unit at the front and rear by pulling the press levers in the directions of the arrows in the diagram, and open the unit.
  • Page 219 • Removing the press roller 3. Remove the two press roller bushings and the roller from the fixing unit. • Removing the press roller separation claws 4. Remove the screws and press roller separation claws. 5. Clean or replace the press roller and/or its separation claws. •...

  • Page 220: Gear

    (6) Detaching and refitting the heat roller and its separation claws Clean or replace the heat roller and/or its separation claws as follows. Procedure 1. Remove the fixing heater (see page 3-3-57). 2. Unlock the fixing unit by pulling the press levers at the front and rear, and open the fixing unit (see Fig.
  • Page 221 • Removing the heat roller separation claws 7. Unhook the separation claw springs from the fixing unit upper guide and heat roller separation claws. 8. Remove the E ring and pull the separation claw shaft out to remove the claws. 9.
  • Page 222 (7) Detaching and refitting the lower eject roller Clean or replace the lower eject roller as follows. Procedure 1. Open the eject cover. 2. Remove the E ring and bushing from the front of the lower eject roller. 3. Remove the two E rings, eject gear 22, spring pin and bushing from the rear of the lower eject roller.
  • Page 223 3-3-10 Others (1) Replacing the ozone filter Replace the ozone filter as follows. Procedure 1. Detach the left cover. 2. Replace the ozone filter with a new one. 3. Refit all the removed parts. Ozone exhaust fan motor Ozone filter Figure 3-3-68 Detaching the ozone filter 3-3-67...
  • Page 224 CONTENTS 3-4 PCB Initial Settings 3-4-1 Replacing the main PCB ..............3-4-1 3-4-2 Adjustment-free variable resistors (VR) ..........3-4-4 1-1-25...

  • Page 225: Replacing The Main Pcb

    3-4-1 Replacing the main PCB After replacing the main PCB, remove the NVRAM from the old main PCB and fit it to the new main PCB. If the new NVRAM is used, perform the following steps. Procedure • Before removing the old NVRAM: 1.
  • Page 226 • After installing the new NVRAM: 7. Insert the power plug and turn the main switch on. 8. Enter simulation mode. 9. Run simulation 70. 10. Run simulation 93 to select the destination. Caution: Running simulation 93 changes the user’s drawer paper size setting as follows.
  • Page 227 Sim. No. Contents Setting the paper size Setting the maximum preset number of copies Setting operation under the toner empty condition Selecting between auto start on/off Setting the optical section fan motor control 12. Exit simulation mode. 13. Reenter the contents of the user settings recorded in step 1. 3-4-3...

  • Page 228: Adjustment-Free Variable Resistors (Vr)

    3-4-2 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, VR201, VR202, VR301, VR401 and VR402 • Composite PCB: VR601, VR602 and VR603 3-4-4...
  • Page 229 CONTENTS 3-5 Self Diagnostics 3-5-1 Self-diagnostic function ............... 3-5-1 (1) Self-diagnostic display ..............3-5-1 1-1-27...
  • Page 230 3-5-1 Self-diagnostic function (1) Self-diagnostic display This unit is equipped with a self-diagnostic function. When it detects a problem with itself, it disables copying and displays the problem as a code consisting of “C” followed by a number between 01 and 90, indicating the nature of the problem. After removing the problem, the self-diagnostic function can be reset by opening and closing the front cover to turn safety switch 1 off and back on.
  • Page 231 Self diagnostic codes Remarks Code Contents Check procedures/ Causes corrective measures NVRAM problem NVRAM (IC3) After turning safety switch 1 Data in the check area problem. off then back on, run simula- (FF0H to FFFH) of the tion 70 and reenter the NVRAM (IC3) do not backup memory contents.
  • Page 232 Remarks Code Contents Check procedures/ Causes corrective measures Scanner motor problem Broken scan- Check for continuity across The home position switch ner motor the scanner motor coil. If does not turn on within 10 coil. none, replace the scanner s after the scanner has motor.
  • Page 233 Remarks Code Contents Check procedures/ Causes corrective measures Lens motor problem Defective lens Check for continuity across The lens home position motor. the coil. If none, replace the switch does not turn on or lens motor. off within 7 s after initial Defective lens Check if CN5-2 on the main operation has started.
  • Page 234 Remarks Code Contents Check procedures/ Causes corrective measures Broken fixing heater fila- Broken fixing Check for continuity. If none, ment heater fila- replace the fixing heater. The fixing stabilization ment. temperature is not reached Fixing heater Check the fixing heater and within 120 s after the main installed in- reinstall if necessary.
  • Page 235 Remarks Code Contents Check procedures/ Causes corrective measures Broken drum thermistor Broken drum Measure the resistance. If it is ∞ Ω, replace the blank wire thermistor The drum thermistor out- wire. lamp unit containing the put is below 0.5 V continu- drum thermistor.
  • Page 236 Remarks Code Contents Check procedures/ Causes corrective measures Copier-ADF serial com- Poor contact Check the connections at munication problem in the connec- CN3 on the main PCB and After originals placed on tor. the connector on the ADF the ADF are detected, a and check for continuity serial communication error across the connector termi-...
  • Page 237 CONTENTS 3-6 Troubleshooting 3-6-1 Image formation problems ..............3-6-1 (1) No image (entirely white)............. 3-6-4 (2) No image (entirely black)............. 3-6-5 (3) Image is too light................. 3-6-6 (4) Background is visible..............3-6-6 (5) A white line appears longitudinally..........3-6-7 (6) A black line appears longitudinally.
  • Page 238 3-6-4 Electrical problems ................3-6-30 (1) The machine does not operate when the main switch is turned on................... 3-6-30 (2) The drive motor does not operate (C20)........3-6-30 (3) The scanner motor does not operate (C30)......3-6-30 (4) The lens motor does not operate (C40).

  • Page 239: Image Formation Problems

    3-6-1 Image formation problems (1) No image (entirely (2) No image (entirely (3) Image is too light. white). black). See page 3-6-4. See page 3-6-5. See page 3-6-6. (4) Background is visible. (5) A white line appears (6) A black line appears longitudinally.
  • Page 240 (10) Image is blurred. (11) The leading edge of (12) The leading edge of the image is consist- the image is sporadi- ently misaligned with cally misaligned with the original. the original. See page 3-6-10. See page 3-6-10. See page 3-6-11. (13) Paper creases.
  • Page 241 (19) Image is not square (20) Image is not square (21) Image is partially longitudinally. laterally. missing laterally. See page 3-6-14. See page 3-6-15. See page 3-6-15. 3-6-3...
  • Page 242 (1) No image Causes (entirely white). 1. No original present. 2. No main charging. 3. No transfer charging. 4. All blank lamps on. 5. Developing section not driven. Causes Check procedures/corrective measures 1. No original present. Place an original in the correct position. 2.

  • Page 243: No Image (Entirely Black)

    Causes Check procedures/corrective measures 4. All blank lamps on. Run simulation 42 and if the check pattern copy is not obtained, replace the main PCB. 5. Developing section Check the gears driving the developing section and not driven. replace any broken gears. (2) No image Causes (entirely black).

  • Page 244: Image Is Too Light

    (3) Image is too light. Causes 1. Insufficient toner. 2. Deteriorated developer. 3. Misadjusted developing section. 4. Dirty or deteriorated drum. Causes Check procedures/corrective measures 1. Insufficient toner. If the add toner indicator is on, replace the cartridge. 2. Deteriorated devel- Check the number of copies made with the current devel- oper.

  • Page 245: A White Line Appears Longitudinally

    (5) A white line appears Causes longitudinally. 1. Dirty or flawed main charger wire. 2. Foreign matter in the developing section. 3. Flawed drum. Causes Check procedures/corrective measures 1. Dirty or flawed main Clean the main charger wire. If the wire is flawed, replace charger wire.

  • Page 246: A Black Line Appears Laterally

    (7) A black line appears Causes laterally. 1. Flawed drum. 2. Poor developing bias wire contact. 3. Dirty developing section. 4. No developing bias output. Causes Check procedures/corrective measures 1. Flawed drum. Check the drum visually. If it is flawed, replace (see page 3-3-40).

  • Page 247: One Side Of The Copy Image Is Darker Than The Other

    (8) One side of the copy Causes image is darker than 1. Unevenly distributed halogen lamp light. the other. 2. Dirty optical section. 3. Dirty main charger wire or grid. Causes Check procedures/corrective measures 1. Unevenly distributed Adjust the positions of the light adjusters (see page halogen lamp light.

  • Page 248: Image Is Blurred

    (10) Image is blurred. Causes 1. Scanner moving erratically. 2. Foreign matter on the scanner rail. 3. Deformed press roller. 4. Drive system problem. Causes Check procedures/corrective measures 1. Scanner moving Adjust the tension of the scanner wire (see page 3-3-23). erratically.

  • Page 249: The Leading Edge Of The Image Is Sporadically Misaligned With The Original

    (12) The leading edge of Causes the image is spo- 1. Registration solenoid installed or operating radically misaligned incorrectly. with the original. Causes Check procedures/corrective measures 1. Registration solenoid Check the installation position and operation of the installed or operating registration solenoid.

  • Page 250: Offset Occurs

    (14) Offset occurs. Causes 1. Cleaning blade installed in the wrong position. 2. Defective cleaning blade. 3. Cleaning lamp fails to light. 4. Abnormally high heat roller control temperature. Causes Check procedures/corrective measures 1. Cleaning blade install- Check the installation position of the cleaning blade and ed in the wrong correct it, if necessary.

  • Page 251: Black Lines Appear On Both Sides Of The Image In Reduction Copies

    (15) Black lines appear Causes on both sides of the 1. Dirty blank lamps. image in reduction 2. Defective blank lamps. copies. 3. Defective main PCB. Causes Check procedures/corrective measures 1. Dirty blank lamps. Clean the blank lamps. 2. Defective blank Check for one-way continuity across the terminals of each lamps.

  • Page 252: Fixing Is Poor

    (17) Fixing is poor. Causes 1. Wrong paper. 2. Defective fixing pressure springs. 3. Flawed press roller. Causes Check procedures/corrective measures 1. Wrong paper. Check if the paper meets specifications. 2. Defective fixing Replace the fixing pressure springs. pressure springs. 3.

  • Page 253: Image Is Not Square Laterally

    (20) Image is not square Causes laterally. 1. The height of the mirrors 4 & 5 frame is adjusted incorrectly. Causes Check procedures/corrective measures 1. The height of the Adjust the lateral squareness of the image (see page mirrors 4 & 5 frame is 3-3-27).

  • Page 254: Pulley

    3-6-2 Paper misfeeds Problem Causes/check procedures Corrective measures A piece of paper torn from copy Check visually and remove it, if A paper jam paper is caught around the reg- any. in the registra- istration switch. tion section is Defective registration switch. With 5 V DC present at CN17-1 detected as on the main PCB, check if...
  • Page 255 Problem Causes/check procedures Corrective measures Replace if deformed. Check if the bypass upper pul- A paper jam ley is deformed. on the bypass Defective registration switch. With 5 V DC present at CN17-1 table is de- on the main PCB, check if tected during CN17-2 on the main PCB goes copying (PF...
  • Page 256 Problem Causes/check procedures Corrective measures Check if the press roller is ex- Clean or replace the press A paper jam tremely dirty or deformed. roller (see page 3-3-62). in the eject Check if the press roller separa- Clean or replace the press section is de- tion claws are extremely dirty or roller separation claws (see...

  • Page 257: Pcb Terminal Voltages

    3-6-3 PCB terminal voltages Precautions • When handling the circuit boards, do not touch the components with bare hands. • ICs can be damaged by static discharges. If a PCB contains ICs, do not touch the ICs, cable connectors or edge connectors. •...
  • Page 258 Terminals (CN) Voltage Remarks Local AC supply AC supply, input voltage Supply for HL, output 24 V DC 24 V DC supply for HVTPCB, output 24 V DC 24 V DC supply for MPCB, output 5 V DC 5 V DC supply for MPCB, output 0/24 V DC (pulse) HL light intensity control PWM, input 0/24 V DC...

  • Page 259: Main Pcb

    (2) Main PCB CN18 CN16 IC22 IC10 IC12 IC13 IC16 IC17 3492801 IC11 IC18 R100 REV:3 CN12 CN14 IC20 IC19 IC15 CN17 IC21 CN15 Terminals (CN) Voltage Remarks 24/0 V DC (pulse) OPCB LED lighting source (SEG a), output 24/0 V DC (pulse) OPCB LED lighting source (SEG b), output 24/0 V DC (pulse)
  • Page 260 Terminals (CN) Voltage Remarks 24/0 V DC (pulse) OPCB scan sink (DEG 0), output 1-10 24/0 V DC (pulse) OPCB scan sink (DEG 1), output 1-11 24/0 V DC (pulse) OPCB scan sink (DEG 2), output 1-12 24/0 V DC (pulse) OPCB scan sink (DEG 3), output 1-13 24/0 V DC (pulse)
  • Page 261 Terminals (CN) Voltage Remarks 5 V DC 5 V DC supply for LHPSW, output AES detection voltage, input 24 V DC 24 V DC supply for AES, output 24 V DC 24 V DC supply for LM, output 24 V DC 24 V DC supply for LM, output 0/24 V DC (pulse) LM coil energization pulse (LM ø0),...
  • Page 262 Terminals (CN) Voltage Remarks 9-12 DTH detection voltage, input 9-13 5 V DC 5 V DC supply for DTH, output 10-1 24 V DC 24 V DC supply for MSW, output 10-2 0/24 V DC MSW off/on, output 11-1 11-2 TNS control voltage, output 11-3 11-2...
  • Page 263 Terminals (CN) Voltage Remarks 15-2 0/5 V DC DM abnormality detection, input 15-3 0/4 V DC DM drive/stop, output 16-1 24 V DC 24 V DC supply for OPFM, output 16-2 0/24 V DC OPFM on/off, output 17-1 17-3 5 V DC 5 V DC supply for RSW, output 17-2 17-3...

  • Page 264: Operation Unit Pcb

    (3) Operation unit PCB 3-6-26...
  • Page 265 Check for continuity across the terminals to inspect each component of the operation unit PCB keyboards. Precautions: • Before starting a continuity check, always turn the copier main switch off, disconnect the power plug from the wall outlet and detach the operation unit PCB from the copier. •...
  • Page 266 Terminals (CN) Remarks Continuity with original size indicator (L3) lit Continuity with original size indicator (L2) lit Continuity with original size indicator (L1) lit Continuity with paper size indicator (L17) Continuity with paper size indicator (L16) Continuity with paper size indicator (L15) Continuity with paper size indicator (L14) lit Continuity with paper size indicator (L13) lit Continuity with paper size indicator (L12) lit...
  • Page 267 Terminals (CN) Remarks Continuity with zoom-down key (K3) pressed, no continuity with the key released. Continuity with exposure adjustment (right) key (K9) pressed, no continuity with the key released. Continuity with auto/manual exposure key (K8) pressed, no continuity with the key released. Continuity with exposure adjustment (left) key (K7) pressed, no continuity with the key released.

  • Page 268: Electrical Problems

    3-6-4 Electrical problems Problem Causes Check procedures/corrective measures No electricity at Measure the input voltage. The machine the power outlet. does not op- The power cord is Check the contact between the power plug erate when not plugged in and the outlet. the main properly.

  • Page 269: The Lens Motor Does Not Operate (C40)

    Problem Causes Check procedures/corrective measures Broken lens motor Check for continuity across the coil. If none, The lens mo- coil. replace the lens motor. tor does not Poor contact in the Check for continuity across the connector operate lens motor connec- terminals.

  • Page 270: The Paper Feed Solenoid Does Not Operate

    Problem Causes Check procedures/corrective measures Broken ozone ex- Check for continuity across the coil. If none, The ozone haust fan motor replace the ozone exhaust fan motor. exhaust fan coil. motor does Poor contact in the Check for continuity across the connector not operate at ozone exhaust fan terminals.
  • Page 271 Problem Causes Check procedures/corrective measures (12) Broken halogen Check for continuity. If none, replace the The halogen lamp filament. halogen lamp (see page 3-3-20). lamp does not Optical section See page 3-6-5. light. thermostat trig- gered. Poor contact in the composite PCB connector termi- nals.

  • Page 272: The Fixing Heater Does Not Turn Off

    Problem Causes Check procedures/corrective measures (16) Dirty sensor part of Check visually and clean the thermistor sen- The fixing the fixing unit ther- sor parts. heater does mistor. not turn off Defective compos- If the fixing heater stays on with CN2-8 on (fixing unit ite PCB.
  • Page 273 Problem Causes Check procedures/corrective measures (19) Broken separation Check visually and replace the separation Separation charger wire. charger wire if it is broken (see page 3-3-49). charging does Poor contact in the Check for continuity across the connector not take high-voltage trans- terminals.

  • Page 274: Displayed Correctly

    Problem Causes Check procedures/corrective measures Poor contact in the (22) Check for continuity across the connector The size of bypass paper terminals. If none, replace them. paper placed length switch con- on the bypass nector terminals. table is not Poor contact in the Check for continuity across the connector displayed cor- bypass paper...

  • Page 275: Others

    Problem Causes Check procedures/corrective measures Poor contact in (24) Check for continuity across the connector OP is display- safety switch 2 terminals. If none, replace them. ed when the connector termi- eject cover is nals. completely Defective safety Check for continuity across the contacts of closed.

  • Page 276: Mechanical Problems

    3-6-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of paper feed Clean with isopropyl alco- No primary pulleys A & B and the bypass upper hol. paper feed. pulley are dirty with paper powder. Electrical problem with the paper See page 3-6-32.
  • Page 277 Problem Causes/check procedures Corrective measures Clean the developing unit. Check if the developing unit is ex- Toner drops tremely dirty. on the paper conveying path. Check if the rollers and gears oper- Grease the bushings and gears. Abnormal ate smoothly. noise is Remedy.
  • Page 278 CONTENTS 3-7 Appendixes Timing chart No. 1 ..................3-7-1 Timing chart No. 2 ..................3-7-2 Timing chart No. 3 ..................3-7-3 Composite PCB 1/3 ..................3-7-4 Composite PCB 2/3 ..................3-7-5 Composite PCB 3/3 ..................3-7-6 Operation unit PCB ..................3-7-7 Main PCB ......................
  • Page 279 1000 ms ICFM CN11-15 Full speed Half speed 300 ms 10 s minimum Off when copying is possible CN15-3 200 ms CN1-20 Copying is possible 69 s or more after the main switch has been turned on. 3-7-1 DC-1560/2050 (KME) S/M...
  • Page 280 Half speed Half speed OEFM CN11-13 Full speed 60 s *1 Time set in simulation 54 *2 1038 ms + time set in simulation 59 *3 147 pulses + (time set in simulation 27) × 2 3-7-2 DC-1560/2050 (KME) S/M...
  • Page 281 Half speed Half speed Full speed 60 s OEFM CN11-13 *1 Time set in simulation 54 *2 1592 ms + time set in simulation 59 *3 147 pulses + (time set in simulation 27) × 2 3-7-3 DC-1560/2050 (KME) S/M...
  • Page 282 R112 NUTRAL C007 Q101 R108 C104 D102 D104 R109 R114 R106 D101 R115 R103 R104 8 7 6 5 ZD102 D103 C102 C105 1 2 3 4 Q102 R102 ZD101 C109 C110 C106 R107 C107 R105 3-7-4 DC-1560/2050 (KME) S/M...
  • Page 283 R203 CN2-6 C204 CN3-2 R201 L301 L302 R301 CN3-3 R205 CN2-3 R204 C306 CN3-1 C205 C202 R304 R305 R202 C301 8 7 6 5 R302 Q301 1 2 3 4 R303 D301 C302 R306 D302 TRNS 3-7-5 DC-1560/2050 (KME) S/M...
  • Page 284 R609 D603 TH601 CR601 C609 C605 VR601 C602 R608 IC601 ZD601 D601 R607 IC601 R603 – R611 D602 L601 – R623 R604 CN1-3 R612 Q602 Q601 C601 R605 C608 CR602 C603 TH602 R613 R624 C604 CN4-3 3-7-6 DC-1560/2050 (KME) S/M...
  • Page 285 Operation unit PCB d. p. 7SEGMENT LED SEG a CN1-8 7seg 7seg 7seg SEG b CN1-7 7seg 7seg 7seg SEG c CN1-6 7seg 7seg 7seg SEG d CN1-5 7seg 7seg 7seg 7SEGMENT LED SEG e CN1-4 7seg 7seg 7seg SEG f CN1-3 7seg 7seg...
  • Page 286 Main PCB CN9-12 (2000H-FFFFH) CN11-3 CN5-5 R108 CN11-26 R101 IC22 Vcc1 Vcc2 _RESET MONI – H ALARM OUT1 CN11-5 OUT2 CN11-6 R102 R110 R109 IC19 IC14 – GRID CONT CN1-24 _CS ROM SEG h CN1-8 CN1-7 SEG g CN1-6 SEG f IC19 CN1-5 SEG e...
  • Page 287 General connection diagram 230 V specifications only DF power source box (Option) DH (Option) 230 V 24 V (Option) specifications 24 V only SSW1 G (24 V) G (24 V) G (5 V) LIVE 240Ω ADF RXD Noise Filter CPCB 15Ω...
  • Page 288 General wiring diagram C18-3 WE C18-1 OE C20 (CN4) P001 LIVE LIVE C55 (CN1) C56 (CN3) LIVE LIVE G(5V) CPCB P002 G(24V) G(24V) G(24V) C17 (CN1) LIVE LHPSW HPSW POWER SOURCE #1 P006 #2 P007 C21 (CN5) C18 (CN2) C19 (CN3) C22 (CN6) #4 P008 C10-1...
  • Page 289 KYOCERA MITA DANMARK A/S KYOCERA MITA Industrivej 11, DK-4632 Bjæverskov, CORPORATION Denmark 2-28, 1-chome, Tamatsukuri, Chuo-ku, Phone: 53671100 Osaka 540-8585, Japan Phone: (06) 6764-3555 Fax: (06) 6764-3981 are registered trademarks of KYOCERA CORPORATION and KYOCERA MITA CORPORATION. Printed in Holland...

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