Kyocera FS-1020D Service Manual
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Kyocera FS-1020D Service Manual

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See also: Operating Manual , User Manual
FS-1020D
SERVICE
MANUAL
Published in Oct. '03

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Summary of Contents for Kyocera FS-1020D

  • Page 1: Service Manual

    FS-1020D SERVICE MANUAL Published in Oct. ’03...
  • Page 2 Revision history Version Data Replaced pages Remarks 14-Oct-2003 5-Nov-2003 1-4-4, 2-1-2, 2-1-3, 2-1-4, 2-1-5 Contents, Address...

  • 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.
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  • Page 9: Table Of Contents

    CONTENTS 1-1 Specifications 1-1-1 Specifications ............................1-1-1 1-1-2 Name of parts ............................1-1-3 (1) Overall ............................1-1-3 (2) Operator panel ..........................1-1-4 1-1-3 Machine cross section .......................... 1-1-5 1-2 Handling Precautions 1-2-1 Process unit (drum) ..........................1-2-1 1-2-2 Installation environment ........................1-2-1 1-3 Installation 1-3-1 Unpacking and installation ........................
  • Page 10 (10) The heater lamp does not turn off....................1-5-19 (11) Main charging is not performed....................1-5-19 (12) Transfer charging is not performed....................1-5-19 (13) A paper jam in the paper feed or exit section is indicated when the power switch is turned on..................... 1-5-19 (14) The LED indicator requesting covers to be closed is displayed when the front cover is closed.
  • Page 11 (2) Main charging ..........................2-1-8 (2-1) Photo conductive drum ......................2-1-8 (2-2) Charging the drum ......................... 2-1-9 (3) Exposure ............................2-1-10 (3-1) Laser scanner unit ....................... 2-1-11 (3-2) Drum surface potential ......................2-1-12 (4) Development ..........................2-1-13 (5) Transfer ............................2-1-14 (6) Fusing ............................
  • Page 12 This page is intentionally left blank. This page is intentionally left blank. 1-1-4...

  • Page 13: Specifications

    Standard memory ......16 MB, expandable up to 272 MB Additional memory ......1 slot (16/32/64/128 MB DIMM) Resolution ........Fast 1200 mode 600 × 600 dpi, with KIR (Kyocera Image Refinement) 300 × 300 dpi, with KIR (Kyocera Image Refinement) Photoconductor ......OPC (drum diameter 30 mm) Charging system ......
  • Page 14 Controller software ......a) Emulation PCL6 (PCL5e+PCLXL) KPDL3 (PostScript 3 compatible) b) Fonts: Bitmap font: 1 Line Printer bitmap font Outline fonts: 35 PCL6 (PCL5e/PCL-XL) fonts 45 KPDL2 fonts: c) Graphic: (1) Raster graphic: 75, 100, 150, 200*, 300, 600* dpi (*200 dpi is supported when the resolution is 600 dpi.) (2) Vector graphic: Line, Box, Circle, Arc, Fill pattern etc.

  • Page 15: Name Of Parts

    1-1-2 Name of parts (1) Overall & Figure 1-1-1 1 Front top cover 0 Extension tray 2 Front cover ! Power switch 3 Process unit @ Memory cover 4 Toner container # Rear cover 5 Main charger cleaner $ Optional interface slot 6 Cassette % Parallel interface connector 7 Paper stopper...

  • Page 16: Operator Panel

    (2) Operator panel Figure 1-1-2 1 Ready indicator (Green) 2 Data indicator (Green) 3 Attention indicator (Red) 4 Toner indicator (Red) 5 CANCEL key 6 GO key 1-1-4...

  • Page 17: Machine Cross Section

    1-1-3 Machine cross section Cassette, MP tray Paper path Optional paper feeder Switchback and refeed (duplex printing) Figure 1-1-2 1 Cassette 7 Transfer section 2 Paper feed unit 8 Fuser unit 3 MP tray 9 Face-down output tray 4 MP tray paper feed unit 0 Switchback/conveying section 5 Process unit ! Refeed unit...
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  • Page 19: Process Unit (Drum)

    1-2-1 Process unit (drum) Note the following when handling or storing the drum. • When removing the process 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 80% RH.
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  • Page 21: Unpacking And Installation

    1-3-1 Unpacking and installation (1) Installation procedure Start Unpack. Remove the tape and protective packing. Install a toner container. Connect the printer cable and power cord. Load paper. Inisializing the pirnter and make test print. Completion of the machine installation. 1-3-1...
  • Page 22 Unpack Figure 1-3-1 Unpacking 1 Printer 2 Power cord 3 Installation guide 4 Toner container 5 Cleaning cloth 6 CD-ROMs 7 Extension tray [For U.S.A only] 1-3-2...
  • Page 23 Remove the tape and protective packing 1. Remove the two tape. Tape Figure 1-3-2 2. Pull the cassette out of the printer. 3. Remove the protective packing from inside the cassette. Protective packing Cassette Figure 1-3-3 1-3-3...
  • Page 24 Install a toner container. Lock lever 1. Open the front top cover. 2. Move the lock lever until it is in its unlocked position (marked “UNLOCK”). Front top cover Figure 1-3-4 3. Shake the toner container horizontally back and forth five or six times so that the toner inside of it becomes evenly distributed.
  • Page 25 5. Set the toner container into the process unit. Toner container Process unit Figure 1-3-7 6. Push in on the areas of the toner container marked Toner container “PUSH HERE” until the container clicks into place in the process unit. Figure 1-3-8 Lock lever 7.
  • Page 26 Connect the printer cable and power cord. 1. Connect the printer cable (parallel or USB). Parallel interface connector Parallel printer cable USB interface connector USB cable Figure 1-3-10 2. Connect the power cord. Power cord AC inlet Figure 1-3-11 1-3-6...
  • Page 27 Load paper. 1. Pull the cassette out of the copier. 2. Set the paper in the cassette. Cassette Figure 1-3-12 Initializing the printer and make test print. 1. Turn on the printer’s power switch. Upon turning on the power, the printer’s 4 indicators flash in sequence until printer initialization is complete, then the indicator ( [on line]) lights steadily.

  • Page 28: Installing The Expanding Memory (Option)

    1-3-2 Installing the expanding memory (option) The main board of the printer is equipped with one socket for memory expansion. Expansion memory is available in the form of DIMM (Dual In-line Memory Module). CAUTION Take precautions that no foreign substances such as metal chips or liquid get inside the printer during the Memory socket Clip...

  • Page 29: Installing The Memory Card (Option)

    1-3-3 Installing the memory card (option) The main board of the printer is equipped with one slot for memory card. CAUTION Take precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process. Operation of the printer during the presence of a foreign substance may lead to fire or electric shock.

  • Page 30: Installing The Network Interface Card (Option)

    1-3-4 Installing the network interface card (option) If the serial interface board kit is installed, remove it to use the network interface card. CAUTION Take precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process.

  • Page 31: Maintenance

    1-4-1 Maintenance (1) Status page The printer can print different types of the status page—the user status page and the service status page. This section exclusively describes information obtainable with the service status page. Information on the service page include various settings for the printer, service statistics, etc. To print a service status page, proceed as follows: Printing the service status page To print a service status page, using the GO key on the operator panel.
  • Page 32 Service information on the status page An example of the service status page is shown below. Most of the service information are located under Service information. Most of these service information on the status page are alphanumerically-coded. Each item is explained on the next page.
  • Page 33 Bit 4 = 0: Kyocera, 1: OEM Bit 5 = 0: For Europe, 1: For US Bit 6 = 0: Non MICR mode, 1: MICR mode Bit 7 = 0: Kyocera, 1: Kyocera Mita Second byte: Displayed in OEM mode only Total print page count...
  • Page 34 Item Description Operator panel lock status 01: Partial lock (displayed only when locked) 02: Full lock NVRAM error 01: ID error (displayed only when any error has oc- 02: Version error curred) 03: Checksum error 04: NVRAM crash error Printable area setting /Top offset/Left offset/Page length/Page width Left offset for each paper source /MP tray/Cassette/Option paper feeder/Duplex refeed...

  • Page 35: Paper Misfeed Detection

    1-5-1 Paper misfeed detection (1) Paper misfeed indication If a paper jam occurs while printing, the printer notifies it by the following combination of the four indicators. Remove the jammed paper as described below. After removal, open and close the top cover once to initialize the jam sensing. (Off) (Lit) Green...

  • Page 36: Self-Diagnosis

    1-5-2 Self-diagnosis (1) Self-diagnostic function Service errors are represented by the alternating flashing of the indicators (LEDs). Each error is represented by the notation of four digits code and can be monitored on the Remote Operation Panel utility. e.g. Call service 2000 is for the main motor error.
  • Page 37 Code Error indications Contents Main motor error 2000 Check procedures/corrective measures START Remove and check harness (2DC2711) between engine board (KP-1046) and main motor at pins 6 to 9 on both ends. Connect circuit tester to pin 8 (MOTORN) of YC04 on engine board +24 V DC at (KP-1046) and ground.
  • Page 38 Code Error indications Contents 4000 Laser scanner unit [Polygon motor] error Check procedures/corrective measures START Replace engine board +24 V DC at pin 5 of (KP-1046). See page 1- YC06 on engine board 6-9. (KP-1046) ? Replace laser scanner Replace engine board unit.

  • Page 39: Kp-1046). See

    Check procedures/corrective measures Continued from previous page. Replace engine board (KP-1046). See page 1- 6-9. Turn power switch on. Replace main board (KP-1050). See page 1- 6-10. End. Turn power switch on. End. Replace harness (2FM2602) between engine board and main board. 1-5-5...

  • Page 40: Does Pin

    Code Error indications Contents 4200 Laser scanner unit [Pin photo diode] error Check procedures/corrective measures START +5 V DC at pin 6 of YC07 on main board (KP-1050) ? Replace main board (KP-1050). See page 1- 6-10. Connect oscilloscope to pin 4 (OUTPEN) of YC07 on main board (KP-1050).

  • Page 41: Unit. See

    Check procedures/corrective measures Continued Continued from previous page. from previous page. Replace main board Replace laser scanner (KP-1050). See page 1- unit. See page 1-6-28. 6-10. Replace main board Turn power switch on. (KP-1050). See page 1- 6-10. Turn power switch on. Replace harness (2DC2714) between End.
  • Page 42 Code Error indications Contents 6000 Fuser unit error Check procedures/corrective measures START Turn power switch off, and remove power cable. Detach connector CN4 on power supply board. Measure resistance between pins 1 and 2 of the detached connector. Replace engine board (KP-1046).
  • Page 43 Code Error indications Contents 7980 Waste toner full [Total page count less than 100,000 pages of printing] Check procedures/corrective measures START Shake the process unit horizontally. Turn power switch off, then on. "7980" error shown? Replace the process unit. Turn power switch off, then on.
  • Page 44 Code Error indications Contents 7990 Waste toner full [Total page count more than 100,000 pages of printing] Check procedures/corrective measures START Shake the process unit horizontally. Turn power switch off, then on. "7990" error shown? Replace the process unit. End. Turn power switch off, then on.
  • Page 45 Check procedures/corrective Contents Code Error indications measures F010 Controller checksum Turn power switch off, then on. If not error solved, replace main board (See page 1-6-10). F020 Controller RAM read/ Remove the expansion memory write error (DIMM). Turn power switch off, then on.

  • Page 46: Image Formation Problems

    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 1-5-13 See page 1-5-13 See page 1-5-13 See page 1-5-14 (8) One side of the copy (5) A white line appears (7) A black line appears (6) A black line appears...
  • Page 47 (1) No image appears Causes (entirely white). 1. Defective process unit installation. 2. No transfer charging. 3. Defective laser scanner unit. Causes Check procedures/corrective measures 1. Defective process unit installation. Check that the process unit is inserted correctly. 2. No transfer charging. Check the transfer bias output on the high voltage board.
  • Page 48 (4) Background is visible. Causes 1. Dicective print density setting. 2. Dicective surface potential of the drum. 3. Defective developing roller. Causes Check procedures/corrective measures 1. Dicective print density setting. Open the printer top cover and check that the process unit is correctly seated.
  • Page 49 (6) A black line appears Causes longitudinally. 1. Contaminated main charger wire. 2. Dirty or flawed drum. 3. Deformed or worn cleaning blade. 4. Deceftive magnet roller (in the process unit). Causes Check procedures/corrective measures 1. Contaminated main charger wire. Clean the main charger wire by pulling the green colored cleaning knob in and out several times.
  • Page 50 (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. Replace the process unit. 2. Dirty contact glass. Clean the contact glass.
  • Page 51 (12) Offset occurs. Causes 1. Defective cleaning blade. Causes Check procedures/corrective measures 1. Defective cleaning blade. Replace the process unit. (13) Image is partly miss- Causes ing. 1. Paper damp. 2. Paper creased. 3. Flawed drum. Causes Check procedures/corrective measures 1.

  • Page 52: Electrical Problems

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

  • Page 53: The Registration Clutch Does Not Operate

    Problem Causes Check procedures/corrective measures Broken registration clutch Check for continuity across the coil. If none, replace the registra- The registration coil. tion clutch. clutch does not op- Poor contact in the regis- Reinsert the connector. Also check for continuity within the con- erate.

  • Page 54: When The Power Switch Is Turned On

    Problem Causes Check procedures/corrective measures (13) A piece of paper torn from Check and remove if any. A paper jam in the copy paper is caught paper feed or exit around registration sensor section is indicated or exit sensor. when the power Defective registration sen- Replace registration sensor if indication of the corresponding switch is turned on.

  • Page 55: Mechanical Problems

    1-5-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the feed roller and Clean with isopropyl alcohol. No primary paper feed. MP feed roller are dirty with paper powder. Check if the feed roller and MP feed roller Check visually and replace any deformed are deformed.
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  • Page 57: Precautions For Assembly And Disassembly

    1-6-1 Precautions for assembly and disassembly (1) Precautions • Be sure to turn the power switch off and disconnect the power plug before starting disassembly. • When handling PWBs (printed wiring boards), do not touch parts with bare hands. The PWBs are susceptible to static charge.

  • Page 58: Removing The Process Unit

    1-6-2 Removing the process unit 1. Open the front top cover. 2. Open the front cover. 3. Lift the process unit together with the toner container out of the printer. Front top cover Front cover Process unit Figure 1-6-1 Removing the process unit CAUTIONS •...

  • Page 59: Removing The Principal Outer Covers

    1-6-3 Removing the principal outer covers (1) Removing the front top cover/face-down output tray 1. Open the front top cover. 2. Remove two screws. 3. Remove the top cover/face-down output tray. Top cover Screws Top cover/ face-down output tray Figure 1-6-2 Removing the top cover/face-down output tray 1-6-3...

  • Page 60: Removing The Right Cover

    (2) Removing the right cover 1. Remove one screw. 2. Remove the side cover. 3. Unlatch the six snaps and one hook hole on the chassis, remove the right cover. Right cover Right cover Screw Snap/Hook Side cover (inside cover) Figure 5-2-3 Removing the right cover (3) Removing the left cover 1.

  • Page 61: Removing The Feed Roller

    1-6-4 Removing the feed roller CAUTION When refit the feed roller, fit the D-cut shaft into the D-shape hole of the feed roller. 1. Remove the paper cassette and the process unit. (See page 1-6-2) 2. Stand the machine the front side up. 3.

  • Page 62: Removing The Mp Feed Roller

    1-6-5 Removing the MP feed roller 1. Remove the engine board (See page 1-6-9). 2. Remove one screw. 3. Remove the grounding plate. 4. Remove one stop ring. 5. Remove the MP feed clutch. MP feed clutch Stop ring Grounding plate Screw Figure 1-6-6 Removing the MP feed clutch 1-6-6...
  • Page 63 6. Remove one screw. 7. Remove the toner sensor and spring. 8. While pressing the latch by using the driver and then remove the paper guide. 9. Remove two screws and then remove the MP feed unit. Paper guide Screw Toner sensor Paper guide Spring...

  • Page 64: Removing The Transfer Roller

    1-6-6 Removing the transfer roller CAUTION Do not touch the transfer roller (sponge) surface. Oil and dust (particles of paper, etc.) on the transfer roller can significantly deteriorate the print quality (white spots, etc.). When refitting the bushes and springs, make sure to refit the black colored bush and spring on the left side. Also, observe the correct direction to which the bush is fit in reference to the paper passing direction.

  • Page 65: Removing The Principal Circuit Boards

    1-6-7 Removing the principal circuit boards (1) Removing the engine board 1. Remove the right cover (See page 1-6-4). 2. Remove all (twelve) connectors from the engine board. 3. Remove three screws. 4. Remove the engine board. * When replacing the board with a new board, remove the EEPROM (U2) from the old board and mount it to the new board.

  • Page 66: Removing The Main Board

    (2) Removing the main board 1. Remove the process unit (See page 1-6-2). 2. Remove the top/face-down output tray and right cover (See pages 1-6-2 and 1-6-3). 3. Remove two connectors from main board. 4. Remove six screws. 5. Remove the controller box (with main board). Screws Connector Screws...
  • Page 67 6. Remove two screws at the back of the main board. 7. Remove three screws from the parallel interface connector and USB connector. 8. Remove the main board. Screws Main board USB interface connector Parallel interface connector Screws Controller box Figure 1-6-12 Removing the main boar 1-6-11...

  • Page 68: Removing The Power Supply Board And High Voltage Board

    (3) Removing the power supply board and high voltage board 1. Remove the process unit (See page 1-6-2). 2. Remove the left cover (See page 1-6-4). 3. Remove three connectors from the power supply board. 4. Remove nine screws. 5. Remove the power supply board and high voltage board. (Note: The high voltage board is directly connected to the bias board.) 6.

  • Page 69: Removing The Bias Board

    (4) Removing the bias board 1. Remove the cassette and process unit (See page 1-6-2). 2. Remove the left cover (See page 1-6-4). 3. Remove the power supply board and high voltage board (See the previous page). 4. Turn the machine with the bottom side up. 5.
  • Page 70 7. Remove five screws. 8. Remove the bottom cover. 9. Remove the three connectors from the bias board. 10. Remove the bias board. Bottom cover Screws Screws Connectors Bias board Connector Figure 1-6-15 Removing the bias board 1-6-14...

  • Page 71: Removing The Main Motor And Drive Unit

    1-6-8 Removing the main motor and drive unit 1. Remove the cassette and process unit (See page 1-6-2). 2. Remove the right cover (See page 1-6-4). 3. Remove three connectors from the main motor. 4. Remove four screws. 5. Remove main motor. Connectors Main motor Screws...
  • Page 72 6. Remove the engine board (See page 1-6-9). 7. Remove wires from wire saddles on the cord cover. 8. Remove one screw. 9. Remove the cord cover. Wire saddle Screw Wire saddles Cord cover Figure 1-6-17 Removing the cord cover 1-6-16...
  • Page 73 10. Remove the main board (See page 1-6-10). 11. Remove one screw and then remove the grounding plate. 12. Remove one screw and then remove the feed clutch. 13. Remove three stop rings. 14. Remove MP feed clutch (gear), feed clutch (gear), and registration clutch (gear). MP feed clutch (gear) Stop ring Grounding...
  • Page 74 15. Remove the four screws. 16. Remove the drive unit. Drive unit Screws Screws Figure 1-6-17 Removing the drive unit 1-6-18...

  • Page 75: Removing And Splitting The Fuser Unit

    1-6-9 Removing and splitting the fuser unit WARNING • The fuser unit is hot after the printer was running. Wait until it cools down. CAUTION • When refitting the fuser unit, make sure the fuser unit gear and the copier’s drive gear are properly meshed with each other.
  • Page 76 6. Remove two screws. 7. Open and split the fuser unit. Screw Fuser unit Screw Figure 1-6-20 Splitting the fuser unit 1-6-20...

  • Page 77: Removing The Separation Craws

    (1) Removing the separation claws WARNING The separation claws are extremely hot immediately after the printer was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (See page 1-6-19). 2. Loosen the stopper screws. 3.

  • Page 78: Removing The Heater Lamp

    (2) Removing the heater lamp WARNING • The heater lamp is extremely hot immediately after the printer was running. • Allow substantial period of time until it cools down. Also, the heater lamp is fragile: Handle it with great care. CAUTION •...

  • Page 79: Removing The Heat Roller

    (3) Removing the heat roller WARNING • The heat roller is extremely hot immediately after the printer was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (See page 1-6-19). 2. Remove the heater lamp (See previous page). 3.
  • Page 80 4. Remove the heat gear Z33, heat R bush, and heat L bush from the heat roller. Heat L bush Heat roller Heat R bush Heat gear Z33 Figure 1-6-25 Removing the heat roller 1-6-24...

  • Page 81: Removing The Fuser Thermistor

    (4) Removing the fuser thermistor 1. Remove and split the fuser unit (See page 1-6-19). 2. Remove the heater lamp (See page 1-6-22). 3. Remove the heat roller (See page 1-6-23). 4. Remove one screw. 5. Remove the fuser thermistor. Screw Fuser thermistor Figure 1-6-26 Removing the fuser thermistor...

  • Page 82: Removing The Thermal Cutout

    (5) Removing the thermal cutout CAUTION • Do not bend the terminals of the thermal cutout. 1. Remove and split the fuser unit (See page 1-6-19). 2. Remove the heater lamp (See page 1-6-22). 3. Remove the heat roller (See page 1-6-23). 4.

  • Page 83: Removing The Press Roller

    (6) Removing the press roller WARNING • The press roller is extremely hot immediately after the printer was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (See page 1-6-19). 2. Remove the press roller from the fuser unit. Press roller Fuser unit Figure 1-6-28 Removing the press roller...

  • Page 84: Removing The Laser Scanner Unit And The Eraser Lamp

    1-6-10 Removing the laser scanner unit and the eraser lamp 1. Remove the right cover and left cover (See page 1-6-4). 2. Remove four connectors. 3. Remove six screws and then remove the LSU Screws shield. Screw * When refitting the LSU shield, tighten a screw in order of 4 from 1.
  • Page 85 4. Remove three screws. 5. Remove two connectors from the laser scanner unit. 6. Remove the laser scanner unit. * When refitting the laser scanner unit, tighten a screw in order of 3 from 1. Screws Laser scanner unit Conncetor Conncetor Figure 1-6-30 Removing the laser scanner unit 1-6-29...
  • Page 86 7. Remove the eraser lamp. Eraser lamp 1-6-31 Removing the eraser lamp 1-6-30...

  • Page 87: Removing The Main Charger Unit

    1-6-11 Removing the main charger unit 1. Remove the process unit from the printer (See page 1-6-2). 2. Unlatch the three snaps, and remove the main charger cap. 3. Draw the main charger unit in the direction of arrow A, then pull it out in the direction of arrow B. Main charger unit Snap Snaps...
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  • Page 89: Upgrading The Firmware On The Main Board

    (1) Firmware program data format Kyocera supplies the following types of data for updating firmware of the different purposes: • System firmware The data to be downloaded are supplied in the following format: System firmware file name example B11K8000.bcmp...

  • Page 90: Downloading The Firmware From The Parallel Interface

    (2) Downloading the firmware from the parallel interface This section explains how to download firmware data from the parallel interface. The printer system can automatically recognize whether the data to be overwritten is for controller firmware. CAUTION Downloading the firmware takes several minutes.

  • Page 91: Downloading The Firmware From The Memory Card

    (3) Downloading the firmware from the memory card To download data written in a memory card (CompactFlash) to the printer, proceed as explained in this section. CAUTION Downloading firmware takes several minutes. Do not turn power off during downloading. If downloading is interrupted by an accidental power failure, etc., the system DIMM may have to be replaced.

  • Page 92: Downloading Error

    (4) Downloading errors The following downloading errors are indicated on LED indicators when an error occurred during downloading the firmware data. Download finished Download errors normally LED indicators LED indicators Description Cause Corrective action Download Obtain normal firmware. Deficit of a file header data error Deficit of a data header File checksum error...

  • Page 93: Paper Feeding System

    2-1-1 Paper feeding system The paper feeding system picks up paper from the cassette, MP tray, or if installed, the paper feeder, feeds it in the copier, and delivers in the output tray. Paper is fed at the precise timing in synchronization with data processing. The paper feeding system finally delivers the printed page to either the face-down or face-up tray as manipulated by the user.
  • Page 94 Paper feed control The following diagram shows interconnectivity of the feeding system components including the sensors and rollers. The engine board provides the signals in conjunction with the electrophotography process that is driven by the main board. Engine board DUDR1 YC13-1 Switchback DUDR2...
  • Page 95 Paper feeding mechanism ⁄ ¤ ⁄ ¤ & Driving power train A For process unit; drum (From main unit) B For process unit; toner container, developing roller etc. (From main unit) C From process unit; drum (To transfer roller) Figure 2-1-3 Paper feeding mechanism 1 Main motor (gear) @ Transfer roller 2 Registration clutch...

  • Page 96: Switchback And Refeed Section

    (2) Switchback and refeed section Figure 2-1-4 Paper switchback/refeed path 1 Refeed roller 2 Refeed pulley 3 Registration sensor (actuator) 4 Conveying roller 5 Conveying pulley 6 Exit sensor (actuator) 7 Guide 8 Lower exit pullery 9 Lower exit roller 0 Upper exit pullery ! Upper exit roller 2-1-4...
  • Page 97 Upper exit roller forward/reverse drive mechanism Face-down tray output Exit roller gear Upper exit roller Idle Latch lever gear From switchback solenoid Drive train from main motor Switchback Paper exit roller (gear) Upper exit roller Idle From gear switchback solenoid Latch lever Drive train from main motor...

  • Page 98: Electrophotographic System

    2-1-2 Electrophotographic system Electrophotography is the technology used in laser printing which transfer data representing texts or graphics objects into a visible image which is developed on the photosensitive drum, finally fusing on paper, using light beam generated by a laser diode. This section provides technical details on the copier’s electrophotography system.

  • Page 99: Process Unit Mechanism

    (1-1) Process unit mechanism Driving power train A For drum (From main unit) B For toner container, developing roller, etc. (From main unit) C For main unit (Transfer roller) D For toner container ¤ & ⁄ ‹ Figure 2-1-7 Process unit mechanism 1 Main charger unit # DLP screw B 2 Charger wire...

  • Page 100: Main Charging

    (2) Main charging (2-1) Photo conductive drum The durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base. The OPC tend to reduce its own electrical conductance when exposed to light. After a cyclic process of charging, exposure, and development, the electrostatic image is constituted over the OPC layer.

  • Page 101: Charging The Drum

    (2-2) Charging the drum The following shows a simplified diagram of the electrophotographic components in relation to the engine system. Charging the drum is done by the main charger unit A. High voltage board Bias Engine board board MHVDR MHVDR1 YC-M CN2-A4 YC11-5...

  • Page 102: Exposure

    (3) Exposure The charged surface of the drum A is then scanned by the laser beam from the laser scanner unit B. Laser beam (LSU) Figure 2-1-10 Exposure The laser beam (780 nm wavelength) beam is dispersed as the polygon motor (polygon mirrors) revolves to reflect the laser beam over the drum.

  • Page 103: Laser Scanner Unit

    (3-1) Laser scanner unit Diversion mirror Figure 2-1-11 Laser scanner unit 1 Laser diode ........... Emits diffused, visible laser. 2 Cylindrical lens ..........Compensates the vertical angle at which the laser beam hits a polygon mirror segment. 3 Polygon mirror (motor) ........Has six mirror segments around its hexagonal circumference; each mirror corresponding to one scanned line width on the drum when laser beam scans on it.

  • Page 104: Drum Surface Potential

    (3-2) Drum surface potential The laser beam is continually switched on and off depending on the print data. It is on for a black (exposed) dot and off for a white (blank) dot. Since the drum surface is evenly charged, whenever it is illuminated by the laser beam, the electrical resistance of the photoconductor is reduced and the potential on the photoconductor is also lowered.

  • Page 105: Development

    (4) Development The latent image constituted on the drum is developed into a visible image. The developing roller A contains a 3-pole (S-N-S) magnet core B and an aluminum cylinder rotating around the magnet core B. Toner attracts to the developing roller A since it is powdery ink made of black resin bound to iron particles.

  • Page 106: Transfer

    (5) Transfer The image developed by toner on the drum A is transferred onto the paper because of the electrical attraction between the toner itself and the transfer roller B. The transfer roller is negatively biased so that the positively charged toner is attracted onto the paper while it is pinched by the drum and the transfer roller.

  • Page 107: Fusing

    (6) Fusing The toner on the paper is molten and pressed into the paper as it passes between the heat roller A and the press roller B in the fuser unit. Figure 2-1-15 Fusing The heat roller has a halogen lamp inside which continuously turns on and off by the thermistor to maintain the constant temperature onto the heat roller surface.

  • Page 108: Fuser Unit Mechanism

    (6-1) Fuser unit mechanism Figure 2-1-16 Fuser unit mechanism 1 Heat roller 7 Heater lamp 2 Idle gear Z34 8 Thermal cutout 3 Exit gear Z23 9 Separator(s) 4 Idle gear Z18 0 Thermistor 5 Heat gear Z33 ! Exit pulley(s) 6 Press roller @ Lower exit roller 2-1-16...

  • Page 109: Cleaning

    (7) Cleaning After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development process. The cleaning blade A is constantly pressed against the drum B and scrapes the residual toner off to the sweep roller C.
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  • Page 111: Electrical Parts Layout

    2-2-1 Electrical parts layout (1) Electrical parts layout fi ⁄ ‹ — › & fl ¤ ‡ Figure 2-2-1 Electrical parts layout 1 Main board (KP-1050) % Power switch 2 Engine board (KP-1046) ^ Temperature thermistor 3 Power supply board &...
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  • Page 113: Main Board

    2-3-1 Main board Xtal(System) EBA22-1 EBIU Address Bus CXIN CXOUT 33.333 MHz EBA22-2 EBCSN0-1, DIMM EBOEN0, EBWEN0 Xtal(video) Slot-1 EBD31-0 VXIN (Core ROM) 37.6687MHz VXOUT EBCSN4, OPRDY, OSC(USB) EBA15-1 IORN, IOWN, DMAACKN Optinal UXIN 48.000MHz OPRSTN interface KUIO-LV EBD31-16 DMAREQ, OPACKN, OPIRN (3.3V) USBDP EBA22, EBA10-1...

  • Page 114: Engine Board

    2-3-2 Engine board Waste Eraser toner lamp sensor Engine board LED indicators (DL1, DL2, DL3, DL4 Key switches (SW1, SW2) Switchback solenoid Reset IC (U5) MP feed clutch (U1) Main board EEPROM (U2) Main motor Temperature thermistor (TH1) Registration Paper MP paper clutch sensor...

  • Page 115: Eraser Lamp Control Circuit

    (1) Eraser lamp control circuit The CPU (U1) turns pin #23 (ERASER) of U1 to H level, transistors (Q14) turns on consequently, and the 24 V DC given at pin #1 of connector YC5 applies to the eraser lamps. The eraser lamps thus illuminate as the current flows through the resistors (R109, R110, and R111), eraser lamp, the pin #2 of connector YC5, transistor Q14 and the ground.

  • Page 116: Heater Lamp Control Circuit

    (2) Heater lamp control circuit Activation of the heater lamp is dominated by the HEAT signal which is derived by the engine CPU (U1) at its pin #1. When its level is high, transistor Q10 turns on, photo-triac PC2 and triac TRA1 turn on simultaneously, and the heater lamp is applied with the primary AC voltage in turn.

  • Page 117: Polygon Motor Control Circuit

    (3) Polygon motor control circuit The main board supplies the 2,799.21 Hz clock pulse (PLGCLK) via the engine board to the PLL control IC (IC1) for the polygon motor. To begin printing, the engine CPU U1 turns PLGDR to H level, the PLL control IC (IC1) starts to revolve the polygon motor so that the revolution is 27,992.1 rpm which depends on the PLGCLK clock pulse.
  • Page 118 Connector Pin No. Signal Voltage Description RSTN 0/5 V DC Reset signal: Reset/Normal Connected SGND Ground Ground to the main EGIRN 0/5 V DC Engine interrupt request signal board SDIR 0/5 V DC Serial line direction signal SBSY 0/5 V DC Serial line busy signal PDMASKN 0/5 V DC...
  • Page 119 Connector Pin No. Signal Voltage Description YC10 5 V DC 5 V DC power supply for waste toner sensor TNFULL 0/5 V DC Waste toner sensor: Toner Full/Normal Connected SGND Ground Ground to the waste toner sensor YC11 SGND Ground Ground SGND Ground...

  • Page 120: Power Supply Board

    2-3-3 Power supply board The power supply board provides the AC power input and DC power and outputs. The high voltage bias generator circuit is mounted on a separate board. A simplified schematic diagram is shown below. Power supply unit Power Current input...
  • Page 121 Connector Pin No. Signal Voltage Description Neutral 120 V AC Power supply for heater lamp Connected 220 - 240 V AC to the main Live 120 V AC Power supply for heater lamp board 220 - 240 V AC 5 V DC 5 V DC power supply Connected 5 V DC...

  • Page 122: Bias Board

    2-3-4 Bias board The bias board contains the developing bias output circuit, registration sensor, and the cassette switch. It also provides a liaison connection to the high voltage board, power supply, and the toner sensor. Bias board Toner TONER TONER sensor SLEEP SLEEP...

  • Page 123: High Voltage Board

    2-3-5 High voltage board The high voltage board contains the high voltage output circuit, interlock switch circuit as well as providing a liaison connection with the power supply board, bias board, and the engine board. High voltage board Bias board +24V3 Main Engine board...

  • Page 124: Interlock Switch

    (1) Interlock switch The interlock switch is located on the high voltage board and opened and closed in conjunction with the front cover or the front top cover via the interlock lever. This switch connects and disconnects the +24 V DC power supply line. If the front cover or the front top cover is open, the interlock switch is open, and the +24 V DC to the high voltage output circuit, bias board, engine board, and the power supply board is disconnected, deactivating the high voltage output, laser output, main motor output for safety.

  • Page 125: Timing Chart No. 1

    Timing chart No. 1 Paper cassette feeding, A4/8 " × 11" paper, simplex printing 2-4-1...

  • Page 126: Timing Chart No. 2

    Timing chart No. 2 Paper cassette feeding, A4/8 " × 11" paper, duplex printing 2-4-2...

  • Page 127: Wiring Diagram

    Wiring diagram 2-4-3...

  • Page 128: Repetitive Defects Gauge

    Repetitive defects gauge First occurrence of defect [25 mm] Upper registration roller [38 mm] Lower registration roller [50 mm] Transfer roller [61 mm] Heat roller, Press roller (Fuser unit) [63 mm] Developing roller (Process unit) [94 mm] Drum (Process unit) 2-4-4...
  • Page 129 MEMO:...
  • Page 130 MEMO:...

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