Kyocera FS-C1020MFP Service Manual [ENG]

FS-C1020MFP

SERVICE

MANUAL

Published in June 2010

845JK113

5JKSM063

Rev.3

CAUTION

RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.

It may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for proper disposal.

ATTENTION

IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE TYPE INCORRECT. METTRE AU REBUT LES BATTERIES UTILISEES SELON LES INSTRUCTIONS DONNEES.

Il peut être illégal de jeter les batteries dans des eaux d’égout municipales. Vérifiez avec les fonctionnaires municipaux de votre région pour les détails concernant des déchets solides et une mise au rebut appropriée.

Revision history

Revision Date Replaced pages Remarks

1 February 2, 2010 Product Information : Page 90

Appendix : Page 32-45

2 February 17, 2010 Product Information : Page 41-42 -

3 June 8, 2010 Product Information : Page 24-25 -

This page is intentionally left blank.

Safety precautions

This booklet provides safety warnings and precautions for our service personnel t o 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.

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.

WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance

with warning messages using this symbol.

CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

Symbols

The triangle ( ) symbol indicates a warning including danger and caution. The specific point of attention is shown inside the symbol.

General warning.

Warning of risk of electric shock.

Warning of high temperature.

indicates a prohibited action. The specific prohibition is shown inside the symbol.

General prohibited action.

Disassembly prohibited.

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. When using an extension cable, always check

that it is adequate for the rated current. .............................................................................................

• Connect the ground wire to a suitab le g round ing point. Not grounding the copier may cause fire or electric shock. Connecting the earth wire to an object not approved for the purpose may cause explosion or electric shock. Never connect the ground cable to any of the following: gas pipes, lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the

proper authorities. ............................................................................................................................

CAUTION:

• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .......

• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ................

• Do not install the copier near a radiator, heater, other heat source or near flammable material.

This may cause fire. .........................................................................................................................

• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool

as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ...........

• 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. ...........................................................

• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical

attention. ......................................................................................................................................

• Advice customers that they must always follow the safety warnings and precautions in the copier’s

instruction handbook. .....................................................................................................................

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 in cluding safety mechanisms

and protective circuits. .......................................... ...........................................................................

• Always use parts having the correct specifications. ..........................................................................

• Always use the thermostat or thermal fuse specified in the service manual or other related brochure when replacing them. Using a piece of wire, for example, could lead to fire or other serious

accident. ..........................................................................................................................................

• When the service manual or other serious brochure specifies a distance or gap for installation of a

part, always use the correct scale and measure carefully. ................................................................

• Always check that the copier is correctly connected to an outlet with a ground connection. .............

• 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. ....................................... ....................................................................................

• Handle the charger sections with care. They are charged to high potentials and may cause electric

shock if handled improperly. ............................................................................................................

CAUTION

• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are

safely secured so they will not be caught in rotating sections. ..........................................................

• Use utmost caution when working on a powered machine. Keep away from chains and belts. ........

• Handle the fixing section with care to avoid burns as it can be extremely hot. ..................................

• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause

abnormally high temperatures. ........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement. ....................

• 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. .............................................................................................

• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ........

• Remove toner completely from electronic components. ...................................................................

• Run wire harnesses carefully so that wires will not be trapped or damaged. ....................................

• After maintenance, always check that all the parts, screws, connectors and wires that were removed, have been refitted correctly. S pecial atte ntion shou ld be p aid to any fo rgotte n 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. Replace with new ones if necessary . ......................................

• Handle greases and solvents with care by following the instructions below: .....................................

Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely. Ventilate the room well while using grease or solvents. Allow applied solvents to evaporate completely before refitting the covers or turning the power switch on. Always wash hands afterwards.

• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to

fire in a furnace, etc. .......................................................................................................................

• Should smoke be seen coming from the copier, remove the power plug from the wall outlet imme-

diately. ............................................................................................................................................

3.Miscellaneous

WARNING

• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the

specified refiner; it may generate toxic gas. .....................................................................................

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Product Information

Product Information ..............................................................................................................5

Specifications .................................................................................................................... 5

Machine Overview............................................................................................................. 6

Component Layout ........................................................................................................6

Paper Path..................................................................................................................... 8

Drive Layout ..................................................................................................................9

Installation........................................................................................................................... 11

Installation Requirements................................................................................................ 11

Environment ................................................................................................................ 11

Machine level............................................................................................................... 11

Machine Space Requirement.......................................................................................12

Power Requirements ...................................................................................................12

Installation Procedure .................................................................................................. 12

Preventive Maintenance .....................................................................................................13

Preventive Maintenance.................................................................................................. 13

Replacement and Adjustment.............................................................................................14

Before You Start .............................................................................................................. 14

Special Tools ...................................................................................................................15

Exterior Covers ...............................................................................................................16

Rear Cover .................................................................................................................. 16

Operation Panel........................................................................................................... 17

Right Cover.................................................................................................................. 18

Left Cover .................................................................................................................... 18

Front Cover Unit .......................................................................................................... 19

Laser Optics .................................................................................................................... 21

Caution Decal Location................................................................................................ 21

Laser Optics Housing Unit ........................................................................................... 21

AIO Cartridge ..................................................................................................................26

AIO Cartridge (All In One Cartridge)............................................................................ 26

Black AIO Motor...........................................................................................................26

Color AIO Motor ........................................................................................................... 29

Image Transfer................................................................................................................ 31

Image Transfer Belt Unit..............................................................................................31

ITB (Image Transfer Belt) Cleaning Unit...................................................................... 32

Agitator Motor .............................................................................................................. 33

ITB (Image Transfer Belt) Contact Motor ..................................................................... 35

Product Information

ITB (Image Transfer Belt) Contact Sensor...................................................................36

TM (Toner Mark) Sensor Base..................................................................................... 37

Waste Toner Bottle Set Sensor....................................................................................38

Waste Toner Overflow Sensor .....................................................................................39

Paper Transfer ................................................................................................................41

Transfer Unit................................................................................................................41

Transfer Roller.............................................................................................................41

Registration Roller ....................................................................................................... 43

Registration Sensor ..................................................................................................... 44

Registration Clutch ...................................................................................................... 44

Image Fusing ..................................................................................................................46

Fusing Unit ..................................................................................................................46

Fusing Lamp................................................................................................................47

Transport/Fusing Motor ...............................................................................................48

Paper Feed .....................................................................................................................50

Paper Feed Clutch....................................................................................................... 50

Paper Feed Roller ....................................................................................................... 50

Separation Pad............................................................................................................51

Paper End Sensor ....................................................................................................... 52

Paper Exit........................................................................................................................ 54

Paper Exit Roller.......................................................................................................... 54

Paper Exit Sensor........................................................................................................ 55

Electrical Components ....................................................................................................57

Controller Board ..........................................................................................................57

EGB (Engine Board).................................................................................................... 59

FCU ............................................................................................................................. 61

Interlock Switches........................................................................................................ 61

Fusing Fan Motor ........................................................................................................62

LSU Fan Motor ............................................................................................................ 63

ID Chip Board .............................................................................................................. 64

PSU ............................................................................................................................. 64

High Voltage Power Supply Board...............................................................................66

Temperature/Humidity Sensor .....................................................................................67

Duplex Motor ............................................................................................................... 67

Speaker .......................................................................................................................68

EEPROM ..................................................................................................................... 69

Product Information

ADF.................................................................................................................................71

ADF Unit ...................................................................................................................... 71

Original Tray ................................................................................................................ 72

ADF Feed Unit.............................................................................................................73

ADF Separation Pad.................................................................................................... 73

ADF Front Cover .........................................................................................................74

ADF Rear Cover .......................................................................................................... 74

ADF Cover...................................................................................................................75

ADF Motor ...................................................................................................................75

Original Set Sensor .....................................................................................................77

ADF Cover Open Sensor.............................................................................................78

ADF Feed Sensor........................................................................................................ 78

ADF Drive Board .........................................................................................................79

Scanner........................................................................................................................... 81

Scanner Unit................................................................................................................81

Scanner Top Cover ......................................................................................................83

Scanner Carriage Unit .................................................................................................84

Exposure Lamp ...........................................................................................................86

Lamp Stabilizer Board..................................................................................................87

Scanner Motor ............................................................................................................. 88

System Maintenance Reference.........................................................................................90

Service Program .............................................................................................................90

Overview...................................................................................................................... 90

Configuration Page Information....................................................................................... 91

Overview...................................................................................................................... 91

Firmware Updating.......................................................................................................... 92

Checking the Machine Firmware Version ....................................................................92

Updating the Controller Firmware................................................................................ 92

Updating Failure ..........................................................................................................98

Updating the Engine Firmware .................................................................................... 99

Boot Loader Firmware ...............................................................................................100

Troubleshooting ................................................................................................................ 101

Troubleshooting Guide .................................................................................................. 101

Image Problems ............................................................................................................ 102

Overview.................................................................................................................... 102

Checking a Sample Printout ...................................................................................... 102

Product Information

INDEX............................................................................................................................... 105

Product Information

Specifications

See "Appendices" for the following information:

 "General Specifications

 "Supported Paper Sizes

Product Information

Machine Overview

Component Layout

Engine

1. Laser Optics Housing Unit

2. Print Cartridge (AIO)

3. Development Roller (AIO)

4. Paper Exit

5. Fusing Unit

6. Fusing Lamp

7. Duplex Path

8. Transfer Roller

9. Registration Roller

10. By-pass

11. Paper Feed Roller

12. ITB (Image Transfer Belt) Unit

13. OPC (AIO)

14. Tray 1

15 EGB/Controller

Product Information

ADF

1. Feed Sensor

2. Feed Roller

3. Separation Roller

4. Pick-up Roller

Scanner

5. Exit Roller

6. Original Set Sensor

7. DF Exposure Glass

1. Scanner Carriage Unit

2. DF Exposure Glass

3. Exposure Glass

4. Carriage Drive Bar

5. White Plate

Product Information

Paper Path

Engine

1. Paper path from tray 1

2. Duplex path

3. By-pass tray

4. Paper path from tray 2 (optional)

ADF

1. Original path

Product Information

Drive Layout

1. Color AIO Motor

2. Black AIO Motor

3. Duplex Motor

4. Transport/Fusing Motor

 Color AIO Motor:

This drives the color AIOs (Cyan, Magenta and Yellow)

 Black AIO Motor:

This drives the black AIO and the ITB (Image Transfer Belt).

 Duplex Motor:

This drives the paper exit roller and the duplex roller.

 Transport/Fusing Motor:

This drives the fusing unit, paper feed roller, registration roller and paper exit roller via

the paper feed clutch, registration clutch and gears.

5. Registration Clutch

6. Paper Feed Clutch

7. Agitator Motor

8. ITB (Image Transfer Belt) Contact Motor

 Registration Clutch:

This transfers drive from the transport/ fusing motor to the registration roller.

 Paper Feed Clutch:

This transfers drive from the transport/ fusing motor to the paper feed roller.

Product Information

 Agitator Motor:

This moves the agitators in the waste toner bottle.

 ITB Contact Motor:

This moves the ITB into contact with and away from the color OPCs.

Installation

Installation Requirements

Environment

1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)

2. Humidity Range: 15% to 80% RH

3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight)

4. Ventilation: 3 times/hr/person

5. Do not put the machine in areas that get sudden temperature changes. This includes:

 Areas directly exposed to cool air from an air conditioner

 Areas directly exposed to heat from a heater.

6. Do not put the machine in areas that get exposed to corrosive gas.

7. Do not install the machine at locations over 2,500 m (8,125 ft.) above sea level.

8. Put the machine on a strong, level base. (Inclination on any side must be no more than

5 mm.)

9. Do not put the machine in areas with strong vibrations.

Machine level

Front to back: Within 5 mm (0.2") of level

Right to left: Within 5 mm (0.2") of level

Installation

Machine Space Requirement

Put the machine near the power source with these clearances:

Left side: Over 20 cm (7.9")

Rear: Over 20 cm (7.9")

Right side: Over 10 cm (4")

Front: Over 70 cm (27.5")

Top: Over 24 cm (9.5")

Power Requirements

 Make sure that the plug is tightly in the outlet.

 Avoid multi-wiring.

 Make sure that you ground the machine.

Input voltage level

Permitted voltage fluctuation: 10%

Do not set anything on the power cord.

120 V, 60 Hz: More than 11 A (for North America)

220 V to 240 V, 50 Hz/60 Hz: More than 6 A (for Europe/ Asia)

Installation Procedure

Refer to the Quick Installation Guide for details about installing the machine.

Preventive Maintenance

See "Appendices" for the "User Replaceable Items".

Replacement and Adjustment

Before You Start

 If there are printer jobs in the machine, print out all jobs in the printer buffer.

 Turn off the main power switch and unplug the machine before you do the

procedures in this section.

Replacement and Adjustment

Special Tools

 PC: Windows 2000/XP/Vista, Windows Server 2003/2003 R2, or Mac OS X.

 USB cable or Crossover cable

Replacement and Adjustment

Exterior Covers

 Turn off the main power switch and unplug the machine before you do the

procedures in this section.

Rear Cover

1. Rear tray cover [A]

2. Rear cover [B] (

x 2)

Replacement and Adjustment

Operation Panel

1. Open the top cover [A].

2. Open the front cover [B].

3. Front harness cover [C] (

x 1)

Replacement and Adjustment

4. Operation panel [D] (

x 1, x 1)

Right Cover

1. Rear cover (→ p.16)

2. Operation panel (→ p.17)

3. Right cover [A] (

x 4)

 Top front screw: M3x8, others: M4x10

Left Cover

1. Rear cover (→ p.16)

Replacement and Adjustment

2. Operation panel (→ p.17)

3. Left cover [A] (

 Top front screw: M3x8, others: M4x10

x 3, hook at arrow mark)

Front Cover Unit

1. Rear cover (→ p.16)

2. Operation panel (→ p.17)

3. Transfer unit (→ p.41)

4. Right cover (→ p.18)

5. Cover link gear unit [A] (

x 2)

Replacement and Adjustment

6. Release the belt [B]

7. Front cover unit [C] (

x 4)

+ 137 hidden pages