Mita-Kyocera KM-1525 Service Manual

SERVICE

MANUAL

Published in Mar.’01

842BV110

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.

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.

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 suitable grounding 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 including 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. 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. 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 main
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

immediately. ......................................................................................................................................

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.................................................................................

CONTENTS

1-1 Specifications

1-1-1 Specifications ....................................................................................................................................... 1-1-1

1-1-2 Parts names and their functions........................................................................................................... 1-1-2

(1) Copier ............................................................................................................................................. 1-1-2

(2) Operation panel .............................................................................................................................. 1-1-3

1-1-3 Machine cross section.......................................................................................................................... 1-1-4

1-1-4 Drive system ........................................................................................................................................ 1-1-5

(1) Drive system 1 (optical section) ...................................................................................................... 1-1-5

(2) Drive system 2 (drive motor drive train) .......................................................................................... 1-1-6

1-2 Handling Precautions

1-2-1 Drum .................................................................................................................................................... 1-2-1

1-2-2 Developer and toner............................................................................................................................. 1-2-1

1-2-3 Installation environment ....................................................................................................................... 1-2-1

1-3 Installation

1-3-1 Unpacking and installation ................................................................................................................... 1-3-1

(1) Installation procedure ..................................................................................................................... 1-3-1

1-3-2 Setting initial copy modes .................................................................................................................. 1-3-12

1-3-3 Copier management........................................................................................................................... 1-3-13

(1) Using the copier management mode ............................................................................................ 1-3-13

(2) Copy default ................................................................................................................................. 1-3-14

1-3-4 Installing the total counter (option) ..................................................................................................... 1-3-16

2BV

1-4 Maintenance Mode

1-4-1 Maintenance mode............................................................................................................................... 1-4-1

(1) Executing a maintenance item ....................................................................................................... 1-4-1

(2) Maintenance mode item list ............................................................................................................ 1-4-2

(3) Contents of maintenance mode items ............................................................................................ 1-4-4

1-5 Troubleshooting

1-5-1 Paper misfeed detection ...................................................................................................................... 1-5-1

(1) Paper misfeed indication ................................................................................................................ 1-5-1

(2) Paper misfeed detection conditions ................................................................................................ 1-5-2

(3) Paper misfeeds ............................................................................................................................... 1-5-5

1-5-2 Self-diagnosis....................................................................................................................................... 1-5-7

(1) Self-diagnostic function .................................................................................................................. 1-5-7

(2) Self-diagnostic codes ..................................................................................................................... 1-5-7

1-5-3 Image formation problems ................................................................................................................. 1-5-11

(1) No image appears (entirely white). ............................................................................................... 1-5-12

(2) No image appears (entirely black). ............................................................................................... 1-5-12

(3) Image is too light. ......................................................................................................................... 1-5-13

(4) Background is visible. ................................................................................................................... 1-5-13

(5) A white line appears longitudinally. .............................................................................................. 1-5-13

(6) A black line appears longitudinally. .............................................................................................. 1-5-14

(7) A black line appears laterally. ....................................................................................................... 1-5-14

(8) One side of the copy image is darker than the other. ................................................................... 1-5-14

(9) Black dots appear on the image. .................................................................................................. 1-5-15

(10) Image is blurred............................................................................................................................ 1-5-15

(11) The leading edge of the image is consistently misaligned with the original. ................................ 1-5-15

(12) The leading edge of the image is sporadically misaligned with the original. ................................ 1-5-16

(13) Paper creases. ............................................................................................................................. 1-5-16

(14) Offset occurs. ............................................................................................................................... 1-5-16

(15) Image is partly missing................................................................................................................. 1-5-17

(16) Fixing is poor. ............................................................................................................................... 1-5-17

1-1-1

2BV

(17) Image is out of focus. ................................................................................................................... 1-5-17

(18) Image center does not align with the original center. ................................................................... 1-5-17

(19) Image is not square...................................................................................................................... 1-5-18

(20) Image contrast is low (carrier scattering)...................................................................................... 1-5-18

1-5-4 Electrical problems ............................................................................................................................. 1-5-19

(1) The machine does not operate when the main switch is turned on. ............................................. 1-5-19

(2) The drive motor does not operate (C200). ................................................................................... 1-5-19

(3) The scanner motor does not operate. .......................................................................................... 1-5-19

(4) The toner feed motor does not operate. ....................................................................................... 1-5-19

(5) Cooling fan motor 1 does not operate. ......................................................................................... 1-5-19

(6) Cooling fan motor 2 does not operate. ......................................................................................... 1-5-19

(7) Cooling fan motor 3 does not operate. ......................................................................................... 1-5-20

(8) The registration clutch does not operate. ..................................................................................... 1-5-20

(9) The paper feed clutch does not operate. ...................................................................................... 1-5-20

(10) The bypass paper feed clutch does not operate. ......................................................................... 1-5-20

(11) The cleaning lamp does not turn on. ............................................................................................ 1-5-20

(12) The exposure lamp does not turn on............................................................................................ 1-5-20

(13) The exposure lamp does not turn off............................................................................................ 1-5-20

(14) The fixing heater does not turn on (C610).................................................................................... 1-5-20

(15) The fixing heater does not turn off................................................................................................ 1-5-20

(16) Main charging is not performed (C510)........................................................................................ 1-5-21

(17) Transfer charging is not performed. ............................................................................................. 1-5-21

(18) No developing bias is output. ....................................................................................................... 1-5-21

(19) The message requesting paper to be loaded is shown when paper is present

in the drawer................................................................................................................................. 1-5-21

(20) A paper jam in the paper feed, paper conveying or fixing section is indicated

when the main switch is turned on. .............................................................................................. 1-5-21

(21) The message requesting covers to be closed is displayed when the front cover and

paper conveying unit are closed................................................................................................... 1-5-22

(22) Others........................................................................................................................................... 1-5-22

1-5-5 Mechanical problems ......................................................................................................................... 1-5-23

(1) No primary paper feed. ................................................................................................................. 1-5-23

(2) No secondary paper feed. ............................................................................................................ 1-5-23

(3) Skewed paper feed. ...................................................................................................................... 1-5-23

(4) The scanner does not travel. ........................................................................................................ 1-5-23

(5) Multiple sheets of paper are fed at one time.................................................................................. 1-5-23

(6) Paper jams. .................................................................................................................................. 1-5-23

(7) Toner drops on the paper conveying path. ................................................................................... 1-5-23

(8) Abnormal noise is heard. .............................................................................................................. 1-5-23

1-6 Assembly and Disassembly

1-6-1 Precautions for assembly and disassembly ......................................................................................... 1-6-1

(1) Precautions ..................................................................................................................................... 1-6-1

(2) Running a maintenance item .......................................................................................................... 1-6-2

1-6-2 Paper feed section ............................................................................................................................... 1-6-3

(1) Detaching and refitting the paper feed pulleys ............................................................................... 1-6-3

(2) Detaching and refitting the bypass paper feed pulley ..................................................................... 1-6-5

(3) Detaching and refitting the left registration cleaner assembly ........................................................ 1-6-7

(4) Detaching and refitting the right registration cleaner assembly ...................................................... 1-6-7

(5) Detaching and refitting the bypass paper width switch ................................................................... 1-6-8

(6) Adjustment after roller and clutch replacement .............................................................................. 1-6-9

(6-1) Adjusting the leading edge registration of image printing...................................................... 1-6-9

(6-2) Adjusting the center line of image printing........................................................................... 1-6-10

(6-3) Adjusting the margins for printing........................................................................................ 1-6-11

(6-4) Adjusting the amount of slack in the paper.......................................................................... 1-6-12

1-6-3 Optical section.................................................................................................................................... 1-6-13

(1) Detaching and refitting the exposure lamp ................................................................................... 1-6-13

1-1-2

2BV

(2) Detaching and refitting the scanner wires .................................................................................... 1-6-14

(2-1) Detaching the scanner wires ............................................................................................... 1-6-14

(2-2) Fitting the scanner wires...................................................................................................... 1-6-15

(3) Detaching and refitting the laser scanner unit .............................................................................. 1-6-18

(4) Adjusting the skew and vertical shifting of the laser scanner unit ................................................ 1-6-20

(4-1) Adjusting the skew of the laser scanner unit ....................................................................... 1-6-20

(4-2) Adjusting the vertical shifting of the laser scanner unit........................................................ 1-6-21

(5) Detaching and refitting the ISU (reference) .................................................................................. 1-6-22

(6) Adjusting the position of the ISU (reference) ................................................................................ 1-6-24

(7) Adjusting the longitudinal squareness (reference) ....................................................................... 1-6-25

(8) Adjusting magnification of the scanner in the main scanning direction ........................................ 1-6-26

(9) Adjusting magnification of the scanner in the auxiliary scanning direction ................................... 1-6-27

(10) Adjusting the scanner leading edge registration........................................................................... 1-6-28

(11) Adjusting the scanner center line ................................................................................................. 1-6-29

(12) Adjusting the margins for scanning an original on the contact glass............................................ 1-6-30

1-6-4 Main charging section ........................................................................................................................ 1-6-31

(1) Detaching and refitting the charger assembly .............................................................................. 1-6-31

(2) Replacing the tungsten wire (reference) ....................................................................................... 1-6-32

1-6-5 Drum section ...................................................................................................................................... 1-6-34

(1) Detaching and refitting the drum .................................................................................................. 1-6-34

1-6-6 Developing section ............................................................................................................................. 1-6-35

(1) Adjusting the position of the doctor blade (reference) .................................................................. 1-6-35

1-6-7 Transfer section ................................................................................................................................. 1-6-36

(1) Detaching and refitting the transfer roller assembly ..................................................................... 1-6-36

1-6-8 Cleaning section................................................................................................................................. 1-6-37

(1) Detaching and refitting the cleaning blade ................................................................................... 1-6-37

(2) Detaching and refitting the drum separation claw assemblies ..................................................... 1-6-38

(3) Detaching and refitting the cleaning lower seal assembly ............................................................ 1-6-38

1-6-9 Fixing section ..................................................................................................................................... 1-6-39

(1) Detaching and refitting the fixing unit ........................................................................................... 1-6-39

(2) Detaching and refitting the fixing unit thermistor .......................................................................... 1-6-40

(3) Detaching and refitting the heat roller separation claws ............................................................... 1-6-40

(4) Detaching and refitting the fixing heater ....................................................................................... 1-6-41

(5) Detaching and refitting the heat roller ........................................................................................... 1-6-42

(6) Detaching and refitting the press roller ......................................................................................... 1-6-44

1-7 Requirements on PCB Replacement

1-7-1 Replacing the main PCB ...................................................................................................................... 1-7-1

1-7-2 Upgrading the firmware on the main PCB............................................................................................ 1-7-3

1-7-3 Adjustment-free variable resistors (VR) ............................................................................................... 1-7-4

2-1 Mechanical construction

2-1-1 Paper feed section ............................................................................................................................... 2-1-1

2-1-2 Main charging section .......................................................................................................................... 2-1-4

2-1-3 Optical section...................................................................................................................................... 2-1-6

(1) Original scanning ............................................................................................................................ 2-1-7

(2) Image printing ................................................................................................................................. 2-1-8

2-1-4 Developing section ............................................................................................................................. 2-1-10

(1) Formation of magnetic brush ........................................................................................................ 2-1-11

(2) Toner density detection by the toner sensor ................................................................................ 2-1-12

(3) Toner density control .................................................................................................................... 2-1-12

(4) Correcting the toner sensor control voltage .................................................................................. 2-1-13

(5) Correcting toner sensor output voltage ........................................................................................ 2-1-14

2-1-5 Transfer and separation section......................................................................................................... 2-1-15

2-1-6 Cleaning section................................................................................................................................. 2-1-17

2-1-7 Charge erasing section ...................................................................................................................... 2-1-18

2-1-8 Fixing section ..................................................................................................................................... 2-1-19

1-1-3

2BV

2-2 Electrical Parts Layout

2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1

(1) PCBs .............................................................................................................................................. 2-2-1

(2) Switches and sensors..................................................................................................................... 2-2-2

(3) Motors............................................................................................................................................. 2-2-3

(4) Other electrical components........................................................................................................... 2-2-4

2-3 Operation of the PCBs

2-3-1 Power source PCB ............................................................................................................................... 2-3-1

2-3-2 Main PCB ............................................................................................................................................. 2-3-3

2-3-3 CCD PCB ............................................................................................................................................. 2-3-8

2-3-4 Laser diode PCB .................................................................................................................................. 2-3-9

2-4 Appendixes

Timing chart No. 1 .......................................................................................................................................... 2-4-1

Timing chart No. 2 .......................................................................................................................................... 2-4-2

Timing chart No. 3 .......................................................................................................................................... 2-4-3

Timing chart No. 4 .......................................................................................................................................... 2-4-4

Maintenance parts list .................................................................................................................................... 2-4-5

Periodic maintenance procedures.................................................................................................................. 2-4-6

General wiring diagram .................................................................................................................................. 2-4-9

1-1-4

1-1-1 Specifications

Type ...............................................Desktop

Copying system..............................Indirect electrostatic system

Originals .........................................Sheets and books

Maximum size: A3

Original feed system ......................Fixed

Copy paper.....................................Drawer: Plain paper (64 – 80 g/m

Bypass table: Plain paper (60 – 160 g/m

Special paper: Transparencies, tracing paper and letterhead

Note: Use the bypass table for special paper.

Copying sizes.................................Maximum: A3

Minimum: A6R/Folio (When the bypass table is used)

Magnification ratios ........................ Manual mode: 50 – 200%, 1% increments

Copy speed ....................................At 100% magnification in copy mode:

A4: 15 copies/min.

A4R: 10 copies/min.

A3: 8 copies/min.

B5: 15 copies/min.

B5R: 10 copies/min.

B4 (257 × 364 mm): 8 copies/min.

First copy time................................ Within 5.5 seconds (A4, 100% magnification, drawer)

Warm-up time.................................Within 30 seconds (room temperature 20°C/68°F, 65% RH)

In preheat/energy saver mode: Within 30 seconds (room temperature 20°C/68°F,

65% RH) [priorty to power save]

In preheat/energy saver mode: Within 15 seconds (room temperature 20°C/68°F,

65% RH) [priorty to recovery]

Paper feed system ......................... Automatic feed

Capacity:

Drawers: 250 sheets

Manual feed

Capacity:

Bypass: 50 sheets (A4, A4R, B5, B5R, A5R, B6R, A6R)

25 sheets (A3, B4, Folio)

Continuous copying........................1 – 250 sheets

Photoconductor ..............................OPC (drum diameter 30 mm)

Charging system ............................ Single positive corona charging

Exposure light source.....................Semiconductor laser

Exposure scanning system ............ Polygon mirror

Developing system.........................Dry, reverse developing (magnetic brush)

Developer: 2-component, ferrite carrier and N29T black toner
Toner density control: toner sensor

Toner replenishing: automatic from a toner cartridge

Transfer system ............................. Transfer roller

Fixing system ................................. Heat roller

Heat source: halogen heaters (910 W)

Control temperature: 180°C (at normal ambient temperature)

Abnormally high temperature protection device: 140°C thermostat

Fixing pressure: 49 N

Charge erasing system .................. Exposure by cleaning lamp

Cleaning system.............................Cleaning blade

Scanning system............................ Flat bed scanning by CCD image sensor

Resolution ...................................... 600 × 600 dpi

Light source....................................Inert gas lamp

Dimensions ....................................550 (W) × 560 (D) × 455 (H) mm

Weight............................................Approx. 38 kg

Floor requirements .........................891 (W) × 560 (D) mm

Functions........................................Self-diagnostics, preheat, automatic copy density control, enlargement/reduction

copy and photo mode

Power source ................................. 220 – 240 V AC, 50/60 Hz, 2.8 A

Power consumption .......................1080W

Option.............................................Total counter

2

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2

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2BV

1-1-1

2BV

1-1-2 Parts names and their functions

(1) Copier

4

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5

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2

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Figure 1-1-1

1 Original cover
2 Operation panel
3 Paper conveying unit
4 Multi-Bypass
5 Insert guides
6 Support tray
7 T oner cartridge
8 Toner cartridge release lever
9 Waste toner tank
0 Waste toner tank release lever
! Cleaning shaft
@ Front cover
# Main switch
$ Copy store section
% Ejection section
^ Drawer
& Platen
* Original size scales
( Length adjustment plate
) Width adjustment lever
⁄ Drawer lift
¤ Handles for transport

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1-1-2

(2) Operation panel

2BV

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1 Start key (Indicator)
2 Stop/Clear key
3 Numeric keys
4 Reset key
5 Interrupt key (Indicator)
6 Energy Saver (preheat) key (Indicator)
7 Manual/Enter key
8 Copy quantity/magnification display
9 Zoom (+) key
0 Zoom (-) key
! Auto mode selection key/APS/AMS indicators
@ Recall key (Indicator)
# Paper Select key
$ Drawer select indicators

54

Figure 1-1-2

% Misfeed location indicators
^ Paper size indicators
& Original key
* Original size indicators
( Misfeed indicator
) Add Paper indicator
⁄ Add Toner indicator
¤ Toner Disposal indicator
‹ Maintenance indicator
› Copy exposure adjustment keys
fi Copy exposure indicators
fl Image mode selection key/Auto Exposure/Text

& Photo/Photo/Text indicators

1-1-3

2BV

1-1-3 Machine cross section

1

8

5

6

7

2

4

Figure 1-1-3 Machine cross section

3

Light path
Paper path

1-1-4

1 Paper feed section
2 Main charging section
3 Optical section
4 Developing section
5 Transfer and paper conveying section
6 Cleaning section
7 Charge erasing section
8 Fixing section

1-1-4 Drive system

(1) Drive system 1 (optical section)

2BV

8

1 Scanner motor gear
2 Gear 44/16
3 Gear 26
4 Scanner wire drum

7

Figure 1-1-4

5 Scanner wire
6 Scanner wire pulley
7 Scanner wire pulley
8 Scanner wire pulley

5

3

4

As viewed from machine front

6

1

2

1-1-5

2BV

(2) Drive system 2 (drive motor drive train)

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As viewed from machine rear

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1 Drive motor gear
2 Gear 58/30
3 Gear 48/27
4 Gear 60
5 Drum gear
6 Transfer roller gear
7 Gear 52/30
8 Gear 32/16
9 Gear 32/16
0 Gear 20
! Gear 20
@ Gear 20
# Idle gear 16

Figure 1-1-5

$ Bypass paper feed clutch gear
% Gear 16
^ Upper paper feed clutch gear
& Gear 30
* Gear 26/14
( Gear 20
) Registration clutch gear
⁄ Gear 15
¤ Gear 18
‹ Gear 20
› Gear 34/23
fi Gear 24
fl Gear 15

‡ Spiral gear 17
— Blade thrust gear 21

· Gear 16
‚ Idle gear
ΠGear 19
„ Gear 23
´ Gear 23
‰ Gear 29
ˇ Fixing gear 19
Á Heat roller gear 35
¨ Idle gear
ˆ Gear 21

1-1-6

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. Avoid abrupt changes in temperature and humidity.

• Avoid exposure to any substance which is harmful to or may affect the quality of the drum.

• Do not touch the drum surface with any object. Should it be touched by hands or stained with oil, clean it.

• If the machine is left open for more than 5 minutes for maintenance, remove the drum and store it in the drum storage

bag (Part No. 78369020).

1-2-2 Developer and toner

Store the developer and toner in a cool, dark place. Avoid direct light and high humidity.

1-2-3 Installation environment

1.Temperature: 10 - 35°C/50 - 95°F

2.Humidity: 15 - 85%RH

3.Power supply: 220 - 240 V AC, 2.8 A

4.Power source frequency: 50 Hz ±0.3%/60 Hz ±0.3%

5.Installation location

• Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or other
strong light when removing paper jams.

• Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directed onto
the machine.

• Avoid dust and vibration.

• Choose a surface capable of supporting the weight of the machine.

• Place the machine on a level surface (maximum allowance inclination: 1° ).

• Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor, such as
mercury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.

• Select a room with good ventilation.

6.Allow sufficient access for proper operation and maintenance of the machine.
Machine front: 1000 mm/39
Machine right: 700 mm/27

3

/8" Machine rear: 100 mm/4"

5

/8" Machine left: 600 mm/235/8"

2BV

df

c

b

e

a: 455 mm/17
b: 550 mm/21

a

c: 718 mm/281/4"
d: 560 mm/22
e: 930 mm/36

15
5

1
5

/16"

/8"
/16"

/8"

f: 418 mm/167/16"

Figure 1-2-1 Installation dimensions

1-2-1

1-3-1 Unpacking and installation

(1) Installation procedure

Start

Unpack.

2BV

Remove the tapes.

Remove the pins holding light source units 1 and 2.

Install the optional devices.

Remove the image formation unit.

Load developer.

Release the cleaning blade.

Install a waste toner tank.

Adjust the fixing pressure.

Connect the power cord.

Carry out initial developer setting

(maintenance item U130).

Load paper.

Output an own-status report

(maintenance item U000).

Exit maintenance mode.

Install a toner cartridge.

Make test copies.

Completion of the machine installation.

1-3-1

2BV

Light source unit 1 pins

Light source unit 2 pin

Figure 1-3-1

1-3-2

Unpack.

2BV

!

@

5

0

)

*(

4

7

9

1

4

8

^

%&⁄

3

#

2

$

1 Copier
2 Outer case
3 Inner frame
4 Upper pads
5 Bottom pads
6 Bottom case
7 Skid
8 Bottom plate
9 Spacer*
0 Machine cover
! Original cover
@ Plastic bag

1

6

Figure 1-3-2 Unpacking

# Bar code labels
$ Hinge joint
% Drawer size sheet
^ Plastic bag
& Error code label*
* Drawer spacers
( Drawer claw spacers
) Power cord
⁄ Paper storage bag

*1: 230 V specifications only.
*2: Asia and Oceania specifications only.

2

1-3-3

2BV

Remove the tapes.

1. Remove the tape holding the front cover and the
power cord, and remove the tape binding the
power cord.

2. Remove the tape holding the drawer.

3. Remove the two tapes holding the paper
conveying unit and bypass tray.

4. Remove the three tapes holding the pins for light
source units 1 and 2.

Light source

unit 2 pin

Light source unit 1 pins

Power cord

Front cover
Drawer

5. Pull the drawer out and remove the tape holding
each of the drawer spacers and then the spacers.

6. Remove the tape holding the fulcrum of the
drawer lift inside the drawer.

Fulcrum of the drawer lift

Bypass tray

Paper conveying unit

Figure 1-3-3

1-3-4

Drawer spacers

Figure 1-3-4

7. Remove the tape holding each of the front and
rear cursors.

2BV

Rear cursor

Front cursor

Figure 1-3-5

8. Remove the tape holding each of the drawer
claw spacers and then the spacers.

9. Refit the drawer.

Drawer claw spacers

Figure 1-3-6

1-3-5

2BV

Remove the pins holding light source units 1 and 2.

1. Remove the two pins for light source unit 1 and
the pin for light source unit 2.

Light source unit 1 pins

Light source unit 2 pin

Figure 1-3-7

Remove the image formation unit.

1. Open the front cover, bypass tray and the paper
conveying unit.

2. Remove the two screws and disconnect the 12­pin connector. While pressing the hook on the
front image formation cover, pull the image
formation unit out.

12-pin
Connector

Hook

Screws

Image formation unit

Figure 1-3-8

1-3-6

Load developer.

1. Remove the developing unit upper cover by
pushing and lifting it in the direction of the arrow
in the diagram.
Caution: Be sure to place the image formation
unit on a level surface when loading developer.

2. Shake the developer bottle well to agitate the
developer.

3. While turning the magnet roller gear in the
direction of the arrow in the diagram, uniformly
pour developer into the image formation unit.
Caution: Never turn the magnet roller gear in the
reverse direction.

2BV

Developing unit

upper cover

Figure 1-3-9

4.Refit the developing unit upper cover.

Release the cleaning blade.

1.Remove the tape holding each of the two
cleaning blade release levers. Apply the cleaning
blade to the drum by gently pushing the cleaning
blade release levers in the direction of the arrows
in the diagram using a screwdriver.

•The cleaning blade comes into contact with the
drum.

Developer

Cleaning blade
release lever

Magnet roller gear

Figure 1-3-10

Tapes

Screwdriver

Figure 1-3-11

1-3-7

2BV

2.Check that the cleaning shaft is inserted as far as
it will go.

3. Refit the image formation unit using the two
screws.

4. Connect the 12-pin connector.

Install a waste toner tank.

1.While holding the waste toner tank release lever
up, fit the waste toner tank in the copier.

12-pin connector

Figure 1-3-12

Waste toner tank
release lever

2. Close the front cover.

Adjust the fixing pressure.

1. Remove the two blue screws.

2.Close the paper conveying unit and the bypass
tray.

1-3-8

Waste toner tank

Figure 1-3-13

Blue screws

Figure 1-3-14

Connect the power cord.

1.Connect the power cord to the connector on the copier.

2.Insert the power plug into the wall outlet.

Carry out initial developer setting (maintenance item U130).

1.Turn the main switch on and enter the maintenance mode by entering “10871087” using the numeric keys.

2.Enter “130” using the numeric keys and press the start key.

3.Press the start key to execute the maintenance item.
The drive stops within approximately 4 minutes and the toner feed start level and toner sensor control voltage are
automatically set.
Each time the copy exposure adjustment keys are pressed, the settings for INPUT, CONTROL, TARGET and
HUMID are displayed on the copy quantity/magnification display in the order presented.

4.Press the stop/clear key.

Load paper.

1.Load paper in the drawer.
Caution: Loading paper before turning the main switch on may cause paper jams.

Output an own-status report (maintenance item U000).

1.Enter “000” using the numeric keys and press the start key.

2.Select “d-L” and press the start key to output a list of the current settings of the maintenance items.

3.Press the stop/clear key.

2BV

Exit maintenance mode.

1. Enter "001" using the numeric keys and press the start key.
The machine exits the maintenance mode.

1-3-9

2BV

Install a toner cartridge.

1. Open the front cover.

2.Shift the toner cartridge release lever to the right
until it stops.

3.Tap the toner cartridge on the top five or six times
and shake it horizontally eight to ten times to
agitate the toner.

Toner cartridge release lever

Figure 1-3-15

4.Align the arrows on the top of the toner cartridge
with the cutouts in the eject tray and then insert
the cartridge into the copier.

5.Secure the toner cartridge by shifting the toner
cartridge release lever to the left until it stops.

6. Close the front cover.

1-3-10

Figure 1-3-16

Cutouts

Toner cartridge

Figure 1-3-17

Make test copies.

1. Place an original and make test copies.
Check if the center lines of the bypass tray and
drawer are correct. If not, adjust the center lines.

Completion of machine installation.

2BV

1-3-11

2BV

1-3-2 Setting initial copy modes

Factory settings are as follows:

Maintenance item

No.

U253 Switching between double and single counts Double count Double count
U254 Turning auto start function on/off On On
U255 Setting auto clear time 90 s 90 s
U256 Turning auto preheat/energy saver function on/off On On
U258 Switching copy operation at toner empty Single mode, Single mode,

detection 70 sheets 70 sheets
U260 Changing the copy count timing After ejection After ejection
U342 Setting the ejection restriction On On
U344 Setting preheat/energy saver mode Energy star Energy star
U348 Setting the copy density adjustment range Special area Special area

Contents

Metric Inch

Factory setting

1-3-12