Mita-Kyocera KM-4230, KM-5230 Service Manual

JACKET(KM4230/5230) 1/1/32, 0:071

SERVICE

MANUAL

Published in Feb. ’00

842A3110

Service

Service Manual

Manual

LABEL(KM4230/5230) 1/1/32, 0:171

KM-4230/5230 (MCE) S/M

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 precautions (MCE) 1/1/32, 0:181

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 ( and caution. The specific point of attention is shown inside the symbol.

) symbol indicates a warning including danger

General warning.

indicates a prohibited action. The specific prohibition is

shown inside the symbol.

Safety precautions (MCE) 1/1/32, 0:182

Warning of risk of electric shock.

Warning of high temperature.

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

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

Safety precautions (MCE) 1/1/32, 0:184

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

Safety precautions (MCE) 1/1/32, 0:185

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

Safety precautions (MCE) 1/1/32, 0:186

CONTENTS

I THEORY AND CONSTRUCTION SECTION

1-1 Specifications

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

1-2 Handling Precautions

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

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

1-3 Mechanical Construction

1-3-1 Parts names and their functions.................................................... 1-3-1

1-3-2 Machine cross section................................................................... 1-3-4

1-3-3 Drive system ................................................................................. 1-3-5

1-3-4 Mechanical construction................................................................ 1-3-8

II ELECTRICAL SECTION

2-1 Electrical Parts Layout

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

2-2 Detection of Paper Misfeed

2-2-1 Paper misfeed detection ............................................................... 2-2-1

2-2-2 Paper misfeed detection conditions .............................................. 2-2-2

2-2-3 Original misfeed detection........................................................... 2-2-14

2-2-4 Original misfeed detection conditions ......................................... 2-2-15

2-3 Operation of the PCBs

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

2-3-2 Engine PCB................................................................................... 2-3-3

2-3-3 Main PCB ...................................................................................... 2-3-4

2-3-4 Memory copy PCB ........................................................................ 2-3-6

2-3-5 Scanner motor PCB ...................................................................... 2-3-8

2-3-6 CCD PCB ...................................................................................... 2-3-9

2-3-7 DF driver PCB ............................................................................. 2-3-11

2-3-8 Operation unit main PCB,operation unit right PCB,and

operation unit left PCB ................................................................ 2-3-12

2-3-9 Deck main PCB (42 ppm: optional/52 ppm: standard) ................ 2-3-16

2A3/4

III SET UP AND ADJUSTMENT SECTION

3-1 Installation

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

3-1-2 Setting initial copy modes ........................................................... 3-1-29

3-1-3 Installing the memory copy kit

(42 ppm: optional/52 ppm: standard) .......................................... 3-1-30

3-1-4 Installing the image memory SIMM (option)................................ 3-1-33

3-1-5 Installing the optical heater (service part) ................................... 3-1-35

3-1-6 Installing the drawer heater (service part) ................................... 3-1-38

3-1-7 Installing the key counter (option) ............................................... 3-1-41

3-1-8 Installing the dehumidfier heaters (service part) ......................... 3-1-44

3-1-9 Installing the MMD host monitorig system device

(optional for 120 V specifications only) ....................................... 3-1-47

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2A3/4

3-2 Maintenance Mode

3-2-1 Maintenance mode........................................................................ 3-2-1

3-2-2 Copier management.................................................................... 3-2-99

3-3 Assembly and Disassembly

3-3-1 Precautions for assembly and disassembly .................................. 3-3-1

3-3-2 Paper feed section ........................................................................ 3-3-3

3-3-3 Optical section............................................................................. 3-3-23

3-3-4 Main charging section ................................................................. 3-3-42

3-3-5 Drum section ............................................................................... 3-3-45

3-3-6 Developing section ...................................................................... 3-3-51

3-3-7 Transfer and separation section.................................................. 3-3-56

3-3-8 Cleaning section.......................................................................... 3-3-59

3-3-9 Fixing section .............................................................................. 3-3-64

3-3-10 Feedshift and duplex section ...................................................... 3-3-80

3-3-11 SRDF section .............................................................................. 3-3-89

3-3-12 Large paper deck section

(42 ppm: optional/52 ppm: standard) ........................................ 3-3-102

3-4 PCB Initial Settings

3-4-1 Replacing the main PCB ............................................................... 3-4-1

3-4-2 Replacing the main PCB ROMs .................................................... 3-4-2

3-4-3 Adjustment-free variable resisters (VR) ........................................ 3-4-3

3-5 Self-Diagnosis

3-5-1 Self-diagnosis................................................................................ 3-5-1

3-6 Troubleshooting

3-6-1 Image formation problems ............................................................ 3-6-1

3-6-2 Paper misfeeds ........................................................................... 3-6-18

3-6-3 PCB terminal voltages................................................................. 3-6-33

3-6-4 Electrical problems ...................................................................... 3-6-73

3-6-5 Mechanical problems .................................................................. 3-6-97

3-7 Appendixes

Timing chart No. 1 .................................................................................... 3-7-1

Timing chart No. 2 .................................................................................... 3-7-2

Timing chart No. 3 .................................................................................... 3-7-3

Timing chart No. 4 .................................................................................... 3-7-4

Timing chart No. 5 .................................................................................... 3-7-5

Timing chart No. 6 .................................................................................... 3-7-6

Timing chart No. 7 .................................................................................... 3-7-7

Timing chart No. 8 .................................................................................... 3-7-8

Timing chart No. 9 .................................................................................... 3-7-9

Timing chart No. 10 ................................................................................ 3-7-10

Timing chart No. 11 ................................................................................ 3-7-11

Timing chart No. 12 ................................................................................ 3-7-12

Power source PCB 1/2 ........................................................................... 3-7-13

Power source PCB 2/2 ........................................................................... 3-7-14

Engine PCB 1/2 ...................................................................................... 3-7-15

Engine PCB 2/2 ...................................................................................... 3-7-16

Main PCB 1/9.......................................................................................... 3-7-17

Main PCB 2/9.......................................................................................... 3-7-18

Main PCB 3/9.......................................................................................... 3-7-19

Main PCB 4/9.......................................................................................... 3-7-20

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Main PCB 5/9.......................................................................................... 3-7-21

Main PCB 6/9.......................................................................................... 3-7-22

Main PCB 7/9.......................................................................................... 3-7-23

Main PCB 8/9.......................................................................................... 3-7-24

Main PCB 9/9.......................................................................................... 3-7-25

Memory copy PCB 1/12.......................................................................... 3-7-26

Memory copy PCB 2/12.......................................................................... 3-7-27

Memory copy PCB 3/12.......................................................................... 3-7-28

Memory copy PCB 4/12.......................................................................... 3-7-29

Memory copy PCB 5/12.......................................................................... 3-7-30

Memory copy PCB 6/12.......................................................................... 3-7-31

Memory copy PCB 7/12.......................................................................... 3-7-32

Memory copy PCB 8/12.......................................................................... 3-7-33

Memory copy PCB 9/12.......................................................................... 3-7-34

Memory copy PCB 10/12........................................................................ 3-7-35

Memory copy PCB 11/12........................................................................ 3-7-36

Memory copy PCB 12/12........................................................................ 3-7-37

Scanner motor PCB................................................................................ 3-7-38

CCD PCB................................................................................................ 3-7-39

DF driver PCB......................................................................................... 3-7-40

Operation unit main PCB 1/2 .................................................................. 3-7-41

Operation unit main PCB 2/2 .................................................................. 3-7-42

Operation unit right PCB......................................................................... 3-7-43

Operation unit left PCB ........................................................................... 3-7-44

Deck main PCB ...................................................................................... 3-7-45

Interface PCB ......................................................................................... 3-7-46

SRDF connection diagram...................................................................... 3-7-47

General connection diagram (42 ppm copier) ........................................ 3-7-48

General connection diagram (52 ppm copier) ........................................ 3-7-49

SRDF wiring diagram.............................................................................. 3-7-50

Large paper deck wiring diagram ........................................................... 3-7-51

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1-1-3

THEOR Y AND

CONSTRUCTION

SECTION

I Theory and

Construction Section

JACKET(KM4230/5230) 1/1/32, 0:072

CONTENTS

1-1 Specifications

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

2A3/4

CONTENTS (2A3/4/E) 1/1/32, 0:095

1-1-5

2A3/4

1-1-1 Specifications

Copier (42 ppm copier)

Type …………………………… Desktop Copying system ……………… Dry, indirect electrostatic system Originals ………………………Sheets and books

Original feed system ………… Fixed Copy paper ……………………Drawer and duplex unit: Plain paper (64 – 80 g/m2)

Copying sizes ………………… Maximum: A3/11" × 17"

Magnification ratios …………… Manual mode: 25 – 400%, 1% increments

Copy speed ……………………At 100% magnification in memory copy mode:

First copy time ………………… 4.5 s or less (A4/11" × 81/2", 100% magnification,

Warm-up time …………………120 s or less (room temperature 20˚C/68˚F, 65%RH) Paper feed system ……………Automatic feed

Photoconductor ………………OPC (drum diameter 60 mm) Charging system ……………… Single positive corona charging, 670 – 730 µA Exposure light source ………… Semiconductor laser Exposure scanning system … Polygon mirror

Maximum size: A3/11" × 17"

Bypass table: Plain paper (60 – 160 g/m2) Special paper: Transparencies, tracing paper, colored paper, letterhead and envelopes (only when used as a printer) Note: Use the bypass table for special paper.

Minimum: A6R/51/2" × 81/2" During duplex copying Maximum: A3/11" × 17" Minimum: A5R/51/2" × 81/2"

Auto copy mode: Fixed ratios Metric

1:1 ± 0.1%, 1:4.00/1:2.00/1:1.41/1:1.06/1:0.75/ 1:0.70/1:0.50/1:0.25

Inch

1:1 ± 0.1%, 1:4.00/1:2.00/1:1.29/1:1.21/1:0.78/ 1:0.64/1:0.50/1:0.25

A4/11" × 81/2": 42 copies/min. A4R/81/2" × 11": 32 copies/min. A3/11" × 17": 24 copies/min. B5 : 42 copies/min. B5R : 36 copies/min. B4 (257 × 364)/81/2" × 14": 28 copies/min.

When the SRDF is used (at 100% magnification):

A4/11" × 81/2": 42 copies/min.

upper drawer, manual copy density control)

Capacity:

Drawers: 550 sheets Manual feed Capacity:

Bypass: 100 sheets

1-1 (2A3/4/E) 1/1/32, 2:451

1-1-1

4230/5230 (MCA) S/M

KM4230/5230 (MCE) S/M

2A3/4

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 ………………Single negative corona charging, –210 µA Separation system ……………Single AC corona charging Fixing system ………………… Heat roller

Heat source: halogen heaters (main 850 W, sub 850 W)

Control temperature: 180˚C/356˚F (at normal ambient

temperature)

Abnormally high temperature protection devices:

140˚C/284˚F thermostat

Fixing pressure: 210 N Charge erasing system ………Exposure by cleaning lamp Cleaning system ………………Cleaning blade Scanning system ……………… Flat bed scanning by CCD image sensor Bit map memory ………………12 MB (standard) Image storage memory ………32 MB (standard) Resolution ………………………600 × 600 dpi Light source …………………… Inert gas lamp (12 W) Dimensions …………………… 627 (W) × 748 (D) × 841 (H) mm

2411/16" (W) × 297/16" (D) × 331/8" (H) Weight ………………………… 129 kg/283.8 lbs Floor requirements ……………1287 mm (W) × 748 (D)mm

505/16" (W) × 297/16" (D) Functions ……………………… (1) Self-diagnostics

(2) Preheat (3) Automatic copy density control (4) Original size detection (5) Automatic paper selection (6) Automatic magnification selection (7) Enlargement/reduction copy (8) Fixed ratio selection

(9) Size zoom mode (10) XY zoom mode (11) Photo mode (12) Duplex copy (13) Margin copy (14) Print page numbers function (15) Split copy (16) Border erasing (17) Sheet copy (18) Transparency backing sheet function (19) Form overlay (20) Combine copy (21) Booklet + cover copy (22) Sort copy (23) Invert copy (24) Mirror image mode

1-1-2

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4230/5230 (MCA) S/M KM4230/5230 (MCE) S/M

2A3/4

(25) Program copy (26) Setting change mode (27) Job build mode (28) Department control (29) Weekly timer (30) Language selection

Power source ………………… 120 V AC, 60 Hz, 10.5 A

220 – 240 V AC, 50 or 60 Hz, 4.9 A

Power consumption …………… 1300 W (for 120 V specifications)

1200 W (for 220-240 V specifications)

Options ………………………… Paper feed desk, large paper deck, finisher, key counter,

key card*, printer unit, memory copy board, additional memory (16 MB/32 MB), booklet stitcher, MMD host monitoring system device* and copy tray*.

* for 120 V specifications only

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1-1-3

4230/5230 (MCA) S/M

KM4230/5230 (MCE) S/M

2A3/4

Copier (52 ppm copier)

Type …………………………… Console Copying system ……………… Dry, indirect electrostatic system Originals ……………………… Sheets and books

Maximum size: A3/11" × 17" Original feed system ………… Fixed Copy paper ……………………Drawer and duplex unit: Plain paper (64 – 80 g/m2)

Bypass table: Plain paper (60 – 160 g/m2)

Special paper: Transparencies, tracing paper, colored

paper, letterhead and envelopes (only when used as a

printer)

Note: Use the bypass table for special paper. Copying sizes ………………… Maximum: A3/11" × 17"

Minimum: A6R/51/2" × 81/2"

During duplex copying

Maximum: A3/11" × 17"

Minimum: A5R/51/2" × 81/2" Magnification ratios …………… Manual mode: 25 – 400%, 1% increments

Auto copy mode: Fixed ratios

Metric

1:1 ± 0.1%, 1:4.00/1:2.00/1:1.41/1:1.06/1:0.75/ 1:0.70/1:0.50/1:0.25

Inch

1:1 ± 0.1%, 1:4.00/1:2.00/1:1.29/1:1.21/1:0.78/ 1:0.64/1:0.50/1:0.25

Copy speed …………………… At 100% magnification in memory copy mode:

A4/11" × 81/2": 52 copies/min. A4R/81/2" × 11": 35 copies/min. A3/11" × 17": 26 copies/min. B5 : 52 copies/min. B5R : 42 copies/min. B4 (257 × 364)/81/2" × 14": 31 copies/min.

When the SRDF is used (at 100% magnification):

A4/11" × 81/2": 42 copies/min.

First copy time ………………… 4.5 s or less (A4/11" × 81/2", 100% magnification,

upper drawer, manual copy density control) Warm-up time …………………180 s or less (room temperature 20˚C/68˚F, 65%RH) Paper feed system …………… Automatic feed

Capacity:

Drawers: 550 sheets Manual feed Capacity:

Bypass: 100 sheets

Photoconductor ………………OPC (drum diameter 60 mm) Charging system ………………Single positive corona charging, 670 – 730 µA 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

1-1-4

1-1 (2A3/4/E) 1/1/32, 2:454

4230/5230 (MCA) S/M KM4230/5230 (MCE) S/M

Toner density control: toner sensor

Heat source: halogen heaters (main 850 W, sub 850W)

Control temperature: 190˚C/374˚F (at normal ambient

temperature)

Abnormally high temperature protection devices:

140˚C/284˚F thermostat

2411/16" (W) × 297/16" (D) × 449/16" (H) Weight ………………………… 160 kg/352 lbs Floor requirements ……………1287 mm (W) × 748 (D)mm

505/16" (W) × 297/16" (D) Functions ……………………… (1) Self-diagnostics

(2) Preheat (3) Automatic copy density control (4) Original size detection (5) Automatic paper selection (6) Automatic magnification selection (7) Enlargement/reduction copy (8) Fixed ratio selection

2A3/4

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1-1-5

4230/5230 (MCA) S/M

KM4230/5230 (MCE) S/M

2A3/4

(28) Department control (29) Weekly timer (30) Language selection

Power source ………………… 120 V AC, 60 Hz, 10.5 A

220 – 240 V AC, 50 or 60 Hz, 4.9 A

Power consumption …………… 1200 W (for 120 V specifications)

1300 W (for 220-240 V specifications)

Options ………………………… Finisher, key counter, key card*, printer unit, additional

memory (16 MB/32 MB) , MMD host monitoring system device* and copy tray* * for 120 V specifications only

SRDF

Original feed system ………… Automatic feed Originals ……………………… Sheets Original weights ……………… Single-sided original mode: 35 – 160 g/m

Double-sided original mode: 50 – 120 g/m

Original paper …………………Plain paper, thermal paper, art paper, colored paper Original sizes …………………A3 – A5R, folio/11" × 17" – 81/2" × 51/2" No. of originals …………………Up to 50 sheets (A3, B4, folio, 11" × 17", 81/2" × 14")

Up to 70 sheets (up to A4/11" × 81/2") Up to 50 sheets in the auto selection mode Art or thermal paper must be fed individually.

Power source ………………… Electrically connected to the copier

Large paper deck

Paper ……………………………Plain paper (64 – 80 g/m2) Paper size ………………………A4/11" × 81/2", B5 Capacity ………………………3000 sheets (1500 sheets × 2) No. of stacks …………………… 2 Power source ………………… Electrically connected to the copier

1-1-6

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4230/5230 (MCA) S/M KM4230/5230 (MCE) S/M

CONTENTS

1-2 Handling Precautions

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

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

2A3/4

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1-1-7

2A3/4

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 (2A3/4/E) 1/1/32, 2:431

1-2-1

PointSource Vi500 (MCE) S/M

CONTENTS

1-3 Mechanical Construction

1-3-1 Parts names and their functions ......................................................... 1-3-1

1-3-2 Machine cross section ........................................................................ 1-3-4

1-3-3 Drive system ....................................................................................... 1-3-5

1-3-4 Mechanical construction ..................................................................... 1-3-8

(1) Paper feed section ...................................................................... 1-3-8

(1-1) Paper feed from the drawers ............................................ 1-3-8

(1-2) Paper feed from the bypass table.................................... 1-3-13

(2) Main charging section ................................................................ 1-3-16

(3) Optical section ............................................................................ 1-3-19

Original scanning........................................................................1-3-20

Image printing............................................................................ 1-3-22

(4) Developing section .................................................................... 1-3-25

Formation of magnetic brush..................................................... 1-3-27

Toner density control................................................................. 1-3-29

Correcting toner feed start level ................................................ 1-3-31

Toner level detection ................................................................. 1-3-34

Toner hopper lockup detection.................................................. 1-3-35

(5) Transfer and separation section ................................................ 1-3-36

Charger wire cleaning ............................................................... 1-3-38

(6) Cleaning section ........................................................................ 1-3-40

(7) Charge erasing section ............................................................. 1-3-41

(8) Fixing section ............................................................................ 1-3-43

Heating the heat roller and detecting temperature .................... 1-3-45

Fixing temperature control......................................................... 1-3-46

Paper separation ....................................................................... 1-3-48

(9) Feedshift and eject section........................................................ 1-3-49

(10) Duplex section ........................................................................... 1-3-51

Duplex copying operation timing ............................................... 1-3-54

(11) SRDF......................................................................................... 1-3-57

(11-1) Original feed section....................................................... 1-3-57

Original feed timing......................................................... 1-3-59

(11-2) Original switchback section ............................................ 1-3-60

Operation of original switchback..................................... 1-3-62

(11-3) Original conveying section.............................................. 1-3-63

Original switchback/conveying timing............................. 1-3-65

(12) Large paper deck (42 ppm: optional/52 ppm: standard) ........... 1-3-67

(12-1) Right cassette primary paper feed.................................. 1-3-69

(12-2) Left cassette primary paper feed .................................... 1-3-72

(12-3) Raising and lowering the lifts.......................................... 1-3-74

(12-4) Detecting the paper level................................................ 1-3-76

2A3/4

CONTENTS (2A3/4/E) 1/1/32, 0:099

1-1-9

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2A3/4

1-3-1 Part names and their functions

• 42 ppm copier

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Figure 1-3-1-a

1 Contact platen 2 Original size indictor lines 3 Operation panel 4 Bypass table 5 Insert guide 6 Support guide 7 Front cover 8 Right cover 9 Duplex unit 0 Re-feeding section

! Duplex unit cover @ Upper drawer # Length guide tab $ Width guide tab % Lower drawer ^ DF original reversing cover & Original set indicator * Original insertion guides ( Original table ) DF opening/closing lever

⁄ Original ejection cover ¤ Paper ejection guide ‹ Main switch › Left cover ﬁ Copy tray* ﬂ Toner cartridge ‡ Toner cartridge release lever ° Image formation unit release button

· Image formation unit handle ‚ Paper transfer unit release lever

Œ Paper feed section knob „ Fixing unit ´ Fixing unit handle ‰ Fixing knob ˇ Fixing unit release lever Á Handles for transport ¨ Paper feed desk* ˆ Large paper deck*

*1: Optional for 120 V specifications. *2: Optional.

1-3-1

1-3-1 (2A3/4/E) 1/1/32, 21:011

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2A3/4

• 52 ppm copier

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Figure 1-3-1-b

1 Contact platen 2 Original size indictor lines 3 Operation panel 4 Bypass table 5 Insert guide 6 Support guide 7 Front cover 8 Right cover 9 Upper drawer 0 Length guide tab ! Width guide tab

@ Lower drawer # Large paper deck $ Deck side cover % Drawer ^ Deck front cover & Lifts * Paper side guides ( DF original reversing cover ) Original set indicator ⁄ Original insertion guides ¤ Original table

‹ DF opening/closing lever › Original ejection cover ﬁ Paper ejection guide ﬂ Main switch ‡ Left cover ° Copy tray*

· Toner cartridge ‚ Toner cartridge release lever Œ Image formation unit release button „ Image formation unit handle ´ Paper transfer unit release lever

‰ Paper feed section knob ˇ Duplex unit Á Re-feeding section ¨ Duplex unit cover ˆ Duplex unit handle Ø Fixing unit ∏ Fixing unit handle Å Fixing knob Í Fixing unit release lever Î Handles for transport

* Optional for 120 V specifications.

1-3-2

1-3-1 (2A3/4/E) 1/1/32, 21:012

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Metric

1 Punch mode key 2 Punch mode indicator 3 Staple sort mode key 4 Staple sort mode indicator 5 Sorter mode key 6 Sort mode indicator 7 Group mode indicator 8 Brightness adjustment control 9 Data indicator 0 Program key ! Manual key @ Add job key # Copier/printer switching key $ Touch panel % Numeric keys ^ Stop/clear key & Print key * Print indicator ( Reset key

Inch

) Auto selection key ⁄ Auto selection indicator ¤ Energy saver key ‹ Energy saver indicator › Interrupt key ﬁ Interrupt indicator

Figure 1-3-2 Operation panel

1-3-3

1-3-1 (2A3/4/E) 1/1/32, 21:013

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1-3-2 Machine cross section

Large paper deck

(page 1-3-67)

Figure 1-3-4 Machine cross section—Large paper deck

(42 ppm: optional/52 ppm: standard)

Paper path

Light path Paper and original path

Figure 1-3-3 Machine cross section—copier and SRDF

1 Paper feed section (page 1-3-8) 2 Main charging section (page 1-3-16) 3 Optical section (page 1-3-19) 4 Developing section (page 1-3-25) 5 Transfer and separation section (page 1-3-36) 6 Cleaning section (page 1-3-40) 7 Charge erasing section (page 1-3-41) 8 Fixing section (page 1-3-43) 9 Feedshift and eject section (page 1-3-49) 0 Duplex section (page 1-3-51) ! SRDF (page 1-3-57)

1-3-4

1-3-1 (2A3/4/E) 1/1/32, 21:014

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1-3-3 Drive system

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As viewed from the machine front

! Gear 35/29 @ Developing drive gear # Gear 31 $ Gear 24 % Gear 20 ^ Registration clutch gear & Upper registration roller gear * Lower registration roller gear ( Gear 39/25 ) Gear 30

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⁄ Gear 37 ¤ Gear 20 ‹ Bypass paper feed clutch gear › Gear 18 ﬁ Gear 16 ﬂ Lower bypass paper feed pulley gear ‡ Gear 16 ° Bypass forwarding pulley gear

· paper feed motor gear ‚ Gear 55/45 Œ Feed clutch 5 gear „ Gear 30 ´ Feed clutch 4 gear ‰ Gear 47 ˇ Gear 40 Á Gear 28 ¨ Gear 34 ˆ Lower feed roller gear Ø Upper feed roller gear ∏ Gear 30 Å Gear 28 Í Feed clutch 1 gear Î Idle pulley 38/23 Ï Paper feed drive belt ˝ Idle pulley 31/42 Ó Feed clutch 2 gear Ô Upper paper feed clutch gear  Upper paper feed pulley gear Ò Gear 21 Ú Forwarding pulley gear ¸ Gear16 ˛ Lower paper feed pulley gear Ç Paper feed tension pulley ◊ Idle pulley 31/42 ı Lower paper feed clutch gear ˜ Upper paper feed pulley gear Â Gear 21 ¯ Forwarding pulley gear ˘ Gear 16 ¿ Lower paper feed pulley gear ¡ Feed clutch 3 gear ™ Feed roller 3 pulley £ Feed drive belt ¢ Feed idle pulley

∞ Tension pulley 10

§ Feed roller 4 pulley ¶ Paper conveying motor gear

• Idle gear 43 ª Duplex unit input gear º Pulley 63/32 œ Paper conveying drive belt ∑ Pulley 36/32 ® Idle gear 36/36 † Idle gear 30 ¥ Gear 26 ø Paper conveying roller π Paper conveying belt “ Paper conveying pulley ‘ Fixing drive gear « Idle gear 30 å Idle gear 26 ß Idle gear 26 ∂ Gear 19 ƒ Pulley 22 © Gear 19 ˙ Feedshift drive belt ∆ Tension pulley 22 ˚ Pulley 22 ¬ Gear 20/28 … Idle gear 29 Ω Idle gear 30 ≈ One-way gear ç Idle gear 20 √ Eject speed switching clutch gear ∫ Gear 26 µ Idle gear 26 ≤ Idle gear 20 ≥ Gear 23 ÷ Pulley 28

` Eject drive belt 1 Tension pulley 28 2 Eject roller pulley 3 Scanner motor pulley 4 Scanner drive belt 5 Scanner drive pulley 6 Scanner wire drum 7 Scanner wire 8 Scanner wire pulley

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1 Drive motor gear 2 Idle pulley 63/35 3 Cleaning drive belt 4 Idle pulley 40/38 5 Blade thrust gear 6 Cleaning spiral gear 7 Idle pulley 80/26 8 Drum drive belt 9 Drum drive tension pulley 0 Drum drive pulley

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Figure 1-3-5 Drive system—copier

1-3-5

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1-3-1 (2A3/4/E) 1/1/32, 21:025

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As viewed from machine rear

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2A3/4

Figure 1-3-6 Drive system—SRDF (inside front of machine)

1 Lower original conveying pulley 25/18 7 Joint gear 14 2 Gear 18/25 8 JAM release gear 14 3 Eject gear 18 9 Tension pulley 4 Middle original conveying pulley 18 0 Eject drive belt 5 Upper original conveying pulley 18 ! Conveying drive belt 2 6 JAM release gear 24

As viewed from machine front

Figure 1-3-7 Drive system—SRDF (inside rear of machine)

1 Original feed motor pulley 0 DF registration pulley 28/18 2 Pulley 35/22/22 ! Idle gear 15 3 Idle gear 26 @ Idle gear 20 4 Original feed clutch gear # Switchback gear 18 5 DF original feed pulley 28 $ DF registration drive belt 6 DF forwarding pulley 20 % Gear 22/35 7 Tension pulley ^ Original conveying motor pulley 8 Original feed drive belt & Gear 28 9 DF forwarding belt * Original conveying drive belt 1

Figure 1-3-8 Drive system—Duplex section

1 Duplex joint gear 9 Forwarding pulley 27 2 Gear 28 0 Gear 18 3 Duplex registration gear 20/30 ! Gear 26 4 Gear 26 @ Paper conveying pulley 40 5 Switchback roller gear # Paper conveying drive belt

6 Forwarding drive gear 18 $ Paper conveying tension pulley 7 Pulley 22 % Paper conveying pulley 20 8 Forwarding belt ^ Paper conveying pulley 20

1-3-6

As viewed from machine front

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As viewed from machine front

Figure 1-3-9 Drive system—Large paper deck

(42 ppm: optional/52 ppm: standard)

1 Belt 180-6 2 Paper feed clutch 1 3 Paper feed clutch 2 4 Paper conveying clutch 5 Gear 20 6 Gear 26 7 Gear 50-20 8 Gear 35-1-20 9 Pulley 18 0 Gear 43-20 ! Pulley S2M-18 @ Gear 16 # Roller 0.8-20

$ Pulley 20, gear 32 % One-way drum ^ Pulley 18-OW & Pulse gear * Belt 258 ( Belt 234 ) Belt 144 ⁄ Gear 1.0-24 ¤ Lift pulley ‹ Left lift belt assembly › Right lift belt assembly ﬁ Paper deck motor gear ﬂ Pulley 16

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1-3-2 (2A3/4/E) 1/1/32, 2:397

1-3-7

2A3/4

1-3-4 Mechanical construction

(1) Paper feed section

The paper section consists of the primary feed and secondary feed subsections. Primary feed conveys paper from the upper drawer, lower drawer or bypass table to the upper and lower registration rollers, at which point secondary feed takes place and the paper travels to the transfer section in sync with the printing timing.

(1-1) Paper feed from the drawers

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Figure 1-3-10 Drawer paper feed and secondary paper feed sections

1-3-8

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1-3-2 (2A3/4/E) 1/1/32, 2:398

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