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

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

SERVICE

MANUAL

Published in Feb. ’00

842A3110

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Service

Service Manual

Manual

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KM-4230/5230 (MCE) S/M

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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.

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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.

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Warning of risk of electric shock.

Warning of high temperature.

General prohibited action.

Disassembly prohibited.

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

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

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

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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

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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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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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THEOR Y AND

CONSTRUCTION

SECTION

I Theory and

Construction Section

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CONTENTS

1-1 Specifications

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

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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

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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

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(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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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

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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

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(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

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CONTENTS

1-2 Handling Precautions

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

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

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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.

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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

Page 23

A A

E E

2A3/4

1-3-1 Part names and their functions

• 42 ppm copier

&*(

90 !

@ $

% ¨

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‹ ›

„ ´ ‰

ﬂ ° ‚

‡

· Œ

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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E E

2AD (MCA)

Page 24

AA A

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2A3/4

• 52 ppm copier

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ﬂ ‡

° Î

‹›ﬁ

· ‚

„

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5 4

9 !

@ $

Ø ∏ Å Í

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

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Page 25

A A

E E

2A3/4

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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Page 26

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2A3/4

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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Page 27

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2A3/4

1-3-3 Drive system

“

‚

„

‰

◊

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

(

)

⁄

! #

‡

‹

ﬁ

›

ﬂ

∏

 ¸ ˛

¡ ™

∞

⁄ 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

≥

∂ƒ

˙ ç

√

≈∫

≤

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

‘

å ¬

∑

… ∆ Ω

ªº

†

•

Figure 1-3-5 Drive system—copier

1-3-5

A A

E E

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

2AD (MCA)

Page 28

AA A

As viewed from machine rear

EE E

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

AA A

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1-3-1 (2A3/4/E) 1/1/32, 21:026

2AD (MCA)

Page 29

2A3/4

(

)

5 %

⁄

›

ﬁ

⁄

‹

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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5 6

0 1

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

1-3-7

Page 30

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

· 4

„

‡

‚

›

‰

ﬁ

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

1-3-8

)

⁄

‹

(

ﬂ

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

Page 31

2A3/4

1 Forwarding pulley 2 Upper paper feed pulley 3 Lower paper feed pulley 4 Upper feed roller 5 Lower feed roller 6 Upper feed guide plate 7 Middle feed guide plate 8 Lower feed guide plate 9 Feed roller 1 0 Feed roller 2 ! Feed roller 3 @ Feed roller 4 # Feed pulley $ Upper registration roller % Lower registration roller ^ Upper registration guide & Lower registration guide * Lower pre-transfer guide ( Feed guide ) Drawer lift ⁄ Lift operation plate ¤ Upper paper feed clutch (PFCL-U) ‹ Lower paper feed clutch (PFCL-L) › Feed clutch 1 (FCL1)

ﬁ Feed clutch 2 (FCL2) ﬂ Feed clutch 3 (FCL3) ‡ Feed clutch 4 (FCL4)

° Feed clutch 5 (FCL5)

· Registration clutch (RCL) ‚ Upper paper switch (PSW-U) Œ Lower paper switch (PSW-L) „ Upper lift limit switch (LICSW-U) ´ Lower lift limit switch (LICSW-L) ‰ Paper feed switch 1 (PFSW1) ˇ Paper feed switch 2 (PFSW2) Á Paper feed switch 3 (PFSW3) ¨ Paper feed switch 4 (PFSW4) ˆ Feed switch (FSW) Ø Registration switch (RSW) ” Upper paper length switch

(PLSW-U)

Å Lower paper length switch

(PLSW-L)

Í*Upper paper width switch

(PWSW-U)

Î*Lower paper width switch

(PWSW-L)

* For inch specifications only.

1-3-2 (2A3/4/E) 1/1/32, 2:399

1-3-9

Page 32

2A3/4

Each drawer consists of a lift driven by the lift motor and other components. Each drawer can hold up to 550 sheets of paper. Paper is fed from the drawer by the rotation of the forwarding pulley and upper paper feed pulley. The lower paper feed pulley prevents multiple sheets from being fed at one time, via the torque limiter.

CN13-4 CN13-7 CN13-10 CN13-13

CN8-B11

RCL

CN8-B2 CN13-1

CN12-A2 CN8-B9

CN12-A4

CN12-A8 CN15-3

CN15-9 CN15-13

CN12-A10 CN15-4

CN15-10 CN15-14

EPCB

LICSW-U

LICSW-L

RSW

FCL5

FCL4

PSW-U

PSW-L

PFCL

FSW

FCL1

PFSW1

FCL2

PFSW2

FCL3

PFSW3

PFSW4

Figure 1-3-11 Drawer paper feed section block diagram

1-3-10

1-3-2 (2A3/4/E) 1/1/32, 2:3910

Page 33

Image ready

2A3/4

Print key

FCL4

FSW

RSW

FCL5

RCL

PFM

PFCL-U

FCL2

PFSW2

FCL1

PFSW1

Auto copy density control, copy paper: A4/11" × 8

174 ms

250 ms

100 ms

50 ms

163 ms

28 ms

ABC D E F G H J K

58 ms

35 ms

100 ms

74 ms 80 ms

35 ms

/2", magnification ratio 100%

Timing chart 1-3-1 Paper feed from the upper drawer

1-3-2 (2A3/4/E) 1/1/32, 2:3911

1-3-11

Page 34

2A3/4

A When the print key is pressed, the paper feed motor (PFM) turns on, and 250 ms later

the drive motor (DM) turns on to start drive for the paper feed section.

B 100 ms after the print key is pressed, the upper paper feed clutch (PFCL-U) turns on,

and the upper and lower paper feed pulleys rotate to start the primary paper feed.

C 50 ms after the upper paper feed clutch (PFCL-U) turns on, feed clutch 2 (FCL2) turns

on, and feed roller 2 rotates.

D 28 ms after the leading edge of the paper turns paper feed switch 2 (PFSW2) on, feed

clutch 1 (FCL1) turns on, and feed roller 1 to rotates.

E 163 ms after paper feed switch 2 (PFSW2) turns on, the upper paper feed clutch (PFCL-

U) turns off.

F 174 ms after the leading edge of the paper turns paper feed switch 1 (PFSW1) on, feed

clutch 4 (FCL4) turns on, and the lower feed roller rotates at high speed to create slack in the paper before registration.

G 58 ms after the trailing edge of the paper turns paper feed switch 2 (PFSW2) turns off,

feed clutch 2 (FCL2) turns off.

H 35 ms after the leading edge of the paper turns the registration switch (RSW) on, feed

clutches 1 and 4 (FCL1 and FCL4) turn off.

I 74 ms after image ready signal turn on, the registration clutch (RCL) turns on, causing

the upper and lower registration rollers to rotate to start secondary paper feed. Simultaneously, feed clutch 5 (FCL5) turns on and the lower feed roller rotates at low speed.

J 100 ms after the trailing edge of the paper turns the feed switch (FSW) off, feed clutch

5 (FCL5) turns off.

K 80 ms after the trailing edge of the paper turns the registration switch (RSW) off, the

registration clutch (RCL) turns off.

1-3-12

1-3-2 (2A3/4/E) 1/1/32, 2:3912

Page 35

(1-2) Paper feed from the bypass table

2A3/4

Figure 1-3-12 Bypass paper feed section

1 Bypass table 2 Bypass upper guide 3 Bypass lower guide 4 Bypass stopper 5 Bypass friction plate 6 Bypass forwarding pulley 7 Bypass upper paper feed pulley 8 Bypass lower paper feed pulley

9 Bypass paper feed clutch

(BYPPFCL)

0 Bypass solenoid (BYPSOL) ! Bypass paper switch (BYPPSW) @ Bypass paper length switch

(BYPPLSW)

# Bypass paper width switch

(BYPPWSW)

$ Bypass table extended detection

switch (BYPEDSW)

The bypass table can hold up to 100 sheets of paper at one time. When the start key is pressed, the bypass solenoid (BYPSOL) turns on, unlocking the bypass stopper and lowering the bypass forwarding pulley until it comes into contact with the paper. This conveys paper placed on the bypass table to the bypass upper and lower paper feed pulleys. The bypass paper feed clutch (BYPPFCL) then turns on, transmitting the drive motor (DM) drive to these pulleys to start primary paper feed. The bypass lower paper feed pulley rotates opposite to the paper feed direction so that the torque limiter prevents multiple sheets from being fed at one time.

1-3-2 (2A3/4/E) 1/1/32, 2:3913

1-3-13

Page 36

2A3/4

CN14-A8 CN14-A4 CN14-A7

CN8-B11

RCL

BYPPSW

BYP

PFCL

BYPSOL

Print key

FSW

RSW

FCL5

RCL

PFM

BYPSOL

BYPPFCL

CN8-B2 CN13-1 CN12-A2

CN8-B9

EPCB

RSW

FCL5

FSW

FCL4

Figure 1-3-13 Bypass paper feed section block diagram

Image ready

115 ms 100 ms65 ms

74 ms 80 ms

250 ms

100 ms

300 ms

90 ms

200 ms

AB C D E G H I J

Auto copy density control, copy paper: A5R/5

Timing chart 1-3-2 Paper feed from the bypass table

1-3-14

1-3-2 (2A3/4/E) 1/1/32, 2:3914

/2" × 81/2", magnification ratio 25%

Page 37

2A3/4

A When the print key is pressed, the paper feed motor (PFM) turns on, and 250 ms later

the drive motor (DM) turn on to start drive for the paper feed section.

B 100 ms after the print key is pressed, the bypass solenoid (BYPSOL) turns on. The

bypass stopper is then unlocked, and the bypass forwarding pulley lowers to forward the paper.

C 300 ms after the bypass solenoid (BYPSOL) turns on, the bypass paper feed clutch

(BYPPFCL) turns on, and the upper and lower bypass paper feed pulleys rotate to start primary paper feed.

D 115 ms after the leading edge of the paper turn the feed switch (FSW) on, feed clutch

5 (FCL5) turns on, and the lower feed roller rotates at low speed to create slack in the paper before registration.

E 200 ms after the feed switch (FSW) turns on, the bypass paper feed clutch (BYPPFCL)

turns off.

F 90 ms after feed clutch 5 (FCL5) turns on, the bypass solenoid (BYPSOL) turns off. G 65 ms after the leading edge of the paper turns the registration switch (RSW) on, feed

clutch 5 (FCL 5) turns off.

H 74 ms after the image ready signal turns on, the registration clutch (RCL) turns on, and

the upper and lower registration rollers rotate to start secondary paper feed. Simultaneously, feed clutch 5 (FCL5) turns on and lower feed roller rotates at low speed.

I 100 ms after the trailing edge of the paper turns the feed switch (FSW) off, feed clutch

5 (FCL5) turns off.

J 80 ms after the trailing edge of the paper turns the registration switch (RSW) off, the

registration clutch (RCL) turns off.

1-3-2 (2A3/4/E) 1/1/32, 2:3915

1-3-15

Page 38

2A3/4

(2) Main charging section

The main charging section consists of the drum and the main charger assembly. The main charger assembly charges the drum so that a latent image is formed on the surface, the charger grid ensuring the charge is applied uniformly.

Main charger assembly

Main charger grid

Tungsten wire

Drum

Figure 1-3-14 Main charging section

1-3-16

1-3-2 (2A3/4/E) 1/1/32, 2:3916

Page 39

2A3/4

Figure 1-3-15 Main charger

1 Main charger front housing 2 Main charger rear housing 3 Main charger front lid 4 Main charger rear lid 5 Main charger shield

CN5-B1 CN5-B13 CN5-B11 CN5-B12

EPCB

24 V DC

MC REM

MC ALM

GRID CONT

6 Tungsten wire 7 Charger spring 8 Charger terminal 9 Charger pin 0 Main charger grid ! Grid tension plate

CN1-13 CN1-1 CN1-3 CN1-2

HVTPCB

Grid

Drum

Figure 1-3-16 Main charging section block diagram

1-3-2 (2A3/4/E) 1/1/32, 2:3917

1-3-17

Page 40

2A3/4

Print key

CFM1

ESW

520 ms

MC REM

PFM

AB C

Auto copy density control, copy paper: A4/11" × 8

360 ms

300 ms

290-30000 ms

/2", magnification ratio 100%

Timing chart1-3-3 Main charging

A When the print key is pressed, the paper feed motor (PFM) turns on. B 520 ms after the paper feed motor (PFM) turns on, main charging (MC REM) starts. C 300 ms after cooling fan motor 1 (CFM1) turns off, main charging (MC REM) is

completed.

1-3-18

1-3-2 (2A3/4/E) 1/1/32, 2:3918

Page 41

2A3/4

(3) Optical section

The optical section consists of the scanner, mirror frame and image scanning unit for scanning and the laser scanner unit for printing.

1 Scanner 2 Mirror frame 3 Mirror 1 4 Mirror 2 5 Mirror 3 6 Exposure lamp (EL) 7 Reflector

Figure 1-3-17 Optical section

8 Image scanning unit 9 Lens 0 Optical rail ! Laser scanner unit (LSU) @ CCD PCB (CCDPCB) # Scanner motor (SM) $ Scanner home position switch

(SHPSW)

1-3-2 (2A3/4/E) 1/1/32, 2:3919

1-3-19

Page 42

2A3/4

Original scanning

The original image is illuminated by the exposure lamp (EL) and scanned by the CCD PCB (CCDPCB) in the image scanning unit via the three mirrors, the reflected light being converted to an electrical signal. The scanner and mirror frame travel to scan on the optical rails on the front and rear of the machine to scan from side to side. The speed of the mirror frame is half the speed of the scanner. When the SRDF is used, the scanner and mirror frame stop at the DF original scanning position to start scanning.

Original

SHPSW

CN4-2

CN2-1–

CN2-6

CN1-1–

CN5-1–

SMPCB INPCB

CN3-1– CN3-6

CN1-16

CN5-16

CN1-1–

CN1-140

MPCB

CN1-1– CN1-6

CN2-1

CN7-1–

CN7-13

CN2-4

CN8-1–

LSU

Drum

CCDPCB

CN11-1–

CN11-11

CN8-5

CN12-1–

CN12-7

CN9-1–

CN9-4

CN1-1–

Figure 1-3-18 Optical section block diagram

1-3-20

1-3-2 (2A3/4/E) 1/1/32, 2:3920

CN1-140

EPCB

CN7-1–

CN7-2

Page 43

2A3/4

Print key

Fwd. rotation

SM Rev. rotation

SHPSW

FVSYNC signal

410 P

414 P

9921 P

Manual copy density control, copy paper: A3/11" × 17", magnification ratio 100%

110 P

Timing chart 1-3-4 Scanner operation

A When the print key is pressed, the scanner motor (SM) reverses for 410 pulses and

then rotates forward.

B 414 pulses after the scanner motor rotates forward, the FVSYNC signal turns on for

9921 pulses for scanning.

C The scanner motor (SM) reverses to return the scanner to the home position. D 110 pulses after the scanner home position switch (SHPSW) turns on, the scanner

motor (SM) turns off, and the scanner stops at its home position.

1-3-2 (2A3/4/E) 1/1/32, 2:3921

1-3-21

Page 44

2A3/4

Image printing

The image data scanned by the CCD PCB (CCDPCB) is processed on the main PCB (MPCB) and transmitted as image printing data to the laser scanner unit (LSU). By repeatedly turning the laser on and off, the laser scanner unit forms a latent image on the drum surface.

• Laser scanner unit

Collimator lenses

Laser diodes (LD)

LD control PCB

BD sensor mirror

Oject mirror

Beam spritter

Lens 1

Lens 3

Lens 2

Polygon mirror

Polygon motor (PM)

Lens 4

Figure 1-3-19 Laser scanner unit (1)

1-3-22

1-3-2 (2A3/4/E) 1/1/32, 2:3922

BD sensor

Motor drive PCB

Cylindrical correcting lens

Page 45

2A3/4

1 Laser diodes: Generate the laser beams that form the latent image on the drum. 2 Collimator lenses: Collimate the diffused laser beams emitted from the laser diodes into

cylindrical beams.

3 Beam splitter: Refracts the laser beam emitted from one of the laser diodes so that it

becomes parallel to the other laser beam, and sends those two beams to lens 1.

4 Polygon mirror: 6-faced mirror that rotates at approximately 29527 rpm. Each face

reflects the laser beams toward the drum in the horizontal (main) scan direction. The motion of the beams across the drum forms one scan line.

5 Lenses 1, 2, 3 and 4: Maintain scanning speed across the drum and beam diameters

constant. These lenses also correct the vertical alignment of the polygon mirror so that the focal plane of the laser beams are always on the drum.

6 Object mirror: Reflects the laser beams onto the drum surface. 7 BD sensor mirror: Directs a laser beam to the BD sensor to generate the horizontal sync

signal.

8 Cylindrical correcting lens: Corrects for the deviation of the laser beam reflected by the

BD sensor mirror.

9 BD sensor: Detects the laser beam reflected by BD sensor mirror, and sends the

detection signal to the main PCB (MPCB). The main PCB (MPCB) uses this signal to determine the horizontal scanning signal timing.

0 Glass dust filter: Prevents dust from entering the unit.

Drum

Figure 1-3-20 Laser scanner unit (2)

1-3-2 (2A3/4/E) 1/1/32, 2:3923

1-3-23

Page 46

2A3/4

The dimensions of the laser beam are as shown in Figure 1-3-19.

70 µm

65 µm

Figure 1-3-21

Scanning in the main direction is provided by the rotating polygon mirror, while scanning in the auxiliary direction is provided by the rotating drum, forming a static latent image on the drum. The static latent image of the letter “A”, for example, is formed on the drum surface as shown in Figure 1-3-22. Electrical charge is dissipated on the area of the drum surface irradiated by the laser. The focal point of the laser beam is moved line by line, and adjacent lines slightly overlap each other.

1-3-24

1-3-2 (2A3/4/E) 1/1/32, 2:3924

Main scanning direction

Auxilary scanning direction

: laser beam is on

Figure 1-3-22

Page 47

(4) Developing section

The developing section consists of the developing unit and the toner recycling assembly.

2A3/4

Developing unit

Toner sub hopper

Figure 1-3-23 Developing section

The developing unit consists of the developing roller where a magnetic brush is formed, the doctor blade and the developing spirals that agitate the developer. The toner recycling assembly consists of the toner main and sub-hoppers. In t he main hopper new toner from the toner cartridge is mixed with residual toner recovered from the cleaning section. The mixture is conveyed by the sub-hopper to the developing unit. The toner level detection sensor (TLDS) checks whether or not toner remains in the main hopper.

1-3-2 (2A3/4/E) 1/1/32, 2:3925

1-3-25

Page 48

2A3/4

Toner cartridge

Toner level sensor

Toner recycle paddle A

Toner cartridge paddle

Toner hopper lockup sensor

Toner cartridge spiral

Toner recycle paddle B

Toner recycle spiral

Cleaning unit

Cleaning spiral

Toner feed motor

Toner main hopper

Toner recycle motor

1-3-26

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Main hopper spiral

Toner sub hopper

Sub hopper spiral

Figure 1-3-24 Toner recycling

Developing unit

Toner flow

Page 49

2A3/4

43.5°

59°

85.5°

74.5°

Magnetic poles on the developing roller

Formation of magnetic brush

The developing roller consists of a magnet roller with five poles and a sleeve roller. Rotation of the sleeve roller around the magnet roller entrains developer, which in turn forms a magnetic brush at pole N1 on the magnet roller. The height of the magnet brush is regulated by the doctor blade; the developing result is affected by the position of the poles on the magnet roller and the position of the doctor blade. A developing bias voltage generated by the high-voltage transformer (HVTPCB) is applied to the developing roller to provide image contrast.

A: Distances beteen the doctor blade and

developing roller: 0.53 ± 0.05 mm

Figure 1-3-25 Forming a magnetic brush

1 Developing unit housing 2 Developing roller 3 Toner sensor (TNS) 4 Doctor blade

5 Developing spiral A 6 Developing spiral B 7 Developing spiral C

N1: 830 N2: 630 N3: 450 S1: 860 S2: 700

× 10 × 10 × 10 × 10 × 10

–4

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CN2-A5 CN2-A6 CN2-A7 CN2-A8

CN2-B3

CN2-A10

CN2-B11

CN2-B9

CN5-B10

CN5-B8 CN1-6 CN5-B1 CN1-13

EPCB

TFM– TFM+ TRM– TRM+

TLDS

TLS

TNS SIG TNS CONT

DB REM

DB CONT

24 V DC

TRM

CN1-4

HVTPCB

TFM

TNS

CN2

Figure 1-3-26 Developing section block diagram

Toner density is detected by the toner sensor (TNS). The sensor section of the toner sensor detects the ratio of toner to carrier in the developer near it and converts it into a voltage. As more toner is used, the ratio of toner to carrier decreases, increasing the toner sensor output voltage. When the ratio drops below the specified value, the increase in toner sensor output voltage triggers toner replenishing. When toner is added and the ratio of toner to carrier returns to normal, the toner sensor output voltage drops to the point where toner replenishing stops.

1-3-28

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Toner density control

Toner density control is conducted using the TARGET value as the reference which is the toner sensor initial output value set by maintenance item U130 when developer is loaded for the first time.

Toner being replenished message

Toner sensor output voltage (V)

Toner empty detection level

Toner empty reset level

Toner feed start level (TARGET by U130)

Toner feed stop level

Toner request message (Toner cartridge to be replaced.)

Aging: 1 min: during copying

Copying

AB CD EF G H IJ

Figure 1-3-27 Toner density control

A When the toner sensor output voltage exceeds the toner feed start level, the toner feed

motor (TFM) and the toner recycle motor (TRM) operate intermittently—on for 0.5 s and off for 1.5 s, and on for 1.0 s and off for 1.0 s, respectively—to replenish toner.

B As toner is replenished, the toner sensor output voltage drops below the toner feed stop

level and replenishing stops.

C Both the toner feed motor (TFM) and toner recycle motor (TRM) operate intermittently—

on for 0.5 s and off for 0.5 s—to replenish toner until the toner sensor output voltage reaches the toner empty reset level after exceeding the toner feed start level.

D The toner feed motor (TFM) and toner recycle motor (TRM) operate intermittently—on

for 1.0 s and off for 1.0 s, and on for 1.5 s and off for 0.5 s, respectively—to replenish toner until the toner sensor output voltage reaches the toner empty detection level after exceeding the toner feed reset level

E When the toner sensor output voltage exceeds the toner empty detection level after

toner replenishing is carried out, the toner being replenished message appears. Both the toner feed motor (TFM) and toner recycle motor (TRM) then operate intermittently—on for 1.5 s and off for 0.5 s—for 1 min. for aging. If the voltage fails to fall to the toner empty reset level, the toner request message appears.

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F When the toner sensor output voltage drops to the toner empty reset level, the toner

being replenished message disappears, and both the toner feed motor (TFM) and toner recycle motor (TRM) operates intermittently—on for 0.5 s and off for 0.5 s—to replenish toner.

G When toner is replenished, the toner sensor output voltage drops below the toner feed

stop level and replenishing stops.

H After the toner cartridge is replaced, both the toner feed motor (TFM) and toner recycle

motor (TRM) operate intermittently—on for 1.5 s and off for 0.5 s—to replenish toner.

I When the toner sensor output voltage drops to the toner feed stop level, the toner request

message disappears. Both the toner feed motor (TFM) and toner recycle motor (TRM) then operate intermittently—on for 1.0 s and off for 1.0 s—to replenish toner.

J When toner is replenished, the toner sensor output voltage drops to the toner feed stop

level and replenishing stops.

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)

Correcting toner feed start level

The toner feed start level is corrected based on the absolute humidity and the drive time so that toner density becomes proper depending on the change of the humidity and the drive time.

• Correction based on the absolute humidity

Correction at the toner feed start level (V)

0.74

– 0.16

0 3.09 10.8

Maintenance item U130 performed.

35.9

Absolute humidity

Figure 1-3-28 Correction based on the absolute humidity

A When maintenance item U130 is carried out for initial developer setting, the toner sensor

control voltage (CONTROL) is set so that the toner sensor outputs 2.01 V when the absolute humidity is 10.8 g/m3.

B When the absolute humidity is between 0 and 10.8 g/m3, the toner feed start level is

decreased with the absolute humidity so that the toner sensor output voltage drops.

C When the absolute humidity is between 10.8 and 35.9 g/m3, the toner feed start level is

increased with the absolute humidity so that the toner sensor output voltage rises.

D When the absolute humidity exceeds 35.9 g/m3, the toner feed start level is increased

by 0.74 V to regulate the toner sensor output.

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Computing the absolute humidity

The external humidity sensor (EHUMSENS) and external temperature thermistor (ETTH) are located on the humidity sensor PCB (HUMPCB). The external humidity sensor (EHUMSENS) converts the relative humidity detected by the humidity sensing element into a voltage and sends it to the engine PCB (EPCB). The main PCB (MPCB)computes the absolute humidity based on this EHUMSENS signal and the temperature (ETTH signal) detected by the external temperature thermistor (ETTH).

EPCB

HUMPCB

Humidity sensing element

ETTH

43ETTH

GND

2 EHUMSENS

CN5-A1

CN5-A2

CN5-A3

EHUMSENS

15 V

CN5-A4

Figure 1-3-29 Absolute humidity computation block diagram

1-3-32

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• Correction based on the total drive motor time

The toner feed start level is also corrected based on the total time the drive motor (DM) has been on from execution of maintenance item U130, so that the toner sensor output is regulated properly.

Correction at the toner feed start level (V)

0.76

0.46

0.36

0.24

10 30 50 150 Drive time (h)

Maintenance item U130 performed.

Figure 1-3-30 Correction based on the total drive motor time

A When maintenance item U130 is carried out for initial developer setting, the total drive

motor time is cleared and the correction for the toner feed start level is reset to 0.

B When the total drive time reaches 10 hours, the toner feed start level is corrected with

a constant value of 0.24 V.

C When the total drive time reaches 30 hours, the toner feed start level is corrected with

a constant value of 0.36 V.

D When the total drive time reaches 50 hours, the toner feed start level is corrected with

a constant value of 0.46 V.

E When the total drive time exceeds 150 hours, the toner feed start level is corrected with

a constant value of 0.76 V.

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Toner level detection

The toner level in the toner main hopper is monitored by the toner level detection sensor (TLDS). It converts the presence or absence of toner in the toner main hopper into a voltage and sends it to the main PCB (MPCB), which triggers a message to request the toner cartridge to be replaced before the recycled toner ratio in the toner main hopper reaches a significant level.

Toner feed motor (TFM)

4.5 V

Toner level detection sensor output voltage

0.5 V

Toner request message Toner empty detection

Toner cartridge to be replaced. Toner empty detection

TFM: on

ignored.

10 s

reactivated.

U 130 performed. Toner empty detection ignored.

1 min. 5 min.

10 s

Toner empty detection reactivated.

10 s

AB C D

Figure 1-3-31 Toner level detection

A When the toner level detection sensor (TLDS) output voltage drops below 0.5 V while

the toner feed motor (TFM) is on, the toner motor drive time starts to be counted.

B If the toner level detection sensor (TLDS) output voltage remains below 0.5 V for 10 s,

the toner request message appears. Note: When the toner request message is displayed under these conditions, the

available copy mode and the number of copies that can be made are restricted as set in maintenance item U258 (see page 3-2-74).

C Toner empty detection is ignored for 1 min. (the toner feed motor on time) after the toner

cartridge has been replaced. If the toner level detection sensor (TLDS) output remains at 4.5 V or above for 10 s, toner empty detection is reactivated.

D Toner empty detection is ignored for 5 min. (the toner feed motor on time) after

maintenance item U130 has been performed for developer initial setting. If the toner level detection sensor (TLDS) output remains at 4.5 V or above for 10 s, toner empty detection is reactivated.

1-3-34

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Toner hopper lockup detection

The amount of recycled toner in the toner main hopper is monitored by the toner hopper lockup sensor (TLS). It converts the presence or absence of toner in the toner main hopper into a voltage and sends it to the main PCB, which prevents toner main hopper lockup as the amount of the recycled toner in the hopper increases.

Toner feed start level

Toner feed stop level

Toner recycle motor

1 min

Toner hopper lockup sensor output voltage (V)

4.5 V

0.5 V

AB C D

Figure 1-3-32 Toner hopper lockup detection

A When the toner hopper lockup sensor (TLS) output voltage is below 0.5 V, toner is

replenished to control toner density.

B When the toner hopper lockup sensor (TLS) output voltage exceeds 4.5 V while toner

sensor output voltage is below the toner feed start level, toner is not replenished.

C When the toner sensor output voltage is over the toner feed start level while the toner

hopper lockup sensor (TLS) output level is over 4.5 V, the toner feed motor (TFM) does not operate, while the toner recycle motor (TRM) operates continuously.

D When the toner hopper lockup sensor (TLS) output voltage is over 4.5 V, the on-time of

the toner recycle motor (TRM) is counted. When the continuous on-time exceeds 1 min., C740 (toner hopper problem) is displayed.

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(5) Transfer and separation section

Drum separation claw

Tungsten wires

Transfer charger assembly

Figure 1-3-33 Transfer and separation section

The transfer and separation section consists of the transfer charger assembly and drum separation claws. The transfer charger assembly consists of the transfer charger that applies a high voltage to transfer the toner image from the drum surface onto the paper, and the separation charger that helps the paper separate from the drum surface. In the transfer charger, a high voltage generated by the high-voltage transformer PCB (HVTPCB) is applied to the both ends of the tungsten wire. The separation charger uses the AC voltage applied from the high-voltage transformer PCB to neutralize the residual charge on the paper after the transfer process. The paper can then separate from the drum under its own weight. The separation claws ensure that the paper separates reliably from the drum.

1-3-36

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CN5-B7 CN5-B6 CN5-B5 CN5-B4 CN5-B3 CN5-B1

EPCB

CN8-B4

CN8-B5

CCM REV

CCM FWD

TC REM

TC CONT

SC REM

SC CONT

ST ALM 24 V DC

CCM

CN1-7 CN1-8 CN1-9 CN1-10 CN1-11 CN1-13

HVTPCB

Drum

SC TC

Figure 1-3-34 Transfer and separation section block diagram

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Charger wire cleaning

The charger wires are cleaned by the transfer charger cleaning pad and separation charger cleaning pad traveling along each wire. The pads are placed on a slider which moves back and forth along the charger cleaning spiral as the spiral is turned by the charger cleaning motor (CCM). The two shield cleaning sponges travel along the transfer charger shield, cleaning the inside of the shield.

Figure 1-3-35 Transfer charger assembly

1 Transfer charger front housing 8 Tungsten wire for separation 2 Transfer charger rear housing 9 Transfer charger cleaning pad 3 Transfer charger front lid 0 Separation charger cleaning pad 4 Transfer charger rear lid ! Shield cleaning sponges 5 Transfer charger shield @ Charger cleaning pad slider 6 Separation guide # Charger cleaning spiral 7 Tungsten wire for transfer $ Charger cleaning motor (CCM)

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Image ready

Print key

CFM1

ESW

MC REM

PFM

SC REM

RSW

RCL

TC REM

520 ms

700 ms

74 ms

210 ms 270 ms

AB C D

Auto copy density control, copy paper: A4/11" × 81/2", magnification ratio 100%

Secondary paper feed start

Secondary paper feed end

360 ms

300 ms

290-30000 ms

80 ms

Timing chart 1-3-5 Transfer and separation

A When the print key is pressed, the paper feed motor (PFM) turns on. B 700 ms after the paper feed motor (PFM) turns on, separation charging (SC REM)

starts.

C 210 m after the registration clutch (RCL) turn on to start secondary paper feed,

transfer charging (TC REM) starts.

D 270 ms after the trailing edge of the paper turns the registration switch (RSW) off,

transfer charging (TC REM) ends.

E 290 to 30000 ms after the main charging (MC REM) ends, the paper feed motor

(PFM) turns off and separation charging (SC REM) ends.

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(6) Cleaning section

The cleaning section consists of the cleaning blade and brush that remove residual toner from the drum surface after the transfer process, and the cleaning spiral that carries the residual toner back to the toner recycling assembly.

Figure 1-3-36 Cleaning section

1 Drum 2 Cleaning blade 3 Cleaning brush 4 Cleaning spiral 5 Lower cleaning seal

1-3-40

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Page 63

(7) Charge erasing section

The cleaning lamp (CL) consists of 36 LEDs which remove residual charge from the drum surface.

Cleaning lamp

Figure 1-3-37 Charge erasing section

2A3/4

EPCB

CN2-A2

CL REM

Drum

Figure 1-3-38 Charge erasing section block diagram

1-3-41

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Print key

PFM

50 ms

AB C

Auto copy density control, copy paper: A4/11" × 81/2", magnification ratio 100%

600 ms

Timing chart 1-3-6 Charge erasing

A When the print key is pressed, the paper feed motor (PFM) turns on. B 50 ms after the paper feed motor (PFM) turns on, the cleaning lamp (CL) lights to

remove the residual charge from the drum surface after the residual toner is removed by the cleaning section.

C 600 ms after the paper feed motor (PFM) turns off, the cleaning lamp (CL) turns off.

1-3-42

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(8) Fixing section

2A3/4

Figure 1-3-39 Fixing section

1 Fixing unit upper cover 2 Fixing unit front guide 3 Fixing unit upper guide 4 Fixing unit lower left guide 5 Heat roller 6 Press roller 7 Heat roller separation claws

8 Fixing heater M (H1) 9 Fixing heater S (H2) 0 Eject switch (ESW) ! Fixing unit thermostat (TH) @ Fixing unit thermistor (FTH) # Press roller separation claws

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The fixing section consists of the parts shown in Figure 1-3-39. When paper reaches the fixing section after the transfer process, it passes between the press roller and heat roller, which is heated by fixing heaters M or S (H1 or H2). Pressure is applied by the pressure springs so that the toner on the paper is melted, fused and fixed onto the paper. When the fixing process is completed, the paper is separated from the heat roller by its separation claws and is ejected from the copier to either the eject section or duplex section.

PRY

Heat roller

TB3

CN10-1 CN10-2

PSPCB

CN4-5

CN4-4

H1 REM

H2 REM

CN6-8

CN6-7

EPCB

Figure 1-3-40 Fixing section block diagram

H1 H2

FTH

CN3-B8

FTH

5 V DC

CN3-B7

1-3-44

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Page 67

Heating the heat roller and detecting temperature

2A3/4

Figure 1-3-41 Heating the heat roller and detecting temperature

1 Heat roller 2 Fixing heater M (H1) 3 Fixing heater S (H2)

The heat roller is heated by fixing heaters M or S (H1 or H2) inside it; its surface temperature is detected by the fixing unit thermistor (FTH) and is regulated by the fixing heaters turning on and off. If the fixing section becomes abnormally hot, either the fixing unit thermistor detects it or fixing unit thermostat (TH) operates, in each case, shutting the power to the fixing heaters off.

4 Fixing unit thermostat (TH) 5 Fixing unit themistor (FTH)

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Fixing temperature control

Copying enabled

MSW

PRY

CCM

PCM

DB REM

CFM1

PCFM

IFFM

*1: 42 ppm: 180°C/356°F 52 ppm: 190°C/374°F

Aging end

3 s

2 s

Charger wire cleaning

200 ms

50 ms

Half speed

1 s

Primary stabilization fixing

temperature 175°C/347°F

Secondary stabilization fixing

270 ms

Full speed

temperature *1

AB C D E F G H I

*2: 42 ppm: 60 s 52 ppm: 120 s

*3: 42 ppm: 116 s 52 ppm: 176 s

600 ms

Half speed

Timing chart 1-3-7 Fixing temperature control

A 2s after the main switch (MSW) is turned on, the power relay (PRY) and fixing

heater M (H1) turn on to heat the heat roller. The charger cleaning motor (CCM) also turns on to clean the charger wire, and cooling fan motor 1 (CFM1) rotates at half speed.

B 1 s after fixing heater M (H1) turns on, the polygon motor (PM) in the laser scanner

unit turns on.

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C When the fixing temperature reaches 175°C/347°F, the copier enters primary

stabilization. 50 ms later the cleaning lamp (CL) and developing bias (DB REM) turn on and primary stabilization starts.

D 200 ms after the cleaning lamp (CL) turns on, the drive motor (DM) turns on. E 270 ms after the drive motor (DM) turns on, the paper conveying motor (PCM),

paper conveying fan motor (PCFM) and image formation section fan motor (IFFM) turn on and cooling fan motor 1 (CFM1) rotates at full speed.

When the fixing temperature reaches 180°C/356°F (42 ppm) or 190°C/374°F (52 ppm), the copier enters secondary stabilization. Fixing heater M (H1) is turned on and off to keep the fixing temperature at 180°C/356°F (42 ppm) or 190°C/374°F (52 ppm) and aging starts.

G 116 s (42 ppm) or 176 s (52 ppm) after the power relay (PRY) turns on or 60 s (42

ppm) or 120 s (52 ppm) after the copier enters secondary stabilization (whichever event occurs first), copying is enables.

H 3 s after copying is enabled, the drive motor (DM), paper conveying motor (PCM)

and image formation section fan motor (IFFM) turn off, and aging ends. Cooling fan motor 1 (CFM1) rotates at half speed.

I 600 ms after aging ends, the cleaning lamp (CL), developing bias (DB REM) and

paper conveying fan motor (PCFM) turn off.

• Fixing control temperature correction

Depending on the ambient temperature, the fixing control temperature is corrected as follows.

Table 1-3-1

Correction for low ambient temperature (Ambient temperature: 17°C/

62.6°F or below) Correction for high ambient

temperature (Ambient temperature: 37°C/

98.6°F or higher)

Fixing heater M or S (H1 or H2) is turned on for 5 s from the start of the copying operation so that the fixing control temperature becomes 190°C/374°F (10°C/18°F higher for 42 ppm) or 195°C/383°F (5°C/9°F higher for 52 ppm).

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Copy setting

Paper feed from upper and lower drawers, bypass table and large paper deck

Continuous copying of 100 or less sheets in duplex copy mode

Fixing control temperature

42 ppm: 190°C/374°F (10°C/18°F higher) 52 ppm: 195°C/383°F (5°C/9°F higher)

42 ppm: 160°C/320°F (20°C/36°F lower) 52 ppm: 170°C/338°F (20°C/36°F lower)

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Paper separation

Paper is separated in the fixing section by the separation claws as shown in Figure 1-3-

42.

Heat roller separation claws

Press roller separation claws

Figure 1-3-42 Paper separation

Heat roller

Press roller

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(9) Feedshift and eject section

The feedshift and eject section consists of the parts shown in Figure 1-3-43. When fixing is complete, the conveying path is switched by the feedshift guide to eject the paper to either the copy tray or duplex unit.

2A3/4

(

Figure 1-3-43 Feedshift and eject section

1 Eject roller 2 Eject pulley 3 Upper eject guide 4 Feedshift guide 5 Upper right feedshift guide 6 Right feedshift roller 7 Left feedshift roller 8 Lower right feedshift guide 9 Lower left feedshift guide 0 Lower feedshift guide

1-3-2 (2A3/4/E) 1/1/32, 2:3949

! Lower feedshift roller @ Feedshift pulley # Left switchback eject guide $ Right middle switchback eject guide % Right switchback feed roller ^ Left switchback feed roller & Lower right switchback eject guide * Feedshift switch (FSSW) ( Switchback eject switch (SBESW)

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2A3/4

CN3-A8 CN3-A9

CN3-B9

CN3-A1

CN3-A4

EPCB

FSSOL1 FSSOL2

SBE

FSSOL

ESW

FSSW

Figure 1-3-44 Feedshift and eject section block diagram

1-3-50

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(10) Duplex section

In duplex copy mode, the paper copied onto the first face (rear face) is sent to the duplex section for side registration and switchback, and refeed for copying onto the second face (front face).

2A3/4

1 Duplex forwarding pulley 2 Upper refeed guide 3 Paper tapping guide 4 Refeed pulley 5 Switchback roller 6 Duplex upper registration roller 7 Duplex lower registration roller 8 Duplex conveying roller 9 Duplex conveying pulley

Figure 1-3-45 Duplex section

0 Duplex eject roller ! Duplex eject pulley @ Side registration guides # Switchback feedshift guide $ Stock switch (STKSW) % Duplex registration switch

(DUPRSW)

^ Duplex paper conveying switch

(DUPPCSW)

& Duplex eject switch (DUPESW)

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When the paper is sent to the duplex section, the duplex paper tapping solenoid (DUPPTSOL) lowers, which forwards the paper by means of the rotation of the duplex forwarding pulley until it is caught by the switchback roller. In duplex copy mode, the switchback feedshift solenoid (SBFSSOL) turns on to operate the switchback feedshift guide. The paper is then sent to the duplex paper conveying section by the rotation of the switchback roller. During switchback ejection, the paper is conveyed to the feedshift and eject section and ejected with the copied face down.

In duplex copy mode During switchback ejection

Figure 1-3-46 Duplex refeed mechanism

1 Duplex forwarding pulley 2 Switchback feedshift guide 3 Paper tapping guide 4 Refeed pulley 5 Switchback roller

1-3-52

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Page 75

CN10-12

CN10-10

SBFSSOL1

SBFSSOL2

SBFSSOL

EPCB

CN9-7

CN9-16

STKSW

DUPRSW

CN10-14

DUPFWDSOL

DUP PTSOL

CN10-8

DUP PCSW

CN9-8

CN9-11

SRM

SRHPSW

Figure 1-3-47 Duplex section block diagram

CN10-1–

CN10-5

2A3/4

CN9-12

DUPESW

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Duplex copying operation timing

Image ready

FSSOL

SBFSSOL

FSSW

DUPFWDSOL

DUPPTSOL

Fwd. rotation SRM

Rev. rotation

SRHPSW

RCL

ESW

STKSW

1160 ms

30 ms

60 ms

74 ms

ABC DEF

Copy paper: A4/11" × 8

/2", 100% magnification

12 P

80 ms

Timing chart 1-3-8 Feedshift and side registration

A 74 ms after the image ready signal turns on during copying onto the first face (back), the

registration clutch (RCL) turns on to start secondary paper feed.

B 1160 ms after the registration clutch (RCL) turns on, the feedshift solenoid (FSSOL)

turns on, operating the feedshift guide to switch the paper path to the duplex unit.

C When the leading edge of the paper turns the eject switch (ESW) on, the switchback

feedshift solenoid (SBFSSOL) turns on, operating the switchback guide to switch the paper path to the duplex unit conveying section.

D 60 ms after copying onto the first face (back) is competed and the trailing edge of the

paper turns the feedshift switch (FSSW) off, the side registration motor (SRM) rotates forward for 12 pulses for side registration. At the same time, the duplex paper tapping solenoid (DUPPTSOL) turns on, and the paper tapping guide lowers to hold down the trailing edge (leading edge during refeed) of the paper that was conveyed to the duplex section.

E 30 ms after the duplex paper tapping solenoid (DUPPTSOL) turns on, the duplex

forwarding solenoid (DUPFWDSOL) turns on, operating the duplex forwarding pulley to forward the paper until it is caught by the switchback roller.

F 80 ms after the stock switch (STKSW) turns off, the duplex tapping solenoid (DUPPTSOL)

and duplex forwarding solenoid (DUPFWDSOL) turn off.

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35 ms

1160 ms

80 ms

360 ms

500 ms 500 ms 500 ms

/2", 100% magnification

5 P

FSSOL

SBFSSOL Fwd. rotation SRM Rev. rotation

SRHPSW DUPRSW

DUPPCSW

DUPESW

FCL1 FCL4

FSW

RSW

FCL5

RCL

ESW

232 ms

30 ms

74 ms 100 ms

ABCD E FG IJ KL MH

Copy paper: A4/11" × 8

Timing chart 1-3-9 Refeed

A 232 ms after the leading edge of the paper turns the duplex eject switch (DUPESW) on,

feed clutch 1 (FCL1) turns on and feed roller 1 rotates.

B 30 ms after the leading edge of the paper turns the feed switch (FSW) on, feed clutch

4 turns on and the lower feed roller rotates at high speed to create slack in the paper before registration.

C 35 ms after the leading edge of the paper turns the registration switch (RSW) on, feed

clutch 1 (FCL1) and feed clutch 4 (FCL4) turn off.

D 74 ms after feed clutch 4 (FCL4) turns off, the registration clutch (RCL) turns on, and the

upper and lower registration rollers rotate to start secondary paper feed. At the same time feed clutch 5 (FCL5) turns on and the lower feed roller rotates at low speed.

E 100 ms after the trailing edge of the paper turns the feed switch (FSW) off, feed clutch

5 (FCL5) turns off.

F 80 ms after the trailing edge of the paper turns the registration switch (RSW) off, the

registration clutch (RCL) turns off.

G 1160 ms after the registration clutch (RCL) turns on, the feedshift solenoid (FSSOL)

turns off.

H 360 ms after copying onto the second face (front) is completed and the eject switch

(ESW) turns off, the switchback feedshift solenoid (SBFSSOL) turns off.

I 500 ms after the switchback feedshift solenoid (SBFSSOL) turns off, the side registration

motor (SRM) reverses to move the side registration guides outwards.

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2A3/4

J When the side registration home position switch (SRHPSW) turns on, the side registration

motor (SRM) turns off.

K 500 ms after the side registration home position switch (SRHPSW) turns on, the side

registration motor (SRM) rotates forward to move the side registration guides inwards.

L When the side registration home position switch (SRHPSW) turns off, the side registration

motor (SRM) turns off.

M 500 ms after the side registration home position switch (SRHPSW) turns off, the side

registration motor (SRM) reverses for 5 pulses, and the side registration guide stops at its home position.

1-3-56

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2A3/4

(11) SRDF

(11-1) Original feed section

The original feed section consists of the parts shown in Figure 1-3-48. An original placed on the original table is conveyed to the original switchback section or the original conveying section.

Figure 1-3-48 Original feed section

1 Original table 2 DF forwarding pulleys 3 DF original feed pulley 4 DF separation pulley 5 DF original feed upper guide 6 DF original feed lower guide 7 Original stopper

2 5 1

6!4

8 DF registration pulley 9 DF registration roller 0 DF registration guide ! Original set switch (OSSW) @ Original feed switch (OFSW) # Original feed clutch (OFCL) $ Original feed solenoid (OFSOL)

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2A3/4

OFSOL

OFSW

CN6-B5

DFDPCB

OFCL

CN5-B12 –

CN5-B13

OSSW

CN5-A5

OFM

CN6-B2

Figure 1-3-49 Original feed section block diagram

CN5-B1 –

CN5-B6

1-3-58

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Original feed timing

2A3/4

OFSOL A

OFSOL R

OFCL

Fwd. rotation

Rev. rotation

OFSW

OSBSW

OCM

DFTSW

200 ms

OffOFM

556 P*

20 ms

288 P*2

+ 30 ms

BCDA

Burst of OFM pulses

Burst of OCM pulses

Timing chart 1-3-10 Original feed (in double-sided original mode)

A The OFSOL A signal turns on for 200 ms and then the original feed solenoid (OFSOL)

turns on, lowering the DF forwarding pulleys and releasing the original stopper to convey the original forward. The original feed clutch (OFCL) simultaneously turns on, rotating the DF original feed pulley to start primary original feed. The original feed motor (OFM) rotates forward during this operation.

B 556 OFM pulses after the leading edge of the original turns the original feed switch

(OFSW) on, the original feed clutch (OFCL) and original feed motor (OFM) turn off. 20 ms later, the rotation of the motor switches to the reverse direction and secondary original feed is performed by rotation of the DF registration roller.

C 288 OFM pulses plus 30 ms after the leading edge of the original turns the DF timing

switch (DFTSW) on, the original feed motor (OFM) turns off.

D After ejection of the original, as the original conveying motor (OCM) turns off, the OFSOL

R signal turns on for 200 ms and the original feed solenoid (OFSOL) turns off.

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2A3/4

(11-2) Original switchback section

The original switchback section consists of the parts shown in Figure 1-3-50. The original from the original feed section or original conveying section is reversed and conveyed to the original conveying section.

Figure 1-3-50 Original switchback section

1 Switchback pulley 2 Switchback roller 3 Switchback feedshift guide 4 Left switchback guide

2 7

5 Switchback guide 6 Original switchback switch (OSBSW) 7 Switchback feedshift solenoid (SBFSSOL) 8 Switchback pressure solenoid (SBPSOL)

1-3-60

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SBPSOL SBFSSOL

OSBSW

2A3/4

CN5-A2 –

CN5-A3

CN6-A5

CN5-B8

DFDPCB

Figure 1-3-51 Original switchback section block diagram

1-3-61

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2A3/4

Operation of original switchback

In the double-sided original mode, the switchback feedshift solenoid (SBFSSOL) turns on, changing the position of the switchback feedshift guide. This switches the path of the original to the original switchback section to where the original is fed. The switchback feedshift solenoid (SBFSSOL) then turns off, allowing the switchback feedshift guide to return to the original position by which the path of the original is switched back to the original conveying section. The now reversed original is carried to the original conveying section and the switchback pressure solenoid (SBPSOL) turns off, releasing the switchback pulley to prevent an original jam in the original switchback section.

Switchback pulley

Switchback feedshift guide

1-3-62

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Figure 1-3-52

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2A3/4

(11-3) Original conveying section

The original conveying section consists of the parts shown in Figure 1-3-53. Synchronized with the copier scanning operation, the original is conveyed across the slit glass and ejected when scanning is complete. In the double-sided original mode, the eject feedshift solenoid (EFSSOL) turns on, moving the eject feedshift guide to switch the path of the original. When the scanning of the first face (reverse face) of the original is complete, the original is conveyed to the original switchback section again.

Figure 1-3-53 Original conveying section

1 Upper original conveying pulley 2 Upper original conveying roller 3 Lower original conveying roller 4 Front scanning pulley 5 Middle original conveying roller 6 Middle original conveying pulley 7 Eject pulley 8 Eject roller

1-3-2 (2A3/4/E) 1/1/32, 2:3963

9 Original conveying guide 0 Eject feedshift guide ! Upper eject guide @ Lower eject guide # Slit glass (copier) $ DF timing switch (DFTSW) % Eject feedshift solenoid (EFSSOL)

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2A3/4

OCM

EFSSOL

DFTSW

1-3-64

CN5-A8 –

CN5-A13

CN6-A14

DFDPCB

CN5-A7

Figure 1-3-54 Original conveying section block diagram

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Original switchback/conveying timing

2A3/4

Fwd. rotation

OFM

Rev. rotation

SBFSSOL

SBPSOL

OSBSW

EFSSOL

DFTSW

Off

OFSW

OCM

556 P*

100 ms

20 ms

115 P*

Scanning speed

30 ms

288 P*

Scanning speed

AB DCEFG

Burst of OFM pulses

Burst of OCM pulses

Timing chart 1-3-11 Reversing the first face of the original

A During primary original feed, when the original feed switch (OFSW) turns on, the

switchback feedshift solenoid (SBFSSOL) also turns on, changing the position of the switchback feedshift guide. This switches the path of the original to the original switchback section.

B 556 OFM pulses plus 20 ms after the original feed switch (OFSW) turns on, the rotation

of the original feed motor (OFM) switches to the reverse direction and the original is conveyed to the switchback section by the rotation of the switchback roller. The switchback pressure solenoid (SBPSOL) simultaneously turns on to operate the switchback pulley.

C When the trailing edge of the original turns the original switchback switch (OSBSW) off,

the switchback feedshift solenoid (SBFSSOL) turns off, the switchback feedshift guide returns to the original position.

D 115 OFM pulses after the original switchback switch (OSBSW) turns off, the original feed

motor (OFM) turns off. 100 ms later, the original feed motor (OFM) rotates forward, switching the rotational direction of the switchback roller. The original in the original switchback section is then reversed and conveyed to the original conveying section.

E Simultaneously as the original feed motor (OFM) starts rotating forward, the original

conveying motor (OCM) turns on to convey the original onto the slit glass. The eject feedshift solenoid (EFSSOL) simultaneously turns on, changing the position of the eject feedshift guide. This switches the path of the original to the original switchback section.

F When the original is conveyed onto the slit glass, the DF timing switch (DFTSW) turns

on. 288 OCM pulses later, the switchback pressure solenoid (SBPSOL).

G 30 ms after the switchback pressure solenoid (SBPSOL) turns off, the original feed motor

(OFM) turns off.

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Scanning request signal : On Scanning

Fwd. rotation

Off

OFM Rev. rotation

OFSW

SBFSSOL

SBPSOL

OSBSW

OCM

EFSSOL

DFTSW

115 P*

564 P*

30 ms

100 ms

speed

327 P*

Scanning speed

100 ms

288 P*

*1 Burst of OFM pulses

30 ms

2337 P*2 + 30 ms

Burst of OCM pulses

Timing chart 1-3-12 Reversing of the second face of the original and ejection

A 564 OFM pulses after the scanning of the first face (reverse face) of the original

completes and the DF timing switch (DFTSW) turns off, the switchback pressure solenoid (SBPSOL) turns on, operationg the switchback pulley.

B When the trailing edge of the original turns the original switchback switch (OSBSW) off,

the eject feedshift solenoid (EFSSOL) turns off and the eject feedshift guide returns to the original position, switching the path of the original to the eject section. Simultaneously, the switchback feedshift solenoid (SBFSSOL) turns off and the switchback feedshift guide returns to the original position.

C 30 ms after the original switchback switch (OSBSW) turns off, the original conveying

motor (OCM) turns off.

D 115 OFM pulses after the original switchback switch (OSBSW) turns off, the original feed

motor (OFM) turns off.

E 100 ms after the original feed motor (OFM) turns off, the motor starts rotating forward,

switching the rotational direction of the switchback roller. The original in the original switchback section is then reversed and conveyed to the original conveying section.

F 327 OFM pulses plus 100 ms after the original feed motor (OFM) turns off, the motor

starts rotating forward again and the original conveying motor (OCM) turns on simultaneously, conveying the original onto the slit glass.

G 288 OFM pulses after the original is conveyed onto the slit glass and the DF timing switch

(DFTSW) turns on, the switchback pressure solenoid (SBPSOL) turns off.

H 30 ms after the switchback pressure solenoid (SBPSOL) turns off, the original feed motor

(OFM) turns off.

I When the scanning request signal turns on, scanning of the second face (front face) of

the original starts.

J 2337 OCM pulses plus 30 ms after scanning of the second face (front face) of the original

completes and the DF timing switch (DFTSW) turns off, the original conveying motor (OCM) turns off, completing the ejection of the original.

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2A3/4

(12) Large paper deck (42 ppm: optional/52 ppm: standard)

The large paper deck consists mainly of the right and left cassettes and separation section. The right cassette primary paper feed section sends paper from the lift to the upper and lower deck separation rollers. When the right cassette becomes empty, the left cassette primary paper feed section conveys paper onto the lift of the right cassette. The upper and lower deck separation rollers in the separation section convey paper received from the right cassette primary paper feed section into the copier, preventing multiple sheets from being fed at one time.

65 43 42 6 41 9

Figure 1-3-55 Mechanical construction (1)

1 Deck paper feed roller 1 2 Deck paper conveying roller 3 Deck paper feed roller 2 4 Pickup arm 5 Paper conveying base 6 Lift 7 Paper guide U

8 Deck side cover 9 Upper deck separation roller 0 Lower deck separation roller ! Bracket @ Paper guide D # Guide pulley $ Air damper

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1-3-67

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2A3/4

68 4 0 ! 3 2 $

)*# @&

Figure 1-3-56 Mechanical construction (2)

⁄ (

1 Paper path sensor 1 (PPSENS1) 2 Paper path sensor 2 (PPSENS2) 3 Paper path sensor 3 (PPSENS3) 4 Paper empty sensor (PESENS) 5 Deck level switch 1 (DLSW1, front) 6 Deck level switch 2 (DLSW2, front) 7 Upper limit switch 1 (UPSW1, rear) 8 Upper limit switch 2 (UPSW2, rear) 9 Paper feed clutch 1 (PFCL1) 0 Paper feed clutch 2 (PFCL2) ! Paper conveying clutch (CCL) @ Paper deck motor pulse sensor 1

(PDMSENS1)

# Paper deck motor pulse sensor 2

(PDMSENS2)

1-3-68

$ Deck open/closed safety switch

(DOSSW)

% Side cover switch (SCSW) ^ Deck paper conveying motor (CM) & Paper deck motor 1 (PDM1) * Paper deck motor 2 (PDM2) ( Paper level detection sensor 1

(PLDSENS1)

) Paper level detection sensor 2

(PLDSENS2)

⁄*Dehumidifier heater 1 (DH1) ¤*Dehumidifier heater 2 (DH2)

* Service part.

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(12-1) Right cassette primary paper feed

As paper feed clutch 1 (PFCL1) turns on, the drive is transmitted to deck paper feed roller 1 and the upper and lower deck separation rollers, starting primary paper feed from the right cassette. The upper and lower deck separation rollers ensure that the paper is fed one sheet at a time and that it is fed into the copier correctly. To prevent multiple sheets from being fed, there is a torque limiter on the lower deck separation roller.

2A3/4

Paper feed signal from the copier

PFSW4 (copier)

PPSENS1

PPSENS2

PPSENS3

FCL3 (copier)

100 ms

64 P (70 ms)

PFCL1

ABC

Timing chart 1-3-13 Right cassette primary paper feed

A The paper feed signal from the copier turns paper feed clutch 1 (PFCL1) on, starting

primary paper feed.

B 64 pulses after paper feed switch 4 (PFSW4) on the copier has been turned on by the

leading edge of the paper, paper feed clutch 1 (PFCL1) turns off.

C 70 ms after paper feed switch 4 (PFSW4) on the copier has turned on, copier feed clutch

3 (FCL3) turns on to feed the paper to complete primary paper feed.

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2A3/4

FCL3

Paper path

Feed roller 4

Upper deck separation roller

PFCL1

Deck paper feed roller 1

Lift

Lower deck separation roller

Feed pulley

Figure 1-3-57 Right cassette paper feed section

Copier

PFSW4

1-3-70

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Page 93

• When the right cassette is empty, its lift serves as a guide for the paper being conveyed from the left cassette lift.

PFSW4 (copier)

PFCL1

2A3/4

PFCL1 PFCL1

CN5-6

CN1-4

CN4-4 CN9-5

PDMPCBI/FPCB

PFSW4 (copier)

Figure 1-3-58 Right cassette primary paper feed section block diagram

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(12-2) Left cassette primary paper feed

As the last sheet in the right cassette is fed, paper feed clutch 2 (PFCL2) and the paper conveying clutch (CCL) turn on for primary feed from the left cassette. Deck paper feed roller 2 and the deck paper conveying roller start to rotate to convey paper from the left cassette onto the right cassette lift.

PFSW4 (copier)

PPSENS1

PPSENS2

PPSENS3

CCL

PFCL2

43 P

ABC D

Timing chart 1-3-14 Left cassette primary paper feed

A When copier paper feed switch 4 (PFSW4) is turned on by the last paper from the right

cassette, paper feed clutch 2 (PFCL2) turns on to start primary paper feed.

B The paper conveying clutch (CCL) turns on as soon as the leading edge of the paper from

the left cassette turns paper path sensor 3 (PPSENS3) on.

C Paper feed clutch 2 (PFCL2) turns off as soon as the leading edge of the paper from the

left cassette turns paper path sensor 2 (PPSENS2) on, completing primary paper feed.

D 43 pluses after the leading edge of the paper from the left cassette turns paper path

sensor 1 (PPSENS1) on, the paper conveying clutch (CCL) turns off and the paper stops in the right cassette.

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Page 95

Paper path

CCLPFCL2

PPSENS3

2A3/4

PFSW4 (copier)

PPSENS2

PPSENS1

Deck paper feed roller 2

Deck paper conveying roller

Figure 1-3-59 Left cassette paper feed section

PFSW4 (copier)

CCLPFCL2

PPSENS2 PPSENS3

PFCL2

CCL

PPSENS1

PPSENS3

CN4-8 CN4-2 CN5-4 CN5-2 CN7-2

I/FPCB

CN2-6 CN2-11 CN1-5 CN1-6 CN1-9

PPSENS2

PPSENS2 PPSENS3

PFCL2

CCL

PPSENS1

CN1-6 CN1-11 CN4-5 CN4-6 CN4-9

PDMPCB

PFSW4 (copier)

CN9-5

Figure 1-3-60 Left cassette primary paper feed section block diagram

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(12-3) Raising and lowering the lifts

The following is a description of the right cassette lift operating mechanism. The left cassette lift operates in the same manner. Paper deck motor 1 (PDM1) drives the right lift belt assembly that winches the belt up and hence raises the lift until it is stopped by deck level switch 1 (DLSW1). When paper is loaded on the lift and the deck is closed, the lift is raised until deck level switch 1 (DLSW1) turns on. When desk level switch 1 (DLSW1) is turned off as the paper on the lift is used, paper deck motor 1 (PDM1) starts to raise the lift until the switch turns on.

Deck level switch 1

Lift

Lift belt assembly

Winch shaft

Air damper

Figure 1-3-61 Raising and lowering the lift

When the deck is opened for removing a jammed paper or other purposes, the winch shaft is released from its holder on paper deck motor 1 (PDM1), allowing the lift to descend under its own weight. The air damper buffers the impact of the descending lift.

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Paper deck motor 1

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2A3/4

DLSW1 DLSW2

DLSW2

PDM2

CN3-3 CN3-9

I/FPCB

CN2-7 CN2-9

DLSW1 DLSW2

Figure 1-3-62 Lift block diagram

PDM1

CN1-7 CN1-9

PDMPCB

DLSW1

CN7-1 CN7-4

PDM1 PDM2

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(12-4) Detecting the paper level

The lift rises as paper in the deck is used. When the remaining number of sheets in either right or left cassette reduces to around 100 to 250 sheets, the projection on the lift belt assembly pushes against the sensor lever which turns the relevant paper level detection sensor 1 or 2 (PLDSENS1/2) on. When both paper level detection sensors 1 and 2 (PLDSENS1, 2) have turned on, the message “Low on paper.” is shown on the copier touch panel. This message is not shown when only one of them is on. As more copies are made with the message on, paper path sensors 1, 2 and 3 (PPSENS1, 2, 3) or the paper empty sensor (PESENS) start to detect absence of paper, and the message on the copier touch panel changes to “Place paper in deck.”

Sensor lever

Paper level detection sensor 1

Lift belt assembly

When paper level detection sensor 1 is off When paper level detection sensor 1 is on

Sensor lever

Paper level detection sensor 1

Figure 1-3-63 Detecting the paper level

PLDSENS2 PLDSENS1

Figure 1-3-64 Paper level detection system block diagram

1-3-76

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CN2-3 CN2-6

PDMPCB

Page 99

ELECTRICAL

SECTION

II Electrical Section

JACKET(KM4230/5230) 1/1/32, 0:073

Page 100

CONTENTS

2-1 Electrical Parts Layout

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

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

(2) SRDF......................................................................................... 2-1-11

(3) Large paper deck (42 ppm: optional/52 ppm: standard) ........... 2-1-15

2A3/4

CONTENTS (2A3/4/E) 1/1/32, 0:0911

1-1-11

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

Specifications and Main Features

Frequently Asked Questions

User Manual