Mita-Kyocera KM-4850W Service Manual
SERVICE
MANUAL
Published in Jun. ’01
842A7110
CAUTION
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent
type recommended by the manufacturer. Dispose of used batteries according to the
manufacturer’s instructions.
CAUTION
Double-pole/neutral fusing.
Safety precautions
This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.
Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION:Bodily injury or damage to property may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.
1. Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. ............................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. .............................................................................................................................
CAUTION:
• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .....
• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..............
• Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. ..........................................................................................................................
• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........
• Always handle the machine by the correct locations when moving it. ..............................................
• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may
cause the copier to move unexpectedly or topple, leading to injury..................................................
• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is
accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention
immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain
medical attention. ..............................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. ........................................................................................................................
2. Precautions for Maintenance
WARNING
• Always remove the power plug from the wall outlet before starting machine disassembly...............
• Always follow the procedures for maintenance described in the service manual and other related
brochures. .........................................................................................................................................
• Under no circumstances attempt to bypass or disable safety features including safety
mechanisms and protective circuits. .................................................................................................
• Always use parts having the correct specifications...........................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related
brochure when replacing them. Using a piece of wire, for example, could lead to fire or other
serious accident. ...............................................................................................................................
• When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ...............................................................
• Always check that the copier is correctly connected to an outlet with a ground connection. ............
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If
it is dirty, clean it to remove the risk of fire or electric shock. ............................................................
• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ..............................................................................................................................
• Handle the charger sections with care. They are charged to high potentials and may cause
electric shock if handled improperly. .................................................................................................
CAUTION
• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections...........................................................
• Use utmost caution when working on a powered machine. Keep away from chains and belts. .......
• Handle the fixing section with care to avoid burns as it can be extremely hot. .................................
• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures...........................................................................................................
• Do not remove the ozone filter, if any, from the copier except for routine replacement....................
• Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. ......................................................................................................
• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. ..............................................................................................
• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........
• Remove toner completely from electronic components. ...................................................................
• Run wire harnesses carefully so that wires will not be trapped or damaged. ...................................
• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten
connector, trapped wire and missing screws. ..................................................................................
• Check that all the caution labels that should be present on the machine according to the
instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................
• Handle greases and solvents with care by following the instructions below: ....................................
· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
· Ventilate the room well while using grease or solvents.
· Allow applied solvents to evaporate completely before refitting the covers or turning the main
switch on.
· Always wash hands afterwards.
• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc...........................................................................................................................
• Should smoke be seen coming from the copier, remove the power plug from the wall outlet
immediately. ......................................................................................................................................
3. Miscellaneous
WARNING
• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than
the specified refiner; it may generate toxic gas. ................................................................................
CONTENTS
1-1 Specifications
1-1-1 Specification ......................................................................................................................................... 1-1-1
1-1-2 part names and functions ..................................................................................................................... 1-1-3
(1) Main unit ....................................................................................................................................... 1-1-3
(2) Operation panel ............................................................................................................................ 1-1-5
1-1-3 Copy process ....................................................................................................................................... 1-1-6
1-1-4 Machine cross sectional view ............................................................................................................... 1-1-7
1-1-5 Machine drive system .......................................................................................................................... 1-1-8
(1) Drive system 1 (driven by the paper feed motor) .......................................................................... 1-1-8
(2) Drive system 2 (driven by the drum motor and fixing motor) ...................................................... 1-1-10
(3) Drive system 3 (driven by the main motor and toner motor) ....................................................... 1-1-11
(4) Drive system 4 (driven by the original motor) ............................................................................. 1-1-11
1-2 Handling Precautions
1-2-1 Handling and storage of the drum ........................................................................................................ 1-2-1
1-2-2 Storage of developer and toner ............................................................................................................ 1-2-1
1-2-3 Handling of the heaters (for 120 V specifications only) ........................................................................ 1-2-1
1-2-4 Paper .................................................................................................................................................... 1-2-1
1-2-5 Installation environment ....................................................................................................................... 1-2-2
2A7
1-3 Installation
1-3-1 Unpacking and installing the copier ..................................................................................................... 1-3-1
(1) Installation procedure .................................................................................................................... 1-3-1
1-3-2 Copy mode initial settings .................................................................................................................. 1-3-12
1-3-3 User Settings ...................................................................................................................................... 1-3-13
(1) Default settings making procedure ............................................................................................. 1-3-13
(2) Making default settings ............................................................................................................... 1-3-14
1-3-4 Installation of the upper roll unit (option) ............................................................................................ 1-3-17
1-3-5 Attaching the original tray ................................................................................................................... 1-3-23
1-3-6 Attaching the key counter (option) ..................................................................................................... 1-3-25
1-3-7 Installing expansion memory (DIMM, option) ..................................................................................... 1-3-26
1-4 Maintenance Mode
1-4-1 Maintenance mode ............................................................................................................................... 1-4-1
(1) Executing a maintenance item ...................................................................................................... 1-4-1
(2) Maintenance mode item list .......................................................................................................... 1-4-2
(3) Contents of maintenance mode items .......................................................................................... 1-4-6
1-5 Troubleshooting
1-5-1 Paper misfeed detection ...................................................................................................................... 1-5-1
(1) Paper misfeed indication ............................................................................................................... 1-5-1
(2) Paper misfeed detection conditions .............................................................................................. 1-5-2
(3) Paper misfeeds ............................................................................................................................. 1-5-7
1-5-2 Self-diagnostic function ...................................................................................................................... 1-5-11
(1) Self-diagnostic display ................................................................................................................ 1-5-11
(2) Self diagnostic codes .................................................................................................................. 1-5-12
1-5-3 Image formation problems ................................................................................................................. 1-5-17
(1) No image (entirely white). ........................................................................................................... 1-5-18
(2) Part or all of the image is solid black. ......................................................................................... 1-5-19
(3) Image is too light. ........................................................................................................................ 1-5-20
(4) Background is visible. ................................................................................................................. 1-5-20
(5) A white line appears longitudinally. ............................................................................................. 1-5-21
(6) A black line appears longitudinally. ............................................................................................. 1-5-21
(7) A black line appears laterally. ..................................................................................................... 1-5-22
(8) One side of the copy image is darker than the other. ................................................................. 1-5-22
1-1-1
2A7
(9) Black dots appear on the image. ................................................................................................ 1-5-23
(10) Image is blurred. ......................................................................................................................... 1-5-23
(11) The leading edge of the image is consistently misaligned with the original. ............................... 1-5-24
(12) The leading edge of the image is sporadically misaligned with the original. ............................... 1-5-24
(13) Paper creases. ............................................................................................................................ 1-5-24
(14) Offset occurs. .............................................................................................................................. 1-5-25
(15) Image is partly missing. .............................................................................................................. 1-5-25
(16) Fixing is poor. .............................................................................................................................. 1-5-25
(17) Image is out of focus. .................................................................................................................. 1-5-26
(18) The center of the image is misaligned with the original. ............................................................. 1-5-26
(19) One forth the A0 width of the image is white. ............................................................................. 1-5-27
(20) One forth the A0 width of the image is black. ............................................................................. 1-5-27
1-5-4 Electrical problems ............................................................................................................................. 1-5-28
(1) The machine does not operate at all when the main switch is turned on. .................................. 1-5-28
(2) The main motor does not operate. .............................................................................................. 1-5-28
(3) The drum motor does not operate. ............................................................................................. 1-5-28
(4) The fixing motor does not operate. ............................................................................................. 1-5-28
(5) The paper feed motor does not operate. .................................................................................... 1-5-28
(6) The original feed motor does not operate. .................................................................................. 1-5-29
(7) The toner feed motor does not operate. ..................................................................................... 1-5-29
(8) The paper conveying fan motor does not operate. ..................................................................... 1-5-29
(9) The fixing unit fan motor does not operate. ................................................................................ 1-5-29
(10) LPH fan motor does not operate. ................................................................................................ 1-5-29
(11) The upper roll winding clutch* does not operate. ........................................................................ 1-5-29
(12) The middle roll winding clutch does not operate. ........................................................................ 1-5-30
(13) The lower roll winding clutch does not operate. .......................................................................... 1-5-30
(14) The upper feed clutch* does not operate. ................................................................................... 1-5-30
(15) The middle feed clutch does not operate. ................................................................................... 1-5-30
(16) The lower feed clutch does not operate. ..................................................................................... 1-5-30
(17) The roll feed clutch does not operate. ......................................................................................... 1-5-30
(18) The roll registration clutch does not operate. .............................................................................. 1-5-31
(19) The bypass registration clutch does not operate. ....................................................................... 1-5-31
(20) The bypass feed clutch does not operate. .................................................................................. 1-5-31
(21) The right or left xenon lamp does not light. ................................................................................. 1-5-31
(22) The right or left xenon lamp does not go off. .............................................................................. 1-5-31
(23) The right, middle or left cleaning lamp does not light. ................................................................. 1-5-31
(24) The main fixing heater does not turn on. .................................................................................... 1-5-32
(25) The sub fixing heater does not turn on. ...................................................................................... 1-5-32
(26) The main fixing heater fails to turn off. ........................................................................................ 1-5-32
(27) The sub fixing heater fails to turn off. .......................................................................................... 1-5-32
(28) No main charging. ....................................................................................................................... 1-5-33
(29) No transfer charging. .................................................................................................................. 1-5-33
(30) No separation charging. .............................................................................................................. 1-5-33
(31) No developing bias voltage. ........................................................................................................ 1-5-33
(32) The scan stop key does not operate. .......................................................................................... 1-5-34
(33) The drum heater does not operate. ............................................................................................ 1-5-34
(34) The upper roll unit heater* does not operate. ............................................................................. 1-5-34
(35) The middle roll unit heater does not operate. ............................................................................. 1-5-34
(36) The lower roll unit heater does not operate. ............................................................................... 1-5-34
(37) The separation claw solenoid does not operate. ........................................................................ 1-5-34
1-5-5 Mechanical problems ......................................................................................................................... 1-5-35
(1) No primary paper feed. ............................................................................................................... 1-5-35
(2) No secondary paper feed. ........................................................................................................... 1-5-36
(3) No original conveying. ................................................................................................................. 1-5-36
(4) Original jam. ................................................................................................................................ 1-5-36
(5) Paper jam. ................................................................................................................................... 1-5-37
(6) Toner falls onto the paper conveying section. ............................................................................ 1-5-37
(7) Abnormal noise. .......................................................................................................................... 1-5-37
1-1-2
1-6 Assembly and Disassembly
1-6-1 Cautions during disassembly and assembly ........................................................................................ 1-6-1
(1) Caution .......................................................................................................................................... 1-6-1
(2) Executing a maintenance item ...................................................................................................... 1-6-2
1-6-2 Original feed and optical section .......................................................................................................... 1-6-3
(1) Attachment and removal of the contact image sensor .................................................................. 1-6-3
(2) Attachment and removal of the LED printhead ............................................................................. 1-6-5
(3) Adjustment of the image focus (LPH height adjustment) .............................................................. 1-6-7
(4) Adjusting scanning magnification .................................................................................................. 1-6-8
(5) Adjusting the scanner leading edge registration ........................................................................... 1-6-9
(6) Adjusting the optical axis (center line) ........................................................................................ 1-6-10
(7) Adjusting the image width in the main scanning direction .......................................................... 1-6-11
(8) Adjusting the exposure amount .................................................................................................. 1-6-12
(9) Adjusting the automatic exposure ............................................................................................... 1-6-13
1-6-3 Developing section ............................................................................................................................. 1-6-14
(1) Replacement of developer .......................................................................................................... 1-6-14
(2) Adjustment of the doctor blade: reference .................................................................................. 1-6-16
(3) Adjustment of position for magnetic brush: reference ................................................................. 1-6-17
1-6-4 Image formation section ..................................................................................................................... 1-6-18
(1) Replacing the drum ..................................................................................................................... 1-6-18
(2) Cleaning the drum: reference ..................................................................................................... 1-6-20
(3) Checking the drum surface potential .......................................................................................... 1-6-21
(4) Replacing the main charger wire ................................................................................................ 1-6-22
(5) Replacing the transfer/separation charger wire .......................................................................... 1-6-24
(6) Replacing the transfer wire ......................................................................................................... 1-6-26
1-6-5 Cleaning section ................................................................................................................................. 1-6-28
(1) Attachment and removal of the cleaning unit .............................................................................. 1-6-28
(2) Attachment and removal of the cleaning blade ........................................................................... 1-6-29
(3) Attachment and removal of the lower cleaning seal ................................................................... 1-6-30
(4) Attachment and removal of the cleaning fur brush ..................................................................... 1-6-31
(5) Attachment and removal of the separation claw ......................................................................... 1-6-32
1-6-6 Fixing section ..................................................................................................................................... 1-6-33
(1) Attachment and removal of the oil roller ..................................................................................... 1-6-33
(2) Attachment and removal of the main and sub fixing heaters ...................................................... 1-6-34
(3) Attachment and removal of the heat roller .................................................................................. 1-6-36
(4) Attachment and removal of the press roller ................................................................................ 1-6-37
(5) Attachment and removal of fixing unit thermistors 1 and 2 (for use with the heat roller) ............ 1-6-38
(6) Attachment and removal of the fixing unit thermostat ................................................................. 1-6-40
(7) Attachment and removal of fixing unit thermistors 3 and 4 (for use with the press roller) .......... 1-6-41
1-6-7 Paper feed section ............................................................................................................................. 1-6-42
(1) Attachment and removal of the cutter unit .................................................................................. 1-6-42
(2) Adjusting printing magnification .................................................................................................. 1-6-43
(3) Adjusting the print start timing ..................................................................................................... 1-6-44
(4) Adjusting the standard cut length ................................................................................................ 1-6-45
(5) Adjusting the synchronized cut length ........................................................................................ 1-6-46
(6) Adjusting the long copy cut length .............................................................................................. 1-6-47
(7) Adjusting the trailing edge margin ............................................................................................... 1-6-48
1-6-8 Paper feed section ............................................................................................................................. 1-6-49
(1) Attachment and removal of the ozone filter ................................................................................ 1-6-49
(2) Attachment and removal of the cooling filter ............................................................................... 1-6-49
2A7
1-7 Requirements on PCB Replacement
1-7-1 Replacing the engine main PCB .......................................................................................................... 1-7-1
1-7-2 Replacing the IPU PCB ........................................................................................................................ 1-7-1
1-7-3 Replacing the scanner PCB ................................................................................................................. 1-7-2
1-7-4 Upgrading the version of the flash ROM firmware (engine main PCB, IPU PCB,
and scanner PCB) ................................................................................................................................ 1-7-3
1-7-5 Fixed variable resistor (VR) .................................................................................................................. 1-7-5
1-1-3
2A7
2-1 Mechanical construction
2-1-1 Mechanical construction of each section ............................................................................................. 2-1-1
(1) Paper feed and conveying section ................................................................................................ 2-1-1
(1-1) Bypass paper feed ............................................................................................................... 2-1-4
(1-2) Roll unit paper feed .............................................................................................................. 2-1-5
(2) Main charger section ..................................................................................................................... 2-1-6
(3) Exposure and original conveying section ...................................................................................... 2-1-9
(4) CIS and LPH section ................................................................................................................... 2-1-12
(5) Developing section ...................................................................................................................... 2-1-16
(6) Transfer/separation section ........................................................................................................ 2-1-20
(7) Cleaning section ......................................................................................................................... 2-1-23
(8) Static eliminator section .............................................................................................................. 2-1-24
(9) Fixing section .............................................................................................................................. 2-1-25
2-2 Electrical Parts Layout
2-2-1 Electric parts layout .............................................................................................................................. 2-2-1
(1) PCBs ............................................................................................................................................. 2-2-1
(2) Switches and sensors ................................................................................................................... 2-2-2
(3) Motors ........................................................................................................................................... 2-2-4
(4) Clutches and heaters .................................................................................................................... 2-2-5
(5) Others ........................................................................................................................................... 2-2-6
2-3 Operation of the PCBs
2-3-1 Power source PCB ............................................................................................................................... 2-3-1
2-3-2 Engine main PCB ................................................................................................................................. 2-3-4
2-3-3 IPU PCB ............................................................................................................................................. 2-3-10
2-3-4 Operation unit PCB ............................................................................................................................ 2-3-15
2-3-5 Scanner PCB ..................................................................................................................................... 2-3-18
2-3-6 Original motor PCB ............................................................................................................................ 2-3-22
2-3-7 Left (right) inverter PCB ..................................................................................................................... 2-3-25
2-4 Appendixes
Timing Chart No. 1 ......................................................................................................................................... 2-4-1
Timing Chart No. 2 ......................................................................................................................................... 2-4-2
Timing Chart No. 3 ......................................................................................................................................... 2-4-3
Timing Chart No. 4 ......................................................................................................................................... 2-4-4
Timing Chart No. 5 ......................................................................................................................................... 2-4-5
Timing Chart No. 6 ......................................................................................................................................... 2-4-6
Image adjustment procedure table ................................................................................................................. 2-4-7
Periodic maintenance procedure .................................................................................................................... 2-4-9
List of maintenance parts ............................................................................................................................. 2-4-11
General wiring diagram ................................................................................................................................ 2-4-12
Power source wiring diagram ....................................................................................................................... 2-4-13
1-1-4
2A7
1-1-1 Specification
Type ............................................... Console type
Copying method ............................. Dry indirect electrostatic photocopying
Original type ................................... Sheet
Original feed method ...................... Fixed platen
Paper.............................................. Plain paper: 64 – 80 g/m2 (fed from the roll unit or bypass table)
Special paper: Vellum, film (fed from the roll unit or bypass table)
Paper roll width: 210 – 920 mm/17" – 36"
Paper roll outer diameter: 180 mm/6
Paper roll inner diameter: 76 mm/3"
Original size ................................... Standard: A0 – A4R (64 – 80 g/m
36" × 48" – 8
1
/2" × 11" (64 – 80 g/m2)
Maximum: 920 (W) × 6,000 (L) mm (64 – 80 g/m
36" (W) × 237" (L) (64 – 80 g/m
Copy size ....................................... Standard: A0 – A4R (64 – 80 g/m
1
36" × 48" – 8
/2" × 11" (64 – 80 g/m2)
Maximum: 920 (W) × 6,000 (L) mm (64 – 80 g/m
36" (W) × 237" (L) (64 – 80 g/m
Effective image width: 920 mm/36"
Void area: Leading/trailing edge: 10 mm or less, right/left edge: 3 mm or less
Copying magnification ratios .......... Manual mode: 25 – 400% (at intervals of 1% or 0.1%)
Fixed ratios:
Metric:
1:1±0.5%, 1:4.000, 1:2.829, 1:2.000, 1:1.410, 1:0.706, 1:0.500, 1:0.352, 1:0.250
Inch:
1:1±0.5%, 1:4.000, 1:2.667, 1:2.588, 1:1.545, 1:1.500, 1:1.333, 1:1.294, 1:0.772,
1:0.750, 1:0.667, 1:0.647, 1:0.500, 1:0.386, 1:0.375, 1:0.250
Copying speed ............................... 4.8 m/minute
First copy time ................................ Within 18 seconds (A1 [36" × 14"] standard size copying)
Warm up time ................................. Within 10 minutes (room temperature 20°C/68°F, 65%RH)
Paper feed system ......................... Automatic feed from the roll unit and manual feed from the bypass table
Continuous copying........................ 1 – 99 copies
Photoconductor .............................. OPC (Drum diameter: 90 mm)
Charging system ............................ Scorotoron charging
Exposure system............................ Scanning exposure of moving original
Resolution ...................................... 600 × 600 dpi
Light source.................................... Xenon lamp
Developing system ......................... Dry (magnetic brush)
Developer: dual component (ferrite carrier and black toner: N26T)
Toner density control: Toner sensor
Toner replenishing: Supply from the bottle cartridge
Transfer system ............................. Single negative corona charging
Separation system ......................... Single AC corona charging
Fixing system ................................. Heat roller
Heat source: Halogen heaters (main: 750 W, sub: 350 W)
Control temperature: 155°C/311°F (plain paper)
150°C/302°F (film)
185°C/365°F (Vellum)
Abnormal temperature increase-prevention device: Thermostat (140°C/284°F)
Fixing pressure: 49N
Charge erasing system .................. Exposure by cleaning lamp
Cleaning system............................. Cleaning blade and cleaning far brush
Memory for storage of image ......... 128 MB as standard (1024 MB at the maximum)
Machine dimensions ...................... 1330 (W) × 704 (D) × 1205 (H) mm
3
/8" (W) × 251/8" (D) × 477/16" (H)
52
Weight ............................................Approx. 252 kg/554.4 lbs. (main unit only)
Installation dimensions ................... 1330 (W) × 774 (D) mm (1330 mm (H) × 1319 (D) with full options)
3
/8" (W) × 301/2" (D) (523/8" (H) × 5115/16 (D) with full options)
52
Functions........................................ AMS, zoom copy, preset R/E, XY zoom, sort, image shift, margin copy, border erase,
mirror copy, preview copy, repeat copy, interrupt, job reserve, program, energy saver,
auto shut-off, self-diagnosis
3
/4" or less
2
)
2
)
2
)
2
)
2
)
2
)
1-1-1
2A7
Power requirement ......................... 120 V AC, 60 Hz, 13 A
220 – 240 V AC, 50 Hz, 7 A
Rated power consumption ............. 1560 W (120 V specifications)
1620 W (220 – 240 V specifications)
Accessories .................................... Copy tray support plate, original loop guide, roll flange
Options ........................................... Roll unit, original tray, key counter, carrier sheet (A0, A1, A2, 36" × 48" and 24" × 36"),
printer/scanner controller, expansion memory (128 MB, 256 MB and 512 MB).
1-1-2
1-1-2 part names and functions
(1) Main unit
2A7
1 Original guides
2 Original cover
3 Original leading edge cover
4 Original loop guide
5 Operation panel
6 Eject cover
7 Ejection release levers
8 Main unit release levers
9 Original table
0 Original holders
Figure 1-1-1
! Bypass table
@ Bypass guide
# Front covers
$ Copy trays
% Copy tray support plates
^ Main switch
& Scanner counter
* Total counter
( Key counter* insert slot
* Optional
1-1-3
2A7
1-1-4
) Right cover
⁄ Toner replenishing slot
¤ Toner replenishing slot screw
‹ Contact glass
› Upper roll unit*
fi Middle roll unit
fl Lower roll unit
‡ Instruction handbook box
Figure 1-1-2
° Waste toner tank
· Paper transport knob
‚ Upper, middle and lower roll unit
heater switches
ΠRoll flange
„ Release levers
´ Roll flange guides
* Optional
(2) Operation panel
Inch
Metric
2A7
1 APS/AMS key
2 100% key
3 Preset R/E key
4 Message display
5 Original Image Type key
6 Auto Exp. key (indicator)
7 Media key
8 Paper Source key
9 Cut Size key
0 */Language key
! Editing key
@ Output Adj. key
# Program Recall key
$ Cursor keys
% OK key
^ Memory indicator
& Repeat Copy key (indicator)
* Add Job key (indicator)
( Sort/Group key (indicator)
) Interrupt key (indicator)
⁄ Preview Copy key (indicator)
¤ Energy Saver key (indicator)
‹ Start key
› Reset key
fi Stop/Clear key
fl Light/Dark indicators
‡ Copy contrast indicators
° Copy contrast keys
· Scan indicator
‚ Copier/Printer/Scanner key (indicator)
ΠNumeric keys
„ Roll Cut key
´ Scan Stop key
Figure 1-1-3
1-1-5
2A7
1-1-3 Copy process
Original
Exposure Original image reading
Original image data read by the
CIS is A/D converted and
Xenon lamp
CIS
image-processed, and the LPH
LEDs light to form a static latent
image on the drum surface.
Developing
Paper
Static latent
LPH
image formation
Toner
Drum
Transfer Separation
Figure 1-1-4 Copy process
Main charging
Fixing
1-1-6
1-1-4 Machine cross sectional view
2A7
*
Original conveying path
Paper conveying path
Figure 1-1-5 Machine cross sectional view
1 Original conveying section
2 Optical section
3 Developing section
4 Image formation section
* The upper roll unit is optional.
5 Cleaning section
6 Fixing section
7 Paper feed/conveying section
1-1-7
2A7
1-1-5 Machine drive system
(1) Drive system 1 (driven by the paper feed motor)
1 Paper feed motor gear
2 Gear 82/35
3 Idle pulley 25/45
4 Pulse plate gear
5 Paper feed section drive belt
6 Drive tension pulley
7 Flange pulley 36
8 Pre-transfer drive pulley 32
9 Feed gear 47
10 Idle gear 30
11 Roll feed clutch
12 Idle gear 30
13 Idle gear 30
14 Roll registration clutch
15 Cartridge drive idle gear
16 Feed gear 40
1-1-8
Figure 1-1-6
17 Bypass feed clutch
18 Bypass registration clutch
19 Pre-transfer drive pulley 32
20 Flange pulley 36
21 Cleaning section drive belt*
22 Drive tension pulley*
23 Idle pulley 32/36*
24 Idle gear 30*
25 Upper roll winding clutch*
26 Roll drive gear 16*
27 Roll drive gear 40*
28 Roll drive gear 26*
29 Roll drive gear 26*
30 Developer spiral roller gear 23*
31 Cleaning section drive gear 25*
32 Roll unit pulley*
33 Roll unit belt*
34 Drum tension pulley*
35 Idle pulley 21*
36 Roll unit pulley*
37 Idle gear 40*
38 Roll flange*
39 Flange pulley 36
40 Pre-transfer drive pulley 32
41 Idle gear 30
42 Upper feed clutch*
43 Developer gear 20
44 Idle gear 30
45 Duplex gear 32
46 Idle gear 25
47 Idle gear 25
48 Drive gear 20T
2A7
49 Pre-transfer drive pulley 32
50 Flange pulley 36
51 Roll winding drive belt
52 Drive tension pulley
53 Idle pulley 32/36
54 Idle gear 30
55 Middle roll winding clutch
56 Roll drive gear 16
57 Roll drive gear 40
58 Roll drive gear 26
59 Roll drive gear 26
60 Developer spiral roller gear 23
61 Cleaning section drive gear 25
62 Roll unit pulley
63 Roll unit belt
64 Drum tension pulley
65 Idle pulley 21
66 Roll unit pulley
67 Idle gear 40
68 Roll flange
69 Flange pulley 36
70 Pre-transfer drive pulley 32
71 Idle gear 30
72 Middle feed clutch
73 Developer gear 20
74 Idle gear 30
75 Duplex gear 32
76 Idle gear 25
77 Idle gear 25
78 Drive gear 20T
79 Pre-transfer drive pulley 32
80 Flange pulley 36
81 Roll winding drive belt
82 Drive tension pulley
83 Idle pulley 32/36
84 Idle gear 30
85 Lower roll winding clutch
86 Roll drive gear 16
87 Roll drive gear 40
88 Roll drive gear 26
89 Roll drive gear 26
90 Developer spiral roller gear 23
91 Cleaning section drive gear 25
92 Roll unit pulley
93 Roll unit belt
94 Drum tension pulley
95 Idle pulley 21
96 Roll unit pulley
97 Idle gear 40
98 Roll flange
99 Flange pulley 36
100 Pre-transfer drive pulley 32
101 Idle gear 30
102 Lower feed clutch
103 Developer gear 20
104 Idle gear 30
105 Duplex gear 32
106 Idle gear 25
107 Idle gear 25
108 Drive gear 20T
* 21 to 39 and 42 are present when the upper roll unit (optional) is installed.
1-1-9
2A7
(2) Drive system 2 (driven by the drum motor and fixing motor)
1 Drum motor gear 40
2 Drum drive pulley 17
3 Drum drive gear 40
4 Drum drive belt
5 Cleaning section drive pulley 36/22
6 Idle pulley 32
7 Drum drive pulley 40
8 Developing unit drive pulley 30
9 Developing unit drive belt
0 Idle pulley 32
! Main pulley 24/32
@ Drive tension pulley
# Pre-transfer drive belt
$ Transfer pulley 32
% Transfer gear 30
^ Pre-transfer drive pulley 32
Figure 1-1-7
& Transfer drive gear 32
* Drive tension pulley
( Cleaning section drive belt
) Fixing motor gear
⁄ Idle gear 21/72
¤ Idle gear 21/63
‹ Drum drive gear 40
› Gear 35
fi Eject idle gear 20
fl Idle gear 24
‡ Heat roller gear 42
° Idle gear 20
· Oil roller gear 16
‚ Idle gear 20
ΠEject idle gear 20
„ Eject roller gear 17
1-1-10
(3) Drive system 3 (driven by the main motor and toner motor)
2A7
1 Pre-transfer drive gear 22
2 Pre-transfer gear 30
3 Idle gear 20
4 Idle gear 20
5 Idle gear 20
6 Post-developing gear 25
7 Gear 18
8 Gear 17
9 Drum joint
0 Drum flange
! Roller mix gear
@ Registration gear 31
# Developer paddle gear
$ Developer roller gear
% Developing unit drive gear 25
^ Toner gear 34
& Toner motor gear 20
Figure 1-1-8
(4) Drive system 4 (driven by the original motor)
Figure 1-1-9
1 Original motor pulley
2 Original feed drive belt
3 Original feed pulley 40
4 Tension pulley 20
5 Original feed pulley 40
6 Original feed pulley 40
7 Eject pulley 26
8 Eject pulley 26
9 Original cover belt
1-1-11
2A7
1-2-1 Handling and storage of the drum
Use the following caution when handling the drum.
• When removing the drum from the main unit, make sure not to expose it to direct sunshine or strong lighting.
• Store the drum where the ambient temperature is kept between –20°C/–4°F and 40°C/104°F and humidity not higher than
85% RH. Sudden changes in temperature and humidity even within the permitted ranges should be avoided, too.
• Avoid atmosphere laden with substances that might chemically damage the drum surface.
• Never touch the drum surface with any object. Protect it from bare or gloved hands; if it is accidentally touched, or stained
with oil, clean it.
1-2-2 Storage of developer and toner
Store developer and toner in a cool, dark place free from direct sunlight or high humidity.
1-2-3 Handling of the heaters (for 120 V specifications only)
This copier is equipped with heaters to avoid condensation inside. These heaters can be individually turned on or off with a
switch. If plain paper or film is kept in the roll units and there is a risk of high humidity, keep their heaters on.
1-2-4 Paper
1. Acceptable paper
• From the upper roll unit*, middle roll unit and lower roll unit
Roll of plain paper (64 – 80 g/m
and inner diameter of 76 mm.
• From the bypass table
Sheet of plain paper (64 – 80 g/m
and length of 297 – 6000 mm.
Other types of paper than the above or stapled sheets of paper cannot be used. If paper is creased, folded or torn, cut
off that part before using.
* Optional
2. Storage of paper
Paper should be stored in a cool, dark place free from direct sunlight, high temperature or humidity. If it is not going to
be used for a long time, take paper out of the roll unit, put it in the original wrapping paper and seal. Vellum must be kept
in a sealed vinyl bag.
2
), vellum and film with a width of 210 – 920 mm, outer diameter of 180 mm maximum
2
), vellum and film of A0 – A4R size (36" × 48" – 81/2 × 11") or width of 210 – 920 mm
1-2-1
2A7
1-2-5 Installation environment
1. Temperature: 10°C – 35°C/50°F – 95°F
2. Humidity: 15% – 85% RH
3. Power source: 120 V AC, 13 A/220 – 240 V AC, 7 A
4. Power source frequency stability: 50 Hz ± 0.3%/60 Hz ± 0.3%
5. Installation location
• Avoid locations with direct sunlight or bright areas such as near windows or with strong lighting. Be sure to avoid letting
direct sunlight or strong light reach the photoconductor when removing jammed paper.
• Avoid locations with high temperature or humidity, low temperature or humidity, and areas with sudden changes in
temperature. Also avoid areas with hot or cold draughts.
• Avoid areas with excessive dust or vibration.
• Be sure that the platform or floor area can support the weight of the equipment.
• Locate on a flat, horizontal surface (maximum inclination of 0.3°).
• Avoid atmosphere laden with substances that might chemically damage the equipment or the photoconductor
(mercury, alkali or acid vapors, inorganic gases, gases such as NOx and SOx, and chlorine-based organic solvents).
• Choose a location with adequate ventilation.
6. There should be sufficient space for operation and maintenance of the equipment:
800 mm/31
1
/2" at front, 500 mm/1911/16" at right and 300 mm/1113/16" at rear and left.
A
B
C
D
A: 1555 mm/631/2"
3
B: 1205 mm/49
C: 1688 mm/68
D: 1073 mm/43
7
13
/16"
/8"
/16"
Figure 1-2-1 Installation measurements
1-2-2
1-3-1 Unpacking and installing the copier
(1) Installation procedure
Start
Unpack the copier.
Remove the retaining tapes. Attach the copy trays and copy tray support plates.
2A7
Attach the cleaning unit.
Set fixing pressure.
Attach the main unit support assemblies.
Adjust the horizontal level of the copier.
Adjust the position of the front covers.
Attach the safety switch actuators.
Set the developer.
Make the initial developer setting
(maintenance item U130).
Add toner.
Coat the cleaning blade with toner
(maintenance item U160).
Attach the original loop guide.
Make a test copy.
End
1-3-1
2A7
Unpack the copier.
1 Machine body
2 Copy trays
3 Roll flange
4 Main unit support assemblies
5 Copy tray support plates
6 Original loop guide
7 Hinge joints
8 M4 × 08 TP-A chrome screws
9 Top pad
0 Bottom pad
! Outer case
Figure 1-3-1 Copier package
@ Top case
# Top board
$ Props
% Skid
^ Dust cover
& Accessory case
* Pad sheet
( Air cap bag
) Air cap bag
⁄ Original cover spacers
¤ Air cap bag
‹ Air cap bag
› Barcode label
fi Vinyl bag
fl Polyethylene bag
‡ Instruction handbook
° Polyethylene bag
· Power cord (230/240 V)
‚ Safety switch actuators
ΠStopper labels
„ BVM3 × 05 cross-head
bronze binding screws
1-3-2
Remove the retaining tapes.
1. Remove the tape retaining the air cap bag.
2. Remove the two tapes retaining the power cord
and then the tape binding the cord. (For 120 V
specifications only)
3. Remove the retaining tape from each main unit
release lever.
4. Remove the four tapes retaining the front covers.
5. Remove the tape retaining the waste toner tank
cover.
2A7
Power cord
Air cap bag
Main unit
release lever
6. Remove the two tapes retaining the original
guide.
7. Pull the main unit release levers and open the
detachable unit.
8. Remove the two tapes retaining the original
cover.
9. Open the original cover and remove the pad.
10. Remove the two spacers from the original cover.
11. Remove the two tapes retaining the original
leading edge cover.
12. Close the detachable unit.
13. Open the front covers and remove the two tapes
from each magnet.
14. Pull out the middle roll unit and remove the tape
retaining the air cap bag with the original loop
guide inside.
15. Pull out the lower roll unit and remove the tape
retaining the air cap bag with the roll flange
inside.
16. Close the front covers.
Original cover spacer
Original guides
Magnets
Figure 1-3-2
Original leading edge coverOriginal cover
Original cover spacer
Magnets
Air cap bags
Figure 1-3-3
1-3-3
2A7
Attach the cleaning unit.
1. Pull the main unit release levers and open the
detachable unit.
2. Remove the screw from each of the right and left
cleaning unit retention stoppers.
3. Slide the right and left cleaning unit retention
stoppers inward and release the cleaning unit.
4. Move the right and left cleaning unit
retention stays from hole A to hole B on
each of the right and left side plates.
* When retaining the cleaning unit, take
care that your fingers are not caught by
the left and right cleaning unit retention
stoppers.
5. Connect the 9-pin connector to the
cleaning unit.
Screw
Cleaning unit
retention stoppers
Screw
Figure 1-3-4
B
B
A
Cleaning unit
A
Cleaning unit
retention stay
6. Secure the right and left cleaning unit
retention stoppers using one screw
removed in step 2 for each stopper.
9-pin connector
Figure 1-3-5
Screw
Cleaning unit retention sttopers
Screw
Figure 1-3-6
1-3-4
Set fixing pressure.
1. Set fixing pressure by rotating the fixing pressure
adjustment nuts at the front and rear of the fixing unit
clockwise until they are tight.
2A7
Fixing pressure adjustment nut
Fixing pressure
adjustment nut
2. Push in the main unit release levers until closing the
detachable unit.
Attach the main unit support assemblies.
1. Open the front covers.
2. Remove the screw retaining the main unit
support assembly cover.
3. Attach the main unit support assembly to
the lower right of the main unit using the
four M4 × 08 TP-A chrome screws.
4. Attach the main unit support assembly to
the lower left of the main unit in the same
way.
5. Rotate the nuts of the main unit support
assemblies and adjust the horizontal
level.
* Adjust the level with the casters of the
main unit off the floor.
M4 × 08 TP-A
chrome screws
Main unit support assembly
Figure 1-3-7
Screw
Cover
Stopper
label
M4 × 08 TP-A
chrome screws
Figure 1-3-8
1-3-5
2A7
Adjust the horizontal level of the unit.
1. Place three levels on the center, right and left of the contact glass and check that the unit is level in all directions.
2. After any leveling adjustments, reattach the main unit support assembly covers using one screw for each cover.
3. Attach the stopper labels to the covers of the right and left main unit support assemblies.
Adjusting the position of the front covers.
1. Open and close the front covers and check that
there are no problems.
2. In case of trouble, loosen the two screws on each of
the top and bottom hinges, adjust the front cover
position and then retighten the screws.
Attach the safety switch actuators.
Front cover
Top hinge
Figure 1-3-9
Screws
Screws
Bottom
hinge
1. Temporarily set the safety switch actuator onto the left
and right front covers using a BVM3 × 05 cross-head
bronze binding screw for each.
2. Adjust the positions of the safety switch actuators so
that the switches are turned on upon closing the front
covers, and then tighten the screws.
BVM3 × 05 cross-head
bronze binding screw
Safety switch
actuator
Front cover
Figure 1-3-10
1-3-6
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