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

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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

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(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

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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

/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

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

/8" (W) × 251/8" (D) × 477/16" (H)

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)

/8" (W) × 301/2" (D) (523/8" (H) × 5115/16 (D) with full options)

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

/4" or less

)

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

Œ Roll 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) Œ Numeric 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

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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

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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

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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

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(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 Œ Eject idle gear 20 „ Eject roller gear 17

1-1-10

(3) Drive system 3 (driven by the main motor and toner motor)

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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

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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.

), vellum and film with a width of 210 – 920 mm, outer diameter of 180 mm maximum

), vellum and film of A0 – A4R size (36" × 48" – 81/2 × 11") or width of 210 – 920 mm

1-2-1

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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

/2" at front, 500 mm/1911/16" at right and 300 mm/1113/16" at rear and left.

A: 1555 mm/631/2"

B: 1205 mm/49 C: 1688 mm/68 D: 1073 mm/43

/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.

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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

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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 Œ Stopper 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.

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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

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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

Cleaning unit

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.

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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

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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

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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