Mita-Kyocera KM-C830, KM-C830D Service Manual
SERVICE
MANUAL
Published in Mar. ’03
842A6112
Revision2
CAUTION
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent
type recommended by the manufacturer. Dispose of used batteries according to the
manufacturer’s instructions.
CAUTION
Double-pole/neutral fusing.
Safety precautions
This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.
Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION:Bodily injury or damage to property may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.
1. Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. ............................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. .............................................................................................................................
CAUTION:
• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .....
• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..............
• Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. ..........................................................................................................................
• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........
• Always handle the machine by the correct locations when moving it. ..............................................
• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may
cause the copier to move unexpectedly or topple, leading to injury..................................................
• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is
accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention
immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain
medical attention. ..............................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. ........................................................................................................................
2. Precautions for Maintenance
WARNING
• Always remove the power plug from the wall outlet before starting machine disassembly...............
• Always follow the procedures for maintenance described in the service manual and other related
brochures. .........................................................................................................................................
• Under no circumstances attempt to bypass or disable safety features including safety
mechanisms and protective circuits. .................................................................................................
• Always use parts having the correct specifications...........................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related
brochure when replacing them. Using a piece of wire, for example, could lead to fire or other
serious accident. ...............................................................................................................................
• When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ...............................................................
• Always check that the copier is correctly connected to an outlet with a ground connection. ............
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If
it is dirty, clean it to remove the risk of fire or electric shock. ............................................................
• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ..............................................................................................................................
• Handle the charger sections with care. They are charged to high potentials and may cause
electric shock if handled improperly. .................................................................................................
CAUTION
• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections...........................................................
• Use utmost caution when working on a powered machine. Keep away from chains and belts. .......
• Handle the fixing section with care to avoid burns as it can be extremely hot. .................................
• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures...........................................................................................................
• Do not remove the ozone filter, if any, from the copier except for routine replacement....................
• Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. ......................................................................................................
• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. ..............................................................................................
• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........
• Remove toner completely from electronic components. ...................................................................
• Run wire harnesses carefully so that wires will not be trapped or damaged. ...................................
• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten
connector, trapped wire and missing screws. ..................................................................................
• Check that all the caution labels that should be present on the machine according to the
instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................
• Handle greases and solvents with care by following the instructions below: ....................................
· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
· Ventilate the room well while using grease or solvents.
· Allow applied solvents to evaporate completely before refitting the covers or turning the main
switch on.
· Always wash hands afterwards.
• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc...........................................................................................................................
• Should smoke be seen coming from the copier, remove the power plug from the wall outlet
immediately. ......................................................................................................................................
3. Miscellaneous
WARNING
• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than
the specified refiner; it may generate toxic gas. ................................................................................
CONTENTS
1-1 Specifications
1-1-1 Specifications ....................................................................................................................................... 1-1-1
1-1-2 Parts names ......................................................................................................................................... 1-1-3
(1) Copier ............................................................................................................................................. 1-1-3
(2) Operation panel .............................................................................................................................. 1-1-4
1-1-3 Machine cross section .......................................................................................................................... 1-1-5
1-2 Handling Precautions
1-2-1 Drum .................................................................................................................................................... 1-2-1
1-2-2 Developer and toner ............................................................................................................................. 1-2-1
1-2-3 Installation environment ....................................................................................................................... 1-2-1
1-3 Installation
1-3-1 Unpacking and installation ................................................................................................................... 1-3-1
(1) Installation procedure ..................................................................................................................... 1-3-1
1-3-2 Setting initial copy modes .................................................................................................................. 1-3-22
1-3-3 Copier management ........................................................................................................................... 1-3-23
(1) Using the copier management mode ............................................................................................ 1-3-23
(2) Setting department management items ........................................................................................ 1-3-24
(3) Copy default ................................................................................................................................. 1-3-25
(4) Machine default ............................................................................................................................ 1-3-27
(5) Language ...................................................................................................................................... 1-3-29
1-3-4 Installing the key counter (option) ...................................................................................................... 1-3-30
1-3-5 Installing the bar code reader (option) ............................................................................................... 1-3-32
1-3-6 Installing the document finisher (option) ............................................................................................ 1-3-34
1-3-7 Installing the memory copy board/network scanner board (option) ................................................... 1-3-45
1-3-8 Installing the printer board (option) .................................................................................................... 1-3-49
1-3-9 Installing the Fax kit (option) .............................................................................................................. 1-3-51
1-3-10 Installing the paper feeder (option) .................................................................................................... 1-3-57
2A6
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 ............................................................................................ 1-4-5
1-5 Troubleshooting
1-5-1 Paper misfeed detection ...................................................................................................................... 1-5-1
(1) Paper misfeed indication ................................................................................................................ 1-5-1
(2) Paper misfeed detection conditions ................................................................................................ 1-5-3
(3) Paper misfeeds ............................................................................................................................. 1-5-14
1-5-2 Self-diagnosis ..................................................................................................................................... 1-5-25
(1) Self-diagnostic function ................................................................................................................ 1-5-25
(2) Self-diagnostic codes ................................................................................................................... 1-5-26
1-5-3 Image formation problems ................................................................................................................. 1-5-52
(1) No image appears (entirely white). ............................................................................................... 1-5-53
(2) No image appears (entirely black). ............................................................................................... 1-5-54
(3) Dirty on the top edge. ................................................................................................................... 1-5-54
(4) Dirty on the back side. .................................................................................................................. 1-5-55
(5) Image is too light. ......................................................................................................................... 1-5-55
(6) Background is visible. ................................................................................................................... 1-5-56
(7) A white line appears longitudinally. .............................................................................................. 1-5-56
(8) A black line appears longitudinally. .............................................................................................. 1-5-57
(9) Oily streaks appears at the top of the page longitudinally. ........................................................... 1-5-57
(10) A black line appears laterally. ....................................................................................................... 1-5-57
1-1-1
2A6-1
(11) One side of the copy image is darker than the other. ................................................................... 1-5-58
(12) Black dots appear on the image. .................................................................................................. 1-5-58
(13) Image is blurred. ........................................................................................................................... 1-5-58
(14) The leading edge of the image is consistently misaligned with the original. ................................ 1-5-59
(15) Paper creases. ............................................................................................................................. 1-5-59
(16) Offset occurs. ............................................................................................................................... 1-5-59
(17) Image is partly missing. ................................................................................................................ 1-5-60
(18) Fixing is poor. ............................................................................................................................... 1-5-60
(19) Image is out of focus. ................................................................................................................... 1-5-60
(20) Image center does not align with the original center. ................................................................... 1-5-61
(21) Blurred image occurs. ................................................................................................................... 1-5-61
(22) Carrier sticking occurs. ................................................................................................................. 1-5-61
(23) A black bar occurs near the center. ........................................................................................... 1-5-61-1
(24) Several horizontal broken streaks occur. .................................................................................. 1-5-61-1
1-5-4 Electrical problems ............................................................................................................................. 1-5-62
(1) The machine does not operate when the main switch is turned on. ............................................. 1-5-62
(2) The main drive motor does not operate (C2000). ......................................................................... 1-5-62
(3) The paper feed motor does not operate (C2500). ........................................................................ 1-5-62
(4) The fuser unit drive motor does not operate. ................................................................................ 1-5-63
(5) The black developer drive motor does not operate (C2101). ....................................................... 1-5-63
(6) The color developers drive motor does not operate (C2102). ...................................................... 1-5-63
(7) The upper intermediate feed motor does not operate. ................................................................. 1-5-63
(8) The lower intermediate feed motor does not operate. .................................................................. 1-5-64
(9) The duplexer drive motor does not operate. ................................................................................. 1-5-64
(10) The yellow toner feed motor does not operate. ............................................................................ 1-5-64
(11) The magenta toner feed motor does not operate. ........................................................................ 1-5-64
(12) The cyan toner feed motor does not operate. .............................................................................. 1-5-64
(13) The black toner feed motor does not operate. .............................................................................. 1-5-64
(14) The face-down unit fan motor does not operate. .......................................................................... 1-5-65
(15) The power supply unit fan motor does not operate. ..................................................................... 1-5-65
(16) The main controller box fan motor does not operate. ................................................................... 1-5-65
(17) The fuser unit fan motor does not operate. .................................................................................. 1-5-65
(18) Paper conveying fan motor 1 or 2 does not operate. ................................................................... 1-5-65
(19) The scanner motor does not operate. .......................................................................................... 1-5-65
(20) The scanner unit fan motor does not operate. .............................................................................. 1-5-65
(21) The electric component unit fan motor does not operate. ............................................................ 1-5-65
(22) The paper feed clutch does not operate. ...................................................................................... 1-5-66
(23) The bypass paper feed clutch does not operate. ......................................................................... 1-5-66
(24) The registration clutch does not operate. ..................................................................................... 1-5-66
(25) The yellow developer drive clutch does not operate. ................................................................... 1-5-66
(26) The magenta developer drive clutch does not operate. ............................................................... 1-5-67
(27) The cyan developer drive clutch does not operate. ...................................................................... 1-5-67
(28) The black developer drive clutch does not operate. ..................................................................... 1-5-67
(29) The duplexer feed clutch does not operate. ................................................................................. 1-5-67
(30) The duplexer refeed clutch does not operate. .............................................................................. 1-5-68
(31) The secondary transfer unit shift clutch does not operate. ........................................................... 1-5-68
(32) The cleaning brush unit drive clutch does not operate. ................................................................ 1-5-68
(33) Transfer charging is not performed. ............................................................................................. 1-5-68
(34) The yellow developer magnet solenoid does not operate. ........................................................... 1-5-68
(35) The magenta developer magnet solenoid does not operate. ....................................................... 1-5-69
(36) The cyan developer magnet solenoid does not operate. .............................................................. 1-5-69
(37) The black developer magnet solenoid does not operate. ............................................................. 1-5-69
(38) The cleaning brush unit shift solenoid does not operate. ............................................................. 1-5-69
(39) The bypass tray bottom plate solenoid does not operate. ............................................................ 1-5-70
(40) The face up/down solenoid does not operate. .............................................................................. 1-5-70
(41) The oil roller up/down solenoid does not operate. ........................................................................ 1-5-70
(42) The duplex paper exit selection solenoid does not operate. ........................................................ 1-5-70
(43) The cleaning lamp does not turn on. ............................................................................................ 1-5-71
(44) The exposure lamp does not turn on. ........................................................................................... 1-5-71
(45) The exposure lamp does not turn off. ........................................................................................... 1-5-71
1-1-2
2A6-1
(46) The fuser heater does not turn on. ............................................................................................... 1-5-71
(47) The fuser heater does not turn off. ............................................................................................... 1-5-71
(48) Main charging is not performed. ................................................................................................... 1-5-72
(49) Transfer charging is not performed. ............................................................................................. 1-5-72
(50) No developing bias is output. ....................................................................................................... 1-5-72
(51) The original size is not detected. .................................................................................................. 1-5-72
(52) The original size is not detected correctly. ................................................................................... 1-5-72
(53) The message requesting paper to be loaded is shown when paper is present on
the bypass tray. ............................................................................................................................ 1-5-72
(54) The size of paper on the bypass tray is not displayed correctly. .................................................. 1-5-72
(55) A paper jam in the paper feed, paper conveying or fuser section is indicated
when the main switch is turned on. .............................................................................................. 1-5-73
(56) The message requesting cover to be closed is displayed when the front cover is closed. .......... 1-5-73
(57) Others. .......................................................................................................................................... 1-5-73
1-5-5 Mechanical problems ......................................................................................................................... 1-5-74
(1) No primary paper feed. ................................................................................................................. 1-5-74
(2) No secondary paper feed. ............................................................................................................ 1-5-74
(3) Skewed paper feed. ...................................................................................................................... 1-5-74
(4) The scanner does not travel. ........................................................................................................ 1-5-74
(5) Multiple sheets of paper are fed at one time.................................................................................. 1-5-74
(6) Paper jams. .................................................................................................................................. 1-5-74
(7) Toner drops on the paper conveying path. ................................................................................... 1-5-75
(8) Abnormal noise is heard. .............................................................................................................. 1-5-75
1-6 Assembly and Disassembly
1-6-1 Precautions for assembly and disassembly ......................................................................................... 1-6-1
(1) Precautions ..................................................................................................................................... 1-6-1
(2) Running a maintenance item .......................................................................................................... 1-6-2
1-6-2 Paper feed section ............................................................................................................................... 1-6-3
(1) Detaching and refitting the bypass tray unit ................................................................................... 1-6-3
(2) Detaching and refitting the bypass feed roller and bypass retard roller ......................................... 1-6-5
(3) Detaching and refitting the face-down unit ..................................................................................... 1-6-6
(4) Detaching and refitting the drive assembly B ................................................................................. 1-6-8
(5) Detaching and refitting the drive assembly A ................................................................................. 1-6-8
(6) Detaching and refitting the paper conveying belts .......................................................................... 1-6-9
(7) Detaching and refitting the paper conveying fan motors 1 and 2 ................................................. 1-6-10
(8) Detaching and refitting the upper and lower registration rollers ................................................... 1-6-11
(9) Detaching and refitting the middle roller ....................................................................................... 1-6-12
(10) Adjustment after roller and clutch replacement ............................................................................ 1-6-13
(10-1) Adjusting the leading edge registration of image printing .................................................... 1-6-13
(10-2) Adjusting the center line of image printing ........................................................................... 1-6-14
(10-3) Adjusting the margins for printing ........................................................................................ 1-6-15
(10-4) Adjusting the amount of slack in the paper .......................................................................... 1-6-16
1-6-3 Optical section .................................................................................................................................... 1-6-17
(1) Detaching and refitting the exposure lamp ................................................................................... 1-6-17
(2) Detaching and refitting the scanner wires .................................................................................... 1-6-19
(2-1) Detaching the scanner wires ............................................................................................... 1-6-19
(2-2) Fitting the scanner wires ...................................................................................................... 1-6-23
(3) Detaching and refitting the ISU (reference) .................................................................................. 1-6-28
(4) Detaching and refitting the original size detection switch ............................................................. 1-6-29
(5) Detaching and refitting the laser scanner unit .............................................................................. 1-6-30
(6) Adjusting magnification of the scanner in the main scanning direction ........................................ 1-6-32
(7) Adjusting magnification of the scanner in the auxiliary scanning direction ................................... 1-6-33
(8) Adjusting the scanner leading edge registration ........................................................................... 1-6-34
(9) Adjusting the scanner center line ................................................................................................. 1-6-35
(10) Adjusting the margins for scanning an original on the contact glass ............................................ 1-6-36
1-6-4 Main charger unit ............................................................................................................................... 1-6-37
(1) Detaching and refitting the main charger unit ............................................................................... 1-6-37
(2) Detaching and refitting the main charger grid ............................................................................... 1-6-37
1-1-3
2A6
1-6-5 Drum section ...................................................................................................................................... 1-6-38
(1) Detaching and refitting the drum unit ............................................................................................ 1-6-38
1-6-6 Primary transfer section ..................................................................................................................... 1-6-39
(1) Detaching and refitting the primary transfer unit ........................................................................... 1-6-39
(2) Detaching and refitting the cleaning brush unit ............................................................................ 1-6-39
1-6-7 Developing section ............................................................................................................................. 1-6-40
(1) Detaching and refitting the developers ......................................................................................... 1-6-40
(2) Detaching and refitting the waste toner duct assembly ................................................................ 1-6-42
(3) Detaching and refitting the black toner feed assembly ................................................................. 1-6-43
(4) Detaching and refitting the black toner container feed assembly ................................................. 1-6-43
(5) Detaching and refitting the black toner feed drive assembly ........................................................ 1-6-44
1-6-8 Secondary transfer section ................................................................................................................ 1-6-45
(1) Detaching and refitting the transfer roller and the separation charger unit ................................... 1-6-45
(2) Detaching and refitting the secondary transfer unit shift clutch .................................................... 1-6-47
1-6-9 Fuser section ...................................................................................................................................... 1-6-48
(1) Detaching and refitting the fuser unit ............................................................................................ 1-6-48
(2) Detaching and refitting the fuser top cover and upper separator bracket ..................................... 1-6-48
(3) Detaching and refitting the upper and lower fuser thermistors ..................................................... 1-6-50
(4) Detaching and refitting the upper and lower thermostats ............................................................. 1-6-52
(5) Detaching and refitting the upper and lower heater lamps ........................................................... 1-6-53
(6) Detaching and refitting the heat roller and the press/heat roller ................................................... 1-6-54
(7) Detaching and refitting the separators of lower separator bracket ............................................... 1-6-58
(8) Detaching and refitting the drive assembly C ............................................................................... 1-6-59
1-6-10 PCBs .................................................................................................................................................. 1-6-60
(1) Detaching and refitting the scanner main PCB ............................................................................. 1-6-60
(2) Detaching and refitting the engine controller PCB ........................................................................ 1-6-61
(3) Detaching and refitting the power supply unit ............................................................................... 1-6-62
(4) Detaching and refitting the developing/cleaning brush bias high voltage PCB ............................ 1-6-64
(5) Detaching and refitting the main charger high voltage unit .......................................................... 1-6-65
(6) Detaching and refitting the separation charger high voltage PCB ................................................ 1-6-66
(7) Detaching and refitting the paper feeder/options relay PCB ........................................................ 1-6-68
(8) Detaching and refitting the transfer roller bias high voltage PCB ................................................. 1-6-68
1-7 Requirements on PCB Replacement
1-7-1 Upgrading the firmware ........................................................................................................................ 1-7-1
1-7-2 Adjustment-free variable resisters (VR) ............................................................................................... 1-7-3
2-1 Mechanical construction
2-1-1 Paper feed unit and transfer unit .......................................................................................................... 2-1-1
(1) Paper feed unit ............................................................................................................................... 2-1-1
(2) Secondary transfer unit .................................................................................................................. 2-1-4
2-1-2 Bypass tray unit .................................................................................................................................... 2-1-5
2-1-3 Scanner unit ......................................................................................................................................... 2-1-7
2-1-4 Developing section ............................................................................................................................. 2-1-11
(1) Yellow developer .......................................................................................................................... 2-1-12
(2) Magenta developer ....................................................................................................................... 2-1-15
(3) Cyan developer ............................................................................................................................ 2-1-18
(4) Black developer ............................................................................................................................ 2-1-21
(5) Transition of toner for development .............................................................................................. 2-1-25
2-1-5 Drum unit and main charger unit ........................................................................................................ 2-1-26
(1) Drum unit ...................................................................................................................................... 2-1-26
(2) Main charger unit .......................................................................................................................... 2-1-30
2-1-6 Primary transfer unit ........................................................................................................................... 2-1-31
(1) Primary transfer unit ..................................................................................................................... 2-1-31
(2) Cleaning brush unit ....................................................................................................................... 2-1-31
2-1-7 Fuser unit ........................................................................................................................................... 2-1-36
2-1-8 Face-down tray unit ............................................................................................................................ 2-1-39
1-1-4
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1
(1) Main frame front, face-down unit and bypass tray unit ................................................................... 2-2-1
(2) Developers, drum unit and main charger unit ................................................................................. 2-2-3
(3) Primary transfer, secondary transfer, paper feeder and fuser units ............................................... 2-2-5
(4) Main frame rear and controller box ................................................................................................. 2-2-7
(5) Scanner unit, electric component unit and operation unit ............................................................... 2-2-9
2-3 Operation of the PCBs
2-3-1 Power source PCB ............................................................................................................................... 2-3-1
2-3-2 Engine controller PCB .......................................................................................................................... 2-3-4
2-3-3 Scanner main PCB ............................................................................................................................. 2-3-13
2-3-4 Operation unit PCB ............................................................................................................................ 2-3-27
2-3-5 CCD PCB ........................................................................................................................................... 2-3-29
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
Maintenance parts list..................................................................................................................................... 2-4-6
Maintenance kits............................................................................................................................................. 2-4-6
General wiring diagram (1) ............................................................................................................................. 2-4-9
General wiring diagram (2) ........................................................................................................................... 2-4-10
2A6
1-1-5
1-1-1 Specifications
Type ............................................... Desktop
Copying system.............................. Indirect electrostatic, intermediate transfer drum
Originals ......................................... Sheets of paper, books and 3-dimensional objects
Maximum size: A3/11" × 17"
Original feed system ...................... Fixed
Copy paper .................................... Drawer: Plain paper (64 – 90 g/m
Bypass table: Plain paper (60 – 220 g/m
Special paper: Transparencies, tracing paper, colored paper, letterhead
and envelopes (when using the printer function only)
Note: Use the bypass table for special paper.
Copying sizes ................................. Maximum: A3/11" × 17"
1
Minimum: A6R/5
/2" × 81/2" (When the bypass table is used)
Magnification ratios ........................ Manual mode: 25 – 400%, 1% increments
Auto copy mode: fixed ratios
Metric
1:1 ± 1.0%, 1:4.00/1:2.00/1:1.41/1:1.15/1:0.81/1:0.70/1:0.50/1:0.25
Inch
1:1 ± 1.0%, 1:4.00/1:2.00/1:1.29/1:1.21/1:0.78/1:0.64/1:0.50/1:0.25
Copy speed ....................................At 100% magnification in copy mode:
A3/11" × 17": 4 copies/15 copies per min. [Color/Monochrome]
1
/2" × 11": 4 copies/15 copies per min. [Color/Monochrome]
A4R/8
A4/11" × 8
A5/5
1
/2": 8 copies/30 copies per min. [Color/Monochrome]
1
/2" × 81/2": 8 copies/30 copies per min. [Color/Monochrome]
First copy time ................................ Approx. 22 s/10.8 s [Color/Monochrome]
Warm-up time................................. Within 300 s (room temperature 20°C/68°F, 65% RH)
Paper feed system ......................... Automatic feeding from drawers (Duplex copiers: 2 drawers, Simplex copiers: 1
drawer; each with a 500 sheet capacity [75 – 90 g/m
Bypass table (150 sheet capacity [75 – 90 g/m
Paper eject system ........................ Face-down tray: 250 sheets
Face-up tray: 150 sheets
Continuous copying ....................... 1 - 999 sheets
Photoconductor ..............................a-Si (drum diameter 80 mm)
Charging system ............................ Single positive corona charging
Exposure light source .................... Semiconductor laser
Exposure scanning system ............ Polygon mirror
Developing system ......................... Dry, reverse developing (magnetic brush)
Developer: 2-component
Toner replenishing: automatic from a toner container
Transfer system ............................. Primary: Intermediate transfer drum (diameter 160 mm)
Secondary: Transfer roller
Separation system ......................... AC corona separation charging
Fixing system ................................. Heat roller and press/heat roller (soft type, diameter 45 mm)
Heat source: 2 halogen heaters (500 W)
Control temperature: 185°C/365°F (at normal ambient temperature)
Abnormally high temperature protection device: thermostat
Charge erasing system .................. Exposure by cleaning lamp (LED array)
Cleaning system ............................ Drum: Cleaning blade
Primary (intermediate) transfer drum: Fur brush
Scanning system ............................ Flat bed scanning by CCD image sensor
Resolution ...................................... 600 × 600 dpi
Light source ................................... Rare gas lamp
Dimensions .................................... 590 (W) × 585 (D) × 853 (H) mm
1
/4" (W) × 231/16" (D) × 339/16" (H)
23
Weight ............................................ Approx. 115 kg/253 lbs. (Simplex copier with the optional paper feeder installed)
Floor requirements .........................1288 (W) × 585 (D) mm
11
/16" (W) × 231/16" (D)
50
2
)
2
)
2
]) or manual feed from the
2
])
2A6
1-1-1
2A6
Functions........................................ Self-diagnosis function, preheat function, auto exposure adjustment function,
original size detection function, auto paper selection mode, original mode,
mono-color mode, auto color original detection function, color image quality
adjustment function, auto magnification selection mode, zoom mode,
preset zoom mode, XY zoom mode, interrupt copying, 2-sided copy modes*1,
*2
page separation modes, margin mode
mirror image mode, print page numbers mode
*2
mode
, presentation mode*2, insert sheet modes*2, layout modes*2,
booklet mode (sheet originals)
*2
BW/Selection mode
, poster mode*2, program function, recall function, sort mode*2,
copy management function
*1
, booklet mode (book originals)*1,
*2
, language selection function
, border erase modes*2, invert mode,
*2
, transparency + backing sheet
*1: Only available in duplex copiers
*2: Requires the optional memory copy board in simplex copiers
Power source ................................. 120 V AC, 60 Hz, 12.0 A
220 – 240 V AC, 50/60 Hz, 6.0 A
Power consumption ....................... Maximum rated power consumption 1260 W
Options ........................................... DF, Paper feeder, Document Finisher, Memory Copy Board*, Casters, Key Counter,
Printer Board, Fax Kit (only available in inch specification copiers), Network Scanner
Board, Bar Cord Reader
*: Standard equipment in duplex copiers
1-1-2
1-1-2 Parts names
(1) Copier
2A6
1
2
3
—
8
9
56 7 # $ %
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(
›
fi
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⁄
‡
‚
1 Original cover
2 Operation panel
3 Main switch
4 Toner container (black)
5 Toner container (yellow)
6 Toner container (magenta)
7 Toner container (cyan)
8 Conveying cover
9 Face-up tray
0 Primary transfer unit release lever
! Primary transfer unit
@ Waste toner tank
# Oil roller unit
$ Paper feed unit
% Paper feed unit release lever
^ Original size indicator lines
‹
Figure 1-1-1
& Platen
* Face-down tray
( Front cover
) Bypass tray
⁄ Bypass extension
¤ Insert guides
‹ Drawer 2
› Drawer 1 (in simplex copiers)
fi Paper length guide release levers
fl Paper width guide release levers
‡ Side cover
— Handles for transport
· Paper size indicator
‚ Paper size indicator (in simplex copiers)
·
Duplex unit (in duplex copiers)
Duplex unit indicator (in duplex copiers)
1-1-3
2A6
(2) Operation panel
• Inch specifications
1 2 3 45 678 9 0! @#
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• Metric specifications
1 2 3 45 678 9 0! @#
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1 Punch key
2 Program key
3 */Language key
4 Auto selection key (Indicator)
5 Book mode key (Indicator)
6 Printer attention indicator
7 Printer ready indicator
8 Printer data indicator
9 Message display
0 Energy saver key (Indicator)
! Interrupt key (Indicator)
@ Stop/Clear key
# Reset key
$ Sort key/Sort indicator/Group
indicator
)
⁄ ¤‹›fifl‡°·‚Œ „ ˇ ¨
Figure 1-1-2
% Transparency film/Card stock
key (indicator)
^ Layout key (Indicator)
& Duplex/Page separation key
(Indicator)
* Digital editing key (Indicator)
( Auto exp. key (Indicator)
) Preset R/E key
⁄ Copy exposure adjustment keys
(Indicators)
¤ Manual key
‹ Original image type key
› Original key
fi Color edit key (Indicator)
fl Paper select key
´‰ Á
‡ Left cursor key/Zoom(-)
— Down cursor key
· Up cursor key
‚ Right cursor key/Zoom(+)
ΠEnter key
„ Numeric keys
´ Black & white key
‰ Full color key
ˇ Start key
Á A.C.S. key
¨ Copier key
1-1-4
1-1-3 Machine cross section
2A6
%
^
&
7
6
543
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$ 298
Figure 1-1-4 Machine cross section
1 Bypass tray unit
2 Paper feed unit
3 Laser scanner unit
4 Main charger unit
5 Drum unit
6 Yellow developer and yellow toner container
7 Magenta developer and magenta toner container
8 Cyan developer and cyan toner container
9 Black developer
@
#
0 Black toner container
! Primary transfer unit
@ Cleaning brush unit
# Secondary transfer unit
$ Fuser unit
% Face-down unit
^ Scanner unit
& Electrical component unit
1-1-5
1-2-1 Drum
Note the following when handling or storing the drum.
• When removing the drum unit, never expose the drum surface to strong direct light.
• Keep the drum at an ambient temperature between -20°C/-4°F and 40°C/104°F and at a relative humidity not higher
than 85% RH. Avoid abrupt changes in temperature and humidity.
• Avoid exposure to any substance which is harmful to or may affect the quality of the drum.
• Do not touch the drum surface with any object. Should it be touched by hands or stained with oil, clean it.
1-2-2 Developer and toner
Store the developer and toner in a cool, dark place. Avoid direct light and high humidity.
1-2-3 Installation environment
1. Temperature: 10 - 32.5°C/50 - 90.5°F
2. Humidity: 20 - 80%RH
3. Power supply: 120 V AC, 12.0 A
4. Power source frequency: 50 Hz ±0.3%/60 Hz ±0.3%
5. Installation location
• Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or other
strong light when removing paper jams.
• Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directed onto
the machine.
• Avoid dust and vibration.
• Choose a surface capable of supporting the weight of the machine.
• Place the machine on a level surface (maximum allowance inclination: 1° ).
• Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor, such as
mercury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.
• Select a room with good ventilation.
6. Allow sufficient access for proper operation and maintenance of the machine.
Machine front: 600 mm/23
Machine right: 500 mm/1911/16" Machine left: 500 mm/1911/16"
220 - 240 V AC, 6.0 A
5
/8" Machine rear: 300 mm/1113/16"
2A6
f
e
b
c
9
a: 853 mm/33
/16"
b: 590 mm/231/4"
d
a
c: 585 mm/23"
Figure 1-2-1 Installation dimensions
1-2-1
1-3-1 Unpacking and installation
(1) Installation procedure
Start
Unpack.
Removing the tapes (drawer)
Attaching the casters (option)
Joining the copier and paper feeder(s).
Fixation of the copier.
2A6
Installing the secondary transfer unit.
Installing the waste toner tank.
Installing the desk stay covers and
attaching the labels.
Removing the tapes (copier).
Remove the pins holding light source units 1 and 2.
Installing the fuser unit and the oil roller unit.
Securing the heat and press/heat rollers.
Installing the four developers.
Installing the toner containers.
Attaching the accessories.
Installing the original cover or the DF (option).
Connect the power cord.
Setting the time zone (maintenance item U 209).
Adjusting the image
(maintenance item U 034 and U410).
Completion of the machine installation.
1-3-1
2A6
Moving the machine
When moving the machine during installation, pull out the four handles for transport on the right and left sides and hold
them.
Handles for transport
1-3-2
Figure 1-3-1
Unpack.
„
2A6
ÒÔÓ
ˆ
1
Áˇ
3
2
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Ú
¨
$
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5
˝
Í
Î
Ï
6
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9
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1 Copier
2 Machine cover
3 Bottom left pad
4 Bottom right pad
5 Upper left pad
6 Uper right pad
7 Skid
8 Hinge joints
9 Lower scanner spacer
0 Outer case
! Inner frame (inside)
@ Innre frame (outside)
# Bar code labels
$ Eject spacer
% developer lower spacers
^ developer spacer
& Cyan developer
4
7
Figure 1-3-2 Unpacking
* Plastic bag
( Magenta developer
) Plastic bag
⁄ Yellow developer
¤ Plastic bag
‹ Operation guide
› Caution label
fi Paper size indication plates
fl Plastic bag
‡ Black developer
— Plastic bag
· Secondary transfer unit
‚ Plastic bag
ΠT/C pad
„ Oil roller unit set
´ Power cord
‰ Power cord spacer
ˇ Fuser unit
Á Plastic bag
¨ Waste toner tank
ˆ Fuser unit spacer
Ø Duct cover spacer
” Filter duct
Å Plastic bag
Í Junction plate
Î M3 × 8 binding tap tight screw
Ï M3 × 4 binding tap tight screw
˝ Plastic bag
Ó Shield gaskets*
Ô Function key (for printer)
Æ Function key (for scanner)
Ò Function key (for fax)*
Ú Plastic bag
*1: 220-230 V specifications only.
*2: 120 V specifications only.
1
2
1-3-3
2A6
Removing the tapes (drawer).
1. Pull upper and lower drawers out and remove the
tape holding each of the drawer lift.
Remove the paper size indication plate.
Drawer lift
Paper size indication plate
Figure 1-3-3
Attaching the casters (option).
Caution:To prevent the copier from tipping over,
the optional caster kit must be installed
when the copier is installed with an
optional paper feeder.
1. Stand the 500 × 2 paper feeder /duplex paper
feeder/optional paper feeder upright on its left
side.
2. Remove each one screw to remove four rubber
pads.
3. Install two optional caster bases onto the bottom
of the paper feeder by using four screws for each.
Be sure to face the longer end towards the front
of the paper feeder.
Caster bases
Screw
Screws
1-3-4
Screws
Figure 1-3-4
Fitting the shield gaskets
(220-240 V specifications only)
1. Remove the release coated paper of the doublefaced tape located on the rear face of the shield
gaskets.
2. Stick two shield gaskets to the top surface of the
paper feeder as shown in the diagram.
* When installing an optional paper feeder, be
sure to fit also two shield gaskets to the optional
paper feeder.
2A6
Shielded gasket
Figure 1-3-5
1-3-5
2A6
Junction plate
Binding tap tight screw
M4 × 8
Joining the copier and paper feeder(s).
1. When installing the optional paper feeder, stack
and join 500 × 2 or duplex paper feeder and
optional paper feeder using the clamp.
Clamp
2. Place the copier on top of the 500 × 2 or duplex
paper feeder.
3. Join the copier and 500 × 2 or duplex paper
feeder with the junction plate using the binding
tap tight screw M4 × 8.
Figure 1-3-6
Figure 1-3-7
1-3-6
Fixation of the copier.
1. Turn the adjusters to adjust the level of the
overall machine.
Caution:To prevent the possibility of accidents
due to tilting the copier body, turn the
adjusters until they make firm contact
with the floor.
2A6
Ajuster
Figure 1-3-8
Installing thedesk stay covers and attaching the labels.
1. Attach the two desk stay covers to the front part
of the two caster stays using the two M4 × 8
chrome screws (1 screw for each cover).
Desk stay
cover
Caster bases
M4 × 8 chrome screws
Desk stay
cover
Figure 1-3-9
1-3-7
2A6
2. Attach the four labels at the locations shown in
the diagram.
Labels
Labels
Figure 1-3-10
3. Attach the caution label at the shown in the
diagram.
Caution label
Figure 1-3-11
1-3-8
Removing the tape (copier).
1. Remove the tape holding the front cover and
face-up tray.
2. Remove the tape holding the bottom of the faceup tray.
3. Remove the three tapes holding the pins for light
source units 1 and 2.
2A6
Light source unit 1 pins
Light source unit
2 pin
Face-up tray
Front cover
Figure 1-3-12
4. Remove the tape holding the original detection
switch.
5. Remove the tape holding the lower scanner
spacer and then remove the spacer.
6. Open the bypass table and remove the paper.
Original detection switch
Lower scanner
spacer
Bypass tray
Figure 1-3-13
1-3-9
2A6
Remove the pins holding light source units 1 and 2.
1. Remove the two pins for light source unit 1 and
the pin for light source unit 2.
Installing the fuser unit and the oil roller unit.
1. Open the front cover.
2. Pull out thoroughly the paper feed unit.
Light source unit 1 pins
Light source unit 2 pin
Figure 1-3-14
Original detection switch
Lower scanner
spacer
1-3-10
Bypass tray
Figure 1-3-15
3. Open the left paper guide by pulling down the
Left paper guide
Fuser unit
Binding tap tight screw
M3 × 8
green-colored handle.
4. Insert the fuser unit onto the paper feed unit.
5. Secure the fuser unit with the binding tap tight
screw M3 × 8.
2A6
6. Remove the oil seal tapes at both ends of the oil
roller unit.
7. Take out the oil roller unit from the case.
Oil seal tape
Figure 1-3-16
Oil seal tape
Oil roller unit
Oil roller unit
Case
Figure 1-3-17
1-3-11
2A6
8. Install the oil roller unit onto the fuser unit until it
is locked at both ends.
Oil roller unit
Figure 1-3-18
Securing the heat and press/heat rollers.
1. Open the fuser top cover by lowering the lock
buttons.
2. Firmly tighten two screws until they stop.
3. Close the left paper guide.
Lock button
Lock button
Fuser top cover
Screws
1-3-12
Figure 1-3-19
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