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KM-1620
SERVICE MANUAL
Published in Oct. '03 842C9112 Revision 2
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. ................................................................................
2C9-1
CONTENTS
1-1 Specifications
1-1-1 Specifications ....................................................................................................................................... 1-1-2 Parts names and their functions ........................................................................................................... (1) Copier ............................................................................................................................................. (2) Operation panel .............................................................................................................................. 1-1-3 Machine cross section .......................................................................................................................... 1-1-4 Drive system ........................................................................................................................................ 1-1-1 1-1-3 1-1-3 1-1-4 1-1-5 1-1-6
1-2 Handling Precautions
1-2-1 Drum .................................................................................................................................................... 1-2-1 1-2-2 Toner .................................................................................................................................................... 1-2-1 1-2-3 Installation environment ....................................................................................................................... 1-2-2
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 .................................................................................................................... 1-3-5 1-3-3 Installing the paper feeder (option) ...................................................................................................... 1-3-6 1-3-4 Installing the DP (option) ...................................................................................................................... 1-3-8 1-3-5 Installing the duplex unit (option) ....................................................................................................... 1-3-11 1-3-6 Installing the drawer heater (option) ................................................................................................... 1-3-14 1-3-7 Installing the key counter (option) ...................................................................................................... 1-3-17
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 1-4-2 Copier management ........................................................................................................................... 1-4-45 (1) Using the copier management mode ............................................................................................ 1-4-45 (2) Setting department management items ........................................................................................ 1-4-46 (3) Copy default ................................................................................................................................. 1-4-46
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 ............................................................................................................................... 1-5-6 1-5-2 Self-diagnosis ..................................................................................................................................... 1-5-15 (1) Self-diagnostic function ................................................................................................................ 1-5-15 (2) Self-diagnostic codes ................................................................................................................... 1-5-15 1-5-3 Image formation problems ................................................................................................................. 1-5-20 (1) No image appears (entirely white). ............................................................................................... 1-5-21 (2) No image appears (entirely black). ............................................................................................... 1-5-21 (3) Image is too light. ......................................................................................................................... 1-5-22 (4) Background is visible. ................................................................................................................... 1-5-22 (5) A white line appears longitudinally. .............................................................................................. 1-5-22 (6) A black line appears longitudinally. .............................................................................................. 1-5-23 1-1-1 (7) A black line appears laterally. ....................................................................................................... 1-5-23 (8) One side of the copy image is darker than the other. ................................................................... 1-5-23 (9) Black dots appear on the image. .................................................................................................. 1-5-24 (10) Image is blurred. ........................................................................................................................... 1-5-24 (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. ................................ 1-5-25 (13) Paper creases. ............................................................................................................................. 1-5-25
2C9 (14) Offset occurs. ............................................................................................................................... (15) Image is partly missing. ................................................................................................................ (16) Fixing is poor. ............................................................................................................................... (17) Image is out of focus. ................................................................................................................... (18) Image center does not align with the original center. ................................................................... 1-5-4 Electrical problems ............................................................................................................................. (1) The machine does not operate when the power switch is turned on. ........................................... (2) The drive motor does not operate (C200). ................................................................................... (3) The registration motor does not operate. ..................................................................................... (4) The exit motor does not operate. .................................................................................................. (5) The scanner motor does not operate. .......................................................................................... (6) Cooling fan motor 1 does not operate. ......................................................................................... (7) Cooling fan motor 2 does not operate. ......................................................................................... (8) The paper feed clutch does not operate. ...................................................................................... (9) The bypass paper feed clutch does not operate. ......................................................................... (10) The cleaning lamp does not turn on. ............................................................................................ (11) The exposure lamp does not turn on. ........................................................................................... (12) The exposure lamp does not turn off. ........................................................................................... (13) The fixing heater does not turn on (C600). ................................................................................... (14) The fixing heater does not turn off. ............................................................................................... (15) Main charging is not performed. ................................................................................................... (16) Transfer charging is not performed. ............................................................................................. (17) No developing bias is output. ....................................................................................................... (18) The original size is not detected. .................................................................................................. (19) The original size is not detected correctly. ................................................................................... (20) The message requesting paper to be loaded is shown when paper is present in the drawer. ..... (21) The size of paper in the drawer is not displayed correctly. ........................................................... (22) A paper jam in the paper feed, paper conveying or fixing section is indicated when the power switch is turned on. ...................................................................................................... (23) The message requesting covers to be closed is displayed when the front cover and left cover are closed. .................................................................................................................... (24) Others. .......................................................................................................................................... 1-5-5 Mechanical problems ......................................................................................................................... (1) No primary paper feed. ................................................................................................................. (2) No secondary paper feed. ............................................................................................................ (3) Skewed paper feed. ...................................................................................................................... (4) The scanner does not travel. ........................................................................................................ (5) Multiple sheets of paper are fed at one time. ................................................................................. (6) Paper jams. .................................................................................................................................. (7) Toner drops on the paper conveying path. ................................................................................... (8) Abnormal noise is heard. .............................................................................................................. 1-5-25 1-5-26 1-5-26 1-5-26 1-5-27 1-5-28 1-5-28 1-5-28 1-5-28 1-5-28 1-5-29 1-5-29 1-5-29 1-5-29 1-5-29 1-5-29 1-5-29 1-5-30 1-5-30 1-5-30 1-5-30 1-5-30 1-5-30 1-5-30 1-5-30 1-5-31 1-5-31 1-5-31 1-5-31 1-5-31 1-5-32 1-5-32 1-5-32 1-5-32 1-5-32 1-5-32 1-5-32 1-5-32 1-5-32
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 separation pulley ................................................................................. 1-6-3 (2) Detaching and refitting the forwarding pulley and paper feed pulley .............................................. 1-6-5 (3) Detaching and refitting the paper conveying unit ........................................................................... 1-6-7 (4) Detaching and refitting the bypass paper feed pulley and bypass separation pad ........................ 1-6-9 (5) Detaching and refitting the registration left roller .......................................................................... 1-6-11 1-1-2 (6) Detaching and refitting the registration cleaner ............................................................................ 1-6-11 (7) Adjustment after roller and clutch replacement ............................................................................ 1-6-12 (7-1) Adjusting the leading edge registration of image printing .................................................... 1-6-12 (7-2) Adjusting the leading edge registration for memory image printing ..................................... 1-6-13 (7-3) Adjusting the center line of image printing ........................................................................... 1-6-14 (7-4) Adjusting the margins for printing ........................................................................................ 1-6-15 (7-5) Adjusting the amount of slack in the paper .......................................................................... 1-6-16
2C9 1-6-3 Optical section .................................................................................................................................... (1) Detaching and refitting the exposure lamp ................................................................................... (2) Detaching and refitting the scanner wires .................................................................................... (2-1) Detaching the scanner wires ............................................................................................... (2-2) Fitting the scanner wires ...................................................................................................... (3) Detaching and refitting the ISU (reference) .................................................................................. (4) Detaching and refitting the laser scanner unit .............................................................................. (5) Adjusting the longitudinal squareness (reference) ....................................................................... (6) Adjusting magnification of the scanner in the main scanning direction ........................................ (7) Adjusting magnification of the scanner in the auxiliary scanning direction ................................... (8) Adjusting the scanner leading edge registration ........................................................................... (9) Adjusting the scanner center line ................................................................................................. (10) Adjusting the margins for scanning an original on the contact glass ............................................ 1-6-4 Drum section ....................................................................................................................................... (1) Detaching and refitting the drum unit ............................................................................................ (2) Detaching and refitting the drum separation claws ....................................................................... (3) Detaching and refitting the main charger unit ............................................................................... 1-6-5 Developing section .............................................................................................................................. (1) Detaching and refitting the developing unit .................................................................................. 1-6-6 Transfer section .................................................................................................................................. (1) Detaching and refitting the transfer roller ..................................................................................... 1-6-7 Fixing section ...................................................................................................................................... (1) Detaching and refitting the fixing unit ........................................................................................... (2) Detaching and refitting the press roller ......................................................................................... (3) Detaching and refitting the fixing heater M and S ......................................................................... (4) Detaching and refitting the heat roller separation claws ............................................................... (5) Detaching and refitting the heat roller ........................................................................................... (6) Detaching and refitting the fixing thermostat ................................................................................ (7) Detaching and refitting the fixing thermistor ................................................................................. 1-6-17 1-6-17 1-6-18 1-6-18 1-6-20 1-6-23 1-6-24 1-6-27 1-6-28 1-6-29 1-6-30 1-6-31 1-6-32 1-6-33 1-6-33 1-6-34 1-6-35 1-6-36 1-6-36 1-6-37 1-6-37 1-6-38 1-6-38 1-6-39 1-6-40 1-6-41 1-6-42 1-6-43 1-6-43
1-7 Requirements on PCB Replacement
1-7-1 Upgrading the firmware on the main PCB ............................................................................................ 1-7-1 1-7-2 Adjustment-free variable resisters (VR) ............................................................................................... 1-7-2 1-7-3 Remarks on engine PCB or main PCB replacement ............................................................................ 1-7-2
2-1 Mechanical construction
2-1-1 Paper feed section ............................................................................................................................... 2-1-1 2-1-2 Optical section ...................................................................................................................................... 2-1-4 (1) Original scanning ............................................................................................................................ 2-1-5 (2) Image printing ................................................................................................................................. 2-1-6 2-1-3 Drum section ........................................................................................................................................ 2-1-8 2-1-4 Developing section ............................................................................................................................. 2-1-10 (1) Formation of magnetic brush ........................................................................................................ 2-1-11 (2) Single component developing system .......................................................................................... 2-1-12 2-1-5 Transfer and separation sections ....................................................................................................... 2-1-13 2-1-6 Fixing section ..................................................................................................................................... 2-1-15 (1) Fixing temperature system ........................................................................................................... 2-1-16 (2) Fixing temperature control based on ambient temperature .......................................................... 2-1-16 2-1-7 Exit and switchback sections ............................................................................................................. 2-1-17 2-1-8 Duplex section .................................................................................................................................... 2-1-18 (1) Paper conveying operation in duplex copying .............................................................................. 2-1-19
2-2 Electrical Parts Layout
1-1-3 2-2-1 2-2-1 2-2-2 2-2-3 2-2-4
2-2-1 Electrical parts layout ........................................................................................................................... (1) PCBs .............................................................................................................................................. (2) Switches and sensors ..................................................................................................................... (3) Motors ............................................................................................................................................. (4) Other electrical components ...........................................................................................................
2C9
2-3 Operation of the PCBs
2-3-1 2-3-2 2-3-3 2-3-4 2-3-5 Power source PCB ............................................................................................................................... 2-3-1 Main PCB ............................................................................................................................................. 2-3-4 Engine PCB .......................................................................................................................................... 2-3-8 Operation unit PCB ............................................................................................................................ 2-3-14 CCD PCB ........................................................................................................................................... 2-3-17
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 Chart of image adjustment procedures .......................................................................................................... 2-4-5 Maintenance parts list ..................................................................................................................................... 2-4-8 Periodic maintenance procedures .................................................................................................................. 2-4-9 Optional devices supplied parts list .............................................................................................................. 2-4-11 General wiring diagram ................................................................................................................................ 2-4-12
1-1-4
2C9
1-1-1 Specifications
Type ............................................... Desktop Copying system .............................. Indirect electrostatic system Originals ......................................... Sheets, books and 3-dimensional objects (Maximum original size: A3) Maximum size: A3/11" × 17" Original feed system ...................... Fixed Copy paper ..................................... Paper weights Drawer: 64 105 g/m2 Bypass table: 45 160 g/m2 Paper type Drawer: Plain paper, recycled paper and colored paper Bypass table: Plain paper, recycled paper, thin paper, thick paper and colored paper Copying sizes ................................. Maximum: A3/11" × 17" Minimum: A6R /51/2" × 81/2" Magnification ratios ........................ Manual mode: 50 200%, 1% increments Copy speed .................................... At 100% magnification in copy mode: A4: 16 copies/min. A4R: 13 copies/min. A3: 8 copies/min. A5R: 10 copies/min. A6R: 10 copies/min. B5: 16 copies/min. B5R: 13 copies/min. B4 (257 × 364 mm): 8 copies/min. 11" × 81/2": 16 copies/min. 81/2" × 11": 10 copies/min. 11" × 17": 8 copies/min. 81/2" × 14": 8 copies/min. First copy time ................................ Approximately 5.9 s (A4/11" × 81/2") Warm-up time ................................. Less then 19 s (room temperature 23°C/73.4°F, 50% RH) Paper feed system ......................... Automatic feed Capacity: Drawers: 300 sheets (80 g/m2) Manual feed Capacity: Bypass: 50 sheets (A4/11" × 81/2" or less) 25 sheets (A3, B4, 11" × 17", 81/2" × 14") Paper ejection system .................... In-machine ejection (face down) Capacity: 250 sheets (80 g/m2) Continuous copying ........................ 1 250 sheets Photoconductor .............................. OPC (drum diameter 30 mm) Charging system ............................ Single positive corona charging Recording system .......................... Semiconductor laser Developing system ......................... Single component developing system Toner: magnetism toner Toner replenishing: automatic from a toner container Transfer system ............................. Transfer roller Separation system ......................... Curvature separation and separation electrode Fixing system ................................. Heat roller Heat source: halogen heaters (120 V specifications:main 550 W, sub 400W/ 220-240 V specifications:main 600 W, sub 450 W) Control temperature: 170°C/338°F (180°C/356°F on and after 6th sheet) Abnormally high temperature protection device: 180°C/356°F thermostat Fixing pressure: 44.1 N Charge erasing system .................. Exposure by cleaning lamp Cleaning system ............................. Cleaning blade Scanning system ............................ Flat bed scanning by CCD image sensor Bitmap memory .............................. 18 MB (standard) Image storage memory .................. 14 MB (standard) Resolution ...................................... 600 × 600 dpi Light source .................................... Inert gas lamp
1-1-1
2C9 Dimensions .................................... 571 (W) × 552 (D) × 502 (H) mm 221/2" (W) × 213/4" (D) × 193/4" (H) Weight ............................................ Approx. 39 kg/85.8 lbs Floor requirements ......................... 885 (W) × 552 (D) mm 3413/16" (W) × 213/4" (D) Functions ........................................ Automatic paper selection, Image quality selection, Automatic sizeing selection function, zoom function, Duplex copy, Divided copy, Binding margin, Border width, Aggregate copy, Sort copy, Eco-copy, Copy program and Section management mode Power source ................................. 120 V AC, 60 Hz, 11 A 220 240 V AC, 50 Hz, 4.5 A (Average) Power consumption ........................ 1320 W Options ........................................... Document processer, paper feeder, duplex unit, key counter
· Duplex unit Type ............................................... Internal type Copy paper ..................................... Paper weights: 60 90 g/m2 Paper type: Plain paper, recycled paper and colored paper Paper sizes .................................... A3 A5R/11" × 17" 51/2" × 81/2" Power source ................................. Electrically connected to the copier Dimensions .................................... 368 (W) × 53 (D) × 180 (H) mm 141/2" (W) × 21/16" (D) × 71/16" (H) Weight ............................................ Approx. 0.65 kg/1.43 lbs
1-1-2
2C9
1-1-2 Parts names and their functions
(1) Copier
Figure 1-1-1
1 Original cover 2 Copy storage section 3 Operation panel 4 Drawer 5 Width guide 6 Length guide 7 Left cover handle 8 Bypass tray 9 Support guide 0 Slider
! Contact glass @ Original size indicator plate # Left cover $ Waste toner box % Toner container release lever ^ Toner container & Cleaner rod * Front cover ( Power switch
1-1-3
2C9 (2) Operation panel Metric
Inch
Figure 1-1-2 1 Start key (Indicator) 2 Stop/Clear key 3 Reset key 4 Numeric keys 5 Energy Saver key (Indicator) 6 Interrupt key (Indicator) 7 Management key 8 Auto Exposure key 9 Copy exposure adjustment keys (Indicators) 0 Eco-copy key ! Image mode selection key @ Program key # Copy quantity/magnification display $ Zoom (+) key % Zoom (-) key ^ Recall%/Enter key & Magnification Select key * Paper Select key ( Paper supply indicator ) Paper supply level indicator / Paper jam indicator ¤ Bypass tray indicator < Original size Select key > Toner recovery indicator fi Toner supply indicator fl Memory overflow indicator Maintenance indicator ° Auto Selection key · Aggregate copy key , Duplex copy key OE Divided key ,, Sort key ´ Border lightening key Margin key Printer type selection key
1-1-4
2C9
1-1-3 Machine cross section
Light path Paper path
Figure 1-1-3 Machine cross section
1 2 3 4 5 6 7 8
Paper feed section Optical section Drum section Developing section Transfer and separation section Fixing section Exit and switchback section Duplex section
1-1-5
2C9
1-1-4 Drive system
Figure 1-1-4
1 2 3 4 5 6 7 8 9 0 ! @ # $
Drive motor gear Gear 122 Registration gear 51 Registration motor gear Gear 32 Gear 25 Gear 25 Gear 20 Paper feed clutch gear Gear 30 Gear 31 Gear 25 Gear 49 Gear 30/23
% ^ & * ( ) / ¤ < > fi fl
Developing gear 25 Developing gear 26 Fixing joint gear 29 Gear 40 Gear 40 Gear 88/34 Gear 40 Fixing joint gear 40 Coupling gear Gear 50 Gear 60 Exit motor gear Gear 43/20
1-1-6
2C9
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 55°C/131°F and at a relative humidity not higher than 90% 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 Toner
Store the toner in a cool, dark place. Avoid direct light and high humidity.
1-2-1
2C9
1-2-3 Installation environment
1. Temperature: 10 - 32.5°C/50 - 90.5°F 2. Humidity: 15 - 80%RH 3. Power supply: 120 V AC, 11 A 220 - 240 V AC, 4.5 A (Average) 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: 1000 mm/393/8" Machine rear: 100 mm/315/16" Machine right: 300 mm/1113/16" Machine left: 300 mm/1113/16"
d a
f c
b e
a: 571 mm/221/2" b: 552 mm/213/4" c: 502 mm/193/4" d: 1371.5 mm/54" e: 1272 mm/501/16" f: 952.5 mm/371/2" Figure 1-2-1 Installation dimensions
1-2-2
2C9
1-3-1 Unpacking and installation
(1) Installation procedure
Start
Unpack. Installing the toner (maintenance item U130).
Install the optional paper feeder.
Load paper. Remove the tapes and pins. Output an own-status report (maintenance item U000).
Install the original cover or the optional DP.
Install the optional duplex unit.
Exit maintenance mode.
Install the toner container.
Make test copies.
Connect the power cord.
Completion of the machine installation.
1-3-1
2C9 Unpack.
Figure 1-3-1 Unpacking 1 Copier 2 Power cord 3 Toner container 4 Outer case 5 Lower left pad 6 Lower right pad 7 Upper left pad 8 Upper right pad 9 Inner frame 0 Left spacer ! Rear spacer @ Rear pad # Skid $ Belt % Cartridge spacer ^ Machine cover & Bar code labels
* Place the machine on a level surface.
1-3-2
2C9 Install the optional paper feeder. 1. Install the optional paper feeder as necessary (see page 1-3-6 to 1-3-7).
Remove the tapes and pins. 1. Remove the eight tapes.
Tape
Tapes
Tape
Tape Tapes
Figure 1-3-2 2. Remove the two pins for light source unit.
Pins
Figure 1-3-3
Install the original cover or the optional DP. 1. Install the original cover or optional DP (see page 1-3-8 to 1-3-10 when installing the DP).
Install the optional duplex unit. 1. Install the optional duplex unit as necessary (see pages 1-3-11 to 1-3-13).
1-3-3
2C9 Install the toner container. 1. Open the front cover. 2. Tap the top of the toner container five to six times. 3. Shake the toner container approximately 10 times in the horizontal direction to stir toner. 4. Turn the toner container release lever and gently push the toner container into the copier. *Push the container all the way into the copier until it locks in place. 5. Restore the toner container release lever. 6. Close the front cover.
Toner container release lever
Toner container
Figure 1-3-4
Connect the power cord. 1. Connect the power cord to the connector on the copier. 2. Insert the power plug into the wall outlet and turn the power switch on. Installing the toner (maintenance item U130). 1. Enter the maintenance mode by entering "10871087" using the numeric keys. 2. Enter "130" using the numeric keys and press the start key. 3. Press the start key to execute the maintenance item. Installation of toner starts and "9" is indicated in the copy quantity display. Each time one minute elapses, the indicated value decrements. When the installation is complete, "Gd" will be displayed if the installation is successful or "nG" will be displayed if it has failed. 4. Press the stop/clear key. Load paper. 1. Load paper in the drawer. Output an own-status report (maintenance item U000). 1. Enter "000" using the numeric keys and press the start key. 2. Select "d-L" and press the start key to output a list of the current settings of the maintenance items. 3. Press the stop/clear key. Exit maintenance mode. 1. Enter "001" using the numeric keys and press the start key. The machine exits the maintenance mode. Make test copies. 1. Place an original and make test copies. Completion of the machine installation.
1-3-4
2C9
1-3-2 Setting initial copy modes
Factory settings are as follows:
Maintenance item No. U253 U254 U255 U258 U260 U342
Contents Switching between double and single counts Turning auto start function on/off Setting auto clear time Switching copy operation at toner empty detection Changing the copy count timing Setting the ejection restriction
Factory setting Double count ON 90s SINGLE MODE After ejection ON
1-3-5
2C9
1-3-3 Installing the paper feeder (option)
1. Place the copier on the paper feeder by aligning the positioning insertion sections of the copier with the positioning pins at the rear part of the paper feeder. * When placing the copier, take care not to hit the copier against the drawer, the pins or ground plate of the paper feeder.
Positioning pins
Paper feeder
Figure 1-3-5 For stacking paper feeders for use: Stack a paper feeder on another paper feeder by aligning the positioning insertion sections of the first paper feeder with the positioning pins at the rear part of the second paper feeder. (Up to three paper feeders can be stacked.)
Positioning pins
Positioning pins
Figure 1-3-6
2. If a type of paper that is not included in the specifications for the standard sheet cassette size is used, replace the cassette size sheet indication with the supplied one. 3. Insert the copier power plug into the wall outlet and turn the copier power switch on. Load paper in the drawer and make test copies to check the operation.
Cassette size sheet indication
Figure 1-3-7
1-3-6
2C9 Adjusting the leading edge timing 1. Run maintenance mode 034. Press the image quality mode key until "Text" is lit. (group 1) First paper feeder: Press the exposure key until "exp3" is lit. (mode 3) Second paper feeder: Press the exposure key until "exp4" is lit. (mode 4) Third paper feeder: Press the exposure key until "exp5" is lit. (mode 5) Make a test copy to check the image. If an adequate image cannot be obtained, carry out the following adjustment. 2. If a copy example a is obtained, increase the adjustment value. If a copy example b is obtained, decrease the adjustment value. Setting range: -5.0 - 10.0 3. Make a test copy again. 4. Repeat steps 2 and 3 until an adequate image is obtained.
Adequate image
Copy example a
Copy example b
Figure 1-3-8 Adjusting the center line 1. Run maintenance mode 034. Press the image quality mode key until "Text" and "Photo" are lit. (group 2) First paper feeder: Press the exposure key until "exp3" is lit. (mode 3) Second paper feeder: Press the exposure key until "exp4" is lit. (mode 4) Third paper feeder: Press the exposure key until "exp5" is lit. (mode 5) Make a test copy to check the image. If an adequate image cannot be obtained, carry out the following adjustment. 2. If a copy example a is obtained, increase the adjustment value. If a copy example b is obtained, decrease the adjustment value. Setting range: -8.0 - 10.0 3. Make a test copy again. 4. Repeat steps 2 and 3 until an adequate image is obtained.
Adequate image
Copy example a
Copy example b
Figure 1-3-9
1-3-7
2C9
1-3-4 Installing the DP (option)
1. Remove the original holder and remove the two screws from the rear top cover. 2. Pass the two pins through the screw holes of the rear top cover and attach them to the lower frame.
Pin Screw Pin Screw
Figure 1-3-10
3. Place the DP on the copier by fitting the pins into the holes at the hinge sections of the DP and sliding them toward the front side.
DP Pin Pin
Hole
Hole
Figure 1-3-11
4. Secure the DP with the two chrome TP screws M4 x 10 and the two screws that have been removed in step 1.
Chrome TP screw M4 x 10 Screw
Chrome TP screw M4 x 10 Screw
DP
Figure 1-3-12
1-3-8
2C9 5. Close the DP, fit the fixing fitting from the rear side of the right hinge, and secure it with the two bronze TP screws M3 x 06. 6. Connect the cable of the DP to the copier. * Be sure to tighten the fixing screws on both side of the connector.
Cable
Fixing fitting Bronze TP screws M3 x 06
Figure 1-3-13
7. Paste the caution label that corresponds to the language according to the destination to the DP.
Caution label
Figure 1-3-14
[Operation check] 1. Prepare an original on which 4 lines are drawn 15 mm from the edges and the center line is drawn. 2. Set the original on the DP and make a test copy to check the copy image. At this time, set the paper guide for the original table and drawer to the paper size to be used. 3. If the copy image does not match the original image, carry out the following adjustments in maintenance mode. · Maintenance mode 070 (sub-scan line adjustment) · Maintenance mode 071 (leading edge timing adjustment) · Maintenance mode 072 (center line adjustment)
15mm 15mm
15mm Center line
Lines
Lines
15mm Original
Figure 1-3-15
1-3-9
2C9-1 Maintenance mode 070 (sub-scan line adjustment) For copy example a: decrease the value. For copy example b: increase the value. Changing the value by one changes the sub-scan line by 0.1%. The larger the value, the larger the magnification of the sub-scan line of the copy image. The smaller the value, the smaller the magnification of the sub-scan line of the copy image.
Original
Copy example a
Copy example b
Figure 1-3-16 Maintenance mode 071 (leading edge timing adjustment) For copy example a: increase the value. For copy example b: decrease the value. Changing the value by one moves the leading edge by 0.17 mm. The larger the value, the later the image scan start timing. The smaller the value, the earlier the image scan start timing.
Original
Copy example a
Copy example b
Figure 1-3-17 Maintenance mode 072 (center line adjustment) For copy example a: increase the value. For copy example b: decrease the value. Changing the value by one moves the center line by 0.17 mm. The larger the value, the center of the image moves toward the right. The smaller the value, the center of the image moves toward the left.
Original
Copy example a
Copy example b
Figure 1-3-18
1-3-10
2C9
1-3-5 Installing the duplex unit (option)
1. Open the left cover. 2. Remove the stop ring and the strap from the rear side. 3. Restore the conveyor section. 4. Remove the fitting projection and pin, and then remove the stopper from the front side. 5. Open the left cover until it is put horizontally.
Stop ring
Fitting projection
Stopper
Strap
Pin
Left cover
Figure 1-3-19 6. Turn the wire guide section of the duplex unit in the direction indicated by the arrow.
Wire guide section
Figure 1-3-20 7. Insert the axis sections of the duplex unit into the Ushape grooves of the conveyer unit.
Axis section
Axis section
Duplex unit
Figure 1-3-21
1-3-11
2C9 8. Press the duplex unit in the direction indicated by the arrow to fit the claws into the conveyer unit.
Duplex unit
Claw
Claw
Figure 1-3-22
9. Secure the duplex unit with the two S tite screws M3 x 06.
Duplex unit
S tite screws M3 x 06
Figure 1-3-23
10. Open the conveyer unit and connect the connector of the duplex unit to the copier. 11. Reattach the removed parts to their original positions. 12. Connect the copier power plug to the wall outlet and turn the copier power switch on.
Duplex unit
Connector
Figure 1-3-24
1-3-12
2C9-1 Adjusting the leading edge timing 1. Run maintenance mode 034. Press the image quality mode key until "Text" is lit. (group 1) Press the exposure key until "exp1" is flashing. (mode 6) Make a test copy in the duplex mode to check the image. If an adequate image cannot be obtained, carry out the following adjustment. 2. If a copy example a is obtained, increase the adjustment value. If a copy example b is obtained, decrease the adjustment value. Setting range: -5.0 - 10.0 3. Make a test copy again. 4. Repeat steps 2 and 3 until an adequate image is obtained.
Adequate image
Copy example a
Copy example b
Figure 1-3-25 Adjusting the center line 1. Run maintenance mode 034. Press the image quality mode key until "Text" and "Photo" are lit. (group 2) Press the exposure key until "exp1" is flashing. (mode 6) Make a test copy in the duplex mode to check the image. If an adequate image cannot be obtained, carry out the following adjustment. 2. If a copy example a is obtained, increase the adjustment value. If a copy example b is obtained, decrease the adjustment value. Setting range: -8.0 - 10.0 3. Make a test copy again. 4. Repeat steps 2 and 3 until an adequate image is obtained.
Adequate image
Copy example a
Copy example b
Figure 1-3-26
1-3-13
2C9
1-3-6 Installing the drawer heater (option)
Drawer heater installation requires the following parts: · Drawer heater (P/N 120 V specifications: 2C960030, 220-240 V specifications: 2C960040) · One (1) M4 × 10 tap-tight S binding screw (P/N B3024100) 1. Remove the right cover. 2. Pull out the drawer. 3. Remove the three screws and then the front right cover.
Front right cover
Figure 1-3-27
1-3-14
2C9 4. Insert the cassette heater from the bottom of the machine and attach it to the copier. 1) Pass the connector of the cassette heater through the hole located in the right frame of the machine to pull it out. 2) Insert the projections at the rear side of the cassette heater mounting plate into the two holes in the rear frame of the machine. 3) Position the screw hole of the drawer heater to the screw hole of the front frame of the machine and secure the heater using the M4 × 10 Taptite S binding screw.
Holes in the rear frame
Projections Drawer heater Hole in the right frame
Screw hole Connector
M4 × 10 tap tight S binding screw
Figure 1-3-28
1-3-15
2C9 5. Remove the two screws and open the power source PCB in the direction indicated by the arrow. * Take care not to open the power source PCB too much. 6. Fit the wire of the drawer heater into the groove of the frame and put it inside the power source PCB. * Fit the wire into the groove so that the band mounted to the wire is located above the frame.
Wire of the drawer heater
Power source PCB
Band
Figure 1-3-29
7. Reattach the power source PCB to its original position and connect the connector of the drawer heater to YC8 of the power source PCB. 8. Refit all the removed parts.
Connector
YC8
Figure 1-3-30
1-3-16
2C9-1
1-3-7 Installing the key counter (option)
Key counter installation requires the following parts: · Key counter cover (P/N 2A360010) · Key counter retainer (P/N 66060030) · Key counter mount (P/N 66060040) · Key counter assembly (P/N 41529210) · Four (4) M4 × 6 bronze TP-A screws (P/N B4304060) · One (1) M4 × 35 round head screw (P/N B0004350) · Two (2) M3 × 6 bronze flat-head screws (P/N B2303060) · One (1) M3 bronze nut (P/N C2303000) · Key counter mounting plate (P/N 2C960100) · Key counter wire (P/N 2C960110)
Procedure 1. Fit the key counter socket assembly to the key counter retainer using the two screws and nut. 2. Fit the key counter mount to the key counter cover using the two screws, and attach the key counter retainer to the mount using the two screws.
M4 × 6 screws (B4304060) Key counter retainer (66060030) Key counter mount (66060040) M3 nut (C2303000) Key counter cover (2A360010)
M4 × 6 screws (B4304060)
Key counter socket assembly (41529210) M3 × 6 flat-head screws (B2303060)
Figure 1-3-31
1-3-17
2C9-1 3. Remove the rear cover. 4. Cut out the aperture plate on the right cover using nippers. 5. Connect the 4-pin connector of the key counter wire (located at a longer distance from the tube) to YC13 on the engine PCB, pass the wire through the two clamps, and pull the other 4-pin connector out from the aperture of the right cover. * Arrange the key counter wire behind the optical system wire as shown in the illustration. 6. Fold the 7-pin connector of the key counter wire back, pass the wire through the clamp at the upper part of the controller box, and hang it.
Aperture 4-pin connector 7-pin connector Clamp
Key counter wire Clamp
YC13 4-pin connector
Figure 1-3-32
7. Pass the connector of the key counter through the aperture of the key counter mounting plate, and engage the projection of key counter mounting plate with the square hole of the key counter cover.
Aperture
4-pin connector
Key counter mounting plate (2C960100)
Key counter cover
Projection Square hole
Figure 1-3-33
1-3-18
2C9-1 8. Connect the 4-pin connector of the key counter to the key counter wire. 9. Engage the projection of the key counter mounting plate with the aperture of the right cover. 10. Secure the key counter cover and the key counter mounting plate together with the copier using a M4 x 35 screw. 11. Refit the rear cover.
Aperture Key counter wire 4-pin connector Projection Key counter cover
M4×35 screw (B0004350) Key counter mounting plate (2C960100)
Figure 1-3-34
12. Insert the key counter into the key counter socket assembly. 13. Turn the main switch on and enter the maintenance mode. 14. Run maintenance item U204 and select "KEYCOUNTER." 15. Exit the maintenance mode. 16. Check that if the key counter is removed, "U1" is displayed in the copy quantity display. 17. Check that the counter counts up as copies are made.
1-3-19
2C9
1-4-1 Maintenance mode
The copier is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item
Start
Enter "10871087" using the numeric keys.
Maintenance mode is entered.
Enter the maintenance item number using the zoom +/- keys or numeric keys.
The maintenance item is selected.
Press the start key.
The selected maintenance item is run.
Press the stop/clear key.
Yes
Repeat the same maintenance item?
No
Yes
Run another maintenance item?
No Enter "001" using the zoom +/- keys or numeric keys and press the start key.
Maintenance mode is exited.
End
1-4-1
2C9 (2) Maintenance mode item list Section General Item Maintenance item contents No. U000 Outputting an own-status report U001 Exiting the maintenance mode U004 Checking the machine number U005 Copying without paper U019 Displaying the ROM version Initialization Drive, paper feed and paper conveying system U020 Initializing all data U021 Initializing memories U030 Checking motor operation U031 Checking switches for paper conveying U032 Checking clutch operation U034 Setting paper timing · Adjusting the leading edge registration · Adjusting the center line U035 Setting folio size · Length · Width U051 Adjusting the amount of slack in the paper U053 Performing fine adjustment of the motor speed · Drive motor speed adjustment · Polygon motor speed adjustment · Exit motor speed adjustment · Registration motor speed adjustment · Motor speed adjustment (for paper feed from bypass tray) · Motor speed adjustment (for paper feed from optional paper feeder) · Motor speed adjustment (in duplex mode) Optical U060 Adjusting the scanner input properties U061 Turning the exposure lamp on U063 Adjusting the shading position U065 Adjusting the scanner magnification · Main scanning direction · auxiliary scanning direction U066 Adjusting the leading edge registration for scanning an original on the contact glass U067 Adjusting the center line for scanning an original on the contact glass U068 Adjusting the scanning position for originals from the DP U070 Adjusting the DP magnification U071 Adjusting the DP scanning timing · Adjusting leading edge registration · Adjusting trailing edge registration U072 Adjusting the DP center line U073 Checking scanner operation U074 Adjusting the DP input light luminosity U087 Turning the DP scanning position adjust mode on/off U088 Setting the input filter (moiré reduction mode) U089 Outputting a MIP-PG pattern U091 Checking shading U092 Adjusting the scanner automatically U093 Setting the exposure density gradient · Text/text and photo/photo mode U099 Checking the original size detection Initial setting* -- -- -- -- -- -- -- -- -- -- 5.1/0/0/0/0/0 -1.2/0/0/0/0/0 330 210 20/0/70/80/80/0 0 0 0 0 0 0 0 12 -- 0 0 12 10 0 0 0 0 0 0 -- 1 35 Off -- -- -- 0/0/0 --
* Initial setting for executing maintenance item U020
1-4-2
2C9 Section High voltage Item Maintenance item contents No. U100 Setting the main high voltage · Grid control voltage · Copy interval · Copy quantity · Correction amount U101 Setting the other high voltages · Developing bias clock frequency · Developing bias clock duty · Transfer control voltage (large size) · Transfer control voltage (small size) · Transfer charging output OFF timing · Transfer charging output ON timing · Separation control voltage · Separation charging output ON timing · Separation charging output OFF timing U110 Checking/clearing the drum count Developing U130 Toner install mode U144 Setting toner loading operation U158 Checking/clearing the developing count Fixing and cleaning U161 Setting the fixing control temperature · Primary stabilization fixing temperature · Secondary stabilization fixing temperature · Copying operation temperature 1 · Copying operation temperature 2 · Number of sheets for fixing control · Number of sheets for fixing control (thick paper) U162 Stabilizing fixing forcibly U163 Resetting the fixing problem data U167 Checking/clearing the fixing count U199 Checking the fixing temperature Operation panel and support equipment U200 Turning all LEDs on U202 Setting the KMAS host monitoring system U203 Operating DP separately U204 Setting the presence or absence of a key card or key counter U207 Checking the operation panel keys U243 Checking the operation of the DP motors and solenoids U244 Checking the DP switches Mode setting U250 Setting the maintenance cycle U251 Checking/clearing the maintenance count U252 Setting the destination U253 Switching between double and single counts U254 Turning auto start function on/off U255 Setting auto clear time U258 Switching copy operation at toner empty detection U260 Changing the copy count timing U265 Setting the destination specifications U332 Setting the size conversion factor U342 Setting the ejection restriction U345 Setting the value for maintenance due indication Initial setting* 135 60 50 10 27 45 168 179 38 34 1 33 43 -- -- 0 -- 140 160 170 180 5 20 -- -- -- -- -- -- -- Off -- -- -- 150000 0 Japan A3 On 90 Single mode After ejection 0 1.0 On --
* Initial setting for executing maintenance item U020
1-4-3
2C9 Section Image processing Item Maintenance item contents No. U402 Adjusting margins of image printing U403 Adjusting margins for scanning an original on the contact glass U404 Adjusting margins for scanning an original from the DP U407 Adjusting the leading edge registration for memory image printing Others U901 Checking/clearing copy counts by paper feed locations U903 Checking/clearing the paper jam counts U904 Checking/clearing the service call counts U905 Checking/clearing counts by the DP U908 Checking the total count U910 Clearing the black ratio data U911 Checking/clearing copy counts by paper size U927 Clearing accounting counter U928 Checking/clearing the machine life counts U990 Checking/clearing the time for the exposure lamp to light U991 Checking the scanner count U993 Outputting a VTC-PG pattern Initial setting* -- -- -- -- -- -- -- --