Kyocera TASKalfa 3500i 4500i 5500i

TTTSERVICEMANUAL

Published in March 2011842LH110

2LHSM060First Edition

ASKalfa 3500iASKalfa 4500iASKalfa 5500i

CAUTION

RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.

It may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for proper disposal.

IL Y A UN RISQUE DDE TYPE INCORRECINSTRUCTIONS DON

Il peut tre illgal de jefonctionnaires municipet une mise au rebut aATTENTION

EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE T. METTRE AU REBUT LES BATTERIES UTILISEES SELON LES NEES.

ter les batteries dans des eaux dgout municipales. Vrifiez avec les aux de votre rgion pour les dtails concernant des dchets solides pproprie.

Revision history

Revision Date Replaced pages Remarks

This page is intentionally left blank.

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 com-pliance 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, light-ning 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 atten-tion. .....................................................................................................................................................

Advice customers that they must always follow the safety warnings and precautions in the copiers 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 acci-dent. ...................................................................................................................................................

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 power 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 immedi-ately. ...................................................................................................................................................

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

Keep the machine away from flammable liquids, gases, and aerosols. A fire or an electric shock might occur. ........................................................................................................................................

2LL/2LJ/2LH

CONTENTS

1-1 Specifications1-1-1 Specifications ........................................................................................................................ 1-1-11-1-2 Parts names .......................................................................................................................... 1-1-5

(1) Machine ............................................................................................................................ 1-1-5(2) Option ............................................................................................................................... 1-1-7(3) Operation panel ................................................................................................................ 1-1-8

1-1-3 Machine cross section ........................................................................................................... 1-1-9

1-2 Installation1-2-1 Installation environment......................................................................................................... 1-2-11-2-2 Unpacking a

(1) Installatio(2) Setting in

1-2-3 Installing the(1) Installing (2) Mounting

1-2-4 Installing the1-2-5 Installing the1-2-6 Installing the1-2-7 Installing the

1-3 Maintenance M1-3-1 Maintenance

(1) Executing(2) Maintena(3) Contents

1-4 Troubleshooting1-4-1 Paper misfee

(1) Paper mis(2) Paper mis

1-4-2 Self-diagnos(1) Self-diagn(2) Self diagn

1-4-3 Image forma(1) No image(2) No image(3) Image is (4) The back(5) White stre(6) Black stre(7) Streaks a(8) One side (9) Spots are

(10) Image is (11) The leadi(12) The leadi(13) Paper is w(14) Offset occ(15) Part of im(16) Fusing is nd installation..................................................................................................... 1-2-2n procedure ....................................................................................................... 1-2-2itial copy modes............................................................................................... 1-2-17 key counter (option)........................................................................................ 1-2-18directly on the device....................................................................................... 1-2-18 on the document table .................................................................................... 1-2-27 key card MK-2 (option for japan only)............................................................. 1-2-35 KMAS (option for japan only) ......................................................................... 1-2-49 coin vender (option for japan only) ................................................................. 1-2-58 cassette heater (option).................................................................................. 1-2-63

ode mode ................................................................................................................ 1-3-1 a maintenance item ......................................................................................... 1-3-1nce modes item list ............................................................................................ 1-3-2of the maintenance mode items ........................................................................ 1-3-9

d detection........................................................................................................ 1-4-1feed indication .................................................................................................. 1-4-1feed detection condition ................................................................................... 1-4-2

tic function ....................................................................................................... 1-4-20ostic function .................................................................................................. 1-4-20ostic codes...................................................................................................... 1-4-21tion problems................................................................................................... 1-4-60 appears (entirely white).................................................................................. 1-4-61 appears (entirely black).................................................................................. 1-4-62too light. ........................................................................................................... 1-4-62ground is colored. ............................................................................................ 1-4-63aks are printed vertically................................................................................. 1-4-63aks are printed vertically. ................................................................................ 1-4-63re printed horizontally. ..................................................................................... 1-4-64of the print image is darker than the other. ..................................................... 1-4-64 printed. ........................................................................................................... 1-4-64blurred.............................................................................................................. 1-4-64ng edge of the image is consistently misaligned with the original. .................. 1-4-65ng edge of the image is sporadically misaligned with the original. .................. 1-4-65rinkled. ........................................................................................................... 1-4-65urs. ................................................................................................................. 1-4-65age is missing. ................................................................................................ 1-4-66loose................................................................................................................ 1-4-66

2LL/2LJ/2LH

(17) Image is out of focus. .....................................................................................................1-4-66(18) Image center does not align with the original center. ..................................................... 1-4-67(19) Unevenly repeating horizontal streaks in the printed objects.

Colored spots in the printed objects. .............................................................................. 1-4-671-4-4 Electric problems ................................................................................................................. 1-4-681-4-5 Mechanical problems........................................................................................................... 1-4-761-4-6 Send error code................................................................................................................... 1-4-78

(1) Scan to SMB error codes ............................................................................................... 1-4-78(2) Scan to FTP error codes ................................................................................................ 1-4-79(3) Scan to E-mail error codes ............................................................................................. 1-4-80

1-4-7 Error codes .......................................................................................................................... 1-4-81(1) Error code....................................................................................................................... 1-4-81(2) Table of general classification ........................................................................................ 1-4-82

(2-1) U00 (2-2) U00 (2-3) U00 (2-4) U00 (2-5) U01 (2-6) U01 (2-7) U01 (2-8) U01

1-5 Assembly and d1-5-1 Precautions

(1) Precautio(2) Drum......(3) Toner .....(4) How to te

1-5-2 Paper feed s(1) Detaching(2) Detaching

separatio(3) Detaching

separatio(4) Detaching(5) Detaching

MP separ1-5-3 Optical sectio

(1) Detaching(2) Detaching(3) Detaching

1-5-4 Image forma(1) Detaching(2) Detaching(3) Detaching(4) Detaching

1-5-5 Transfer sec(1) Detaching(2) Detaching

1-5-6 Fuser section(1) Detaching

1-5-7 PWBs..........(1) Detaching4XX error code table: Interrupted phase B ..................................................... 1-4-846XX error code table: Problems with the unit ................................................. 1-4-848XX error code table: Page transmission error............................................... 1-4-849XX error code table: Page reception error .................................................... 1-4-840XX error code table: G3 transmission........................................................... 1-4-851XX error code table: G3 reception ................................................................ 1-4-867XX error code table: V.34 transmission ........................................................ 1-4-878XX error code table: V.34 reception.............................................................. 1-4-87

isassemblyfor assembly and disassembly........................................................................... 1-5-1ns....................................................................................................................... 1-5-1........................................................................................................................... 1-5-1........................................................................................................................... 1-5-1ll a genuine Kyocera Mita toner container ......................................................... 1-5-2ection................................................................................................................. 1-5-3 and refitting the primary paper feed unit.......................................................... 1-5-3 and refitting the forwarding pulley, paper feed pulley and

n pulley. [35 ppm model].................................................................................... 1-5-7 and refitting the forwarding pulley, paper feed pulley and

n pulley. [45 ppm model / 55 ppm model]........................................................ 1-5-10 and refitting the MP tray paper feed unit ....................................................... 1-5-11 and refitting the MP forwarding pulley, MP paper feed pulley and ation pulley ...................................................................................................... 1-5-14n ..................................................................................................................... 1-5-19 and refitting the exposure lamp ..................................................................... 1-5-19 and refitting the ISU....................................................................................... 1-5-22 and refitting the LSU...................................................................................... 1-5-24

tion section ...................................................................................................... 1-5-26 and refitting the inner unit.............................................................................. 1-5-26 and refitting the developer unit ...................................................................... 1-5-28 and refitting the drum unit.............................................................................. 1-5-29 and refitting the charger roller unit................................................................. 1-5-31

tion................................................................................................................... 1-5-32 and refitting the paper conveying unit ........................................................... 1-5-32 and refitting the transfer belt unit................................................................... 1-5-34....................................................................................................................... 1-5-36 and reffiting the fuser unit.............................................................................. 1-5-36

......................................................................................................................... 1-5-38 and refitting the main PWB............................................................................ 1-5-38

2LL/2LJ/2LH

(2) Detaching and refitting the engine PWB......................................................................... 1-5-43(3) Detaching and refitting the power source PWB.............................................................. 1-5-45(4) Detaching and refitting the high voltage PWB ................................................................ 1-5-47(5) Detaching and refitting the operation PWB .................................................................... 1-5-48(6) Detaching and refitting the fuser heater PWB ................................................................ 1-5-52

1-5-8 Drive section........................................................................................................................ 1-5-57(1) Detaching and refitting the drum drive unit..................................................................... 1-5-57(2) Detaching and refitting the developer drive unit ............................................................. 1-5-58(3) Detaching and refitting the fuser drive unit and feed drive unit ...................................... 1-5-59(4) Detaching and refitting the lift motor 1 and 2.................................................................. 1-5-65

1-5-9 Others.................................................................................................................................. 1-5-66(1) Detaching the eject filter ................................................................................................. 1-5-66(2) Detaching and refitting the toner filter............................................................................. 1-5-67(3) Detaching(4) Detaching(5) Detaching

1-6 Requirements o1-6-1 Upgrading th1-6-2 Remarks on 1-6-3 Remarks on

2-1 Mechanical Con2-1-1 Paper feed/c

(1) Cassette (2) MP tray p(3) Paper con

2-1-2 Drum section2-1-3 Developer se2-1-4 Optical sectio

(1) Image sc(2) Laser sca

2-1-5 Transfer/Sep(1) Transfer b

2-1-6 Fuser section2-1-7 Eject/Feedsh2-1-8 Duplex conv

2-2 Electrical Parts2-2-1 Electrical par

(1) PWBs.....(2) Switches (3) Motors....(4) Fan moto(5) Others....

2-3 Operation of the2-3-1 Main PWB...2-3-2 Engine PWB2-3-3 Power sourc2-3-4 ISC PWB ....2-3-5 Operation PW2-3-6 Front PWB .. and refitting the belt filter ............................................................................... 1-5-68 and refitting the hard disk unit ....................................................................... 1-5-69 and refitting the eject unit .............................................................................. 1-5-71

n PWB Replacemente firmware ......................................................................................................... 1-6-1main PWB replacement..................................................................................... 1-6-2engine PWB replacement ................................................................................. 1-6-4

structiononveying section ............................................................................................... 2-1-1paper feed section............................................................................................. 2-1-1aper feed section............................................................................................... 2-1-3veying section .................................................................................................. 2-1-5......................................................................................................................... 2-1-8

ction................................................................................................................ 2-1-10n ..................................................................................................................... 2-1-12

anner section ................................................................................................... 2-1-12nner section .................................................................................................... 2-1-14aration section ................................................................................................ 2-1-17elt unit section ................................................................................................ 2-1-17....................................................................................................................... 2-1-19

ift section ........................................................................................................ 2-1-21eying section.................................................................................................... 2-1-23

Layoutts layout ............................................................................................................ 2-2-1........................................................................................................................... 2-2-1and sensors....................................................................................................... 2-2-4........................................................................................................................... 2-2-6rs ....................................................................................................................... 2-2-8........................................................................................................................... 2-2-9

PWBs........................................................................................................................... 2-3-1........................................................................................................................ 2-3-11

e PWB ............................................................................................................. 2-3-29......................................................................................................................... 2-3-33

B 1................................................................................................................. 2-3-38......................................................................................................................... 2-3-43

2LL/2LJ/2LH

2-3-7 Feed PWB 1 ........................................................................................................................ 2-3-492-3-8 Feed PWB 2 ........................................................................................................................ 2-3-592-3-9 Relay PWB .......................................................................................................................... 2-3-65

2-3-10 LSU relay PWB.................................................................................................................... 2-3-71

2-4 Appendixes2-4-1 Appendixes............................................................................................................................ 2-4-1

(1) Maintenance kits............................................................................................................... 2-4-1(2) Repetitive defects gauge .................................................................................................. 2-4-2(3) Firmware environment commands ................................................................................... 2-4-3(4) Chart of image adjustment procedures ............................................................................ 2-4-9(5) Wiring diagram ............................................................................................................... 2-4-11

INSTALLATION GUDOCUMEPAPER FLARGE CSIDE DEC1000-SHE4000-SHEFINISHERCENTERMAILBOXPUNCH UINNER JORIGHT JOFAX SystIDENT PROCESSOREEDERAPACITY FEEDERKETS FINISHERETS FINISHER ATTACHMENT KIT

-FOLDING UNIT

NITB SEPARATORB SEPARATOR

em

2LL/2LJ/2LH

1-1 Specifications

1-1-1 Specifications

Machine

ItemSpecifications

35 ppm 45 ppm 55 ppm

Type Desktop

Printing method Electrophotography by semiconductor laser

Originals Sheet, Book, 3-dimensional objects (maximum original size: A3/Ledger)

Original feed system Fixed

Paper weightCasse

MP tra

Paper type

Casse

MP tra

Paper size

Casse

MP tra

Zoom level

Copying speed

First copy time(A4, feed from casset

Warm-up time

(22 C/71.6 F, 60% RH)

Power

Low Po

Sleep1-1-1

tte 60 to 220 g/m2

y 60 to 300 g/m2

ttePlain, Rough, Vellum, Recycled, Preprinted, Bond, Color (Colour),Prepunched, Letterhead, Thick, High Quality, Custom 1 to 8 (Duplex: Same as simplex)

yPlain, Transparency (OHP film), Rough, Vellum, Labels, Recycled,Preprinted, Bond, Cardstock, Color (Colour), Prepunched, Letterhead,Thick, Coated, Envelope, High Quality, Custom 1 to 8

tte A3, B4, A4, A4R, B5, B5R, A5R, Ledger, Legal, Letter, LetterR, Statement, Oficio II, 12 18", Folio, 8K, 16K, 16KR

y

A3, B4, A4, A4R, B5, ISO B5, B5R, A5R, B6R, A6R, Return postcard, Postcards, Envelope DL, Envelope C5, Envelope C4, Envelope #10 (Commercial #10), Envelope #9 (Commercial #9), Envelope #6 (Commercial #6 3/4), Envelope Monarch, Youkei 2, Youkei 4, Ledger, Legal, Letter, LetterR, ExecutiveR, Statement, Oficio II, 12 18", Folio, 8K, 16K, 16KR, Custom

Manual mode : 25 to 400%, 1% incrementsAuto mode : Preset Zoom

A4 : 35 ppmLetter : 35 ppmA4R : 24 ppmLetterR : 24 ppmA3 : 17 ppmLedger : 17 ppmB4 : 21 ppmLegal : 21 ppmB5 : 35 ppm



te)5.6 s or less 4.7 s or less 4.3 s or less

on 23 s or less 23 s or less 23 s or less

wer 10 s or less 10 s or less 10 s or less

16 s or less 16 s or less 16 s or less

2LL/2LJ/2LH

Paper capacity

Cassette 550 sheets (64 g/m2)

500 sheets (80 g/m2)

MP tray

A4/Letter or less165 sheets (64 g/m2) 150 sheets (80 g/m2)More than Letter/A455 sheets (64 g/m2) 50 sheets (80 g/m2)

Output tray capacity

Top tray 250 sheets (80 g/m2)

with inner job sepa

30 sheets (80 g/m2)

with rigjob sepa

Continuous copying

Light source

Scanning system

Photoconductor

Image write system

Charging system

Developing system

Transfer system

Separation system

Cleaning system

Charge erasing syste

Fusing system

CPU

Main memory

Standa

Maxim

Hard Disk

InterfaceStanda

Optio

Resolution

ItemSpecifications

35 ppm 45 ppm 55 ppm1-1-2

rator

ht rator

100 sheets (80 g/m2)

1 to 999 sheets

LED

Flat bed scanning by CCD image sensor

a-Si (drum diameter 40 mm)

Semiconductor laser

Charger roller

Touch down developing systemDeveloper: 2-componentToner replenishing: Automatic from the toner container

Transfer belt and roller

Small diameter separation, Separation electrode

Counter blade, Cleaning roller

m Exposure by cleaning lamp (LED)

Heat roller fusingHeat source: Halogen heatersAbnormally high temperature protection devices: thermostat

PowerPC 750CL/600 MHz

rd 1024 MB

um 2048 MB

160 GB or more

rdUSB Interface connector: 1 (USB Hi-Speed)USB port: 2 (Hi-Speed USB)Network interface: 1 (10 BASE-T/100 BASE-TX/1000 BASE-T)

n Fax slot: 2Network interface: 1 (10 BASE-T/100 BASE-TX/1000 BASE-T)

600 600 dpi

2LL/2LJ/2LH

Printer

Operating environment

Temperature 10 to 32.5 C/50 to 90.5 F

Humidity 15 to 80% RH

Altitude 2,500 m/8,202 ft or less

Brightness 1,500 lux or less

Dimensions(W D H)

machine only

668 767 747 mm26 5/16 30 3/16 29 3/8

with paper feeder

668 767 1053 mm26 5/16 30 3/16 41 7/16

Space required (W

Weight

Power source

Options

Item

Printing speed

Resolution

Operating system

Interface

Page description langu

ItemSpecifications

35 ppm 45 ppm 55 ppm1-1-3

D) 977 767 mm (using MP tray)38 7/16 30 3/16 (using MP tray)

82 kg / 180.8 lb

120 V AC, 60 Hz, more than 12.0 A220 - 240 V AC, 50/60 Hz, more than 7.2 A

Document processor, Original cover, Paper feeder, Large capacity feeder, Side deck, 1000-sheet finisher, 4000-sheet finisher, Center-folding unit, Mailbox, Punch unit, Inner job separator, Right job separator, Key counter, Fax kit, Expansion memory, Internet fax kit (A), Data security kit, Printed document guard kit, Emulation option kit, Gigabit ethernet board and document table

Specifications


Same as copying speed.

600 x 600 dpi

Windows XP, Windows Server 2003, Windows Vista, Windows 7, Windows Server 2008, Apple Macintosh OS 10.x

USB interface connector: 1 (USB Hi-speed)Network interface: 1 (10BASE-T/100BASE-TX/1000BASE-T)

age PRESCRIBE

2LL/2LJ/2LH

Scanner

*1 Available operating sys

*2 Available operating sys

NOTE: These specification

ItemSpecifications


System requirements CPU: 600 Mhz or higherRAM: 128 MB or more

Resolution 600 dpi, 400 dpi, 300 dpi, 200 dpi, 200 100 dpi, 200 400 dpi

File format TIFF, JPEG, XPS, PDF (MMR/JPEG compression), PDF (high compression)

Scanning speed(A4 landscape,

300 dpi, Image quality:

Text/Photo orig-inal)

SimplexB/W : 80 images/minColor: 50 images/min

Dup

Interface

Network protocol

Transmission system1-1-4

tem: Windows XP, Windows Server 2003, Windows Vista, Windows Server 2008,Windows 7

tem: Windows Vista, Windows 7, Windows Server 2008

s are subject to change without notice.

lexB/W : 160 images/minColor: 80 images/min

Ethernet (10 BASE-T/100 BASE-TX/1000 BASE-T)

TCP/IP

PC transmission SMB Scan to SMB FTP Scan to FTP, FTP over SSLE-mail transmission SNTP Scan to E-mailTWAIN scan*1WIA scan*2

2LL/2LJ/2LH

1-1-2 Parts names

(1) Machine

41

14

15

16

13

1. Ori2. Slit3. Ton4. Pla5. Clip6. Op7. Ha8. Re1-1-5

Figure 1-1-1

8

12

5

7 9 10

3

62

11

ginal size indicator plate glasser containerten (Contact glass) holder

eration panelndleslease button

9. Waste toner box10. Waste toner tray11. Front cover12. Toner container release lever13. Network interface connector14. USB port15. USB interface connector16. Option interface

2LL/2LJ/2LH

25

22 23 20

19

18

26

17

36

24 24

17. Inn18. Do19. Ori20. US21. Ca22. Pa23. Gu24. Pa25. Pa26. Pa1-1-6

Figure 1-1-2

35

32

34

30

31

33

27

29

21

28

er traycument processor (option)ginal cover (option)B portssettesper length guideide lock leverper width guideper width adjusting tabper conveying unit

27. Paper conveying unit lever28. Duplex cover lever29. Duplex cover30. MP paper width guide31. MP support Tray32. MP (Multi-Purpose) tray33. Paper conveying cover lever34. Paper conveying cover 35. Handle36. Main power switch

2LL/2LJ/2LH

(2) Option

2

3

9

10

7

1. Machi2. Docum3. Docum4. Paper5. Large 1-1-7

Figure 1-1-3

4

5

6

8

1

neent processor (dual scan DP)ent processor (reversed DP)

feedercapacity feeder

6. Side deck7. 1000-sheet finisher8. 4000-sheet finisher9. Center-folding unit

10. Mailbox

2LL/2LJ/2LH

(3) Operation panel

1

13 14 15

2 3

1. Program key2. Status/Job cancel ke3. Copy key4. Accessibility display 5. Help key6. Quick no. search key7. Clear key8. Reset key9. System menu key 1-1-8

Figure 1-1-4

16 17 1918 20 21 22 23 24 25 26

4 5 6 7 8 109 11 12

y

key

10. Power key11. Counter key12. Main power indicator13. Application key14. Document box key15. Send key16. FAX key*17. Processing indicator18. Numeric keys

19. Memory indicator20. Enter key21. Attention indicator22. Start key23. Stop key24. Interrupt key25. Authentication/Logout key26. Energy saver key

*: Option

2LL/2LJ/2LH

1-1-3 Machine cross section

11

4

1. Ca2. MP3. Pa4. Op5. Las6. Dru1-1-9

Figure 1-1-5

1

2

9

12

8

5

6

10

3

7

Paper path

ssette paper feed section tray paper feed sectionper conveying sectiontical sectioner scanner unitm unit

7. Developer unit8. Toner container section9. Transfer/Separation sections

10. Fuser section11. Eject/Feed shift sections12. Duplex section

2LL/2LJ/2LH1-1-10


2LL/2LJ/2LH

1-2 Installation

1-2-1 Installation environment

1. Temperature: 10 to 32.5C/50 to 90.5F2. Humidity: 15 to 80% RH3. Power supply: 120 V AC, 12.0 A

220 - 240 V AC, 7.2 A4. Power source frequency: 50 Hz 2%/60 Hz 2%5. Installation location

Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sun-light or other strong light when removing paper jams.Avoid locations subject to high temperature and high humidity or low temperature and low humidity; an abrupt change in the environmental temperature; and cool or hot, direct air.Avoid places subject toChoose a surface capPlace the machine on Avoid air-borne substaas mercury, acidic of avents.Select a well-ventilated

6. Allow sufficient accessMachine front : 100 cmMachine rear : 10 cmMachine right : 35 cmMachine left : 30 cmMachine top : 40 cm

30cm/111-2-1

dust and vibrations.able of supporting the weight of the machine.a level surface (maximum allowance inclination: 1).nces that may adversely affect the machine or degrade the photoconductor, such lkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic sol-

location. for proper operation and maintenance of the machine./39 3/8"/ 3 15/16"/13 3/4"/11 13/16"/15 3/4"

Figure 1-2-1

13/16" 35cm/13 3/4"

Top 40cm/15 3/4"

10cm/3 15/16"

100cm/39 3/8"

2LL/2LJ/2LH

1-2-2 Unpacking and installation

(1) Installation procedure

Unpacking

Removin

Removing th

Installing the pa

Release the lock of th

Start

Release of l

Loadi

Installing the

Unlocking the de

Installing other optional devices

Replacing oper

Installing the origina1-2-2

g the tapes

e eject spacer

per feeder (option)

e scanner mirror frame

ift plate stopper

ng paper

toner containers

veloper waste exit

Installing toner

Print out the user setting list

Make test copies

Connect the power cord

ation panel sheet

Exit maintenance mode

l platen or DP (option)

Setting the delivery date

(maintenance item U278)

Output an own-status report

(maintenance item U000)

Installing the cassette heater (option)

Completion of the machine installation.

2LL/2LJ/2LH

Moving the machineWhen moving the machine, pull out three carrying handles, and move with carrying handles and the hand-hold.1-2-3

Figure 1-2-2

Carrying

handle

Carrying

handle Carrying

handle

Handhold

2LL/2LJ/2LH

Place the machine on a

Unpacking

10

13

15

16,17,

18,19,20

23

23

2

23

14

21

9

8

1.2.3.4.5.6.7.8.9.

10.11.12.1-2-4

Figure 1-2-3

level surface.

56

11

3

4

23

2323

7

12

221

MachineOuter caseInner caseTop padSkidBottom sheetBottom padBottom front left padBottom front right padBottom rear left padBottom rear right padRear pad

13. Machine cover14. Document tray15. Power cord16. Plastic bag17. Paper size plates18. Paper media plates19. Operation panel sheets20. Operation guide etc.21. Eject spacer22. Barcode label23. Hinge joints

2LL/2LJ/2LH

1. Remove the eject spacer and silica gel from the eject section.

1. Remove three tapes two A3 papers.

2. Remove seven tapesthree protect sheets.

Removing the eject spacer

Silica gel

Removing the tapes1-2-5

Figure 1-2-4

and then remove

and then remove

Figure 1-2-5

Eject spacer

Tape

Tape

Tape

A3 papers

Tapes

TapeTape

Protect sheet

Protect sheet

Protect sheet

Tapes

Tape

2LL/2LJ/2LH

3. Remove eight tapes.

1. Install the optional pacapacity feeder as ne

2. Verify levelness at ththe contact glass usinand adjust the level bof the machine to opt

Tape

Tape Tape

Installing the paper fee1-2-6

Figure 1-2-6

per feeder or large cessary.

e four corners of g a level gauge, olts at the bottom imize levelness.

Tapes

Tapes

Tape

der (option)

2LL/2LJ/2LH

1. Remove the scanner lock cover.2. Mount the scanner lock cover in the

reverse manner to restore in the original location.

Release the lock of the scanner mirror frame1-2-7

Figure 1-2-7

Scanner lock cover

[Locked] [Released]

2LL/2LJ/2LH

1. Pull cassette 1 and 2 out.2. Remove the lift plate stopper from each

cassette and attach it to the storage location.When moving the machine, attach the lift plate in original position.

1. Squeeze the ends ofpaper length guide anto fit the length of the

Release of lift plate stopper

Lift plate

stopper

Loading paper1-2-8

Figure 1-2-8

the bottom of the d move the guide

paper.

Figure 1-2-9

Cassette

Paper length guide

2LL/2LJ/2LH

2. Press the guide lock lever to release the lock.

3. Grasp the paper width adjusting tab and move the paper width guides to fit the paper.

4. Align the paper flush side of the cassette.

*: Before loading the panot curled or folded.

*: Ensure that the loadeexceed the level indic

Guide lock lever1-2-9

Figure 1-2-10

against the right

per, be sure that it is

d paper does not ated.

Figure 1-2-11

Paper width

adjusting tabpaper width guides

Paper

2LL/2LJ/2LH

5. Press the guide lock lever to lock.

6. Fold the paper size pmedia plate in two an

7. Gently push the cass

Guide lock lever1-2-10

Figure 1-2-12

late and the paper d insert.ette back in.

Figure 1-2-13

Paper media plate

Paper size plate

2LL/2LJ/2LH

1. Open the front cover.2. Hold the toner container vertically and

hit the upper part about 5 times. Invert the toner container so that the other end is up, and hit in the same way.

3. Shake the toner container in a wide ver-tical curve like motion about 5 times.

4. Install the toner conta5. Turn down the toner

lever to lock the tone

Installing the toner containers1-2-11

Figure 1-2-14

iner.container release r container.

Figure 1-2-15

Toner container

Toner container

Toner container

Toner containerrelease lever

2LL/2LJ/2LH

CautionTo ease setup, the device was shipped with the developer unit already replenished with developer. Therefore, to prevent developer from spilling during shipping, a developer shutter is equipped with the developer unit.To disengage the shutter, use the following procedure: Note that if the shutter is not completely disengaged aplace, the developer in tmay clog at the outlet cathe developer unit.

1. Press the fixing pin a*: Fully insert the fixing

protrusions vertical adegrees clockwise. Mprotrusions are then

2. Remove a screw andright wards.

3. Fix the lever using thremoved at the right unlock the developer

*: When the device is sremoved, use the revlock in the developerto observe this cautiodeteriorated print qua(7460).

Unlocking the developer waste exit1-2-12

nd retained in he developer unit using a damage to

nd rotate.pin with keeping the nd rotate it by 90 ake sure that the

horizontal.

Figure 1-2-16

slide the lever

e screw previously screw hole and waste exit.hipped again or erse procedure to waste exit. Failure n could result in lity and/or C call

Figure 1-2-17

ProtrusionsProtrusions

1

2

[Locked] [Released]

Fixing pin Fixing pin

Screw

Lever

1

2

Screw

Lever

3

[Locked] [Released]

2LL/2LJ/2LH

1. Insert a flat-head screwdriver and slide the operation panel covers A and B to remove them.

2. Remove the clear pa

Replacing operation panel sheet1-2-13

Figure 1-2-18

nel.

Figure 1-2-19

Operation panel

cover A

Operation panel

cover B

Clear panel

2LL/2LJ/2LH

3. Remove the operation panel sheet.4. Replace the operation panel sheet of

the corresponding language.5. Refit the clear panel.6. Refit the operation panel covers A and

B.

1. Install optional origina

1. Install the optional detor, document finisheetc.) as necessary.

1. Install the optional canecessary (see page

1. Connect the power ccord connector on remachine.

2. Connect the power plet.

Operation

panel sheet

Installing the original p

Installing other optiona

Installing the cassette

Connect the power co1-2-14

Figure 1-2-20

l platen or DP.

vices (job separa-r and/or fax kit

ssette heater as 1-2-63).

ord to the power ar lower of the

lug to the wall out-

laten or DP (option)

l devices

heater (option)

rd

2LL/2LJ/2LH

1. Turn the main power switch on. Toner installation is started.

2. The drive chain is disengaged when toner installation is completed.Run maintenance mode U132 if [Add Toner] remains displayed even after the drive chain is disengaged (see page 1-3-79).

1. Enter the maintenancing 10871087 using t

2. Enter 278 using the npress the start key.

3. Select [Today].4. Press the start key. T

set.5. Press the stop key to

1. Enter 000 using the npress the start key.

2. Select [Maintenance]start key. A status rep

3. Press the stop key to

1. Enter 001 using the npress the start key. Tthe maintenance mod

Installing toner

Setting the delivery da

Output an own-status

Exit maintenance mod1-2-15

e mode by enter-he numeric keys.umeric keys and

he delivery date is

exit.

umeric keys and

and press the ort is output. exit.

umeric keys and he machine exits e.

te (maintenance item U278)

report (maintenance item U000)

e

2LL/2LJ/2LH

1. Select [Report Print] to output the user various setting reports.

1. Place an original and make test copies.

Print out the user setting list

Make test copies

Completion of the mac1-2-16

hine installation

2LL/2LJ/2LH

(2) Setting initial copy modesFactory settings are as follows:

Maintenanceitem No. Contents Factory setting

U253 Switching between double and single counts DBL(A3/Ledger)

U260 Selecting the timing for copy counting Eject

U285 Setting service status page On

U323 Setting abnormal temperature and humidity warning On

U325 Setting the paper interval Off/1

U326 Settin

U327 Settin

U343 Switch1-2-17

g the black line cleaning indication On/8

g the cassette heater control Off

ing between duplex/simplex copy mode Off

2LL/2LJ/2LH

1-2-3 Installing the key counter (option)

(1) Installing directly on the device

Key counter installation

Supplied parts of key co

Parts

Key counter

Key counter set

Key counter wire

M4 nut

Parts

Key counter socket assem

Key counter cover retaine

Key counter retainer

Key counter cover

Key counter mount

Edging

Band

M3 x 8 tap-tight P screw


M4 x 10 tap-tight S screw

M3 x 6 bronze flat-head s


M3 nut

M3 x 8 bronze binding sc


M4 x 6 chrome TP screw

M4 x 10 chrome TP screw1-2-18

requires the following parts:

unter set (302A369708):

Quantity Part.No.

1 3025418011

1 302A369708

1 302K946AJ0

2 3CY06030

Quantity Part.No.

bly 1 3029236241

r 1 302GR03010

1 302GR03020

1 3066060011

1 3066060041

2 7YZM210006++H01

1 M21AH010

1 5MBTPB3008PW++R

2 5MBTPB4010PW++R

2 5MBTPB4010TW++R

crew 2 7BB003306H

2 7BB100420H

1 7BC1003055++H01

rew 1 B1B03080

1 B1B54300

5 B4A04060

2 B4A04100

2LL/2LJ/2LH

Procedure1. Press the power key on the operation

panel to off. Make sure that the power indicator and the memory indicator are off before turning off the main power switch. And then unplug the power cable from the wall outlet.

2. Fit the key counter socket assembly to the key counter retainer using two screws and nut.

3. Fit the key counter mount to the key counter cover using two screws.

4. Fit the key counter retainer to the key counter mount using

5. Pull the paper convey6. Remove two screws

the ISU right cover.7. Remove the screw an

then remove the righ

Key counter mount

M4 x 6 screw

M4 x 6 screw

M3 nut


M4 x 6 screw1-2-19

two screws.

Figure 1-2-21

ing unit out.and then remove

d five hooks and t upper cover.

Figure 1-2-22

M3 x 6 flat-head screws Key counter cover

M4 x 6 screw

Key counter socket assembly

ISU rightcover

Screws

Right upper cover

Screw

Right upper cover

HooksHook

Hook

2LL/2LJ/2LH

8. Cut out the aperture plate on the right upper cover using nippers.

9. Remove seven screwremove the rear uppe

Aperture1-2-20

Figure 1-2-23

s and then r cover.

Figure 1-2-24

Right upper cover

Rear upper cover

Screws

Screws

Screw

Screws

2LL/2LJ/2LH

10. Open the controller lid.11. Remove two screws.12. Unhook six hooks and then remove the

left upper cover.

13. Release seven wire stroller box.

14. Remove the wire hold

Left upper cover1-2-21

Figure 1-2-25

addles on the con-

er.

Figure 1-2-26

ScrewsController lid

Left upper cover

Hooks

Hooks

Hook

Wire holder

Wire saddles

Wire saddles

Wire saddle

Controller box

Wire saddle

2LL/2LJ/2LH

15. Remove the following connectors that connected to the main PWB from the outside of the control box.YC25YC11YC30YC24YC3 (FFC connector with a lock)YC17 (BK)YC21 (WH)YC12

*: When removing the Fconnector with a lockafter released by liftin(see figure a).

*: When connecting theprojection in the termby knocking down theinserting the FFC to tboth projections are h(see figure b).

Controller box

Main PWB

YC121-2-22

FC from the FFC , remove the FFC g up the lock lever

FFC that there is a inal both sides, lock lock lever after

he connector until idden

Figure 1-2-27

[State of lock] [Lock release/FFC detaching]

Main PWB

[FFC connection/Lock]

a

b

1Lock lever

Lock lever

FFC

2

2Lock lever

FFC

YC25

YC11YC30

YC24

YC3

YC21YC17

FFC connector with a lock

1

Projection

Projection

2LL/2LJ/2LH

16. Remove five screws.17. Unhook two hooks and then remove the

controller box.

18. Connect the connectter wire to the connecengine PWB.

Hook

Hook

Screws

Controller box1-2-23

Figure 1-2-28

or of the key coun-tor YC24 on the

Figure 1-2-29

ScrewsScrew

Engine PWB

Key counter wire

YC24

Engine PWB

2LL/2LJ/2LH

19. Remove two wire holders.20. Route the key counter wire through the

wire guide and fix it at the wire holders.

21. Release three wire sa22. Remove the wire hold23. Route the key counte

three wire saddles anfix it at the wire holde

24. Refit the controller bo25. Refit the left upper co

upper cover.

key counter wire1-2-24

Figure 1-2-30

ddles.er.r wire through the d wire guide and r.x.ver and the rear

Figure 1-2-31

Wire holders

Wire guide

Wire holder

Wire saddles

Wire saddle

Wire guide

key counter wire

2LL/2LJ/2LH

26. Mount two M4 nuts at the back of the right upper cover.

27. Insert the projection ocover retainer in the aright upper cover.

28. Fit the key counter cothe two M4 x 20 scre

M4 nuts1-2-25

Figure 1-2-32

f the key counter perture of the

ver retainer using ws.

Figure 1-2-33

Right upper cover

Right upper cover

Aperture

Key counter

cover retainer

M4 x 20 screw

M4 x 20 screw

Projection

2LL/2LJ/2LH

29. Pass the connector of the key counter wire through the aperture in the right upper cover.

30. Refit the right upper cover.31. Refit the ISU right cover.32. Close the paper conveying unit.

33. Connect the key counthe key counter wire.

34. Fit the key counter comachine using the M

35. Insert the key countecounter socket assem

36. Turn the main power enter the maintenanc

37. Run maintenance item[Key-Counter] (see p

38. Exit the maintenance39. Check that the messa

key counter to be inson the touch panel wter is pulled out.

40. Check that the countcopies are made.

Right upper cover

Aperture1-2-26

Figure 1-2-34

ter signal cable to

ver to the 4 x 6 screw.

r into the key bly.

switch on and e mode. U204 and select

age 1-3-97). mode.ge requesting the

erted is displayed hen the key coun-

er counts up as

Figure 1-2-35

Key counter wire

Key counter

cover

Key counter

wire

Key counter wire

Key counter

signal cable

M4 x 6 screw

2LL/2LJ/2LH

(2) Mounting on the document table

Key counter installation

Supplied parts of key co

Parts

Key counter

Key counter set

Key counter wire

Document table

Parts

Key counter socket assem

Key counter cover retaine


Key counter cover

Key counter mount

Edging

Band




M3 x 6 bronze flat-head s


M3 nut

M3 x 8 bronze binding sc


M4 x 6 chrome TP screw

M4 x 10 chrome TP screw1-2-27

requires the following parts:

unter set (302A369708):

Quantity Part.No.

1 3025418011

1 302A369708

1 302K946AJ0

1 1902H70UN1 (option)

Quantity Part.No.

bly 1 3029236241

r 1 302GR03010

1 302GR03020

1 3066060011

1 3066060041

2 7YZM210006++H01

1 M21AH010

1 5MBTPB3008PW++R

2 5MBTPB4010PW++R

2 5MBTPB4010TW++R

crew 2 7BB003306H

2 7BB100420H

1 7BC1003055++H01

rew 1 B1B03080

1 B1B54300

5 B4A04060

2 B4A04100

2LL/2LJ/2LH

Procedure1. Perform steps 1 through 25 as

explained in (1) Installing directly on the device.


3. Fit the tray stay to the right upper cover using two M4 x 14 screws.

*: Secure the screws mnuts do not fall.

M4 nutM4 nut1-2-28

aking sure that the

Figure 1-2-36

M4 nut

M4 nut

Right upper coverM4 x 14 screw

M4 x 14 screw

Tray stay

Right upper cover

M4 x 14 screw

M4 nut

2LL/2LJ/2LH

4. Fit the tray retainer to the machine using the M4 x 8 screw.

*: The procedure described above is not required if an optional right job separator has been installed.

5. Pass the connector owire through the aperupper cover.

6. Refit the right upper c7. Refit the ISU right co8. Close the paper conv

Tray retainer

M4 x 8 screw1-2-29

Figure 1-2-37

f the key counter ture in the right

over.ver.eying unit.

Figure 1-2-38

Tray retainer

M4 x 8 screw

Right upper cover

Screw

Key counter wire

Aperture

2LL/2LJ/2LH

9. Snap in the tray mount to the tray stay and fix using two M4 x 8 screws. M4 x 8 screw

M4 x 8 screw1-2-30

Figure 1-2-39

Tray stayTray mount

2LL/2LJ/2LH

10. Cut out the aperture plate on the tray cover using nippers.

11. Fit the tray cover to the tray stay using four M4 x 8 screws.

12. Fit the key counter cotwo M4 x 20 tap-tight

M4 x 8 screws

Aperture

Tray cover

M4 x 8 screws1-2-31

Figure 1-2-40

ver retainer using S screws.

Figure 1-2-41

Tray cover

Key counter

cover retainer

M4 x 20

tap-tight S

screw

M4 x 20

tap-tight S

screw

2LL/2LJ/2LH

13. Pass the key counter signal cable through the aperture in the document table.

14. Fit the key counter cover to the docu-ment table using the M4 x 6 screw.

15. Connect the key counter signal cable to the key counter wire.

Key counter

cover

Key counter

signal cable

M4 x 6 screw1-2-32

Figure 1-2-42

Aperture

Key counter

signal cable

Key counter wire

2LL/2LJ/2LH

16. Fit the tray lower cover.Install the key counter signal cable and key counter wire so that they are held behind the tray lower cover.

Tray lower cover1-2-33

Figure 1-2-43

Connector

2LL/2LJ/2LH

17. Secure the tray lower cover with two pins.

18. Adhere the sheet ontdocument table.

19. Insert the key countecounter socket assem


21. Run maintenance item[Key-Counter] (see p

22. Exit the maintenance23. Check that the messa

key counter to be inson the touch panel wter is pulled out.

24. Check that the countcopies are made.


Figure 1-2-44

o right side of the

r into the key bly.

switch on and e mode. U204 and select

age 1-3-97). mode.ge requesting the

erted is displayed hen the key coun-

er counts up as

Figure 1-2-45

Pin

Pin

Sheet

Document table

2LL/2LJ/2LH

1-2-4 Installing the key card MK-2 (option for japan only)

Key card installation requires the following parts:

Parts Quantity Part.No.

Key card MK-2 1 8J272002 (option)

MK-2 mount 1Supplied with MK-2

M4 x 16 screw 2

Document table 1 1902H70UN1 (option)

M4 x 20 tap-tight S screw 2 7BB100420H1-2-35

2LL/2LJ/2LH



2. Pull the paper conveying unit out.3. Remove two screws and then remove

the ISU right cover.4. Remove the screw and five hooks and

then remove the right upper cover.

5. Remove seven screwremove the rear uppe

ISU rightcover

Screws

Right upper cover1-2-36

Figure 1-2-46

s and then r cover.

Figure 1-2-47

Screw

Right upper cover

HooksHook

Hook

Rear upper cover

Screws

Screws

Screw

Screws

2LL/2LJ/2LH

6. Open the controller lid.7. Remove two screws.8. Unhook six hooks and then remove the

left upper cover.

9. Release seven wire stroller box.

10. Remove the wire hold

Left upper cover1-2-37

Figure 1-2-48

addles on the con-

er.

Figure 1-2-49

ScrewsController lid

Left upper cover

Hooks

Hooks

Hook

Wire holder

Wire saddles

Wire saddles

Wire saddle

Controller box

Wire saddle

2LL/2LJ/2LH

11. Remove the following connectors that connected to the main PWB from the outside of the control box.YC25YC11YC30YC24YC3 (FFC connector with a lock)YC17 (BK)YC21 (WH)YC12

*: When removing the Fconnector with a lockafter released by liftin(see figure a).

*: When connecting theprojection in the termby knocking down theinserting the FFC to tboth projections are h(see figure b).

Controller box

Main PWB

YC121-2-38

FC from the FFC , remove the FFC g up the lock lever

FFC that there is a inal both sides, lock lock lever after

he connector until idden

Figure 1-2-50

[State of lock] [Lock release/FFC detaching]

Main PWB

[FFC connection/Lock]

a

b

1Lock lever

Lock lever

FFC

2

2Lock lever

FFC

YC25

YC11YC30

YC24

YC3

YC21YC17

FFC connector with a lock

1

Projection

Projection

2LL/2LJ/2LH

12. Remove five screws.13. Unhook two hooks and then remove the

controller box.

14. Cut out the aperture upper cover using nip

Hook

Hook

Screws

Controller box1-2-39

Figure 1-2-51

plate on the right pers.

Figure 1-2-52

ScrewsScrew

Right upper cover

Aperture

2LL/2LJ/2LH


16. Fit the tray stay to the right upper cover using two M4 x 14 screws.

*: Secure the screws mnuts do not fall.

M4 nutM4 nut1-2-40

aking sure that the

Figure 1-2-53

M4 nut

M4 nut

Right upper coverM4 x 14 screw

M4 x 14 screw

Tray stay

Right upper cover

M4 x 14 screw

M4 nut

2LL/2LJ/2LH

17. Snap in the tray mount to the tray stay and fix using two M4 x 8 screws.

18. Cut out the aperture cover using nippers.

M4 x 8 screw

M4 x 8 screw1-2-41

Figure 1-2-54

plate on the tray

Figure 1-2-55

Tray stayTray mount

ApertureTray cover

2LL/2LJ/2LH

19. Pass the MK-2 signal cable through the aperture in the tray cover, tray stay and right upper cover.

Aperture

MK-2

MK-2 signal cable1-2-42

Figure 1-2-56

Tray stay

Right upper cover

Aperture

Tray corer

Aperture

MK-2 signal cable

2LL/2LJ/2LH

20. Connect the connector of the MK-2 sig-nal cable to the connector YC25 on the engine PWB.

21. Remove the screw from the machine.22. Fix the MK-2 signal cable to the ground

terminal with the screw that was removed.

Ground terminal

Screw1-2-43

Figure 1-2-57

Engine PWB

MK-2 signal cable

Screw

Ground terminal

YC25

Engine PWB

2LL/2LJ/2LH

23. Remove three wire holders.24. Route the MK-2 signal cable through

the wire guide and fix it at three wire holders.

*: Dress the MK-2 signal wire away from the scanner motor and fix.

25. Refit the controller box.26. Refit the left upper cover and the rear

upper cover.

Wire holder

Wire guideScanner

motor1-2-44

Figure 1-2-58

Wire holders

Wire guide

MK-2 signal cable

2LL/2LJ/2LH

27. Fit the tray retainer to the machine using the M4 x 8 screw.

*: The procedure described above is not required if an optional right job separator has been installed.

28. Refit the right upper c29. Refit the ISU right co30. Close the paper conv31. Fit the tray cover to th

four M4 x 8 screws.

Tray retainer

M4 x 8 screw1-2-45

Figure 1-2-59

over.ver.eying unit.e tray stay using

Figure 1-2-60

Tray retainer

M4 x 8 screw

M4 x 8 screws

Tray cover

Tray stay

M4 x 8 screws

2LL/2LJ/2LH

32. Remove the four screws securing the MK-2 cover; attach the MK-2 mount to the MK-2, and secure using the four screws.

33. Fit the MK-2 to the dousing two M4 x 20 ta

Screws

Screws

MK-21-2-46

Figure 1-2-61

cument table p-tight S screws.

Figure 1-2-62

MK-2 mount

Screws

Screws

MK-2

MK-2

Document table



2LL/2LJ/2LH

34. Fit the tray lower cover.35. Secure the tray lower cover with two

pins.


Figure 1-2-63

Pin

Pin

2LL/2LJ/2LH

36. Adhere the sheet onto right side of the document table.

37. Turn the main power switch on and enter the maintenance mode.

38. Run maintenance item U204 and select [Key-Card] (see page 1-3-97).

39. Exit the maintenance mode.

Sheet

Document table1-2-48

Figure 1-2-64

2LL/2LJ/2LH

1-2-5 Installing the KMAS (option for japan only)

KMAS installation requires the following parts:

Using the PHS module

Supplied parts of KMAS

Using a modem


PHS module 1 HM000080 (option)

PHS signal cable 1 023CK200 (option)

KMAS interface PWB 1 023CK000 (option)

M3 x 16 bronze binding s

Ferrite core

Clamp

KMAS wire set

Parts

KMAS wire

Spacer A

Spacer B

Parts

RS-232C signal cable

RS-232C relay cable

KMAS interface PWB1-2-49

wire set (302K994610):

crew 2 B3323160

1 2A027770

1 M2105910

1 302K994610

Quantity Part.No.

1 302K946AG0

1 7YZM510009++H01

3 7YZM510011++H01

Quantity Part.No.

1 303CK60011

1 303CK60041

1 023CK000 (option)

2LL/2LJ/2LH

ProcedureTo fix KMAS, perform the following procedure:

Fitting the KMAS interface PWB

Setting the DIP switch

Using the

Fitting the

and PHS m

Start1-2-50

PHS module

PHS signal cable

odule

Using a modem

Fitting the RS-232C signal cable

Initializing the KMAS

End

2LL/2LJ/2LH

Setting the DIP switch1. Configure DIP switches 1 to 4 on the

KMAS interface board as follows:

DIP SW No.

1 PHS mON: UOFF:

2 ModeON: POFF:

3 CommdeviceON: 9OFF:

4 CommnotifyiSwitchON: MOFF:

1 2 3 4

ON

DIP switch

KMAS interface PWB1-2-51

Figure 1-2-65

Description Remarks

odule/modem switchingse modemUse PHS module

m outgoing switchingulseTone

This is required when modem is used.

unication speed switching with the

600bps19200bps

Set to OFF.

unication log when automatically ng service callsing messagesessage is fixed

Normal message is used

When ON, the message is Call a service representative.When OFF, the message will vary depend-ing on communication status. To setup the system with automatic accounting only, ON may be set.

2LL/2LJ/2LH

Fitting the KMAS interface PWB2. Remove seven screws and then

remove the rear upper cover.

3. Attach one spacer A B to the side of the co

Rear upper cover

Screws

Screws1-2-52

Figure 1-2-66

and three spacers ntroller box.

Figure 1-2-67

Screws

Screw

Spacer B

Spacer B

Spacer A

Controller box

Spacer B

2LL/2LJ/2LH

4. Insert the KMAS interface PWB to three spacers B.

5. Remove YC7 and YCPWB and connector omor. Remove the rela

Spacer B

Spacer B1-2-53

Figure 1-2-68

23 on the main f the controller fan y wire.

Figure 1-2-69

KMAS interface PWB

Spacer B

Controller

fan motor

YC23

YC7

Relay wire

Main PWB

2LL/2LJ/2LH

6. Connect the connector of the KMAS wire to the connector YC1 on the KMAS PWB.

7. Connect the connector of the KMAS wire to controller fan motor, YC7 and YC23 on the main PWB.

KMAS wire

YC11-2-54

Figure 1-2-70

KMAS interface PWB

Controller fan motor

YC23

YC7

KMAS wire

Main PWB

2LL/2LJ/2LH

8. Pass the KMAS wire through the edging of the controller box and wire saddle and then fasten the KMAS wire.

Fitting the PHS signal caule

9. Remove two screws the lid from the rear u

10. Pass the PHS signal aperture in the rear u

11. Secure the PHS signupper cover with two

KMAS wire

Edging1-2-55

Figure 1-2-71

ble and PHS mod-

and then remove pper cover.cable through the pper cover.al cable to rear screws.

Figure 1-2-72

Wire saddle

Screw

Screw

Screw

Lid

Rear upper cover

PHS signal cable

Screw

2LL/2LJ/2LH

12. Connect the connector of the PHS sig-nal cable to the connector YC2 on the KMAS interface PWB.

13. Refit the rear upper cover.

14. Fit the PHS module tusing two M3 x 16 sc

YC2

KMAS

interface PWB1-2-56

Figure 1-2-73

o rear upper cover rews.

Figure 1-2-74

PHS signal

cable

Rear upper cover

PHS module

M3 x 16 screws

2LL/2LJ/2LH

15. Wrap the PHS signal cable around the ferrite core a turn.

16. Connect the connector of the PHS sig-nal cable to PHS module.

17. Fit the clamp to PHS signal cable.18. After using alcohol to clean the rear

upper cover, adhere the clamp to rear upper cover.

Fitting the RS-232C sign1. By referring to the ins

fix the PHS signal wirnector at the end of tcable to the YC3 conKMAS interface PWBIf the wire length is sh232C extension cable

2. Connect the RS-232Cthe modem.

Initializing the KMAS1. Turn the main power

enter the maintenanc2. Run maintenance ite

forms [Init/Set TEL N95).

3. Exit the maintenance

PHS module

Ferrite core1-2-57

Figure 1-2-75

al cabletructions given to e, insert the con-he RS-232C relay nector on the .ort, use a RS-. signal cable to

switch on and e mode.m U202 and Per-o.] (see page 1-3-

mode.

PHS signal cable

Clamp

PHS signal cable

2LL/2LJ/2LH

1-2-6 Installing the coin vender (option for japan only)

Coin vender installation requires the following parts:

Procedure1. Press the power key

panel to off. Make suindicator and the memoff before turning off switch. And then unpcable from the wall o

2. Fit the vender base tousing four M4 x 6 scr


Coin vender 1 1905H99JP0 (option)

Vender wire 1Supplied with coin venderFerrite core 1

Clamp 1

Vender signal cable 1 302K946AE01-2-58

on the operation re that the power

ory indicator are the main power lug the power utlet. coin vender

ews.

Figure 1-2-76

Coin vender

M4 x 6 screws

M4 x 6 screws

Vender base

2LL/2LJ/2LH

3. Remove seven screws and then remove the rear upper cover.

4. Remove eight screws5. Release two hanging

remove the rear lowe

Rear upper cover

Screws

Screws1-2-59

Figure 1-2-77

. parts and then r cover.

Figure 1-2-78

Screws

Screw

Rear lower cover

Screw

Screw

Screws

Screws

2LL/2LJ/2LH

6. Remove two screws and then remove the lid.

7. Connect the connectsignal cable to the cothe engine PWB.

8. Pass the vender signthe wire guide and tethen fasten the cable1-2-60

Figure 1-2-79

or of the vender nnector YC23 on

al cable through n wire saddles and .

Figure 1-2-80

Screws

Lid

YC23

Wire saddlesVender

signal cable

Engine PWB

Wire saddles

Wire saddle

Wire saddles

Wire saddle

Wire guide

2LL/2LJ/2LH

9. Pass the vender wire through the aper-ture in the IF mount.

10. Secure the vender wire with two screws removed in step 6.

11. Secure the ground terminal of the vender wire to rear frame with the screw.

12. Connect the connector of the vender wire to connector of the vender signal cable.

13. Refit the rear lower a14. Connect the signal ca

to connector of the ve

Ground terminal

Screw1-2-61

Figure 1-2-81

nd upper covers.ble of coin vender nder wire.

Figure 1-2-82

Screws

Vender wire

Ground terminal

Screw

Vender

signal cable

IF mount

Signal cable of

coin vender

Vender wire

2LL/2LJ/2LH

15. Fit the ferrite core to signal cable of coin vender.

16. Fit the clamp to signal cable of coin vender.

17. Remove a screw from the coin vender and fix the coin vender with a clamp.

18. Affix the price size deside of the coin vend


20. Run maintenance movate 'Coin vender is iconfiguring the coin v(see page 1-3-98).

21. Exit the maintenance

Clamp

Coin vender1-2-62

Figure 1-2-83

cal at the right er operation panel.

Figure 1-2-84

switch on and e mode.de U206 and acti-

nstalled. Continue ender required

mode.

Screw

Ferrite core

Signal cable

of coin vender

Signal cable of

coin vender

Price size seal

2LL/2LJ/2LH

1-2-7 Installing the cassette heater (option)

Cassette heater installation requires the following parts:

Supplied parts of cassette heater set (302K994930):

Supplied parts of casset


Cassette heater set (120V) 1 302K994930

Cassette heater set (240V) 1 302K994940


Cassette heater (120V)

Wire saddle


Parts

Cassette heater (240V)

Wire saddle

M3 x 8 tap-tight S screw1-2-63

te heater set (302K994940):

1 302H794620

3 7YZM610001++H0

2 7BB700308H

Quantity Part.No.

1 302H794610

3 7YZM610001++H0

2 7BB700308H

2LL/2LJ/2LH



2. Pull the cassette 1 forward.3. Remove the pin and then remove the

cassette 1.

4. Pull the cassette 2 fo5. Remove the pin and

cassette 3.

Pin1-2-64

Figure 1-2-85

rward.then remove the

Figure 1-2-86

Cassette1

Pin

Cassette2

2LL/2LJ/2LH

6. Fit three wire saddles on the bottom frame of the machine.

7. Fit the cassette heater using two M3 x 8 screws.1-2-65

Figure 1-2-87

Cassette heater

Screw

Screw

Wire saddle

Wire saddle

Wire saddle

2LL/2LJ/2LH

8. Connect the connector of the cassette heater to the connector in the rear frame of the machine.

9. Pass the wire of the cassette heater through three wire saddles and then fasten the wire.

Wire saddles

Wire saddle1-2-66

Figure 1-2-88

Cassette heater

Connector

2LL/2LJ/2LH

1-3 Maintenance Mode

1-3-1 Maintenance mode

The machine is equipped with a maintenance function which can be used to maintain and service the machine.

(1) Executing a maintenance item

Ent

Enter

number us

The select

P

P

Start

m

Run

Yes

Yes

Ente

up/dow

an1-3-1

er 10871087 using

the numeric keys.

the maintenance item

ing the cursor up/down keys

or numeric keys.

ed maintenance item is run.

ress the stop key.

ress the start key.

End

Maintenance mode is entered.

The maintenance item is selected.

Maintenance mode is exited.

Repeat the same

aintenance item?

another maintenance

item?

No

No

r 001 using the cursor

n keys or numeric keys

d press the start key.

2LL/2LJ/2LH

(2) Maintenance modes item list

Section ItemNo. Content of maintenance itemInitial setting

35ppm 45ppm 55ppm

General U000 Outputting an own-status report -

U001 Exiting the maintenance mode -

U002 Setting the factory default data -

U003 Setting the service telephone number -

U004 Setting the machine number -

U010 Setting the maintenance mode ID -

U019 Disp

Initializa-tion

U021 Mem

U024 HDD

Drive, paper feed and paper conveying system

U030 Chec

U031 Chec

U032 Chec

U033 Chec

U034 Adju

LSU

LSU

U035 Setti

U037 Chec

U039 Adju

U051 Adju

U052 Setti

Set

Loo

Set

U053 Setti

Mot

Mot

Mot

Mot

Mot1-3-2

laying the ROM version -

ory initializing -

formatting -

king the operation of the motors -

king switches and sensors for paper conveying -

king the operation of the clutches -

king the operation of the solenoids -

sting the print start timing

Out Top 0/0/0/0/0/0/0/0/0/0/0/0

Out Left 0/0/0/0/0/0/0

ng the printing area for folio paper 330/210

king the operation of the fan motors -

sting the magnification 0

sting the deflection in the paper 1/1/1/1/1/1

-5/0/-5/0/-5/0

-8/-1/-8/-1/-8/-1

ng the fuser motor control

Loop Sensor -

p Sensor Control On/On/On/On/On/On

Loop Sensor Valid On

ng the adjustment of the motor speed

er1 78 60 49

er2 953/-/69 736/33/53

596/27/43

er3 0/23/0/0/66/0/-/-/-

0/18/0/0/-94/0/42/-10/-10

0/14/0/0/-76/0/34/

-8/-8

er1 Half 156 120 97

er2 Half 1907/-/137

1473/66/106

1191/54/86

2LL/2LJ/2LH

Drive, paper feed and paper conveying system

U053 Moter3 Half 0/23/0/0/132/0/

-/-/-

0/18/0/0/-188/0/84/-20/-20

0/14/0/0/-152/0/68/-16/-16

U059 Setting fan mode

Fan Mode Mode1

Cooling Mode 0

Optical U061 Checking the operation of the exposure lamp -

U063 Adjusting the shading position 0

U065 Adju

U066 Adju

U067 Adju

U068 AdjuDP

U070 Adju

U071 Adju

U072 Adju

U073 Chec

U074 DP in

U087 Setti

U089 Outp

U091 Setti

U099 Adju

High voltage

U100 Adju

Adj

Set

Set

Adj

Set

Set

Chk


35ppm 45ppm 55ppm1-3-3

sting the scanner magnification 0/0

sting the scanner leading edge registration 0/0

sting the scanner center line 0/0

sting the scanning position for originals from the 0/0

sting the DP magnification 0/0/0

sting the DP scanning timing 0/0/0/0

sting the DP center line 0/0/0

king the scanner operation -

put response adjustment 1

ng DP reading position modification operation 125/125/125

utting a MIP-PG pattern -

ng the white line correction 112/112/112/75/0

sting original size detection DP is not installed20/30/40/20/30/40/20/30/40

DP is installed50/50/50/50/50/50/50/50/50

sting main high voltage

AC Bias -

AC Auto Adj On

DC Bias -

DC Bias 0/0

Low Temp 1

Charger Freq 9160

Current -

2LL/2LJ/2LH

High voltage

U106 Setting the voltage for the secondary transfer

Light/Normal1 1st 145/143/136

161/158/149

177/173/163

Light/Normal1 2nd 138/127/121

152/137/129

165/148/138

Normal2/3 1st 145/143/136

161/158/149

177/173/163

Normal2/3 2nd 138/127/ 152/137/ 165/148/

Hea

Hea

Hea

Hea

OHP

Bias

U110 Chec

U111 Chec

U117 Chec

U118 Disp

U119 Setti

U127 Chec

U128 Setti

Developer U130 Tone

U131 Adju

Man

Mod

U132 Repl

U135 Chec

U136 Setti

U139 Dispmach



121 129 138

vy1-3 1st Half 122/122/118

130/130/126

116/116/114

vy1-3 2nd Half 115/115/105

122/122/109

121/121/109

vy4/5 1st Half 118/118/115

126/126/121

134/134/128

vy4/5 2nd Half 115/115/105

121/121/109

128/128/113

150/150/150

162/162/162

179/179/179

163/163/108/100

163/163/113/102

163/163/117/105

king the drum count -

king the drum drive time -

king the drum number -

laying the drum history -

ng the drum -

king/clearing the transfer count -

ng transfer high-voltage timing -20/0/-10 -18/0/-10 -15/0/-10

r installation -

sting the toner sensor control voltage -

ual 107 120 128

e Auto

enishing toner forcibly -

king toner motor operation -

ng toner near end detection 3

laying the temperature and humidity outside the ine

-

2LL/2LJ/2LH

Developer U140 Displaying developer bias

Sleeve DC 62 62 70

Sleeve AC 159 159 150

Mag DC 148 148 180

Mag AC 101 101 199

Sleeve Freq 5345 5511 5345

Sleeve Duty 37 37 68

Mag

AC

U147 Setti

Timi

Mod

Upp

Mini

U148 Setti

U155 Chec

Sup

Emp

U156 Setti

U157 Chec

U158 Chec

Fuser U161 Setti

War

Prin

U163 Rese

U167 Chec

U199 Disp



Duty 37 37 68

Calib Default

12Mode1

ng for toner applying operation

ng 4/35 4/45 4/55

e Mode1

er Limit 2.0

mum 10

ng drum refresh mode 2

king sensors for toner -

ply 512/512/512/512

ty 100/100/100/100

ng the toner replenishment level -

king the developer drive time -

king the developer count -

ng the fuser control temperature

m Up 110/110/155/150/155/160

110/110/160/155/160/160

110/110/170/165/170/160

t 175/185/10

165/175/5

160/170/0

tting the fuser problem data -

king/clearing the fuser count -

laying fuser heater temperature -

2LL/2LJ/2LH

Operationpanel andsupportequipment

U200 Turning all LEDs on -

U201 Initializing the touch panel -

U202 Setting the KMAS host monitoring system -

U203 Checking DP operation -

U204 Setting the presence or absence of a key card or key counter

Off/Coin Vender

U206 Setting the presence or absence of a coin vender

On/O

No C

Pric

U207 Chec

U208 Setti

U211 Settitor

U221 Setti

U222 Setti

U223 Oper

U224 Pane

U234 Setti

U237 Setti

U240 Chec

U241 Checisher

U243 Chec

U244 Chec

U245 Chec

U246 Setti

Finis

Boo

U247 Setti

U249 Finis

Mode setting

U250 Chec

U251 Chec

U252 Setti

U253 Switc

U260 Sele


35ppm 45p

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Kyocera TASKalfa 3500i 4500i 5500i

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