KPOWERSCIENCE KP3828 Series Maintenance Manual Download Page 1

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ISO 9001 CERTIFIED

TAIWAN BUSINESS DEPARTMENT:

8FL.,No. 276, Sec.1,Ta-Tung Rd., Hsi-Chih City, Taipei Hsien 221,Taiwan
TEL:886-2-2647-5855 FAX:886-2-2643-1151

CHINA BUSINESS DEPARTMENT:

No. 4, Lane 185, Huan-Ho St., Hsi-Chih City, Taipei Hsien 221,Taiwan
TEL:886-2-2694-8799 FAX:886-2-2694-6657

INTERNATIONAL BUSINESS DEPARTMENT:

No. 4, Lane 185, Huan-Ho St., Hsi-Chih City, Taipei Hsien 221,Taiwan
TEL:886-2-2694-8799 FAX:886-2-2694-6657

KP3828 Series

Maintenance Manual

VER 2.6.

-2006

KPOWERSCIENCE CO.,LTD.

Summary of Contents for KP3828 Series

Page 1: ...643 1151 CHINA BUSINESS DEPARTMENT No 4 Lane 185 Huan Ho St Hsi Chih City Taipei Hsien 221 Taiwan TEL 886 2 2694 8799 FAX 886 2 2694 6657 INTERNATIONAL BUSINESS DEPARTMENT No 4 Lane 185 Huan Ho St Hsi Chih City Taipei Hsien 221 Taiwan TEL 886 2 2694 8799 FAX 886 2 2694 6657 KP3828 Series Maintenance Manual VER 2 6 4 9 2006 KPOWERSCIENCE CO LTD ...

Page 2: ...er1 Overview Chapter2 Principles Chapter3 Installation Chapter4 Electrical System Chapter5 Adjustments Chapter6 Periodic Maintenance Chapter7 Parts Replacement Chapter8 Troubleshooting Appendix I KMPU Circuit Diagram ...

Page 3: ...Chapter1 Overview 1 1 External View 1 1 1 2 Specifications 1 2 1 3 Features 1 4 1 4 Diagram 1 5 1 5 Configuration 1 6 1 6 Operations and Adjustments 1 11 ...

Page 4: ...Chapter 1 Overview ...

Page 5: ...1 1 1 1 External View External View ...

Page 6: ...eaning system Blade type cleaning system Fusing method Flash fusing with Xenon lamp Paper feed Input Tractor feed automatic paper loading without waste of paper Transport Suction belt feed Paper exit Roller Printing Face up print Paper hopper 3000 sheets 64g m2 Stacker capacity 3000 sheets 64g m2 Dimension 805 mm W 1270 mm H 850 mm D Weight 220 240 with stacker 2 Power Power supply 220V 10 single ...

Page 7: ... 4 Environment Temperature Operating 10 to 30 C Non operating 10 to 35 C Humidity Operating 30 to 80 RH Non operating 10 to 80 RH non condensing Inclination of floor 1 angle max 5 Reliability Monthly duty cycle 500K 550K 600K pages 8 5 length B W 5 Mechanical life 5 years or 18 000 000 pages 8 5 Warm up time 60 seconds max First page print time 25 seconds max MTBF 2 000 hours Safety regulation BSM...

Page 8: ...e low hardware and consumable costs offer higher cost efficiency than existing competing brands 4 LED exposure for enhanced printing resolution Exposure LEDs are arranged widthwise at a density equivalent to the printing resolution of 300 dots per 1 inch 300dpi and exposure is executed one line at a time The KP3828 Series therefore achieves a higher accuracy of printing lineation 5 Flash fusing wh...

Page 9: ...1 5 1 4 Diagram Video interface Host computer Controller Optional Panel interface Operation panel Printer KP3828 Series KMPU Power stacker ...

Page 10: ...loping section Developing unit 4 Transfer separation section Transfer charger Separation charger 5 Cleaning section Blade Waste toner box 6 Fuser section Fusing lamp Xenon lamp 7 Paper feed paper transport section Fanfold paper tractor Transport unit Scuff roller assembly 8 Power stacker Fanfold paper stacker ...

Page 11: ...1 7 Fig 1 1 COVER Right side cover 2 Left side cover Top cover Rear cover Right side cover 1 Front cover lower Front cover upper ...

Page 12: ...1 8 Fig 1 2 Fuser unit Main charger Cleaning unit Transport unit Developing unit Waste toner box DC power supply Fusing power supply ...

Page 13: ...1 9 Fig 1 3 Developing motor Elevator motor KMPU board LED array Paper out motor Air filter blower Print controller Varistor Drum motor Fuser exit blower ...

Page 14: ...1 10 Fig 1 4 Transport unit Cleaning unit Fuser unit Pre charger Transfer charger OPC drum Erase lamp unit Main charger LED array Developing unit ...

Page 15: ...Page feeding of fanfold paper 5 Feeding of paper by 0 5 inch line feed 6 Printing on fanfold paper 7 Output of fanfold paper 8 Folding of fanfold paper 2 Adjustments by the KMPU Board 1 Change of standard value of the LED strobe 2 Change of printing starting position X Y 3 Change of the target value of the drum surface potential 4 Change of the DC component of the developing bias 5 Change of the e...

Page 16: ...er 2 7 2 1 6 Pre charger 2 10 2 1 7 Cleaning Unit 2 11 2 1 8 Fuser Unit 2 12 2 2 Drive System Descriptions 2 13 2 2 1 Paper in Drive 2 14 2 2 2 OPC Drum Drive 2 15 2 2 3 Developing Drive 2 16 2 2 4 Transport Unit Drive 2 17 2 2 5 Paper out Drive 2 18 2 3 Sensor System Descriptions 2 19 2 3 1 Paper Empty 2 19 2 3 2 Paper in 2 20 2 3 3 Transport 2 21 2 3 4 Paper Output 2 21 ...

Page 17: ...Chapter 2 Principles ...

Page 18: ...its as the followings Erase lamp unit Main charger Led array Developing unit Transfer charger Pre charger Blade cleaning unit Fuser unit Fig 2 1 Main charger LED array Erase lamp unit Surface potential sensor Blade cleaning unit Waste toner Remaining toner OPC Drum Pre charger Fuser unit Developing unit Paper Separation wire Transfer wire ...

Page 19: ...o ensure that the OPC drum is uniformly charged before exposure exposing the drum surface to light from the erase lamp unit in the first printing step to neutralize residual charge Fig 2 2 OPC Drum Erase lamp unit Residual charge ...

Page 20: ...hat is grounded via a varistor If the amount of corona discharge varies with the operation environment temperature humidity soiling of the main charger etc the OPC drum surface potential cannot be kept constant To ensure a known potential on the drum surface the OPC drum surface potential is monitored by surface potential sensor and then the main charger current is controlled according to the resu...

Page 21: ...e image data fed from the host computer illuminates and rotates the drum to form an electrostatic latent print image on the positively charged drum surface The LED array consists of LED elements that are arranged in the direction of printing width and related to printing pixels on a one to one basis It converts one raster horizontal scanning line of image data into a row of illumination dots Fig 2...

Page 22: ... electrostatic latent image formed in the exposure step so that a developed image visible image is formed on the OPC drum surface The developing roller consists of the inner pole magnet roller and the sleeve roller Fig 2 6 Developing roller Magnet roller Sleeve roller N N N N S S S S ...

Page 23: ...and the OPC drum surface potential is greater than the magnetic force exerted between the toner and inner pole magnet As a result the positively charged toner is attracted to the neutralized area of the OPC drum surface latent image Fig 2 7 As the roller surface potential is rendered positive as mentioned above the toner is properly attracted to the electrostatic latent image area on the OPC drum ...

Page 24: ... the developing unit Therefore when the paper supplied from the tractor is closely attached to the OPC drum surface on which the print image is developed and the back surface of the paper is negatively charged by transfer wire the toner attracted to the OPC drum surface is transferred onto the paper Fig 2 8 OPC Drum Paper supply guide Transfer wire Paper ...

Page 25: ... the transfer section has adhered to the drum and would not leave the drum if this situation were allowed to continue Therefore to separate the paper from the drum separation wire eliminates the charge from the paper immediately after completion of toner image transfer using DC bias Fig 2 9 OPC Drum Paper Separation wire Transfer wire Paper supply guide ...

Page 26: ...e are integrated into a single unit transfer charger together with the paper supply guide and paper transport section An elevator motor vertically drives them Fig 2 10 Transport unit Transport belt OPC drum Paper supply guide Transfer charger ...

Page 27: ...ed onto the paper Such remaining toner should be positively charged due to the friction with the carrier in the developing unit Therefore when paper separations is completed the pre charger is executed in order to positively charge all the toner particles remaining on the drum surface in preparation for the next drum cleaning step Fig 2 11 OPC Drum Pre charger ...

Page 28: ...es which have been positively charged in the pre charger section are scraped away with a blade The toner is finally carried by a screw conveyor and placed in a waste toner box Fig 2 12 Blade Waste toner Remaining toner Screw conveyor Pre charger OPC Drum ...

Page 29: ...ig 2 13 This printer uses a xenon lamp to provide flashlight on the paper to fix the toner The toner is heated to a high temperature so that it is fixed by fusing onto the paper Xenon lamp Melted and fixed Unfixed toner Paper ...

Page 30: ...printer drive system is illustrated in Fig 2 14 below Fig 2 14 Main body Splitter solenoid Fuser unit Developing motor Developing unit Toner supply clutch Drum motor Paper in motor Elevator motor Transport unit Splitter motor Paper out motor ...

Page 31: ...4 2 2 1 Paper in Drive The paper in motor drives the tractor Fig 2 15 Encoder Tractor Support shaft Gear 46 Gear 44 23 Gear 22 Paper in motor Paper guide Support shaft Direction in which paper is conveyed ...

Page 32: ...2 15 2 2 2 OPC Drum Drive The drum motor drives the OPC drum and the cleaning unit Fig 2 16 Cleaning unit driving shaft Drum driving shaft Outer diameter of the drum Gear Gear Gear Drum motor Gear ...

Page 33: ... developing unit driving motor drives the shafts One of these two shafts drives the inner pole magnet roller and at the same time the other shaft drives the sleeve roller Fig 2 17 Sleeve driving gear Sleeve driving gear Developing unit side Sleeve Developing motor Magnet roller driving gear Magnet roller driving gear Developing unit side Magnet roller ...

Page 34: ...2 17 2 2 4 Transfer Unit Drive The transfer unit moves up and down when the cam installed on the elevator motor shaft rotates Fig 2 18 Cam Cam Elevator motor Transfer unit Transfer charger ...

Page 35: ...5 Paper out Drive The rollers are driven along with the following rollers by the paper out motor 1 Transport roller 2 Scuff roller Fig 2 19 Transport roller Gear Gear Gear Gear Gear Feed motor Gear Scuff roller ...

Page 36: ...r empty sensor is used to determine whether the fanfold paper is installed Fig 2 21 Paper empty sensor inside the guide Paper out section Paper transport section Paper in section Paper Sensor PTPS Sensor PMS Scuff roller OPC Drum Sensor PTS Transport roller Transport belt Tractor Paper empty sensor PES Paper Sensor POPS Splitter Scuff SW ...

Page 37: ...the controller the paper set on the tractor is automatically advanced upon OPC drum surface and the image on the OPC drum is transferred onto the paper while advancing Fig 2 22 OPC Drum Sensor PTS Transport belt Transfer point Loading position Tractor Paper Paper empty sensor PES ...

Page 38: ...paper leading end reaches the toner transfer point and stays there until printing is completed The suction fan draws the paper from below and the transport belt carries the paper from below the fuser unit to the output section To prevent sagging of the paper at the perforations the paper out motor operates at a higher speed than the OPC drum to drive the transport belts at a slightly higher speed ...

Page 39: ... 7 Setting Toner Cartridge 3 12 3 8 Setting Others 3 14 3 9 Setting up of the AC Power Cable 3 15 3 9 1 AC Power Cable Specification 3 15 3 9 2 Attach AC Power Cable in USA 3 15 3 9 3 Attach AC Power Cable in Europe 3 16 3 9 4 Attach the Plug 3 17 3 9 5 Verify Grounding 3 18 3 10 Setting the Paper 3 20 3 11 Power on 3 23 3 12 Engine Self Test Printing 3 23 ...

Page 40: ...Chapter 3 Installation ...

Page 41: ...er and the circuit breaker before installing 2 Do not use the printer on carpet The printer may not operate normally due to cotton fiber and static electricity 3 Do not operate the printer near heating source dusty location and direct sunlight 4 Do not place the printer on any unstable place 5 Do not put the printer near combustibles 6 Install the printer in a well air conditioning room 7 Do not o...

Page 42: ...3 2 Installation space Fig 3 1 1000 800 1270 1000 800 KP3828 Series 1000 500 805 1000 Maintenance zone Stacker Operation zone Front Dimensions in mm ...

Page 43: ...it with a forklift and avoid exposing it to vibration or shock 2 The forks of a forklift truck must always be inserted in the prescribed direction 3 Casters may be used for transportation only on level floor surface inside an office 4 The printer must not be inclined by more than 10 5 The printer must not be dropped from more than 3 cm in height ...

Page 44: ...3 4 Unpacking Step 1 Remove the binding bands Step 2 Take off the top plate Fig 3 2 Step 3 Raise and remove the outer cover Step 4 Remove the vinyl bag Fig 3 3 Binding bands Top plate Outer cover Vinyl bag ...

Page 45: ...ruck to lift the printer and set the printer on a level floor Step 9 Adjust up the level feet of the printer engine with a wrench by turning it until the lower surface of the base frame remains at 70 mm above the floor level Place a level on the top cover to ensure the level feet kept at the same level Fig 3 5 Board 70mm Level foot ...

Page 46: ...quickly as possible 4 When mounting the drum push the drum properly into the inner end and then turn the drum to align the slits of the drum with the pins of the drum shaft until a click sound is heard 5 In order to prevent damaging the drum confirm that the transfer elevator is at the down position and that the notch part of the shaft is horizontal Step 10 Open the front cover upper Step 11 Open ...

Page 47: ...3 7 Step 13 Remove the nut from the drum shaft Fig 3 7 Nut ...

Page 48: ... turn the drum to fit the drum securely Fig 3 9 Step 16 Remove the drum support rod and securely tighten the nut Put the drum plate back and tighten the 3 thumbscrews If a blade type cleaning unit is installed turn the green lock lever of the cleaning unit to the lock position vertically to 12 o clock direction Drum shaft Drum support rod OPC Drum ...

Page 49: ... Step 18 Loosen the 3 screws and then remove the upper cover of the developer introduction section of the developing unit Fig 3 10 Step 19 Take out the developer and attach the nozzle to the developer bottle Fig 3 11 Screws Developing unit Cover Nozzle Developer bottle ...

Page 50: ...loper introduction port Fig 3 12 Step 21 Rotate the developing roller a few times by turning the knob at the side with your hand so that the developer will settle uniformly across the roll Step 22 Mount the upper cover and tighten the 3 screws Fig 3 13 Developer Slit Developer introduction port Cover ...

Page 51: ...nit has been inserted all the way in turn the lever downward by 120 to the position shown in Fig 3 15 to ensure the developing unit has been set firmly If the lever could not be turned downward turn the developing roller knob and engage it with the gear at the rear and then push in the developing unit firmly Fig 3 15 Developing unit Developing roller knob Lever Positioning pin ...

Page 52: ...idge with the cover tape facing up and shake the cartridge 4 or 5 times as shown by the arrows Fig 3 16 Step 26 With the cover tape facing up insert the cartridge into the toner hopper and slowly peel off the cover tape in the direction of the arrow on the tape Fig 3 17 Cover tape Toner hopper Cover tape ...

Page 53: ...3 13 Step 27 After inserting the toner cartridge into the toner hopper turn the toner cartridge clockwise by 180 to move the slit of the toner cartridge upward from the position of pin Fig 3 18 Slit Pin ...

Page 54: ...4 3 8 Setting Others Step 28 Remove the rubber bands and tapes that are securing the transport unit Step 29 Remove all other tapes attached to the interior of the engine Step 30 Close the front cover upper ...

Page 55: ... of 15mm 2 An insulated grounding conductor that is identical in size insulation material and thickness to the grounded and ungrounded branch circuit supply conductors except that it is green with or without one or more yellow stripes is to be installed as part of the branch circuit that supplies the unit or system The grounding conductor described is to be connected to earth at the service equipm...

Page 56: ... 1 Prepare the AC power cable as follows Strip 40mm from the outer insulation jacket of the AC power cable Cut the Brown and Blue wires 10mm shorter than the Green Yellow wire Strip the wires as appropriate for the terminals used Clamp the terminals onto the wires in accordance with the manufacturer s instructions 2 Attach the AC power cable to the printer as follows Connect the Green Yellow wire ...

Page 57: ...sed 3 Attach the plug to the AC power cable in USA as follows Connect the Green Yellow wire to the plug terminal marked with E or PE or the safety earth symbol or green or green yellow Connect the White wire to the plug terminal marked with N or black Connect the Black wire to the plug terminal marked with L or W or red 4 Attach the plug to the AC power cable in Europe as follows Connect the Green...

Page 58: ...rify that the grounding conductor in the AC power cable is connected to the printer terminal marked FG and to the plug terminal marked with E or PE or the safety earth symbol or green or green yellow WARNING THIS APPARATUS MUST BE GROUNDED ...

Page 59: ...3 19 Fig 3 19 AC power terminal box AC cable Breaker Turn on AC power terminal box KMPU board ...

Page 60: ...0 3 10 Setting the Paper Step 37 Confirm the left tractor is set at the left end and align the left side of the paper carton with the alignment mark as in Fig 3 21 Fig 3 20 Fig 3 21 Tractor Alignment mark ...

Page 61: ...n is at the peak see Fig 3 24 Step 40 Open the paper holder levers on the tractors and set the leading end of the paper on the tractors Set the paper so that 4 or 5 of the tractor pins engage with the holes of the paper Move the right holder lever to a position where the tension of the paper is not too tight or too loose Paper empty sensor guide ...

Page 62: ...3 22 Step 41 Close the paper holder levers and lock the green lock lever Fig 3 23 Fig 3 24 Perforation Paper holder levers Green lock lever ...

Page 63: ...s support pure engine self test without controller Set Dip switch SWA to self test mode then turn on the power and perform engine self test printing For another applications changing the setting of Dip switch SWA can change the mode Fig 3 25 SWA 1 2 3 4 KMPU board ON Engine checker mode ON No drum initial when engine power on ON Debug message SWB SWA ON Engine self test ...

Page 64: ...Chapter4 Electrical System 4 1 Diagram 4 1 4 2 Electrical Configuration 4 2 4 3 Input Output Signals 4 5 ...

Page 65: ...Chapter 4 Electrical System ...

Page 66: ...4 1 4 1 Diagram Fig 4 1 Host computer Controller Optional Panel interface Operation panel Printer Video interface KP3828 Series KMPU Power stacker ...

Page 67: ...rical Configuration The electrical system of this printer Fig 4 2 LED array Sensor Actuator High voltage power supply Controller KMPU board 220V Power stacker Fusing power supply DC power supply 220V Operation panel ...

Page 68: ... Sensors and actuators Fig 4 3 Sensor POPS Sensor PMS Scuff SW Transport unit connector Sensor PTPS Fusing power supply Suction fan Xenon lamp Fuser unit connector Paper out motor Power stacker KMPU Board ...

Page 69: ...nsor Cleaning unit set sensor Drum surface potential sensor LED array thermal sensor Lamp temperature fuse Toner density sensor Toner supply clutch Erase lamp unit Page counter 8 5 Drum encoder Fuser exit blower Air filter blower Lamp thermistor DC power supply Fuser unit connector Elevator motor Transfer unit upper limit sensor Paper in motor Encoder Drum motor Sensor PTS Paper empty sensor Front...

Page 70: ...4 5 4 3 Input Output Signals I O signal block diagram of the KMPU Fig 4 5 KMPU I O Signal Block Diagram ...

Page 71: ...5 1 Operation Panel 5 1 5 2 KMPU Board 5 3 5 3 Setting Dip switches 5 4 5 4 Checking Individual Engine Status 5 5 5 5 Adjusting Toner Density 5 9 5 6 Adjusting Fusing Power Supply 5 10 5 7 Adjusting High Voltage Supply 5 11 ...

Page 72: ...Chapter 5 Adjustments ...

Page 73: ...Error exists Clear the error message FORM LENGTH Set paper length LINE FEED Manually feed paper by 1 2 INCH FORM FEED Manually feed paper by one page SPLIT Split fanfold paper TEST Self test MENU Enter or exit the main menu SAVE Set the value of the selected function Select previous sub menu or increase the value Select next sub menu or decrease the value Ready Data Error ON Line Line Feed Split F...

Page 74: ... printer is not in the on line state The operator has to press the ON LINE key to clear the error message Meanwhile LINE FEED key and SPLIT key are applicable Out No error exists 3 Error Indicators Fig 5 2 PES Paper Empty Sensor LED is blinking No paper exists PTS Paper Top Sensor LED is blinking Paper is jammed at PTS PTPS Paper Transport Position Sensor LED is blinking Paper is jammed at PTPS PM...

Page 75: ...ft 1 76V D8 Power LED red color R9 Erase Lamp Unit J1 PELDRV 16V D9 Flash while KMPU CPU is running or deadlock R10 Toner Density J2 TDSCNT 4 8V 5 2V D10 Toner supply LED light on while supply toner D15 Status of toner density same as D5 LED D16 Status of PMS sensor flash while paper moving CN6 CN2 CN9 CN7 CN1 CN10 CN5 CN11 R9 R10 CPU VR1 VR2 VR3 VR4 SWB SWA CN8 PROGRAM MAINTENANCE CN3 FPGA BOOT R...

Page 76: ...printer will perform engine self test printing 3 Engine checker mode Set Dip switch SWA pin 4 ON to change the printer to engine checker mode and detach video interface connector 37 pins from CN1 on KMPU board and remove panel interface connector 9 pins from the controller side then connect to P2 connector on KMPU board then turn on the power The printer will perform under engine checker mode ON E...

Page 77: ... key to enter sub menus ERROR indicator is on red 2 Press key or key to select the item you want to check Then press TEST key to start the test DATA indicator is on green To stop the test press TEST key again ERROR indicator is on red 3 Press MENU key to exit OPERATION menu DATA indicator is on green When SENSOR is selected 1 Press SAVE key to enter sub menus 2 Press key or key to select the item ...

Page 78: ...n saved 5 Press MENU key to exit the item DATA indicator is off Press key or key to select other item you want to check or press MENU key to exit SETTING menu DATA indicator is on green When VOLUME is selected 1 Press SAVE key to enter sub menus DATA indicator is off 2 Press key or key to select the item you want to check Values cannot be changed 3 Press MENU key to exit VOLUME menu DATA indicator...

Page 79: ... MOTOR 0B DEVELOP MTR 12 SEPARAT CLAW 14 SPLIT SOLEN 16 TONER SUPPLY 18 SUCTION FAN 1C VENTILAT FAN 1D FUSER EX FAN 1E AIR FILTER 20 MAIN CHARGER 21 DEVELOP BIAS 22 TRANS CHARGE 23 SEPA CHARGER 24 PRE CHARGER 25 CLEAN BIAS 26 FLASH POWER 28 ERASE LAMP L 29 ERASE LAMP H SENSOR 00 DRUM ENCODER 01 TRANSPORT UP 02 SPLIT HOME 03 SPLIT REAR 04 PI ENCODER 05 PTS 06 PMS 07 POPS 08 PTPS ...

Page 80: ...ULL 0E NO W TNR BOX 0F NO TONER 14 LED OVERHEAT 18 DRUM MTR ERR 1D FUSER TEM HI 1E FLASH PWR ER SETTING 05 LED STROBE 07 IMAGE X0 08 IMAGE Y0 10 DSPS SETUP 11 DEVELOP BIAS 1B SPLIT OFFSET 22 STANDBY TIME VOLUME 10 DSPS VALUE 18 FIRMWARE VER 24 ENGINE MODEL 30 SWA VALUE 31 SWB VALUE ...

Page 81: ... of the digital multimeter to the J7 SGND of KMPU board and the plus terminal to J2 TDSCNT of KMPU board 2 Adjust R10 of KMPU board so that the reading on the digital multimeter shows the voltage 4 8V is standard plus is darker minus is lighter than the standard ...

Page 82: ...5 10 5 6 Adjusting Fusing Power Supply Turn V ADJ of the fusing power supply and set to the desired voltage normally set to 1850V Fig 5 5 1950 1700 V ADJ 1900 1850 1800 1750 ...

Page 83: ...Supply HV2 transformer output terminal and then connect the black probe into the High Voltage Supply HV2 wire See Fig 5 6 Turn on PRE CHARGE under ENGINE CHECK selection and then adjust High Voltage Supply VR201 See Fig 5 7 Turn VR201 clockwise to increase the current Turn VR201 counterclockwise to decrease the current Adjust VR201 to 0 20mA Fig 5 6 Fig 5 7 ...

Page 84: ...rmer output terminal and then connect the black probe into the High Voltage Supply HV wire See Fig 5 8 Turn on TRANSFER CHARGE under ENGINE CHECK selection and then adjust High Voltage Supply VR401 See Fig 5 9 Turn VR401 clockwise to increase the current Turn VR401 counterclockwise to decrease the current Adjust VR401 to 0 45mA Fig 5 8 Fig 5 9 ...

Page 85: ...Voltage Supply V1 and then connect the black probe into the Case GND See Fig 5 10 Turn on CLEAN BIAS under ENGINE CHECK selection and then adjust High Voltage Supply VR601 See Fig 5 11 Turn VR601 clockwise to increase the voltage Turn VR601 counterclockwise to decrease the voltage Adjust VR601 to 550V Fig 5 10 Fig 5 11 ...

Page 86: ...Voltage Supply V2 and then connect the black probe into the Case GND See Fig 5 12 Turn on CLEAN BIAS under ENGINE CHECK selection and then adjust High Voltage Supply VR701 See Fig 5 13 Turn VR701 clockwise to increase the voltage Turn VR701 counterclockwise to decrease the voltage Adjust VR701 to 275V Fig 5 12 Fig 5 13 ...

Page 87: ...nto J2 See Fig 5 14 and then connect the black probe into J7 See Fig 5 15 The accomplishment of the task is shown in Fig 5 16 Adjust R10 of the KMPU board See Fig 5 17 Turn R10 clockwise to decrease the voltage Turn R10 counterclockwise to increase the voltage Adjust R10 to 4 8V Fig 5 14 Fig 5 15 ...

Page 88: ...5 16 Fig 5 16 Fig 5 17 ...

Page 89: ...e Front Cover 6 5 6 3 3 Developing Unit Hopper Area 6 6 6 3 4 Cleaning Unit Area 6 6 6 3 5 Fuser Unit Area 6 7 6 3 6 Waste Toner Box Unit Area 6 7 6 3 7 Transport Unit 6 8 6 3 8 Main Charger 6 9 6 3 9 Pre charger and Transfer Charger 6 12 6 3 10 OPC Drum 6 14 6 3 11 LED Array 6 16 6 3 12 Erase Lamp Unit 6 16 6 3 13 Fuser Unit Cover Glass 6 17 6 3 14 Developing Unit 6 18 6 3 15 Removing the Develop...

Page 90: ...Chapter 6 Periodic Maintenance ...

Page 91: ...inting accuracy of KP3828 Series at a level that will not be a problem in terms of practical use it is important to perform periodic maintenance of consumable parts The periods of cleaning and replacing the consumable parts are indicated below according to the parts ...

Page 92: ...ages Every 300 000 pages Remarks Main charger Clean Replace Transfer charger Clean Replace Pre charger Clean Replace Toner cartridge 700 g Replace Replace when the Toner Empty indication appears Waste toner box Replace Replace when the Waste Toner Full indication appears Paper empty sensor area Clean Tractor unit Clean Transport unit Clean Transport belt Clean Table 6 1 ...

Page 93: ...charger Clean Replace Transfer charger Clean Replace Pre charger Clean Replace OPC drum Replace Erase lamp unit Clean LED array Clean Cleaning unit Blade type Replace Guide rail section of pre charger Clean Developing unit Clean Replace Developer 700 g Replace Guide section of developing unit Clean Guide plate below separation claw Clean Waste toner box unit Clean to be continued ...

Page 94: ... Others Remarks Paper empty sensor area Clean Tractor unit Clean Transfer guide plate Clean Transport unit Clean Transport belt Replace Capacitor Replace Every 2 4 million pages Xenon lamp Replace Air filter Replace Cover glass Clean Fusing power supply unit filter Clean Clean with a vacuum cleaner Table 6 2 ...

Page 95: ...cuum cleaner to remove the paper dust etc that are scattered across the tractor unit Fig 6 1 6 3 2 Inside the Front Cover Open the front cover and use a vacuum cleaner to remove the scattered toner paper dust etc Fig 6 2 Front cover Upper Tractor ...

Page 96: ...6 6 6 3 3 Developing Unit Hopper Area Fig 6 3 6 3 4 Cleaning Unit Area Fig 6 4 Cleaning unit ...

Page 97: ...6 7 6 3 5 Fuser Unit Area Fig 6 5 6 3 6 Waste Toner Box Unit Area Press down the opening lever to open the waste toner box unit Fig 6 6 Fuser unit Opening lever Waste toner box unit ...

Page 98: ...transport unit and remove the scattered toner paper dust etc with a vacuum cleaner Fig 6 7 2 Wipe off the dirt on the transport surface with alcohol tissue Fig 6 8 3 After cleaning insert the transport unit back as it was originally and when the transport unit comes in contact with the inner end raise the green lever to the right and close the waste toner box unit Transport unit Green lever Transp...

Page 99: ... Handle the chargers carefully to prevent damaging or cutting the charger wires 1 Loosen the thumbscrew and pull the main charger out Fig 6 9 2 Use the brush to wipe off the dust on the main charger Fig 6 10 Thumbscrew Main charger ...

Page 100: ...6 10 3 Loosen the screw to detach the stainless mesh panel Fig 6 11 4 Use the wire cleaner applied with alcohol to clean the wire of the main charger Fig 6 11a Screw Stainless mesh panel Wire cleaner ...

Page 101: ...panel on top of the stainless spring plate Fig 6 11b 6 Align the phosphor copper plate with the screw below Then tighten the screw Fig 6 11c 7 Insert the main charger to its original location and tighten the thumbscrew Stainless spring plate Stainless mesh panel Screw Screw Phosphor copper plate Stainless mesh panel Alignment ...

Page 102: ...nsfer charger is at the down position If the transfer charger is not at the down position use a slotted screwdriver to turn the transfer elevator drive shaft counterclockwise to lower the transfer charger to the down position Then loosen the thumbscrew and pull out the transfer charger Fig 6 12b Fig 6 12a Fig 6 12b Thumbscrew Pre charger Transfer charger Transfer elevator drive shaft Thumbscrew ...

Page 103: ... charger 4 Clean the wires of the pre charger Fig 6 12c and transfer charger Fig 6 12d with the wire cleaner Fig 6 12c Fig 6 12d 5 After cleaning insert the pre charger and transfer charger to their original locations and tighten the thumbscrews Pre charger Transfer charger ...

Page 104: ...wiping stains may deteriorate if the drum is left in the main body for a long time with wiping stains on it After cleaning has been completed and the drum has been installed in the main body be sure to perform printing on paper of the maximum size until it can be confirmed that there are no effects due to wiping stains Wiping stains should generally disappear after a few dozen pages 1 Take out the...

Page 105: ...6 15 2 Wipe the drum surface with the special cloth Fig 6 14 Drum Special cloth ...

Page 106: ...sert your hand from the OPC drum mounting section and clean the dirt on the LED array with alcohol Fig 6 15 6 3 12 Erase Lamp Unit 1 Remove the screws for the erase lamp unit and pull out the erase lamp unit 2 Use the brush to wipe off the dirt on the erase lamp unit that has been taken out Fig 6 16 LED array Erase lamp unit ...

Page 107: ...ration handle the unit after it has cooled fully b Do not make scratches on the cover glass or touch the cover glass directly with your hands 1 Take out the fuser unit see 7 2 17 Fuser Unit 2 Use cotton cloth with alcohol to clean the cover glass Then use the cover glass scraper to scrape off the dirt remained on the fuser unit cover glass surface Fig 6 17 Scraper Cover glass ...

Page 108: ... 1 Take out the developing unit see 7 2 6 Developing Unit 2 Clean by sucking up the toner attached to the toner scatter prevention brush of the developing unit with a vacuum cleaner Fig 6 18 Toner scatter prevention brush Vacuum ...

Page 109: ...ean the toner trough of the developing unit with a vacuum cleaner 3 Remove the screws that secure the cover of the developing unit and remove the cover Fig 6 19 4 Lay a sheet and turn the developing unit upside down over the sheet to drop the developer on the sheet Shake the developing unit up down and sideways so that developer will not remain in the inner side of the developing unit Fig 6 20 She...

Page 110: ... the cover mounting screw the left one Fig 6 21 6 Use a vacuum cleaner to remove the developer attached to the developing roller of the developing unit Shake the developing unit up down and sideways and repeat this step until the developer no longer becomes attached to the developing roller Fig 6 22 7 Clean the entire developing unit with a vacuum cleaner To the ground line connecting the main bod...

Page 111: ...Setting the Developing Unit 7 8 7 2 8 Toner Cartridge 7 9 7 2 9 OPC Drum 7 11 7 2 10 Drum Peripheral Equipment 7 15 7 2 11 Main Charger Pre charger Transfer Charger 7 16 7 2 12 Cleaning Unit 7 16 7 2 13 Drum Support Roller 7 17 7 2 14 Air Filter 7 18 7 2 15 Transport Unit 7 19 7 2 16 Transport Belt 7 22 7 2 17 Fuser Unit 7 27 7 2 18 Xenon Lamp 7 28 7 2 19 Fuse Set 7 31 7 3 Inside the Front Cover L...

Page 112: ...n Motor Unit 7 44 7 4 8 Elevator Motor Unit 7 44 7 4 9 Varistor of the Main Charger 7 45 7 5 Inside the Left Side Cover 7 46 7 5 1 Paper Output Unit 7 46 7 5 2 Sensor POPS 7 47 7 6 Inside the Right Side Cover 7 48 7 6 1 Tractor Unit 7 48 7 6 2 Sensor PTS 7 49 7 6 3 Paper Empty Sensor 7 50 7 7 Inside the Top Cover 7 51 7 7 1 High Voltage Power Supply 7 52 7 7 2 LED Array 7 53 7 7 3 Cleaning Unit Se...

Page 113: ...Chapter 7 Parts Replacement ...

Page 114: ... Do not operate the printer with parts removed except when performing inspection adjustment or other work that is specifically designated in this manual 7 1 Cover Fig 7 1 Right side cover 2 Left side cover Top cover Rear cover Right side cover 1 Front cover lower Front cover upper ...

Page 115: ...unit Developing unit Waste toner box DC power supply Fusing power supply Toner cartridge 7 2 Inside the Front Cover Upper The units shown in Fig 7 2 are installed inside the front cover Fig 7 2 Fuser unit Cleaning unit Air filter ...

Page 116: ...ll condition To the lower left side of the box is the waste toner box set sensor that detects whether the box is set or not Fig 7 3 7 2 2 Waste Toner Box When the waste toner box becomes full replace it with a new box by following the steps below and discard the box full of waste toner 1 Press down the opening lever to open the waste toner box unit Fig 7 4 Waste toner box Waste toner full sensor W...

Page 117: ... the waste toner box Fig 7 5 3 Install a new waste toner box 7 2 3 Waste Toner Full Sensor Remove the waste toner box from the waste toner box unit and then remove the waste toner box full sensor by the following steps 1 Disconnect the connectors Fig 7 6 Connectors Opening lever Cap Waste toner box ...

Page 118: ... emitting and receiving and then remove the boards Fig 7 7 7 2 4 Waste Toner Box Set Sensor To remove the waste toner box set sensor disconnect the connector and then remove the screws that secure the sensor bracket Fig 7 8 Screws Screws Bracket Connector Screws ...

Page 119: ... remove the waste toner box unit remove the connector and waste toner box firstly Then release the spring and remove the waste toner box unit by lifting it Remove sensors and then replace with a new waste toner box unit Fig 7 9 Spring ...

Page 120: ...procedures below to remove the developing unit from the main body 1 Turn the lever by 120 to the right to detach the developing roller from the OPC drum Fig 7 10 2 Hold the lever with one hand and pull out the unit partially Fig 7 11 Lever ...

Page 121: ... the positioning pin on the main body 2 After the developing unit has been inserted all the way in turn the lever downwards by 120 to the position shown in Fig 7 13 to ensure the developing unit has been set firmly 3 If the lever could not be turned downwards turn the developing roller knob and engage it with the gear at the rear and then push in the developing unit firmly Fig 7 13 Hanger Developi...

Page 122: ...Turn the toner cartridge counterclockwise by 180 to align the slit of the toner cartridge with the pin of the developing unit and pull out the cartridge Dispose the removed cartridge in a vinyl bag for collecting cartridges Fig 7 14 2 Take out a new cartridge from the vinyl bag Hold the toner cartridge with the cover tape facing up and shake the cartridge 4 or 5 times as shown by the arrows Fig 7 ...

Page 123: ...f the cover tape in the direction of the arrow on the tape Fig 7 16 4 After inserting the toner cartridge into the toner hopper turn the toner cartridge clockwise by 180 to move the slit of the toner cartridge upward from the position of pin Fig 7 17 Toner hopper Cover tape Slit Pin Toner cartridge ...

Page 124: ...sure to ambient air be sure to store the drum in the box before and after replacement 4 To mount the drum push the drum properly into the inner end and then turn the drum to align the slits of the drum with the pins of the drum shaft until a click sound is heard 5 In order to prevent damaging the drum confirm that the transfer elevator is at the down position and that the notch part of the shaft i...

Page 125: ...r elevator drive shaft counterclockwise to lower the transfer charger to the down position Fig 7 19 3 If a blade type cleaning unit is installed make sure the green lock lever of the cleaning unit is turned to the open position horizontally to 3 o clock direction Loosen the 3 thumbscrews and remove the drum plate Fig 7 20 Transfer charger Transfer elevator drive shaft Thumbscrews Drum plate ...

Page 126: ...7 13 4 Remove the nut from the drum shaft Fig 7 21 5 Attach the drum support rod to the drum shaft Fig 7 22 Drum support rod Drum shaft Nut ...

Page 127: ...e side of the drum when taking out the drum In other words be sure to use both hands to take out the drum However be careful not to touch the drum surface with your hands Fig 7 23 For installation of the OPC drum please see 3 5 Setting OPC Drum OPC Drum ...

Page 128: ...in charger pre charger transfer charger and erase lamp unit can be removed without removing the drum plate 2 The cleaning unit is removed with the drum plate being removed The drum support rollers are removed with both the drum plate and the OPC drum being moved 3 The Led array and drum surface potential sensor are removed from the top cover with both the developing unit and the OPC drum being rem...

Page 129: ...during printing 2 Never touch the charger power supply since high voltage is applied 7 2 12 Cleaning Unit Remove the drum plate and then remove the cleaning unit by grasping the handle and pulling the unit out When replace a blade type cleaning unit turn the green lock lever of the cleaning unit to the open position horizontally to 3 o clock direction before removing or inserting the unit After in...

Page 130: ... rollers are provided near part from which the drum is to be removed so that the drum surface will not come contact with the metal parts in the vicinity The rollers are removed by removing screws securing the bracket Fig 7 26 Drum support rollers ...

Page 131: ...7 18 7 2 14 Air Filter 1 Remove the screws at the front cover and then remove the air filter cover Fig 7 27 2 Pull the air filter out Fig 7 28 ...

Page 132: ...19 7 2 15 Transport Unit The transport unit is removed as follows 1 Remove the waste toner box unit in advance 2 Turn the green lever to the left to lower the transport unit and pull out the unit Fig 7 29 ...

Page 133: ...slide rails to the unit For the screws at the rear shift the unit so that the screws are matched in position with the holes of the rails so that the screws can be seem through the holes and then remove the screws Fig 7 30 Fig 7 31 Side rail Screws Side rail Screws ...

Page 134: ...ove the unit Fig 7 32 The transport unit has the following replaceable parts 1 Transport belt 2 Suction Fan 3 Connector block for the transfer charger The methods for removing the respective replacement parts are described in the following pages ...

Page 135: ...re to put a rest underneath it to protect the protruding tips of the sensor levers Also be careful when handling the lever 1 Remove the suction fan and disconnect the sensor connectors Fig 7 33 2 Restore the transport unit to its original position Remove the screws securing the output guide and then remove the output guide Fig 7 34 Connectors Suction fan Screws Output guide ...

Page 136: ...3 3 Remove the screw and then the stainless plate Fig 7 35 4 Remove the E rings securing the drive shaft to the unit frame and remove the bearing Fig 7 36 Bearing E ring Unit frame A A A A Stainless plate ...

Page 137: ...it frame Remove the screw fastening the ground wire and remove the wire Fig 7 37 6 Remove the E rings holding the drive shaft to the base conveyor and then slide the bearing off the shaft Fig 7 38 Ground Screw A A Bearing E ring Drive shaft A A ...

Page 138: ...transport belt be careful to distinguish the new belt s front side from the backside The surface of the front side is smooth while the surface of the backside is rough Adjust the distance between the drive shafts according to the length of the belt Fig 7 40 Transport belts Backside rough surface Front side smooth surface ...

Page 139: ...stening the base conveyor and adjust the tension of the belt by turning the setscrew with a hexagonal wrench Fig 7 41 10 Adjust the height of the belt Firmly tighten the screws to secure the adjustment Fig 7 42 Setscrew Screws A A Base conveyor Belt Screws ...

Page 140: ...sport surface Fig 7 43 WARNING Be careful of handling the fuser unit The unit reaches high temperatures immediately after operation over 141 when temperature fuse is blown Also never touch the cover glass with your hands This fuser unit has the following replaceable parts 1 Xenon lamp 2 Fuse set 3 Fuser cover glass 4 Xenon lamp trigger coil unit 5 HV connector for fuser unit Fuser unit Green lever...

Page 141: ... the fuser unit that has been removed from the main body with the cover glass facing up Fig 7 44 2 Remove the screws securing the paper guide on the entrance side of the unit and remove the paper guide Fig 7 45 Screws Paper guide ...

Page 142: ...3 Remove the screws that secure the glass frame to the fuser box and remove the glass frame Fig 7 46 4 Remove the screws securing the lamp terminals Fig 7 47 Screws Screw Xenon lamp Screws Screws Glass frame ...

Page 143: ...7 30 5 Remove the screw from the front bracket and the rear bracket Then remove the lamp Fig 7 48 Screw ...

Page 144: ...7 31 7 2 19 Fuse Set 1 Remove the screw securing the fuse holder to the fuse box Fig 7 49 2 Remove the screw securing the fuse holder cover Fig 7 50 Fuse box Fuse holder Screw Screw Fuse holder ...

Page 145: ...7 32 3 Open the cover remove the screws securing the fuse set and remove the fuse Fig 7 51 Screws Fuse Set ...

Page 146: ...2 Remove the connectors and screws from the rear side of the DC power supply 3 Remove the screws from the front side and then take out the DC power supply from the front side Fig 7 52 4 Remove the screws on the sides of the DC power supply 5 Remove the screws that secure the DC power supply board Fig 7 53 Screws Connectors Screws Screws ...

Page 147: ...ver lower and the rear cover before the following steps 2 Turn off the power switch and turn off the breaker and disconnect the main power plug Wait at least 5 minutes 3 Remove the connectors J11 and TRG from the fusing power supply box and remove the terminal block cover and disconnect the AC lines L and N 4 Remove the screw that fastens the FG wire from main body Fig 7 54 J11 Connector TRG Conne...

Page 148: ...d disconnect the high voltage cable disconnect the red cable firstly then the black cable Fig 7 55 CAUTION Be aware that red cable connect to the marked end and the black cable connect to the marked end Screws High voltage cable red High voltage cable black ...

Page 149: ... 8 Insert the new fusing power supply box 9 Align the screw holes on the fusing power supply box with those on the printer base and then secure the fusing power supply box with the screws Reattach the connectors and high voltage cables by reversing the steps of disconnecting the high voltage cables and removing the connectors Screws ...

Page 150: ...g manner 1 Remove all connectors and cords connected to the fusing power supply unit remove the screws that secure the fusing power supply power supply box and pull the fusing power supply box out see 7 3 2 Fusing Power Supply Unit 2 Loosen the screws that secure the side covers of the fusing power supply box and remove the covers Fig 7 57 3 Remove the screws that secure the rear cover of the fusi...

Page 151: ...7 38 4 Remove the nuts at the upper part of the capacitor and remove the respective cables Fig 7 59 5 Remove the screws that secure the capacitor and remove the capacitor Fig 7 60 Nuts Screws ...

Page 152: ...the Rear Cover Fig 7 61 Developing motor Elevator motor KMPU board LED array Paper out motor Air filter blower Print controller Varistor Drum motor Fuser exit blower DCMTR DRV board Surface potential measurement board ...

Page 153: ...7 40 7 4 1 KMPU Board 1 Remove the screws and remove the cover 2 Remove the connectors 3 Remove the screws that secure the KMPU board Fig 7 62 Fig 7 63 Screws Screws Screws ...

Page 154: ...7 41 7 4 2 DCMTR DRV Board 1 Remove the connectors 2 Remove the screws that secure the DCMTR DRV board Fig 7 64 Screws ...

Page 155: ...otective cover 2 Remove the connectors 3 Remove the screw pillars that secure the surface potential measurement board Fig 7 65 7 4 4 Drum Motor Unit 1 Disconnect the connector 2 Remove the screws and pull out the drum motor unit Fig 7 66 Screws Connector Connectors Screw pillars ...

Page 156: ...ectors 2 Remove the screws and remove the developing motor unit Fig 7 67 7 4 6 Paper out Motor Unit 1 Disconnect the connector 2 Remove the E ring 3 Remove the screws and pull out the paper out motor unit Fig 7 68 Screws Connectors Screws Connector E ring ...

Page 157: ...e cover 3 Push out motor connector 4 Remove the screws that secure the motor and remove the motor Fig 7 69 7 4 8 Elevator Motor Unit 1 Disconnect the motor connector and sensor connector 2 Remove the screws and pull out the elevator motor unit Fig 7 70 Screws Motor connector Screws Motor connector Sensor connector ...

Page 158: ...7 45 7 4 9 Varistor of the Main Charger Remove the main charger varistor by removing the screws that secure the plate to the rear panel Fig 7 73 Screws Varistor ...

Page 159: ...7 46 7 5 Inside the Left Side Cover 7 5 1 Paper Output Unit 1 Remove the screw in the front 2 Remove the screw in the rear and then pull out the unit Fig 7 74 Fig 7 75 Screws Screws ...

Page 160: ...7 47 7 5 2 Sensor POPS 1 Remove the connector 1 pc 2 Remove the screws of the sensor bracket and remove the sensor POPS Fig 7 76 POPS Connector ...

Page 161: ...ctor Unit 1 Remove the screws in the front side and remove the screws in the rear side 2 Disconnect the connectors 3 Remove the screws of the right side cover 1 and 2 and then pull out the tractor unit Fig 7 77 Fig 7 78 Screws Connectors Rear side ...

Page 162: ...7 49 7 6 2 Sensor PTS 1 Disconnect the connector on the inner side 2 Remove the screws and remove the PTS Fig 7 79 Fig 7 80 Connector PTS Screw Screws ...

Page 163: ...7 50 7 6 3 Paper Empty Sensor 1 Remove the screws 2 Remove the paper empty sensor from the bracket Fig 7 81 Screws Screws ...

Page 164: ...7 51 7 7 Inside the Top Cover Fig 7 82 Scuff switch Cleaning unit set sensor Sensor POPS High voltage power supply LED array Drum surface potential sensor ...

Page 165: ...utput terminal and then removing the screws securing the high voltage power supply Fig 7 83 CAUTION When installing the high voltage power supply be sure to properly connect the connectors The signal names are written on the terminal sides of the high voltage wire and the unit Screws Frame ground terminal Connectors Screws High voltage wire ...

Page 166: ...m beforehand in order to remove this unit see 7 1 Cover 7 2 6 Developing Unit and 7 2 9 OPC Drum 1 Disconnect the connectors from the LED array and remove the screw on the LED array thermal sensor Fig 7 84 2 Remove the screws securing the LED array Fig 7 85 Screws Screws Connectors Screw LED array thermal sensor ...

Page 167: ... and right mounting brackets and then insert the alignment pins into the holes of LED array mounting brackets Fig 7 87 5 Use screws to attach the LED array to the left and right LED array mounting brackets then pull out the alignment pins 6 Connect LED array connectors and use screw to attach the LED array thermal sensor to its original position Alignment pins ...

Page 168: ... panel so that the contacts close when the cleaning unit is set Fig 7 88 To remove this sensor disconnect the connector on the rear side remove the screws securing the bracket put your hand in from the top of the rear panel and extract the sensor with the bracket attached and remove the screws securing the sensor to the bracket Fig 7 89 Cleaning unit set sensor Bracket Screws ...

Page 169: ...7 56 7 7 4 Drum Surface Potential Sensor 1 Remove the screws that secure the rear sensor bracket Fig 7 90 2 Remove the screws on the front side Fig 7 91 Screws Screws ...

Page 170: ...7 57 3 Remove the holders that secure the sensor to the bracket and remove the sensor Fig 7 92 Drum support roller Holders Drum surface potential ...

Page 171: ...hapter8 Troubleshooting 8 1 Troubleshooting of the Main Body Mechanism 8 1 8 2 Remedies for Transport Failure 8 22 8 3 Remedies for Developing Unit Errors 8 32 8 4 Causes of and Remedies for Errors 8 37 ...

Page 172: ...Chapter 8 Troubleshooting ...

Page 173: ...or failure upper limit position 0D Transfer elevator motor failure down limit position 12 Paper remaining in fuser section PTPS see 8 2 Remedies for Transport Failure 13 Paper remaining in paper output section POPS see 8 2 Remedies for Transport Failure 16 Abnormal paper position PTS also see 8 2 Remedies for Transport Failure 17 High voltage failure 18 Drum motor failure 19 Surface potential too ...

Page 174: ...oltage will be approximately 24 V 02 No fanfold paper If the No Fanfold Paper error occurs when the power is turned on Procedure Points to be checked Remedy Checking method 1 Is the fanfold paper supplied from between the paper empty sensor PES guide and the printer body If YES go to 2 If NO supply the fanfold paper from between the PES guide and the printer body 2 Is the PES normal If YES go to 3...

Page 175: ...PTS is blocked and will be approximately 0 V when the PTS is not blocked 3 Is the tractor position appropriate If YES go to 4 If NO move the tractor to the left end However if there is a fault in the KMPU board replace the KMPU board If there is fault in the paper in motor go to 4 Bring the positive lead of a digital multimeter in contact with pin 23 of CN5 of the KMPU board and the negative lead ...

Page 176: ...set the scuff roller lever to the closed condition and then measure the resistance across pin 17 and pin 18 of jack CN7 of the Scuff SW with a digital multimeter If normal the resistance will be approximately 0 Ω 3 Is the KMPU board normal If NO replace the KMPU board after checking the harness After inserting CN7 of the KMPU board bring the positive lead of a digital multimeter in contact with pi...

Page 177: ...f YES go to 4 If NO replace CPS1 Bring the positive lead of a digital multimeter in contact with pin 3 of CN7 of the KMPU board and the negative lead in contact with SG pin 4 and measure the voltage If normal the voltage will be approximately 0 V when the splitter is at the rear side and will be approximately 5 V when the splitter is away from the rear side 4 Is the motor driver power supply norma...

Page 178: ...he splitter is driven from the front to the rear side Bring the positive lead of a digital multimeter in contact with pin 26 of CN9 of the KMPU board and the negative lead in contact with PG pin 12 and measure the voltage If normal the voltage will become approximately 24V upon one return operation in which the splitter is driven from the rear to the front side 6 Is the splitter motor normal If NO...

Page 179: ...it set properly If YES go to 5 If NO set the transport unit correctly 5 Is the transfer elevator motor normal If YES go to 6 If NO replace the transfer elevator motor Turn the POWER switch ON If normal the transfer elevator motor operates at the proper timing during the power on initialization process 6 Is the transfer elevator motor overloaded If NO go to 7 If YES replace the KMPU board Check as ...

Page 180: ... go to 9 If NO adjust the positions of the sensor and the blind Mount the transfer elevator motor and transfer unit upper limit sensor to the main body set the transfer unit and then check the following Bring the positive lead of a digital multimeter in contact with pin 31 of CN6 of the KMPU board and the negative lead in contact with SG pin32 and measure the voltage If normal the voltage will be ...

Page 181: ...e light paper paper dust etc 2 Is PTS normal If NO replace PTS after checking the harness Bring the positive lead of a digital multimeter in contact with pin 23 of CN5 of the KMPU board and the negative lead in contact with SG pin 24 and measure the voltage If normal the voltage will be approximately 5 V when the PTS is blocked and will be approximately 0 V when the PTS is not blocked ...

Page 182: ...board and the negative lead in contact with pin SG pin 26 and then measure the voltage immediately after the power is turned on If normal the voltage will be approximately 5V 4 Is the developing unit normal See 8 3 Remedies for Developing Unit Errors Judge by checking whether the error is one that occurs at the timing at which the developing unit motor is started during power on initialization but...

Page 183: ...ng during the power on initialization process 19 Surface potential too high Procedure Points to be checked Remedy Checking method 1 Is the high voltage power supply normal If YES replace drum surface potential sensor DSPS assembly If NO replace the high voltage power supply Connect the positive terminal of an ammeter range 3mA to the HV1 terminal of the high voltage power supply unit and the negat...

Page 184: ...he KMPU board and the negative lead in contact with SG pin 8 Remove the jack from J11 of the fusing power supply and short pins 7 and 8 of the jack Turn on the power in this condition and measure the voltage If normal the voltage will be approximately 0 V However if a fusing power supply error message is displayed even though the voltage measured above is approximately 0 V replace the KMPU board 5...

Page 185: ...d in contact with SG J7 Remove the jack from J11 of the fusing power supply and short pins 9 and 10 of the jack Turn on the power in this condition and measure the voltage If normal the voltage will be approximately 0 V 3 Is there a fault in the fusing power supply If YES replace the fusing power supply Connect the jack to J11 of the fusing power supply Bring the positive lead of a digital multime...

Page 186: ...e the resistance across pins 3 and 4 of J9 with a digital multimeter If normal the resistance will be approximately 0 Ω 4 Is the KMPU board normal If YES go to 5 If NO follow the instructions to the right Check as follows Short pins 3 and pin 4 of connector CN9 of the KMPU board Bring the positive lead of a digital multimeter in contact with pin 2 of U37 LM339MA of the KMPU board and the negative ...

Page 187: ...ciently to approximately 30 and then check the following 2 points Bring the positive lead of a digital multimeter in contact with pin 4 of U37 LM339MA of the KMPU board and the negative lead in contact with SG J7 and measure the voltage If normal the voltage will be approximately 3 7 0 5V Remove connection jack J9 from connector CN9 of the KMPU board and measure the resistance across pins 1 and 2 ...

Page 188: ...nitialization process Turn the POWER switch OFF Connect the original developing motor back to the connector of DC board Is the fuse blown Replace the DC board Is the DC board normal Replace the DC board YES NO YES YES Does the developing motor start up at the proper timing during power on initialization Measure the resistance across the ends of fuse of the DC board with a digital multimeter The fu...

Page 189: ... Replace the developing motor END NO Turn the POWER switch ON If it s normal the developing motor operates at the proper timing during the power on initialization process Is the developing motor normal YES ...

Page 190: ...nd 40 of J5 with a digital multimeter If normal the resistance will be approximately 0Ω 3 Is the KMPU board normal If NO replace the KMPU board If the error is not eliminated even though the measured voltage indicated in the right column is approximately 0 V replace the KMPU board Connect J5 to connector CN5 of the KMPU board Bring the positive lead of a digital multimeter in contact with pin 39 o...

Page 191: ...ard and the negative lead in contact with SG pin 12 and check the following 2 points Block the light emitting window of WTBF with your hand and measure the voltage If normal the voltage will be approximately 0 43 V Release your hand from the light emitting window of WTBF and measure the voltage If normal the voltage will be approximately 0 55 V The voltage measured when the light emitting window o...

Page 192: ... 17 and 18 of J5 with a digital multimeter If normal the resistance will be approximately 0 Ω 3 Is the KMPU board normal If NO replace the KMPU board If the error is not eliminated even though the measured voltage indicated in the right column is approximately 0 V replace the KMPU board Connect J5 to connector CN5 of the KMPU board Bring the positive lead of a digital multimeter in contact with pi...

Page 193: ... of a digital multimeter in contact with pin 6 of U37 LM339MA of the KMPU board and the negative lead in contact with SG J7 and measure the voltage If normal the voltage will be approximately 3 7 0 5 V Remove connection jack J5 from connector CN5 of the KMPU board and measure the resistance across pins 37 and 38 of connection jack J5 with a digital multimeter If normal the resistance will be appro...

Page 194: ...on 2 Transfer separation and fuser sections 3 Post fusing and transport sections 4 Paper output section The following jam detection sensors are positioned at the above sections Sensors 1 Paper feed section PES PTS 2 Transfer separation and fuser sections PTPS 3 Post fusing and transport sections PMS 4 Paper output section POPS Fig 8 1 SENSOR S POSITION POPS PMS PTPS PTS PES ...

Page 195: ... the positive lead of a digital multimeter in contact with pin 5 of CN8 of the KMPU board and the negative lead in contact with SG pin 6 and measure the voltage Block the light emitting window of the PES guide and measure the voltage If the voltage is approximately 0 62 V PES is normal in the ON condition Let light be incident upon the light emitting window of the PES guide and measure the voltage...

Page 196: ...t light be incident upon the PTS and measure the voltage If the voltage is approximately 0 V PTS is normal in the OFF condition 3 Is the tractor position appropriate If YES go to 4 If NO move the tractor to the left end However if there is a fault in the KMPU board replace the KMPU board If there is fault in the paper in motor go to 4 Bring the positive lead of a digital multimeter in contact with...

Page 197: ... remaining in fuser section Procedure Points to be checked Remedy Checking method 1 Is there paper remaining in the fuser section at the position of PTPS If YES remove the remaining paper If NO go to 2 2 Is the paper transport position sensor PTPS lever lowered If YES raise the lever If NO go to 3 3 Is the transport unit set properly If YES go to 4 In NO set the transport unit properly 4 Is PTPS n...

Page 198: ...lever and measure the voltage If normal the voltage will be approximately 0 V 4 Is the suction fan normal If YES go to 5 If NO follow the procedure indicated in the column to the right Check as follows Bring the positive lead of a digital multimeter in contact with pin 14 of CN9 of the KMPU board and the negative lead in contact with SG pin 12 and measure the voltage Is the voltage approximately 2...

Page 199: ... the spring enter between the sensor and the bracket 5 Check the operation of the sensor While keeping the PTPS bracket A level press down the PTPS lever by approximately 40 mm in the direction of the arrow and then let your finger go slowly Confirm that the lever returns without fail and that a sound is made when the lever and the bracket contact each other at part B If the lever does not return ...

Page 200: ...fusing scuff roller nip the paper so that the paper lies over the PMS encoder Check the voltage while turning the jam removal knob to the right and left If normal the voltage will fluctuate between approximately 0 V and approximately 5 V Transport Failure at the Paper Output Section 05 Paper jam at paper output section Procedure Points to be checked Remedy Checking method 1 Is the green lever of t...

Page 201: ...the paper out position sensor POPS lever lowered If NO go to 3 If YES raise the lever 3 Is POPS normal If NO replace POPS after checking the harness Bring the positive lead of a digital multimeter in contact with pin 15 of CN7 of the KMPU board and the negative lead in contact with SG pin 16 and measure the voltage If normal the voltage will be approximately 5 V when the POPS lever is pressed down...

Page 202: ...s set is wrong 2 Transfer separation and fuser sections 12 Paper remaining in fuser section Applicable sensor PTPS 03 Paper jam at fuser Applicable sensor PTPS Paper Jam at Fuser occurs frequently Angle of PTPS actuator Warping of the transport belt Suction force Printing paper Printing pattern and flash voltage 3 Post fusing and transport sections 04 Paper jam after fusing Applicable sensor PMS P...

Page 203: ... paper output section Applicable sensor POPS 05 Paper jam at paper output section Applicable sensor POPS Paper hits the paper guide The output tray cannot contain paper Paper hits the exit side of the top cover The solenoid actuator is mounted poorly ...

Page 204: ...ermined by the toner supply rate and the toner density sensor output Toner supplying is performed when the toner density sensor indicates that the toner is light at the timing of toner supply monitoring In this process the toner supply clutch is engaged for 1 second to cause the supply roller to rotate to thereby supply the toner Toner density monitoring is continued while the developing unit moto...

Page 205: ...board malfunction of the toner empty sensor circuit Remove jack J6 from CN6 of the KMPU board and bring the positive lead of a digital multimeter in contact with pin 2 of U39 LM339MA of the KMPU board and the negative lead in contact with SG J7 and measure the voltage If normal the voltage will be approximately 0 V when the power is turned on and will be approximately 5 V when pin 19 of CN6 of the...

Page 206: ... board Disconnect pin 14 of CN6 of the KMPU board Bring the positive lead of a digital multimeter in contact with the collector of Q11 2SC2120 of the KMPU board and the negative lead in contact with SG and measure the voltage If normal the voltage will be approximately 0 V when pin 14 of CN6 of the KMPU board and pin 29 5V of CN6 are shorted 3 Is the toner supply clutch normal If YES go to 4 If NO...

Page 207: ...t Remove the 3 screws that fix cover of the developing unit and remove the cover Fig 8 4 Turn the developing unit knob in the direction of the arrow to rotate the developing roller The doctor blade will thereby catch foreign matter paper dust lumps of toner etc and the voids on the developing roller will appear prominently Fig 8 5 Screws Developing unit Cover Knob Voids Doctor blade ...

Page 208: ...ping roller by pulling the scraper towards you Fig 8 6 Turn the developing unit knob and continue removing the foreign matter until there are no more voids on the developing roller Attach the cover of the developing unit and install the developing unit in the main body Note The gap between the doctor blade and the developing roller is 0 27 mm Void Doctor blade Developing roller Scraper Foreign mat...

Page 209: ... the air filter blower electrical countermeasures Install the fuser cover glass If the cover glass is broken replace the glass Cause The air filter is not installed The frame packing section of the air filter is strained The air filter has reached the end of its life The air filter blower is stopped The fuser cover glass is not installed or is broken Phenomenon 1 Toner odor is emitted from the air...

Page 210: ...ass mounting plate A Clean the cover glass with a scraper B Provide process conditions so that toner and carrier are not scattered around C Check whether the bias voltage is applied to the transport unit Cause The fuser exit blower is stopped Or the rotation speed of the blower is too low The glass mounting plate has undergone deformation due to heat The cover glass is soiled by attached toner etc...

Page 211: ...ower Install the fuser cover glass If the cover glass is broken replace the glass A Check the 24 V power supply system B Replace the fan Cause The fuser exit blower is stopped Or the rotation speed of the blower is too low The fuser cover glass is not installed or is broken The fuser unit upper fan is stopped Phenomenon 1 The Fuser unit overheat error occurs ...

Page 212: ... scattered around B Clean or replace the xenon lamp Set the flash charging voltage to the prescribed value 1850 V Cause The xenon lamp is out of gas Malfunction of the fusing power supply The trigger line of the xenon lamp is too close to a metal part and is leaking Poor contact of the lamp housing high voltage connector The xenon lamp is soiled by attached toner The flash charging voltage is too ...

Page 213: ...he end of its life replace the lamp A If the toner density is abnormally high 13 or more replace the developing unit B Review the electronic photography process Use paper recommended Install the xenon lamp correctly Cause Lowering of the luminance of the xenon lamp The toner density is high and too much toner becomes attached to the paper Paper recommended is not used The xenon lamp is not mounted...

Page 214: ...failure Error Nos 1E 1F Remarks Be careful of the harness anode cathode trigger when replacing the xenon lamp Remedy Install the xenon lamp correctly Cause The xenon lamp is not installed Phenomenon 1 Fusing power supply failure ...

Page 215: ...ther or not 24 V DC is applied to the fan B Replace the fan Install the fuser cover glass If the glass is broken replace the glass Remove the jammed sheet or shred of paper Replace the PTPS Cause The transport unit is lowered The suction fan is stopped The fuser cover glass is not installed or is broken A jammed sheet or shred of paper has been left in the transport section The PTPS sensor lever i...

Page 216: ...r with sandpaper finer than 400 A If the spring is detached replace or reattach the spring B If the movement of the lever is poor correct the lever movement strain of sheet metal etc Cause The sheet or shred of paper that caused the jam is left in the transport section The roller of PMS does not rotate smoothly A shred of paper etc is left in the paper transport system The jam sensor lever is soil...

Page 217: ...nit to the floating condition electrically Be especially careful of the metal parts of the lamp housing Replace the charger Install the charger properly Cause The transport unit is in contact with the FG Frame Ground section The corona wire of the charger is cut Poor installation of the charger Phenomenon 1 High voltage failure ...

Page 218: ...ion of the drum is uneven Blocking of toner occurs at the auger unit and the rotation load of the cleaning unit increases A torn piece of paper is attached to the leading end of the paper Deviation of the print starting setting The leading end of the paper is torn Deviation of the print starting setting Deviation of the setting Deviation of the tractor Phenomenon 1 Flaws on the OPC drum are develo...

Page 219: ...in and then fix the LED array Cause The rear face of the printer is too close to the wall Failure of fuser section cooling stoppage of fuser exit blower or fuser unit upper fan Malfunction of the LED array The developing bias setting is too low The LED strobe duty setting is too small The LED array is close to the end of its life Toner is attached to LED array Alignment is not performed by using t...

Page 220: ... attached to the surface of the LED array lens A lump of toner or debris clogs the doctor blade of the developing unit Abnormal rotation of the inner pole magnet of the developing roller abnormal rotation due to loosening of the ratchet of developing unit Phenomenon 11 The print is out of focus and unclear 12 Poor transfer low printing density occurs at parts in the paper transport direction 13 Th...

Page 221: ...ng unit If oil is attached to the OPC drum surface as well clean the drum surface with special cloth Cause Moistened paper is used Toner or debris is attached to the corona wire of the main charger Toner or debris is attached to the mesh grid of the main charger Toner or debris is attached to the corona wire of the pre charger A shred of paper gets caught inside the cleaning unit when a paper jam ...

Page 222: ... Cause The surface potential setting is too low The developing bias setting is too high The developing bias setting is too low The surface potential setting is too high Toner or debris is attached to the corona wire of the separation charger Toner has accumulated below the pre charger and part of this toner is dropping on the printed surface Phenomenon 20 Stains appear across the entire sheet 21 T...

Page 223: ...ness of the perforation the paper will not come in close contact with the drum at parts near the perforation and the print will not be transferred onto such parts of the paper Thus an image on which a large amount of toner is deposited remains on the drum and part of this toner remains even after the cleaning process and is retransferred onto the paper in the subsequent transfer process Phenomenon...

Page 224: ...unit is not pushed in adequately Breakage of the sensor An excessive load is applied to the transport unit and the stepping motor stalls The transfer elevator is at a neutral position besides the UP and DOWN positions and is started at this position Phenomenon 1 Transfer motor failure Error No 0C 0D The transfer elevator does not move to the UP DOWN position 2 The transfer elevator does not start ...

Page 225: ...oling air to flow Check the operation of the fuser exit blower and the fuser unit upper fan and perform replacement if necessary Cause The coverage or the LED strobe duty is abnormally high The rear face of the printer is too close to the wall Failure of fuser section cooling stoppage of fuser exit blower or fuser unit upper fan Phenomenon 1 LED array overheat Error No 32 2 LED array overheat Erro...

Page 226: ...size Replace the front cover sensor Cause The sheet size and the pattern are not matched with each other Malfunction of the front cover sensor Phenomenon 1 The print pattern is printed beyond the size of the sheet or is too small 2 Initialization is not completed does not enter the ready state ...

Page 227: ...hen the waste toner box is not installed during non regular work Remedy Replace the cleaning unit Cause Toner blocking occurs at the auger section and the rotation load on the cleaning unit increases Phenomenon 1 A sound is made that indicates the cleaning unit drive belt is skipping gear ...

Page 228: ...th a vacuum cleaner B Replace the developing unit C If the drive motor is faulty replace the motor Cause The rotation of the sleeve of the developing roller is stopped the inner pole magnet is rotating Phenomenon 1 The developer overflows out to the front face of the developing roller ...

Page 229: ...bber seal Or replace the developing unit Cause The urethane rubber seal on the front face of the developing roller is peeled and toner is discharged from this part Phenomenon 1 A small amount of toner is discharged at times from a position below the developing roller ...

Page 230: ...Appendix I KMPU Circuit Diagram ...

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KPOWERSCIENCE KP3828 Series, Maintenance Manual

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Summary of Contents for KP3828 Series

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