imagistics cm3520 User manual

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cm3520 Copier
Field Service Manual

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cm3520 Service Manual SAFETY AND IMPORTANT WARNING ITEMS
S-1
Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, Imagistics International Inc. strongly recommends that all
servicing be performed only by Imagistics-trained service technicians.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, Imagistics does not warrant, either explicitly or implicitly,
that the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.
In this Service Manual, each of three expressions " DANGER", " WARNING", and
" CAUTION" is defined as follows together with a symbol mark to be used in a limited
meaning.
When servicing the product, the relevant works (disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with the utmost of care.
Symbols used for safety and important warning items are defined as follows:
SAFETY AND IMPORTANT WARNING ITEMS
IMPORTANT NOTICE
DESCRIPTION ITEMS FOR DANGER,
WARNING AND CAUTION
DANGER: Action having a high possibility of suffering death or serious injury
WARNING: Action having a possibility of suffering death or serious injury
CAUTION: Action having a possibility of suffering a slight wound, medium
trouble, and property damage
:Precaution when servicing the
product. General
precaution Electric hazard High temperature
:Prohibition when servicing the
product. General
prohibition Do not touch with wet hand Do not disassemble
:Direction when servicing the
product. General
instruction Unplug Ground/Earth

SAFETY AND IMPORTANT WARNING ITEMS cm3520 Service Manual
S-2
[1] MODIFICATIONS NOT AUTHORIZED BY IMAGISTICS:
SAFETY WARNINGS
DANGER : PROHIBITED ACTIONS
• Using any cables or power cord not specified by Imagis-
tics.
• Using any fuse or thermostat not specified by Imagistics.
Safety will not be assured, leading to a risk of fire and
injury.
• Disabling fuse functions or bridging fuse terminals with
wire, metal clips, solder or similar object.
• Disabling relay functions (such as wedging paper between
relay contacts).
• Disabling safety functions (interlocks, safety circuits, etc.).
Safety will not be assured, leading to a risk of fire and
injury.
• Making any modification to the product unless instructed
otherwise by Imagistics.
• Using parts not specified by Imagistics.

cm3520 Service Manual SAFETY AND IMPORTANT WARNING ITEMS
S-3
[2] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE
This product was tested extensively before being shipped to ensure that all applicable
safety standards are met, in order to protect the customer and service personnel from the
risk of injury. However, in daily use, any electrical equipment may be subject to parts wear
and eventual failure. In order to maintain safety and reliability, service personnel must per-
form regular safety checks.
1. Power Supply
WARNING: Wall Outlet
• Check that main voltage is as specified. Plug the power
cord into the dedicated wall outlet with a capacity greater
than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
• If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.
WARNING: Power Plug and Cord
• Make sure the power cord is plugged into the wall outlet
securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
• Check if the power cord is damaged. Check if the sheath is
damaged.
If the power plug, cord, or sheath are damaged, replace
with a new power cord (with plug and connector on each
end) specified by Imagistics. Using the damaged power
cord may result in fire or electric shock.

SAFETY AND IMPORTANT WARNING ITEMS cm3520 Service Manual
S-4
• When using the power cord (inlet type) that came with this
product, be sure to observe the following precautions:
a. Make sure the connector is securely inserted in the inlet
on the rear panel of the product.
Secure the cord with a fixture properly.
b. If the power cord or sheath is damaged, replace with a
new power cord (with plugs on both ends) specified by
Imagistics.
If the power cord (inlet type) is not connected to the
product securely, a contact problem may lead to
increased resistance, overheating, and risk of fire.
• Check that the power cord is not stepped on or pinched by
a table and so on.
Overheating may occur there, leading to a risk of fire.
• Do not bundle or tie the power cord.
Overheating may occur there, leading to a risk of fire.
• Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
WARNING: Power Plug and Cord
WARNING: Wiring
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.

cm3520 Service Manual SAFETY AND IMPORTANT WARNING ITEMS
S-5
2. Installation Requirements
• When an extension cord is required, use the one specified.
Current that can flow in the extension cord is limited, so
using an extension cord that is too long may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
WARNING: Wiring
WARNING: Ground connection
• Check if the product is grounded properly.
If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
WARNING: Prohibited Installation Place
• Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.
• Do not place the product in a place exposed to water such
as rain.
A risk of fire and electric shock exists.
WARNING: When not using product for a long time
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.

SAFETY AND IMPORTANT WARNING ITEMS cm3520 Service Manual
S-6
CAUTION: Ventilation
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
CAUTION: Fixing
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
CAUTION: Inspection before Servicing
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure, using only the prescribed tools. Do not make any
adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect
the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
• The area around the fixing unit is hot.
You may get burned.

cm3520 Service Manual SAFETY AND IMPORTANT WARNING ITEMS
S-7
WARNING: Work Performed with the product Powered
• Take every care when making adjustments or performing
an operation check with the product powered.
If you make adjustments or perform an operation check
with the external cover detached, you may touch live or
high-voltage parts or you may be caught in moving gears
or the timing belt, leading to a risk of injury.
• Take every care when servicing with the external cover
detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
WARNING: Safety Checkpoints
• Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.
Current can leak, leading to a risk of electric shock or
fire.
• Carefully remove all toner remnants and dust from electri-
cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
• Check high-voltage cables and sheaths for any damage.
Current can leak, leading to a risk of electric shock or
fire.
• Check electrode units such as a charging corona unit for
deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.

SAFETY AND IMPORTANT WARNING ITEMS cm3520 Service Manual
S-8
• Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mount-
ing position.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authorities.
Improper replacement can cause an explosion.
• After replacing a part to which AC voltage is applied (e.g.,
optical lamp and fixing lamp), be sure to check the installa-
tion state.
A risk of fire exists.
• Check the interlock switch and actuator for loosening and
check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).
• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.
• Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
WARNING: Safety Checkpoints

cm3520 Service Manual SAFETY AND IMPORTANT WARNING ITEMS
S-9
WARNING: HANDLING OF CONSUMABLES
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
CAUTION: HANDLING OF SERVICE MATERIALS
• Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.
• Do not replace the cover or turn the product ON before
any solvent remnants on the cleaned parts have fully
evaporated.
A risk of fire exists.
• Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
A risk of fire exists.
• When using any solvent, ventilate the room well.
Breathing large quantities of organic solvents can lead to
discomfort.

SAFETY AND IMPORTANT WARNING ITEMS cm3520 Service Manual
S-10
[3] MEASURES TO TAKE IN CASE OF AN ACCIDENT
1. If an accident has occurred, the local Imagistics district office must be notified so that
immediate emergency measures can be taken to provide relief to affected persons
and to prevent further damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and Imagistics must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by Imagistics.
[4] CONCLUSION
1. Safety of users and customer engineers depends highly on accurate maintenance and
administration. Therefore, safety can be maintained by the appropriate daily service
work conducted by the customer engineer.
2. When performing service, each product on the site must be tested for safety. The cus-
tomer engineer must verify the safety of parts and ensure appropriate management of
the equipment.
[5] FUSE
[6] LED Radiation Safety
• This product is a copier which operates by means of a LED (light emitting diodes) expo-
sure system. There is no possibility of danger from the LED optical radiation, because
the LED optical radiation level dose not exceed the accessible radiation limit of class 1
under all conditions of operation, maintenance, service and failure.
CAUTION
Double pole / neutral fusing
ATTENTION
Double pôle / fusible sur le neutre.

cm3520 Service Manual SAFETY AND IMPORTANT WARNING ITEMS
S-11
Caution labels shown are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.
INDICATION OF WARNING ON THE MACHINE
4036fsS001c0
High voltage
High voltage High temperature
High temperature

SAFETY AND IMPORTANT WARNING ITEMS cm3520 Service Manual
S-12
4036fsS002c0
4036fsS003c0
Do not throw into a fire
High voltage
High voltage

cm3520 Field Service Manual
i
I GeneralII MaintenanceIII Adjustment/SettingIV TroubleshootingV Appendix
CONTENTS
I General
1. System Configuration...........................................................................................1-1
2. Product Specifications..........................................................................................1-3
2.1 Type...................................................................................................................1-3
2.2 Functions...........................................................................................................1-3
2.3 Types of Paper...................................................................................................1-4
2.4 Maintenance......................................................................................................1-4
2.5 Machine Specifications......................................................................................1-4
2.6 Operating Environment......................................................................................1-4
2.7 Built-In Controllers.............................................................................................1-5
II Maintenance
1. Periodical Check ..................................................................................................2-1
1.1 Service Schedule...............................................................................................2-1
1.2 Maintenance Items ............................................................................................2-1
1.2.1 Parts to Be Replaced by Users (CRU) .........................................................2-1
1.2.2 Maintenance Call (per 60,000-print).............................................................2-2
1.2.3 Periodical Parts Replacement 1 (per 150,000-print) ....................................2-2
1.2.4 Periodical Parts Replacement 2 (per 200,000-print) ....................................2-2
1.2.5 Periodical Parts Replacement 3 (per 300,000-print) ....................................2-3
1.3 Maintenance Parts.............................................................................................2-4
1.4 Concept of Parts Life.........................................................................................2-6
1.5 Maintenance Procedure (Periodical Check Parts).............................................2-8
1.5.1 Paper Take-up Roller....................................................................................2-8
1.5.2 Separation Roller..........................................................................................2-8
1.5.3 Separation Roller 2.......................................................................................2-9
1.5.4 Paper Take-up Roller..................................................................................2-11
1.5.5 Pick-up Roller .............................................................................................2-14
1.5.6 Transport Roller..........................................................................................2-15
1.5.7 Cleaning of Synchronizing Roller ...............................................................2-16
1.5.8 Paper Dust Remover ..................................................................................2-16
1.5.9 Cleaning of Transport Roller.......................................................................2-17
1.5.10 Cleaning of 2nd Image Transfer Entrance Upper Guide.............................2-17
1.5.11 Cleaning of Scanner Rail............................................................................2-17
1.5.12 Cleaning of the Mirrors (1st/2nd/3rd)..........................................................2-18
1.5.13 Cleaning of the Lens...................................................................................2-18

cm3520 Field Service Manual
ii
I GeneralII MaintenanceIII Adjustment/SettingIV TroubleshootingV Appendix
1.5.14 Cleaning of the Original Glass ...................................................................2-19
1.5.15 Cleaning of the CCD Sensor......................................................................2-19
1.5.16 Replacing the Waste Toner Bottle..............................................................2-20
1.5.17 Cleaning of the Area Around the Waste Toner Collecting Port...................2-21
1.5.18 Replacing Ozone Filter...............................................................................2-21
1.5.19 Cleaning of the Comb Electrode ................................................................2-21
1.5.20 Cleaning LPH Assy ....................................................................................2-22
1.5.21 Replacement of the Deodorant Filter .........................................................2-22
1.5.22 Replacing the 2nd Image Transfer Roller Unit............................................2-23
1.5.23 Image Transfer Belt Unit.............................................................................2-24
1.5.24 Replacing the Imaging Unit (C, M, Y, Bk)...................................................2-26
1.5.25 Replacing the Fusing Unit..........................................................................2-29
2. Service Tool .......................................................................................................2-30
2.1 CE Tool List .....................................................................................................2-30
2.2 Copy Materials ................................................................................................2-31
2.2.1 Imaging Unit Single Parts (IU).................................................................... 2-31
2.2.2 Toner Cartridge Single Parts (T/C).............................................................2-31
2.2.3 Waste Toner Bottle..................................................................................... 2-31
2.2.4 Maintenance Kit..........................................................................................2-31
3. Firmware Upgrade.............................................................................................2-32
3.1 Preparations for Firmware Rewriting...............................................................2-32
3.1.1 Service Environment..................................................................................2-32
3.1.2 Application to Be Used...............................................................................2-32
3.1.3 Installing the Cygwin ..................................................................................2-32
3.1.4 Writing into the Compact Flash..................................................................2-33
3.2 Firmware Rewriting .........................................................................................2-35
3.2.1 Updating Method........................................................................................2-35
3.2.2 Action When Data Transfer Fails................................................................2-36
4. Other..................................................................................................................2-37
4.1 Disassembly/Adjustment Prohibited Items......................................................2-37
4.2 Disassembly/Assembly List (Other Parts) .......................................................2-38
4.3 Disassembly/Assembly Procedure..................................................................2-40
4.3.1 IR Right Cover/Front Right Cover/Bypass Right & Left Cover....................2-40
4.3.2 Exit Tray/IR Left Cover/Rear Left Cover/Left Front Cover........................... 2-41
4.3.3 Front Door/Panel Cover/Paper Setting Dial Cover......................................2-42
4.3.4 Lower Rear Cover/Tray 2 Rear Cover/Rear Cover/
Rear Right Cover/Tray 2 Rear Right Cover/Wiring Cover...........................2-42
4.3.5 IR Upper Front Cover/IR Upper Right Cover/IR Upper Rear Cover ...........2-43

cm3520 Field Service Manual
iii
I GeneralII MaintenanceIII Adjustment/SettingIV TroubleshootingV Appendix
4.3.6 Original Glass/IR Front Cover.....................................................................2-44
4.3.7 Control Panel..............................................................................................2-44
4.3.8 Tray 1..........................................................................................................2-45
4.3.9 Tray 2..........................................................................................................2-46
4.3.10 Scanner Motor Drive Board........................................................................2-46
4.3.11 CCD Unit ....................................................................................................2-47
4.3.12 Image Processing Board............................................................................2-48
4.3.13 Control Board .............................................................................................2-49
4.3.14 MFP Control Board.....................................................................................2-50
4.3.15 High Voltage Unit/1.....................................................................................2-52
4.3.16 High Voltage Unit/2.....................................................................................2-53
4.3.17 Tray 1 Paper Size Board.............................................................................2-54
4.3.18 DC Power Supply .......................................................................................2-54
4.3.19 LED Drive Board.........................................................................................2-56
4.3.20 Paper Type Board.......................................................................................2-57
4.3.21 Tech. Rep. Setting Switches Board ............................................................2-57
4.3.22 Tray 2 Board ...............................................................................................2-58
4.3.23 Tray 2 Paper Size Board.............................................................................2-58
4.3.24 Inverter Board.............................................................................................2-59
4.3.25 Multi Bypass Unit........................................................................................2-59
4.3.26 Toner Hopper Unit ......................................................................................2-60
4.3.27 LPH Unit.....................................................................................................2-62
4.3.28 Scanner Motor............................................................................................2-64
4.3.29 Scanner Assy .............................................................................................2-66
4.3.30 Scanner Drive Cables.................................................................................2-67
4.3.31 Winding of the Scanner Drive Cables.........................................................2-69
4.3.32 PWB Box ....................................................................................................2-74
4.3.33 Main Motor..................................................................................................2-75
4.3.34 Fusing Drive Motor .....................................................................................2-75
4.3.35 Toner Supply Motor C/Bk............................................................................2-76
4.3.36 Toner Supply Motor Y/M.............................................................................2-76
4.3.37 Color PC Drum Motor.................................................................................2-77
4.3.38 Color Developing Motor..............................................................................2-79
4.3.39 Bk PC Motor...............................................................................................2-79
4.3.40 1st Image Transfer Pressure/Retraction Motor...........................................2-80
4.3.41 2nd Image Transfer Pressure/Retraction Motor..........................................2-80
4.3.42 Intermediate Transport Motor.....................................................................2-81

cm3520 Field Service Manual
iv
I GeneralII MaintenanceIII Adjustment/SettingIV TroubleshootingV Appendix
4.3.43 Fusing Pressure Roller Pressure/Retraction Motor....................................2-83
4.3.44 Cleaning Brush Motor ................................................................................2-86
4.3.45 AIDC/Registration Sensor/1,2 ....................................................................2-87
4.3.46 LPH ............................................................................................................ 2-88
4.3.47 ATDC Sensor Y/M/C...................................................................................2-92
4.4 Mount the Optional Original Size Detecting Sensors ......................................2-93
4.5 Option Counter................................................................................................ 2-94
4.5.1 Installation of the Mechanical Counter.......................................................2-94
4.5.2 Installation Method for the Key Counter.....................................................2-95
III Adjustment/Setting
1. How to Use the Adjustment Section ....................................................................3-1
2. Adjustment Item List ............................................................................................3-2
3. Utility Mode.......................................................................................................... 3-4
3.1 Utility Mode Function Tree................................................................................. 3-4
3.1.1 Administrator Mode Function Tree ............................................................... 3-5
3.2 Utility Mode Function Setting Procedure...........................................................3-7
3.2.1 Procedure.....................................................................................................3-7
3.2.2 Exiting...........................................................................................................3-7
3.2.3 Changing the Setting Value in Utility Mode Functions..................................3-7
3.3 Settings in the Store.......................................................................................... 3-8
3.3.1 Reset Mode.................................................................................................. 3-8
3.3.2 Mode Store................................................................................................... 3-8
3.4 Counter List.......................................................................................................3-8
3.5 Controller Detail.................................................................................................3-8
3.6 User’s Choice: 1................................................................................................3-9
3.6.1 1/2 ................................................................................................................ 3-9
3.6.2 2/2 ................................................................................................................ 3-9
3.7 User’s Choice: 2..............................................................................................3-10
3.7.1 1/3 .............................................................................................................. 3-10
3.7.2 2/3 .............................................................................................................. 3-11
3.7.3 3/3 .............................................................................................................. 3-12
3.8 Copy Program Recall ......................................................................................3-13
3.9 Printer Setting..................................................................................................3-13
3.9.1 Default Setting............................................................................................3-13
3.9.2 Report Types..............................................................................................3-15
3.10 Unit Life Indication...........................................................................................3-15
3.11 Settings in the Admin. Mode ...........................................................................3-16
3.11.1 Admin. Set.................................................................................................. 3-16