Kyocera FS-C1020MFP User manual

SERVICE
MANUAL
Published in April 2008
5JLSM060
First Edition
FS-C1020MFP

CAUTION
RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF
USED BATTERIES ACCORDING TO THE INSTRUCTIONS.
It may be illegal to dispose of this battery into the municipal waste stream. Check with your local
solid waste officials for details in your area for proper disposal.
ATTENTION
IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE
TYPE INCORRECT. METTRE AU REBUT LES BATTERIES UTILISEES SELON LES INSTRUC-
TIONS DONNEES.
Il peut être illégal de jeter les batteries dans des eaux d’égout municipales. Vérifiez avec les fonc-
tionnaires municipaux de votre région pour les détails concernant des déchets solides et une mise
au rebut appropriée.

Revision history
Revision Date Replaced pages Remarks

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Safety precautions
This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.

1.Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. .............................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. ............................................................................................................................
CAUTION:
• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .......
• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ................
• Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. .........................................................................................................................
• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ...........
• Always handle the machine by the correct locations when moving it. ...............................................
• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause
the copier to move unexpectedly or topple, leading to injury. ...........................................................
• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is acciden-
tally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immedi-
ately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical
attention. ......................................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. .....................................................................................................................

2.Precautions for Maintenance
WARNING
• Always remove the power plug from the wall outlet before starting machine disassembly. ...............
• Always follow the procedures for maintenance described in the service manual and other related
brochures. .......................................................................................................................................
• Under no circumstances attempt to bypass or disable safety features including safety mechanisms
and protective circuits. .....................................................................................................................
• Always use parts having the correct specifications. ..........................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related bro-
chure when replacing them. Using a piece of wire, for example, could lead to fire or other serious
accident. ..........................................................................................................................................
• When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ................................................................
• Always check that the copier is correctly connected to an outlet with a ground connection. .............
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it
is dirty, clean it to remove the risk of fire or electric shock. ..............................................................
• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ...........................................................................................................................
• Handle the charger sections with care. They are charged to high potentials and may cause electric
shock if handled improperly. ............................................................................................................
CAUTION
• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections. ..........................................................
• Use utmost caution when working on a powered machine. Keep away from chains and belts. ........
• Handle the fixing section with care to avoid burns as it can be extremely hot. ..................................
• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures. ........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement. ....................
• Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. .....................................................................................................
• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. .............................................................................................
• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ........
• Remove toner completely from electronic components. ...................................................................
• Run wire harnesses carefully so that wires will not be trapped or damaged. ....................................
• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten connector,
trapped wire and missing screws. ...................................................................................................
• Check that all the caution labels that should be present on the machine according to the instruction
handbook are clean and not peeling. Replace with new ones if necessary. ......................................
• Handle greases and solvents with care by following the instructions below: .....................................
Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
Ventilate the room well while using grease or solvents.
Allow applied solvents to evaporate completely before refitting the covers or turning the power switch on.
Always wash hands afterwards.
• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc. .......................................................................................................................
• Should smoke be seen coming from the copier, remove the power plug from the wall outlet imme-
diately. ............................................................................................................................................
3.Miscellaneous
WARNING
• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the
specified refiner; it may generate toxic gas. .....................................................................................

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Product Information
1
Product Information .............................................................................................................. 5
Specifications .................................................................................................................... 5
Machine Overview............................................................................................................. 6
Component Layout ........................................................................................................ 6
Paper Path.....................................................................................................................8
Drive Layout .................................................................................................................. 9
Installation........................................................................................................................... 11
Installation Requirements................................................................................................ 11
Environment ................................................................................................................ 11
Machine level............................................................................................................... 11
Machine Space Requirement....................................................................................... 12
Power Requirements ................................................................................................... 12
Installation Procedure .................................................................................................. 12
Preventive Maintenance ..................................................................................................... 13
Preventive Maintenance.................................................................................................. 13
Replacement and Adjustment ............................................................................................. 14
Before You Start .............................................................................................................. 14
Special Tools ...................................................................................................................15
Exterior Covers ............................................................................................................... 16
Rear Cover .................................................................................................................. 16
Operation Panel........................................................................................................... 17
Right Cover.................................................................................................................. 18
Left Cover .................................................................................................................... 18
Front Cover Unit .......................................................................................................... 19
Laser Optics ....................................................................................................................21
Caution Decal Location................................................................................................ 21
Laser Optics Housing Unit ........................................................................................... 21
AIO Cartridge ..................................................................................................................26
AIO Cartridge (All In One Cartridge)............................................................................ 26
Black AIO Motor........................................................................................................... 26
Color AIO Motor........................................................................................................... 29
Image Transfer ................................................................................................................ 31
Image Transfer Belt Unit .............................................................................................. 31
ITB (Image Transfer Belt) Cleaning Unit ...................................................................... 32
Agitator Motor .............................................................................................................. 33
ITB (Image Transfer Belt) Contact Motor ..................................................................... 35

Product Information
2
ITB (Image Transfer Belt) Contact Sensor................................................................... 36
TM (Toner Mark) Sensor Base..................................................................................... 37
Waste Toner Bottle Set Sensor.................................................................................... 38
Waste Toner Overflow Sensor ..................................................................................... 39
Paper Transfer ................................................................................................................ 41
Transfer Unit................................................................................................................ 41
Transfer Roller ............................................................................................................. 41
Registration Roller ....................................................................................................... 43
Registration Sensor ..................................................................................................... 44
Registration Clutch ...................................................................................................... 44
Image Fusing .................................................................................................................. 46
Fusing Unit .................................................................................................................. 46
Fusing Lamp................................................................................................................ 47
Transport/Fusing Motor ............................................................................................... 48
Paper Feed .....................................................................................................................50
Paper Feed Clutch....................................................................................................... 50
Paper Feed Roller ....................................................................................................... 50
Separation Pad............................................................................................................ 51
Paper End Sensor ....................................................................................................... 52
Paper Exit........................................................................................................................ 54
Paper Exit Roller.......................................................................................................... 54
Paper Exit Sensor........................................................................................................ 55
Electrical Components .................................................................................................... 57
Controller Board .......................................................................................................... 57
EGB (Engine Board).................................................................................................... 59
FCU .............................................................................................................................61
Interlock Switches........................................................................................................ 61
Fusing Fan Motor ........................................................................................................ 62
LSU Fan Motor ............................................................................................................ 63
ID Chip Board .............................................................................................................. 64
PSU .............................................................................................................................64
High Voltage Power Supply Board............................................................................... 66
Temperature/Humidity Sensor ..................................................................................... 67
Duplex Motor ............................................................................................................... 67
Speaker ....................................................................................................................... 68
EEPROM ..................................................................................................................... 69

Product Information
3
ADF................................................................................................................................. 71
ADF Unit ...................................................................................................................... 71
Original Tray ................................................................................................................ 72
ADF Feed Unit............................................................................................................. 73
ADF Separation Pad.................................................................................................... 73
ADF Front Cover ......................................................................................................... 74
ADF Rear Cover .......................................................................................................... 74
ADF Cover................................................................................................................... 75
ADF Motor ................................................................................................................... 75
Original Set Sensor .....................................................................................................77
ADF Cover Open Sensor............................................................................................. 78
ADF Feed Sensor........................................................................................................ 78
ADF Drive Board ......................................................................................................... 79
Scanner........................................................................................................................... 81
Scanner Unit................................................................................................................ 81
Scanner Top Cover ...................................................................................................... 83
Scanner Carriage Unit ................................................................................................. 84
Exposure Lamp ........................................................................................................... 86
Lamp Stabilizer Board.................................................................................................. 87
Scanner Motor ............................................................................................................. 88
System Maintenance Reference......................................................................................... 90
Service Program ............................................................................................................. 90
Overview...................................................................................................................... 90
Configuration Page Information....................................................................................... 91
Overview...................................................................................................................... 91
Firmware Updating.......................................................................................................... 92
Checking the Machine Firmware Version .................................................................... 92
Updating the Controller Firmware................................................................................ 92
Updating Failure .......................................................................................................... 98
Updating the Engine Firmware .................................................................................... 99
Boot Loader Firmware ............................................................................................... 100
Troubleshooting ................................................................................................................101
Troubleshooting Guide .................................................................................................. 101
Image Problems ............................................................................................................ 102
Overview.................................................................................................................... 102
Checking a Sample Printout ......................................................................................102

Product Information
4
INDEX............................................................................................................................... 105

Product Information
5
Product Information
Specifications
See "Appendices" for the following information:
"General Specifications"
"Supported Paper Sizes"

Product Information
6
Machine Overview
Component Layout
Engine
1. Laser Optics Housing Unit
2. Print Cartridge (AIO)
3. Development Roller (AIO)
4. Paper Exit
5. Fusing Unit
6. Fusing Lamp
7. Duplex Path
8. Transfer Roller
9. Registration Roller
10. By-pass
11. Paper Feed Roller
12. ITB (Image Transfer Belt) Unit
13. OPC (AIO)
14. Tray 1
15 EGB/Controller

Product Information
7
ADF
1. Feed Sensor
2. Feed Roller
3. Separation Roller
4. Pick-up Roller
5. Exit Roller
6. Original Set Sensor
7. DF Exposure Glass
Scanner
1. Scanner Carriage Unit
2. DF Exposure Glass
3. Exposure Glass
4. Carriage Drive Bar
5. White Plate

Product Information
8
Paper Path
Engine
1. Paper path from tray 1
2. Duplex path
3. By-pass tray
4. Paper path from tray 2 (optional)
ADF
1. Original path

Product Information
9
Drive Layout
1. Color AIO Motor
2. Black AIO Motor
3. Duplex Motor
4. Transport/Fusing Motor
5. Registration Clutch
6. Paper Feed Clutch
7. Agitator Motor
8. ITB (Image Transfer Belt) Contact Motor
Color AIO Motor:
This drives the color AIOs (Cyan, Magenta and Yellow)
Black AIO Motor:
This drives the black AIO and the ITB (Image Transfer Belt).
Duplex Motor:
This drives the paper exit roller and the duplex roller.
Transport/Fusing Motor:
This drives the fusing unit, paper feed roller, registration roller and paper exit roller via
the paper feed clutch, registration clutch and gears.
Registration Clutch:
This transfers drive from the transport/ fusing motor to the registration roller.
Paper Feed Clutch:
This transfers drive from the transport/ fusing motor to the paper feed roller.

Product Information
10
Agitator Motor:
This moves the agitators in the waste toner bottle.
ITB Contact Motor:
This moves the ITB into contact with and away from the color OPCs.