Kyocera KM-4050 User manual

SERVICE
MANUAL
Published in Jul ’06
2GN70760
KM-3050
KM-4050
KM-5050

CAUTION
DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH
THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE OF
USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS.
ATTENTION
IL Y A DANGER D’EXPLOSION S’IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE.
REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MÊME TYPE OU D’UN TYPE REC-
OMMANDÉ PAR LE CONSTRUCTEUR. METTRE AU RÉBUT LES BATTERIES USAGÉES CON-
FORMÉMENT AUX INSTRUCTIONS DU FABRICANT.

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

2GN/2GP/2GR
CONTENTS
1-1 Specifications
1-1-1 Specifications..........................................................................................................................................1-1-1
1-1-2 Parts names............................................................................................................................................1-1-4
(1) Machine.............................................................................................................................................1-1-4
(2) Operation panel.................................................................................................................................1-1-5
1-1-3 Machine cross section ............................................................................................................................1-1-6
1-2 Installation
1-2-1 Installation environment.........................................................................................................................1-2-1
1-2-2 Unpacking and installation......................................................................................................................1-2-2
(1) Installation procedure........................................................................................................................1-2-2
(2) Setting initial copy modes................................................................................................................1-2-10
1-2-3 Installing the key counter (option).........................................................................................................1-2-11
1-3 Maintenance Mode
1-3-1 Maintenance mode .................................................................................................................................1-3-1
(1) Executing a maintenance item..........................................................................................................1-3-1
(2) Maintenance modes item list.............................................................................................................1-3-2
(3) Contents of the maintenance mode items.........................................................................................1-3-6
1-4 Troubleshooting
1-4-1 Paper misfeed detection.........................................................................................................................1-4-1
(1) Paper misfeed indication...................................................................................................................1-4-1
(2) Paper misfeed detection conditions ..................................................................................................1-4-2
(3) Paper misfeeds ...............................................................................................................................1-4-11
1-4-2 Self-diagnosis .......................................................................................................................................1-4-22
(1) Self-diagnostic function...................................................................................................................1-4-22
(2) Self diagnostic codes ......................................................................................................................1-4-23
1-4-3 Image formation problems....................................................................................................................1-4-44
(1) No image appears (entirely white)...................................................................................................1-4-45
(2) No image appears (entirely black)...................................................................................................1-4-45
(3) Image is too light.............................................................................................................................1-4-46
(4) Background is visible.......................................................................................................................1-4-46
(5) A white line appears longitudinally..................................................................................................1-4-46
(6) A black line appears longitudinally..................................................................................................1-4-47
(7) A black line appears laterally...........................................................................................................1-4-47
(8) One side of the copy image is darker than the other.......................................................................1-4-47
(9) Black dots appear on the image......................................................................................................1-4-47
(10) Image is blurred...............................................................................................................................1-4-48
(11) The leading edge of the image is consistently misaligned with the original....................................1-4-48
(12) The leading edge of the image is sporadically misaligned with the original....................................1-4-48
(13) Paper creases.................................................................................................................................1-4-48
(14) Offset occurs...................................................................................................................................1-4-49
(15) Image is partly missing....................................................................................................................1-4-49
(16) Fusing is poor..................................................................................................................................1-4-49
(17) Image is out of focus.......................................................................................................................1-4-49
(18) Image center does not align with the original center.......................................................................1-4-50
(19) Image is not square.........................................................................................................................1-4-50
1-4-4 Electric problems ..................................................................................................................................1-4-51
1-4-5 Mechanical problems............................................................................................................................1-4-55
1-5 Assembly and Disassembly
1-5-1 Precautions for assembly and disassembly............................................................................................1-5-1
(1) Precautions .......................................................................................................................................1-5-1
(2) Drum..................................................................................................................................................1-5-1
(3) Toner.................................................................................................................................................1-5-1
1-5-2 Paper feed section..................................................................................................................................1-5-2
(1) Detaching and refitting the forwarding, paper feed and separation pulleys ......................................1-5-2
(2) Detaching and refitting the MP separation, MP paper feed and MP forwarding pulleys ...................1-5-4
(3) Detaching and refitting the left and right registration cleaner............................................................1-5-9