Kyocera KM-4230 User manual

4230/5230 S/M (MCA)
SERVICE
MANUAL
Published in June ’00
2A370761
Revision 1
KM-4230/5230
KM-4230 / 5230

CAUTION
DANGEROFEXPLOSIONIFBATTERYISINCORRECTLYRE-
PLACED.REPLACEONLYWITHTHESAMEOREQUIVALENT
TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE
OF USED BATTERIES ACCORDING TO THE MANUFAC-
TURER’S INSTRUCTIONS.
ATTENTION
IL Y A DANGER D’EXPLOSION S’IL Y A REMPLACEMENT IN-
CORRECT 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 CONFORMÉMENT AUX INSTRUC-
TIONS DU FABRICANT.

SERVICE
MANUAL
KM-4230/5230

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 accidentally ingested, drink a lot of water to dilute it in
the stomach and obtain medical attention immediately. If it gets into the
eyes, rinse immediately with copious amounts of water and obtain
medical 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 brochure 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 main 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 immediately. ..................................................
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. .........................................................................................................

1-1-1
2A3/4
CONTENTS
I THEORY AND CONSTRUCTION SECTION
1-1 Specifications
1-1-1 Specifications ................................................................................ 1-1-1
1-2 Handling Precautions
1-2-1 Drum ............................................................................................. 1-2-1
1-2-2 Developer and toner...................................................................... 1-2-1
1-3 Mechanical Construction
1-3-1 Parts names and their functions.................................................... 1-3-1
1-3-2 Machine cross section................................................................... 1-3-4
1-3-3 Drive system ................................................................................. 1-3-5
1-3-4 Mechanical construction................................................................ 1-3-8
II ELECTRICAL SECTION
2-1 Electrical Parts Layout
2-1-1 Electrical parts layout .................................................................... 2-1-1
2-2 Detection of Paper Misfeed
2-2-1 Paper misfeed detection ............................................................... 2-2-1
2-2-2 Paper misfeed detection conditions .............................................. 2-2-2
2-2-3 Original misfeed detection........................................................... 2-2-14
2-2-4 Original misfeed detection conditions ......................................... 2-2-15
2-3 Operation of the PCBs
2-3-1 Power source PCB........................................................................ 2-3-1
2-3-2 Engine PCB................................................................................... 2-3-3
2-3-3 Main PCB ...................................................................................... 2-3-4
2-3-4 Memory copy PCB ........................................................................ 2-3-6
2-3-5 Scanner motor PCB ...................................................................... 2-3-8
2-3-6 CCD PCB ...................................................................................... 2-3-9
2-3-7 DF driver PCB ............................................................................. 2-3-11
2-3-8 Operation unit main PCB,operation unit right PCB,and
operation unit left PCB ................................................................ 2-3-12
2-3-9 Deck main PCB (42 ppm: optional/52 ppm: standard)................ 2-3-16
III SET UP AND ADJUSTMENT SECTION
3-1 Installation
3-1-1 Unpacking and installation ............................................................ 3-1-1
3-1-2 Setting initial copy modes ........................................................... 3-1-29
3-1-3 Installing the memory copy kit
(42 ppm: optional/52 ppm: standard) .......................................... 3-1-30
3-1-4 Installing the image memory SIMM (option)................................ 3-1-33
3-1-5 Installing the optical heater (service part) ................................... 3-1-35
3-1-6 Installing the drawer heater (service part)................................... 3-1-38
3-1-7 Installing the key counter (option) ............................................... 3-1-41
3-1-8 Installing the dehumidfier heaters (service part) ......................... 3-1-44
3-1-9 Installing the MMD host monitorig system device
(optional for 120 V specifications only) ....................................... 3-1-47

1-1-2
2A3/4
3-2 Maintenance Mode
3-2-1 Maintenance mode........................................................................ 3-2-1
3-2-2 Copier management.................................................................... 3-2-99
3-3 Assembly and Disassembly
3-3-1 Precautions for assembly and disassembly .................................. 3-3-1
3-3-2 Paper feed section ........................................................................ 3-3-3
3-3-3 Optical section............................................................................. 3-3-23
3-3-4 Main charging section ................................................................. 3-3-42
3-3-5 Drum section ............................................................................... 3-3-45
3-3-6 Developing section ...................................................................... 3-3-51
3-3-7 Transfer and separation section.................................................. 3-3-56
3-3-8 Cleaning section.......................................................................... 3-3-59
3-3-9 Fixing section .............................................................................. 3-3-64
3-3-10 Feedshift and duplex section ...................................................... 3-3-80
3-3-11 SRDF section .............................................................................. 3-3-89
3-3-12 Large paper deck section
(42 ppm: optional/52 ppm: standard) ........................................ 3-3-102
3-4 PCB Initial Settings
3-4-1 Replacing the main PCB ............................................................... 3-4-1
3-4-2 Replacing the main PCB ROMs.................................................... 3-4-2
3-4-3 Adjustment-free variable resisters (VR) ........................................ 3-4-3
3-5 Self-Diagnosis
3-5-1 Self-diagnosis................................................................................ 3-5-1
3-6 Troubleshooting
3-6-1 Image formation problems ............................................................ 3-6-1
3-6-2 Paper misfeeds ........................................................................... 3-6-18
3-6-3 PCB terminal voltages................................................................. 3-6-33
3-6-4 Electrical problems ...................................................................... 3-6-73
3-6-5 Mechanical problems .................................................................. 3-6-97
3-7 Appendixes
Timing chart No. 1 .................................................................................... 3-7-1
Timing chart No. 2 .................................................................................... 3-7-2
Timing chart No. 3 .................................................................................... 3-7-3
Timing chart No. 4 .................................................................................... 3-7-4
Timing chart No. 5 .................................................................................... 3-7-5
Timing chart No. 6 .................................................................................... 3-7-6
Timing chart No. 7 .................................................................................... 3-7-7
Timing chart No. 8 .................................................................................... 3-7-8
Timing chart No. 9 .................................................................................... 3-7-9
Timing chart No. 10 ................................................................................ 3-7-10
Timing chart No. 11 ................................................................................ 3-7-11
Timing chart No. 12 ................................................................................ 3-7-12
Power source PCB 1/2 ........................................................................... 3-7-13
Power source PCB 2/2 ........................................................................... 3-7-14
Engine PCB 1/2 ...................................................................................... 3-7-15
Engine PCB 2/2 ...................................................................................... 3-7-16
Main PCB 1/9.......................................................................................... 3-7-17
Main PCB 2/9.......................................................................................... 3-7-18
Main PCB 3/9.......................................................................................... 3-7-19
Main PCB 4/9.......................................................................................... 3-7-20

1-1-3
2A3/4
Main PCB 5/9.......................................................................................... 3-7-21
Main PCB 6/9.......................................................................................... 3-7-22
Main PCB 7/9.......................................................................................... 3-7-23
Main PCB 8/9.......................................................................................... 3-7-24
Main PCB 9/9.......................................................................................... 3-7-25
Memory copy PCB 1/12.......................................................................... 3-7-26
Memory copy PCB 2/12.......................................................................... 3-7-27
Memory copy PCB 3/12.......................................................................... 3-7-28
Memory copy PCB 4/12.......................................................................... 3-7-29
Memory copy PCB 5/12.......................................................................... 3-7-30
Memory copy PCB 6/12.......................................................................... 3-7-31
Memory copy PCB 7/12.......................................................................... 3-7-32
Memory copy PCB 8/12.......................................................................... 3-7-33
Memory copy PCB 9/12.......................................................................... 3-7-34
Memory copy PCB 10/12........................................................................ 3-7-35
Memory copy PCB 11/12........................................................................ 3-7-36
Memory copy PCB 12/12........................................................................ 3-7-37
Scanner motor PCB................................................................................ 3-7-38
CCD PCB................................................................................................ 3-7-39
DF driver PCB......................................................................................... 3-7-40
Operation unit main PCB 1/2 .................................................................. 3-7-41
Operation unit main PCB 2/2 .................................................................. 3-7-42
Operation unit right PCB......................................................................... 3-7-43
Operation unit left PCB ........................................................................... 3-7-44
Deck main PCB ...................................................................................... 3-7-45
Interface PCB ......................................................................................... 3-7-46
SRDF connection diagram...................................................................... 3-7-47
General connection diagram (42 ppm copier) ........................................ 3-7-48
General connection diagram (52 ppm copier) ........................................ 3-7-49
SRDF wiring diagram.............................................................................. 3-7-50
Large paper deck wiring diagram ........................................................... 3-7-51

4230/5230 S/M (MCA)
THEORY AND
CONSTRUCTION
SECTION
I
I Theory and
Construction Section

1-1-5
2A3/4
CONTENTS
1-1 Specifications
1-1-1 Specifications ...................................................................................... 1-1-1

2A3/4
1-1-1
1-1-1 Specifications
Copier (42 ppm copier)
Type ……………………………Desktop
Copying system ………………Dry, indirect electrostatic system
Originals ………………………Sheets and books
Maximum size: A3/11" ×17"
Original feed system …………Fixed
Copy paper ……………………Drawer and duplex unit: Plain paper (64 – 80 g/m2)
Bypass table: Plain paper (60 – 160 g/m2)
Special paper: Transparencies, tracing paper, colored
paper, letterhead and envelopes (only when used as a
printer)
Note: Use the bypass table for special paper.
Copying sizes …………………Maximum: A3/11" ×17"
Minimum: A6R/51/2" ×81/2"
During duplex copying
Maximum: A3/11" ×17"
Minimum: A5R/51/2" ×81/2"
Magnification ratios ……………Manual mode: 25 – 400%, 1% increments
Auto copy mode: Fixed ratios
Metric
1:1 ±0.1%, 1:4.00/1:2.00/1:1.41/1:1.06/1:0.75/
1:0.70/1:0.50/1:0.25
Inch
1:1 ±0.1%, 1:4.00/1:2.00/1:1.29/1:1.21/1:0.78/
1:0.64/1:0.50/1:0.25
Copy speed ……………………At 100% magnification in memory copy mode:
A4/11" ×81/2": 42 copies/min.
A4R/81/2" ×11": 32 copies/min.
A3/11" ×17": 24 copies/min.
B5 : 42 copies/min.
B5R : 36 copies/min.
B4 (257 ×364)/81/2" ×14": 28 copies/min.
When the SRDF is used (at 100% magnification):
A4/11" ×81/2": 42 copies/min.
First copy time …………………4.5 s or less (A4/11" ×81/2", 100% magnification,
upper drawer, manual copy density control)
Warm-up time …………………120 s or less (room temperature 20˚C/68˚F, 65%RH)
Paper feed system ……………Automatic feed
Capacity:
Drawers: 550 sheets
Manual feed
Capacity:
Bypass: 100 sheets
Photoconductor ………………OPC (drum diameter 60 mm)
Charging system ………………Single positive corona charging, 670 – 730 µA
Exposure light source …………Semiconductor laser
Exposure scanning system …Polygon mirror

2A3/4
1-1-2
Developing system ……………Dry, reverse developing (magnetic brush)
Developer: 2-component, ferrite carrier and N29T black
toner
Toner density control: toner sensor
Toner replenishing: automatic from a toner cartridge
Transfer system ………………Single negative corona charging, –210 µA
Separation system ……………Single AC corona charging
Fixing system …………………Heat roller
Heat source: halogen heaters (main 850 W, sub 850 W)
Control temperature: 180˚C/356˚F (at normal ambient
temperature)
Abnormally high temperature protection devices:
140˚C/284˚F thermostat
Fixing pressure: 210 N
Charge erasing system ………Exposure by cleaning lamp
Cleaning system ………………Cleaning blade
Scanning system ………………Flat bed scanning by CCD image sensor
Bit map memory ………………12 MB (standard)
Image storage memory ………32 MB (standard)
Resolution ………………………600 ×600 dpi
Light source ……………………Inert gas lamp (12 W)
Dimensions ……………………627 (W) ×748 (D) ×841 (H) mm
2411/16" (W) ×297/16" (D) ×331/8" (H)
Weight …………………………129 kg/283.8 lbs
Floor requirements ……………1287 mm (W) ×748 (D)mm
505/16" (W) ×297/16" (D)
Functions ……………………… (1) Self-diagnostics
(2) Preheat
(3) Automatic copy density control
(4) Original size detection
(5) Automatic paper selection
(6) Automatic magnification selection
(7) Enlargement/reduction copy
(8) Fixed ratio selection
(9) Size zoom mode
(10) XY zoom mode
(11) Photo mode
(12) Duplex copy
(13) Margin copy
(14) Print page numbers function
(15) Split copy
(16) Border erasing
(17) Sheet copy
(18) Transparency backing sheet function
(19) Form overlay
(20) Combine copy
(21) Booklet + cover copy
(22) Sort copy
(23) Invert copy
(24) Mirror image mode

2A3/4-1
1-1-3
(25) Program copy
(26) Setting change mode
(27) Job build mode
(28) Department control
(29) Weekly timer
(30) Language selection
Power source …………………120 V AC, 60 Hz, 10.5 A
220 – 240 V AC, 50 or 60 Hz, 4.9 A
Power consumption ……………1300 W (for 120 V specifications)
1200 W (for 220-240 V specifications)
Options …………………………Paper feed desk, large paper deck, finisher, key counter,
printer unit, memory copy board, additional
memory (16 MB/32 MB), booklet stitcher,
and copy tray*.
* for 120 V specifications only

2A3/4
1-1-4
Copier (52 ppm copier)
Type ……………………………Console
Copying system ………………Dry, indirect electrostatic system
Originals ………………………Sheets and books
Maximum size: A3/11" ×17"
Original feed system …………Fixed
Copy paper ……………………Drawer and duplex unit: Plain paper (64 – 80 g/m2)
Bypass table: Plain paper (60 – 160 g/m2)
Special paper: Transparencies, tracing paper, colored
paper, letterhead and envelopes (only when used as a
printer)
Note: Use the bypass table for special paper.
Copying sizes …………………Maximum: A3/11" ×17"
Minimum: A6R/51/2" ×81/2"
During duplex copying
Maximum: A3/11" ×17"
Minimum: A5R/51/2" ×81/2"
Magnification ratios ……………Manual mode: 25 – 400%, 1% increments
Auto copy mode: Fixed ratios
Metric
1:1 ±0.1%, 1:4.00/1:2.00/1:1.41/1:1.06/1:0.75/
1:0.70/1:0.50/1:0.25
Inch
1:1 ±0.1%, 1:4.00/1:2.00/1:1.29/1:1.21/1:0.78/
1:0.64/1:0.50/1:0.25
Copy speed ……………………At 100% magnification in memory copy mode:
A4/11" ×81/2": 52 copies/min.
A4R/81/2" ×11": 35 copies/min.
A3/11" ×17": 26 copies/min.
B5 : 52 copies/min.
B5R : 42 copies/min.
B4 (257 ×364)/81/2" ×14": 31 copies/min.
When the SRDF is used (at 100% magnification):
A4/11" ×81/2": 52 copies/min.
First copy time …………………4.5 s or less (A4/11" ×81/2", 100% magnification,
upper drawer, manual copy density control)
Warm-up time …………………180 s or less (room temperature 20˚C/68˚F, 65%RH)
Paper feed system ……………Automatic feed
Capacity:
Drawers: 550 sheets
Manual feed
Capacity:
Bypass: 100 sheets
Photoconductor ………………OPC (drum diameter 60 mm)
Charging system ………………Single positive corona charging, 670 – 730 µA
Exposure light source …………Semiconductor laser
Exposure scanning system …Polygon mirror
Developing system ……………Dry, reverse developing (magnetic brush)
Developer: 2-component, ferrite carrier and N29T black
toner

2A3/4
1-1-5
Toner density control: toner sensor
Toner replenishing: automatic from a toner cartridge
Transfer system ………………Single negative corona charging, –210 µA
Separation system ……………Single AC corona charging
Fixing system …………………Heat roller
Heat source: halogen heaters (main 850 W, sub 850W)
Control temperature: 190˚C/374˚F (at normal ambient
temperature)
Abnormally high temperature protection devices:
140˚C/284˚F thermostat
Fixing pressure: 210 N
Charge erasing system ………Exposure by cleaning lamp
Cleaning system ………………Cleaning blade
Scanning system ………………Flat bed scanning by CCD image sensor
Bit map memory ………………12 MB (standard)
Image storage memory ………32 MB (standard)
Resolution ………………………600 ×600 dpi
Light source ……………………Inert gas lamp (12 W)
Dimensions ……………………627 (W) ×748 (D) ×1131 (H) mm
2411/16" (W) ×297/16" (D) ×449/16" (H)
Weight …………………………160 kg/352 lbs
Floor requirements ……………1287 mm (W) ×748 (D)mm
505/16" (W) ×297/16" (D)
Functions ……………………… (1) Self-diagnostics
(2) Preheat
(3) Automatic copy density control
(4) Original size detection
(5) Automatic paper selection
(6) Automatic magnification selection
(7) Enlargement/reduction copy
(8) Fixed ratio selection
(9) Size zoom mode
(10) XY zoom mode
(11) Photo mode
(12) Duplex copy
(13) Margin copy
(14) Print page numbers function
(15) Split copy
(16) Border erasing
(17) Sheet copy
(18) Transparency backing sheet function
(19) Form overlay
(20) Combine copy
(21) Booklet + cover copy
(22) Sort copy
(23) Invert copy
(24) Mirror image mode
(25) Program copy
(26) Setting change mode
(27) Job build mode

2A3/4-1
1-1-6
(28) Department control
(29) Weekly timer
(30) Language selection
Power source …………………120 V AC, 60 Hz, 10.5 A
220 – 240 V AC, 50 or 60 Hz, 4.9 A
Power consumption ……………1200 W (for 120 V specifications)
1300 W (for 220-240 V specifications)
Options …………………………Finisher, key counter, printer unit, additional
memory (16 MB/32 MB) ,
and copy tray*
* for 120 V specifications only
SRDF
Original feed system …………Automatic feed
Originals ………………………Sheets
Original weights ………………Single-sided original mode: 35 – 160 g/m2
Double-sided original mode: 50 – 120 g/m2
Original paper …………………Plain paper, thermal paper, art paper, colored paper
Original sizes …………………A3 – A5R, folio/11" ×17" – 81/2" ×51/2"
No. of originals …………………Up to 50 sheets (A3, B4, folio, 11" ×17", 81/2" ×14")
Up to 70 sheets (up to A4/11" ×81/2")
Up to 50 sheets in the auto selection mode
Art or thermal paper must be fed individually.
Power source …………………Electrically connected to the copier
Large paper deck
Paper ……………………………Plain paper (64 – 80 g/m2)
Paper size ………………………A4/11" ×81/2", B5
Capacity ………………………3000 sheets (1500 sheets ×2)
No. of stacks ……………………2
Power source …………………Electrically connected to the copier