Kyocera TASKalfa 3500i TASKalfa 4500i TASKalfa 5500i Service Manual, Rev. 5 December 2013


Rev. 5, December 2013
Accurate, clear and concise text, combined with detailed illustrations, lists of error code, instruction and diagrams, guide you through procedure of repair, remediate, maintenance and adjustments your copier, printer or scanner.
Present service manual Kyocera TASKalfa 3500i TASKalfa 4500i TASKalfa 5500i contain clear instructions and procedures on how to fix the problems occurring in your equipment.
The information contained in this repair manual is necessary for the repair, but also prevention, resulting in a longer life of your equipment.
Format of the manual: PDF, makes it easy to navigate, instant download and print. English language.
To see what contain, please read table of contents:

1-1 SPECIFICATIONS
1-1-1 Specifications
1-1-2 Parts names
(1) Machine
(2) Option
(3) Operation panel
1-1-3 Machine cross section

1-2 INSTALLATION
1-2-1 Installation environment
1-2-2 Unpacking and installation
(1) Installation procedure
(2) Setting initial copy modes
1-2-3 Installing the key counter (option)
(1) Installing directly on the device
(2) Mounting on the document table
1-2-4 Installing the key card MK-2 (option for japan only)
1-2-5 Installing the KMAS (option for japan only)
1-2-6 Installing the coin vender (option for japan only)
1-2-7 Installing the cassette heater (option)
1-2-8 Installing the gigabit ethernet board (option)
1-2-9 Installing the IC card reader holder (option)
1-2-10 Installing the keyboard holder (option)
1-2-11 Installing the handset (option for japan only)
(1) Installing directly on the device
(2) Mounting on the document table

1-3 MAINTENANCE MODE
1-3-1 Maintenance mode
(1) Executing a maintenance item
(2) Maintenance modes item list
(3) Contents of the maintenance mode items

1-4 TROUBLESHOOTING
1-4-1 Paper misfeed detection
(1) Paper misfeed indication
(2) Paper misfeed detection condition
1-4-2 Troubleshooting
(1) First check items
(2) Items and corrective actions relating to the device that will cause paper jam
(3) Paper jam at feeding from cassette 1
Electrical parts that could cause paper jam during paper travelling
at the primary feeding (to regist roller)
(4) Paper jam at feeding from cassette 2
Electrical parts that could cause paper jam during paper travelling
at the primary feeding ( to regist roller)
(5) Paper jam during manual feeding
Electrical parts that could cause paper jam during paper travelling
at the primary feeding ( to regist roller)
2LL/2LJ/2LH-3
(6) Paper jam at the duplex re-feeding part
Electrical parts that could cause paper jam during paper travelling
at the primary feeding ( to regist roller)
(7) Electrical parts that could cause paper jam at the transfer part
(8) Electrical parts that could cause paper jam at the fuser and eject parts
(9) Electrical parts that could cause paper jam at the duplex part
(10) Electrical parts that could cause paper jam at the BR (bridge) part
(11) Electrical parts that could cause paper jam at the DF paper entry,
feedshift and subtray left eject part
(12) Electrical parts that could cause paper jam at the DF process part
(13) Electrical parts that could cause paper jam at the DF eject tray part
(14) Electrical parts that could cause paper jam at the CF conveying part
1-4-3 Self-diagnostic function
(1) Self-diagnostic function
(2) Self diagnostic codes
1-4-4 Image formation problems
1-4-5 Poor image (due to DP and scanner reading)
(1) No image appears (entirely white)
(2) No image appears (entirely black)
(3) Image is too light
(4) The background is colored
(5) White streaks are printed vertically
(6) Black streaks appear longitudinally
(7) Streaks are printed horizontally
(8) One side of the print image is darker or brighter than the other
(9) Black dots appear on the image
(10) Image is blurred
(11) The leading edge of the image is consistently misaligned with the original
(12) Part of image is missing
(13) Image is out of focus
(14) Image center does not align with the original center
(15) Moires
(16) Skewed image
(17) Abnormal image
1-4-6 Poor image (Image rendering problems: printer engine
(1) No image appears (entirely white)
(2) No image appears (entirely black)
(3) Image is too light
(4) The background is colored
(5) White streaks are printed vertically
(6) Black streaks appear longitudinally
(7) Black or white streaks appear horizontally
(8) Uneven density longitudinally
(9) Uneven density horizontally
(10) Black dots appear on the image
(11) Offset occurs
(12) Image is partly missing
(13) Image is out of focus
(14) Poor grayscale reproducibility
(15) Unevenly repeating horizontal streaks in the printed objects.
Spots in the printed objects
(16) mage is blurred (Shifted transferring)
(17) The leading edge of the image is consistently misaligned with the original
(18) The leading edge of the image is sporadically misaligned with the original
2LL/2LJ/2LH-2
(19) Paper is wrinkled
(20) Fusing is loose
(21) Image center does not align with the original center
(22) Dirty paper edges with toner
(23) Dirty reverse side of paper
1-4-7 Electric problems
1-4-8 Mechanical problems
1-4-9 Send error code
(1) Scan to SMB error codes
(2) Scan to FTP error codes
(3) Scan to E-mail error codes
1-4-10 Error codes
(1) Error code
(2) Table of general classification
(2-1) U004XX error code table: Interrupted phase B
(2-2) U006XX error code table: Problems with the unit
(2-3) U008XX error code table: Page transmission error
(2-4) U009XX error code table: Page reception error
(2-5) U010XX error code table: G3 transmission
(2-6) U011XX error code table: G3 reception
(2-7) U017XX error code table: V.34 transmission
(2-8) U018XX error code table: V.34 reception

1-5 ASSEMBLY AND DISASSEMBLY
1-5-1 Precautions for assembly and disassembly
(1) Precautions
(2) Drum
(3) Toner
(4) How to tell a genuine Kyocera toner container
1-5-2 Paper feed section
(1) Detaching and refitting the primary paper feed unit
(2) Detaching and refitting the forwarding pulley,
paper feed pulley and separation pulley. [35 ppm model]
(3) Detaching and refitting the forwarding pulley,
paper feed pulley and separation pulley. [45 ppm model / 55 ppm model]
(4) Detaching and refitting the MP tray paper feed unit
(5) Detaching and refitting the MP forwarding pulley,
MP paper feed pulley and MP separation pulley
1-5-3 Optical section
(1) Detaching and refitting the exposure lamp
(2) Detaching and refitting the scanner wires
(3) Detaching and refitting the ISU
(4) Detaching and refitting the LSU
1-5-4 Image formation section
(1) Detaching and refitting the inner unit
(2) Detaching and refitting the developer unit
(3) Detaching and refitting the drum unit
(4) Detaching and refitting the charger roller unit
1-5-5 Transfer section
(1) Detaching and refitting the paper conveying unit
(2) Detaching and refitting the transfer belt unit
(3) Clean the conveying section
2LL/2LJ/2LH-3
1-5-6 Fuser section
(1) Detaching and refitting the fuser unit
1-5-7 PWBs
(1) Detaching and refitting the main PWB
(2) Detaching and refitting the engine PWB
(3) Detaching and refitting the power source PWB
(4) Detaching and refitting the high voltage PWB
(5) Detaching and refitting the operation PWB
(6) Detaching and refitting the fuser heater PWB
1-5-8 Drive section
(1) Detaching and refitting the drum drive unit
(2) Detaching and refitting the developer drive unit
(3) Detaching and refitting the fuser drive unit and feed drive unit
(4) Detaching and refitting the lift motor 1 and 2
1-5-9 Others
(1) Detaching the eject filter
(2) Detaching and refitting the toner filter
(3) Detaching and refitting the left filter
(4) Detaching and refitting the belt filter
(5) Detaching and refitting the LSU filter
(6) Detaching and refitting the drum filter and developer filter
(7) Detaching and refitting the hard disk unit
(8) Detaching and refitting the eject unit
(9) Direction of installing the principal fan motors
(10) Skewed paper feeding check/adjustment

1-6 REQUIREMENTS ON PWB REPLACEMENT
1-6-1 Upgrading the firmware
1-6-2 Remarks on main PWB replacement
1-6-3 Remarks on engine PWB replacement
2-1 Mechanical Construction
2-1-1 Paper feed/conveying section
(1) Cassette paper feed section
(2) MP tray paper feed section
(3) Paper conveying section
2-1-2 Drum section
2-1-3 Developer section
2-1-4 Optical section
(1) Image scanner section
(2) Laser scanner section
2-1-5 Transfer/Separation section
(1) Transfer belt unit section
2-1-6 Fuser section
2-1-7 Eject/Feedshift section
2-1-8 Duplex conveying section
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout
(1) PWBs
(2) Switches and sensors
(3) Motors
2LL/2LJ/2LH-3
(4) Fan motors
(5) Others
2-3 Operation of the PWBs
2-3-1 Main PWB
2-3-2 Engine PWB
2-3-3 Power source PWB
2-3-4 ISC PWB
2-3-5 Operation PWB 1
2-3-6 Front PWB
2-3-7 Feed PWB 1
2-3-8 Feed PWB 2
2-3-9 Relay PWB
2-3-10 LSU relay PWB
2-4 Appendixes
2-4-1 Appendixes
(1) List of maintenance parts
(2) Maintenance kits
(3) Periodic maintenance procedures
(4) Inner Cleaning
(5) Repetitive defects gauge
(6) Firmware environment commands
(7) System Error (Fxxxx) Outline
(8) Timing chart
(9) Chart of image adjustment procedures
(10) Wiring diagram

INSTALLATION GUIDE
DOCUMENT PROCESSOR
PAPER FEEDER
LARGE CAPACITY FEEDER
SIDE DECK
1000-SHEETS FINISHER
4000-SHEETS FINISHER
FINISHER ATTACHMENT KIT
CENTER-FOLDING UNIT
MAILBOX
PUNCH UNIT
INNER JOB SEPARATOR
100-SHEETS INNER JOB SEPARATOR
RIGHT JOB SEPARATOR
BANNER GUIDE
FAX System
DOCUMENT TABLE

Number of pages: 1025.