Panasonic KX-P7100 manual

© 2001 Kyushu Matsushita Electric Co., Ltd. All rights reserved. Unauthorize d copying and distribution is a violation of law. KX-P7100 Laser Printe r ORDER NO.KM60108623C0 G0[...]

2 KX-P7100[...]

1 Introduction 4 1.1. Specification s 4 1.2. Indicators 9 1.3. Parts Identification 11 1.4. Component Layout and Paper Path 12 1.5. Electrical Components and Sensor Boards 13 1.6. Switches and Solenoids 14 1.7. Print Process 15 1.8. Paper Feed 17 1.9. Laser Scan Unit ( Exposure ) 18 1.10. Fuser Unit 20 1.11. Paper Ejection and Paper Switchback 21 2[...]

1 Introduction 1.1. Specifications 1.1.1. Printer 4 KX-P7100[...]

1.1.2. Paper 5 KX-P7100[...]

1.1.3. Interfac e, Options, Accessories, and Supplies 6 KX-P7100[...]

1.1.4. Others 1.1.4.1. About Media Available Media and Media Size Available Paper Weight s and Capacity 7 KX-P7100[...]

Recom mende d Media Transp arency : · To avoid damag ing the printer, do not use ink jet transpa rency. · Transpa rencies and adhesive materia l of labels should be stable at 205°C ( 400°F ), the printer’s maximu m temper ature. · Re-using transpa rencies that have been fed through the printer once ( for example, after jams or if the transpa[...]

1.2. Indicators 1.2.1. Printer Panel 1.2.2. Indicato rs / Button Three indicato rs show the followin g printer’ s status. For detailed informa tion on the printer status and recove ry, see Section 9.1. 9 KX-P7100[...]

10 KX-P7100[...]

1.3. Parts Identification 1.3.1. Front Side View 1.3.2. Rear Side View 11 KX-P7100[...]

1.4. Component Layout and Paper Path 12 KX-P7100[...]

1.5. Electrical Components and Sensor Boards 13 KX-P7100[...]

1.6. Switches and Solenoids 14 KX-P7100[...]

1.7. Print Process 1.7.1. Charge The charge corona applies a high, uniform positive charge to the surface of the organic photoc onduct or ( OPC ) drum. The charge level is approximately 900 VDC and remain s because the OPC drum has a high electric al resistan ce when concea led in darkne ss. 1.7.2. Exposu re The laser beam passes through the collim[...]

Cleaning: After transfe r, residua l toner remain s on the drum surface , and for next printing, the residua l toner reache s to the development area via charge and exposu re. The charge level of the OPC corresp onds to the white backgr ound is +900VDC, andthe bias voltage of the conduc tive roller is approx. +350VD C. Therefo r the positively char[...]

1.8. Paper Feed Media Tray The main motor drives the pickup roller after the pickup solenoi d is energized, which engages the pickup roller clutch and feeds a sheet of paper. The paper is pushed to the paper feed roller, which overdrives the paper slightly causing a bucklet o ensure the paper is aligned with the stationa ry registra tion roller. Wh[...]

1.9. Laser Scan Unit ( Exposure ) 1.9.1. Operatio n Theory The light beam from the laser diode ( light source ) is modula ted by the digital signal (nVIDEO) and conver ted to paralle l light waves by the collimator lens. The beam is then sent to the rotating polygon mirror (polygo n scanne r), where it is reflecte dthroug h the lens and then focuse[...]

1.9.3. Collima tor Lens The collima tor lens conver ts light from the laser diode to parallel light. This aids in scannin g and provide s better conver gence to a dot. 1.9.4. Polygon Scanne r The polygon scanne r consist s of a 6-sided mirror directly driven by a brushless DC motor at a rate 20,078 .74 rpm. The laser beam is reflected across the OP[...]

1.10. Fuser Unit A 600W heat lamp ( halogen lamp ) heats the surface of the teflon-c oated heat roller to approximately 190°C ( 374°F ), a thermis tor monito rs the heat roller temper ature, and the CPU control s the ON/OFF timing of the lamp. The thermo stat is mounte d 2.5mm away from the heat roller. If the ambien t temper ature reache s 180°[...]

1.11. Paper Ejection and Paper Switchback A. Norma l Printing Mode ( Not Duplex Mode ) After fusing, paper is fed to the output tray by the switchback roller and switchback pinch roller. The paper exit/ADU paper jam sensor detects paper. If paper does not arrive at the sensor within a predete rmined period of time, “Jamat A” is displayed, and i[...]

2 Installation, Setup, and Repacking 2.1. Installation Requirements 2.1.1. Environment 1. Tempe rature Range :10 °C - 32.5 °C ( 50 °F - 90.5 °F ) ( Tempe rature fluctuat ion ± 10 °C per hour or less ) 2. Humidi ty Range :20% RH - 80% RH ( Humidi ty fluctuat ion ± 20 °C per hour or less ) 3. Printer Weight :10 kg ( 22 lbs. ) 4. Place the uni[...]

(4) Slide the side pins of the toner cartridge into the drum unit. (5) Push down the toner cartridg e as shown to lock in place. Note: To preven t any damag e to the drum unit, · Do not touch the black drum surface ( A ). · Do not expose to light for more than 5 minute s. · Do not expose to direct sunligh t. (6) Open the front door. (7) Insert t[...]

2.3. Repacking Prepare the unit before shippin g. Note: It is highly recomm ended that users keep the origina l carton and ALL packing materia ls. Please follow these instruct ions when transpo rting or shippin g the printer. · The printer weights about 10 kg {22 lbs}. · Please use the origina l carton and all of the original packing materia ls. [...]

(4) While pushing the drum unit ( 1 ), lift the toner cartridge up (2) . (5) Replac e the shippin g cover on the toner cartridge. (6) Insert the toner cartridge into a plastic bag (1) and seal the end of the bag tightly (2,3). (7) Wrap the drum unit with the protect ive sheet to protect the drum surface . 25 KX-P7100[...]

(8) Insert the drum unit into a plastic bag and seal the end of the bag tightly. (9) Wipe off any loose toner in and around the printer. Note: · If a toner vacuum is available, it is the best tool for cleanin g spilled toner. Do not use a standard office vacuum ; the toner will not be retaine d by typical vacuum dust collecta ors. (10) Close the f[...]

3 Removal and Replacemen t Procedures 3.1. Front and Rear Covers (1) Remov e the Front Cover by releasin g the hooks. (2) Remov e the Rear Cover by releasing the hooks. 27 KX-P7100[...]

3.1.1. Front Cover Disasse mbly (1) Remov e the Pinch Roller Holder Assem bly ( 2 screws ). (2) Remov e the Paper Guide Pinion Gear ( 1 screws ). (3) Remov e the Guide Racks ( 2 screw ). 3.1.2. Rear Cover Disasse mbly (1) Releas e the Shaft from the hook by pushing the shaft suppor t in the arrow directio n. (2) Separa te the Shaft, 2 Rollers and 2[...]

3.2. Right, Left and Top Covers 3.2.1. Right Cover 1. Remov e the screw. 2. Releas e the 2 hooks from the bottom side of printer. 3. Remov e the Right Cover. 4. Remov e the LED Indicato r Cover and Continu e Button ( 1 screw ). 3.2.2. Left Cover 1. Remov e the screw. 2. Releas e the 2 hooks from the bottom side of printer. 3. Remov e the Left Cover[...]

3.3. Laser Scanning Unit ( LSU ) Before handlin g, remove the Right, Left and Top Covers ( see Section 3.2 ). (1) Remov e the 3 screws. (2) Discon nect the 2 connec tors from the LSU. 3.4. Relay Board (B) Before handlin g, remove the Left Cover ( see Section 3.2 ). (1) Remov e the connec tor from the Relay Board ( B ). (2) Remov e the 2 screws. (3)[...]

Before handlin g, remove the Left Cover ( see Section 3.2 ). 3.5. High Voltage Board and Power Supply Unit 3.5.1. High Voltage Board (1) Remov e the screw ( A ) and 5 screws ( B ). Caution : Screw ( A ) is different from screws ( B ). When reinsta lling the screw, return it to the origina l position. (2) Discon nect the Flat Cable from the High Vol[...]

3.5.2. Power Supply Unit (1) Discon nect the 2 connec tors. (2) Remov e the 3 screws ( A ) and 2 screws ( B ). Caution : The screw ( A ) differs from the screw ( B ). When reinsta lling the screw, return it to the origina l position. (3) Remov e the Power Supply Unit. 3.5.3. Power Supply Unit Disasse mbly (1) Remov e the Inlet Bracket with Power Le[...]

Before handlin g, remove the Right Cover ( see Section 3.2 ). 3.6. Indicator Board and Toner Empty Sensor Board Before handlin g, remove the Right Cover ( see Section 3.2 ). (1) Discon nect the Flat Cable from the Indicato r Board. (2) Remov e the Indicato r Board. (3) Remov e the screw. (4) Remov e the Toner Empty Sensor Board. (5) Discon nect the[...]

3.7.2. Fuser Drive Gear (1) Remov e screw ( A ) and 6 screws ( B ). Caution : Screw ( A ) is differe nt from screw ( B ). When reinsta lling the screw ( A ), return it to the original position. (2) Remov e the Fuser Drive Gear Bracke t. (3) Remov e the Fuser Drive Gear and Interme diate Gear. Caution: Be careful not to lose the plastic ring behind [...]

3.9. Gear Support Bracket, Motor and Drive Gear Unit Before handlin g, perform the followin g steps A - B : A. Remov e the Right Cover ( see Section 3.2 ). B. Remov e the Main Board Shield Cover ( see Section 3.7.1 ). 3.9.1. Gear Support Bracket (1) Discon nect the connec tor CN13 from the Main Controller Board. (2) Remov e screw ( A ) and 4 screws[...]

3.9.3. Drive Gear Unit Disasse mbly (1) Remov e the Motor ( 2 screws ) from the Drive Gear Unit. (2) Remov e the 5 screws. (3) Remov e the Motor Bracke t. (4) All gears can be removed after removi ng the plastic ring. 36 KX-P7100[...]

3.10. Upper Exit Roller Holder Before handlin g, perform the followin g steps A - B : A. Remov e the Right, Left and Top Covers ( see Section 3.2 ). B. Remov e the Main Board Shield Cover ( see Section 3.7.1 ). 3.10.1. Upper Exit Roller Holder (1) Remov e the 4 screws. (2) Separa te the Upper Exit Roller Holder. (3) Discon nect connector CN14 on th[...]

3.11. Fuser Unit Before perform ing the following steps, remove the upper Exit Roller Holder ( see Section 3.10 ). (1) Discon nect connector CN9 on the Main Controller Board. (2) Discon nect the connec tor CN202 from the Power Supply Unit. (3) Discon nect the connec tor CN407 from the Relay Board (B). (4) Remov e the 4 screws. (5) Remov e the Fuser[...]

Note: When reinstalling the exit roller rubber to the lower exit roller shaft, ensure it is installed as shown in figure-( A ). 3.11.2. Heat Lamp (1) Remov e the Side Fuser Cover ( 2 screws ). (2) Remov e the screw ( A ) and screw ( B ) from the ends of Heat Lamp Termin als. (3) Slide out the Heat Lamp. Caution: · Do not touch the heat lamp with y[...]

3.11.4. Thermostat (1) Remov e the 2 screw ( A ) and Therma l Fuse. (2) Remov e the screw ( B ) and Thermo stat. Caution : · When reinsta lling the thermo stat, both end termin als must be positioned under the terminals of therma l fuse and lead wire as shown in the followi ng figure, or thermo stat cannot proper ly measu re the surfac e temper at[...]

3.11.5. Paper Exit / ADU Paper Jam Sensor Lever and Paper Exit / ADU Paper Jam Sensor Board 1. Remov e the Fuser Unit ( see section 3.11 ). 2. Remov e the Paper Exit/ADU Paper Jam Sensor Lever with spring. 3. Discon nect the flat cable. 4. Remov e the Paper/A DU Paper Jam Sensor Board by releasin g the hooks. 41 KX-P7100[...]

3.12. Pickup, Paper Feed, Registration and Transfer Rollers Before handlin g, perform the followin g steps A - B : A. Remove the Gear Suppor t Bracket and 8 gears ( see Section 3.9.1 ). B. Remov e the Front Cover ( see Section 3.1.1 ). 3.12.1. Pickup Roller and Pickup Solenoi d 1. Releas e the bushing hook and slide out the bushing . 2. Slide the P[...]

3.12.2. Paper Feed Roller / Registra tion Roller 3.12.2.1 . Paper Feed Roller 1. Slide out the bushing from the Paper Feed Roller Shaft. 2. Remov e the Paper Feed Roller Gear and Drive Wheel by releasing the hook from the Paper Feed Roller Shaft. Then, remove the Paper Feed Roller Shaft. 3.12.2.2 . Registra tion Roller 1. Slide out the bushing from[...]

3.13. Transfer Roller Assembly Before handlin g, perform the followin g step. A. Remov e the Front Cover ( see Section 3.1.1 ). 1. Remove the 2 Transfe r Roller Holders . 2. Remov e the Transfe r Roller Assem bly by pulling up it. Caution: · Do not touch the surfac e of Transf er Roller to preven t any print quality proble ms. 44 KX-P7100[...]

3.14. Auto Duplex Unit, ADU Registration Roller and ADU Pinch Roller Before handlin g, perform the followin g steps A-B : A. Remove the Paper Cassette and OPC Drum Unit. B. Place the printer up side down. 3.14.1. Auto Duplex Unit ( ADU ) (1) Remov e the 2 screws ( A ) and 4 screws ( B ). Caution: Screw ( A ) is differen t from screws ( B ). When re[...]

3.14.1.2 . Auto Duplex Disasse mbly 1. The ADU Pinch Roller Plate can be separa ted from the Registration Roller Plate by removi ng the screw ( A ). 2. The ADU Jam Release Pan can be separa ted from the Registration Roller Plate by removing the 2 screws ( B ) and 2 springs. 46 KX-P7100[...]

3.15. Registration Sensor, Paper Top Detection Sensor and Registration & Paper Top Detection Sensor Board Before handlin g, perform the followin g steps A - D : A. Remove the Paper Cassette and OPC Drum Unit. B. Remove the Left and Right Covers ( see Section s 3.2.1 and 3.2.2 ). C. Place the printer upside down. D. Remove the Auto Duplex Unit ([...]

48 KX-P7100[...]

4 Electronic Circuit Description and Diagrams 4.1. Block Diagram Noise Filter Rectifier Thermistor Voltage Control Circuit Voltage Detector +24V +5V Fuser Driver Heat Lamp Thermal Fuse Thermostat Thermister TH +24V IR nCHGCTL nDBCTL nTRCTL nDB nTR TE_LED Charger Current Grid Voltage Transfer (+, - 2 way) OPC Drum DEV BIAS Toner Box Developer High V[...]

4.2. Connection Diagram 1 nTECTL 2 +5V 3 nTR 4 nTRCTL 5 nDB 6 nDBCH 7 nCHGCTL 8 +24VGND 9 +24VGND 10 +24VIR 1 2 3 4 Dev.Bias Transfer Grid Charge CN501 Process Unit Transfer Roller 1 Live 2 Neutral CN201 1 LAMP 1 2 (NC) 3 COMMON CN202 1 nFCTL 2 +5VGND 3 +5V 4 +24VGND 5 +24VGND 6 +24V 7 +24V CN251 Power Supply Unit (PSU) High Voltage Power Supply Un[...]

4.3. Power Supply The power supply circuit generates +5Vdc and +24Vdc . It also supplie s AC Voltage to the halogen heat lamp in the fuser unit. 51 KX-P7100[...]

4.4. Main Control Board 4.4.1. Main Control CPU This CPU is an 8-bit microco ntroller which is compatible with the Intel 80C51. It contain s the two types of memor y: ROM : 4k bytes, RAM : 128 bytes The CPU control s the RIP block of this printer. The main function s are as follows : 1) Initialization and control of GDI ASIC 2) Control the interfac[...]

4.4.2. GDI ASIC ( IC3 ) 1) CPU Interface The CPU interface consists of an 8-bit data bus and control signals between GDI ASIC and CPU. 2) DRAM I/F This block controls DRAM, which is the buffer where transient print data is stored. 3) KME ASIC I/F This block is the interface with the KME ASIC ( IC6 ). It receives the compressed print data through KM[...]

4.4.3. USB Chip This USB Chip is a custom ized USB-P arallel Convertor. The Paralle l side of this USB chip is suitable for the GDI ASIC via KME ASIC. 4.4.4. DRAM A 2MByte EDO DRAM, which is organiz ed as 1,048,5 76 words x 16 bits, is mounte d on this Main board. DRAM is used as the transie nt buffer for print data from the host PC to Engine . 54 [...]

4.4.5. ASIC ( KME ) (A) This block is the serial commu nication interfac e with the Engine CPU ( IC11 ). (B) This block is the interfac e with the GDI Contro ller CPU ( IC1 ). (C) This block is the Steppin g Motor Contro ller ( CH0 ) to control the main motor. (D) This block is anothe r Steppin g Motor Contro ller ( CH1 ), and it is not used for th[...]

4.4.6. Clock The system clock ( 12.00M Hz ) is genera ted by IC6 and X3, and it is supplie d to the CPU ( IC1 and IC11 ) and USB chip through IC6, pin4. The video data clock ( 53.84 MHz ) is genera ted by IC2 and X2, and it is supplie d to the ASIC ( IC3 and IC6). 56 KX-P7100[...]

4.4.7. Reset Circuit Reset signal is genera ted when the power is turned on. The reset circuit initializes the CPU ( IC1 & IC11 ), the ASIC ( IC3 & IC6 ) and the USB Chip. Approx imately 100~80 0 msec after turning on the power, pin4 of IC10 goes high. 57 KX-P7100[...]

4.4.8. Main Motor Drive Circuit The main motor ( 2-phas e steppin g motor ) is driven by IC14 ( bipolar constant current driver ). The SMOA, SMONA, SMOB and SMONB signals shown below are used to control motor directio n. when the signals are output as shown below, the main motor rotates . Full Speed Mode ( 2 phase excitati on ): Half speed Mode ( 1[...]

Motor Driver True Table I N1o r4 I N2o r3 O U T 1o r4 O U T 2o r3 L L OFF OFF L H L H H L H L H H OFF OFF Note: Motor Curren t will be cut off in case of “OFF” conditio n above. Motor Driver True Table for Current Chopping Level I0 I1 Current ratio L L 100% L H 33% Motor Drive Mode Mode Speed Current ratio 1st Hold for rotating Stop 33% Warm Up[...]

4.4.9. Laser Scanning Unit Control Circuit The laser unit consist s of laser drive circuit and scanne r motor drive circuit. Laser control signals are as follows . nVIDEO: This is actual data being printed. nLDON: When the nLDON signal is low, the laser unit is activated. When front door is opened, the laser unit is deactivated. nHSYNC: This is a h[...]

4.4.10. Fuser Temper ature Control Circuit The fuser temper ature is control led by IC11 ( Engine CPU ). IC11 has an analog to digital ( A/D ) conver ter ( AN0-AN 7 ). Thermi stor TH is connec ted to IC11 ( AN0 ). When IC11 ( Pin31 ) is low, Q7 is turned off. And Q4 is turned on. ThenH eat lamp inside fuser unit is turned on. Abnorm al temper ature[...]

4.4.11. High Voltage Control Circuit 1. Charge Control Circuit This circuit consist s of a DC-DC converter, which boosts +24V to approx imately +5.4kV ( constan t current approx. +300µA ) for the charge corona . nCHGCTL signal control s the charge output. If the signal goes low,the output is turned on. 2. Grid Circuit When the charge circuit is ac[...]

4.4.12. EEPROM Control Circuit This printer has 2kbit EEPRO M ( IC12 ). Page Count Data, Calibra tion Data, etc. are saved on the IC. The EEPRO M control signals are explain ed as follows . EEPCS: This is the chip select signal. EEPCLK: This is the serial data transfer clock. EEPDO: This is the serial data from CPU ( IC11 ) to EEPROM ( IC12 ). EEPD[...]

4.4.13. Safety Interloc k SW This printer has two safety interloc k switches: front door safety interlock switch, and an OPC drum unit safety interlock switch. +24V power is supplied to the front door safety interloc k switch. When the front door is opened, the frontdo or safety interloc k switch is opened and shuts off the main motor driver power [...]

4.4.14. Solenoi ds Control Circuit This printer has three solenoi ds: pickup solenoi d, registra tion solenoi d and a switchb ack solenoi d. 4.4.14.1 . The Pickup Control Solenoid Drive Circuit The pickup solenoi d is used for picking up the media from the media tray. The CPU IC11 outputs high level PUCTL signal from pin41 to the transistor Q20. Th[...]

4.4.14.3 . The Switchb ack Solenoi d Drive Control Circuit The switchback solenoi d is used for controlling media switchb ack when the printer is auto duplex printing. The CPU IC11 outputs high level EXITCTL signal from pin43 to the transistor Q22. The transist or Q22 and Q25 are turned on and supplie s +24Vpo wer to the solenoi d. 66 KX-P7100[...]

4.4.15. Sensors Circuit The printer has three photo sensors: Registration sensor , Top sensor and Exit sensor . 4.4.15.1 . Registra tion Sensor Circuit Registration sensor detects that the media is in front of the Registration Roller. When the registration sensor detects the media, nREGS EN signal changes from high level to low level. 4.4.15.2 . To[...]

4.4.15.3 . Exit Sensor Circuit Exit sensor detects that the media is at the rear of the Fuser Roller ( Exit of the printer ). When the exit sensor detects the media, nEXITS EN signal change s from high level to low level. +5VSP is the power of the photo sensors. When the5VCTL signal at pin32 of IC11 ( CPU ) is low level, the transist or Q13 is turn[...]

4.4.16. Fan Control Circuit FANCTL: 1. Full Power Mode When FANCT L signal ( pin 6, IC11 ) is high, pin 7 of IC9 goes high, transist ors Q15 and Q17 are turned on. This supplie s +24V Power to Fan motor and rotates the Fan. 2. Reduci ng Power Mode ( Quiet Mode ) Pulse signal ( see below ) is output from pin 6 of IC11. This pulse signal is integrate[...]

4.4.17. Internal Engine I / F (Control CPU - Engine CPU) The communicat ion I/F signal between Control CPU and Engine CPU in main board is as follows. PPRDY: Printer Engine had been Powered On. nPRDY: Engine status is ready for communicat ion. nTOP: A vertical synchronous signal which indicates the home position in a recording sheet. nHSYNC: A hori[...]

4.5. Timing Chart 4.5.1. Printing Timing 4.5.2. Horizon tal Timing ( Relation ship between nHSYNC and Video Signal ) 71 KX-P7100[...]

4.5.3. Engine I / F Commu nication 72 KX-P7100[...]

5 Schematic Diagram 5.1. Main Control Board 1 A 2 3 4 5 6 H G F E D C B 6 2 1 3 4 5 C B A G F E D 1/6 (Main Control Board) KX-P7100 500 ns 0.6 s 500 ns (53.84 MHz) VCLK 002:B3;002:B4;003:A4 IC1 P11 P10 NC1 P12 P13 P14 P15 P16 P17 RST RXD NC2 TXD nINT0 nINT1 T0 T1 nWR nRD XTAL2 NC3 A8 A9 A10 A11 A12 A13 A14 A15 nPSEN ALE/nPROG NC4 nEA/VPP AD7 AD6 AD[...]

1 A 2 3 4 5 6 H G F E D C B 6 2 1 3 4 5 C B A G F E D (Main Control Board) KX-P7100 2/6 IC3 MD1 71 nCAS 54 nIOCS1 88 nHSYNC 26 PIOD7 6 PIOD6 8 PIOD5 9 MA14 62 MA13 61 MA12 60 MD4 68 MD3 69 MD2 70 MA5 44 MA4 42 MA3 41 MA2 39 MA1 38 MA0 37 nMOE 55 nRAS0B 53 nRAS0A 52 RAS1 51 MD0 73 VDD 64 SIOD5/GIO5 34 ASTB 76 nWR 75 nRD 74 VDD 84 MA8 48 MA7 46 MA6 4[...]

1 A 2 3 4 5 6 H G F E D C B 6 2 1 3 4 5 C B A G F E D (Main Control Board) KX-P7100 3/6 83 ns IC6 AI[1] 17 nVIDEO 69 nLDEN 67 nADJUST 68 nLEDO0 63 nLEDO1 64 nLEDO2 65 CI[3] 23 CI[2] 22 CI[1] 21 AI[4] 14 AI[3] 15 AI[2] 16 EO[1] 19 EO[0] 29 EFI[4] 90 EFI[3] 89 EFI[2] 88 EFI[1] 87 EFI[0] 86 nHSYNC 71 SEL 30 nBD 66 AI[0] 18 VDD 1 BI[5] 41 ABO[3] 80 ABO[...]

1 A 2 3 4 5 6 H G F E D C B 6 2 1 3 4 5 C B A G F E D (Main Control Board) KX-P7100 4/6 CN6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 100p C65 100p C66 100p C67 100p C69 100p C71 DA7 3 21 DA6 3 21 DA5 3 21 DA11 3 2 1 DA10 3 2 1 DA9 3 2 1 DA8 3 2 1 100p C165 100p C164 100p C163 100p C162 1k RA[...]

1 A 2 3 4 5 6 H G F E D C B 6 2 1 3 4 5 C B A G F E D (Main Control Board) KX-P7100 5/6 Not Used SNRCTL 005:F2 SNRCLK 005:D4 Q9 nSNRLD 005:F2 TRPWM 005:G3 DBPWM 005:G4 Q3 Q6 +24V +24VIR +24V EEPCLK 005:H2 EEPCS 005:H2 SNRCLK 005:G5 PUCTL 006:A1 REGCTL 006:A2 5VCTL 006:A4 DBCH 005:F2 CHGCTL 005:F2 TRCTL 005:F2 EEPDO 005:H2 DBPWM 005:C5 TRPWM 005:C5 [...]

1 A 2 3 4 5 6 H G F E D C B 6 2 1 3 4 5 C B A G F E D (Main Control Board) KX-P7100 6/6 2800 s EXITCTL 005:F5 FANCTL 005:F2 FANERR 005:D3 nREGSEN 005:F5 nTOPSEN 005:F2 nEXITSEN 005:F5 +5VLD +5VSP +24V +24VIR CN19 1 2 3 CN12 1 2 0.1u C111 +24V REGCTL 005:F5 PUCTL 005:F5 CN13 1 2 Q13 Q17 +24V +24V FG-C FG-D FG-B FG-C FG-B FG-A FG-D +24V 10k R118 IC14[...]

5.2. Sens ors, Indicator and Rela y Boards 1 A 2 3 4 5 6 H G F E D C B 6 2 1 3 4 5 C B A G F E D SW401 180 R406 180 R408 180 R407 PI402 180 R401 180 R404 PI405 PI406 180 R405 D403 D404 D405 CN406 1 2 3 4 5 6 CN402 4 3 2 1 CN401 5 4 3 2 1 PI451 CN451 1 2 5VGND nTOPSEN nREGSEN +5V +5VSP 5VGND nEXITSEN REG-TOP EXIT JAM SENSOR(REGISTRATION,TOP) JAM SEN[...]

KX-P7100 80[...]

6 Explanation of Connectors 6.1. Main Board 6.1.1. CN1 ( to Front Panel ) Pin No. Signal Name Description Direction 1 2 3 4 5 6 +5V nKEY nLEDO 0 nLEDO 1 nLEDO 2 5VGND ---- Key Input Ready LED (Green) Error LED (Red) Toner LED (Yellow) OUT IN OUT OUT OUT --- CN1 (to Front Panel) 6.1.2. CN2 ( OPC Drum Unit Interloc k SW ) Pin No. Signal Name Descript[...]

6.1.4. CN4 ( USB I / F Connec tor ) Pin No. Signal Name Description Direction 1 2 3 4 5 6 VBUS D- D+ GND GND(FG) GND(FG) N.C. USB Differential Data - USB Differential Data + --- --- --- --- IN / OUT IN / OUT --- --- --- CN4 (USB Interface Connector) 6.1.5. CN6 ( Centron ics Parallel I/F) Pin No. Signal Name Description Direction 1 2 3 4 5 6 7 8 9 1[...]

6.1.6. CN7 ( PSU-MAIN Connec tor ) Pin No. Signal Name Description Direction 1 2 3 4 5 6 7 nFCTL 5VGND +5V 24VGND 24VGND +24V +24V Fuser ON/OFF Control GND for +5V +5V from Power Source (PSU) GND for +24V GND for +24V +24V from Power Source (PSU) +24V from Power Source (PSU) OUT --- IN --- --- IN IN CN7 (PSU-MAIN Connector) 6.1.7. CN8 ( Door + 24V [...]

6.1.10. CN11 ( Polygon Motor ) Pin No. Signal Name Description Direction 1 2 3 4 5 nSNRCLK nSNRLD nSNRCTL 24VGND +24V Scanner Clock Scanner Lock Scanner Control ------ ------ OUT IN OUT --- OUT CN11 (Polygon Motor) 6.1.11. CN12 ( Pickup Solenoi d ) Pin No. Signal Name Description Direction 1 2 PUSOL_CTL +24VGND Pick Up Solenoid Control ------ OUT -[...]

6.1.15. CN16 ( EXIT Sensor ) Pin No. Signal Name Description Direction 1 2 3 4 +5VSP 5VGND 5VGND nEXITSEN +5V (Power Save Controlled) GND GND EXIT Sensor OUT --- --- IN CN16 (EXIT Sensor) 6.1.16. CN18 ( MAIN Motor ) Pin No. Signal Name Description Direction 1 2 3 4 AOUT nAOUT nBOUT BOUT MOTOR_A MOTOR_A MOTOR_B MOTOR_B OUT OUT OUT OUT CN18 (Main Mot[...]

6.2. Registration & Paper Top Sensor Board 6.2.1. CN401 ( REG-TO P Sensor ) Pin No. Signal Name Description Direction 1 2 3 4 5 nTOPSEN nREGSEN 5VGND 5VGND +5V TOP Sensor Registration Sensor GND GND +5V OUT OUT --- --- IN CN401 (REG-TOP Sensor) 6.3. Paper Exit / ADU Paper Jam Sensor Board 6.3.1. CN402 ( EXIT Sensor ) Pin No. Signal Name Descrip[...]

6.6. Toner Empty Sensor Board 6.6.1. CN451 ( Toner Empty Sensor ) Pin No. Signal Name Description Direction 1 2 TE_ROUT +5VGND Toner Empty Sensor GND --- CN451 (Toner Empty Sensor) OUT 87 KX-P7100[...]

7 Component Reference Guide 7.1. IC1 ( Main Control CPU ) IC1 (Main Control CPU) Pin No. Symbol In/Out Function Pin No. Symbol In/Out Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 NC1 P10 P11 P12 P13 P14 P15 P16 P17 RST RXD NC2 TXD nINT0 nINT1 T0 T1 nWR nRD XTAL2 XTAL1 GND - Out Out - Out In - - - In Out - Out In In - In Out Out[...]

7.3. IC3 ( GDI ASIC ) IC3 (GDI ASIC) Pin No. Symbol In/Out Function Pin No. Symbol In/Out Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 PEND BUSY nACK nSTROB VSS PIOD7 VDD PIOD6 PIOD5 PIOD4 PIOD3 PIOD2 PIOD1 PIOD0 PCLK VDD SIOAO nSIOCS SIOWR SIOR[...]

7.4. IC5 ( DRAM ) IC5 (DRAM) Pin No. Symbol In/Out Function Pin No. Symbol In/Out Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 VCC1 DQ1 DQ2 DQ3 DQ4 VCC2 DQ5 DQ6 DQ7 DQ8 NC1 - - - NC5 NC6 nWE nRAS NC7 NC8 A0 A1 A2 A3 VCC3 - In/Out In/Out In/Out In/Out - In/Out In/Out In/Out In/Out - - - - - - In In - - In In In In - +5V[...]

7.5. IC6 ( ASIC ) IC6 (ASIC) Symbol In/Out Function Symbol In/Out Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 VDD CLKR CLKI CLKOUT VSS NRST RSTO nLED0 nLED1 nLED2 AI7 AI6 AI5 AI4 AI3 AI2 AI1 AI0 EO1 CI0 CI1 CI2 CI3 EO2 VDD GND EO3 EO4 EO0 SEL D[...]

7.6. IC8 ( USB Chip ) IC8 (USB Chip) Pin No. Symbol In/Out Function Pin No. Symbol In/Out Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 NC1 RESET nSTROBE BUSY D0 D1 D2 D3 VCC1 GND1 D4 D5 D6 D7 VCP D+ D- VCC2 GND2 NC2 - In Out In Out Out Out Out - - Out Out Out Out Out In/Out In/Out - - - N.C. System Reset signal Strobe signal Busy sig[...]

7.9. IC11 ( Engine Control CPU ) IC11 (Engine Control CPU) Pin No. Symbol In/Out Function Pin No. Symbol In/Out Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 UI2 INT27 AN0 P51 P52 P53 P54 P55 P56 P57 AVCC AVR AVSS INT10 P61 INT12 P63 P64 nRST MOD0 MOD1 X0 X1 VSS P27 P26 P25 P24 P23 PPGO2 PPGO1 P20 -[...]

7.11. IC14 ( Motor driver IC ) IC14 (Motor driver IC) Pin No. Symbol In/Out Function Pin No. Symbol In/Out Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LG VREF VSA I0 IN2 IN1 VCC1 VMMA OUT1 RSA OUT2 NC1 PG NC2 - - In In In In - - Out Out Out - - - GND +5V Voltage detector (A) Output current ratio control signal Phase signal (nA) input Phase signal (A)[...]

The following tools are recomm ended. 1. Toner vacuum cleaner 2. Blower brush 3. Cleanin g alcohol 4. Cleanin g cotton 5. Cotton swabs 8 Preventative Maintenance 8.1. General The preven tative mainte nance ( PM ) schedule is every 2,000 impres sions. Adherin g to this schedule will ensure maximu m print quality and reduce machin e downtim e and ser[...]

When print is faded or indicato rs show the following status, the replace ment of a supply is needed . 96 KX-P7100[...]

8.4.2. Service Maintenance 8.4.2.1. Mainten ance Cycle The followin g table shows the service cycle of the main parts. Item Average Life Service (x 1000 pages) 18 36 54 72 90 108 Fuser Unit 90,000 pages *1 R Transfer Roller 90,000 pages *1 R Retard Pad Assembly 90,000 pages R R: R eplace (Service Man R eplaceable) * 1 Average life is based on an av[...]

9 Troubleshoo ting 9.1. Self-Diagnostic Indicators The printer indicate s error conditions using the ON, OFF and blinking states of the Ready, Error and Toner/D rum unit LED indicato rs. The printer status and error code are display ed on the printer status display on the host compu ter screen. The Status Display softwar e must be installed on the [...]

9.1.3. User Error 99 KX-P7100[...]

9.1.4. Call for Service 100 KX-P7100[...]

9.2. Initial Troubleshooting Flowchart 101 KX-P7100[...]

9.3. No Operation 102 KX-P7100[...]

9.4. Print Quality 9.4.1. White Vertical Line in Print 103 KX-P7100[...]

9.4.2. Blank Print 104 KX-P7100[...]

9.4.3. Dark Vertical Line in Print 105 KX-P7100[...]

9.4.4. Dark Horizontal Line in Print 106 KX-P7100[...]

9.4.5. Dirty Backgro und 107 KX-P7100[...]

9.4.6. All-black Print 108 KX-P7100[...]

9.4.7. Light Print 109 KX-P7100[...]

9.4.8. Ghostin g 110 KX-P7100[...]

9.4.9. Black or White Dots 111 KX-P7100[...]

9.4.10. Toner Spatter 112 KX-P7100[...]

9.5. Paper Jam 9.5.1. Media Tray Empty or Misfeed 113 KX-P7100[...]

9.5.2. Jam at A 114 KX-P7100[...]

9.5.3. Jam at B 115 KX-P7100[...]

9.5.4. Jam at C 116 KX-P7100[...]

9.5.5. Jam at D, E 117 KX-P7100[...]

9.6. Call Service 9.6.1. E20 118 KX-P7100[...]

119 KX-P7100[...]

9.6.2. E30 120 KX-P7100[...]

9.6.3. E31 121 KX-P7100[...]

9.6.4. E32 122 KX-P7100[...]

9.6.5. E50 123 KX-P7100[...]

9.6.6. E54 9.6.7. E71 124 KX-P7100[...]

9.6.8. E73 9.6.9. E81 125 KX-P7100[...]

10 Replacemen t Parts List with Lubrication Guide 10.1. Exterior 126 KX-P7100[...]

Ref. No. Part No. Part Name & Description a1 PJYK2P7100M Front Cover Assembly a2 PJHRB0043Z Paper Guide (R) a3 PJHRB0044Z Paper Guide (L) a4 PJHRB0045Z Guide Rack a5 PJHRB0046Z Paper Guide Pinion Gear a6 PJBAB0011Z Hook a7 PJYKP7100M Pinch Roller Holder Assembly a8 PJDSB0034Z Pinch Roller Spring a9 PJDRB0017Z Pinch Roller a10 PJKEB0012Z Paper S[...]

10.2. Right Side Parts Ref. No. Part No. Part Name & Description Remarks b1 PJZC2P7100M Gear Support Bracket b2 PJWMP7100M Registration Solenoid Assembly b3 PJDSB0038Z Registration Lever Spring b4 PJUSB0025Z Earth Spring b5 PJHRB0327Z Clamp b6 PJZH1P7100M Fuser Drive Gear Bracket b7 PJDGB0051Z Fuser Drive Gear b8 PJDGB0050Z Fuser Intermediate G[...]

Ref. No. Part No. Part Name & Description Remarks b12 PJDGB0052Z ADU Drive Gear b13 PJDGB0070Z Registration Drive Gear b14 PJDGB0072Z Idle Gear Z19 b15 PJDGB0071Z Double Teeth Gear b16 PJDGB0073Z Idle Gear Z14 b17 PJDGB0028Z Ratchet Gear b18 PJDGB0043Z Registration Arm Gear b19 PJDGB0029Z Planetary Gear Z18 b20 PJDGB0042Z Registration Internal [...]

10.2.2. Pickup Roller and Paper Feed Roller Ref. No. Part No. Part Name & Description d1 PJWM1P7100M Pickup Solenoid Assembly d2 PJZE1P7100M Pickup Lever Assembly d3 PJDSB0038Z Pickup Spring d4 PJDGB0040Z Pickup Internal Gear d5 PJDGB0029Z Planetary Gear d6 PJDGB0041Z Pickup Arm Gear d7 PJDGB0027Z Ratchet Gear d8 PJZFP7100M Pickup Roller Shaft [...]

10.2.3. Motor and Drive Gear Unit Ref. No. Part No. Part Name & Description e1 PJMDB0032Z Motor Bracket e2 PJJQP5566Z Motor e3 PJZHP7100M Drive Gear Bracket Assembly e4 PJDGB0048Z OPC Gear ( A ) e5 PJDGB0049Z Fuser Gear e6 PJDGB0056Z Registration Gear ( A ) e7 PJDGB0069Z Registration Gear ( B ) e8 PJDGB0047Z OPC Gear ( B ) e9 PJNW525Z Plastic R[...]

10.3. Left Side Parts ( Power Supply Unit and High Voltage Board ) Ref. No. Part No. Part Name & Description Remarks f1 PJWSP7100M Power Lead Wire Assembly f2 PJMCB0042Z Inlet Bracket f3 PJLP1S58Z Power Supply Board Complete Non-Repairable f4 PJMCB0004Z Enclosure Cover f5 PJWP7P7100M High Voltage Board Complete Non-Repairable f6 XYN3+F8 Screw 3[...]

10.4. Rear and Top Side Parts Ref. No. Part No. Part Name & Description Remarks g1 PJZC1P7100M Upper Exit Roller Holder Cover Assembly g2 PJDSB0016Z Ratchet Spring g3 PJDPB0001Z Upper Exit Roller Solenoid with Plunger g4 PJDGB0024Z Upper Exit Roller Drive Gear Z21 g5 PJDGB0027Z Black Ratchet Gear g6 PJDGB0026Z Upper Exit Roller Drive Gear Z36 g[...]

10.4.1. Fuser Unit 134 KX-P7100[...]

Ref. No. Part No. Part Name & Description h1 PJDFB0122Z Fuser Drive Shaft h2 PJRTS10Z Thermistor h3 PJZCP7100M Heat Roller Holder Assembly h4 PJMDB0019Z Fuser Earth h5 PJZC3P7100M Side Fuser Cover Assembly h6 PJDGB0023Z Fuser Gear Z24 h7 PJDGB0024Z Fuser Gear Z21 h8 PJDGB0022Z Lower Exit Roller Gear h9 PJZR3P7100M Lower Exit Roller Assembly (bl[...]

10.5. Bottom Side Parts Ref. No. Part No. Part Name & Description Remarks j1 PJUAB0024Z Bottom Stay j2 PJZUP7100M Jam Release Pan with Knob j3 PJNW317Z Plastic Ring j4 PJDFB0009Z A/D Roller Shaft j5 PJDSB0041Z Pinch Roller Spring 136 KX-P7100[...]

Ref. No. Part No. Part Name & Description Remarks j6 PJDRB0018Z Auto Duplex Pinch Roller j7 PJMDB0020Z ADU Pinch Roller Plate j8 PJUAB0005Z ADU Registration Roller Plate j9 PJDJ05041RZ Bushing j10 PJDRB0014Z ADU Registration Roller Shaft j11 PJDJ05011CZ Bushing j12 PJDGB0030Z A/D Unit Joint Gear j13 PJDSB0017Z Spring j14 PJNEB0003Z Screw j15 PJ[...]

10.6. Mechanical Base Ref. No. Part No. Part Name & Description k1 PJHRB0324Z Transfer Roller Holder k2 PJDSB0040Z Transfer Spring k3 PJDJB0020Z U Bearing k4 PJHRB0038Z Pressure Arm (L) k5 PJHRB0037Z Pressure Arm (R) k6 PJUSB0011Z Earth Plate k7 PJUSB0008Z Transfer Roll Bias Plate k8 PJDRB0024Z Transfer Roller k9 PJDSB0026Z OPC Spring (L) k10 P[...]

10.7. Media Tray ( Paper Cassette ) Ref. No. Part No. Part Name & Description m1 PJZEP7100M Retard Pad Assembly m2 PJMDB0026Z Media Lifter m3 PJHSB0007Z Friction Pad m4 PJDSB0021Z Retard Pad Spring m5 PJHRB0031Z Media Side Guide (R) m6 PJHRB0032Z Media Side Guide (L) m7 PJDSB0022Z Friction Spring m8 PJDSB0020Z Stopper Spring m9 PJHRB0034Z Stopp[...]

10.8. Packing Ref. No. Part No. Part Name & Description Remarks n1 PJWRP7100M CD-ROM n2 PJQQB0002Z Setup Guide ( English ) n3 PJPNB0026Z Pad for CD-ROM n4 PFJA1030Z Power Cord n5 PJPNB0024Z Top Pad (L) n6 PJPNB0025Z Top Pad (R) n7 PJPNB0031Z Bottom Pad (R) n8 PJPNB0030Z Bottom Pad (L) n9 PJPGB0012Z Carton Box 140 KX-P7100[...]

10.9. Main Control Board Component Side View 141 KX-P7100[...]

Parts Side View 142 KX-P7100[...]

10.9.1. ICs Ref. No. Part No. Part Name & Description IC1 PJWIP7100M IC (Main Control CPU/ROM) IC2 TC74HCUV04FT IC (Standard Logic) IC3 D6004 IC (GDI-ASIC) IC5 IS41C16100K5 IC (DRAM) IC6 PJVANG0022Z IC (KME-ASIC) IC8 GL107AS IC (USB Bridge) IC9 PJVINJM2903M IC (Comparator) IC10 PST3642UR IC (Reset) IC11 PJWI1P7100M IC (Engine CPU/ROM) IC12 C3EB[...]

Ref. No. Part No. Part Name & Description C112 ECUX1H332KBV Ceramic / 3300p / 50V C114-C117 ECUV1H102KBV Ceramic / 1000p / 50V C119-C121 ECUV1H102KBV Ceramic / 1000p / 50V C144/C145 ECUV1C104ZFV Ceramic / 0.1 / 16V C147-C149 ECJ1VF1H104Z Ceramic / 0.1 / 50V C150 ECUV1H101JCV Ceramic / 100p / 50V C166 ECJ1VF1H104Z Ceramic / 0.1 / 50V C168 ECUV1H[...]

Ref. No. Part No. Part Name & Description R121 ERJ3GSYJ183V Chip Resistor / 18k (1/16W) R122 ERJ12YJ120H Chip Resistor / 12 (1/2W) R123 ERX1SGR47P Metal / 0.47 (1W) R124 ERJ12YJ120H Chip Resistor / 12 (1/2W) R129/R130 ERJ3GSYJ100V Chip Resistor / 10 (1/16W) R132/R133 ERJ3GSYJ100V Chip Resistor / 10 (1/16W) R136-R139 ERJ3GSYJ100V Chip Resistor /[...]

10.9.5. Connectors Ref. No. Part No. Part Name & Description CN1 06FE-BT-VK-N Connector (for Indicator Board) CN2 PJJP03AK01Z Connector (for 5V Interlock Switch) CN3 PJJP252Z Connector (for LSU) CN4 PJJS04EZ03Z Connector (for USB Interface) CN6 PJJS714Z Connector (for Centronics Interface) CN7 B7B-XH-A Connector (for Power Supply) CN8 B3B-EH Co[...]

10.10. Registration & Paper Top Detection Sensor Board All resistor values are in OHMs. Ref. No. Part No. Part Name & Description R401/R404 ERDS2TJ181T Resistor / 180 (1/4W) PI402/PI405 LTH301-07P1M Photo-interrupter CN401 05FE-ST-VK-N Connector 1 PJUP1055Z-A Bare PCB 10.11. Paper Exit / ADU Paper Jam Sensor Board Resisto r values is in OHM[...]

Ref. No. Part No. Part Name & Description 1 PJUP1055Z-C Bare PCB 10.13. Toner Empty Sensor Board Ref. No. Part No. Part Name & Description PI451 B3HA00000029 Photo Transistor CN451 6-173981-2 Connector 1 PJUP1055Z-D Bare PCB 10.14. Relay Board (A) Resisto r value is in OHMs. Ref. No. Part No. Part Name & Description R409 D1AB5006A002 Re[...]