Panasonic KX-FL501 Paper

rights reserved. Unauthorized copying and

distribution is a violation of law.

KX-FL501

(for U.S.A.)

Compact Laser Plain Paper FAX

ORDER NO. KMF0002391C1

F7

1 INTRODUCTION 4

1.1. SAFETY PRECAUTIONS

4

1.2. INSULATION RESISTANCE TEST

4

1.3. FOR SERVICE TECHNICIANS

4

1.4. BATTERY CAUTION

4

1.5. AC CAUTION

5

1.6. PERSONAL SAFETY PRECAUTIONS

5

1.7. SERVICE PRECAUTIONS

6

1.8. FEATURES

7

1.9. SPECIFICATIONS

8

1.10. OPTIONAL ACCESSORIES

8

1.11. TEST CHART

9

1.12. LOCATION OF CONTROLS

11

1.13. CONNECTIONS

13

1.14. INSTALLATION

14

1.15. MAINTENANCE ITEMS AND COMPONENT LOCATIONS

22

2 TROUBLESHOOTING GUIDE

27

2.1. TROUBLESHOOTING SUMMARY

27

2.2. USER RECOVERABLE ERRORS

28

2.3. TROUBLESHOOTING DETAILS

33

2.4. PROGRAMMING AND LISTS

101

2.5. TEST FUNCTIONS

114

3 ADJUSTMENTS

120

3.1. ADJUSTING THE FEEDER PRESSURE

120

4 DISASSEMBLY INSTRUCTIONS

121

4.1. HOW TO REMOVE THE BOTTOM PLATE

121

4.2. HOW TO REMOVE THE OPERATION PANEL BLOCK

122

4.3. HOW TO REMOVE THE OPERATION PANEL BLOCK

123

4.4. HOW TO REMOVE THE TRANSFER ROLLER AND

IMAGE SENSOR

124

4.5. HOW TO REMOVE THE SEPERATION RUBBUR AND

DOCUMENT FEED ROLLERROLLER

124

4.6. HOW TO REMOVE THE ANALOG BOARD, LASER

SCANNING UNIT AND SPEAKER

125

4.7. HOW TO REMOVE THE AC INLET AND POWER

SUPPLY BOARD

126

4.8. HOW TO REMOVE THE DIGITAL BOARD AND MOTOR

DRIVE BOARD

127

4.9. HOW TO REMOVE THE BACK COVER SECTION

128

4.10. HOW TO REMOVE THE FUSER UNIT AND HANDSET

CRADLE

129

4.11. HOW TO REMOVE THE MAIN FRAME

129

4.12. HOW TO REMOVE THE H.V.P.S.BOARD

130

4.13. HOW TO REMOVE THE HEAT ROLLER AND EXIT

ROLLER

131

4.14. HOW TO REMOVE THE PRESSURE ROLLER

132

4.15. HOW TO REMOVE THE MOTOR BLOCK1

133

4.16. HOW TO REMOVE THE MOTOR BLOCK2

134

4.17. HOW TO REMOVE THE MOTOR BLOCK3

135

4.18. INSTALLATION POSITION OF THE LEAD (1)

136

4.19. INSTALLATION POSITION OF THE LEAD (2)

137

4.20. INSTALLATION POSITION OF THE LEAD (3)

138

4.21. INSTALLATION POSITION OF THE LEAD (4)

139

5 HOW TO REPLACE THE FLAT PACKAGE IC

140

5.1. PREPARATION

140

5.2. FLAT PACKAGE IC REMOVAL PROCEDURE

140

5.3. FLAT PACKAGE IC INSTALLATION PROCEDURE

141

5.4. BRIDGE MODIFICATION PROCEDURE

141

6 PRINTING OPERATION PRINCIPLE

142

6.1. FL501 Process chart and Process Bias

142

6.2. CHARGING

142

6.3. EXPOSING

143

6.4. LASER SCANNING UNIT LOCATIONS

143

6.5. DEVELOPING AND TRANSCRIPTION

144

6.6. CLEANING

145

6.7. FIXING

146

6.8. TIMING CHART (When Printing Two Sheets of Paper)

147

6.9. IMAGE READING

148

6.10. DOCUMENT TRANSMISSION

149

6.11. PRINTING

150

6.12. PAPER PICKUP

151

6.13. INITIALIZATION

152

6.14. Timing Chart [Initialising (Short)]

153

6.15. Timing Chart [Initialising (Long)]

153

6.16. Timing Chart (when the registration sensor is turned OFF

then ON during initialising)

154

7 CIRCUIT OPERATIONS

155

7.1. CONNECTION DIAGRAM

155

7.2. GENERAL BLOCK DIAGRAM

158

7.3. FACSIMILE SECTION

160

7.4. CIS CONTROL SECTION

186

7.5. STEPPING MOTOR DRIVE SECTION

187

7.6. FAN MOTOR SECTION

190

7.7. LSU (Laser Scanning Unit) SECTION

191

7.8. SENSORS AND SWITCHES SECTION

193

7.9. OPERATION BOARD SECTION

200

7.10. LCD SECTION

201

7.11. HVPS (High Voltage Power Supply) SECTION

202

7.12. POWER SUPPLY BOARD SECTION

205

8 TERMINAL GUIDE OF THE IC S TRANSISTORS AND DIODES

211

9 FIXTURES AND TOOLS

212

10 CABINET, MECHANICAL AND ELECTRICAL PARTS

LOCATION

213

10.1. GENERAL SECTON

213

10.2. OPERATION PANEL SECTION

214

10.3. CABINET/P.C.B. BLOCK

216

10.4. PICK UP BLOCK

217

10.5. CABINET BLOCK

218

CONTENTS

Page Page

2

KX-FL501

10.6. FUSER BLOCK 219

10.7. MAIN FRAME BLOCK

220

10.8. MOTOR BLOCK

221

10.9. ACTUAL SIZE OF SCREWS AND WASHER

222

11 ACCESSORIES AND PACKING MATERIALS

223

12 REPLACEMENT PARTS LIST

224

12.1. CABINET AND ELECTRICAL PARTS

224

12.2. ACCESORIES AND PACKING MATERIALS

226

12.3. DIGITAL BOARD PARTS

226

12.4. ANALOG BOARD PARTS

229

12.5. OPERATION BOARD PARTS

230

12.6. HIGH VOLTAGE POWER SUPPLY BOARD PARTS

230

12.7. LOW VOLTAGE POWER SUPPLY BOARD PARTS

231

12.8. MOTOR DRIVE BOARD PARTS

232

12.9. SENSOR BOARD PARTS

232

12.10. VARISTOR BOARD PARTS

232

12.11. FIXTURES AND TOOLS

232

13 FOR THE SCHEMATIC DIAGRAMS

233

14 PRINTED CIRCUIT BOARD

235

14.1. DIGITAL BOARD

235

14.2. ANALOG BOARD

237

14.3. POWER SUPPLY BOARD

239

14.4. OPERATION BOARD

240

14.5. SENSOR BOARD

242

14.6. VARISTOR BOARD

242

14.7. MOTOR DRIVE BOARD

242

15 SCHEMATIC DIAGRAM

243

15.1. DIGITAL BOARD (NO. 1)

243

15.2. DIGITAL BOARD (NO. 2)

244

15.3. ANALOG BOARD

245

15.4. POWER SUPPLY BOARD

246

15.5. OPERATION BOARD

248

15.6. SENSOR BOARD

249

15.7. VARISTOR BOARD

249

15.8. MOTOR DRIVE BOARD

249

3

KX-FL501

1 INTRODUCTION

1.1. SAFETY PRECAUTIONS

1. Before servicing, unplug the AC power cord to prevent an electric shock.

2. When replacing parts, use only the manufacturer´s recommended components.

3. Check the condition of the power cord. Replace if wear or damage is evident.

4. After servicing, be sure to restore the lead dress, insulation barriers, insulation papers, shields, etc.

5. Before returning the serviced equipment to the customer, be sure to perform the following insulation resistance test to prevent

the customer from being exposed to shock hazards.

1.2. INSULATION RESISTANCE TEST

1. Unplug the power cord and short the two prongs of the plug with a jumper wire.

2. Turn on the power switch.

3. Measure the resistance value with an ohmmeter between the jumpered AC plug and each exposed metal cabinet part

(screw heads, control shafts, bottom frame, etc.).

Note: Some exposed parts may be isolated from the chassis by design. These will read infinity.

4. If the measurement is outside the specified limits, there is a possibility of a shock hazard.

1.3. FOR SERVICE TECHNICIANS

ICs and LSIs are vulnerable to static electricity.

When repairing, the following precautions will help prevent recurring malfunctions.

1. Cover the plastic part´s boxes with aluminum foil.

2. Ground the soldering irons.

3. Use a conductive mat on the worktable.

4. Do not touch the IC or LSI pins with bare fingers.

1.4. BATTERY CAUTION

CAUTION

Danger of explosion if the battery is replaced incorrectly. Replace only with the same or equivalent type recommended by the

manufacturer. Discard used batteries according to following caution:

Disposal of lithium batteries should be performed by permitted, professional disposal firms knowledgeable in state government

federal and local hazardous materials and hazardous waste transportation and disposal requirements.

A battery continues to have no transportation limitations as long as it is separated to prevent short circuits and packed in strong

packaging.

Commercial firms that dispose of any quantity of lithium cells should have a mechanism in place to account for their ultimate

disposition. This is a good practice for all types of commercial or industrial waste.

Recommend Type Number:

CR2032 (BAT501) Manufactured by MATSUSHITA

CR2032 (BAT501) Manufactured by SONY

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KX-FL501

1.5. AC CAUTION

For safety, before closing the lower cabinet, please make sure of the following precautions.

1. The earth lead is fixed with the screw.

2. The AC connector is connected properly.

3. Wind the earth lead around the core 5 times.

4. Wind the earth AC around the core 4 times.

1.6. PERSONAL SAFETY PRECAUTIONS

1.6.1. MOVING SECTIONS OF THE UNIT

Be careful not to let your hair, clothes, fingers, accessories, etc., become caught in any moving sections of the unit.

The moving sections of the unit are the rollers and a gear. There is a separation roller and a document feed roller which are rotated

by the document feed motor. A gear rotates the two rollers. Be careful not to touch them with your hands, especially when the unit

is operating.

5

KX-FL501

1.6.2. LIVE ELECTRICAL SECTIONS

All the electrical sections of the unit supplied with AC power by the AC power cord are live.

Never disassemble the unit for service with the AC power supply plugged in.

CAUTION:

AC voltage is supplied to the primary side of the power supply unit. Therefore, always unplug the AC power cord before

disassembling for service.

1.7. SERVICE PRECAUTIONS

1.7.1. PRECAUTIONS TO PREVENT DAMAGE FROM STATIC ELECTRICITY

Electrical charges accumulate on a person. For instance, clothes rubbing together can damage electric elements or change their

electrical characteristics. In order to prevent static electricity, touch a metallic part that is grounded to release the static electricity.

Never touch the electrical sections such as the power supply unit, etc.

6

KX-FL501

General

· Help function

Please refer to .(P.27) to print below features.

Display:

1. QUICK SET UP

2. FEATURE LIST

3. JOG-DIAL

4. FAX SND/RCV

5. COPIER

6. Q and A

7. ERRORS

8. REPORTS

9. CALLER ID

· LCD (Liquid Crystal Display) readout

· TAM (Telephone answering machine) interface

· IQ-FAX

TM

(for U.S.A. only)

This feature can only be used by those who apply to the

FaxSav service.

IQ-FAX is intelligent faxing which allows you to send faxes

via the internet by using the IQ-FAX button.

Behind the IQ-FAX button is the FaxSav Global Fax

Network which manages the delivery of your fax to any fax

machine in the world. It routes your fax via the best and

most time efficient route and will automatically resend your

fax for you, if the receiving fax machine is unavailable.

This "fax-only" network has the added advantage of cost

efficiency due to the internet being integrated into the net

work. Every fax is secure since the FaxSav net work utilizes

the highest encryption legally allowed, ensuring that your

documents stay secure. You get the benefits of carefree

faxing with savings associated with the use of the internet.

It is simple, quick, and secure.

Plain Paper Facsimile Machine

· 8 second transmission speed *

· Letter/Legal, G3 compatible

· Automatic document feeder (15 sheets)

· Fax pager call

· Quick scan

· Resolution: /Fine/Super fine/Photo/Photo with text (64 level)

· Broad cast with Jog-Dial

· 150-sheet paper capacity (16lb~20 lb.)

· Automatic fax/phone switching

· Distinctive ring detection **

* The 8 second speed is based upon the ITU-T No. 1 Test

Chart on the condition that memory transmission is performed.

** Subscription to distinctive ring services is required.

Large Memory (24 pages)... Performed by DRAM

Approx. 170 pages of memory reception

Approx. 120 pages of memory transmission

Integrated Telephone System

· On-hook dialing

· Monitor speaker

· Voice muting

· Redialing function

· 100-Station telephone directory with Jog Dial

Enhanced Copier Function

· Multi-copy function (up to 99 copies)

· Enlargement and reduction

· Collate

· 64-Level halftone

1.8. FEATURES

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KX-FL501

1.9. SPECIFICATIONS

Applicable Lines: Public Switched Telephone Network

Document Size: Max. 216 mm (8 1/2") in width

Max. 600 mm (23 5/8") in length

Effective Scanning Width: 208 mm (8 3/16")

Recording Paper Size: Letter: 216×279 mm (8 1/2"×11")

Legal: 216×356 mm (8 1/2"×14")

Effective Printing Width: 208 mm (8 3/16")

Transmission Time*: Approx. 8 s/page (ECM-MMR)**

Scanning Density: Horizontal:

8 pels/mm (203 pels/inch)

Vertical:

3.85 lines/mm (98 lines/inch)—STANDARD mode

7.7 lines/mm (196 lines/inch)—FINE/PHOTO/PHOTO WITH TEXT mode

15.4 lines/mm (392 lines/inch)—SUPER FINE Mode

Halftone Level: 64-level

Scanner Type: Contact Image Sensor (CIS)

Printer Type: Laser beam printer

Data Compression System: Modified Huffman (MH), Modified READ (MR), Modified Modified READ (MMR)

Modem Speed: 14,400/12,000/9,600/7,200/4,800/2,400 bps; Automatic Fallback

Operating Environment: 10°C—32.5°C (50°F—90.5°F), 20—80% RH (Relative Humidity)

Dimensions (H×W×D): 190 mm × 417 mm × 345 mm (7 1/2"×16 2/5"×13 3/5")

Mass (Weight): Approx. 6.5 kg (14.3 lb.)

Power Consumption: Standby: Approx. 5 W

Transmission: Approx. 25 W

Reception: Approx. 200 W

Copy: Approx. 200 W

Maximum: Approx. 560 W (When the fuser unit turns on)

Power Supply: 120 V AC, 60 Hz

Memory Capacity: Approx. 120 pages of memory transmission

Approx. 170 pages of memory reception

(Based on ITU-T No. 1 Test Chart in standard resolution.)

Laser diode properities: Laser output: Max. 5 mW

Wave length: 760 nm—800 nm

Emission duration: Contiuous

Print Speed: 10 ppm (page per minute)

Printing Resolution: 600 × 600 dpi

* Transmission speed depends upon the contents of the pages, resolution, telephone line conditions and capability of the other

party’s machine.

** Transmission speed is based upon the ITU-T No. 1 Test Chart and original mode. (Refer to "1.11. ITU-T No. 1 Test Chart".) If

the capability of the other party´s machine is inferior to your unit, the transmission time may be longer.

Note:

· Any details given in these instructions are subject to change without notice.

· The pictures and illustrations in these instructions may vary slightly from the actual product.

Design and specifications are subject to change without notice.

1.10. OPTIONAL ACCESSORIES

Model No. Description Specifications

KX-FA76 Toner cartridge 1 toner cartridge

KX-FA77 Drum unit 1 drum unit

8

KX-FL501

1.11. TEST CHART

1.11.1. ITU-T No.1 TEST CHART

9

KX-FL501

1.11.2. ITU-T No.2 TEST CHART

10

KX-FL501

1.12. LOCATION OF CONTROLS

1.12.1. OVERVIEW

Note:

*The document stacker and paper stacker may not be shown in all illustrations.

11

KX-FL501

1.12.2. CONTROL PANEL

12

KX-FL501

1.13. CONNECTIONS

(1) Connect the handset cord.

(2) Connect the telephone line cord.

(3) Connect the power cord.

· When the power is turned on for the first time, the unit will print some basic information.

Note:

· For additional equipment protection, we recommend the use of a surge protector. The following types are available;

TELESPIKE BLOK MODEL TSB (TRIPPE MFG. CO.), SPIKE BLOK MODEL SK6-0 (TRIPPE MFG. CO.), SUPER MAX

(PANAMAX) or MP1 (ITW LINX).

The warranty does not cover damage due to power line surges or lightning.

· When you operate this product, the power outlet should be near the product and easily accessible.

· If you want to connect an answering machine to the unit.

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KX-FL501

1.14. INSTALLATION

1.14.1. INSTALLATION SPACE

The space required to install the unit is shown below.

The dimensions given are necessary for the unit to operate efficiently.

Note:

· Avoid excessive heat or humidity.

· Use the unit within the following ranges of temperature and humidity.

· Ambient temperature: 5°C to 35°C

· Relative humidity: 20% to 80% (without condensation)

· Power cord length should be less than 5 meters (16.4 feet). Using a longer cord may reduce the voltage or cause

malfunctions.

· Avoid direct sunlight.

· Do not install near devices which contain magnets or generate magnetic fields.

· Do not subject the unit to strong physical shock or vibration.

· Keep the unit clean. Dust accumulation can prevent the unit from functioning properly.

· To protect the unit from damage, hold both sides when you move it.

1.14.2. INSTALLING THE PAPER TRAY

Install the paper tray into the two slots on the back of the unit firmly unit

(

). Let it lean back until it clicks into place ( ).

Note:

· Do not place the unit in areas where the paper tray may be

obstructed by a wall, etc.

14

KX-FL501

1.14.3. INSTALLING THE RECORDING PAPER

Letter* or legal** size recording paper can be loaded. The unit can hold up to 150 sheets of 60 g/m

2

to 75 g/m

2

(16 lb. to 20lb.)

paper or 120 sheets of 90 g/m

2

(24 lb.) paper.

*Letter=216 mm × 279 mm (8 1/2” × 11”)

**Legal=216 mm × 356 mm (8 1/2" × 14")

The unit is set for letter size paper by default. If you want to use legal size paper, change the setting (feature # 16).

1. Fan the stack of paper to prevent a paper jam.

2. Insert the paper into the recording paper entrance.

· The paper should not be over the tab.

· If the paper is not inserted correctly, readjust the paper

or the paper may jam.

Note for recording paper:

· Avoid using paper with a cotton and/or fiber content that is over 20%, such as letterhead paper or paper used for

resumes.

· Do not use different types or thicknesses of paper at the same time. This may cause a paper jam.

· Avoid extremely smooth or shiny paper that is highly textured.

· Avoid paper that is coated, damaged or wrinkled.

Note:

· Avoid double-sided printing

· Do not use paper printed from this unit for double-sided printing with other copiers or printers, or the paper may jam.

· Some paper only accepts print on one side. Try using the other side of paper if you are not happy with the print quality.

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KX-FL501

1.14.4. ADDING PAPER TO THE PAPER TRAY

1.

2.

3.

4.

Remove all of the installed paper.

Add paper to the removed paper and straighten.

Fan the stack of paper.

Insert the paper into the recording paper entrance.

1.14.5. DOCUMENTS THE UNIT CAN FEED

Note:

· Remove chips, staples or other similar fastening objects.

· Check that ink, paste or correction fluid has dried.

· Do not send the following types of documents. Use copies for fax transmission.

— Chemically treated paper such as carbon or carbon less duplicating paper

— Electrostatically charged paper

— Heavily curled, creased or torn paper

— Paper with a coated surface

— Paper with a faint image

— Paper with printing on the opposite side that can be seen through the front (e.q. newspaper)

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KX-FL501

1.14.6. SETTING YOUR LOGO

The logo can be your company, division or name.

1. Press .

Display:

2. Press , then .

3. Press .

4. Enter your logo, up to 30 characters, using the dial

keypad.

Example: Bill

1. Press

twice.

2. Press six times.

3. Press six times.

4. Press to move the cursor to the next space and

press

six times.

5. Press .

6. Press .

Note:

· You can enter your logo by rotating

.

To correct a mistake

· Press

or to move the cursor to the incorrect character,

then make the correction.

To insert a character

1. Press

or to move the cursor to the position to the right of

where you want to insert the character.

2. Press

(Insert) to insert a space and enter

the character.

To delete a character

· Move the cursor to the character you want to delete and press

.

17

KX-FL501

1.14.7. TO SELECT CHARACTERS WITH THE DIAL KEYPAD

1.14.8. TO SELECT CHARACTERS USING THE JOG DIAL

Instead of pressing the dial keys, you can select characters using the JOG DIAL.

1. Rotate unit the desired character is

displayed.

2. Press to move the cursor to the next space.

· The character displayed in step 1 is inserted.

3. Return to step 1 to enter the next character.

Display order of characters

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KX-FL501

1.14.9. REPLACING THE TONER CARTRIDGE AND THE DRUM UNIT

When the display shows the following message, replace the toner cartridge and drum unit with new ones.

The following is available for replacement.

KX-FA76: Toner cartridge

KX-FA77: Drum unit

Caution:

· The drum unit contains a photosensitive drum. Exposing it to light may damage the drum. Once you have opened the

protection bag:

—Do not expose the drum unit to light for more than 5 minutes.

—Do not touch or scratch the green drum surface.

—Do not place the drum unit near dust or dirt, or in a high humidity area.

—Do not expose the drum unit to direct sunlight.

· Do not unplug the fax machine to prevent loss of fax documents in memory.

· Do not pour any toner into the toner cartridge.

1. Remove the new toner cartridge from the protection

bag. Peel off the seal from the toner cartridge.

2. Push the front cover open button then open the front

cover.

3. Tap on the used toner cartridge several times to

allow the remaining toner to fall into the drum unit.

Remove the drum and toner unit by holding the two

tabs.

4. Turn the two levers on the used toner cartridge

firmly.

5. Pull up the right edge of the used toner cartridge

(

). Remove the cartridge from the drum unit ( ).

· The toner may stick to the cartridge and the durm unit.

Be careful in handling.

· Do not drop the toner on the green drum surface.

· Put the used toner cartridge into the protection bag.

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KX-FL501

6. If you replace the drum unit at the same time, remove

the new drum unit from the protection bag. Remove

the protection bar from the drum unit.

With Panasonic face up on the toner cartridge, match

the red arrows on the cartridge and the drum unit.

7. Slide the tab of the toner cartridge into the slot of the

drum unit.

8a. Hold right side of the toner cartridge under the lip on

the drum unit and...

8b. Turn the two levers on the toner cartridge with film

pressure.

9. The toner cartridge is installed when the triangles

match.

10. Tap on the toner cartridge several times to allow the

toner to fall into the drum unit. Grab the tabs, and

rock the drum and toner unit from side to side

several times.

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KX-FL501

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