Page 1: Service Manual
FS-C8026N SERVICE MANUAL Published in Oct. '03...
Page 2 Revision history Version Data Replaced Remarks 24-Oct.-2003 18-Dec.-2003 Overall revised...
Page 3: Safety Precautions
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.
Page 4 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.
Page 5: Installation Precautions
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..................... •...
Page 6: Precautions For Maintenance
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.
Page 7 • 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.
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Page 9: Table Of Contents
CONTENTS 1-1 Specifications 1-1-1 Specifications............................1-1-1 1-1-2 Parts names............................1-1-3 (1) Printer..............................1-1-3 (2) Operation panel..........................1-1-4 1-1-3 Cross section view ..........................1-1-5 1-2 Handling Precautions 1-2-1 Drum (process unit) ..........................1-2-1 1-2-2 Installation environment ..........................1-2-1 1-3 Installation 1-3-1 Unpacking and installation ........................1-3-1 (1) Installation procedure ........................1-3-1 1-3-2 Installing expansion memory (optional) ....................1-3-10 1-3-3 Installing a memory card (optional).......................1-3-11 1-3-4 Installing the network interface card (optional) ..................1-3-12...
Page 10 (2) Detaching and refitting the engine controller PWB................1-6-26 (3) Detaching and refitting the power supply PWB ................1-6-27 (4) Detaching and refitting the main high voltage PWB ................1-6-29 (5) Detaching and refitting the bias high voltage PWB .................1-6-30 (6) Detaching and refitting the LPH drive PWB ..................1-6-31 (7) Detaching and refitting the front relay PWB ..................1-6-32 1-6-9 Others ..............................1-6-33 (1) Detaching and refitting the developing MCY motor.................1-6-33...
Page 11: Specifications
1-1 Specifications 1-1-1 Specifications Type ..........Floor Printing system ....... Electrophotographic printing (tandem) Paper type ........Cassette: Plain paper (60 to 105 g/m Recycled paper (105 to 220 g/m Thick paper (90 to 105 g/m Thin paper (60 to 64 g/m MP tray: Plain paper (60 to 105 g/m Recycled paper (60 to 90 g/m Thick paper (105 to 220 g/m...
Page 12 Controller hardware ......CPU: Power PC750CXe (600 MHz) System ROM: 8 MB (16 Mbit × 2) × 2 Font ROM: 4 MB (32 Mbit × 1) Main RAM: 128 MB standard (on-board); expanding up to 512 MB (256 MB × 2) at the maximum by adding optional expansion memory Optional expansion RAM (DIMM): 1 slot 168-pin DIMM (64, 128 or 256 MB)
Page 13: Parts Names
1-1-2 Parts names (1) Printer Figure 1-1-1 Operation panel 16. Cyan main charger unit Front cover 17. Magenta main charger unit Right cover 1 18. Paper cassette Right cover 2 19. Eject cover MP tray 20. Fuser unit Paper feed unit 21.
Page 14 (2) Operation panel 8 10 11 9 13 12 Figure 1-1-2 Message display Right key( ?) Interface indicator (INTERFACE) 10. Up key( ) Paper size indicator (SIZE) 11. Down key( ) Paper type indicator (TYPE) 12. Menu key (MENU) Ready indicator (READY) 13.
Page 15: Cross Section View
1-1-3 Cross section view Paper path Paper path (Optional equipment) Figure 1-1-3 Paper cassette 12. Cyan toner container Primary paper feed unit 13. Yellow toner container MP tray 14. Black toner container MP tray feed unit 15. Magenta main charger unit Paper feeder feed section 16.
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Page 17: Drum (Process Unit)
1-2 Handling Precautions 1-2-1 Drum (process unit) Note the following when handling or storing the drum (process unit). • When removing the drum (process unit), never expose the drum surface to strong direct light. • Avoid abrupt changes in temperature and humidity. •...
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Page 19: Unpacking And Installation
1-3 Installation 1-3-1 Unpacking and installation (1) Installation procedure Start Unpacking. Installing the process units and main charger units. Installing the toner containers. Installing the waste toner box. Securing the fuser press screws. Loading paper. Connecting the cable. Printing a status page for test. Completion of the machine installation.
Page 20 Unpacking. Figure 1-3-2 Unpacking Printer Yellow main charger unit Installation Guide, Quick Guide, 10. Black main charger unit Quick Configuration Guide and 11. Waste toner box (two) two CD-ROM 12. Cyan toner container Cyan process unit 13. Magenta toner container Magenta process unit 14.
Page 21 Installing the process units and main charger units. 1. Open the front cover. 2. Pull out the paper feed unit (transfer unit). 3. Push up the four LED print heads (levers) while pushing down each lock levers. LED print head (lever) 4.
Page 22 7. Turn the lock lever to the left (to release). 8. Install the four process units in order of magenta, cyan, yellow and black. 9. Turn the lock lever to the right (to lock). 10. Refit the drum holder, (To lock) (To release) Lock lever Cyan...
Page 23 Installing the toner containers. 1. Shake the four toner containers second to third times. Toner container Figure 1-3-7 2. Install the toner containers. 3. Close the toner container covers. Black toner container Yellow toner container Cyan toner container Magenta toner container Toner container cover Figure 1-3-8 1-3-5...
Page 24 Installing the waste toner box. 1. Remove the four caps and attach the cap holder section. Caps Cap holder section Waste toner box Figure 1-3-9 2. Install the waste toner box to the printer. Waste toner box Figure 1-3-10 1-3-6...
Page 25 Securing the fuser press screws. 1. Open the eject cover. 2. Pull out the fuser unit. Fuser unit 3. Tighten the two fuser press screws until they stop. 4. Close the fuser unit and eject cover. Eject cover Fuser press screws Figure 1-3-11 1-3-7...
Page 26 Loading paper. 1. Pull out the paper cassette. 2. Remove the guide holder. Protect sheet 3. Load the paper to the cassette and adjust the paper guides according to the paper size. 4. Open MP tray and remove the protect sheet. 5.
Page 27 Connecting the cable. 1. Connect the interface connector of the printer (parallel, USB or the ethernet) to PC or network. 2. Connect the power cord to the printer AC inlet. Parallel interface 3. Connect the power cord to the wall outlet. connector Parallel cable...
Page 28: Installing Expansion Memory (Optional)
1-3-2 Installing expansion memory (optional) <Procedure> 1. Turn off printer power. * Caution: Do not insert or remove expansion memory while printer power is on. Doing so may cause damage to the printer and the expansion memory. 2. Remove two screws and then remove the main controller PWB.
Page 29: Installing A Memory Card (Optional)
1-3-3 Installing a memory card (optional) <Procedure> 1. Turn off printer power. * Caution: Do not insert or remove memory card while printer power is on. Doing so may cause damage to the printer and the mem- ory card. 2. Insert the memory card into the memory card slot.
Page 30: Installing The Network Interface Card (Optional)
1-3-4 Installing the network interface card (optional) <Procedure> 1. Turn off printer power. 2. Remove the two screws and then remove the optional interface slot cover. 3. Insert the network interface card into the optional interface slot. 4. Use the two screws to secure the network interface card.
Page 31: Installing The Hard Disk Unit (Optional)
1-3-5 Installing the hard disk unit (optional) <Procedure> 1. Turn off printer power. 2. Remove the two screws and remove the optional interface slot cover. 3. Insert the hard disk unit into the optional interface slot. 4. Use the two screws to secure the hard disk unit.
Page 32: Installing The Dehumidifier Heater (Optional)
1-3-6 Installing the dehumidifier heater (optional) Dehumidifier heater installation requires the following parts: • Dehumidifier heater (P/N 2BG28740): for 120 V specifications • Dehumidifier heater (P/N 2BG28750): for 220 - 240 V specifications • Two binding screws [bind tap tight-S M3 × 6 trivalent chromate] (P/N B1A53060A) <Procedure>...
Page 33 7. Remove the connectors for protection from the connectors for power supply and dehu- midifier heater. 8. Connect the connector for power supply and connector for dehumidifier heater. 9. Refit all the removed parts. Connectors for protection Connector for power supply Connector for dehumidifier heater Figure 1-3-21...
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Page 35: Service Mode
1-4 Maintenance Mode 1-4-1 Service mode The printer is equipped with various service mode that can be accessed with the MENU key operation on the operation panel. (1) Executing service mode Message display Ready PAR A4 PLAIN Press the MENU key. Print Menu Map 2.
Page 36 Service items Description Printing a status page for service purpose >>Print Description Status Page Prints a status page for service purpose. The status page includes various printing settings and service cumulatives. Purpose To acquire the current printing environmental parameters and cumulative information. Procedure 1.Enter the service mode [>>Print Status Page].
Page 37 Service items Description Service information [A003/0000][C1][22.00A][03/03] Total page 9690 /P00/S00/F00/N00/D10:DM0301.DAN (7) (8) (9) (10) /0020/0020/1061/0811/ (11) (12) (13) /AAAAAAA/AAAAAAA/AAAAAAA (14) /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA (15) /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA (16) /AAAAAAA/AAAAAAA/AAAAAAA/ (17) /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ (18) /AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ (19) (20) (21) AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ (22) /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ /0000/0000/0000/0000/0000/ (23) (24) (25) /0000/0000/0000/0000/ /RS2/[0003-0003]/0/30/88 (26)
Page 38 1 = 0: Overseas, 1: Domestic (Japan) OEM mode only)] bit 2, 3 (Not used) bit 4 = 0: Kyocera, 1: OEM bit 5 = 0: For Europe, 1: For US bit 6 = 0: Non MICR mode, 1: MICR mode...
Page 39 Service items Description Items Description (19) Maintenance kit counter MK counter A/B/C/D/ (20) Optional finisher counter (1) Optional finisher multi tray counter 1/2/3/4/5/ (21) Optional finisher counter (2) Finisher total/Main tray/Sub tray/Main tray (face down)/ Main tray (face up)/Booklet tray (booklet)/Saddle stitch count/Punch count/Staple total counts/Upper left staple/ Lower left staple/Central 2 places staple/ (22)
Page 40 Service items Description Items Description (35) Calibration information /Background value (S-wave) /Background value (P- wave)/Dark current (S-wave) /Dark current (P-wave)/Bias data magenta/cyan/yellow/black/Overabundance value (S-wave) /Overabundance value (P-wave) /Performance/ E0: Normal E1: Abnormal calibration discontinuance of sensor value E2: Calibration discontinuance request from engine con- troller PWB (36) Measure bias data...
Page 41 Service items Description Printing an event log (EVENT LOG) >>Print Description Event Log Prints the history of paper misfeeds and self-diagnostic errors including up to 16 items from the latest occurrence of such an error. (If the number of errors exceeds 16, errors will be deleted sequentially from the oldest one.) Purpose To allow machine malfunction analysis based on the frequency of paper misfeeds and self...
Page 42 Service items Description Test Page 1 >>Print Description Test Page 1 Printing a test page that has four colors printed on a sheet. Purpose To check the activation of the process units. Start Enter the service mode (>>Printing Test Page 1). Press the ENTER key twice.
Page 43 Service items Description Adjusting the high density mode >>High Density Description Mode During continuous printing of data with a high print ratio, such as pages that have great deal of heavy or solid images, etc., the printing density may eventually decline. It is possible to pre- vent such a drop in the printing density by changing the setting for the high density mode.
Page 44 Service items Description Counter reset for the maintenance kit A >>Maintenance Description The "Install MK [A]" message means that maintenance kit A should be replaced at every 300,000 images of printing. The interval counter must be reset using this service item. MK-810A Maintenance kit A includes the following units: Transfer unit: [Part No.: ***********] Fuser unit: [Part No.: ***********]...
Page 45 Service items Description Counter reset for the maintenance kit C >>Maintenance Description The "Install MK [C]" message means that maintenance kit C should be replaced at every 300,000 images of printing. The interval counter must be reset using this service item. MK-810C Maintenance kit C includes the following units: Drum kit Y: [Part No.: ***********] Drum kit M: [Part No.: ***********]...
Page 46: Maintenance Mode
Checking the operation of the clutches A: Service See page 1-4-15. C: Factory [U032] Machine code >Check Solenoid> A76: FS-C8026N Checking the operation of solenoids See page 1-4-16. [U033] >Adjust Paper > Adjusting the print start timing See page 1-4-17.
Page 47 Continue from the previous page Adjusting the amount of >Set of Paper > slack in the paper [U051] Loop See page 1-4-19. Setting the destination >Sel. Destinatio> See page 1-4-34. [U252] Adjusting the optional >DU Adjust > duplex unit [U052] Adjusting the margins for See page 1-4-20.
Page 48 U No. Description U002 Setting the factory default data Description Restore the machine conditions to the factory default settings. Purpose Used to return the machine settings to initial settings. Method 1. Enter the maintenance mode and press the [ / ] key to display "U002". 2.
Page 49 U No. Description U031 Checking sensors for paper conveying Description Displays the ON/OFF status of each paper detection sensor on the paper conveying path. Purpose To check the operation of the sensors for paper conveying. Method 1. Enter the maintenance mode and press the [ / ] key to display "U031". >Check Switches>...
Page 50 U No. Description U032 Checking the operation of the clutches Description Turn each clutch ON. Purpose To check the operation of each clutch. Method 1. Enter the maintenance mode and press the [ / ] key to display "U032". >Check Clutches> [U032] 2.
Page 51 U No. Description U033 Checking the operation of the solenoids Description Applies current toe each solenoid in order to check its ON status. Purpose To check the operation of each solenoid. Method 1. Enter the maintenance mode and press the [ / ] key to display "U033". >Check Solenoid>...
Page 52 U No. Description U034 Adjusting the print start timing Method 1. Enter the maintenance mode and press the [ / ] key to display "U034". >Adjust Paper > [U034] 2. Press the [ ] key to display the submenu screen. 3.
Page 53 U No. Description U037 Checking the operation of the fan motors Description Drives the fan motors. Purpose To check the operation of the fan motors. Method 1. Enter the maintenance mode and press the [ / ] key to display "U037". >Check Fan Mt >...
Page 54 U No. Description U051 Adjusting the amount of slack in the paper Description Changes the preset value of the amount of slack of registration position. Purpose To adjust when the leading edge of the image is not printed or fluctuates irregularly or paper is bent in Z shape.
Page 55 U No. Description U052 Adjusting the optional duplex unit Description Adjusts the side registration of the duplex unit. In addition, drives duplex side registration motor. Purpose To check the operation of duplex side registration motor. Method 1. Enter the maintenance mode and press the [ / ] key to display "U052". >DU Adjust >...
Page 56 U No. Description U053 Setting the adjustment of the motor speed Description Performs fine adjustment of the speeds of the motors. Purpose Used to adjust the speed of the respective motors when the magnification is not correct. Method 1. Enter the maintenance mode and press the [ / ] key to display "U053". >Adjust Motor >...
Page 57 U No. Description U053 4. Press the [ENTER] key. "_" will blink. (continue) >BeltMot_adj [053.1] 5. Press the [ / ] key to move "_" to the digit position at which the value is to be changed and press the [ / ] or key to change the preset value.
Page 58 U No. Description U116 Adjusting adhesion output Description Sets the suction voltage for each paper type. Purpose Basically, the setting need not be changed. If any problem such as folds of leading edge of paper or dirt occurs, change the setting. Method 1.
Page 59 U No. Description U116 Submenu display Description Setting Initial (continue) range setting Paper interval, Full speed 0 to 60 >>Atr_adj_off Paper interval, Half speed 0 to 255 >>Atr_inpap Transfer belt cleaning setting A 0 to 255 >>Atr_inpap_half Transfer belt cleaning setting B 0 to 255 >>Atr_chk_cln_a Color printing, Plain paper, Half speed, Second...
Page 60 U No. Description U128 Setting transfer high-voltage timing Description Adjusts the ON/OFF timing of transfer high-voltage output for each paper type and each mode. Purpose Basically, the setting need not be changed. If any problem such as faulty images or dirt on the back sur- face occurs, change the setting.
Page 61 U No. Description U131 Adjusting toner sensors control voltage Description Adjusts the toner sensor control voltage. Method 1. Enter the maintenance mode and press the [ / ] key to display "U131". >Adjust tonerCo> [U131] 2. Press the [ ] key to display the submenu screen. 3.
Page 62 U No. Description U140 Setting the developing bias output Description Sets the developing bias output. Purpose To change the setting when any density problems, such as too dark or light, occur. Method 1. Enter the maintenance mode and press the [ / ] key to display "U140". >Adjust MDB >...
Page 63 U No. Description U147 Setting for toner applying operation Description Sets enabling/disabling operation for consuming charged toner in the developer unit and sets the time for placing when enabling. Purpose If user uses many graphic images, turn the setting off. Method 1.
Page 64 U No. Description U155 Displaying the toner sensor output Description Displays the toner sensor output value. Purpose To check the output value for each color when any image problems occur. Method 1. Enter the maintenance mode and press the [ / ] key to display "U155". >Check TonerSen>...
Page 65 U No. Description U157 Checking/cleaning the developing drive time Description Displays the developing drive time for checking, or cleaning a figure, which is used as a reference when correcting the toner control. Purpose To check the developing drive time after replacing the developer unit. Method 1.
Page 66 U No. Description U161 Setting the fixing control temperature Description Changes the fixing control temperature. Purpose Normally you do not need to change the settings. However, this item can be used to prevent curling or creasing of paper, or solve a fixing problem on thick paper. Method 1.
Page 67 U No. Description U208 Setting paper feeder paper size Description Sets the paper size for cassettes 3 (right deck) and 4 (left deck) in the optional paper feeder PF-647. Purpose To change the setting according to the user. Method 1. Enter the maintenance mode and press the [ / ] key to display "U208". >Set LCF Feeder>...
Page 68 U No. Description U248 Changing the paper ejection device setting Description Adjusts the paper flexure level in the punch mode when the optional document finisher is installed in your printer. Also sets the limit for the number of punches that can be mode, and displays or clears or changes the waste punch count.
Page 69 U No. Description U252 Setting the destination Description Sets operation procedures and displayed screens according to the destination in which the machine is used. Method 1. Enter the maintenance mode and press the [ / ] key to display "U252". >Sel.Destinatio>...
Page 70 U No. Description U410 Adjusting the halftone automatically Description Carries out processing for the data acquisition that is required in order to perform either automatic adjust- ment of the half tone or the image density correction operation. Purpose Performed when the quality of reproduced halftones has dropped. Method Automatic calibration 1.
Page 71 U No. Description U410 Submenu display Description Setting Initial (continue) range setting Deviation checking PG sheets printing [MP >>Prt chart MPT tray] Adjustment data 1-a input [MP tray] 0 to 20 >>1-a (MPT) Adjustment data 1-b input [MP tray] 0 to 20 >>1-b (MPT) Adjustment data 1-c input [MP tray]...
Page 72 U No. Description U410 4. Press the [ENTER] key. "?" will be displayed. (continue) >>Prt chart CASS [410.3] 5. Press the [ENTER] key. Two deviation checking PG sheets are output. Deviation checking PG sheets Scale FEEDSET FEEDSET 1-a( )CASS 2-a( )CASS 1-b( )CASS...
Page 73 U No. Description U464 Setting the image density correction operation Description Turns image density correction ON/OFF. Also sets the number of printing after which image density cor- rection is initiated. Purpose To restrict image density correction when poor image quality is generated. Method 1.
Page 74 U No. Description U465 Data reference for image correction Description References the data related to image density correction. Purpose To check the corresponding data. Method 1. Enter the maintenance mode and press the [ / ] key to display "U465". >Show ColorCalib>...
Page 75 U No. Description U467 Setting color registration correction Description Sets color registration correction. Method 1. Enter the maintenance mode and press the [ / ] key to display "U467". >RegCalib set > [U467] 2. Press the [ ] key to display the submenu screen. 3.
Page 76 U No. Description U468 Data reference for color registration correction Method 1. Enter the maintenance mode and press the [ / ] key to display "U468". >Show RegCalib> [U468] 2. Press the [ ] key to display the submenu screen. 3.
Page 77: Paper Misfeed Detection
1-5 Troubleshooting 1-5-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the printer immediately stops printing and displays the paper misfeed message on the operator panel. To remove paper misfeed in the printer, pull out the paper cassette or open right cover 1, right cover 2, paper feed unit (transfer unit), eject cover and fuser unit.
Page 78: Paper Misfeed Detection
(2) Paper misfeed detection 1. Upper feed sensor 2. Registration sensor 3. Fuser conveying sensor 4. Face-up exit sensor 5. Face-down tray paper full sensor 6. Duplex conveying sensor 7. Lower feed sensor Finisher Paper feeder PF-640 Paper feeder PF-645 Duplex unit DU-640 Paper path...
Page 79: Self-Diagnosis
1-5-2 Self-diagnosis (1) Self-diagnostic function This printer is equipped with self-diagnostic function. When a problem is detected, the printer stops printing and display an error message on the operator panel. An error message consists of a message prompting a contact to service personnel, total print count, and a four-digit error code (0121 to 8330) indicating the type of the error.
Page 80: Self Diagnostic Codes
(2) Self diagnostic codes Remarks Code Contents Causes Check procedures/corrective measures 0121 EEPROM read error (drum PWB K) Poor contact in the Check the connection of connector YC9 on • When data is transmitted to the connector termi- the engine controller PWB and the continuity EEPROM on drum PWB K, the ACK nals.
Page 81 Remarks Code Contents Causes Check procedures/corrective measures 0310 LPH drive PWB communication error Poor contact in the Check the connection of connector YC31 on • When an error in communication with connector termi- the engine controller PWB and the connec- the CPU for LPH control on the LPH nals.
Page 82 Remarks Code Contents Causes Check procedures/corrective measures 0710 Paper feeder EEPROM error 2 (lower Poor contact in the Check the connection of connector YC27 on of optional paper feeder PF-640) connector termi- the engine controller PWB. Repair or • When power is turned on, an error is nals.
Page 83 Remarks Code Contents Causes Check procedures/corrective measures 1110 Cassette lift motor error (middle cas- Defective bottom Check to see if the bottom plate can move sette of optional paper feeder PF-645) plate elevation smoothly and repair it if any problem is •...
Page 84 Remarks Code Contents Causes Check procedures/corrective measures 1160 Cassette lift motor error (upper of Defective bottom Check to see if the bottom plate can move paper feeder PF-640) plate elevation smoothly and repair it if any problem is • The paper feeder limit detection sen- mechanism.
Page 85 Remarks Code Contents Causes Check procedures/corrective measures 2202 Drum motor C error Poor contact in the Check the connection of connector YC5 on • After the motor drive ON signal is out- connector termi- the engine controller PWB. Repair or put and 3 s elapses, the rated speed nals.
Page 86 Remarks Code Contents Causes Check procedures/corrective measures 2710 Waste toner box motor error Overload on the Check to see if the waste toner in the waste • After the motor drive remote signal is waste toner box toner box is solidified. If any problem is turned on, the overcurrent detection motor.
Page 87 Remarks Code Contents Causes Check procedures/corrective measures 6000 Upper fuser heater lamp break Installation defec- Check the mounting state of the upper fuser • The time for increasing the tempera- tiveness on upper thermistor. If any problem is found, repair it ture at the upper fuser heater lamp to fuser thermistor.
Page 88 Remarks Code Contents Causes Check procedures/corrective measures 6030 Upper fuser thermistor break error Defective engine Replace the engine controller PWB (see • After the fuser heater lamp is turned controller PWB. page 1-6-26). on, the temperature at the upper fuser Defective harness Check the insertion of connectors of the °...
Page 89 Remarks Code Contents Causes Check procedures/corrective measures 6050 Upper fuser thermistor abnormal tem- Installation defec- Check the mounting state of the upper fuser perature detection tiveness on upper thermistor. If any problem is found, repair it • During copying, the temperature at the fuser thermistor.
Page 90 Remarks Code Contents Causes Check procedures/corrective measures 6120 Lower fuser thermistor detection Defective engine Replace the engine controller PWB (see error controller PWB. page 1-6-26). • The temperature at the lower fuser Defective fuser Replace the fuser PWB. ° ° roller 205 C/401 F or more is...
Page 91 Remarks Code Contents Causes Check procedures/corrective measures 6150 Lower fuser thermistor abnormal tem- Installation defec- Check the mounting state of the lower fuser perature detection tiveness on lower thermistor. If any problem is found, repair it • During copying, the temperature at the fuser thermistor.
Page 92 Remarks Code Contents Causes Check procedures/corrective measures 7002 Toner motor C error Defective toner Replace the toner motor C. • After the toner motor C drive signal is motor C. turned on, the toner motor C overcur- Defective engine Replace the engine controller PWB (see rent detection signal is detected con- controller PWB.
Page 93 Remarks Code Contents Causes Check procedures/corrective measures 7301 Toner hopper error (black process Black toner con- Check the state of the black toner container unit) tainer is not and install it properly. • When black toner is replenished (sim- installed. ple replenishment), if the replenish- Defective engine Replace the engine controller PWB (see...
Page 94 Remarks Code Contents Causes Check procedures/corrective measures 7800 Broken external thermistor wire Poor contact in the Check the connection of connector YC3 on • The thermistor output value is 4.5 V or connector termi- the engine controller PWB and the continuity more.
Page 95 Remarks Code Contents Causes Check procedures/corrective measures 8040 Optional document finisher lower Phase shift of the Correct the phase of the lower paper con- paper conveying belt problem lower paper con- veying belt and check for correct operation. • During initialization, the intermediate veying belt.
Page 96 Remarks Code Contents Causes Check procedures/corrective measures 8150 Optional document finisher multi job Loose connection Reinsert the connector. Also check for conti- tray problem of the multi job tray nuity within the connector cable. If none, • When the multi job tray is not detected elevation motor remedy or replace the cable.
Page 97 Remarks Code Contents Causes Check procedures/corrective measures 8180 Optional document finisher rear Loose connection Reinsert the connector. Also check for conti- upper side-registration guide problem of the rear upper nuity within the connector cable. If none, • During initialization, the rear upper side-registration remedy or replace the cable.
Page 98 Remarks Code Contents Causes Check procedures/corrective measures 8210 Optional document finisher front sta- Loose connection Reinsert the connector. Also check for conti- pler problem of the front stapler nuity within the connector cable. If none, • During initialization, the front stapler is motor connector.
Page 99 Remarks Code Contents Causes Check procedures/corrective measures 8240 Optional document finisher rear Loose connection Reinsert the connector. Also check for conti- clincher problem of the rear clincher nuity within the connector cable. If none, • During initialization, the rear clincher is motor connector.
Page 100 Remarks Code Contents Causes Check procedures/corrective measures 8320 Optional document finisher centerfold Loose connection Reinsert the connector. Also check for conti- unit centering plate problem of the centering nuity within the connector cable. If none, • During initialization, the centering plate plate motor con- remedy or replace the cable.
Page 101: Electric Problems
1-5-3 Electric problems Problem Causes Check procedures/corrective measures No electricity at the power Measure the input voltage. The machine does outlet. not operate when the The power cord is not Check the contact between the power plug and the outlet. power switch is plugged in properly.
Page 102 Problem Causes Check procedures/corrective measures Poor contact in the drum Reinsert the connector. Also check for continuity within the con- The drum motor C motor C connector termi- nector cable. If none, remedy or replace the cable. does not operate nals.
Page 103 Problem Causes Check procedures/corrective measures (10) Poor contact in the toner Reinsert the connector. Also check for continuity within the con- The toner motor C motor C connector termi- nector cable. If none, remedy or replace the cable. does not operate. nals.
Page 104 Problem Causes Check procedures/corrective measures (15) Poor contact in the cassette Reinsert the connector. Also check for continuity within the con- The cassette lift lift motor connector termi- nector cable. If none, remedy or replace the cable. motor does not oper- nals.
Page 105 Problem Causes Check procedures/corrective measures (21) Broken conveying L clutch Check for continuity across the coil. If none, replace the conveying The conveying L coil. L clutch. clutch does not oper- Poor contact in the convey- Reinsert the connector. Also check for continuity within the con- ate.
Page 106 Problem Causes Check procedures/corrective measures (26) Broken MP tray feed clutch Check for continuity across the coil. If none, replace the MP tray The MP tray feed coil. feed clutch. clutch does not oper- Poor contact in the MP tray Reinsert the connector.
Page 107 Problem Causes Check procedures/corrective measures (32) Defective bias high voltage Run maintenance item U033 and check if YC2-7 and YC2-9 on The face-up exit PWB. the bias high voltage PWB go low. If not, replace the bias high solenoid does not voltage PWB.
Page 108 Problem Causes Check procedures/corrective measures (39) Poor contact in the eraser Reinsert the connector. Also check for continuity within the con- The eraser lamp Y lamp Y connector terminals. nector cable. If none, remedy or replace the cable. does not turn on. Defective eraser lamp Y.
Page 109 Problem Causes Check procedures/corrective measures (44) Faulty connection of con- See page 1-5-37. No transfer bias is nector of engine controller output. PWB. Faulty connection of con- nector of transfer relay PWB. Faulty connection of con- nector of transfer high volt- age PWB and high voltage output terminal (tab).
Page 110 Problem Causes Check procedures/corrective measures (48) A piece of paper torn from Check and remove if any. A paper jam in the copy paper is caught paper feed, paper around upper/lower feed conveying or fuser sensor, registration sensor, section is indicated fuser conveying sensor, when the power duplex conveying sensor,...
Page 111 Problem Causes Check procedures/corrective measures (49) Poor contact in the connec- Reinsert the connector. Also check for continuity within the con- The message tor terminals of front cover nector cable. If none, remedy or replace the cable. requesting cover to open/close switch.
Page 112: Image Formation Problems
1-5-4 Image formation problems (1) No image (2) No image (3) Dirty on the (4) Image is too (5) The back- appears appears back side. light. ground is col- (entirely white). (entirely black). ored. See page 1-5-37 See page 1-5-38 See page 1-5-38 See page 1-5-39 See page 1-5-40...
Page 113 (1) No image appears Causes (entirely white). 1. The LED print head has not done functioning. 2. Defective developing bias output. 3. Defective transfer bias output. 4. Defective driving system of the developer unit of the process unit. Causes Check procedures/corrective measures 1.
Page 114 (2) No image appears Causes (entirely black). 1. No main charging. 2. Defective LPH drive PWB. Causes Check procedures/corrective measures 1. No main charging. A. Poor insertion main charger unit. Reinstall the main charger unit. B. Broken main charger wire. Replace the main charger unit.
Page 115 (4) Image is too light. Causes 1. Defective developing bias output. 2. Dirty drum. 3. Defective color calibration. 4. Dirty SELFOC lens of LED print head. 5. Defective transfer bias output. Causes Check procedures/corrective measures 1. Defective developing bias output. A.
Page 116 (5) The background is colored. Causes 1. Defective developing bias output. 2. Defective color calibration. 3. Defective transfer adsorption roller bias output. 4. Poor insertion main charger unit. Causes Check procedures/corrective measures 1. Defective developing bias output. A. Defective process unit. Check the four colors of image by using the test print of service mode.
Page 117 (6) A white line appears Causes longitudinally. 1. Defective LED print head output. 2. Defective main charging output. 3. Foreign object in the developer unit of a process unit. 4. Adhesion of soiling to transfer roller. 5. Adhesion to lower part of the process unit. Causes Check procedures/corrective measures 1.
Page 118 (7) A black line appears Causes longitudinally. 1. Dirty main charger wire. 2. Dirty or flawed drum. 3. Deformed or worn cleaning blade in the drum unit of a process unit. 4. Defective adsorption roller. 5. Worn transfer belt. Causes Check procedures/corrective measures 1.
Page 119 (9) Black dots appear on the image. Causes 1. Dirty or flawed drum. 2. Deformed or worn cleaning blade in the drum unit of a process unit. 3. Defective adsorption roller of the transfer unit. 4. Flawed developing roller in the developing unit of a process unit. 5.
Page 120 (11) Paper creases. Causes 1. Paper curled. 2. Paper damp. Causes Check procedures/corrective measures 1. Paper curled. Check the paper storage conditions, replace the paper. 2. Paper damp. Check the paper storage conditions, replace the paper. (12) Offset occurs. Causes 1.
Page 121 (14) Fixing is poor. Causes 1. Wrong types of paper. 2. Defective pressure for the lower fuser roller. 3. Flawed upper or lower fuser roller. Causes Check procedures/corrective measures 1. Wrong types of paper. Check if the paper meets specifications, replace paper. 2.
Page 122: Mechanical Problems
1-5-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following rollers or Clean with isopropyl alcohol. No primary paper feed. pulleys are dirty with paper powder: lower feed pulley, feed B pulley, forwarding roller, paper feed roller, feed B roller, MP tray paper feed roller and MP tray retard roller.
Page 123: Precautions For Assembly And Disassembly
1-6 Assembly and Disassembly 1-6-1 Precautions for assembly and disassembly (1) Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly. When handling PWBs (printed wiring boards), do not touch parts with bare hands. The PWBs are susceptible to static charge.
Page 124: Outer Covers
1-6-2 Outer covers (1) Detaching and refitting the top cover <Procedure> 1. Open the front cover. Operation panel 2. Remove the hook and then remove the operation panel. 3. Remove one connector and then remove the operation panel. Connector Hook Figure 1-6-1 4.
Page 125 5. Push the lever and remove the ozone filter cover. Ozone filter cover Lever Figure 1-6-3 Filter 6. Push the lever and remove the filter. Lever Figure 1-6-4 1-6-3...
Page 126 7. Open MP tray. Screws 8. Remove four screws and then remove the Top cover Screws top cover. MP tray Figure 1-6-5 1-6-4...
Page 127: Detaching And Refitting The Rear Cover
(2) Detaching and refitting the rear cover <Procedure> 1. Remove eleven screws and then remove the rear cover. Rear cover Screw Figure 1-6-6 1-6-5...
Page 128: Detaching And Refitting The Eject Cover (Eject Cover Assembly)
(3) Detaching and refitting the eject cover (eject cover assembly) <Procedure> 1. Release two hooks from the hook holes and remove the left cover (left cover assembly). Hook hole Hook Hook hole Hook Left cover Left cover Figure 1-6-7 2. Remove one screw and then remove one pin.
Page 129: Primary Paper Feed Unit
1-6-3 Primary paper feed unit (1) Detaching and refitting the primary paper feed unit <Procedure> 1. Open right cover 1. 2. Remove one band. 3. Remove right cover 1. Band Band Right cover 1 Figure 1-6-9 1-6-7...
Page 130 4. Pull out the paper feed unit (transfer unit). 5. Remove one connector. Connector 6. Push the claw and remove the primary paper feed unit. Paper feed unit (transfer unit) Claw Primary paper feed unit Figure 1-6-10 1-6-8...
Page 131: Detaching And Refitting The Paper Feed Roller
(2) Detaching and refitting the paper feed roller <Procedure> 1. Remove the primary paper feed unit (See previous page). 2. Pull up the primary paper feed assembly and then remove the assembly from the bearing. Primary paper feed assembly Primary paper feed unit Figure 1-6-11 3.
Page 132: Detaching And Refitting The Lower Paper Feed Pulley
(3) Detaching and refitting the lower paper feed pulley <Procedure> 1. Remove the paper feed roller (See previous page). 2. Remove two stoppers and slide the shaft to remove the bearing, insulator, paper feed pulley release lever, spring, lower paper feed pulley, pin and torque limiter 360.
Page 133: Mp Tray Feed Unit
1-6-4 MP tray feed unit (1) Detaching and refitting the MP tray feed roller and MP tray retard roller <Procedure> MP tray feed roller 1. Pull out the paper feed unit (transfer unit). 2. Open the MP tray. 3. Release one claw and remove the MP tray feed roller.
Page 134: Transfer Unit
1-6-5 Transfer unit (1) Detaching and refitting the transfer unit <Procedure> 1. Open front cover and then remove the waste toner box. 2. Remove the one screw and then remove stopper plate. 3. Pull out the paper feed unit (transfer unit) until stops.
Page 135: Process Section
1-6-6 Process section (1) Detaching and refitting the process unit <Procedure> 1. Open the front cover. 2. Push the release lever and remove the waste toner box. 3. Open four toner container covers and remove four toner containers. Release lever Toner container covers Front cover Waste toner box...
Page 136 7. Remove two screws, and pull two release levers and remove the drum holder. Drum holder Release lever Release lever Screw Screw Figure 1-6-19 8. Turn the lock lever to the left (to release). 9. Remove four process units in order of black, yellow, cyan and magenta.
Page 137: Detaching And Refitting The Drum Unit And Developer
(2) Detaching and refitting the drum unit and developer <Procedure> 1. Remove the process unit (See page 1-6-13). Process unit 2. Remove two screws and then remove the drum front plate. Drum front plate Screws Figure 1-6-21 3. Remove the front DS spring (Long) and the rear DS spring (Short) from the front side and the rear side of the process unit (bottom side).
Page 138 4. Open the claw and remove the drive joint. 5. Pull out the front boss of the developer from Boss the boss receptacle of the drum unit and then pull out the rear boss from the boss receptacle. 6. Remove one connector and separate the Developer developer and drum unit.
Page 139: Fuser Unit
1-6-7 Fuser unit (1) Detaching and refitting the fuser unit <Procedure> 1. Open the eject cover. 2. Pull out the fuser unit until stops. 3. While lifting the fuser unit a little, remove it together with the rail. Fuser unit * To remove only the fuser unit, remove the two pins.
Page 140: Detaching And Refitting The Upper And Lower Fuser Thermistors, Upper And Lower Fuser Thermostats, Upper And Lower Fuser Heater Lamps And Upper And Lower Fuser Rollers
(2) Detaching and refitting the upper and lower fuser thermistors, upper and lower fuser thermostats, upper and lower fuser heater lamps and upper and lower fuser rollers <Procedure> 1. Remove the fuser unit (See page previous page). 2. Remove one screw and then remove the fuser handle.
Page 141 5. Remove the upper fuser cover. Upper fuser cover Figure 1-6-27 6. Remove the harness sheet. 7. Remove one tub from the terminal of upper fuser thermistor. Lower fuser thermistor 8. Remove one tub from the terminal of lower fuser thermistor. Harness sheet Upper fuser thermistor...
Page 142 9. Remove one screw and round terminal from the terminal of upper fuser heater lamp. 10. Remove one screw from the terminal of lower fuser heater lamp. Upper fuser heater lamp Lower fuser heater lamp Figure 1-6-29 11. Remove one tub from the terminal of upper fuser thermistor.
Page 143 13. Remove one screw and then remove upper Upper fuser entrance guide fuser thermistor. 14. Remove two screws and then remove the Screws upper fuser thermostat. 15. Remove one hook and then remove the Screws upper fuser entrance guide. Upper fuser Hook thermostat...
Page 144 17. Remove one hook and then remove the rear fuser heater holder. Hook Rear fuser heater holder Figure 1-6-33 18. Remove two hooks and then remove the front fuser heater holder. Hook Hook Front fuser heater holder Figure 1-6-34 1-6-22...
Page 145 19. Remove the upper fuser frame. Upper fuser frame Figure 1-6-35 20. Loosen two fuser press screws. Upper fuser roller 21. Remove two C-rings. 22. Remove one fuser gear Z38S. 23. Remove two fuser bearings. 24. Remove two fuser bushes. 25.
Page 146 26. Pull up the lower fuser roller. Lower fuser roller 27. Remove two fuser bearings, fuser bushes and one C-ring. Fuser bearing Fuser bush C-ring Fuser bush Fuser bearing Figure 1-6-37 28. Remove one connector. 29. Remove one screw and then remove the Screw lower fuser thermistor mounting plate.
Page 147: Pwbs
1-6-8 PWBs (1) Detaching and refitting the main controller PWB <Procedure> 1. Turn off the power switch and then remove the power cord. 2. Remove two screws and then remove the main controller PWB. Screws Main controller PWB Figure 1-6-39 1-6-25...
Page 148: Detaching And Refitting The Engine Controller Pwb
(2) Detaching and refitting the engine controller PWB <Procedure> 1. Remove the main controller PWB (See pre- Screws vious page). 2. Remove five connectors. 3. Remove four screws and then remove the main controller box. Connectors Main controller box Screws Figure 1-6-40 4.
Page 149: Detaching And Refitting The Power Supply Pwb
(3) Detaching and refitting the power supply PWB <Procedure> Power supply unit 1. Remove the rear cover (See page 1-6-5). 2. Remove seven connectors and two tubs. Connectors Connectors Connector Tub (white) Tub (red) Connector Connector Figure 1-6-42 3. Remove the four screws and then remove the power supply unit.
Page 150 4. Remove one connector and two screws, Screws and then remove the power supply PWB cooling fan motor. Power supply PWB 5. Remove two tubs and seven screws, and then remove the power supply PWB. Screws Screws Connector Tubs Power supply PWB cooling fan motor Power supply unit box Screw...
Page 151: Detaching And Refitting The Main High Voltage Pwb
(4) Detaching and refitting the main high voltage PWB <Procedure> 1. Remove the top cover (See page 1-6-2). 2. Remove the rear cover. Tubs 3. Remove eight tubs and one connector. Connector Main high voltage PWB Tubs Figure 1-6-45 4. Remove three screws and then remove the main high voltage PWB.
Page 152: Detaching And Refitting The Bias High Voltage Pwb
(5) Detaching and refitting the bias high voltage PWB <Procedure> 1. Remove the eject cover (eject cover assem- bly). (See page 1-6-6.) 2. Remove four tubs and one connector. 3. Remove two screws and then remove the bias high voltage PWB. 4.
Page 153: Detaching And Refitting The Lph Drive Pwb
(6) Detaching and refitting the LPH drive PWB <Procedure> 1. Remove the top cover (See page 1-6-2). 2. Remove three screws and then remove the LPH drive PWB cover. 3. Remove the all (fourteen) connectors from the LPH drive PWB. 4.
Page 154: Detaching And Refitting The Front Relay Pwb
(7) Detaching and refitting the front relay PWB <Procedure> 1. Remove two screws and then remove the Drum cover left inner cover. 2. Remove two screws and then remove the drum cover. Screw Screw Screw Left inner cover Screw Figure 1-6-49 3.
Page 155: Others
1-6-9 Others (1) Detaching and refitting the developing MCY motor <Procedure> 1. Remove the main controller box (See page 1-6-26). 2. Remove one connector. 3. Remove two screws and then remove the developing MCY motor. 4. Check or replace the developing MCY motor and then refit all the removed parts.
Page 156: Detaching And Refitting The Drum Motors K, M, C And Y
(2) Detaching and refitting the drum motors K, M, C and Y <Procedure> 1. Remove the main controller box (See page 1-6-26). 2. Remove one connector. Drum motor C 3. Remove two screws and then remove the Drum motor Y Drum motor M drum motor K.
Page 157: Detaching And Refitting The Toner Motors K, M, C And Y
(3) Detaching and refitting the toner motors K, M, C and Y <Procedure> 1. Remove the drum motors K, M, C and Y (See previous page). Toner motor C 2. Remove one connector. Toner motor Y 3. Remove one screw and then remove the toner motor M.
Page 158: Detaching And Refitting The Cassette Lift Motor
(4) Detaching and refitting the cassette lift motor <Procedure> 1. Remove the rear cover (See page 1-6-5). 2. Remove one connector. 3. Remove one screw and then remove the cassette lift motor. 4. Check or replace the cassette lift motor and then refit all the removed parts.
Page 159: Detaching And Refitting The Paper Feed Motor
(5) Detaching and refitting the paper feed motor <Procedure> 1. Remove the rear cover (See page 1-6-5). 2. Remove one connector. Paper feed motor 3. Remove three screws and then remove the Connector paper feed motor. 4. Check or replace the paper feed motor and then refit all the removed parts.
Page 160: Detaching And Refitting The Paper Feed Drive Unit
(6) Detaching and refitting the paper feed drive unit <Procedure> 1. Remove the main controller box (See page 1-6-26). 2. Remove the right rear cover. 3. Remove one connector. 4. Remove one stopper and then remove the paper feeder feed H clutch. Paper feed drive unit 5.
Page 161: Detaching And Refitting The Developing K/Fuser Motor
(7) Detaching and refitting the developing K/fuser motor <Procedure> 1. Remove the power supply unit (See page 1- 6-27). 2. Remove one connector. 3. Remove three screws and then remove the developing K/fuser motor. 4. Check or replace the developing K/fuser motor and then refit all the removed parts.
Page 162: Detaching And Refitting The Ozone Filter
(8) Detaching and refitting the ozone filter <Procedure> 1. Push the lever and remove the ozone filter cover. 2. Remove the ozone filter from the ozone filter cover. 3. Check or replace the ozone filter and then refit all the removed parts. Ozone filter Ozone filter cover Lever...
Page 163: Detaching And Refitting The Led Print Head
(9) Detaching and refitting the LED print head <Procedure> The procedure for removing the LED print head (LPH) for yellow is described below as an exam- ple. Use the same procedure for LPH for the other colors. 1. Remove the top cover (see page 1-6-4). 2.
Page 164 10. Remove the connector Y from the LPH drive LPH stay Screw PWB. (machine inside) 11. Remove the screw from the cable clamp. Screw Screw Rear LPH holder 12. Remove the screw from the rear LPH holder. Cable clamp 13. Remove the screw from the LPH stay. Connector LPH drive PWB Figure 1-6-61...
Page 165 17. Remove the two spring and LPH from the Spring front and rear LPH holders. Front LPH holder 18. Check the LPH and then refit all the removed parts. 19. Adjust the focus of the LED print head (see page 1-6-44). Spring If the LPH is replaced with a new one, reat- Connector...
Page 166: Adjusting The Focus Of The Led Print Head
(10) Adjusting the focus of the LED print head <Procedure> 1. Set A3/11” x 17” paper on the cassette. Block Block * For clear explanation, the 2. Mount the memory card (CF) that includes halftone density is more the PG program for LPH focus adjustment enhanced than actual output.
Page 167 6. Remove the front and rear top covers. Rear top cover Front top cover Figure 1-6-66 7. Open the front cover. Yellow toner container 8. Open the toner container cover with the Cyan toner container same color as the LPH to be adjusted, and Magenta Black toner container remove the toner container.
Page 168 9. Insert a long screwdriver through the open- ing on the side to be adjusted into the machine and position the tip of the screw- driver to the pin head of the pin for LPH adjustment. Driver 10. At the first adjustment, turn the screwdriver °...
Page 169: Paper Feed Section
2-1 Mechanical construction 2-1-1 Paper feed section As the paper feed methods, this printer provides paper feed from the paper cassette which can hold 500 sheets of paper, paper feed from the MP tray which can hold 150 sheets of paper (75g/m ), and, in addition, paper feed from the optional paper feeder.
Page 170 Clutch PWB E24V (R1) G(24V) G(5V) Engine controller PWB 1-15 R24V1 23-1 LOCK Paper feed 1-14 R24V1 23-2 motor 1-13 G(24V) 23-3 1-12 G(24V) 23-4 Paper feeder 1-11 G(5V) 23-5 feed L 1-10 23-6 E24V clucth YC23 PF MOT REM 23-7 PF MOT LOCK 23-8...
Page 171: Mp Tray Feed Unit And Paper Feed Unit
(2) MP tray feed unit and paper feed unit The MP tray feed unit and the paper feed unit are fitted on the rail as a unit and can be detached from and refitted to the printer. The MP tray feed unit moves paper loaded in the MP tray with the paper lift mechanism constructed of the lift plate up/ down solenoid and the MP tray lift plate so that the paper comes in contact with the MP tray feed roller.
Page 172 MP tray feed unit MP tray PWB MP tray paper sensor Engine controller PWB BYPAS CL Paper feed 13-1 unit detection G(5V) BYPAS U/D SOL 13-2 switch E24V 13-3 G(24V) 13-4 Registration G(5V) BYPAS U/D SW sensor 13-5 BYPAS SW 13-6 MPF SET 13-7...
Page 173: Process Section
2-1-2 Process section The process section consists of the developing section, the process units that integrate the drum and cleaning sections, the main charger unit on each process unit that can be detached and refitted, and the LED print head mounted to the printer frame.
Page 174 Engine controller PWB Toner sensor VR PWB K TS K CNT E24V Toner TSENS1 AN2 sensor K G(5V) ERASE LMP K LMP K 24V DRUM EEPROM DATA K Eraser G(5V) lamp K DRUM EEPROM SCLK BK 9-10 Drum PWB K R24V2 T SUP MOT K + 9-11...
Page 175 (2) Main charger unit The main charger units have the same shape for four colors: magenta, cyan, yellow, and black.Main charger unit is com- prised of the main charger wire, main charger grid, main charger shield, and the main charger cleaner which are modular- ized and fitted to the process unit.
Page 176 (3) LED print head The LED print head, which has effective printing width of 303.126 mm, consists of 56 LED chips to which 7,168 illuminant (LED) devices in total are mounted, two lines of SELFOC lens arrays, etc. The image data processed on the main control- ler PWB is transferred to the LPH drive PWB through the engine interface PWB, and each illuminant (LED) device on/off drive is controlled on the LPH drive PWB based on the image data to output LED light dots onto the drum surface.
Page 177 Engine interface PWB LPH drive PWB Main controller PWB PVCLK34P 7-32 PVCLK34N 7-31 PGVSYNC 3P 7-30 PGVSYNC 3N 7-29 PGHSYNC 3P 7-28 PGHSYNC 3N 7-27 YC12 PSPGT 3P 7-26 PSPGT 3N 7-25 PVDA0 3P 7-24 PVDA0 3N 2-10 7-23 PVDA1 3P 2-11 7-22 PVDA1 3N...
Page 178: Transfer Section
2-1-3 Transfer section The transfer section includes the transfer belt, four transfer rollers opposed to the color drums of the process units, trans- fer high voltage PWB, etc. and is configured as a transfer unit. The transfer unit is connected to the paper feed section mounted to the rail and can be pulled out from the printer.
Page 179 Transfer roller Y Transfer bearing Transfer lever Transfer roller K Transfer cam Transfer bearing Transfer roller lift motor Transfer bearing Lift roller bearing Transfer roller M Transfer roller C Transfer bearing Transfer lift roller Transfer Transfer lever Transfer bearing Transfer Transfer belt bearing Lift roller bearing...
Page 180 Transfer unit Transfer roller lift home position sensor Transfer roller Transfer belt lift motor Absorption roller Transfer roller Transfer motor Transfer high voltage PWB 16151413121110 9 8 7 6 5 4 3 2 1 2 3 4 5 6 Transfer relay PWB Toner ID sensor 2 Toner ID...
Page 181 A full color image is developed by recoating four colors on the paper which adsorbs into the transfer belt. If the density of each color is not kept constant, the resultant color image will be deteriorated. The two toner ID sensors mounted on the transfer belt maintain the constant color fidelity.
Page 182: Fuser Section
2-1-4 Fuser section (1) Fuser unit The fuser section includes two units of fuser rollers, fuser heater lamps, fuser thermistors, and fuser thermostats respec- φ tively and is configured as a fuser unit. Both the upper and lower fuser rollers are of a 45 soft type.
Page 183 Power supply PWB Fuser unit HEATER L Upper fuser thermostat #250 Upper fuser heater lamp HEATER1 OUT N HEATER2 OUT N Lower fuser heater lamp Engine controller PWB Lower fuser thermostat E24V(F1) 19-10 WEB SOL 19-9 19-8 FIX N/O SIG 19-7 FIX SET Fuser PWB...
Page 184: Exit Section
2-1-5 Exit section (1) Eject unit and face-down exit section The eject unit switches ejection destination for paper that is output from the fuser unit. If the ejection destination is the optional duplex unit, the duplex change guide is activated. Normally, the duplex change guide does not operate, and paper is fed along the guide upper surface in the vertical direction.
Page 185 Engine controller PWB Face-down tray paper full sensor 35-3 YC35 U.FEED SW 35-2 G(5V) 35-1 Bias high voltage PWB R24V2(SOL) Face-up 21-2 exit sensor YC21 G(24V)(SOL) 21-4 G(5V) SIDE FEED SW Duplex exit solenoid DUP OUT SOL E24V DUP OUT OFF SOL Face-up FACE U/D SOL SIDE FEED SW...
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Page 187: Electrical Parts Layout
2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) Main front, upper, left, inner and paper cassette 25 26 Figure 2-2-1 Main front, upper, left, inner and paper cassette Operator panel PWB........Indicates the LCD message display and LED indicators. Controls key inputs.
Page 188 13. Duplex conveying sensor......Detects paper jam at the outlet for the duplexer. 14. Cassette length size switch......Detects paper length in the paper cassette. 15. Cassette width size switch ......Detects paper width in the paper cassette. 16. Front cover open/close switch ..... Detects the front cover is open. 17.
Page 189: Main Rear
(2) Main rear 19 15 Figure 2-2-2 Main rear Engine controller PWB......... Controls printer hardware such as high voltage/bias output control, paper conveying system control, and fuser temperature control, etc. Main controller PWB ........Controls the software such as the print data processing, interface with PC and the network, etc.
Page 190 20. Cassette lift motor ........Operates the cassette operation plate inside the paper cassette. 21. Main charger fan motor........ Sweeps out ozone generated in the main charger unit. 22. Main controller PWB cooling fan motor..Dissipates heat from the main controller PWB. 23.
Page 191: Main Right And Primary Paper Feed Unit
(3) Main right and primary paper feed unit Primary paper feed unit Figure 2-2-3 Main right and primary paper feed unit Cassette paper sensor ......... Detects paper in the paper cassette. Bottom plate limit detection sensor ....Detects activation of upper limit of the bottom plate in the paper cassette. Lower feed sensor ........
Page 192: Paper Feed Unit, Mp Tray Unit And Transfer Unit
(4) Paper feed unit, MP tray unit and transfer unit MP tray unit Paper feed unit Transfer unit Figure 2-2-4 Paper feed unit, MP tray unit and transfer unit Transfer relay PWB........Consists the wiring relay circuit of the engine controller PWB. MP tray PWB ..........
Page 193: Process Unit And Fuser Unit
(5) Process unit and fuser unit Process unit Fuser unit Figure 2-2-5 Process unit and fuser unit Fuser PWB........... Consists fuse for discriminating between new and old fuser units. Toner sensor VR PWB K, C, M, Y....Consists VR for adjusting toner sensor in each color process unit. Drum PWB K, C, M, Y........
Page 194 This page is intentionally left blank. 2-2-8...
Page 195: Power Supply Pwb
2-3 Operation of the PWBs 2-3-1 Power supply PWB Power switch Zero cross signal dehumidifier generation heater circuit control circuit E24V Switching E3.3V AC L IN circuit Noise AC N IN filter E24V Sleep mode Fuser heater control lamp control circuit circuit GND(24V)
Page 196 Connector Pin No. Signal Voltage Description AC L IN 220 - 240 V AC AC power input 120 V AC Connected AC N IN 220 - 240 V AC AC power input to the AC 120 V AC inlet, fuser HEATER L 220 - 240 V AC Power supply for upper and lower fuser heater lamp...
Page 197 Connector Pin No. Signal Voltage Description G(5V) Ground (signal) Connected G(5V) Ground (signal) to the G(5V) Ground (signal) engine con- G(5V) Ground (signal) troller PWB, G(5V) Ground (signal) and engine 3.3V 3.3 V DC 3.3 V DC power output interface 3.3V 3.3 V DC 3.3 V DC power output...
Page 198: Engine Controller Pwb
2-3-2 Engine controller PWB Engine controller PWB Engine interface PWB, Data bus Main Address bus controller (U7) LPH drive PWB Input/Output Flash control Buffer memory (switches, (U11) (U44) sensors, motors, etc.) Buffer (U25) SRAM Input/Output (U42) (IC18) control (U10) (switches, sensors, motors, SRAM...
Page 199 Connector Pin No. Signal Voltage Description 5 V DC 5 V DC power input Connected G(5V) Ground (signal) to the power G(24V) Ground (power) supply PWB 24 V DC 24 V DC power input HEATER1 0/5 V DC Upper fuser heater lamp: On/Off Connected HEATER2 0/5 V DC...
Page 200 Connector Pin No. Signal Voltage Description E24V 24 V DC 24 V DC power output Connected G(24V) Ground (power) to the drum 5 V DC 5 V DC power output motor C, G(5V) Ground (signal) drum motor DRUM MOT 0/5 V DC Drum motor C: On/Off M, drum C REM...
Page 201 Connector Pin No. Signal Voltage Description E24V 24 V DC 24 V DC power output Connected E24V 24 V DC 24 V DC power output to the devel- G(24V) Ground (power) oping MCY G(24V) Ground (power) motor G(5V) Ground (signal) 5 V DC 5 V DC power output DV MOT...
Page 202 Connector Pin No. Signal Voltage Description YC11 CNT M Analog Toner sensor M control voltage Connected E24V 24 V DC 24 V DC power output to the toner TSENS M Analog Toner sensor M detection input sensor M, G(5V) Ground (signal) eraser lamp ERASE 0 /24 V DC...
Page 203 Connector Pin No. Signal Voltage Description YC14 FAX RELAY 0/5 V DC Not used YC15 G(5V) Ground (signal) Connected LIFT SW 0/5 V DC Bottom plate limit detection sensor: On/Off to the bot- 5 V DC 5 V DC power output tom plate G(5V) Ground (signal)
Page 204 Connector Pin No. Signal Voltage Description YC21 E24V 24 V DC 24 V DC power output Connected E24V 24 V DC 24 V DC power output to the devel- G(24V) Ground (power) oping bias G(24V) Ground (power) high voltage DB MCY 0 /24 V DC Developing bias (M, C, Y) high voltage output: On/Off DB K REM...
Page 205 Connector Pin No. Signal Voltage Description YC23 E24V(R1) 24 V DC 24 V DC power output Connected E24V(R1) 24 V DC 24 V DC power output to the clutch G(24V) Ground (power) G(24V) Ground (power) G(5V) Ground (signal) 5 V DC 5 V DC power output MOTOR 0/5 V DC...
Page 206 Connector Pin No. Signal Voltage Description DESK/ 0/5 V DC(pulse) Paper feeder serial communication signal (transmit) YC27 DECK TXD Connected G(5V) Ground (signal) to the paper DESK/ 0/5 V DC(pulse) Paper feeder serial communication signal (receive) feeder DECK RXD (optional) G(5V) Ground (signal) RES DECK...
Page 207 Connector Pin No. Signal Voltage Description DUP P.E 0/5 V DC Duplex paper entrance sensor: On/Off YC29 Connected DUP SIDE 0/5 V DC Duplex side registration home position sensor: On/Off to the H.P SIG duplex DUP EJECT 0/5 V DC Duplex eject sensor: On/Off DUP REG- 0/5 V DC...
Page 208 Connector Pin No. Signal Voltage Description VSYNC 0/5 V DC(pulse) LPH drive PWB control horizontal synchronization sig- YC31 Connected Ground (signal) to the LPH RESET 0/5 V DC LPH drive PWB control reset signal dirve PWB Ground (signal) 0/5 V DC(pulse) LPH drive PWB serial communication signal (receive) Ground (signal) 0/5 V DC(pulse)
Page 209 Connector Pin No. Signal Voltage Description YC35 Ground (signal) Connected U.EJECT 0/5 V DC Face-down tray paper full sensor: On/Off to the face- down tray 5 V DC 5 V DC power output paper full sensor YC36 Not used G(24V) YC38 PB REM Not used...
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Page 211: Appendixes
2-4 Appendixes 2-4-1 Appendixes (1) Timing chart No.1 From the power switch turned on to machine stabilization 2-4-1...
Page 212: Timing Chart No.2 Cassette Paper Feeding, Color Printing, Paper Size A4
(2) Timing chart No.2 Cassette paper feeding, Color printing, Paper size A4 2-4-2...
Page 213: Timing Chart No.3 Cassette Paper Feeding, Color Printing, Paper Size A3
(3) Timing chart No.3 Cassette paper feeding, Color printing, Paper size A3 2-4-3...
Page 214: Timing Chart No.4 Mp Tray Paper Feeding, Color Printing, Paper Size A4
(4) Timing chart No.4 MP tray paper feeding, Color printing, Paper size A4 2-4-4...
Page 215: Timing Chart No.5 Mp Tray Paper Feeding, Color Printing, Paper Size A3
(5) Timing chart No.5 MP tray paper feeding, Color printing, Paper size A3 2-4-5...
Page 216: Timing Chart No.6 Paper Feeder Pf-645 Lower Cassette Paper Feeding, Color Printing, Paper Size A4
(6) Timing chart No.6 Paper feeder PF-645 lower cassette paper feeding, Color printing, Paper size A4 2-4-6...
Page 217: Timing Chart No.6 Paper Feeder Pf-645 Lower Cassette Paper Feeding, Color Printing, Paper Size A3
(7) Timing chart No.6 Paper feeder PF-645 lower cassette paper feeding, Color printing, Paper size A3 2-4-7...
Page 218 MEMO...

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