Kyocera FS-2020D Service Manual
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Kyocera FS-2020D Service Manual

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See also: Operating Manual , User Manual
FS-2020D
FS-3920DN
FS-4020DN
SERVICE
MANUAL
Published in March 2010
2J2SM065
Rev. 5
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Summary of Contents for Kyocera FS-2020D

  • Page 1 FS-2020D FS-3920DN FS-4020DN SERVICE MANUAL Published in March 2010 2J2SM065 Rev. 5 Downloaded from www.Manualslib.com manuals search engine...
  • Page 2 CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS. It may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for proper disposal. ATTENTION IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE TYPE INCORRECT.

  • Page 3: Revision History

    Revision history Revision Date Replaced pages Remarks April 10, 2009 1-1-2 June 18, 2009 1-3-2, 1-3-3, 1-3-4, 1-3-5, 1-3-6 October 30, 2009 1-1-2 December 15, 2009 CONTENTS, 1-2-1, 1-3-2, 1-3-4, 1-4-7, 1-4-8, 1-5-2, 1-5-22 to 1-5-24, 1-5-40, 2-1-10, 2-1-11, 2-2-1 to 2-2-4, 2-3-2, 2-3-3, 2-3-6, 2-4-1 to 2-4-5 March 26, 2010 1-3-11 to 1-3-15...
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  • Page 5: 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 6 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 7: 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 8: 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 9 • Do not remove the ozone filter, if any, from the copier except for routine replacement..... • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself...................... •...
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  • Page 11 (1) Precautions ............................1-5-1 (2) Drum..............................1-5-1 (3) Toner container ..........................1-5-1 (4) How to tell a genuine Kyocera Mita toner container................1-5-2 1-5-2 Outer covers ............................1-5-3 (1) Detaching and refitting the top cover....................1-5-3 (2) Detaching and refitting the right cover and left cover ................1-5-4 1-5-3 Paper feed section ..........................1-5-6...
  • Page 12 2J0/2J1/2J2-4 1-5-6 Transfer/separation section ........................1-5-14 (1) Detaching and refitting the transfer roller and separation charger brush unit .........1-5-14 1-5-7 Fuser section ............................1-5-16 (1) Detaching and refitting the fuser unit....................1-5-16 (2) Detaching and refitting the fuser heater lamp .................1-5-17 (3) Detaching and refitting the heat roller .....................1-5-20 (4) Detaching and refitting the press roller....................1-5-21 (5) Detaching and refitting the fuser thermistor 1/2 and thermal cutout..........1-5-22 1-5-8 PWBs ..............................1-5-25...
  • Page 13 2J0/2J1/2J2 1-1 Specifications 1-1-1 Specifications Printing method....... Semiconductor laser and electrophotography Printing speeds ....... Simplex: 35/37 ppm printer 40/42 ppm printer 45/47 ppm printer A6: 21 ppm A6: 22 ppm A6: 23 ppm A5: 21 ppm A5: 22 ppm A5: 23 ppm A4: 35 ppm A4: 40 ppm A4: 45 ppm...
  • Page 14 2J0/2J1/2J2-3 ° ° Warm-up time......... Power on (22 C/71.6 F, 60%RH): 35/37 ppm printer 40/42 ppm printer 45/47 ppm printer 17 seconds or less 17 seconds or less 17 seconds or less Sleep: 35/37 ppm printer 40/42 ppm printer 45/47 ppm printer 15.5 seconds or less 15 seconds or less 15 seconds or less...
  • Page 15 2J0/2J1/2J2 Power source........35/37 ppm printer 40/42 ppm printer 45/47 ppm printer 120 V AC, 60 Hz, 7.6 A 120 V AC, 60 Hz, 7.7 A 120 V AC, 60 Hz, 7.7 A (U.S.A./Canada) (U.S.A./Canada) (U.S.A./Canada) 220 - 240 V AC, 220 - 240 V AC, 220 - 240 V AC, 50/60 Hz, 4.1 A...
  • Page 16 2J0/2J1/2J2 1-1-2 Parts names (1) Overall 35/37 ppm printer 40/42 and 45/47 ppm printers (EUR/USA model) (EUR/USA model) Figure 1-1-1 Top cover 13. USB interface connector Paper stopper 14. Network indicators Top tray (40/42 and 45/47 ppm printers Right cover [EUR/USA model] only) Operation panel 15.
  • Page 17 2J0/2J1/2J2 (2) Operation panel 35/37 ppm printer 40/42 and 45/47 ppm printers (EUR/USA model) (EUR/USA model) Figure 1-1-2 Indicators Message display Cursor keys GO key Cancel key OK key MENU key 1-1-5 Downloaded from www.Manualslib.com manuals search engine...
  • Page 18 2J0/2J1/2J2 1-1-3 Machine cross section 35/37 ppm printer (EUR/USA model) Paper path Paper path (optional) Figure 1-1-3 Machine cross section (35/37 ppm printer [EUR/USA model]) Rear unit MP (Multi-Purpose) tray 10. Fuser unit MP tray paper feed unit 11. Transfer/separation section Toner container 12.
  • Page 19 2J0/2J1/2J2 40/42 and 45/47 ppm printers (EUR/USA model) Paper path Paper path (optional) Figure 1-1-4 Machine cross section (40/42 and 45/47 ppm printers [EUR/USA model]) MP (Multi-Purpose) tray Rear unit MP tray paper feed unit 10. Fuser unit Toner container 11.
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  • Page 21 2J0/2J1/2J2-4 1-2 Installation 1-2-1 Installation environment ° ° Temperature: 10 to 32.5 C/50 to 90.5 Humidity: 15 to 80%RH Power supply: 120 V AC, 7.7 A 220 - 240 V AC, 4.2 A ± ± Power source frequency: 50 Hz 0.3%/60 Hz 0.3% Installation location...
  • Page 22 2J0/2J1/2J2 1-2-2 Unpacking (1) Unpacking 35/37 ppm printer [EUR/USA model] 40/42 and 45/47 ppm printers [EUR/USA model] Figure 1-2-2 Unpacking Printer Plastic bag Outer case 10. Installation guide etc. Bottom pad L 11. Plastic bag Bottom pad R 12. Toner container Machine cover 13.
  • Page 23 2J0/2J1/2J2 1-2-3 Installing the expanded memory (option) <Procedure> 1. Power off the printer and unplug the printer power cord. 2. Open the right side cover. 3. Remove the screw and open the inner cover. Right side cover Inner cover Screw Figure 1-2-3 4.
  • Page 24 2J0/2J1/2J2 1-2-4 Installing the memory card (option) <Procedure> 1. Turn off the printer and disconnect the power cord and printer cable. 2. Remove two screws and then open the option interface slot cover. 3. Install the memory card into the memory card slot.

  • Page 25: Maintenance Mode

    2J0/2J1/2J2 1-3 Maintenance Mode 1-3-1 Maintenance mode The printer is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item Message display Ready Press the MENU key. Report Print > Press the key several times until [Adjust/Maintenance >] is displayed.

  • Page 26: Service Status Page

    2J0/2J1/2J2-4 (2) Contents of maintenance mode items Maintenance items Description Printing a status page for service purpose Description Prints a status page for service purpose. The status page includes various printing settings >>Print and service cumulative. Status Page Purpose To acquire the current printing environmental parameters and cumulative information. Procedure Enter the maintenance mode [>>Print Status Page].
  • Page 27 2J0/2J1/2J2-2 Maintenance items Description Service status page (2) Service Status Page Printer Firmware Version 2J0_2000.000.000 2008.08.08 [XXXXXXXX] [XXXXXXXX] [XXXXXXXX] [XXXXXXXX] Engine Information NVRAM Version _1F31225_1F31225 MAC Address 00:00:00:00:00:00 100/100 0/0/0/0/0/0/ 0/0/0/0/0/0/ 0/0/0/0/0/0/0/0/ 0000000/0000000/0000000/0000000/0000000/0000000/0000000/ 0000000/0000000/0000000/0000000/ F00/U00/0/0/0/0/70/00/00/00/00/abcde/1/ 0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/ 0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/ 0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E 12345678/11223344/00001234abcd567800001234abcd5678/01234567890123456789012345678901/0008/00/07 XXXXXXXX/t/ FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/ FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/ FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/FFFFFFFFFFFFFFFF/...
  • Page 28 2J0/2J1/2J2-4 Maintenance items Description Detail of service status page Items Description Firmware version Engine software version Engine boot version Main ROM version Panel mask version Used memory Local time zone Installed options Digital Dot Coverage Number of pages printed converted in reference to A4 or Letter size. FRPO settings Machine serial No.
  • Page 29 2J0/2J1/2J2-2 Maintenance items Description Items Description Life counter Machine/MP tray/Printer cassette/Paper feeder 1/Paper feeder 2/ Paper feeder 3/Duplex printing (The first line) Life counter Bulk paper feeder/Envelope feeder/Drum unit/Maintenance kit (The second line) Operation panel lock status 00: Off 01: Partial lock 02: Full lock USB information 00: Not connected...
  • Page 30 2J0/2J1/2J2-2 Maintenance items Description Items Description SPD information RFID information RFID reader/writer version infor- mation Toner install information 0: Off t: On Engine parameter information Hexadecimal, 512 bytes Drum status Drum surface potential Drum sensitivity Quantity of light (LSU) DRT parameter coefficient Optional paper feeder software Paper feeder 1/Paper feeder 2/Paper feeder 3/Bulk paper feeder version...
  • Page 31 1. Enter the maintenance mode [>>Print Test Page]. 2. Press the OK key. [>>Print Test Page?] will be displayed. 3. Press the OK key. A sheet of test page will be printed. Completion FS-2020D SN:SPL8307597 Counter:1135 Figure 1-3-3 Test page...
  • Page 32 2J0/2J1/2J2 Maintenance items Description Counter reset for the maintenance kit Description >>Maintenance The "Install MK" message means that maintenance kit should be replaced at 300,000 pages of printing. The interval counter must be manually reset using this service item. Maintenance kit MK-340 (for 35/37 ppm printer [EUR/USA model]) Maintenance kit MK-350 (for 40/42 ppm printer [EUR/USA model]) Maintenance kit MK-360 (for 45/47 ppm printer [EUR/USA model]) Maintenance kit includes the following units:...
  • Page 33 2J0/2J1/2J2 Maintenance items Description Automatic drum surface refreshing Description The drum surface refreshing operation is normally performed when the power is turned on to >>DRUM-CTRL the printer or during warm-up when the printer is recovering from the Sleep mode, but even then only at those times that the temperature/humidity sensor detects the drum surface to be in a state of dew condensation.
  • Page 34 2J0/2J1/2J2 (3) Printing an event log (EVENT LOG) Service items Description Printing an event log Printing an event log (EVENT LOG) (EVENT LOG) Description Prints a history list of occurrences of paper jam, self-diagnostics, toner replacements, etc. Purpose To allow machine malfunction analysis based on the frequency of paper misfeeds, self diag- nostic errors and replacements.

  • Page 35: Event Log

    2J0/2J1/2J2-5 Service items Description Detail of event log Event Log Printer Firmware Version 2J0_2000.000.000 2008.08.09 [XXXXXXXX] [XXXXXXXX] [XXXXXXXX] [XXXXXXXX] Paper Jam Log Service Call Log Count. Event Descriptions Count. Service Code 9999999 10. 01. 88. 01. 01 1111111 00. 0000 8888888 10.
  • Page 36 2J0/2J1/2J2-5 Service items Description Items Description Paper Jam Log # Count. Event Remembers 1 to 16 of occur- The total page Log code (2 digit, hexadecimal, rence. If the occurrence of count at the time 5 categories) the previous paper jam is of the paper less than 16, all of the paper jam.
  • Page 37 2J0/2J1/2J2-5 Service items Description Items Description E0: Paper misfeed occurs due to forced stop when an error occurs during print- cont. ing. (such as opening of a cover) [00] E1: The length of paper is shorter than designated for the paper cassette. [47] E2: A5 lengthwise paper has been fed despite the paper cassette is set to A4 width wise (see reference 1 below).
  • Page 38 2J0/2J1/2J2-5 Service items Description Items Description Detail of jam location cont. 35/37 ppm printer Paper jam locations Printer (EUR/USA model) Cassette 1 Cassette 2 (Paper feeder 1) Cassette 3 (Paper feeder 2) Cassette 4 (Paper feeder 3) Envelope feeder MP tray Rear unit Inside the printer Paper feeder 1...
  • Page 39 2J0/2J1/2J2-5 Service items Description Items Description (b) Detail of paper source (Hexadecimal) cont. 00: MP tray 01: Paper cassette 1 (printer) 02: Paper cassette 2 (paper feeder 1) 03: Paper cassette 3 (paper feeder 2) 04: Paper cassette 4 (paper feeder 3) 05: - 06: - 07: -...
  • Page 40 2J0/2J1/2J2 Service items Description Items Description Maintenance Count. Item Remembers 1 to 8 of The total page count at the Code of maintenance replacing occurrence of replace- time of the replacement of item (1 byte, 2 categories) ment. If the occurrence of the toner container.
  • Page 41 2J0/2J1/2J2 1-4 Troubleshooting 1-4-1 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 operation panel. To remove paper misfed in the printer, pull out the paper cassette, pull out the rear unit, remove the devel- oping unit or open the duplex cover.
  • Page 42 2J0/2J1/2J2 1-4-2 Self-diagnostic function (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 operation panel. An error message consists of a message prompting a contact to service personnel, total print count, and a four-digit error code indicating the type of the error.
  • Page 43 2J0/2J1/2J2 Remarks Code Contents Causes Check procedures/corrective measures 0420 Paper feeder communication error Improper installa- Follow installation instruction carefully again. Communication error between engine tion paper feeder. PWB and optional paper feeder. Defective harness Reinsert the connector. Also check for conti- between connect-L nuity within the connector harness.
  • Page 44 2J0/2J1/2J2 Remarks Code Contents Causes Check procedures/corrective measures 1150 Lift motor descent error Defective bulk Replace the bulk paper feeder’s tray bottom *40/42 and 45/47 ppm printers (EUR/ paper feeder’s tray position sensor. USA model) only bottom position Optional bulk paper feeder’s tray bottom sensor.
  • Page 45 2J0/2J1/2J2 Remarks Code Contents Causes Check procedures/corrective measures 4000 Polygon motor (laser scanner unit) Defective harness Reinsert the connector. Also check for conti- error between polygon nuity within the connector harness. If none, POLRDYN signal does not go low within motor and main remedy or replace the harness.
  • Page 46 2J0/2J1/2J2 Remarks Code Contents Causes Check procedures/corrective measures 6000 Broken fuser heater lamp wire Poor contact in the Reinsert the connector (See page 1-5-22). ° fuser thermistor 1 The temperature does not reach 100 ° connector termi- F after the fuser heater lamp has nals.
  • Page 47 2J0/2J1/2J2-4 Remarks Code Contents Causes Check procedures/corrective measures 6400 Zero cross signal error Defective harness Reinsert the connector. Also check for conti- The ZCROSS signal does not reach the between connect-L nuity within the connector harness. If none, engine PWB for more than 2 s. PWB (YC8) and remedy or replace the harness.
  • Page 48 2J0/2J1/2J2-4 Remarks Code Contents Causes Check procedures/corrective measures Communication problem between the Defective main Turn the power switch off/on to restart the F000 main PWB and operation panel PWB PWB. printer.If the error is not resolved, replace Communication is failed between the main PWB (See page 1-5-30).
  • Page 49 2J0/2J1/2J2 1-4-3 Image formation problems (1)Completely blank (2)All-black printout. (3)Dropouts. (4)Black dots. (5)Black horizontal printout. streaks. See page See page 1-4-10 See page 1-4-11 See page 1-4-11 See page 1-4-13 1-4-9/1-4-10 (6)Black vertical (7)Unsharpness. (8)Gray background. (9)Dirt on the top (10)Undulated print- streaks.
  • Page 50 2J0/2J1/2J2 Print example Causes Check procedures/corrective measures Poor contact of engine Check the installation position of the engine PWB. develop- PWB’s developing bias out- Refer to figure1-4-3 above. ing bias put terminal and printer’s output. contact (spring). Poor contact of engine Check the installation of the developing unit.
  • Page 51 2J0/2J1/2J2 (3) Dropouts. Print example Causes Check procedures/corrective measures Defective developing roller (develop- If the defects occur at regular intervals of 39 mm/1 " (See 9/16 ing unit). page 2-4-1), the problem may be the damaged developing roller (in the developing unit). Replace developing unit. If a developing unit which is known to work normally is avail- able for check, replace the current developing unit in the printer with the normal one.
  • Page 52 2J0/2J1/2J2 Cleaning the drum surface 1. Remove the drum unit (See page 1-5-12). 2. Remove the main charger unit (See page 1- 5-13). 3. Hold the drum unit at an angle shown right figure. Use care not to drop foreign objects into the drum.
  • Page 53 2J0/2J1/2J2 (5) Black horizontal streaks. Print example Causes Check procedures/corrective measures Defective drum unit's ground. Defective drum unit's ground. The contact (spring) in the drum unit and its counter part, the drum grounding terminal in the printer, must be in a good contact. (See page 1-4-10, refer to figure 1-4-5) Defective drum unit.
  • Page 54 2J0/2J1/2J2 (8) Gray background. Print example Causes Check procedures/corrective measures Print density setting. The print density may be set too high. Try adjusting the print density. For details refer to the printer's operation guide. Defective drum surface potential. If a drum unit which is known to work normally is available for check, replace the current drum unit in the printer with the nor- mal one.
  • Page 55 2J0/2J1/2J2 1-4-4 Electric problems Problem Causes Check procedures/corrective measures Defective waste toner sen- Replace the drum unit (See page 1-5-12). Defective waste sor. toner box detecting. Defective connection Check the connection of connectors between drum PWB (YC1) between drum PWB (YC1) and connect-L PWB (YC3).
  • Page 56 2J0/2J1/2J2 Problem Causes Check procedures/corrective measures Broken power cord. Replace the power cord. Defective message The power cord is not Check the contact between the printer’s AC inlet and the AC displaying (LCD) [2]. plugged in properly. power outlet. No message appears on the message dis- No electricity at the AC Measure the AC input voltage.
  • Page 57 2J0/2J1/2J2 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following rollers Clean with isopropyl alcohol. No primary paper feed. are dirty with paper powder: pickup roller, paper feed roller and MP tray feed roller. Check if the pickup roller, paper feed roller Check visually and replace any deformed and MP tray feed roller are deformed.
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  • Page 59 2J0/2J1/2J2 1-5 Assembly and Disassembly 1-5-1 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, do not touch connectors with bare hands or damage the PWB. Do not touch any PWB containing ICs with bare hands or any object prone to static charge.
  • Page 60 A black-colored band when seen through the left side window ( A shiny or gold-colored band when seen through the right side window ( The above will reveal that the toner container is a genuine Kyocera Mita branded toner container, otherwise, it is a coun- terfeit.
  • Page 61 2J0/2J1/2J2 1-5-2 Outer covers (1) Detaching and refitting the top cover Procedure 1. Open the top cover. 2. Remove two screws. 3. Remove the one connector and then remove the top cover. Top cover Screw Screw Connector Figure 1-5-3 1-5-3 Downloaded from www.Manualslib.com manuals search engine...
  • Page 62 2J0/2J1/2J2 (2) Detaching and refitting the right cover and left cover Procedure 1. Remove the paper cassette. 2. Open the MP tray. 3. Remove the top cover (See page 1-5-3). 4. Release five latches and then remove the right cover. Latch Latch Latch...
  • Page 63 2J0/2J1/2J2 5. Open the left side cover and then remove Rear upper cover the waste toner box. 6. Remove the one screw. 7. Draw the rear unit. 8. Open the rear upper cover. 9. Release six latches and then remove the left cover.
  • Page 64 2J0/2J1/2J2 1-5-3 Paper feed section (1) Detaching and refitting the paper feed assembly (paper feed roller and pickup roller) Procedure 1. Remove the paper cassette. 2. While pushing the lock and then slide the paper feed roller pin. 3. While pressing the lever and then remove the paper feed assembly.
  • Page 65 2J0/2J1/2J2 (2) Detaching and refitting the retard roller Procedure 1. Remove the paper cassette. Paper cassette 2. Push the bottom plate down until it locks Bottom plate (35/37 ppm printer [EUR/USA model] only). 3. Release the two latches and then remove the retard guide.
  • Page 66 2J0/2J1/2J2 (3) Detaching and refitting the registration upper and lower roller Procedure 1. Remove the developing unit (See page 1-5- Spring 11). 2. Remove the spring. 3. Pull the registration upper roller. Registration upper roller Figure 1-5-9 4. Remove the registration upper roller from the bush.
  • Page 67 2J0/2J1/2J2 6. Remove the registration lower roller. Gear 7. Remove the stopper, gear and three bushes Stopper from the registration lower roller. Bush Bush 8. Check or replace the registration upper and lower roller and refit all the removed parts. Registration lower roller Bush...
  • Page 68 2J0/2J1/2J2 (4) Detaching and refitting the MP tray paper feed roller Procedure 1. Open the MP tray. 2. Grasp and pull the MP tray upwards until it is removed from the printer. MP tray Figure 1-5-12 3. Pull the MP tray paper feed roller holder. (1) 4.
  • Page 69 2J0/2J1/2J2 1-5-4 Developing section (1) Detaching and refitting the developing unit Procedure 1. Open the top cover. 2. Open the MP tray. Top cover 3. Remove the developing unit. 4. Check or replace the developing unit and refit all the removed parts. Developing unit MP tray Figure 1-5-14...
  • Page 70 2J0/2J1/2J2 1-5-5 Drum section (1) Detaching and refitting the drum unit Procedure 1. Remove the developing unit (See page 1-5- Left side cover 11). 2. Open the left side cover and then remove the waste toner box. 3. Unlock the drum unit lock and then remove the drum unit.
  • Page 71 2J0/2J1/2J2 (2) Detaching and refitting the main charger unit Procedure 1. Remove the drum unit (See page 1-5-12). Main charger unit 2. Unlock the lock lever and then remove the main charger unit. 3. Check or replace the main charger unit and Lock lever refit all the removed parts.
  • Page 72 2J0/2J1/2J2 1-5-6 Transfer/separation section (1) Detaching and refitting the transfer roller and separation charger brush unit Procedure 1. Remove the developing unit (See page 1-5- Hook Hook 11). Hook Hook 2. Remove the drum unit (See page 1-5-12). 3. Slide the paper chute guide and unhook the hooks.
  • Page 73 2J0/2J1/2J2 6. Release four latches and then remove the separation charger brush unit. 7. Check or replace the transfer roller and sep- aration charger brush unit and refit all the Separation charger removed parts. brush unit CAUTION: Note the following, when refitting the separation charger brush unit.
  • Page 74 2J0/2J1/2J2 1-5-7 Fuser section (1) Detaching and refitting the fuser unit Procedure 1. Draw the rear unit. 2. Insert a flat-blade screwdriver to push the fuser lock (gray colored) on the rear unit and the fuser unit is separated from the rear unit (rails).
  • Page 75 2J0/2J1/2J2 (2) Detaching and refitting the fuser heater lamp Procedure 1. Remove the fuser unit (See page 1-5-16). 2. Open the exit upper guide. Screw Screw 3. Remove four screws. Exit upper guide Screw Screw Figure 1-5-21 1-5-17 Downloaded from www.Manualslib.com manuals search engine...
  • Page 76 2J0/2J1/2J2 4. Detach the fuser upper frame. Fuser upper frame Fuser rod Spring Fuser rod Spring Figure 1-5-22 5. Remove the one screw from the fuser heater lamp. Screw Fuser heater lamp Figure 1-5-23 1-5-18 Downloaded from www.Manualslib.com manuals search engine...
  • Page 77 2J0/2J1/2J2 6. Remove the one screw and one terminal Fuser heater lamp from the fuser heater lamp. Screw 7. Remove the fuser heater lamp. 8. Check or replace the fuser heater lamp and refit all the removed parts. Terminal Seat the fuser heater lamp aligning its watt- age mark and welding mark faced with the correct direction and side.
  • Page 78 2J0/2J1/2J2 (3) Detaching and refitting the heat roller Procedure 1. Remove the fuser heater lamp (See page 1- Assembly 5-17). 2. Unhook two bearing retainer’s hooks and then remove the heat roller (assembly) from the fuser upper frame. Bearing retainer 3.
  • Page 79 2J0/2J1/2J2 (4) Detaching and refitting the press roller Procedure 1. Remove the fuser unit (See page 1-5-16). 2. Open the fuser upper frame (See page 1-5- 17). Press roller 3. Remove the press roller from the fuser lower frame. 4. Check or replace the press roller and refit all the removed parts.
  • Page 80 2J0/2J1/2J2-4 (5) Detaching and refitting the fuser thermistor 1/2 and thermal cutout Procedure 1. Remove the fuser unit (See page 1-5-16). Lock lever 2. Turn the fuser unit bottom side up. 3. Release three lock levers and then remove the wire cover. Wire cover Lock lever Lock lever...
  • Page 81 2J0/2J1/2J2-4 6. Remove the wires from the ten clamps. 7. Remove one connector. Wires Wires Clamps Clamps Clamps Wires Connector Clamp Clamp Figure 1-5-29 8. Remove the heat roller (See page 1-5-20). 9. Remove the one screw and then remove the Screw fuser thermistor 1.
  • Page 82 2J0/2J1/2J2-4 10. Remove the one screw (nut) and then remove the fuser thermistor 2 (40/42 and Screw 45/47 ppm printers [EUR/USA model] only). Fuser thermistor 2 Figure 1-5-31 11. Remove the two screws (nuts) and then remove the terminal and cord plate. Screw 12.
  • Page 83 2J0/2J1/2J2 1-5-8 PWBs (1) Detaching and refitting the engine PWB Procedure 1. Remove the developing unit (See page 1-5- 11). Screw 2. Remove the drum unit (See page 1-5-12). 3. Remove the top cover (See page 1-5-3). 4. Remove the left cover (See page 1-5-4). 5.
  • Page 84 2J0/2J1/2J2 11. Remove the cord cover (40/42 and 45/47 ppm printers [EUR/USA model] only). 12. Remove the connector (40/42 and 45/47 ppm printers [EUR/USA model] only). 13. Detach the joint. 14. Remove the six screws and then remove the DU base. Joint Cord cover Connector...
  • Page 85 2J0/2J1/2J2 15. Release four snaps. 16. Remove one tab. 17. Remove five connectors. Snap Snap Snap Snap Connectors Connectors Figure 1-5-36 1-5-27 Downloaded from www.Manualslib.com manuals search engine...
  • Page 86 2J0/2J1/2J2 18. Remove four screws. Screw Screw Screw Screw Figure 1-5-37 19. Detach the engine PWB assembly. 20. Remove four connectors. 21. Remove the engine PWB assembly. Connectors Connectors Engine PWB assembly Figure 1-5-38 1-5-28 Downloaded from www.Manualslib.com manuals search engine...
  • Page 87 2J0/2J1/2J2 22. Remove one connector. 23. Remove two screws-A and then remove the EEPROM HV plate. 24. Remove two screws-B and then remove the engine R grounding plate, engine L ground- ing plate and shield plate. 25. Check or replace the engine PWB and refit Engine L all the removed parts.
  • Page 88 2J0/2J1/2J2 (2) Detaching and refitting the main PWB Procedure 1. Remove the top cover (See page 1-5-3). Connectors 2. Remove the right cover (See page 1-5-4). Connect-R PWB Main PWB 3. Remove the following connectors from the main PWB. Six connectors: 35/37 and 40/42 ppm print- ers (EUR/USA model) Seven connectors: 45/47 ppm printer (EUR/ USA model)
  • Page 89 2J0/2J1/2J2 7. Draw the rear unit. 8. Remove six screws and then remove the controller box (main PWB). Screw Screw Screw Rear unit Screw Screw Controller box Screw (Main PWB) Figure 1-5-41 9. Remove five screws and then remove the main PWB from the controller box.
  • Page 90 2J0/2J1/2J2 (3) Detaching and refitting the power source unit (PWB) Procedure 1. Remove the top cover (See page 1-5-3). 2. Remove the right cover (See page 1-5-4). 3. Remove the drum unit (See page 1-5-12). 4. Remove one connector (YC11) from the connect-L PWB.
  • Page 91 2J0/2J1/2J2 7. Remove seven screws-A and drum ground- Grounding ing plate and two grounding terminals. terminal 8. Remove one screw-B and grounding termi- nal. 9. Remove the AC inlet. Screw-B AC inlet Screw-A (M3) Screw-A Screw-A (M3) Drum grounding plate Screw-A Grounding Screw-A...
  • Page 92 2J0/2J1/2J2 13. Remove one connector. 14. Remove six screws and then remove the power source PWB. Screw Screw 15. Check or replace the power source PWB and refit all the removed parts. Screw Power source PWB Connector Heat sink plate Screws Power source PWB plate Screws...
  • Page 93 2J0/2J1/2J2 1-5-9 Others (1) Detaching and refitting the paper feed drive unit Procedure 1. Remove the paper cassette. Clamp 2. Remove the developing unit (See page 1-5- 11). Right fan motor 3. Remove the top cover (See page 1-5-3). Connect-R PWB 4.
  • Page 94 2J0/2J1/2J2 9. Remove three screws and then remove the paper feed drive unit. 10. Check or replace the paper feed drive unit and refit all the removed parts. To refit the paper feed drive unit, make sure mesh of gears. Screw Screw Gear...
  • Page 95 2J0/2J1/2J2 (2) Detaching and refitting the main drive unit Procedure 1. Remove the top cover (See page 1-5-3). 2. Remove the right cover (See page 1-5-4). 3. Remove the controller box (See page 1-5- 30). 4. Remove two connectors. 5. Remove five screws and then remove the Screw main drive unit.
  • Page 96 2J0/2J1/2J2 (3) Detaching and refitting the laser scanner unit Procedure 1. Remove the top cover (See page 1-5-3). 2. Remove the right cover (See page 1-5-4). Main PWB 3. Remove the following connectors from the main PWB. Two connectors: 35/37 and 40/42 ppm print- ers (EUR/USA model) Three connectors: 45/47 ppm printer (EUR/ USA model)
  • Page 97 2J0/2J1/2J2 4. Remove four screws and then remove the laser scanner unit. 5. Check or replace the laser scanner unit and refit all the removed parts. Laser scanner unit 35/37 and 40/42 ppm printers (EUR/USA model) Screw Screw Screw Screw 45/47 ppm printer (EUR/USA model) Laser scanner unit...
  • Page 98 2J0/2J1/2J2-4 (4) Direction of installing the principal fan motors When detaching or refitting the left fan motor or right fan motor, be careful of the airflow direction (intake or exhaust). Intake Left fan motor (Rating label: Inside) Intake Right fan motor (Rating label: Inside) Figure 1-5-52 1-5-40...

  • Page 99: Downloading Firmware

    2J0/2J1/2J2 1-6 Firmware 1-6-1 Downloading firmware The system firmware can be update by downloading new firmware. Downloading can be made either by directly sending the new firmware using a USB memory or memory card that contains the new firmware. Firmware file name example Engine firmware DL_ENGN.
  • Page 100 2J0/2J1/2J2 (1) Downloading the firmware from the USB memory To download data written in a USB memory to the printer, proceed as explained in this section. CAUTION Downloading firmware takes several minutes. Do not turn power off during downloading. If downloading is interrupted by an accidental power failure, etc., the main PWB may have to be replaced.
  • Page 101 2J0/2J1/2J2 (2) Downloading the firmware from the memory card To download data written in a memory card (CompactFlash) to the printer, proceed as explained in this section. CAUTION Downloading firmware takes several minutes. Do not turn power off during downloading. If downloading is interrupted by an accidental power failure, etc., the main PWB may have to be replaced.
  • Page 102 2J0/2J1/2J2 7. Remove the formatted memory card from the memory card slot. To PC 8. Insert the memory card to the PC's slot or to Memory card the adaptor. 9. Copy the firmware files to download to the root directory of the memory card. 10.
  • Page 103 2J0/2J1/2J2 2-1 Mechanical Construction 2-1-1 Paper feed section Paper feed section consists of the paper feed unit that feeds paper from the paper cassette and the MP tray paper feed unit that feeds paper from the MP tray, and the paper feed conveying section that conveys the fed paper to the transfer/ separation section.
  • Page 104 2J0/2J1/2J2 (2) MP tray paper feed section The MP tray can contain about 100 pages. Feeding is performed by the rotation of the MP tray feed roller from the MP tray. Function of the MP tray friction pad prevents papers from multiple feeding. Figure 2-1-3 MP tray paper feed section MP tray paper feed roller Bottom plate...
  • Page 105 2J0/2J1/2J2 (3) Paper feed conveying section The conveying section consists of the parts shown in the following illustration and conveys papers from the paper cassette or the MP tray to the transfer/separation section when papers are fed. Paper by feeding or refeeding is conveyed by the middle feed roller to the position where the registration sensor is turned on, and then sent to the transfer/separation sec- tion by the upper registration roller and lower registration roller.

  • Page 106: Drum Section

    2J0/2J1/2J2 2-1-2 Drum section (1) Drum section The drum unit includes a photoconductive drum, eraser lamp, cleaning blade and, a main charger unit. The drum unit is removable with the main charger unit. Figure 2-1-7 Drum section Drum Main charger case Charger roller cleaning roller Main charger roller Main high voltage output (DC + AC)

  • Page 107: Expose Section

    2J0/2J1/2J2 2-1-3 Expose section (1) Laser scanner unit The charged surface of the drum is then scanned by the laser beam from the laser scanner unit. The laser beam is dis- persed as the polygon motor revolves to reflect the laser beam over the drum. Various lenses and mirror are housed in the laser scanner unit, adjust the diameter of the laser beam, and focalize it at the drum surface.
  • Page 108 2J0/2J1/2J2 Laser scanner unit POLCLK Polygon YC11-5 POLRDYN motor YC12-1 POLONN YC12-2 PDMASKN YC12-4 Laser beam Pin-photo sensor YC16-2 Engine PWB PD PWB Main PWB Laser Laser Drum diode diode OUTPEN YC12-3 PCONT YC11-12 PWB 1 PWB 2* SAMPLEN1 YC11-10 VDATAP1 YC11-8 VDATAN1...

  • Page 109: Developing Section

    2J0/2J1/2J2 2-1-4 Developing section (1) Developing section The developing section consists of the developing unit and the toner container. The developing unit consists of the devel- oping roller where a magnetic brush is formed, the doctor blade and the agitator A and B that agitate the toner. Also, the toner sensor checks whether or not toner remains in the developing unit.
  • Page 110 2J0/2J1/2J2 2-1-5 Transfer/separation section (1) Transfer/separation section The image developed by toner on the drum is transferred onto the paper because of the electrical attraction between the toner itself and the transfer roller. The transfer roller is negatively biased so that the positively charged toner is attracted onto the paper while it is pinched by the drum and the transfer roller.

  • Page 111: Cleaning Section

    2J0/2J1/2J2 2-1-6 Cleaning section After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development process. The cleaning blade is constantly pressed against the drum and scrapes the residual toner off to the cleaning roller.
  • Page 112 2J0/2J1/2J2-4 2-1-7 Fuser section (1) Fuser unit The fuser section consists of the following parts and fixes the toner that is transferred to the paper at the transfer/separa- tion section. The paper sent from the transfer/separation section is interleaved between the heat roller and the press roller. The heat roller is heated by the fuser heater lamp installed inside, and the toner is fused by heat and pressure and fixed onto the paper because the press roller is pressed by the fuser press spring.
  • Page 113 2J0/2J1/2J2-4 35/37 ppm printer Fuser unit (EUR/USA model) Power source Thermal cutout LIVE YC102-3 COMMON Fuser YC102-1 thermistor 1 THERM1 YC506-8 Fuser heater lamp Heat roller EXITPAP YC506-6 Paper exit sensor Engine PWB 40/42 and 45/47 ppm printers (EUR/USA model) Fuser unit Power source Thermal cutout...
  • Page 114 2J0/2J1/2J2 2-1-8 Paper exit section/rear unit (1) Paper exit section/rear unit The paper exit section transports the paper which passed the fuser unit towards the top tray, face up tray (option*) or duplex conveying section. *: 40/42 and 45/47 ppm printers (EUR/USA model) only. 40/42 and 45/47 ppm printers (EUR/USA model) 35/37 ppm printer...
  • Page 115 2J0/2J1/2J2 Face down tray paper full sensor Connect-L Face down tray paper HPAP FDPFULN YC503-6 Connect-L full sensor AUTA1 YC9-11 AUTB3 YC9-10 FDPFULN HPAP AUTB1 YC503-6 YC9-9 AUTB3 YC9-8 AUTA1 YC9-11 AUTA3 Switch back Connect-R YC9-10 AUTB1 motor YC9-9 AUTB3 YC9-8 Engine Connect-R...
  • Page 116 2J0/2J1/2J2 2-1-9 Duplex conveying section (1) Duplex conveying section Figure 2-1-21Duplex conveying section DU roller DU feed pulley DU base DU lower guide Duplex jam sensor (actuator) Feed upper guide Connect-R PWB Engine PWB Duplex jam sensor DUDRN Duplex YC502-2 clutch* *: 40/42 and 45/47 ppm printers (EUR/USA model) only.
  • Page 117 2J0/2J1/2J2-4 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) Electrical parts layout Drum unit Fuser unit Developing unit 35/37 ppm printer (EUR/USA model) Figure 2-2-1 Electrical parts layout (35/37 ppm printer [EUR/USA model]) 2-2-1 Downloaded from www.Manualslib.com manuals search engine...
  • Page 118 2J0/2J1/2J2-4 Fuser unit Drum unit Developing unit 40/42 ppm printer (EUR/USA model) Figure 2-2-2Electrical parts layout (40/42 ppm printer [EUR/USA model]) 2-2-2 Downloaded from www.Manualslib.com manuals search engine...
  • Page 119 2J0/2J1/2J2-4 Fuser unit Drum unit Developing unit 45/47 ppm printer (EUR/USA model) Figure 2-2-3Electrical parts layout (45/47 ppm printer [EUR/USA model]) Main PWB ............ Controls the software such as the print data processing and provides the interface with computers. Engine PWB..........Controls printer hardware such as high voltage/bias output control, paper conveying system control, and fuser temperature control, etc.
  • Page 120 2J0/2J1/2J2-4 13. Power source unit ........Generates 24 V DC and 5 V DC power source. Controls the fuser heater lamp. 14. Power switch..........Turns ON/OFF the AC power source. 15. Interlock switch ..........Shuts off 24 V DC power line when the top cover is opened. 16.
  • Page 121 2J0/2J1/2J2 2-3 Operation of the PWBs 2-3-1 Power source PWB Connect-L PWB Power source PWB Envelope feeder detection switch* HANDSN MP tray paper feed sensor ZCROSS Zero cross signal circuit SWSLEEPN Power switch Switching AC input regulator +5V1 circuit +24V1 Interlock switch +24V2...
  • Page 122 2J0/2J1/2J2-4 YC102 Figure 2-3-2Power source PWB silk-screen diagram Connector Pin No. Signal Voltage Description YC101 LIVE 120 V AC AC power input Connected 220 - 240 V AC to the AC N.C. Not used inlet NEUTRAL 120 V AC AC power input 220 - 240 V AC YC102 COMMON1...

  • Page 123: Engine Pwb

    2J0/2J1/2J2-4 2-3-2 Engine PWB Right fan Fuser unit MP tray paper Duplex Developer Registration Middle feed Paper feed Lift motor* motor switch feed solenoid clutch* solenoid clutch clutch clutch Connect-R PWB Operation Polygon panel PWB PWB 1 PWB 2* PD PWB motor Exit fan Switchback...
  • Page 124 2J0/2J1/2J2 YC506 15Pin 9Pin YC501 YC503 YC502 YC11 Figure 2-3-4Engine PWB silk-screen diagram 2-3-4 Downloaded from www.Manualslib.com manuals search engine...
  • Page 125 2J0/2J1/2J2 Connector Signal Voltage Description OPSDO 0/5 V DC (pulse) Paper feeder serial communication data output signal Connected +24V3 24 V DC 24 V DC power source (via interlock switch) to the con- +24V3 24 V DC 24 V DC power source (via interlock switch) nect-L PWB Ground (YC7)
  • Page 126 2J0/2J1/2J2-4 Connector Signal Voltage Description YC506 FUSER-L 2 to 5 V DC Envelope switch-L setting detection voltage (4 levels) Connected FUSER-R 02 to 5 V DC Envelope switch-R setting detection voltage (4 levels) to the fuser +5V1 5 V DC 5 V DC power source unit THERM3...
  • Page 127 2J0/2J1/2J2 Connector Signal Voltage Description YC12 POLRDYN 0/5 V DC Polygon motor ready signal Connected POLONN 0/5 V DC Polygon motor: On/Off to the main OUTPEN 0/5 V DC Print data output enable signal PDMASKN 0/5 V DC PD mask control signal SBSY 0/5 V DC Engine busy signal...
  • Page 128 2J0/2J1/2J2 This page is intentionally left blank. 2-3-8 Downloaded from www.Manualslib.com manuals search engine...
  • Page 129 2J0/2J1/2J2-4 2-4 Appendixes Repetitive defects gauge First occurrence of defect 36 mm ( 1 " [Upper registration roller] 7/16 38.5 mm ( 1 " [Main charger roller] 39 mm ( 1 " [Developing roller] 9/16 52 mm ( 2 " [Lower registration roller] 1/16 58 mm ( 2...
  • Page 130 2J0/2J1/2J2-4 This page is intentionally left blank. 2-4-2 Downloaded from www.Manualslib.com manuals search engine...
  • Page 131 2J0/2J1/2J2-4 Wiring diagram (35 ppm printer) Waste toner Eraser Photo Connected to the optional paper feeder Feed fan sensor PWB lamp PWB (YC1) transistor Operation panel PWB motor APC PWB 1 (YC5) PD PWB (YC1) (YC1) +3.3V Polygon motor (YC1) (YC6) (YC2) WTNFUL...
  • Page 132 2J0/2J1/2J2-4 Wiring diagram (40 ppm printer) Lift sensor Waste toner Eraser Photo Connected to the optional paper feeder Feed fan sensor PWB lamp PWB (YC1) transistor Operation panel PWB motor APC PWB 1 (YC5) PD PWB (YC1) (YC1) +3.3V Polygon motor (YC1) (YC6) (YC2)
  • Page 133 2J0/2J1/2J2-4 Wiring diagram (45 ppm printer) Lift sensor Waste toner Eraser Photo Connected to the optional paper feeder APC PWB 2 APC PWB 1 Feed fan PD PWB sensor PWB lamp PWB transistor Operation panel PWB motor (YC1) (YC1) (YC5) (YC1) (YC1) Polygon motor...
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