MINOLTA-QMS PagePro 4100 Series Service Manual
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MINOLTA-QMS PagePro 4100 Series Service Manual

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PagePro 4100 Series
.minolta-qms.com
Service Manual
1750041-001B
The essentials of imaging
www.minolta-qms.com

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Summary of Contents for MINOLTA-QMS PagePro 4100 Series

  • Page 1 PagePro 4100 Series .minolta-qms.com Service Manual 1750041-001B The essentials of imaging www.minolta-qms.com...
  • Page 3 Trademark Acknowledgments The MINOLTA-QMS logo is a trademark of MINOLTA-QMS, Inc. PagePro is a trademark of Minolta Co., Ltd. LaserJet and PCL are registered trademarks of Hewlett-Packard Company. Centronics is a registered trademark of Centronics Inc. MS-DOS, Microsoft, and Windows are registered trademarks of Microsoft Corporation.
  • Page 4 Safety Precautions for Inspection and Service When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure the utmost safety. *Depending on the model, some of the precautions given on the following pages do not apply. Different markings are used to denote specific meanings as detailed below.
  • Page 5 3.Use the specified parts. • For replacement parts, always use the genuine parts specified in the manufac- turer’s Parts Manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possi- ble electric shock or fire. •...
  • Page 6 10.Restore all parts and harnesses to their original positions. • To ensure safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, and sharp edges, or being crushed.
  • Page 7 3.Precautions for Working Environment • The product must be placed on a flat, level surface that is stable and secure. • Never place this product or its parts on an unsteady or tilting workbench when servicing. • Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period time.
  • Page 8 Other Precautions • To reassemble the product, reverse the order of disassembly unless otherwise specified. • While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses. • The magnet roller generates a strong magnetic field, therefore it should not come in close contact with a watch, floppy disk, magnetic card, or CRT tube.
  • Page 9 Used Batteries Precautions (ALL Areas) CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. (Germany only) VORSICHT! Explosinsgefahr bei unsachgemäßen austausch der batterie. Ersatz nur durch denselben oder einen vom hersteller empfohlenen ähnlichen typ.
  • Page 10 SAFETY INFORMATION This printer is a page printer which operates by means of a laser. There is no possibility of danger from the laser, provided the printer is operated according to the instructions in this manual. Since radiation emitted by the laser is completely confined within protective housing, the laser beam cannot escape from the machine during any phase of user operation.
  • Page 11 For Denmark Users; ADVARSEL Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion. Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC825 sikkerheds kravene. For Finland, Sweden Users; VARNING! Osynlig laserstråining när denna del är öppnad och spärren är urkopplad. Betrakta ej stråien.
  • Page 12 WARNING LABEL...

  • Page 13: Table Of Contents

    CONTENTS 1. INSTALLATION ..................1 1-1. Installation Environment ..................1 1-2. Usage Environment .....................1 1-3. Installing the Power Supply.................1 1-4. Installation Space....................2 1-4-1. Standard ....................2 1-4-2. With 2nd, 3rd Paper Cassette Unit and Duplex Unit (Options) ....2 2. GENERAL INFORMATION ..............3 2-1.
  • Page 14 3-2-1. Multi-purpose Tray ................37 3-2-2. Second and Third Paper Cassette Unit ..........39 3-3. Imaging Cartridge....................41 3-3-1. Overview ....................41 3-3-2. Toner Empty Detection .................42 3-4. Drum Charge .....................43 3-5. Laser Exposure ....................44 3-6. Development......................46 3-7. Image Transfer....................47 3-8. Fusing ........................48 3-8-1. An Overview ..................48 3-8-2.
  • Page 15 Entrance Sensor (DUP_PSR) ..............87 4-5-27. Removal of the Duplex Exit Sensor (DUP_PS1) ........88 4-5-28. Removal of the Duplex Cover Sensor (DUP_OPEN) ..................89 5. ADJUSTMENT ..................90 5-1. Adjustment of Image Registration..............90 5-2. Adjustment of Interlock Switch Position ............91 6. TROUBLESHOOTING................92 6-1.

  • Page 16: Installation

    1. INSTALLATION 1-1. Installation Environment When installing the printer, avoid the types of locations listed below, both for safety considerations and to avoid breakdowns. •Areas with high temperatures or humidity, or with low temperatures and humidity •Areas where the temperature and/or humidity fluctuate sharply •Areas where the printer will be in direct sunlight •Areas near a cooler, heater, or ventilation opening or in the direct path of wind •Areas near oil stoves or other heat-generating equipment...

  • Page 17: Installation Space

    1-4. Installation Space 1-4-1. Standard 511 mm 20"-1/8" 1-4-2. With 2nd and 3rd Paper Cassette Units and Duplex Unit (Options) 536.7 mm 21"-1/8"...

  • Page 18: General Information

    2. GENERAL INFORMATION 2-1. Specifications 2-1-1. Printer Type Desktop Laser Beam Printer Printing System Electrophotographic Exposure System Laser diode + Polygon Mirror scanning Resolution 600 x 600 dpi, 1200 x 600 dpi Media Size Custom (Width: 86 to 216 mm x Length: 148 to 356 mm) (Width: 3-1/3”...

  • Page 19: Options

    Developing system Single element developing system FMT (Fine Micro Toning) system Density control Bias adjusting system Image transfer system Transfer Roller system PC Drum OPC (Organic Photo conductor) PC Drum cleaning system Blade system Paper separating system Curvature separating system and charge neutralizing pin Fusing system Heated roller system Dimensions...

  • Page 20: 2Nd And 3Rd Paper Cassette Unit

    2-1-3. 2nd and 3rd Paper Cassette Unit Media Type Ordinary plain paper (60-90 g/m ; 16 to 24 lbs), Recycled paper (60-90 g/m ; 16 to 24 lbs) Media Size A4, B5, Legal, Letter, Executive (identified by cassette type) Cassette capacity 500 sheets Paper feeding system With paper claw separation mechanism...

  • Page 21: Controller (For 4100E, 4100Gn)

    2-1-5. Controller (for 4100E, 4100GN) PowerPC and QuickPrint, 66 MHz Imaging Method Band Buffer method (bitmap method) Memory configuration Standard ROM: 4 MB Standard RAM: 8 MB DRAM SIMM slot: 2 slots (for optional DRAM: up to max. 104 MB RAM There is necessity to be faster than 60 nsec on the speed of DRAM SIMM PS SIMM slot: 1 slot (for optional PS-ROM)

  • Page 22: Parts Identification

    2-2. Parts Identification 1. Control Panel 2. Face-down Tray 3. Manual Feed Guide 4. Multi-purpose Tray 5. Paper Cassette 6. 3rd Paper Cassette Unit (Option) 7. 2nd Paper Cassette Unit (Standard for 4100GN) 8. Power Switch 9. Top Cover Release Button 10.
  • Page 23 11. Duplex Unit (Option) 12. Power Cord Socket 13. Power Cord 14. Parallel Interface Connector...

  • Page 24: Component Layout

    2-3. Component Layout 1. Face-down Tray 15. Paper Take-up Roller 2. Print Head Unit (PH) 16. Duplex Unit 3. Paper Empty Sensor (P_EMP1) 17. Duplex Entrance Sensor (DUP_PSR) 4. Manual Feed Tray 18. Duplex Exit Sensor (DUP_PS1) 5. Multipurpose Tray 19.

  • Page 25: Drive Section

    2-4. Drive Section 2-4-1. Overview The Main Motor (M1) transmits the drive to the rollers of the printer, the 2nd/3rd Paper Cassette Units, and the Duplex Unit via each gear as shown below. 1. Drive flow (fusing) PC Drum 2. Drive flow (PC Drum) 10.

  • Page 26: Electrical Components Layout

    2-5. Electrical Components Layout 2-5-1. Printer JOG_POS1 PWB-C (PWB-P) PWB-OP (PWB-O) PWB-G PWB-A P_ENP1 Heater Lamp PWB-A Mechanical Control Board High Voltage Board PWB-C Controller Board (4100E, 4100GN) JOG_POS1 Jog Position Sensor PWB-A Mechanical Control Board (4100GN only) Main Motor Toner Empty Sensor PWB-G Fusing Unit Cooling Fan...

  • Page 27: Controller (For 4100E, 4100Gn)

    2-5-2. Controller (for 4100E, 4100GN) PWB-C PWB-RS SIMM Network Interface Card (4100GN: Standard, 4100E: Option) Controller Board PWB-C PWB-RS PS-ROM Board (Option) SIMM SIMM (Option) 2-5-3. Controller (for 4100W, 4110W) PWB-P Network Interface (Option) PWB-P Controller Board SIMM SIMM (Option)

  • Page 28: 2Nd Paper Cassette Unit (Option For 4100E, 4100W)

    2-5-4. 2nd Paper Cassette Unit (Option for 4100E, 4100W, 4110W), 3rd Paper Cassette Unit (Option for 4100E, 4100GN, 4100W, 4110W) PWB-A SW21 (SW31) SL21 (SL31) Paper Empty Sensor PWB-A Connecting Board SL21 Paper Take-up Solenoid (SL31) SW21 Cassette Detecting Switch (SW31)

  • Page 29: Duplex Unit (Option)

    2-5-5. Duplex Unit (Option) DUP_PSR DUP_OPEN PWB-A DUP_PS1 SL41 DUP_OPEN Duplex Cover Sensor DUP_PS1 Duplex Exit Sensor DUP_PSR Duplex Entrance Sensor Switchback Motor Transfer Motor PWB-A Control Board for Duplex Unit SL41 Skew Correction Solenoid...

  • Page 30: Electrical Parts Function

    2-6. Electrical Parts Function 2-6-1. Printer Symbol Name Function Heater Lamp Heats the Heat Roller (650 W). High Voltage Unit Supplies power to the following sections: •Rotating Charge Brush: Charged voltage • Sleeve Roller: Developing bias voltage •Toner Regulation Plate: Developing blade voltage •Toner Collecting Plate: Collection blade voltage •Image Transfer Roller: Image transfer voltage JOG_POS1 Jog Position Sensor...
  • Page 31 Symbol Name Function PWB-D Laser Diode Drive Detects the starting point of printing via the laser Board (inside of the diode and SOS sensor, and exposes the PC Drum Print Head Unit) with the laser beam according to the image signals.

  • Page 32: 2Nd Paper Cassette Unit (Option For 4100E, 4100Gn)

    2-6-2. 2nd Paper Cassette Unit (Option for 4100E, 4100GN), 3rd Paper Cassette Unit (Option for 4100E, 4100GN, 4110W, 4100W) Symbol Name Function Paper Empty Sensor Detects the presence of paper. (on the PWB-A) The signal is "low" when the paper is detected. PWB-A Connecting Board Sends and receives power and control signals...

  • Page 33: Explanation Of The Control Panel For 4100E, 4100Gn

    2-7. Explanation of the Control Panel for 4100E, 4100GN The Control Panel has three indicator lights and one button. Ready (Green) Error (Red) Paper (Amber) Panel Button 2-7-1. Indicator Lights Different combinations of the three indicator lights indicate the current printer status and let the user know what the printer is doing.

  • Page 34: Indicator Status

    2-7-2. Indicator Status Ready Paper Error Printer Status (green) (amber) (red) Printer is ready. Power is off. Receiving data via parallel interface; Blinking printing in progress. Blinking Receiving data via network interface. Blinking Blinking Blinking Canceling job. Blinking Blinking Warming up. "Power on"...

  • Page 35: Control Panel Button Function

    2-7-3. Control Panel Button Function Depending on the status of the printer, the control panel button performs any one of the following operations. •Job cancel •Print configuration page •Form feed Job Cancel Use the following procedure whenever you want to the cancel the current job. 1.

  • Page 36: Test Print Function

    2-7-4. Test Print Function Perform the following operation to print a test page showing the current printer settings. Operation Briefly press the control panel button. Configuration Page Sample...

  • Page 37: Explanation Of The Control Panel For 4100W

    2-8. Explanation of the Control Panel for 4100W, 4110W The Control Panel has four indicator lights and one button. Error (Amber) Ready (Green) Toner (Amber) Panel Button Paper (Amber) 2-8-1. Indicator Lights Different combinations of the four indicator lights indicate the current printer status and let the user know what the printer is doing.

  • Page 38: Indicator Status

    2-8-3. Indicator Status Error Toner Paper Ready Printer Status Printer Initializing. Toner Empty. The imaging cartridge is out of toner. Press the Panel Button in the event of a toner empty. Fatal Error. Press the Panel Button in the event of a Fatal Error.
  • Page 39 When a Paper Empty occurs: Error Toner Paper Ready Indicate cause of Printer Status Fatal Error Blinking Tray 1 Paper Empty The paper supply of Multipurpose Tray is empty. Press the Tray 2 Paper Empty Panel The paper supply of 2nd paper Button cassette is empty.
  • Page 40 When a Operator Error occurrs: Error Toner Paper Ready Indicate cause of Printer Status Fatal Error Blinking Paper Misfeed at Paper Take-up Section. (2nd Paper Cassette) Cover Open The top cover is open. Paper Size Error The paper-size setting of the printer driver does not match the size of paper that has been detected in the tray.
  • Page 41 When a Fatal Error occurrs: Error Toner Paper Ready Indicate Printer Status cause of Fatal Error Engine error Blinking Blinking Blinking (P/H cooling fan error). Engine error Blinking Blinking (Fusing Unit low temperature error). Engine error Blinking Blinking (Fusing Unit warm up error). Engine error Blinking (polygon scanner).

  • Page 42: Electrical Service Parts On P.w.boards

    2-9. Electrical Service Parts on P.W.Boards 2-9-1. PWB-C (Controller Board for 4100E, 4100GN) PJ3(50P) IC26 XTAL2 XTAL1 IC11 IC12 IC10 SIMM3 IC13 SIMM4 PJ2(30P) Symbol Item Explanation PowerPC and QuickPrint, 66 MHz IC10 ASIC Peerless QP1700 IC11 DRAM 2 MB (60nsec. First Page mode Type) IC12 DRAM 2 MB (60nsec.

  • Page 43: Pwb-P (Controller Board For 4100W)

    2-9-2. PWB-P (Controller Board for 4100W, 4110W) XTAL2 PJ3(50P) IC11 PJ1(30P) Symbol Item Explanation Hitachi Zenographics, 20MHz Image Compression Pixel Magic PM2MJ-33MHz (JBIG Compression) ASIC ASIC ALTERA FLEX EPF6016QC208-2 EEPROM 1,024bit DRAM 2 MB (60nsec. First Page mode Type) IC8, 9 SRAM 64KB (for mode setting and counters) IC11...

  • Page 44: Pwb-A (Mechanical Control)

    2-9-3. PWB-A (Mechanical Control) CN1 (30P) CN14 (3P) CN1 (5P) CN15 (14P) CN1 (5P) CN5 (7P) CN8 (6P) CN4 (11P) CN9 (5P) CN11 (12P) CN13 (2P) CN3 (2P) CN12 (8P) CN2 (2P) CN6 (4P) CN7 (4P) Jog Motor Drive IC (4100GN only) Adjusts the Image Registration margin.

  • Page 45: Hv1 (High Voltage Unit)

    2-9-5. HV1 (High Voltage Unit) Drum Charging Bias terminal (DC-1286V/DC-800V) Developing Bias terminal (DC-300V) Toner Blade Bias terminal (DC-550V) Toner Blade Bias terminal (DC-550V) Image Transfer Bias terminal (DC3000V/DC-1000V max) Dial for factory adjustment (Available only at factory)

  • Page 46: Nic (Network Interface Card)

    2-9-6. NIC (Network Interface Card) Jumper Post Default Position Settings 10/100 Base T (for 4100E, 4100GN) 10 Base T/2 (for 4100E, 4100GN) THIN 10 BT AUTO 4110s019...
  • Page 47 10/100 Base T for 4100W, 4110W TEST The 4100W and 4110W NIC are different and each has a unique part number, even though the graphic shown is identical for both. The difference between the 2 NICs is chip-based.

  • Page 48: Video Interface (Engine I/F)

    2-10. Video Interface (Engine I/F) This section explains the video interface between the Engine and Controller. 2-10-1. Overview of Video Interface The Engine and Controller use a video interface to carry out the following functions. •The transfer of image data. •Mutual exchange (and confirmation) of data on the progress of the printing sequence.

  • Page 49: Description Of Signals

    2-10-2. Description of Signals Signals Meaning of Signals /CPRDY This signal indicates that the Controller is ready for communication with the Engine following initialization of the CPU in the Controller after the main power is turned on. The signal becomes active when communication is enabled.

  • Page 50: Timing Chart

    2-11. Timing Chart 2-11-1. Print Starting more than 100ºC or 212ºF Printing command (/PRINT) 10-30msec Polygon Motor (M2) 6.0sec Paper Take-Up Sensor (PS1) 2.4sec 0.8-2.6sec Paper Take-Up Solenoid (SL1/SL21) 0.34sec Main Motor (M1) Drum charge -1200V (24.0mm) 2.47sec 0.3sec 2.23sec 0.7sec 0.3sec 0.3sec...

  • Page 51: Mechanical/Electrical

    3. MECHANICAL/ELECTRICAL 3-1. Paper Path Paper can be fed into the printer either from the Multipurpose Tray (250 sheets) or the Manual Feed Port (1 sheet). The paper feed system can be extended to a 4-way system by installing the optional Second Paper Cassette Unit (500 sheets) and 3rd Paper Cassette Unit (500 sheets).

  • Page 52: Paper Take-Up Section

    3-2. Paper Take-up Section 3-2-1. Multipurpose Tray Mechanism - When the Paper Take-Up Solenoid (SL1) is energized, the drive of the Main Motor (M1) is transmitted to the Paper Take-Up Roller via the Paper Take-Up Clutch (one- way clutch) to turn the Paper Take-Up Roller one revolution. - At the same time, the Depressing Cam turns and lifts the Tray Lifting Plate, and the first (top) sheet of paper on the tray is fed into the printer.
  • Page 53 Standing by Taking up the paper Tray Tray Lifting Plate Depressing Cam Paper Empty Detection The Paper Empty Sensor (PE1) on the upper section of the Multipurpose Tray determines whether paper is loaded in the tray. When paper is present, the actuator is lifted and the sensor is deactivated.

  • Page 54: Second And Third Paper Cassette Unit

    3-2-2. Second and Third Paper Cassette Unit Mechanism - The Second and Third Paper Cassette Units have the same configuration. - As drive motors are not installed in these units, the drive for feeding and transporting paper (power from M1) is transmitted from the printer via the Drive Transmission Gear. - Although the feeding method is the same as the Multipurpose Tray in the printer, the corner separation system is applied as the paper separating method.
  • Page 55 Cassette Type Detection Cassette Detection Switch (SW21) with sector levers are provided in the Second Paper Cassette Unit. When the paper cassette is inserted, the projections on the side of the cas- sette push and turn on the switches corresponding to each paper size. These three switches are provided as a set, and the printer recognizes the cassette type (paper size) by the combination of ON/OFF states of the switches.

  • Page 56: Imaging Cartridge

    3-3. Imaging Cartridge 3-3-1. Overview The imaging cartridge is a unit that integrates functions for charging, developing, clean- ing, supplying toner, and storing waste toner. Section names and Functions Name Function 1 Laser Exposure Emits a laser beam from the laser exposure section 2 Waste toner section Removes and collects excess toner.

  • Page 57: Toner Empty Detection

    Name Function 10 Toner Transport Roller Transfers toner to the sleeve roller section. PC Drum protection cover Covers and protects the PC Drum when taking the imaging cartridge out of the printer. Toner Agitating blade Agitates the toner in the Toner Hopper and sends the toner to the Toner Transport Roller.

  • Page 58: Drum Charge

    3-4. Drum Charge - The PC Drum is charged with static electricity before laser exposure. - The Rotating Charge Brush and the Precharge-film are used for the charging method. - The Rotating Brush charging and Precharge-film charging generate little ozone in the printer.

  • Page 59: Laser Exposure

    3-5. Laser Exposure Laser exposure is the process of creating an invisible static charge image on the PC Drum by the laser beam emitted from the Print Head Unit. This process is controlled as follows in order to appropriately time image printing. PC Drum Laser Diode Print Head Unit (PH1)
  • Page 60 Printing Area - The controller sends the VIDEO signal of the appropriate paper size to the engine. - The controller determines the starting point of printing according to the TOD signal (sub-scanning direction) sent from the engine (PWB-A) and the HSYNC signal. - Laser exposure is started when the print head receives the VIDEO signal.

  • Page 61: Development

    3-6. Development Toner is applied to the invisible static image on the PC Drum and a toner image is created on the drum surface. PC Drum Ground (PC Drum) Sleeve Roller Developing Bias Toner Transport Roller Toner Blade Bias Terminal Toner Blade Lower Seal Bias Lower Seal...

  • Page 62: Image Transfer

    3-7. Image Transfer - Image transfer is the process of transferring the toner image created on the PC Drum in the developing process to paper. - Roller Image Transfer is used instead of Corona Image Transfer as the image transfer method.

  • Page 63: Fusing

    3-8. Fusing 3-8-1. An Overview - The toner image transferred to the paper is fused to the paper in the Fusing Section. - A heat roller system is used as the fusing system. The toner is fused on the paper as it is pressed between the Backup Roller and Heat Roller heated by the Heater Lamp.

  • Page 64: Fusing Temperature Control Circuit

    3-8-2. Fusing Temperature Control Circuit - The Thermistor (TH1) detects the surface temperature of the Fusing Heat Roller and inputs that analog voltage into IC1A-78. Corresponding to this data, the Heater Lamp ON/OFF signal is output from IC1A-55, causing the Heater Lamp (H1) to turn ON or OFF to control the fusing temperature.
  • Page 65 The printer is initialized upon power being supplied. The printer then starts warming-up and the Heater Lamp lights. This lamp is lit until the temperature of the Heat Roller reaches approximately 200°C/392ºF. The temperature is controlled as follows. Mode 1 The temperature is controlled to maintain about 124°C/255ºF during standby and 200°C/ 392ºF during printing.

  • Page 66: Paper Exit

    3-9. Paper Exit 3-9-1. Overview - The Main Motor (M1) transmits drive to the Paper Exit Roller via the gears. The paper is discharged onto the tray with the printed side facing down. 3-9-2. Jog Tray Function (4100GN only) - The jog tray function enables the Paper Exit Roller to slide to the left and right so that paper is sorted and discharged at different positions on the tray while printing.
  • Page 67 - The jog tray function is activated when paper exits the fusing section and the Paper Exit Sensor (PS3) is turned off. - The Jog Motor (M4) rotates forward when the Paper Exit Sensor (PS3) is turned off. The paper is discharged, sliding to the side (jog position 2), while the Paper Exit Roller is sliding.

  • Page 68: Duplex Unit (Option)

    3-10. Duplex Unit (Option) The Paper Exit Roller is connected to the Switchback Motor (M41) by the connection lever and gear when the Duplex Unit is installed to the printer. For simplex printing The printed paper passes the Paper Exit Sensor and is discharged by the Paper Exit Roller.

  • Page 69: Maintenance/Disassembly

    4. MAINTENANCE/DISASSEMBLY 4-1. Precautions for Maintenance/Disassembly 4-1-1. Precautions for Disassembly Observe the following precautions whenever servicing the printer. - Be sure to unplug the printer from the outlet before attempting to service the printer. - To reassemble the printer, reverse the order of disassembly unless otherwise specified. - The printer should not be operated anytime during disassembly.

  • Page 70: Parts Not To Be Touched

    4-1-3. Parts not to be touched The following parts should not be removed, disassembled, or adjusted. - Print Head Unit - The parts where the mounting screws are painted red. 4-1-4. Instructions for Handling the PWBs with MOS ICs The following precautions must be observed when handling circuit boards with MOS (Metal Oxide Semiconductor) ICs.

  • Page 71: Maintenance Schedule List

    4-2. Maintenance Schedule List Replacement Cycle Replacement Cycle Parts (Unit) Cleaning Cycle (Continuous Printing) (Single Printing) Imaging Cartridge approximately 9,000 approximately 7,200 none (separately sold) simplex prints simplex prints Imaging Cartridge approximately 5,000 approximately 4,000 (provided with none simplex prints simplex prints printer) Imaging Transfer...

  • Page 72: Screws

    4-4. Screws D x L D x L D x L Illust. Illust. Illust. (mm) (mm) (mm) 3501 3907 1308 3541 3923 3x10 3541 3704 1112 4012 3727 3435 3x30...

  • Page 73: Disassembly Procedures

    4-5. Disassembly Procedures 4-5-1. Disassembly Procedure Chart 4-5-2 4-5-3 Open the Top Cover Imaging Cartridge Paper Take-up Roller Paper Tray 4-5-4 Image Transfer Roller 4-5-5 4-5-6 Right Cover Control Panel 4-5-5 Left Cover 4-5-5 4-5-7 4-5-7 Front Cover Controller Board (PWB-C, P) Mechanical Control Board (PWB-A) 4-5-8 Paper Take-up Solenoid (SL1)

  • Page 74: Before Disassembly Preparation

    4-5-2. Before Disassembly Preparation Before disassembling the machine, the following units need to be removed. Push the Top Cover Release Button and fully open the Top Cover. Remove the Imaging Cartridge. Remove the Paper Tray. Top Cover Release Button Imaging Cartridge Top Cover Paper Tray...

  • Page 75: Replacing The Paper Take-Up Roller

    4-5-3. Replacing the Paper Take-up Roller Replace the Paper Take-up Roller approximately every 150,000 simplex prints. Open the Paper Take-up Roller Cover and remove the Paper Take-up Roller. (1 screw) NOTE: When installing the roller, fit the positioning pin on the back side of the roller into the hole of the shaft.

  • Page 76: Replacing The Image Transfer Roller

    4-5-4. Replacing the Image Transfer Roller Replace the Image Transfer Roller approximately every 150,000 simplex prints. Never touch the surface of the Image Transfer Roller or contaminate it with chemicals or toner. Any depression or contamination on the roller will affect the printing quality. •...
  • Page 77 Remove the left and right roller holders, bushings, and gear from the original Image Transfer Roller and attach them to the new one. Insert the new roller into the Transfer Roller holder and raise the lever of the bushings. Imaging Transfer Roller Gear Bushing Holding Screw...

  • Page 78: Removal Of The Right Cover, The Left Cover And The

    4-5-5. Removal of the Right Cover, the Left Cover and the Front Cover Remove the Right Cover. (2 screws) Remove the Left Cover. (2 screws) Remove the Front Cover. (2 screws) NOTE: When reinstalling each cover, securely insert the projections of the cover into the cutouts in the printer frame.

  • Page 79: Removal Of The Control Panel

    4-5-6. Removal of the Control Panel Remove the Controller Cover. (4 screws) Remove the Control Panel. (2 screws, 1 connector) 3541 3541 3544 3544 3544 3544 Controller Cover Control Panel...

  • Page 80: Control Board (Pwb-A)

    4-5-7. Removal of the Controller Board (PWB-C, P) and the Mechanical Control Board (PWB-A) Remove the Harness Cover. (1 screw) Remove the Board Cover A. (10 screws) 3727 3544 3544 3544 3544 3544 3544 3544 3544 3544 3544 Harness Cover Board Cover A Remove Board Cover B.
  • Page 81 Remove the Controller Board (PWB-C or PWB-P). (4 screws, 1 connector) 3541 3541 3541 3541 Controller Board (4100E, 4100GN: PWB-C, 4100W: PWB-P) After unplugging all connectors on the Mechanical Control Board (PWB-A), remove the Mechanical Control Board (PWB-A). (4 screws) Mechanical Control Board (PWB-A)

  • Page 82: Removal Of The Paper Take-Up Solenoid (Sl1)

    4-5-8. Removal of the Paper Take-up Solenoid (SL1) Remove the upper section of the printer. (4 screws, 1 connector) 3544 3544 3544 3544 3544 Remove the Paper Take-up Solenoid (SL1). (1 screw, 1 connector) 3727...

  • Page 83: Replacing The Transfer Roller

    4-5-9. Replacing the Transfer Roller Replace the Transfer Roller approximately every 150,000 sheets of print. Holding the Transfer Roller Holder, move the Transfer Rolls apart to both sides Transfer Rolls Transfer Roller Holder...
  • Page 84 Hold the Transfer Roller Holder tightly and pull the Transfer Roller out from the right side. Disconnect the transfer roller at the joint and remove it. NOTE: • Attach the New Transfer Roller so that the guide film is placed upward. •...

  • Page 85: Removal Of The Top Cover

    4-5-10. Removal of the Top Cover Remove the connectors (2 pieces) between the Top Cover and the printer. Remove the Shoulder Screw and washer from the Stopper Guide. NOTE: Hold the upper cover with your hand, or the cover may fall when the screw is removed. Remove the screw between the Top Cover and Rear Cover.

  • Page 86: Removal Of The Rear Cover

    4-5-11. Removal of the Rear Cover Remove the Rear Cover. (6 screws, 1 connector) NOTE: Do not lose the connector cover. 3544 3544 3544 3727 3727 3544 Rear Cover Connector Cover 4-5-12. Removal of the Fusing Unit Cooling Fan (M3) Remove the Cooling Fan Cover.

  • Page 87: Removal Of The Fusing Unit

    4-5-13. Removal of the Fusing Unit Replace the Fusing Unit about every 50,000 sheets of print. Remove the Fusing Unit. (3 screws, Fixing Plate, 3 connectors) 3544 3544 3544 Fusing Unit Fixing Plate NOTE: Once the Fusing Unit is removed, use the following instructions to make repairs when image quality problems or parts failure occur.

  • Page 88: Disassembly Of The Fusing Unit

    4-5-14. Disassembly of the Fusing Unit Remove two screws. Press the left and right claws (4 in total) and separate the upper and lower fusing units. 3727 3727 Remove the Backup roller. Slide the Front Fusing Guide Plate in direction (1) and pull it in direction (2) to remove one side of the plate.
  • Page 89 Remove the Terminal Plate. (2 screws) Pull out the Heater Lamp (H1). NOTE: • When reinstalling the lamp, position the voltage mark on the fusing drive gear side. • Be sure not to touch the lamp surface with bare hands. 3727 3727 Terminal Plate...
  • Page 90 Remove the four Fusing Paper Separators. Slide the Heat Roller in direction (1) and pull it in direction (2) to remove one side of the roller. Then pull the roller in direction (3) to remove it completely. NOTE: In order not to scratch the surface of the Heat Roller with the Fusing Separators, lift the Separators as much as possible when removing or installing the roller.
  • Page 91 Remove the four Fusing Paper Separators. Remove the Thermistor (TH1). (1 screw) NOTE: Route the harness along the bottom of the Fusing unit when attaching the Thermistor, as shown in the following figure. Remove the Thermostat (TS1). (2 screw) 3727 3727 3727 Fusing Paper Separators...

  • Page 92: Removal Of The Paper Exit Sensor (Ps3)

    4-5-15. Removal of the Paper Exit Sensor (PS3) Remove the Paper Exit Sensor (PS3) from the Fusing Unit. Fusing Unit Paper Exit Sensor (PS3)

  • Page 93: Removal Of The Print Head Unit (Ph)

    4-5-16. Removal of the Print Head Unit (PH) Remove the Duct. (1 screw) Remove the Cover. Unplug the two connectors from PWB-A and remove the harness from the cord hold- ers. Remove the Print Head Unit (PH). (6 screws) 3544 3544 3544 3544...

  • Page 94: Removal Of The Interlock Switch (S2)

    4-5-17. Removal of the Interlock Switch (S2) Remove the Interlock Switch (S2) and unplug two connectors. Orange 3520 3520 Interlock Switch (S2) 4-5-18. Removal of the High Voltage Board (HV1) Remove the High Voltage Board Cover with High Voltage Board. (2 connectors) Remove the High Voltage Board (HV1) from the Cover.

  • Page 95: Removal Of The Power Unit (Pu1)

    4-5-19. Removal of the Power Unit (PU1) Remove the Duplex Connector Holder. (1 screw) Remove the Power Unit (PU1). (3 screws, 6 connectors) 3727 3727 3727 3727 Duplex Connector Holder Power Unit (PU1) 4-5-20. Removal of the Left Frame Remove the Cover Stay Guide. (2 screws) Remove the Left Frame.

  • Page 96: Removal Of The Main Motor (M1), The Print Head Cooling Fan (M5) And The Power Switch (S1)

    4-5-21. Removal of the Main Motor (M1), the Print Head Cool- ing Fan (M5) and the Power Switch (S1) Separate the Drive Unit Cover and the Left Frame. (6 screws) Drive Unit Cover Left Frame...
  • Page 97 Remove the Main Motor (M1). (4 screws) Remove the Print Head Cooling Fan (M5). (2 screws) Remove the Power Switch (S1). (2 connectors) 4012 4012 4012 3435 4012 3435 Main Motor (M1) Power Switch (S1) Print Head Cooling Fan (M5)

  • Page 98: Toner Empty Sensor (Pwb-G)

    4-5-22. Removal of the Paper Empty Sensor (P_ENP1) and Toner Empty Sensor (PWB-G) Remove the Imaging Cartridge Cover. Imaging Cartridge Cover Remove the Paper Empty Sensor (P_ENP1) and unplug the connector. Remove the Toner Empty Sensor (PWB-G) and unplug the connector. Paper Empty Sensor (P_ENP1) Toner Empty Sensor (PWB-G)

  • Page 99: Removal Of The Paper Take-Up Sensor (Ps1)

    4-5-23. Removal of the Paper Take-up Sensor (PS1) Remove the Image Transfer Guide Assembly Image Transfer Guide Assembly. Remove the Paper Take-up Sensor (PS1), and unplug a connector. Paper Take-up Sensor(PS1)

  • Page 100: Removal Of The Jog Motor (M4) And The Jog Position Sensor (Jog_Pos1): 4100Gn Only

    4-5-24. Removal of the Jog Motor (M4) and the Jog Position Sensor (JOG_POS1): 4100GN only Remove the Jog Motor Cover from the Top Cover. (3 screws) 3501 3727 3727 Top Cover Jog Motor Cover Remove the Jog Motor (M4). (2 screws) Remove the Jog Position Sensor (JOG_POS1) and unplug the connector.

  • Page 101: Replacement Of The 2Nd And 3Rd Paper Take-Up Roller

    4-5-25. Replacement of the 2nd and 3rd Paper Take-up Roller Replace the Paper Take-up Roller approximately every 150,000 sheets of print. Separate the printer and 2nd/3rd Paper Casette Unit. As shown in the figure, remove the Paper Take-up Rollers. (1) Pull up on the lever of the roller. (2) Pull it to the right.

  • Page 102: Removal Of The Switchback Motor (M41), The Transfer Motor

    4-5-26. Removal of the Switchback Motor (M41), the Transfer Motor (M42), the Skew Correction Solenoid (SL41) and the Duplex Entrance Sensor (DUP_PSR) Remove the Left Cover of the Duplex Unit. (1 screw) Remove the Board Cover. (2 screw) Remove the Switchback Motor (M41). (2 screws, 1 connector) Remove the Transfer Motor (M42).

  • Page 103: Removal Of The Duplex Exit Sensor (Dup_Ps1)

    4-5-27. Removal of the Duplex Exit Sensor (DUP_PS1) Open the Bottom Cover of the Duplex Unit. (2 screws) Remove the Duplex Exit Sensor (DUP_PS1) and unplug the connector. 3907 3907 Bottom Cover Duplex Exit Sensor (DUP_PS1)

  • Page 104: Removal Of The Duplex Cover Sensor (Dup_Open)

    4-5-28. Removal of the Duplex Cover Sensor (DUP_OPEN) Remove the Rear Cover of the Duplex Unit. (2 shoulder screws, and 1 screw) Remove the Right Cover. (1 screw) Remove the Duplex Cover Sensor (DUP_OPEN) and unplug the connector. 3907 3541 Rear Cover Right Cover Shoulder Screw...

  • Page 105: Adjustment

    5. ADJUSTMENT 5-1. Adjustment of Image Registration After the Mechanical Control Board (PWB-A) is replaced, print an image sample. If the starting position of the image (registration gap (d)=4mm) in the sub-scanning direction is not suitable, adjust the gap by following one of the procedures described below. Remove the right cover so that VR1 of PWB-A can be adjusted.

  • Page 106: Adjustment Of Interlock Switch Position

    5-2. Adjustment of Interlock Switch Position When the Top cover is closed and the power supply does not come back on even though the Power Switch (S1) is turned ON, check and adjust the position of the Interlock Switch (S2) following the procedure below. Remove the left cover, right cover and front cover.

  • Page 107: Troubleshooting

    6. TROUBLESHOOTING 6-1. Paper Misfeed Detection 6-1-1. Overview The printer recognizes if paper remains inside the printer by detecting the status of the Paper Take-Up Sensor (PS1) and the Paper Exit Sensor (PS3). A paper misfeed is detected by the timing that PS1 and PS3 become activated or deactivated. When a paper misfeed is detected, the drive for all elements is stopped, excluding the two following cases.

  • Page 108: Malfunction Detection

    6-2. Malfunction Detection When any of the following problems are detected, all driving units are turned off with the corresponding hardware error issued to the control panel. 6-2-1. Fusing Malfunction (1) The Thermistor detecting temperature has exceeded 240°C/464ºF for 50 msec. during temperature control.

  • Page 109: Troubleshooting For Paper Misfeed

    6-3. Troubleshooting for Paper Misfeed 6-3-1. Paper misfeed occurred when the Power Switch (S1) is turned ON Check Remedy → Paper left in machine. Remove the paper. ↓No → Do the Paper Take-up Sensor (PS1), Correct the Sensor lever movement. the Paper Exit Sensor (PS3), Duplex Duplex Entrance Sensor (DUP_PSR) →...

  • Page 110: Paper Misfeed Occurred At The Paper Exit Section

    6-3-3. Paper misfeed occurred at the paper exit section Check Remedy → Is the Image Transfer Roller Replace the Image Transfer Roller. deformed, worn, or dirty with paper dust? ↓No → Is the Fusing roller deformed, worn, Replace the Fusing Unit. or dirty with paper dust? ↓No →...

  • Page 111: Troubleshooting For Malfunctions (4100E/4100Gn)

    6-4. Troubleshooting for Malfunctions (4100E/4100GN) 6-4-1. No power Check Remedy → Has the Power Switch (S1) been Turn on the Power Switch (S1). turned ON? ↓Yes → Has the Power Cord been securely Plug in the power cord. connected to the printer? ↓Yes →...

  • Page 112: Engine Error (Laser Or Main Motor)

    6-4-3. Engine error (laser or main motor) Check Remedy → The Main Motor (M1) rotates when Replace M1. the Power Switch (S1) is turned ON. Replace PWB-A. ↓Yes → Laser Malfunction Replace the Print Head Unit. Replace PWB-A. Replace PWB-C. 6-4-4.

  • Page 113: Troubleshooting For Malfunctions (4100W)

    6-5. Troubleshooting for Malfunctions (4100W/4110W) 6-5-1. No power Check Remedy → Has the Power Switch (S1) been Turn on the Power Switch (S1). turned ON? ↓Yes → Has the Power Cord been securely Plug in the power cord. connected to the printer? ↓Yes →...

  • Page 114: Engine Error (Fusing Unit Warm-Up Error)

    6-5-3. Engine error (Fusing Unit warm-up error) Check Remedy → Is an error shown after the printer has Replace the Thermistor (TH1) or Fusing completed warming up? Unit. ↓No Replace PWB-A. → Is the Fusing Unit warm? Replace the Thermistor (TH1) or Fusing Unit.

  • Page 115: Engine Error (Hsync)

    6-5-6. Engine error (HSYNC) Check Remedy HSYNC Signal Malfunction Replace the Print Head Unit. Replace PWB-A. Replace PWB-P. 6-5-7. Engine error (main motor) Check Remedy → The Main Motor (M1) rotates when Replace M1. the Power Switch (S1) is turned ON. Replace PWB-A.

  • Page 116: Engine Error (Controller)

    6-5-11. Engine error (Controller) Fatal Error Remedy Controller Malfunction Replace optional SIMM. Replace PWB-A. Replace PWB-P. 6-5-12. I/O error (Parallel, Network) Fatal Error Remedy Parallel Port Malfunction Replace Interface Cable. Replace PWB-P. Network Port Malfunction Replace Network Cable. Replace NIC. Replace PWB-P.

  • Page 117: Image Quality Troubleshooting

    6-6. Image Quality Troubleshooting When an image problem occurs, exchange the Imaging Cartridge for a new one and determine whether the cause of the problem is due to one of the cartridges or something else in the printer. If an image quality problem occurs with the printer, please refer to the following chart to help determine the defective unit.
  • Page 118 Symptom Possible Cause Remedy Blank print Toner Empty in Imaging Replace the Imaging Cartridge. Cartridge Defective PC Drum Replace the Imaging Cartridge. (end of life) Improper laser exposure Replace Print Head. Replace PWB-A. Replace PWB-C. (4100E, 4100GN) Replace PWB-P. (4100W) Poor image transfer Replace the Image Transfer Roller.
  • Page 119 Symptom Possible Cause Remedy Toner smudges on Dust or damage on the Replace the Fusing Unit or backside Fusing Roller. Fusing Roller. Dust or damage on the Replace the Image Transfer Imaging Transfer Roller. Roller. Toner on paper path. Clean the paper path inside of the printer.
  • Page 120 Symptom Possible Cause Remedy White/Black lines and Scratch on the PC Drum. Replace the Imaging Cartridge. bands Defective Print Head Unit. Replace the Print Head Unit. Replace PWB-A. Replace PWB-C. (4100E, 4100GN) Replace PWB-P. (4100W) Offset image Defective Fusing Roller. Replace the Fusing Unit or Fusing Roller.
  • Page 121 ADJUSTMENT 90 Adjustment of Image Registration 90 Adjustment of Interlock Switch Position 91 Before Disassembly Preparation 59 Black print 103 Blank print 103 Cassette Type Detection 40 Component Layout 9 Control Panel Button Function 20 Cooling Fan Motor Malfunction 93 Development 46 Disassembly of the Fusing Unit 73 Disassembly Procedure Chart 58...
  • Page 122 GENERAL INFORMATION 3 I/O error (Parallel, Network) 101 Image Transfer 47 Imaging Cartridge 41 Indicator Lights 18, 22 Indicator Status 19, 23 INSTALLATION 1 Installation Environment 1 Installation Space 2 Installing the Power Supply 1 Instructions for Handling the PWBs with MOS ICs 55 Jog Motor Malfunction (18N only) 93 Jog Tray Function (18N only) 51 Laser Exposure 44...
  • Page 123 Precautions for Handling the Imaging Cartridge 55 Precautions for Handling the Laser Equipment 54 Precautions for Maintenance/Disassembly 54 PWB 28 Removal of the Control Panel 64 Removal of the Controller Board (PWB-C) and the Mechanical Control Board (PWB-A) 65 Removal of the Duplex Cover Sensor (DUP_OPEN) 89 Removal of the Duplex Exit Sensor (DUP_PS1) 88 Removal of the Fusing Unit 72 Removal of the Fusing Unit Cooling Fan (M3) 71...
  • Page 124 Usage Environment 1 Video Interface (Engine I/F) 33 White spots 103 White/Black lines and bands 105...
  • Page 125 Second Paper Cassette Unit 4100GN: Standard 4100W/4110W, 4100E: Option...
  • Page 126 PagePro 4100W/4110W 4100W/4110W...

This manual is also suitable for:

Pagepro 4100gnPagepro 4100ePagepro 4100wPagepro 4110w

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