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Kyocera FS C5020N - Color LED Printer Service Manual

Service manual
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See also: Operating Manual , User Manual
FS-C5020N
FS-C5030N
SERVICE
MANUAL
Published in September 2006
842F3115
2F3SM065
Rev.5

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Summary of Contents for Kyocera FS C5020N - Color LED Printer

  • Page 1: Service Manual

    FS-C5020N FS-C5030N SERVICE MANUAL Published in September 2006 842F3115 2F3SM065 Rev.5...
  • Page 2 Revision history Revision Date Replaced Remarks 13 April 2005 Revised all Combined: 24 ppm printer (2F4) 8 July 2005 1-1-1, 1-1-2, 1-1-3, 1-1-4, 1-3-9, 1-4-10, 1-5-3, 1-5-4, 1-5-5, 1-5-6, 1-5-17, 1-5-18, 1-5-19, 1-5-20, 1-5-25, 1-5-33, 1-6-13, 1-6-23, 1-6-42, 1-6-47, 1-6-49, 1-6-52, 2-1-10, 2-1-16, 2-1-19, 2-1-20, 2-2-2, 2-3-3, 2-4-25 15 December 2005 1-4-12, 1-4-13...
  • Page 3 2F3/2F4-3.0 CONTENTS 1-1 Specifications 1-1-1 Specifications............................1-1-1 1-1-2 Parts names............................1-1-5 (1) Overall ...............................1-1-5 (2) Operation panel..........................1-1-6 1-1-3 Cross section view ..........................1-1-7 1-2 Handling Precautions 1-2-1 Drum 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) ....................1-3-8 1-3-3 Installing a memory card (optional).......................1-3-10 1-3-4 Installing the network interface card (optional) ..................1-3-11...
  • Page 4 2F3/2F4-5 (1) Detaching and refitting the primary transfer unit ................1-6-22 (2) Detaching and refitting the primary transfer belt ................1-6-22 (3) Replacing the primary transfer unit ....................1-6-23 (4) Detaching and refitting the primary transfer cleaning unit ...............1-6-24 1-6-8 Fuser unit (16 ppm printer) ........................1-6-25 (1) Detaching and refitting the fuser unit....................1-6-25 (2) Detaching and refitting the fuser thermistor 1 and 2, fuser thermostat 1 and 2, fuser heater lamp 1 and 2, heat roller, and press roller..................1-6-26...
  • Page 5 2F3/2F4-3.0 2-4 Appendixes 2-4-1 Appendixes .............................2-4-1 (1) Timing chart No. 1 Paper cassette, A4 size (16 ppm printer)............2-4-1 (2) Timing chart No. 2 Paper cassette, Legal size (16 ppm printer) ............2-4-2 (3) Timing chart No. 3 Paper cassette, Letter size (16 ppm printer)............2-4-3 (4) Timing chart No.
  • Page 6 2F3/2F4 This page is intentionally left blank.

  • Page 7: 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 8 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 9: 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 10: Specifications 1

    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 11 • Do not remove the ozone filter, if any, from the printer 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...................... •...
  • Page 12 This page is intentionally left blank.
  • Page 13 2F3/2F4-3.0 1-1 Specifications 1-1-1 Specifications 16 ppm printer (FS-C5020N) Type ..........Desktop Printing system ....... Electrophotographic printing (tandem) Paper type ........Cassette: Plain paper (60 to 90 g/m Recycled paper (60 to 90 g/m Thick paper (90 to 105 g/m MP tray: Plain paper (60 to 90 g/m Recycled paper (60 to 90 g/m Thick paper (90 to 200 g/m...
  • Page 14 2F3/2F4-3.0 Controller hardware ......CPU: Power PC750CXr (400 MHz) System ROM: 8 MB (32 Mbit Font ROM: 2 MB (16 Mbit Main RAM: 128 MB standard (DIMM); expanding up to 1024 MB (512 MB 2) at the maximum by adding optional expansion memory Optional expansion RAM (DIMM): 2 slot (1 slot is used for standard memory) 100-pin DIMM (64, 128, 256 or 512 MB) Interface..........
  • Page 15 2F3/2F4-3.0 24 ppm printer (FS-C5030N) Type ..........Desktop Printing system ....... Electrophotographic printing (tandem) Paper type ........Cassette: Plain paper (60 to 90 g/m Recycled paper (60 to 90 g/m Thick paper (90 to 105 g/m MP tray: Plain paper (60 to 90 g/m Recycled paper (60 to 90 g/m Thick paper (90 to 200 g/m Special paper: Transparencies, labels, envelopes, postcards, tracing paper...
  • Page 16 2F3/2F4-3.0 Controller hardware ......CPU: Power PC750FX (600 MHz) System ROM: 8 MB (32 Mbit Font ROM: 2 MB (16 Mbit Main RAM: 128 MB standard (DIMM); expanding up to 1024 MB (512 MB 2) at the maximum by adding optional expansion memory Optional expansion RAM (DIMM): 2 slot (1 slot is used for standard memory) 100-pin DIMM (64, 128, 256 or 512 MB) Interface..........

  • Page 17: Parts Names 1

    2F3/2F4 1-1-2 Parts names (1) Overall USA/Canada European countries Figure 1-1-1 Top cover 11. Paper gauge 21. Rear cover Magenta toner container 12. Left side cover 22. Fuser cover Cyan toner container 13. Waste toner box 23. Paper feed unit release lever Yellow toner container 14.
  • Page 18 2F3/2F4 (2) Operation panel Figure 1-1-2 u [?] key (Right) Message display 10. p key (Up) Interface indicator (INTERFACE) 11. q key (Down) Paper size indicator (SIZE) Paper type indicator (TYPE) 12. MENU key Ready indicator (READY) 13. ENTER key Data indicator (DATA) 14.
  • Page 19 2F3/2F4 1-1-3 Cross section view 24 ppm printer 16 ppm printer Optional duplexer Optional paper feeders Paper path (Main unit) Paper path (Optional unit) Figure 1-1-3 Black drum unit 12. Magenta toner container Yellow drum unit 13. Primary transfer unit Cyan drum unit 14.
  • Page 20 2F3/2F4 This page is intentionally left blank. 1-1-8...
  • Page 21 2F3/2F4 1-2 Handling Precautions 1-2-1 Drum unit Note the following when handling or storing the drum (drum unit). Note the following when handling or storing the drum unit. • When removing the drum unit, never expose the drum surface to strong direct light. •...
  • Page 22 2F3/2F4 This page is intentionally left blank. 1-2-2...
  • Page 23 2F3/2F4 1-3 Installation 1-3-1 Unpacking and installation (1) Installation procedure Start Unpacking Installing the toner containers Installing the waste toner box Loading paper Connecting the cables Printing a status page for test Completion of the machine installation Figure 1-3-1 1-3-1...
  • Page 24 2F3/2F4 Unpacking. European/Pacific U.S.A./Canada countries Figure 1-3-2 Unpacking Figure 1-3-3 1. Printer 4. Cyan toner container 2. Document and software 5. Yellow toner container Installation guide 6. Black toner container Basic operation guide 7. Waste toner boxes (one is a spare) CD-ROMs 8.
  • Page 25 2F3/2F4 1. Open the top cover and remove the packing item. 2. Remove the packing cover and all packing Top cover tapes. Packing item Packing cover Figure 1-3-4 1-3-3...
  • Page 26 2F3/2F4 Installing the toner containers. 1. Shake the black toner container several times to loosen the toner inside. Black toner container Figure 1-3-5 2. Open the top cover. 3. Install the black toner container into the printer. The black toner container must be installed in the front most developer.
  • Page 27 2F3/2F4 4. Push in the black toner container firmly until it locks in the developer. Black toner container Figure 1-3-7 5. Turn the lock lever backward to the lock position. 6. Install other toner containers in the same Lock lever procedure.
  • Page 28 2F3/2F4 Installing the waste toner box. 1. Open the side cover. 2. Install the waste toner box. 3. Close the side cover. Side cover Waste toner box Figure 1-3-9 Loading paper . 1. Remove the cassette from the printer. 2. Adjust the paper guides and the paper stop- per according to the paper size to be used.
  • Page 29 2F3/2F4 Connecting the cable. 1. Connect the USB, ethernet, or parallel cable between the printer and the computer. 2. Connect the power cord to the printer AC inlet. 3. Connect the power cord to the wall outlet. AC inlet Ethernet Parallel Power cord Figure 1-3-11...
  • Page 30 2F3/2F4 1-3-2 Installing expansion memory (optional) <Procedure> 1. Turn off printer power. Caution: Do not insert or remove expan- sion memory while printer power is on. Doing so may cause damage to the printer and the expansion memory. 2. If a memory card is currently installed in the memory card slot (See the figure), remove the memory card first.
  • Page 31 2F3/2F4-3.0 4. Open the stoppers of the memory socket. 5. Insert the memory so that the two notches of Memory the memory are engaged with the projec- (DIMM) tions of the memory socket. Stopper 6. Close the stoppers of the memory socket. 7.
  • Page 32 2F3/2F4 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 33 2F3/2F4 1-3-4 Installing the network interface card (optional) <Procedure> 1. Turn off printer power. Optional interface slot 2. Remove the two screws and then remove the optional interface slot cover. 3. Insert the network interface card into the optional interface slot. IB-22 4.
  • Page 34 2F3/2F4 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 optional interface slot cover. 3. Insert the hard disk unit into the optional interface slot. 4.
  • Page 35 2F3/2F4 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 --- A4 PLAIN Press the MENU key. Print Menu Map Press the...
  • Page 36 2F3/2F4 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.

  • Page 37: Toner Coverage

    2F3/2F4-5 Service items Description Toner coverage K: Black C: Cyan Number of pages printed coverted M: Magenta Toner coverage (%) in reference to A4 or Letter size. Y: Yellow Toner Coverage / 3.4/Toner Coverage(%) Average K)/13266.4 / 1.1/Toner Coverage(%) Average C)/9277.4 / 1.8/Toner Coverage(%) Average M)/9277.4 / 1.6/Toner Coverage(%) Average Y)/9277.4 / 0.1/ 0.0/ 0.0/ 0.0/(Toner Coverage(%) Last Page /K/C/M/Y/)
  • Page 38 2F3/2F4-5 Service items Description Service information (24 ppm printer) Service information [2F4_1000.013.002/2F4_3000.007.004][C1][22.00A][03/03] Printed page(s) 9690 /P00/S00/U00/F00/N00/D10:DM0301.DAN:0002001001210052 /0020/0020/1061/0811/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ /AAAAAAA/AAAAAAA/ /AAAAAAA/ /AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ /AAAAAAA/ /AAAAAAA/ /0000/0000/0000/0000/0000/ /0000/0000/0000/0000/ /00000000/00000000/00000000/00000000/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ /RS2/[0003-0003]/0/30/88/0/ 00.00.00.00.00.00 A:1234567890123456 /03030303/03030303/03030303/03000000/00000000/03030303/03030303/ SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E SPD2:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E CT01:/0000/0000/0000/0000 CT02:/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000 CT03:/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000...
  • Page 39 Bit 0 = 1: (Fixed) Bit 1 = 0: Overseas, 1: Domestic (Japan) 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 40 2F3/2F4-5 Service items Description Items Description Paper exit position counter /Duplexer/ Drum life counter /Black/Cyan/Magenta/Yellow/ Primary transfer unit life counter Developing units conuter /Black/Cyan/Magenta/Yellow/ Color print counter Maintenance kit counter Optional unit software version /Paper feeder1/Paper feeder 2/Paper feeder 3/Envelope feeder/Duplexer Drum ID /Black/Cyan/ Magenta/Yellow/...
  • Page 41 2F3/2F4-5 Service items Description Items Description Each 2 bytes in the following order: Calibration information 2 (CT02 to CT09) /99.6%/95%/85%/70%/55%/40%/27%/15%/ [I/O output data information] CT02: /S-wave background Magenta/ P-wave background Magenta/ CT03: /S-wave background Cyan/ P-wave background Cyan/ CT04: /S-wave background Yellow/ P-wave background Yellow/ CT05: /S-wave background Black/ P-wave background Black/ CT06: /S-wave patch Magenta/ P-wave patch Magenta/ CT07: /S-wave patch Cyan/ P-wave patch Cyan/...
  • Page 42 2F3/2F4 Service items Description Table 1-4-1 Media type attribute Paper feed source Paper destination Yes/ Type adjust Paper Envelope Duplexer Face- Face- Type default cassette tray feeder down tray up tray Plain Normal2 Transparency Extra Thick NO Preprinted Normal2 Labels Thick1 Bond Normal2...
  • Page 43 2F3/2F4 Service items Description Printing an event log (EVENT LOG) >>Print Event Log Description 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 44 [First byte/second byte (dis- bit 2, 3 (Not used) played in OEM mode only)] bit 4 = 0: Kyocera, 1: OEM bit 5 = 0: For Europe, 1: For US bit 6 = 0: Non MICR mode, 1: MICR mode...
  • Page 45 2F3/2F4 Service items Description Items Description 11: Paper does not pass the registration sensor. [48] 12: Paper remains at the registration sensor when power is turned on. [48] cont. 20: Paper does not arrive at the exit sensor. [48] 21: Paper does not pass the exit sensor. [48] 22: Paper remains at the exit sensor when power is turned on.
  • Page 46 2F3/2F4-4 Service items Description Items Description (c) Detail of paper source (Hexadecimal) cont. 00: MP tray 03: Paper cassette 3 07: Duplexer 01: Paper cassette 1 04: Paper cassette 4 08: Not used 02: Paper cassette 2 05 to 06: Not used 09: Envelope feeder (d) Detail of paper size (Hexadecimal) 01: Monarch...
  • Page 47 2F3/2F4-4 Service items Description Items Description Service Call Count. Service Code (Self diagnostic ellor) Log Remembers 1 to 8th of The total page count at Example occurrence of self diag- the time of the self diag- 01.6000 nostics error. If the nostics error.
  • Page 48 2F3/2F4 Service items Description Execution of color calibration >>Color Calibration Description Executing the density of color using. Purpose To carry out color calibration manually besides it can be carried out automatically each time the printer is turned on. Procedure 1. Enter the service mode [>>Color Calibration]. 2.
  • Page 49 2F3/2F4-5 Service items Description Counter reset for the maintenance kit >>Maintenance Description The "Install MK" message means that maintenance kit should be replaced at 200,000 images of printing. The interval counter must be manually reset using this service item. Maintenance kit includes the following units: 16 ppm printer 24 ppm printer For USA/...
  • Page 50 2F3/2F4 Service items Description Setting the paper feed operation (printer driver priority mode) >>Paper feed Description With printer driver priority mode, when selecting the specific paper feed location (a cassette or MP tray) with the printer driver (it is not automatic selection), paper is fed from the selected location.
  • Page 51 2F3/2F4 Service items Description Drum surface refreshing >>Drum Description Rotates the drum approximately 3 minutes with toner lightly applied onto the drum using the high-voltage output contorl of the engine contorller PWB. The cleaning blade in the durm unit scrapes toner off the drum surface to clean it. Purpose To clean the drum surface when image failure occurs due to contamination.
  • Page 52 2F3/2F4 1-4-2 Maintenance (1) Method of removing the toner soiling which comes in contact with heat roller and press roller/belt When misfeeding has occurred in the fuser unit, misfeed paper can coil around the heat roller or the press roller/belt. Removing the misfed paper will cause, there are times when the toner soiling remains in the heat roller or the press roller/belt).
  • Page 53 2F3/2F4 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 operation panel. To remove paper misfed in the printer, pull out the paper cassette, pull out the paper feed unit or open the rear cover.
  • Page 54 2F3/2F4 (2) Paper misfeed detection Paper full sensor MP paper sensor Exit sensor Registration sensor Paper path Figure 1-5-1 Paper misfeed detection 1-5-2...
  • Page 55 2F3/2F4-3.0 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 operation panel. An error message consists of a message prompting a contact to service personnel, total print count, and a four-digit error code (2 digits for F0 only) indicating the type of the error.
  • Page 56 2F3/2F4-3.0 Remarks Code Contents Causes Check procedures/corrective measures 0460 Duplexer communication error Defective engine Replace the engine controller PWB (A0004). • When turning on power, the ASIC of controller PWB See page 1-6-41. the engine controller PWB (A0004) (A0004). recognized the optional duplexer DU- Defective duplexer After removing or replacing the duplexer 300/301, but when it becomes not be...
  • Page 57 2F3/2F4-3.0 Remarks Code Contents Causes Check procedures/corrective measures 0951 LED print head 4 (EEPROM) commu- Defective LED print Replace the LED print head 4. See page 1- nication error [black drum unit] head 4. 6-15. • The LED print head 4 (EEPROM) of Installing the LED Install the compatible LED print head to the the black drum unit does not communi-...
  • Page 58 2F3/2F4-3.0 Remarks Code Contents Causes Check procedures/corrective measures 0953 LED print head 1 (EEPROM) commu- Defective LED print Replace the LED print head 1. See page 1- nication error [magenta drum unit] head 1. 6-15. • The LED print head 1 (EEPROM) of Installing the LED Install the compatible LED print head to the the magenta drum unit does not com-...
  • Page 59 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 1200 Side registration motor error Defective duplexer Refer to the duplexer DU-300/301's service • The duplexer PWB of the optional DU-300/301. manual. duplexer cannot detect the home posi- Defective engine Replace the engine controller PWB (A0004). tion of the adjust guide.
  • Page 60 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 5302 Eraser lamp 2 error (cyan drum unit) Defective eraser Replace the eraser lamp 2 [PWB] (KP- • The eraser lamp 2 [PWB] (KP-1090) of lamp 2 [PWB] (KP- 1090). the cyan drum unit does not communi- 1090).
  • Page 61 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 5303 Eraser lamp 1 error (magenta drum Defective eraser Replace the eraser lamp 1 [PWB] (KP- unit) lamp 1 [PWB] (KP- 1090). • The eraser lamp 1 [PWB] (KP-1090) of 1090). the magenta drum unit does not com- Defective engine Replace the engine controller PWB (A0004).
  • Page 62 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 5304 Eraser lamp 3 error (yellow drum unit) Defective eraser Replace the eraser lamp 3 [PWB] (KP- • The eraser lamp 3 [PWB] (KP-1090) of lamp 3 [PWB] (KP- 1090). the yellow drum unit does not commu- 1090).
  • Page 63 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 6000 Fuser temperature time-out error Defective installa- Check the installation condition of fuser ther- (heat roller) tion condition of mistor 1, if there is trouble, remedy or • Doing the control which turns on the fuser thermistor 1.
  • Page 64 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 6020 Fuser abnormal high temperature Defective engine Replace the engine controller PWB (A0004). error (heat roller) controller PWB See page 1-6-41. • Abnormal high fuser temperature of (A0004). the heat roller was detected. Defective fuser Replace the fuser PWB (KP-970* /A0003*...
  • Page 65 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 6100 Fuser temperature time-out error Defective installa- Check the installation condition of fuser ther- (press roller) tion condition of mistor 2, if there is trouble, remedy or (16 ppm • Doin g the control which turns on the fuser thermistor 2.
  • Page 66 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 6130 Fuser thermistor 2 broken error Defective engine Replace the engine controller PWB (A0004). (press roller) controller PWB See page 1-6-41. (16 ppm • It was judged it has been broken from (A0004).
  • Page 67 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 7002 Toner motor 2 overcurrent detection Defective toner Replace the toner motor 2. See page 1-6- error (cyan toner) motor 2. • The engine controller PWB (A0004) Defective engine Replace the engine controller PWB (A0004). detected the overcurrent of toner controller PWB See page 1-6-41.
  • Page 68 2F3/2F4 Remarks Code Contents Causes Check procedures/corrective measures 7402 Cyan developer unit non- installing Defective harness Check the damage of harness of the toner error of the toner sensor sensor 2, check the connection of the con- • The toner sensor 2 inside the cyan 2, defective con- nector with the cyan developer unit and developer unit did not output the den-...
  • Page 69 2F3/2F4-3.0 Remarks Code Contents Causes Check procedures/corrective measures 7404 Yellow developer unit non- installing Defective harness Check the damage of harness of the toner error of the toner sensor sensor 3, check the connection of the con- • The toner sensor 3 inside the yellow 3, defective con- nector with the yellow developer unit and the developer unit did not output the den-...
  • Page 70 2F3/2F4-3.0 Remarks Code Contents Causes Check procedures/corrective measures 7412 Cyan drum unit non- installing error Defective harness Check the connection of the cyan drum unit • The EEPROM (U401) on the drum between drum and the printer main unit, check the continu- PWB 2 (KP-972) inside the cyan drum PWB 2 (KP-972) ity of the harness (S02867), if there is trou-...
  • Page 71 2F3/2F4-3.0 Remarks Code Contents Causes Check procedures/corrective measures 7414 Yellow drum unit non- installing error Defective harness Check the connection of the yellow drum • The EEPROM (U401) on the drum between drum unit and the printer main unit, check the con- PWB 3 (KP-972) inside the yellow PWB 3 (KP-972) tinuity of the harness (S02867), if there is...
  • Page 72 2F3/2F4-3.0 Remarks Code Contents Causes Check procedures/corrective measures D020 Engine firmware error Malfunction of the Turn the power off/on to restart the printer. • engine firmware or If the error is not resolved, check the update Serious status inconsistency that is fatal to keep controlling in the engine defective engine information on the engine firmware.

  • Page 73: Electrical Problems 1

    2F3/2F4 1-5-3 Electrical problems Problem Causes Check procedures/corrective measures Right edge of the top cover Close the top cover securely. "Close top cover" floating, it is not closed display is not completely. cancelled to closing Defective top cover switch Replace the top cover switch 2. the top cover.

  • Page 74: Cassette

    2F3/2F4 Problem Causes Check procedures/corrective measures Defective top cover/paper Replace the sensor PWB (A0001). "Close paper trans- feed unit switch (SW701) of fer unit" display is not the sensor PWB (A0001). cancelled to closing Malfunctioning interlock rod Check to see if the interlock rod malfunctions. If it malfunctions, the paper feed unit.
  • Page 75 2F3/2F4 Problem Causes Check procedures/corrective measures Defective cassette size Replace the cassette size switch. The paper size is not switch. recognized as the Defective sensor PWB Replace the sensor PWB (A0001). size set with the (A0001). paper size dial. Defective harness (S02861) Check the continuity of the harness (S02861), check the connec- between cassette size tion YC703 connector of sensor PWB (A0001), if there is trouble,...
  • Page 76 2F3/2F4 1-5-4 Image formation problems (1) No image (2) No image (3) A specific color (4) The back side (5) Image is too appears appears is printed solid. gets dirty. light. (entirely white). (entirely black). See page 1-5-25. See page 1-5-25. See page 1-5-26.
  • Page 77 2F3/2F4-3.0 (1) No image appears (entirely Causes white). 1. The LED print head has not done functioning. 2. Defective developing sleeve bias or developing magnet bias output. 3. Defective secondary transfer bias output. 4. Malfunction of the developer installation. Causes Check procedures/corrective measures 1.
  • Page 78 2F3/2F4 (3) A specific color is printed solid. Causes 1. Defective main charger unit which corresponds to the color causing the prob- lem. 2. Disconnected main charger wire. Causes Check procedures/corrective measures 1. Defective main charger unit which corre- Check if the main charger unit is properly seated. If necessary, reseat it sponds to the color causing the problem.
  • Page 79 2F3/2F4 (5) 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. Causes Check procedures/corrective measures 1. Defective developing bias output. A. Defective developer. Check the four colors of image by using the test print of service mode. If the defect appears on a particular color, replace the developer for that color.
  • Page 80 2F3/2F4 (6) The background is colored. Causes 1. Defective developing sleeve bias output. 2. Defective primary transfer cleaning unit. 3. Defective color calibration. Causes Check procedures/corrective measures 1. Defective developing sleeve bias output. A. Defective developer. Check the four colors of image by using the test print of service mode. If the defect appears on a particular color, replace the developer for that color.
  • Page 81 2F3/2F4 (7) White streaks are printed Causes vertically. 1. Defective LED print head output. 2. Defective main charging output. 3. Foreign object in one of the developers. 4. Adhesion of soiling to primary transfer belt. Causes Check procedures/corrective measures 1. Defective LED print head output. A.
  • Page 82 2F3/2F4 (8) Black streaks are printed Causes vertically. 1. Dirty main charger wire. 2. Poor insertion of the main charger wire cleaner. 3. Dirty or flawed drum. 4. Deformed or worn cleaning blade in the drum unit. 5. Defect fur brush of the primary transfer cleaning unit. 6.
  • Page 83 2F3/2F4 (10) Spots are printed. Causes 1. Dirty or flawed drum. 2. Deformed or worn cleaning blade in the drum unit. 3. Defect fur brush of the primary transfer cleaning unit. 4. Flawed developing sleeve roller. 5. Dirty heat roller and press roller* /belt* Causes Check procedures/corrective measures...
  • Page 84 2F3/2F4 (12) Paper is wrinkled. 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. (13) Offset occurs. Causes 1.
  • Page 85 2F3/2F4-3.0 (15) Fusing is loose. Causes 1. Wrong types of paper. 2. Defective pressure for the heat roller and press roller (press belt). 3. Flawed heat roller or press roller* /belt* Causes Check procedures/corrective measures 1. Wrong types of paper. Check if the paper meets specifications, replace paper.
  • Page 86 2F3/2F4 This page is intentionally left blank. 1-5-34...
  • Page 87 2F3/2F4-5 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, 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 88: Figure 1

    2F3/2F4 1-6-2 Outer covers (1) Detaching and refitting the top cover Procedure 1. Open the rear cover. 2. Open the top cover. 3. Remove the opening and closing axis from the main unit frame and then remove the upper cover. Top cover Figure 1-6-1 1-6-2...
  • Page 89 2F3/2F4 (2) Detaching and refitting the rear cover Procedure 1. Open the rear cover. 2. Remove the opening and closing axis from the main unit frame and then remove the rear cover. Rear cover Figure 1-6-2 1-6-3...
  • Page 90 2F3/2F4 (3) Detaching and refitting the right cover Procedure 1. Remove the top cover (See page 1-6-2). Screw 2. Remove the one screw. Right cover Figure 1-6-3 3. Remove the paper feed unit (See page 1-6-6). 4. Using a flat blade screwdriver, unlatch the Right cover right cover at the nine positions as shown in the diagram.
  • Page 91 2F3/2F4 (4) Detaching and refitting the left cover Procedure 1. Remove the top cover (See page 1-6-2). Open the left side cover and then remove the one screw. Left cover Waste toner box 3. Remove the waste toner box. To remove Lock lever waste toner box, press the lock lever in.
  • Page 92 2F3/2F4 1-6-3 Paper feed unit (1) Detaching and refitting the paper feed unit Procedure 1. Pull out the paper feed unit until stop. 2. While pressing the left and right lock release buttons and then remove the paper feed unit. Lock release button Lock release button...
  • Page 93 2F3/2F4 (2) Detaching and refitting the paper feed roller Procedure 1. Remove the paper feed unit (See previous page). 2. Turn over the paper feed unit. Latches 3. While pushing the lock release buttons and then detach the joint. 4. Unlatch the latches and then remove paper feed roller unit.
  • Page 94 2F3/2F4 (3) Detaching and refitting the retard roller Procedure 1. Remove the paper cassette. 2. Unlatch the two latches and then remove the retard roller holder. 3. Remove the retard roller from retard roller Retard roller holder. Retard Paper cassette roller 4.
  • Page 95 2F3/2F4 (4) Detaching and refitting the secondary transfer roller Procedure 1. Remove the paper feed unit (See page 1-6- 2. Removing the hook by sliding and then remove the paper chute. 3. Remove the secondary transfer roller. 4. Remove the transfer roller gear. 5.
  • Page 96 2F3/2F4 1-6-4 MP tray feed unit (1) Detaching and refitting the MP tray feed unit Procedure 1. Remove the paper feed unit (See page 1-6- Latch 2. Remove the paper right cover (See page 1- 6-4). 3. Remove the main high voltage PWB (See page 1-6-45).
  • Page 97 2F3/2F4 (2) Detaching and refitting the MP tray feed roller Procedure 1. Remove the paper feed unit (See page 1-6-6). 2. Pull up the MP tray holder and then sliding 3. Remove the MP tray feed roller. 4. Check or replace the MP tray feed roller and then refit all the removed parts.
  • Page 98 2F3/2F4 1-6-5 Developing section (1) Detaching and refitting the developer unit Procedure 1. Open the top cover. 2. Remove the one connector. 3. While releasing two release levers and then remove the developer unit. (Use the same Release lever Connector procedure for other developers.) Release lever Developer unit...
  • Page 99 2F3/2F4-3.0 1-6-6 Drum section Connector cover (1) Detaching and refitting the drum unit (Magenta) To replace the drum unit and the engine controller Connector cover PWB at the same time, turn on the printer after (Cyan) replacing either one. Check that the printer operates properly and then turn off the printer.
  • Page 100 2F3/2F4 5. While releasing two release levers and then remove the drum unit. (also 4 colors with the Release lever same procedure, there is no order.) Drum unit (Yellow) 6. Check or replace the drum unit and then refit all the removed parts. Release lever (Magenta) Drum unit...
  • Page 101 2F3/2F4 (2) Replacing the LED print head and drum unit Replacement kit (packing contents) Drum unit 16 ppm 24 ppm printer printer Remark Item DK-510 DK-520 Drum unit FFC (white) FFC (blue) With conductive FFC (blue) tape (for black) LED print head Conductive tape 16 ppm 24 ppm...
  • Page 102 2F3/2F4 6. Turn the release lever and remove the drum unit. Figure 1-6-20 Hook 7. Remove the three hooks and then remove Hook the LED print head cover from the drum unit. 8. Remove the FFCs form the LED print head Hook cover.
  • Page 103 2F3/2F4 10. Unlock the connector hook on the LED print head and then pull the white FFC out. 11. Using the same procedure, pull the blue FFC out. UNLOCK UNLOCK Figure 1-6-23 12. Insert the new blue FFC vertically into the connector.
  • Page 104 2F3/2F4 13. Turn the connector hook down to lock the new blue FFC. 14. Using the same procedure, connect the new white FFC to the connector. LOCK Figure 1-6-25 LED print head 15. Attach the LED print head into the new drum unit.
  • Page 105 2F3/2F4 17. Pass the blue and white FFCs to opening of the LED print head cover. 18. Store the FFCs in the crevice between LED print head (metal) and sponge. 19. Close the LED print head cover and hold the three hooks.
  • Page 106 2F3/2F4 Release lever Drum unit 21 . Refit the drum unit into the printer, and lock the release levers. Release lever Figure 1-6-30 FFC connectors LED print heads 22. Connect one connector. relay PWB 23. Insert the blue and white FFCs horizontally to the FFC connectors (LED print heads relay PWB).
  • Page 107 2F3/2F4 24. Refit the connector cover. 25. Refit the developer units and toner contain- ers to the printer. 26. Close the top cover. (Magenta) Connector cover (Cyan) (Black) (Yellow) Figure 1-6-32 27. Turn the power on. Print a test page - selected from the service mode MENU of the operation panel.
  • Page 108 2F3/2F4-5 1-6-7 Primary transfer section (1) Detaching and refitting the primary transfer unit Procedure Primary transfer unit (belt) 1. Remove the all drum units (See page 1-6- 13). 2. Pull two handles and raise. Handle 3. Remove the primary transfer unit with the Handle handles.
  • Page 109 2F3/2F4-5 (3) Replacing the primary transfer unit NOTE: Check that the engine firmware version of the 16 ppm printer is 004.004 or later, and then replace the primary transfer unit. Procedure Primary transfer unit (belt) Connect the power cord and then turn on the power switch.
  • Page 110 2F3/2F4-5 (4) Detaching and refitting the primary transfer cleaning unit Procedure 1. Remove the primary transfer unit (See page 1-6-16). 2. Pull out the primary transfer cleaning unit from the main unit frame a little with under- neath the right 3.
  • Page 111 2F3/2F4 1-6-8 Fuser unit (16 ppm printer) (1) Detaching and refitting the fuser unit Procedure 1. Remove the rear cover (See page 1-6-3). 2. Remove the right cover and left cover (See page 1-6-4, 1-6-5). 3. Remove the two screws and then remove the fuser unit.
  • Page 112 2F3/2F4 (2) Detaching and refitting the fuser thermistor 1 and 2, fuser thermostat 1 and 2, fuser heater lamp 1 and 2, heat roller, and press roller Procedure 1. Remove the fuser unit (See previous page). 2. While two latches unlatching, remove the fuser bottom cover by making slide.
  • Page 113 2F3/2F4 5. Remove the three connectors from the fuser PWB. 6. Remove the one tab. 7. While unlatching the latches and then remove the fuse unit connector. 8. Remove the terminal. Latch Fuser PWB Connectors Latch Fuser unit connector Connector Terminal Figure 1-6-39 9.
  • Page 114 2F3/2F4 10. Remove the one screw and then remove the fuser right cover. 11. Remove the fuser heater lamp 1 and 2. Fuser heater lamp 1 (Heat roller: 500 W) Fuser heater lamp 2 (Press roller: 350 W) Screw Fuser right cover Figure 1-6-41 12.

  • Page 115: Table Of Contents

    2F3/2F4 15. Remove the two screws and then remove Screws the fuser thermostat 1. 16. Remove the one screw and then remove the fuser thermistor 1. Fuser thermostat 1 Fuser upper cover Fuser thermistor 1 Screw Figure 1-6-43 17. Remove the user lower guide. Screws 18.

  • Page 116: Figure

    2F3/2F4 21. Remove the one C-ring, fuser gear, one C- ring, one bush and, one bearing. 22. Remove the one C-ring, one bush and, one bearing. 23. Remove the heat roller. C-ring Fuser gear C-ring Heat roller Bush Bearing Bearing Bush C-ring Figure 1-6-45...

  • Page 117: Figure

    2F3/2F4 24. Remove the two bushes and two bearings. 25. Remove the right stay, left stay and press roller. 26. Check or replace the fuser thermistor 1 and 2, fuser thermostat 1 and 2, fuser heater lamp 1 and 2, heat roller and, press roller then refit all the removed parts.

  • Page 118: Remove The Two Screws And Then Remove

    2F3/2F4 1-6-9 Fuser unit (24 ppm printer) (1) Detaching and refitting the fuser unit Procedure 1. Remove the rear cover (See page 1-6-3). 2. Remove the right cover and left cover (See page 1-6-4, 1-6-5). 3. Remove the two screws and then remove the fuser unit.
  • Page 119 2F3/2F4 (2) Detaching and refitting the fuser thermistor 1, fuser thermostat 1, fuser heater lamp, heat roller, and press belt Procedure 1. Remove the fuser unit (See previous page). 2. Remove the one screw and then the termi- nal and nut. Screw Terminal Figure 1-6-48...
  • Page 120 2F3/2F4 6. Remove the one tab from the terminal. 7. Remove the Lamp hold seal L. 8. Remove the wire form the two wire clamps. 9. Remove the one screw. 10. While unlatching the latch and then detach the fuser R cover. 11.

  • Page 121: Fuser Thermostat 1

    2F3/2F4 14. Remove the one tab from the terminal. 15. While removing the fuser UP cover and then Screws remove the wire. 16. Remove the one screw and then remove the fuser thermistor 1. 17. Remove the two screws and then remove the fuser thermostat 1.
  • Page 122 2F3/2F4 18. While sliding (direction of the arrow ) the exit guide and then detach the axis. 19. While detaching the axis and then remove the exit guide. Axis hole Axis Spring Axis hole Axis Exit guide Spring Figure 1-6-52 20.
  • Page 123 2F3/2F4 22. Remove the two press plates and two pressure springs. Press plate Pressure spring Press plate Pressure spring Figure 1-6-54 23. Remove the two screws and then remove Screw the fuser B stay. 24. Remove the two screws and then remove Screw the fuser C stay.
  • Page 124 2F3/2F4 25. Remove the press belt assembly. Press belt assembly Figure 1-6-56 26. Remove the two roller holders with pitch Roller holder plates. Pitch plate 27. Remove the belt roller A and belt roller. 28. Remove the each two bearings. Bearings Belt roller A Belt roller A...
  • Page 125 2F3/2F4 29. Remove the two screws and then remove the exit UP guide. Remove the two C-rings. Remove the stopper ring and heat Z43S gear. Remove the two bearings. 33. Remove the heat roller with bushes. 34. Remove the two bushes from heat roller. Bush Heat roller C-ring...
  • Page 126 2F3/2F4 1-6-10 PWBs (1) Detaching and refitting the main controller PWB Procedure 1. Turn off the power switch and then remove the power cord. 2. When the optional memory card has been installed in the memory card slot already, remove that. 3.
  • Page 127 2F3/2F4-3.0 (2) Detaching and refitting the engine controller PWB and power supply PWB To replace the engine controller PWB and the Connectors drum unit at the same time, turn on the printer after replacing either one. Check that the printer operates properly and then turn off the printer.
  • Page 128 2F3/2F4 8. Remove the six screws and then remove the controller box cover. Screws Controller box cover Screws Figure 1-6-62 9. Remove the five screws. 10. Remove the two* /three* connectors and Connector then removing the connection with the power supply PWB, remove the engine controller PWB.
  • Page 129 2F3/2F4 11. The EEPROM (U12) removing from the EEPROM (U12) socket of the old engine controller PWB, it does again to install in the socket of the new engine controller PWB. Engine controller PWB Figure 1-6-64 12. Remove the three screws, one terminal, one washer and then remove the power supply PWB.
  • Page 130 2F3/2F4 (3) Detaching and refitting the LED print heads relay PWB Procedure 1. Remove the left cover (see page 1-6-4). 2. Remove the one screw. 3. Remove the two connectors and two tabs. 4. Unlatch the four latches and then remove the LED print heads relay PWB.
  • Page 131 2F3/2F4 (4) Detaching and refitting the main high voltage PWB Procedure 1. Remove the right cover (See page 1-6-4). 2. Unlatch the four latches and remove the one connector and then remove the main high voltage PWB. 3. Check or replace the main high voltage PWB and then refit all the removed parts.
  • Page 132 2F3/2F4 (5) Detaching and refitting the bias high voltage PWB Procedure 1. Remove the right cover (See page 1-6-4). 2. Unlatch the five latches and remove the two connectors and then remove the bias high voltage PWB. 3. Check or replace the bias high voltage PWB and then refit all the removed parts.
  • Page 133 2F3/2F4-3.0 1-6-11 Others (1) Detaching and refitting the main drive unit Procedure 1. Remove the right cover (See page 1-6-4). 2. Remove the nine connectors from the main drive unit. 3. Remove the one connector. 4. Remove the six screws and four terminals then remove the main drive unit.
  • Page 134 2F3/2F4 (2) Detaching and refitting the paper feed drive unit Procedure 1. Remove the right cover (See page 1-6-4). Connectors 2. Remove five connectors. 3. Remove the harness from the two wire hooks. Wire hooks Connectors Figure 1-6-70 4. Remove the three screws and then remove the paper feed drive unit.
  • Page 135 2F3/2F4-3.0 (3) Detaching and refitting the fuser drive unit Procedure 1. Remove the right cover (See page 1-6-4). 2. Remove the main drive unit (See page 1-6-47). 3. Remove the one connector. 4. Remove the two screws and the remove the fuser drive unit.
  • Page 136 2F3/2F4 (4) Detaching and refitting the toner motor 1, 2, 3 and 4 Procedure 1. Remove the right cover (See page 1-6-4). 2. Remove the one connector. 3. Remove the hole which is inserted into the Toner motor (Black) projection of main unit frame side, slide Hooks toner motor 4 to up in order to remove the hook.
  • Page 137 2F3/2F4 (5) Detaching and refitting the ozone filters Procedure 1. Open the top cover. 2. Remove the ozone filters from the ozone fan motor 1 and 2. 3. Check or replace the ozone filters and then Ozone filters refit all the removed parts. Ozone fan motor 2 Ozone fan motor 1 Figure 1-6-74...
  • Page 138 2F3/2F4-3.0 (6) Detaching and refitting the waste toner duct Procedure 1. Remove the primary transfer unit (See page 1-6-22). 2. Remove the primary transfer cleaning unit (See page 1-6-24) 3. Unlatch the three latches and then remove the waste toner duct. 4.
  • Page 139 2F3/2F4 1-7 Firmware 1-7-1 Downloading firmware The system firmware can be update by downloading new firmware. Downloading can be made either by directly sending the new firmware from PC via the parallel interface or using a memory card that contains the new firmware. Firmware file name example S2F3_1000001021.cmp Software ID...
  • Page 140 2F3/2F4 (1) Downloading the firmware from the parallel interface To download the system firmware using the parallel interface, use the procedure below. Note that you can download both the system and engine firmware at a time. 1. Turn printer and PC power off. 2.
  • Page 141 2F3/2F4 (2) Downloading the firmware from the memory card The procedure below provides how to download firmware from a memory card. Note that you can download both the sys- tem and engine firmware at a time. 1. Turn printer power off. 2.
  • Page 142 2F3/2F4 10. Confirm that the printer's power switch is set to off. 11. Insert the memory card into the printer's memory card slot. Memory card slot Memory card Memory card slot Figure 1-7-7 12. Turn printer power on. Power switch: On 13.
  • Page 143 2F3/2F4 2-1 Mechanical Construction 2-1-1 Paper feed section There is paper feed from the paper cassette which can load paper 500 and paper feed from the MP tray which can load paper 100 in paper feed method of this printer. The paper feed section is composed of paper cassette, paper feed unit, paper feed drive unit, MP tray and, MP tray feed unit.
  • Page 144 2F3/2F4 The paper size dial has predetermined patterns of activating the paper size switches using concaves and convexes according to paper sizes. SW1, SW2, and SW3 produce corresponding signals for paper sizes. Engine controller PWB Sensor PWB CAS0 CAS0 CAS1 CAS1 Paper size dial CAS2...
  • Page 145 2F3/2F4 Paper gauge sensing circuit The actuator which has a light reflector at one end keeps tracking of the height of the paper stack in the paper cassette. The angle of the reflector varies according to the actuator angle which means the amount of paper remaining. As the reflector moves across the detecting surface of paper gauge sensor (photo interrupter) 1 and 2, the on and off states of these sensors vary in combination as shown in the table below, allowing to determine the amount of remaining paper in the cassette.
  • Page 146 2F3/2F4 Secondary Upper transfer roller registration roller Lower registration roller Guide rollers To fuser unit From paper cassette Feed roller Pickup roller Figure 2-1-5 Paper feed unit Engine controller PWB Feed clutch FEDCLDR YC11-6 Registration clutch REGCLDR YC11-4 Feed motor STFDA YC11-14 STFDAN...
  • Page 147 2F3/2F4 (2) Paper feeding from MP tray The MP tray bottom which is driven by the MP feed solenoid press the paper against the MP feed roller. The sheet is rewound to the MP feed roller, then forward to the registration roller by means of the MP middle roller. Figure 2-1-7 MP tray paper feed section MP frame MP middle tray...
  • Page 148 2F3/2F4 Engine controller PWB MP feed solenoid MPSOLDR YC11-8 Feed motor STFDA YC11-14 STFDAN YC11-15 STFDB YC11-16 STFDBN YC11-17 Figure 2-1-9 MP tray paper feed section block diagram 2-1-6...
  • Page 149 2F3/2F4 2-1-2 Developing section (1) Developer unit Developing section is composed of mixer screw, developing blade, developing magnet roller and, developing sleeve. Figure 2-1-10 Developer unit Developing sleeve Mixer screw A Developing magnet roller Developer case Doctor blade Developer lid Mixer screw B Developer case Toner sensor...
  • Page 150 2F3/2F4 : Developing magnet roller Black developer : Developing sleeve : Toner sensor Output* Output* Output* Engine controller PWB Developing Yellow HVCLK1 sleeve bias developer YC5-2 HVCLK2 output circuit YC5-3 HVCLK3 YC5-4 HVCLK4 Output* YC5-5 Output* HVBDATD YC5-6 HVBCLKD converter Cyan YC5-7 HVBLATD...
  • Page 151 2F3/2F4 (2) Touch down developing method Touchdown development system is a development system having the best of both mono-component system and dual component system. Dual component developer which is a powder of mixture of toner and carrier powder is continuously agitated by mixer screws A and B in the toner hopper in the developer unit.
  • Page 152 2F3/2F4-3.0 (3) Developer drive stop mechanism Developer drive stop mechanism detaches the drive transmission of developers other than black developer at the time of monochrome printing and makes stop, drives only black developer due to the movable part and the operation of developer drive stop motor with idle plate lever, cam lever, cam gear and idle arm plate etc.
  • Page 153 2F3/2F4 2-1-3 Drum section The drum unit includes a photoconductive drum, eraser lamp, LED print head, cleaning blade and, a main charger unit. The drum unit is removable with the main charger unit. (1) Drum unit The tandem development system uses four drum units which are isomorphic to each other, in cyan, magenta, yellow, and black colors.
  • Page 154 2F3/2F4 Eraser lamp [PWB] LED print head Waste toner exit screw Cleaning blade Drum : Waste toner flow To waste toner duct Figure 2-1-16 Drum unit 2-1-12...
  • Page 155 2F3/2F4 LED print heads relay PWB VTXDP0 to 11 VTXDN0 to 11 YC2-11 to 20, 27 to 40 : LED print head (LPH PWB) 1, 2, 3, 4 VTXCLKN, P Main YC2-31, 32 controller : Elaser lamp [PWB] 1, 2, 3, 4 VRXDP0 ,1 VRXDN0 ,1 : Drum PWB 1, 2, 3, 4...
  • Page 156 2F3/2F4 (2) Waste toner ejecting mechanism The waste toner which is ejected from the drum units drops on the waste toner conveyer through a duct. The waste toner is conveyed towards the primary transfer cleaning unit, finally stored in the waste toner box. Primary transfer cleaning unit From...
  • Page 157 2F3/2F4 (3) LED print head The LED print head is comprised of SELFOC lens array, and an LPH PWB. The LPH PWB arrays 5184 of LED chips in line. It also includes the driver circuit for the LED chips. The light which is switched on and off depending on video data irradiate the drum through the SELFOC lens, to form an image.
  • Page 158 2F3/2F4-3.0 Data to print is processed by the main controller PWB and transferred to the LED print head relay PWB in synchronization with VIDEO signal through the engine controller PWB. VIDEO signal is sent from ASIC (U22) on the mail controller PWB to ASIC (U1) on the LED print head relay PWB using LVDS method.
  • Page 159 2F3/2F4 (4) Main charger unit Main charger unit is comprised of the main charger wire, main charger grid, main charger shield, and the main charger cleaner which are modularized and fitted to the drum unit. Figure 2-1-21 Main chrger wire Main charger grid Main charger shield Main charger cleaner...
  • Page 160 2F3/2F4 Main high voltage PWB Main charger unit Output* Shield Wire Grid Engine controller PWB Zener PWB 1 Drum MCH1DR YC1-2 YC6-2 MCH2DR YC1-3 YC6-3 MCH3DR YC1-4 YC6-4 MCH4DR Magenta drum unit YC1-5 YC6-5 Main charger unit Output* Shield Main high voltage Wire output circuit...
  • Page 161 2F3/2F4-3.0 2-1-4 Primary transfer section Primary transfer section is composed of the primary transfer unit and primary transfer cleaning unit. (1) Primary transfer unit The primary transfer unit is comprised of the primary transfer belt, tension rollers, and four primary transfer rollers of col- ors.
  • Page 162 2F3/2F4-3.0 Figure 2-1-26 Tension roller Primary transfer roller (black) Backup roller Primary transfer belt Drive base Backup gear 29H Primary transfer roller (magenta) (10) Image gear 22H Primary transfer roller (cyan) (11) Image gear 28S Primary transfer roller (yellow) (12) Toner ID sensor (mounted on the main frame) (Black) (Cyan) (Yellow)
  • Page 163 2F3/2F4 (2) Primary transfer cleaning unit The primary transfer cleaning unit is composed of the fur brush, brush cleaning roller, cleaning blade and, cleaning screw. After secondary transferring is done, the toner which remains in the primary transfer belt is collected back in the waste toner box.
  • Page 164 2F3/2F4 Fur brush Brush cleaning roller Cleaning frame Engine controller PWB Main high voltage PWB YC1-7 HVADATD Fur brush YC6-6 Output 500 V DC converter YC1-8 HVACLKD bias output YC6-7 (IC501) circuit YC1-9 HVALATD YC6-8 Figure 2-1-29 Primary transfer cleaning unit block diagram From waste toner duct : Waste toner flow...
  • Page 165 2F3/2F4 A full color image is developed by recoating four colors on the primary transfer belt. If the density of each color is not kept constant, the resultant color image will be deteriorated. The toner ID sensor mounted on the primary transfer belt to the printer main unit side maintains the constant color fidelity.
  • Page 166 2F3/2F4 2-1-5 Secondary transfer and separation section The secondary transfer and separation section includes the secondary transfer roller which is installed on the paper feed unit. The secondary transfer roller is applied by the bias high voltage PWB of DC bias. The image constituted by toner on the primary transfer belt is transferred on paper by means of the difference in potential.
  • Page 167 2F3/2F4 The primary transfer roller bias is triggered by a serial data which is generated by the engine controller PWB and derived from the bias high voltage PWB. The engine controller PWB converts current and voltage into serial data and applies it to the bias high voltage PWB.
  • Page 168 2F3/2F4 2-1-6 Fuser section (1) Fuser unit (16 ppm printer) The fuser unit is composed of the heat roller, press roller, fuser heater lamp 1, fuser heater lamp 2, and the change guide. Paper sent from the secondary transfer and separation section is applied with heat and pressure to permanently fuse toner on paper.
  • Page 169 2F3/2F4 To face-down tray Change guide Upper exit roller To optional duplexer or face-up tray Lower exit roller From paper feed unit Heat roller Press roller Figure 2-1-36 Fuser unit (16 ppm printer) Engine controller PWB Power supply PWB Fuser PWB FUDR FUSOLDR YC12-6...
  • Page 170 2F3/2F4 (2) Fuser unit (24 ppm printer) The fuser unit is composed of the heat roller, press belt, fuser heater lamp 1, and the change guide. Paper sent from the secondary transfer and separation section is applied with heat and pressure to permanently fuse toner on paper. The change guide switches the destination of paper to the face-down tray or optional face-up tray.
  • Page 171 2F3/2F4 Change guide face-down tray To optional duplexer or face-up tray Exit pulley Exit roller From paper feed unit Press belt roller Heat roller Press belt Press belt roller Figure 2-1-39 Fuser unit (24 ppm printer) Engine controller PWB Power supply PWB Fuser PWB FUDR FUSOLDR...
  • Page 172 2F3/2F4 This page is intentionally left blank. 2-1-30...
  • Page 173 2F3/2F4 2-2-1 Electrical parts layout (1) Main frame and controller box CONTROLLER BOX Figure 2-2-1 Main frame and controller box Main controller PWB ........Controls the software such as the print data processing and provides the interface with computers. Engine controller PWB......... Controls printer hardware such as high voltage/bias output control, paper conveying system control, and fuser temperature control, etc.
  • Page 174 2F3/2F4-3.0 Sensor PWB ..........Consists the top cover/paper feed unit switch, side cover switch, top cover switch 1, paper gauge switch 1/2, registration sensor, and, wiring relay circuit. Operation panel PWB ........Indicates the LCD message display and LED indicators. Controls key inputs.
  • Page 175 2F3/2F4 (2) Drum unit, developer unit and fuser unit FUSER UNIT (16 ppm printer) DRUM UNIT DEVELOPER UNIT FUSER UNIT (24 ppm printer) Figure 2-2-2 Drum unit, developer unit and fuser unit Drum PWB 1, 2, 3, 4 ........Drum PWB 1 (magenta), drum PWB 2 (cyan), drum PWB 3 (yellow), drum PWB 4 (black) wiring relay circuit inside each color drum unit.
  • Page 176 2F3/2F4 This page is intentionally left blank. 2-2-4...
  • Page 177 2F3/2F4 2-3 Operation of the PWBs 2-3-1 Power supply PWB Power supply PWB Engine Power Current controller switch fuse input Rectifier Transformer circuit (T1) Noise +24V1 filter 24 V DC circuit rectifier/ smoothing (Q1) circuit (Q2) +5V1 5 V DC rectifier/ smoothing circuit...
  • Page 178 2F3/2F4 Connector Pin No. Signal Voltage Description AC (LIVE) 220 - 240 V AC AC power input Connected 120 V AC to the AC Frame ground inlet 220 - 240 V AC AC power input (NEUTRAL) 120 V AC YC901 Analog Fuser thermistor 1 detection voltage output Connected...
  • Page 179 2F3/2F4-3.0 2-3-2 Engine controller PWB Engine controller PWB Operation Sensors/switches signals Sensor panel Reset IC RESET (U10) Data/Address Micro RESET multiplex bus controller Address bus Main (U8) controller Flash Cooling memory Address bus fan motor (U9) (24 ppm LED print heads control EEPROM printer (U12)
  • Page 180 2F3/2F4 (1) Fuser heater lamps control circuit Engine controller PWB Power supply PWB Pulse AC input Zero cross ZCROSS signal detection circuit ASIC (U13) TRA1 HEAT1DR Fuser heater lamp 1 ON circuit HEAT1ON HEAT2DR TRA2 Fuser abnormal temparature H1HTEMP detection +5V1 circuit (U1-1)
  • Page 181 2F3/2F4 (2) Interlock and 24 V DC power supply circuit Sensor PWB Engine controller PWB Power supply PWB Top cover/ Side cover feed unit switch switch +24V1 24 V DC +24V2 +24V1 +24V1 output +24V3 circuit +24V2 SLEEP +24V2 +24V2 Main high voltage PWB +24V3...
  • Page 182 2F3/2F4 Connector Pin No. Signal Voltage Description +24V1 24 V DC 24 V DC power output Connected +24V1 24 V DC 24 V DC power output to the sen- +24V1 24 V DC 24 V DC power output sor PWB +24V1 24 V DC 24 V DC power output...
  • Page 183 2F3/2F4 Connector Pin No. Signal Voltage Description VTXDN11 Analog LED print head control video data signal (LVDS) Connected VTXDP11 Analog LED print head control video data signal (LVDS) to the LED +3.3V1 5 V DC 3.3 V DC power output print heads +5V1 5 V DC...
  • Page 184 2F3/2F4 Connector Pin No. Signal Voltage Description +24V2 24 V DC 24 V DC power output (via top cover/paper feed unit switch) Connected HVCLK1 3KHz rectangular Developing sleeve (magenta) output to the bias wave high voltage HVCLK2 3KHz rectangular Developing sleeve (cyan) output wave HVCLK3 3KHz rectangular...
  • Page 185 2F3/2F4 Connector Pin No. Signal Voltage Description VRXDP0 Analog LED print head control video data signal (LVDS) Connected VRXDP1 Analog LED print head control video data signal (LVDS) to the main VRXCLKP 0/3.3 V DC (pulse) LED print head control clock signal controller VTXDP5 Analog...
  • Page 186 2F3/2F4 Connector Pin No. Signal Voltage Description YC11 TCOV0P2 DC0V/5V Top cover switch: Top cover Close/Open Connected Ground to the regis- +24V2 24 V DC 24 V DC power (via top cover/paper feed unit switch) tration REGCLDR 0/24 V DC Registration clutch: On/Off clutch, feed +24V2...
  • Page 187 2F3/2F4 Connector Pin No. Signal Voltage Description YC12 Analog Fuser thermistor 1 detection voltage input Connected Analog Fuser thermistor 2 detection voltage input to the power FDSOLDR 0/24 V DC (pulse) Face up/down solenoid control signal supply PWB +5V2 5 V DC 5 V DC power input RCOVOPN 0/5 V DC...
  • Page 188 2F3/2F4 2-3-3 Main controller circuit CPUD [31-0] PPC750CXr ASIC CPUDH [31-0] [31-0] [23-2] MA [12-0] MDQ [31-0] Trans- MCSN [4:1], MCKE [4:0] Latch EXTBOEN ceiver MRASN, MCASN, MWEN, MBA [1:0], MDQS [3:0] DM [3:0], MCKP [6,4:3,1:0] SDRAM MCKN [6,4:3,1:0] FPCLK, FPDIR, FPDAT, MREFOUTP, MREFOUTN, FPRSTN, SCLKN, SO, SI, Engine...
  • Page 189 2F3/2F4 2-4 Appendixes 2-4-1 Appendixes (1) Timing chart No. 1 Paper cassette, A4 size (16 ppm printer) 2-4-1...
  • Page 190 2F3/2F4 (2) Timing chart No. 2 Paper cassette, Legal size (16 ppm printer) 2-4-2...
  • Page 191 2F3/2F4 (3) Timing chart No. 3 Paper cassette, Letter size (16 ppm printer) 2-4-3...
  • Page 192 2F3/2F4 (4) Timing chart No. 4 MP tray, A4 size (16 ppm printer) 2-4-4...
  • Page 193 2F3/2F4 (5) Timing chart No. 5 MP tray, Legal size (16 ppm printer) 2-4-5...
  • Page 194 2F3/2F4 (6) Timing chart No. 6 MP tray, Letter size (16 ppm printer) 2-4-6...
  • Page 195 2F3/2F4 (7) Timing chart No. 7 Optional paper feeder, A4 size (16 ppm printer) 2-4-7...
  • Page 196 2F3/2F4 (8) Timing chart No. 8 Paper cassette, A4 size, Slow mode 1 [75 %] (16 ppm printer) 2-4-8...
  • Page 197 2F3/2F4 (9) Timing chart No. 9 Paper cassette, A4 size, Slow mode 2 [55 %] (16 ppm printer) 2-4-9...
  • Page 198 2F3/2F4 (10) Timing chart No. 10 MP tray, Transparency (16 ppm printer) 2-4-10...
  • Page 199 2F3/2F4 (11) Timing chart No. 11 Paper cassette, A4 size (24 ppm printer) 0 (s) Eraser lamp 13116 Main charger (M) 2352 8694 Main charger (C) 2826 9170 Main charger (Y) 3307 9644 Main charger (K) 3777 10118 Developing magnet bias (M) 3209 8485 Developing sleeve bias (M)
  • Page 200 2F3/2F4 (12) Timing chart No. 12 Paper cassette, Legal size (24 ppm printer) 0 (s) Eraser lamp 13586 Main charger (M) 2118 9129 Main charger (C) 2569 9605 Main charger (Y) 3076 10068 Main charger (K) 3546 10545 Developing magnet bias (M) 8917 2976 Developing sleeve bias (M)
  • Page 201 2F3/2F4 (13) Timing chart No. 13 Paper cassette, Letter size (24 ppm printer) 0 (s) Eraser lamp 12617 Main charger (M) 2118 8155 Main charger (C) 2597 8626 Main charger (Y) 3069 9100 Main charger (K) 3548 9574 Developing magnet bias (M) 2970 7950 Developing sleeve bias (M)
  • Page 202 2F3/2F4 (14) Timing chart No.14 MP tray, A4 size (24 ppm printer) 0 (s) Eraser lamp 13094 Main charger (M) 8640 2126 Main charger (C) 2604 9110 Main charger (Y) 3075 9585 Main charger (K) 10062 3555 Developing magnet bias (M) 2976 8427 Developing sleeve bias (M)
  • Page 203 2F3/2F4 (15) Timing chart No. 15 MP tray, Legal size (24 ppm printer) 0 (s) Eraser lamp 13836 Main charger (M) 2118 9368 Main charger (C) 2597 9840 Main charger (Y) 3067 10319 Main charger (K) 3547 10789 Developing magnet bias (M) 2967 9161 Developing sleeve bias (M)
  • Page 204 2F3/2F4 (16) Timing chart No. 16 MP tray, Letter size (24 ppm printer) 0 (s) Eraser lamp 12888 Main charger (M) 2128 8429 Main charger (C) 2607 8904 Main charger (Y) 3077 9373 Main charger (K) 3559 9845 Developing magnet bias (M) 2988 8218 Developing sleeve bias (M)
  • Page 205 2F3/2F4 (17) Timing chart No. 17 Optional paper feeder, A4 size (24 ppm printer) 0 (s) Eraser lamp 12856 Main charger (M) 2127 8393 Main charger (C) 2605 8867 Main charger (Y) 3077 9345 Main charger (K) 3556 9814 Developing magnet bias (M) 2979 8180 Developing sleeve bias (M)
  • Page 206 2F3/2F4 (18) Timing chart No. 18 Paper cassette, A4 size, Slow mode 1 [75 %] (24 ppm printer) Eraser lamp 15074 Main charger (M) 9195 Main charger (C) 1385 9823 Main charger (Y) 2015 10455 Main charger (K) 2646 11089 Developing magnet bias (M) 1887 8913...
  • Page 207 2F3/2F4 (19) Timing chart No. 19 Paper cassette, A4 size, Slow mode 2 [50 %] (24 ppm printer) Eraser lamp 21720 Main charger (M) 12924 Main charger (C) 1260 13871 Main charger (Y) 2210 14825 Main charger (K) 3162 15774 Developing magnet bias (M) 2011 12507...
  • Page 208 2F3/2F4 (20) Timing chart No. 20 MP tray, Transparency (24 ppm printer) 0 (s) Eraser lamp 13094 Main charger (M) 8640 2126 Main charger (C) 2604 9110 Main charger (Y) 3075 9585 Main charger (K) 10062 3555 Developing magnet bias (M) 2976 8427 Developing sleeve bias (M)
  • Page 209 2F3/2F4 (21) Wiring diagram (16 ppm printer) S02848 FPRSETN FPCLK WETCK2 FPDIR WETCK1 WTNSENS FPDATA AIRTEMP WTNLEDN +5V1 WTSENS +5V1 S02847 WTLEDDR S02863 S02881 motor MPFSENS2 stop drive DVEMOTB MPFSENS1 +5V1 Developer DVEMOTA HVBLATD STFSBN HVBCLKD STFSB HVBDATD STFSAN HVCLK4 STFSA HVCLK3 HVCLK2...
  • Page 210 2F3/2F4 (KP-931) Zener S02868 ERASEDR S02867 +5V1 EECLK EEDATA ERS1DR VDD2 VDD2 VDD2 VDD2 VDD1 VDD1 (S02977) (S02976) VDD1 ADATA20 42/41 42/41 ADATA21 +5V1/+3.3V1 44/43 44/43 ADATA22 +5V1/+5V1 46/45 46/45 ADATA23 GND/+5V2 48/47 48/47 ADATA24 DU-300/301 unit Duplex GND/GND ADATA25 50/49 50/49 PF-60...
  • Page 211 2F3/2F4 (22) Wiring diagram (24 ppm printer) S02848 FPRSETN FPCLK WETCK2 FPDIR WETCK1 WTNSENS FPDATA AIRTEMP WTNLEDN +5V1 WTSENS +5V1 S02847 WTLEDDR S02863 S02881 motor MPFSENS2 stop drive DVEMOTB MPFSENS1 DVEMOTA +5V1 Developer HVBLATD STFSBN HVBCLKD STFSB HVBDATD STFSAN HVCLK4 STFSA HVCLK3 HVCLK2...
  • Page 212 2F3/2F4 (KP-931) Zener S02868 ERASEDR S02867 +5V1 EECLK EEDATA ERS1DR VDD2 VDD2 VDD2 VDD2 VDD1 VDD1 (S02977) (S02976) VDD1 ADATA20 42/41 42/41 ADATA21 +5V1/+3.3V1 44/43 44/43 ADATA22 +5V1/+5V1 46/45 46/45 ADATA23 GND/+5V2 48/47 48/47 ADATA24 DU-301 unit Duplex GND/GND ADATA25 50/49 50/49 PF-60...
  • Page 213 2F3/2F4-3.0 (23) Repetitive defects gauge First occurrence of defect 31.16 mm [Upper registration roller] 33.28 mm [Developing sleeve] 51.21 mm [Lower registration roller] 59.33 mm [Secondary transfer roller] 94.4 mm [Drum] 113.04 mm [Heat roller Press roller, 16 ppm printer] 114.61 mm [Heat roller, 24 ppm printer] 2-4-25...
  • Page 214 2F3/2F4 This page is intentionally left blank. 2-4-26...

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