Brother HL-2400C Service Manual
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Brother HL-2400C Service Manual

Brother HL-2400C Service Manual

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R
COLOR LASER PRINTER

SERVICE MANUAL

MODEL:HL-2400C
Jan. '98
54S002BE0

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Summary of Contents for Brother HL-2400C

  • Page 1: Service Manual

    COLOR LASER PRINTER SERVICE MANUAL MODEL:HL-2400C Jan. ‘98 54S002BE0...
  • Page 2 COLOR LASER PRINTER SERVICE MANUAL MODEL:HL-2400C...
  • Page 3 Specifications are subject to change without notice. Trademarks: The brother logo is a registered trademark of Brother Industries, Ltd. Apple, the Apple Logo, and Macintosh are trademarks, registered in the United States and other countries, and True Type is a trademark of Apple computer, Inc.
  • Page 4 (here-in-after referred to as "this machine" or "the printer"). This information is vital to the service technician to maintain the high printing quality and performance of the printer. This service manual covers the HL-2400C color laser printer. This manual consists of the following chapters:...

  • Page 5: Table Of Contents

    CONTENTS CHAPTER I PRODUCT OUTLINE............ I 1. FEATURES...................... I-1 2. PARTS NAMES & FUNCTIONS ..............I-4 3. INTERNAL STRUCTURE ................I-6 4. DESCRIPTION OF CONTROL PANEL ............I-7 4.1 Video Controller Mode......................I-7 4.2 Engine Controller Mode......................I-7 CHAPTER II SPECIFICATIONS ............II-1 1.
  • Page 6 2. STRUCTURE OF THE CONTROL SYSTEM ..........IV-27 2.1 Basic Structure......................... IV-27 2.2 Control System......................... IV-36 2.3 Main PCB (Video Controller PCB)..................IV-46 2.4 Power Supply Unit......................IV-58 2.5 High Voltage Power Supply Unit ..................IV-61 2.6 Wiring Diagram......................... IV-64 CHAPTER V CONTROL PANEL OPERATION ......V-1 1.
  • Page 7 CHAPTER VII DISASSEMBLY.............VII-1 1. BEFORE STARTING DISASSEMBLY............VII-1 1.1 Precautions ........................VII-1 1.2 Preparation of Disassembly ....................VII-1 2. PARTS NAME ....................VII-3 2.1 Cover..........................VII-3 2.2 Circuit Boards (PCBs) ....................... VII-4 2.3 Motor Units........................VII-4 2.4 Clutches and Solenoids ....................VII-5 2.5 Sensors ..........................
  • Page 8 REGULATIONS LASER SAFETY (FOR 110-120 V MODEL ONLY) This printer is certified as a Class I laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation.
  • Page 9 IEC 825 SPECIFICATION (FOR 220-240 V MODEL ONLY) This printer is a Class 1 laser product as defined in IEC 825 specifications. The label shown below is attached in countries where required. CLASS 1LASER PRODUCT APPAREIL Å LASER DE CLASSE 1 LASER KLASSE 1 PRODUKT This printer has a Class 3B Laser Diode which emits invisible laser radiation in the Scanner Unit.

  • Page 10: Safety Instructions

    SAFETY INSTRUCTIONS SAFETY PRINCIPLE 1) Before starting any operations, read this manual thoroughly. Especially read the safety instructions in this section carefully and ensure that you understand the contents. 2) Perform all the operations by following the procedures described in this manual. Follow all the cautions and warnings set out in the procedures and on safety labels affixed to the machine.
  • Page 11 WARNING HAZARDOUS VOLTAGE May cause serious injuries or fatal accidents. Voltage is now applied from the power supply of printer. There is a danger of electrical shock if you touch the active area inside the printer. Be sure to turn the power supply switch OFF and pull the plug out from the power outlet before starting maintenance work on the printer.
  • Page 12 CAUTION HAZARDOUS POWDER Toner is a fine powder which can cause a powder explosion if disposed of into a fire. Under no circumstances dispose of toner into a fire. CAUTION HAZARDOUS POWDER Toner is a fine powder which may cause irritation to the eyes and respiratory organs if inhaled.

  • Page 13: Laser Caution Label

    BROTHER INDUSTRIES, LTD. MADE IN JAPAN FCC ID : B3QHLC1 BROTHER PRINTER HL SERIES COVERED This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions : (1) This device may BY ONE OR MORE FOLLOWING PATENTS:...

  • Page 14: Shipment Of The Printer

    SHIPMENT OF THE PRINTER If for any reason you must ship the printer, carefully package the printer to avoid any damage during transit. It is recommended that you save and use the original packaging. The printer should also be adequately insured with the carrier. CAUTION •...

  • Page 15: Chapter Iproduct Outline

    CHAPTER I PRODUCT OUTLINE...
  • Page 16 CONTENTS CHAPTER I PRODUCT OUTLINE........... I-1 1. FEATURES..................... I-1 2. PARTS NAMES & FUNCTIONS ..............I-4 3. INTERNAL STRUCTURE ................I-6 4. DESCRIPTION OF CONTROL PANEL ............I-7 4.1 Video Controller Mode ......................I-7 4.2 Engine Controller Mode ......................I-7...

  • Page 17: Features

    CHAPTER I PRODUCT OUTLINE FEATURES This printer has the following features: 2400 x 600 dpi Class Resolution The printer prints pages with a resolution of 600 dots per inch (dpi) as default. It also provides higher quality printout which is the equivalent of 2400 x 600 dpi resolution when using HRC or CAPT.
  • Page 18 ® The printer can emulate Hewlett-Packard Color PCL 5C (PCL6 ® monochrome mode) and PostScript Level 2 language emulation (Brother BR-Script Level 2) printers, the industry-standard HP-GL™ ® ® ® plotter as well as EPSON FX-850™, and IBM Proprinter XL printers (in monochrome mode).
  • Page 19 PCMCIA Card Slot The printer has two PCMCIA card slots (Type II cards: 2 slots available, Type III cards: 1 slot available). The following cards can be installed; • PCMCIA-compatible flash memory card • HDD card • PCMCIA Fax Modem card Saving User Settings It is possible to operate the printer differently from other users with the panel button settings.

  • Page 20: Parts Names & Functions

    PARTS NAMES & FUNCTIONS <Front View> 1. Top Cover 2. Control Panel 4. Power Button 3. Front Cover Media cassette Fig.1-1 <Rear View> 7. Controller Box 5. Power Inlet 6. Rear Access Cover Fig.1-2...
  • Page 21 Part Name Outline of Functions To act as an upper enclosure and also as a Top Cover paper tray for printed paper. Control Panel To display the status of printer operation. To act as a front enclosure, opened when Front Cover replacing a toner cartridge or waste toner pack.

  • Page 22: Internal Structure

    INTERNAL STRUCTURE <Cross Sectional View > 4.Fusing Unit 3.Drum Cleaner 2.OPC Belt Cartridge 1.Toner Cartridge (K,Y,M,C) Unit 5.Transfer Discharger 7.Paper 11.Scanner Unit Roller 8.Transfer 9.Media Cassette 6.Transfer Drum 12.Register Roller 10.Paper Pick- up Roller Fig.1-3 Components Name Outline of Functions Contain the toner (K, Y, M, C) for developing.

  • Page 23: Description Of Control Panel

    DESCRIPTION OF CONTROL PANEL The printer control panel provides control of the printer including test printing, maintenance operations performed by the video controller and also the ones which are performed by the engine controller. The Video Controller Mode and the Engine Controller Mode have some common functions.
  • Page 24 Copy Pages Orientation Feeder Emulation Mode Toner Ready On Line Data Form Feed Alarm Feeder Mode Font Emulation Economy Test Continue Shift Copy Reset Fig.1-4 LED / Button Name LCD: 16 character by 2 lines Ready LED On Line LED Data LED Select button Form Feed / Feeder button...

  • Page 25: Chapter Ii Specifications

    CHAPTER II SPECIFICATIONS...
  • Page 26 CONTENTS CHAPTER II SPECIFICATIONS ............. II-1 1. RATING ......................II-1 2. GENERAL SPECIFICATIONS ............... II-2 2.1. Printing..........................II-2 2.2. Functions ..........................II-3 2.3. Electrical and Mechanical ....................II-3 2.4. Paper Specification......................II-4 2.4.1 Printable Media & Cassette Capacity ................II-4 2.4.2 Printed Output ........................II-5 2.4.3 Recommended Paper Specifications................II-5 2.4.4 Effective Printing Area....................II-5 2.4.5 Paper Feed Jam Rate....................II-7 3.

  • Page 27: Rating

    CHAPTER II SPECIFICATIONS RATING WARNING Use the power supply cable supplied with the printer, or a similar cable complying with the following specification (3-wire power cable with ground). Use of an “out of specification” cable may result in an electric shock. Destination Voltage (V) Frequency (Hz)

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS 2.1. Printing Print method: Electrophotography by semiconductor laser beam scanning Resolution: 300 x 300 dots per inch (Normal) 600 x 600 dots per inch (Fine) The resolution can be enhanced to 2400 dpi class by using the HRC(High Resolution Control) and CAPT (Color Advanced Photoscale Technology) features.

  • Page 29: Functions

    2.2. Functions CPU: MB86832 (SPARC architecture) Emulation: Automatic emulation selection HP Color Printer (PCL5C) including HP LaserJet 4+ (PCL5e) and HP LaserJet 5 (PCL6 monochrome) BR-Script Level 2 (Adobe PostScript Level 2 compatible) HP-GL EPSON FX-850 IBM Proprinter XL Interface: Automatic interface selection between the bi-directional parallel, RS- 232C serial and MIO interface.

  • Page 30: Paper Specification

    2.4. Paper Specification 2.4.1 Printable Media & Cassette Capacity The standard media cassette (upper cassette) is supplied with the printer. The optional lower tray unit and the optional Legal cassette can also be installed. Note: The standard cassettes (including the optional lower tray unit) and the optional Legal cassette are interchangeable between the upper and the lower feeder.

  • Page 31: Printed Output

    2.4.2 Printed Output 250 sheets of 75g/m (20lb) paper / plain paper can be stacked in the output tray. Face-down print delivery Note: Face down: Delivers the printed side of the paper downwards Environment: 17.5 ∼ 27.0°C, 50 ∼ 70%RH 2.4.3 Recommended Paper Specifications Item...
  • Page 32 Table 2-1: Effective Printing Areas Size 210.0mm 297.0mm 203.2mm 288.5mm 3.4mm 4.23mm 8.27” 11.69” 8.0” 11.36” 0.13” 0.17” (2,480 dots) (3,507 dots) (2,400 dots) (3,407 dots) (40 dots) (50 dots) 215.9mm 279.4mm 207.44mm 271.0mm 4.23mm Letter 8.5” 11.0” 8.16” 10.67” 0.17”...

  • Page 33: Paper Feed Jam Rate

    Print guarantee area <Plain paper> Paper:5mm Other:10mm Non printable area Print Non guarantee guarantee area area Paper:4mm Other:10mm <Envelope> Non printable area Non guarantee area Print guarantee 42mm area 16mm COM10:68mm COM10:68mm DL:40mm DL:40mm 2.4.5 Paper Feed Jam Rate Less than 1 misfeed per 2000 pages under normal environmental conditions. Less than 1 misfeed per 1000 pages outside the normal environmental conditions.

  • Page 34: Environmental Condition

    ENVIRONMENTAL CONDITION Ambient Temperature / Humidity / Altitude Under Operational conditions: 10.0 ∼ 32.5 ° C, 20 ∼ 80%RH (See the figure below.) Recommended Condition; 17.5 ∼ 27.0°C 50 ∼ 70%RH 17.5 20 27 30 32.5 40 Ambient Temperature ( ) C Under Non Operational conditions: 5.0 ∼...
  • Page 35 Storage and Transportation Environment of Printer The following defines the storage and transportation environment of printers that have been packed according to Brother specification. However, this section does not cover the OPC belt cartridge and toner cartridges. Normal 0°C ∼ 35°C (35°F ∼ 95°F) Conditions High Temperature: 35°C ∼...

  • Page 36: Chapter Iii Installation

    CHAPTER III INSTALLATION...
  • Page 37 CONTENTS CHAPTER III INSTALLATION ............III-1 1. CONDITIONS REQUIRED FOR INSTALLATION......... III-1 1.1. Environmental Conditions....................III-1 1.2. Basic Layout of Printer Set-up Location ................III-1 2. UNPACKING....................III-2 2.1 Unpacking of Printer ......................III-2 2.2 Unpack the Starter Kit......................III-4 3. INSTALLATION WORK ................III-5 3.1 Install the OPC Belt Cartridge....................III-5 3.2 Install the Toner Cartridge to the Printer................III-6 3.3 Install the Oil Bottle and Fuser Cleaner ................III-7...

  • Page 38: Conditions Required For Installation

    CHAPTER III INSTALLATION CONDITIONS REQUIRED FOR INSTALLATION Any Laser beam printer is likely to be influenced by the environment of the set-up location. If the printer is set-up in an inappropriate location, the printer may not perform as expected. Therefore, the following factors should be taken into consideration before deciding where to set-up the printer.

  • Page 39: Unpacking

    UNPACKING WARNING • The package containing a printer weighs approximately 40kg (80lbs), so it is too heavy for one person to carry. It needs two adults to move the printer. Since the printer is a precision machine, make sure that it is carried slowly with care so that no impact occurs to the printer while moving it.
  • Page 40 Starter Kit Packing (U) Outer Box Polyethylene Bag (T) Polyethylene Bag (OPC) Polyethylene Polyethylene Bag (CL) Bag (ST) Polyethylene Bag (OIL) Starter Kit Packing (L) Silica Gel (EN) Silica Gel (ST) Outer Box Upper Packing Syringe Tape Power Cord Costomize Cleaning Brush Polyethylene...

  • Page 41: Unpack The Starter Kit

    Unpack the Starter Kit <Unpacking Procedure> Open the vinyl bag and slide off the cardboard sleeve covering the starter kit. Confirm all of the following parts are inside the starter kit packing box. Kit Name Appearance Quantity Y (Yellow) M (Magenta) C (Cyan) Toner Cartridge K (Black)

  • Page 42: Installation Work

    INSTALLATION WORK Install the unit parts of the starter kit into the printer according to the following procedures: Install the OPC Belt Cartridge PRECAUTION • Do not directly touch the OPC belt surface with bare hands or gloves. • If the belt is exposed for more than two minutes to a light source of 800 lux, the belt may be damaged.
  • Page 43 5) Install the new OPC belt cartridge into the guides at both sides in the printer. Fig.3-6 6) Set the belt cartridge lock lever at both sides (left and right). Fig.3-7 Install the Toner Cartridges into the Printer 1) Rock each of the cartridges 3 to 4 times through 30 to the horizontal.

  • Page 44: Install The Oil Bottle And Fuser Cleaner

    Note: The installation order of the four toner cartridges should be from the bottom to the top, in terms of colors this is in the order Cyan (C), Magenta (M), Yellow (Y), and Black (K). Close the front cover. Fig.3-11 Install the Oil Bottle and Fuser Cleaner 1) Pull out and remove the orange Orange protective...

  • Page 45: Test Print

    Test Print After completing the installation work, perform a test print. The test print should be done in the Video Controller Mode and checked for correct print output. If there appear to be any print problems then the test print in the Engine Controller Mode should be used if necessary.
  • Page 46 Note: Refer to the table below for each test mode item. Display Message Test Mode Description DEMO PAGE Prints out the demonstration. Performs the printer test and prints TEST PRINT out the test pattern. Prints out a list of panel button PRINT CONFIG settings you have configured as user settings for the printer.

  • Page 47: On-Line Printing (Video Controller Mode Only)

    14) Press the Font button to stop the test print and then push the power button in order to shut off the power supply to the printer. (This switch is push-on/push-off type.) Power Button 15) Unplug the power cable from the outlet. PRECAUTION •...

  • Page 48: Chapter Iv Structure Of System Components

    CHAPTER IV STRUCTURE OF SYSTEM COMPONENTS...
  • Page 49 CONTENTS CHAPTER IV STRUCTURE OF SYSTEM COMPONENTS... IV-1 1. BASIC STRUCTURE .................IV-1 1.1 Print System and Transfer System ................. IV-6 1.1.1 Structure of the Printer ..................... IV-7 1.1.2 Basic Structure of the Printing System..............IV-8 1.1.3 Details of Each Process ..................IV-10 1.2 Scanning System ......................

  • Page 50: Basic Structure

    CHAPTER IV STRUCTURE OF SYSTEM COMPONENTS BASIC STRUCTURE <Mechanical & Electrical Structures> This laser beam color printer (hereinafter called “Printer”) consists of five mechanical systems; Print, Transfer, Scanning, Paper Transport and Control System. The printer produces color printing through the interactive operations of these five systems as shown in Fig.4-1.
  • Page 51 Main Motor Develope Motor I/F Controller Paper Exit Paper Exit Unit Drum Cleaner Unit MCTL Fusing Unit I/F Control Drum Cleaning OPC Belt Sequence Control Operation Development Laser Control Transfer Drum Paper Discharger Transfer Unit First Transfer AC Discharger Unit Transfer Roller Second Transfer Scanner Unit...
  • Page 52 Control System The control system consists of the following 4 (four) control parts and runs the printer by processing the interface signals transmitted from the Host computer and interfacing to the print, transfer, scanning and transport systems. • Sequence Control •...
  • Page 53 OPC Belt Toner Cartridge Transfer Drum Fig.4-3 Toner M M M C C C C C Y Y Y Y Y Y . First Transfer Transfer Drum Y Y Y Y Y Y M M M C C C C C .
  • Page 54 <Structure of the OPC Belt> The OPC belt consists of a surface layer having a photoconductor (OPC) of organic material, the inner layer of an insulator material (PET / Mylar) and an aluminum deposit layer in between. The OPC belt is located as shown in Fig.4-5 as the main part of the print system.

  • Page 55: Print System And Transfer System

    Print System and Transfer System Fig.4-7 shows the basic structure of the print system having the OPC belt as the main part and the transfer system having the transfer drum as the main part. Color printing is achieved by actuating in sequence each process in the print system and transfer system. 4 cycles of actions 1 to 6 are required to form a full 24 bit color image on the transfer drum, only one cycle of actions 7, 8 and 9 is required to transfer the image to the paper from the transfer drum ready for fixing by actions 10 and 11.

  • Page 56: Structure Of The Printer

    1.1.1 Structure of the Printer Component Part Process Charger Charging Scanner Unit Exposing Toner Cartridge Developing OPC Belt Receives the Image Transfer Drum Transfers the Image Belt Discharger Erase Lamp Discharges the Belt Cleaning Blade Cleaning the Belt Transfer Roller Transferring Paper Discharger Discharges the Paper...

  • Page 57: Basic Structure Of The Printing System

    1.1.2 Basic Structure of the Printing System A toner image is formed through the potential of the OPC belt varying in each of the charger, exposure, development, transfer and cleaning processes. Process of Print System (See Fig.4-9.) i) The OPC belt is biased to the voltage -CBV(V) by the power supply CBV. ii) A negative high voltage is applied to the charger unit by the power supply CHV, and a corona is generated as the result.
  • Page 58 Variation of OPC Belt Potential (See Fig.4-10.) i) The OPC belt is initially biased to -CBV(V). ii) The OPC belt surface is evenly charged to V (V) in the charging process. iii) The potential of the exposure part of the OPC belt is reduced to -VR(V) as it is exposed to the laser beam in the process of exposing, and an electrostatic latent image is formed on the OPC belt as the result.

  • Page 59: Details Of Each Process

    1.1.3 Details of Each Process Charging The charging process ensures that the OPC belt is evenly charged by the charger system. Structure of the Charger Unit (Refer to Fig.4-8 and Fig.4-11) i) The charger unit is located as shown in Fig.4-8. ii) The charger unit consists of the case, corona wire and grid.
  • Page 60 Exposing The exposing process means that the OPC belt surface is exposed to the laser beam to form an electrostatic latent image. Structure of Scanner Unit i) The scanner unit is located as shown in Fig.4-8. ii) The source of the laser beam is a semiconductor laser. iii) The laser light is scanned onto the OPC belt by converting the laser light to a beam of light through the lens and reflective mirror to form an electrostatic latent image.
  • Page 61 Developing The developing process means that an electrostatic latent image on the OPC belt is made visible by depositing toner onto the exposed areas of the OPC belt. Structure of the Toner Cartridge (Refer to Fig.4-8 & 4.14.) i) The toner cartridge is located as shown in Fig.4-8. ii) Four toner cartridges are made available from the top to bottom in the order black, yellow, magenta and cyan.
  • Page 62 Developer roller Toner OPC Belt Fig.4-15 Toner (M) Exposing Developing Fig.4-16 IV-13...
  • Page 63 First Transfer (Drum) The first transfer process means that the toner image on the OPC belt is transferred onto the transfer drum. Structure of the Transfer Drum (Refer to Fig.4-8.) i) The drum is located as shown in Fig.4-8. ii) Material of the drum is aluminum. iii) Semiconductor rubber is used to provide the drum surface as shown in Fig.4- iv) The transfer drum rotates by contacting and synchronizing with the OPC belt.
  • Page 64 First Transfer Process (Refer to Fig.4-18.) i) The OPC belt has been through the development process and contacts and synchronizes with the transfer drum. ii) The OPC belt has been biased to the potential of -CBV(V). The potential of the transfer drum is nearly GND.
  • Page 65 Belt Discharging (Erase Lamp) The belt discharging process means that upon completion of the drum transfer process, an LED light is radiated onto the OPC belt prior to mechanically cleaning the belt to discharge the residual charge. Structure of Erase Lamp i) The erase lamp is located as shown in Fig.4-8.
  • Page 66 Belt Cleaning The belt cleaning process means that the residual toner adhering to the OPC belt surface is mechanically scavenged. Structure of Belt Cleaning The blade for the belt cleaning is located relative to the OPC belt cartridge as shown in Fig.4-8. Process of Belt Cleaning (Refer to Fig.4-20.) There is residual toner on the OPC belt as it has not been completely transferred in the drum transfer process.
  • Page 67 Second Transfer (Paper) The second transfer process is where the toner image on the transfer drum is transferred onto the transported paper. Second Transfer Structure i) The transfer roller for the paper transfer is located as shown in Fig.4-8. ii) The transfer roller is normally kept out of contact with the transfer drum until the second transfer process starts.
  • Page 68 Paper Discharging The paper discharging process is where the transported paper onto which the toner transfer has been completed is separated from the transfer drum by applying an AC charge to the paper. Structure of Paper Discharger (Refer to Fig.4-22.) i) The AC charger unit for discharge the paper is located as shown in Fig.4-8.
  • Page 69 Drum Cleaning The drum cleaning process is where the residual toner on the transfer drum is removed. Structure of Drum Cleaning (Refer to Fig.4-23.) i) The drum cleaning unit is located as shown in Fig.4-8. ii) The drum cleaning brush is a semiconductor type so that the brush can clean the surface of the rotating transfer drum.

  • Page 70: Scanning System

    Scanning System This printer employs a semiconductor laser diode as a light source. This laser diode is switched according to the transmitted image data (video signal). The generated laser light scans over the OPC belt through a polygon mirror and lens, by which method electrostatic latent images will be formed on the OPC belt.
  • Page 71 Specification: Specification of the Scanner Unit is as follows; Item Specifications Rated Output of Laser Diode 5mW. Wave Length of Laser Beam Approx.785nm. Scanning Density 600dpi Scanning Width 220mm Scanner Motor speed 23,936rpm Number of Polygon Mirror Faces IV-22...

  • Page 72: Paper Transportation System

    Paper Transportation System Outline This printer employs automatic paper feeding from the media cassette. When toner images are formed on the transfer drum through the operations of the print system and transfer system, paper is fed by the pick-up roller and transported to the register roller.
  • Page 73 Media Cassette Paper Discharger Unit Paper Pick-up Roller Fusing Unit Register Roller Paper Exit Unit Transfer Part Paper Exit Roller Fig.4-25 IV-24...

  • Page 74: Fusing Unit

    Fusing Unit The fusing unit employs a thermal fusing system using heater lamps in the rollers. Paper carrying the combined toner image passes between the heat rollers. Heat and pressure is applied to the paper when passing between the heat rollers so that the toner image is melted and fused onto the paper.
  • Page 75 Fusing Process (Refer to Fig.4-27.) Silicone oil supplied from the oil bottle is applied to the surface of fuser roller. The toner image has been transferred onto the paper, but not yet fused. Transported paper passes between the heater roller and back-up roller.

  • Page 76: Structure Of The Control System

    STRUCTURE OF THE CONTROL SYSTEM Basic Structure 2.1.1 Electrical System and Functions Most of the main electrical parts of this printer are controlled by the MCTL (engine controller) PCB. <Structure of the Sequence Control> The basic structure of the sequence control is shown in Fig.4-28. Print Process Control: To control the print process from the paper feed through to the paper exit.
  • Page 77 Cooling Scanner Control Motor Panel Host Computer ATC (4 pcs.) Belt Drum Sensor Sensor MCTL (Engine Controller) Sequence Control Controller Control Laser Control Temperature Control Video Controller Toner Empty Sensing Control Control Panel Control Error Processing Program Cleaning Roller Sensor Paper Empty Sensor High Voltage Unit Paper Feeding Sensor...
  • Page 78 <Layout & Function of the Electrical Parts> Print PCB (Refer to Fig. 4-29.) Name Function To receive the print data from the host computer, Video Controller PCB convert it into image data and then send the printing image data to the MCTL PCB. To control the sequence of processes of the printer: Fusing Temperature Control, Laser Output Engine Controller...
  • Page 79 6. Erase Lamp 3. Control Panel PCB 8. IOD2 PCB 10. High-voltage Power Supply (HVU) PCB 7. IOD1 PCB 1. Video 2. Engine Controller PCB Controller (MCTL) PCB 4. LDU 9. Power Supply (LVPS) PCB 5. PDU Fig.4-29 IV-30...
  • Page 80 Motors (Refer to Fig.4-30.) Name Code Function To drive the OPC belt and the paper Main Motor transport system. To drive the toner cartridge and the Developing Motor developing system. Scanner Motor To scan the laser beam To exhaust the ozone from the printer Ozone Fan Motor OZFAN (charger unit).
  • Page 81 Clutches and Solenoids (Refer to Fig.4-31.) Name Code Function To feed paper by coupling the feeding roller to the main gear unit at the Paper Feed Clutch PCLU correct timing for paper feeding. To transport paper by coupling the register roller to the main gear unit Registration Clutch RECL synchronized with the rotation of the...
  • Page 82 Layout of Clutches and Solenoids 11. Drum Cleaner Solenoid 3. Fuser Clutch 4. Cleaner Clutch 10. Transfer Solenoid 2. Registration Clutch 1. Paper Feed Clutch 8. Developer Clutch (K) 7. Developer Clutch (Y) 6. Developer Clutch (M) 5. Developer Clutch (C) 9.
  • Page 83 Sensors Name Code Function Paper Size Sensor Photo sensor to detect the paper size. Photo sensor to detect when paper is Paper Feeding Sensor fed from the media cassette. Photo sensor to detect that paper is Paper Exit Sensor exited from the paper exit unit. Photo sensor to detect if paper is Paper Empty Sensor loaded in the media cassette.
  • Page 84 14. Temperature Sensor (Thermistor to 3. Paper Exit Sensor detect) 7. Drum Jam Sensor 13. Cleaning Roller Sensor 5. Oil Sensor 10. Toner Empty Sensor 9. Belt Sensor 8. Drum Encoder 12. Developing Sensor Photo Sensor 6. OHP Sensor 11. Waste 2.

  • Page 85: Control System

    Control System 2.2.1 Control of the Print Process A Micro CPU mounted on the MCTL PCB controls the print processes. <Print Sequence Diagram> Cooling Scanner Control Motor Panel Host Computer ATC (4 pcs.) Belt Drum Sensor Sensor MCTL (Engine Controller) Sequence Control Controller Control...
  • Page 86 Control Block Diagram (Refer to Fig.4-33.) Name Function To control the sequence of printer Sequence Control operations. To control the temperature of the fixing Temperature Control unit. To detect the toner empty status of each Toner Empty Sensing Control toner cartridge. To control the control panel indications Control Panel Control and the operational signals.
  • Page 87 Laser Drive Control Circuit Laser Drive Control Circuit (LDC) consists of the video signal input circuit, laser drive circuit, laser diode, output sensing circuit and output control circuit, as shown in Fig.4-34. <Operation> (1) When the video signal is received, the laser drive control circuit switches the laser diode according to the video signal data.
  • Page 88 MCTL PCB OPC Belt PRINT Signal Frequency Control Circuit Scaner Motor Laser Beam Scanning Synchronizie Control Circuit Control Circuit LDC PCB VIDEO Signal Fig.4-34...
  • Page 89 Control of the Fusing Temperature Each roller of the fusing unit is controlled to maintain the appropriate temperature so that toner will be fixed correctly onto the print paper. <Basic Structure of Temperature Control (Fig.4-35)> FLS: Thyristor to switch the power supply to the heat lamp. TFU1/TFU2 Temperature fuse to shut down the circuit for safety when the temperature becomes too hot within the fixing unit.
  • Page 90 <Basic Structure of Fuser Control> RY-1 ACOFF-P RY-1 HON-N Fusing Unit THERR ACOFF HON GA/CPU Fig.4-35...
  • Page 91 To maintain the temperature for fixing of the toner at 140 ° C by turning the thyristor on and off. Reference temperature ( ° C) to identify that it is excessively hot inside the fusing unit. When it reaches this point ( ° C), the relay RY turns off, the power supply to the heat lamp is shut down and the printer stops operating.
  • Page 92 ( 4) Interface Control <General> (a) Interface Type The video interface handles laser image data that corresponds to dots for printing but does not store image data in a buffer. The video data signals of the input image data switches the semiconductor laser diode to form a print image. (b) Interface Connection Operator Panel...
  • Page 93 (c) Interface Circuit (Printer side) Table 4-1: Interface Circuit Interface Circuit Signal Name • VIDEO-N • VIDEO-P M5M34050 • HSYNC-N • HSYNC-P M5M34050 • PRREQ-N • COMMAND-N • ID1-N 0.01 F • ID2-N SN74LS14 • VSYNC-N 3.3K • IREADY-N • STATUS-N •...
  • Page 94 (d) Connector Pin Assignment The connector in the printer to connect to the controller board is type 128A-064S2B-:13A(DDK) or the equivalent. Table 4-2: Connector Pin Assignment Pin No. Signal Name Pin No. Signal Name PSGND PSGND PSGND PSGND PSGND PSGND PSGND PSGND VIDEO-P...

  • Page 95: Main Pcb (Video Controller Pcb

    Main PCB (Video Controller PCB) 2.3.1 Outline The Main PCB consists of the circuits which perform the following functions; • Receive the printing data from the computer. • Convert the received data to the bitmap data such as characters or graphics. •...

  • Page 96: Circuit

    2.3.2 Circuit CPU block • Model name: MB86832-100 (SPARC lite), RISC CPU manufactured by Fujitsu • Clock speed: 33.1776MHz (external) / 99.5328MHz (internal) • Cache memory: 8KB (Command cache) / 8KB (Data cache) • Appearance: 176-pin QFP ASIC block • Model name: MF87F1610 manufactured by Fujitsu •...
  • Page 97 SIMM block SIMM (Single-Inline-Memory-Module) allows memory extension by up to 96MB. 3 SIMM sockets are available. The following type of SIMM can be installed into each slot. • Appearance: 72-pin • Memory type: Fast page or EDO (automatic selection) • Access time: less than 80nsec.
  • Page 98 <HSYNC> Horizontal synchronization signal for printing <VIDEO> Video data signal <COMMAND> Command signal sent from the controller to the engine <STATUS> Status signal sent from the engine to the controller Fig.4-38 shows the timing of each signal after the power switch is turned on. Power On 210s MAX.
  • Page 99 Note: • Based on “Asynchronous Communication” method. • Command/Status communication must keep the “Handshake Rule”. • Baud rate is 9600 bps. • Frame format: - one (1) start bit, - eight (8) data bits (Start bit side is LSB, Parity bit is MSB), - one (1) odd parity bit, - one (1) stop bit.
  • Page 100 Appendix 1. Main PCB Circuit Diagram, (1/7) CODE UK391301 NAME B48K299CIR (1/7) IV - 51...
  • Page 101 Appendix 2. Main PCB Circuit Diagram, (2/7) CODE UK391302 NAME B48K299CIR (2/7) IV - 52...
  • Page 102 Appendix 3. Main PCB Circuit Diagram, (3/7) CODE UK391303 NAME B48K299CIR (3/7) IV - 53...
  • Page 103 Appendix 4. Main PCB Circuit Diagram, (4/7) CODE UK391304 NAME B48K299CIR (4/7) IV - 54...
  • Page 104 Appendix 5. Main PCB Circuit Diagram, (5/7) CODE UK391305 NAME B48K299CIR (5/7) IV - 55...
  • Page 105 Appendix 6. Main PCB Circuit Diagram, (6/7) CODE UK391306 NAME B48K299CIR (6/7) IV - 56...
  • Page 106 Appendix 7. Main PCB Circuit Diagram, (7/7) CODE UK391307 NAME B48K299CIR (7/7) IV - 57...

  • Page 107: Power Supply Unit

    Power Supply Unit Outputs and Use Output Terminal Rated Output +5V-1 For control of the printer 4.8 ∼ 5.3V, 7.5A +5V-1R For control of the laser +5V-2 For control of the interface +24V-1 +24V, 4.5A For control of printer charging. 120V, 8A (For USA) For connection of the fuser heater (HP).
  • Page 108 Layout of Connector Pin Assignment - Power Supply Unit - ACN1 ACN3 ACN2 Main SW Inret PC Pin Black White White Black Fig.4-40...
  • Page 109 Connector Pin Assignment ACN1 ACN2 Manufacture: MoLex Manufacture: MoLex Type: 53313-2215 Type: 5277-02A Pin # Signal Name Interface Pin # Signal Name Interface +24V Output through +5V-1 +5V-1 Output DSW-O Door Switch Signal Ground +24V Output through SGND DSW-I (+5V type ground) Door Switch +5V-1 +5V-1 Output...

  • Page 110: High Voltage Power Supply Unit

    High Voltage Power Supply Unit Outputs and Function Function Power Supply (P/S) P/S Name Approx.Output Voltage CHV(-) 4.6KV Charging HVRD6190 619V 200V ∼ 900V First Transfer CBV(-) 200V ∼ 400V DBV(-A) Developing Bias 200V ∼ 400V DBV(-B) 400V ∼ 3,000V Second Transfer THV(+) Transfer Roller Cleaning...
  • Page 111 Layout of Connector Pin Assignment - High Voltage Power Supply Unit - FCBV BON1 DBV(K) DBV(Y) High Voltage MODEL DBV(M) ACOUT DBV(C) CHVOUT Fig.4-41...
  • Page 112 Connector Pin Assignment BCN1 BCN2 Manufacture: MoLex Manufacture: MoLex Type: 53313-1815 Type: 53324-0410 Pin # Signal Name Interface Pin # Signal Name Interface +24V-1 +24V-1 Thermistor 1 PGND PGND Thermistor 2 Sensor Signal of Fusing FUCHK FUCHK Fuser Check Unit Installation. PGND PGND FUCHKGND...
  • Page 114 (1) DCN2: IOD1 PCB - Power Supply Unit (22 pins) Pin No. Signal Pin No. Signal +5v - 1 SGND +5v - 1 SGND ACSYNC - N SGND +24V SGND +5v - 1R ACOFF - P HON - N TESTI2 +24V - 1 TESTO2 +24V - 1...
  • Page 115 (5) DCN1: MCTL PCB - IOD1 PCB (50 pins) Pin No. Signal Pin No. Signal SGND PGND SGND PGND +5v - 1 +24v - 1 +5v - 1 HON - N +5v - 1 SGND +5v - 1 ACOFF - P I/OAD2 +5v - 1R I/OAD1...
  • Page 116 (8) DCN6: IOD1 - Upper Paper Size Sensor (11) DCN8: IOD1 - Lower Feeder Unit IOD1 - OHP Sensor Pin No. Signal Pin No. Signal +24v - 1 +5v - 1 +24v - 1 PSU1 PKCLLON - N PSU2 SPSLLON - N PSU3 +5v - 1 PSU4...
  • Page 117 (14) ECN1: MCTL PCB - IOD1 (20 pins) (19) ECN3: IOD2 - Developer Solenoid Pin No. Signal Pin No. Signal DCL(C)ON - P +5v - 1 DCL(M)ON - P TBFL2 - N DCL(Y)ON - P SGND DCL(K)ON - P +5v - 1 PSL(KY)ON - P GHPSEN1 PSL(MC)ON - P...
  • Page 118 (25) ECN10: IOD2 - Cleaner Solenoid (31) ACN3: Power Supply Unit - MCTL Pin No. Signal Pin No. Signal +24v - 1 +5v - 2 +5v - 2 SGND FBSLON - N (32) ACN2: Power Supply Unit - (26) ECN8: IOD2 - Transfer Solenoid Interlock Switch (2 pins) Pin No.
  • Page 119 (30) LCN: MCTL - LDU (20 pins) Pin No. Signal +5v - R LDREF2 LDREF3 +5v - 1 LDREF1 LDREF0 LREADY LCONT2 LCONT1 VIDEO - P VIDEO - N BDT - P BDT - N SGND SGND SCMCLK SCMRDY - N SCMON - N PGND +24v - 1...

  • Page 120: Chapter V Control Panel Operation

    CHAPTER V CONTROL PANEL OPERATION...
  • Page 121 CONTENTS CHAPTER V CONTROL PANEL OPERATION ......V-1 1. PANEL LAYOUT ..................V-1 2. VIDEO CONTROLLER MODE..............V-2 2.1 Configuration of Operational Mode .................. V-2 2.2 Toner Save Mode / Power Save Mode ................V-3 2.3 Line Test Mode ........................ V-4 2.4 DRAM Test Mode ......................V-8 2.5 Program Version Display Mode ..................

  • Page 122: Panel Layout

    CHAPTER V CONTROL PANEL OPERATION PANEL LAYOUT Copy Pages Orientation Feeder Emulation Mode Toner Ready On Line Data Form Feed Alarm Feeder Mode Font Emulation Economy Test Continue Shift Copy Reset Fig.5-1 LED / Button Name LCD: 16 character by 2 lines Ready LED On Line LED Data LED...

  • Page 123: Video Controller Mode

    VIDEO CONTROLLER MODE This section describes the operation and maintenance functions in the Video Controller Mode. Configuration of Operational Mode This printer has various functions as set out in Table 5-1 for users to easily perform general test printing, general settings and some maintenance work. (1) Normal Mode: After turning on the printer, the printer goes into Normal Mode.

  • Page 124: Toner Save Mode / Power Save Mode

    Toner Save Mode / Power Save Mode The toner save mode allows you to reduce the printer running cost and improve the life expectancy of the toner cartridge. The power save mode allows you to save electricity when the printer is on but not being used.

  • Page 125: Line Test Mode

    Line Test Mode This mode tests the following items; Item Self-test Description LCD TEST Displays the checker pattern LED TEST Checks that all LEDs are on / off. SW TEST Checks that all buttons work correctly. SENSOR TEST Checks that all sensors work correctly. RAM SIZE TEST Displays the NVRAM size TRAY 1 CHECK...
  • Page 126 5) Press the Continue button to implement SW TEST. The LEDs are all off, and then the following display appears. Check that the corresponding number appears when pressing the buttons on the control panel. Corresponding button number on the panel X X X X X X X X 1 2 3 4 5 6 7 8 6) Press the Continue button to implement the SENSOR TEST.
  • Page 127 7) Press the Continue button to implement the RAM SIZE CHECK. The RAM size installed into the printer is displayed as follows; R A M C H E C K S T A R T R A M S I Z E = 1 6 M Standard Model: RAM SIZE = 16 MB...
  • Page 128 11)Press the Continue button to implement FLASH CARD2 R/W TEST. C A R D 2 R / W S T A R T C A R D 2 R / W O K CARD2 R/W OK: The flash memory card works correctly. CARD2 R/W ERROR: The flash memory card has a problem.

  • Page 129: Dram Test Mode

    DRAM Test Mode This mode tests the memory and optional SIMMs installed on the main (video controller) PCB. <Procedure> 1) To start the test program: While holding down the button, turn on the power. “DRAM CHECK START” will be displayed. Press the Continue button to start the DRAM check. 2) The LCD will display “START DRAM TEST”, and the Data LED blinks.

  • Page 130: Program Version Display Mode

    Program Version Display Mode This mode displays the firmware version of the controllers. <Procedure> 1) While holding down the Font button, turn on the power. 2) Hold down the Font button until Year/Month/Date of the program is displayed. P R O G X X X X / X X / X X Year Date Month...

  • Page 131: Test Print Mode

    Test Print Mode This mode prints the specified pattern continuously in order to check the engine. <Procedure> 1) Turn the printer to off-line. 2) While holding down the Shift button, press the Sel button. The message 'TEST PATTERN' appears. Press the SET button to enter the test mode and use the buttons to select a test.

  • Page 132: Engine Controller Mode

    ENGINE CONTROLLER MODE This section describes the operation and setting procedures for each engine test in the Engine Controller Mode. In order to go into the Engine Controller Mode, turn on the printer while holding down the Mode, Set and buttons.
  • Page 133 Table 5-2 Turn on the printer while pressing the Mode, Set and buttons. Normal Mode READY Ready LED OFF On Line LED ON WAIT Ready LED BLINKING PRINT Ready LED OFF CHK MEDIA Ready LED ON NO MEDIA NO TRAY REPLACE * TONER CHECK FUSER OIL CHK CLEANING ROLLER...

  • Page 134: Operation Of Normal Mode

    Operation of Normal Mode Normal Mode displays on the control panel the operational status of the printer when in the “ONLINE” state and the necessary information for the operator to implement ordinary maintenance work. Operation Procedures 1) Press the power button to turn on the printer while holding down the Mode, Set and buttons.
  • Page 135 Code No. LCD Message Description of Message • The Ready LED is lit. • The engine has completed the 00 READY [*1] warming-up process and is now ready U:[*2] L:[*3][*4] to print. [*1]: Applicable paper feeder is indicated as follows; /UPP: Upper Cassette /LOW: Lower Cassette [*2] / [*3]:...
  • Page 136 Code No. LCD Message Description of Message • The engine is idling. 11-1 • The Ready LED is lit. 11 CHK MEDIA [*1] [*4] [*1]: Applicable paper feeder is indicated as follows; /UPP: Upper Cassette /LOW: Lower Cassette • Confirm whether the applicable paper cassette is loaded with paper.
  • Page 137 Code No. LCD Message Description of Message • The engine is idling. 14-1 CHECK FUSER OIL • The Ready LED is lit. • Replace the fuser oil bottle with a new one. 14 CHECK [*5] • This message will be automatically FUSER OIL[*F0] cleared by opening &...
  • Page 138 Code No. LCD Message Description of Message • The engine is idling. 16-2 ALIGN FUSER CL ROLLER • The Ready LED is lit. • The cleaning roller is not installed. Reconfirm the installation status of the 16 ALIGN FUSER cleaning roller. CL ROLLER [*4] •...
  • Page 139 Code No. LCD Message Description of Message • The engine is in standby. 18-1 CLOSE PANEL • The Ready LED is lit. 18 CLOSE PANEL [*8]: The open cover is indicated as follows; [*8] [*4] FRONT: Front Cover TOP: Paper Exit Cover •...

  • Page 140: Service Mode

    Service Mode Service mode is a unique mode for the maintenance of the printer only, without the video controller card. In this mode, you can check the operation status of the printer engine Off- line and also carry out maintenance work for each of the printer components. Procedure 1) Hold down the Mode, Set and buttons and turn the printer Power on.
  • Page 141 GRID PRINT A single color or two color (R,G,B) Grid Pattern and a full color Stripe Pattern can be printed as Test Prints. Procedure Description of Procedures LCD Message 1) Press the Continue button. (a) → (b) SERVICE MODE TEST PRINT/NEXT 2) Using the Set or button, select the desired pattern (ex.
  • Page 142 NEXT CARE INFORMATION Information relating to the replacement timing of periodical replacement parts can be obtained. This is the life for each of the components in images or pages. Procedure Description of Procedures LCD Message 1) Press the Continue button after selecting Screen (a) “NEXT CARE INFO”.
  • Page 143 CASSETTE TYPE The type of paper feeding cassette can be selected. Type A is for the USA, type B is for Europe and type C is for Japan. Procedure Description of Procedures LCD Message 1) Press the Continue button after selecting Screen (a) “CASSETTE TYPE”.
  • Page 144 EACH IMAGE Number of created images for each color used in printing can be confirmed. Procedure Description of Procedures LCD Message 1) Press the Continue button after selecting Screen (a) “EACH IMAGE” mode. SERVICE MODE (a) → (b) EACH IMAGE 2) Using the Set or button, select the required color and then press the Continue...
  • Page 145 CLEAR CARE Care Code counters displayed on the LCD can be cleared. Make sure that you clear the relevant CLEAR CARE mode whenever replacing periodical replacement parts with new ones. This mode should only be used to reset the counters after replacement of faulty consumables before their life expectancy is reached.
  • Page 146 MEDIA MANAGE The signal from the OHP sensor can be ignored when the media is selected to OHP. However, this mode should not be used under normal circumstances. Procedure Description of Procedures LCD Message 1) Press the Continue button after selecting Screen (a) “MEDIA MANAGE”.
  • Page 147 FACTORY MODE This mode consists of 9 (nine) modes for the confirmation of operation and the resetting functions necessary for maintenance work. CAUTION Before using this mode, ensure that you have the information available to reset the Page and Image counters to the correct values. See 34 TOTAL PAGES and 35 EACH IMAGE for information on how to get the readings before starting working with these functions.
  • Page 148 DP CHECK Each individual colour Toner cartridge can be driven. Procedure Description of Procedures LCD Message 1) Press the Continue button after selecting Screen (a) “DP CHECK”. 39 FACTORY MODE (a) → (b) DP CHECK 2) Using the Set or button, select the desired color and then press the Continue button.
  • Page 149 BD CHECK Laser beam position and laser power can be checked. Procedure Description of Procedures LCD Message 1) Press the Continue button after selecting (a) → (b) screen (a) “BD CHECK”. 39 FACTORY MODE BD CHECK 2) The scanner motor scans the laser beam as it is rotating.
  • Page 150 MARGIN ADJUST The position of the top margin and left margin can be confirmed and adjusted within the range -3.5mm max. and +3.5mm max. Note: It is recommended to use the default value in normal use. Do not perform this mode frequently.
  • Page 151 LIFE PERIOD Replacement life of the periodical replacement parts can be set. Note: It is recommended to use the default value in normal use. Do not adjust these settings without authorization. Procedure Description of Procedures LCD Message 1) Press the Continue button after selecting Screen (a) “LIFE PERIOD”...
  • Page 152 NVRAM TUNE UP This mode is not used in normal operations, but is used when fine adjustment of the HVPSU voltage values is required. Do not use this mode unless you are sure that you understand the effects of making adjustments to the various charge voltages in the HVPSU.
  • Page 153 45-1 LP TUNE UP This mode should be used when optical density, line thickness and/or color reproduction needs to be adjusted. The adjustment is made by changing the laser power against the reference value 0 (zero) in the range -4 to +4. Note: Do not perform this mode frequently.
  • Page 154 45-2 THV TUNE UP This mode shall be used when the transfer voltage needs to be adjusted due to errors such as transfer failure onto the media. The adjustment is used to change the transfer voltage, subject to the media to be used, against the reference value 0 (zero) in the range -4 to +4.
  • Page 155 45-3 DBV TUNE UP This mode shall be used when the image optical density needs to be adjusted. Adjustment of the developer bias voltage against the reference value 0 (zero) in the range -4 and +4. Note: Do not perform this mode frequently. Description of Procedures LCD Message 1) Press the Continue button after selecting...
  • Page 156 45-4 CBV TUNE UP This mode should be used when image defects attributed to the OPC belt need to be improved. Adjustment is to alter the OPC belt bias voltage against the reference value 0 (zero) in the range -4 to +4. Note: Do not perform this mode frequently.
  • Page 157 45-5 FBV TUNE UP This mode should be used when image defects attributed to the transfer drum need to be improved. Adjustment is to adjust the drum cleaner bias voltage against the reference value 0 (zero) in the range -4 and +4. Note: Do not perform this mode frequently.
  • Page 158 NVRAM INITIAL This mode can initialize (data clear) all the data in the NVRAM on the MCTL PCB. CAUTION BEFORE USING THIS MODE, THE VALUES FROM ‘34 TOTAL PAGES’ AND ‘35 EACH IMAGE’ MUST BE READ TO ENABLE THE CORRECT VALUES TO BE RESET USING FUNCTIONS 47 AND 48.
  • Page 159 EACH IMAGE SET This mode can reset the number of total pages of each color in the NVRAM whenever NVRAM INITIAL is executed or the MCTL PCB is replaced. Note: Do not perform this mode other than when replacing the MCTL PCB. Description of Procedures LCD Message 1) Press the Continue button after selecting...

  • Page 160: Adjustment Work Procedures

    Adjustment Work Procedures 3.4.1 Adjustment of Top and Left Margin The top and left margins can be adjusted by button operation on the control panel. <Purpose> If there is no top margin or left margin set for the print guarantee area or when the MCTL PCB is replaced, the adjustment of top and left margin will be required.

  • Page 161: 3.4.2 Setting Of Engine Nvram Data

    3.4.2 Setting of Engine NVRAM Data As data in the NVRAM has been preset to the optimum value at the factory, it is not necessary to change the preset values under normal conditions. However, fine adjustment may be required subject to the media or operational conditions. <Purpose>...

  • Page 162: 3.4.3 Confirmation And Setting Of Total Number Of Printouts

    3.4.3 Confirmation and Setting of Total Number of Printouts The total number of printouts is stored in the RAM. Confirmation and setting of total number of printouts can be carried out on the control panel. <Purpose> Total number of printouts will be reset when changing the MCTL PCB or executing an NVRAM INITIAL.

  • Page 163: 3.4.5 Initial Setting Of Engine Nvram

    3.4.5 Initial Setting of Engine NVRAM Implement the initial setting at the replacement of MCTL PCB after clearing the contents of NVRAM. <Purpose> The number of images for each color will be reset when changing the MCTL PCB or executing NVRAM INITIAL. <Procedures of Setting>...

  • Page 164: Chapter Vi Periodic Maintenance

    CHAPTER VI PERIODIC MAINTENANCE...
  • Page 165 CONTENTS CHAPTER VI PERIODIC MAINTENANCE ........VI-1 1. GENERAL.....................VI-1 1.1 Handling Precautions......................VI-1 1.1.1 List of Maintenance Tools..................VI-2 1.1.2 List of Consumables for Maintenance ..............VI-3 1.2 Periodic Maintenance Cleaning ..................VI-4 1.2.1 Cleaning the Register Roller..................VI-7 1.2.2 Cleaning the Paper Guide ..................VI-8 1.2.3 Cleaning the Paper Exit Roller .................

  • Page 166: General

    CHAPTER VI PERIODIC MAINTENANCE GENERAL Handling Precautions Since this high quality laser printer is a precision equipment, daily checking and periodic maintenance is indispensable to maintain the expected high performance. The following is the list of important precautions & action items for maintenance and periodic replacement parts: 1) Refrain from any operation, disassembly or modification that is not set out in this manual.

  • Page 167: List Of Maintenance Tools

    1.1.1 List of Maintenance Tools Table 6-1 below lists the maintenance tools required for the printer. Table 6-1 Tool Name Function Phillips Screwdriver #1 For M3 Phillips Screwdriver #2 For M4 Phillips Screwdriver (short shank) #2 For M4 Slotted Screwdriver #1 For slotted head screw (M3) Slotted Screwdriver #2 For slotted head screw (M4, M5)

  • Page 168: List Of Consumables For Maintenance

    1.1.2 List of Consumables for Maintenance Table 6-2 below lists the consumables for maintenance. Table 6-2 Tool Name Quantity Function Toner Cartridge (Y) 1 piece Test Print Toner Cartridge (M) 1 piece Test Print Toner Cartridge (C) 1 piece Test Print Toner Cartridge (K) 1 piece Test Print...

  • Page 169: Periodic Maintenance Cleaning

    Periodic Maintenance Cleaning See Table 6-3 for details of periodic maintenance cleaning for the following parts. 1) Register Roller 2) Paper Guide 3) Paper Exit Roller 4) Transfer Roller 5) Paper Discharger 6) OPC Belt Cartridge 7) Transfer Drum 8) Dustproof Glass of the Scanner Unit 9) Printer Interior WARNING •...
  • Page 170 Periodic Maintenance Cleaning Work Table 6-3 Parts Name Cleaning Work Cleaning Cycle *1 Description Section (Condition or Case) • Defective image 1. Open the transfer unit. • Smeared paper Register Roller 2. Clean roller and surrounding area using a 1.2.1 •...
  • Page 171 Periodic Maintenance Cleaning Work Table 6-3 Parts Name Cleaning Work Cleaning Cycle *1 Description Page (Condition or Case) 1. Remove the transfer drum. • Defective image Transfer Drum 2. Clean the dirt from the transfer drum 1.2.7 • Periodic maintenance surface using a cloth.

  • Page 172: Cleaning The Register Roller

    1.2.1 Cleaning the Register Roller The register roller should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. <Tools to Prepare> Cotton cloth (2 ∼ 3 pieces) <Cleaning Procedure> 1) Turn off the power supply, and unplug the power cable. 2) Open the rear access cover (transfer unit).

  • Page 173: Cleaning The Paper Guide

    1.2.2 Cleaning the Paper Guide The paper guide should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. <Tools to Prepare> Cotton cloth (2 ∼ 3 pieces) <Cleaning Procedure> 1) Remove the media cassette from the printer. 2) Remove paper in the media cassette.

  • Page 174: Cleaning The Transfer Roller

    1.2.4 Cleaning the Transfer Roller The transfer roller should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. <Tools to Prepare> Cotton cloth (2 ∼ 3 pieces) <Cleaning Procedure> 1) Turn off the power supply, and unplug the power cable. 2) Open the rear access cover (transfer unit).

  • Page 175: Cleaning The Paper Discharger

    1.2.5 Cleaning the Paper Discharger The paper discharger should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. <Tools to Prepare> 1) Cotton cloth (2 ∼ 3 pieces) 2) Cotton swab (2 ∼ 3 pieces) <Cleaning Procedure>...

  • Page 176: Cleaning The Opc Belt Cartridge

    1.2.6 Cleaning the OPC Belt Cartridge The OPC belt cartridge should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. PRECAUTION • Do not directly touch the OPC belt surface with bare hands or gloves. •...

  • Page 177: Cleaning The Transfer Drum

    1.2.7 Cleaning the Transfer Drum The transfer drum should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. <Tools to Prepare> Cotton cloth (2 ∼ 3 pieces) <Cleaning Procedure> 1) Turn off the power supply. 2) Open the rear access cover.

  • Page 178: Cleaning The Dustproof Glass In The Scanner Unit

    1.2.8 Cleaning the Dustproof Glass in the Scanner Unit The dustproof glass in the scanner unit should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. <Tools to Prepare> 1) Cotton cloth (2 ∼ 3 pieces) 2) Cotton swab (2 ∼...

  • Page 179: Cleaning The Printer Interior

    1.2.9 Cleaning the Printer Interior The printer interior (bottom) should be cleaned according to the periodic maintenance cleaning cycle set out in Table 6-3. <Tools to Prepare> 1) Toner vacuum cleaner 2) Cotton cloth (2 ∼ 3 pieces) <Cleaning Procedure> 1) Open the top cover and the front cover.

  • Page 180: Periodic Maintenance Parts And Maintenance Cycle

    Periodic Maintenance Parts and Maintenance Cycle Maintenance Work should be implemented according to the “Periodic Maintenance Parts and Maintenance Cycle” set out in Table 6-4. VI-15...
  • Page 181 Table 6-4: Periodic Maintenance Parts and Maintenance Cycle Maintenance Parts Description Replacement Cycle *1 Parts Name Function Section (Condition or Case) 50K images or 12 Consists of the OPC belt and forms OPC Belt months whichever Accessory an electrostatic latent image. Cartridge comes first.
  • Page 182 These figures are based on an average of 5% coverage of the printable area for one color using laser paper. The frequency of replacement will vary, depending on the complexity of the prints, the percentage of coverage, and the type of media.

  • Page 183: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE PROCEDURES The printer displays messages on the control panel screen to indicate replacement is due for most of the periodic maintenance parts in both the Video Controller Mode and the Engine Controller Mode. However, the procedure to clear the message differs between the two modes. The following sections describe the Video Controller Mode messages only and should be used when replacing parts that have reached their life.
  • Page 184 3) Release the belt cartridge lock levers at both sides (left & right). (Fig.6-11) 4) Pull out the OPC belt cartridge. Belt cartridge lock lever (Left) Belt cartridge lock lever (Right) Fig.6-11 5) Prepare a new belt cartridge. Remove the protective sheet from a new OPC belt cartridge, and then pull and remove the tension release pins from both sides (left &...

  • Page 185: Fusing Unit Replacement

    Fusing Unit Replacement <Criterion of Replacement> The fusing unit should be replaced with a new one according to the periodical maintenance cycle set out in Table 6-4. When the time is due for replacement of the fusing unit, the following message appears on the control panel.
  • Page 186 PR98311 CAUTION When removing the fusing unit, take care to keep the unit level so that no oil leakage or spillage occurs. When shipping the printer, remove the oil bottle and the fuser cleaner from the fusing unit. After removing the oil bottle, be sure to remove the oil remaining in the fusing unit with the supplied syringe.

  • Page 187: Transfer Roller Replacement

    Transfer Roller Replacement <Criterion of Replacement> The transfer roller should be replaced at the same time as a new discharger unit according to the periodical maintenance cycle set out in Table 6-4. When time is due for replacement of the transfer roller, the following message appears on the control panel.
  • Page 188 2) Push the tab of the left hand side to remove the shaft from the installation hole at the right side first, then remove the transfer roller. (Fig.6-20) 3) Install a new transfer roller into the printer. 4) Fix the transfer roller with the lock lever.

  • Page 189: Paper Discharger Unit Replacement

    Paper Discharger Unit Replacement <Criterion of Replacement> The paper discharger should be replaced with a new discharger unit at the same time as the Transfer roller according to the periodical maintenance cycle set out in Table 6-4. When time is due for replacement of paper discharger unit, the following message appears on the control panel.
  • Page 190 Sequence of Replacement 1) Pull the right hand side of the paper discharger slightly, then lift it out of the transfer unit to remove the paper discharger. (Fig.6-22) Lever Paper Discharger Fig.6-22 2) Clean the area where the paper discharger unit is mounted. (Fig.6- 3) Install the new paper discharger unit into the transfer unit.

  • Page 191: Drum Cleaner Replacement

    Drum Cleaner Replacement <Criterion of Replacement> The drum cleaner should be replaced with a new one according to the periodical maintenance cycle set out in Table 6-4. When time is due for replacement of the drum cleaner, the following message appears on the control panel.
  • Page 192 2) Holding the handle located on the Drum Cleaner top of the drum cleaner, push it Handle backwards. 3) Remove the drum cleaner by lifting it out. (Fig.6-25) Fig.6-25 4) Clean the area where the drum cleaner is mounted. (Fig.6-26) 5) Install a new drum cleaner into the printer.

  • Page 193: Ozone Filter Replacement

    Ozone Filter Replacement <Criterion of Replacement> The ozone filter should be replaced with a new one according to the periodical maintenance cycle set out in Table 6-4. This is to prevent ozone from being exhausted due to the deterioration of the ozone filter. PRECAUTION Ozone filter should be replaced with a new filter every 12 months, otherwise it may cause an offensive smell.

  • Page 194: Paper Feed Roller And Separator Pad Replacement

    Paper Feed Roller and Separator Pad Replacement <Criterion of Replacement> The paper feeding roller and separator pad should be replaced with new ones according to the periodical maintenance cycle set out in Table 6-4. When time is due for replacement of the paper feed roller and separator pad, the following message appears on the control panel.

  • Page 195: Transfer Drum Replacement

    Transfer Drum Replacement <Criterion of Replacement> The transfer drum should be replaced with a new one according to the periodical maintenance cycle set out in the Table 6-4. When time is due for replacement of the transfer drum, the following message appears on the control panel.

  • Page 196: Chapter Vii Disassembly

    CHAPTER VII DISASSEMBLY...
  • Page 197     CHAPTER VII DISASSEMBLY............ VII-1 1. BEFORE STARTING DISASSEMBLY ............VII-1 1.1 Precautions ........................VII-1 1.2 Preparation of Disassembly ................... VII-1 2. PARTS NAME...................VII-3 2.1 Cover ..........................VII-3 2.2 Circuit Boards (PCBs)....................VII-4 2.3 Motor Units........................VII-4 2.4 Clutches and Solenoids ....................
  • Page 198 4.2.14 Oil Sensor (OIL) ....................VII-24 4.2.15 Interlock Switch (Front) (for Front Cover)............. VII-25 4.3 Left Side of the Printer ....................VII-26 4.3.1 MCTL PCB ......................VII-26 4.3.2 High Voltage Unit....................VII-27 4.3.3 Interlock Switch (Rear) ................... VII-28 4.3.4 Drum Encoder Sensor (EN) ................... VII-29 4.3.5 Fuser Connector.....................

  • Page 199: Precautions

    CHAPTER VII DISASSEMBLY BEFORE STARTING DISASSEMBLY Precautions Follow the precautions described below during maintenance work. (1) Do not implement any operation, disassembly or modification which is not set out in this manual. (3) This printer incorporates dangerous parts subject to warnings such as “High Temperature”, “High Voltage”...
  • Page 200 Table 7-1: Table of Screw Sizes Used in the Printer Size and Shape of Screw Class Code Name of Screw Remarks M-Thread Length Sharp BT3X8 BT3X12 10mm Cross recessed Used for plastic parts. head tapping screw BT4X8 BT4X10 10mm Used for steel parts fitted to ST3X6 S tight screw...

  • Page 201: Parts Name

    PARTS NAME Cover <Front View> Upper Cover Control Panel 4.2.5 Top Cover (Paper Exit Unit) 4.4.2 Power Button Side Cover (R) 4.1.1 Front Cover (Front Cover Unit) 4.5.1 Media Cassette Base Cover (R) 4.1.2 Fig.7-1 <Rear View> Cleaner Cover Upper Side Cover (LU) 4.2.9 4.2.1 Side Cover (L)

  • Page 202: Circuit Boards (Pcbs)

    Circuit Boards (PCBs) Erase Lamp 4.2.12 Panel PCB 4.2.2 IOD2 PCB 4.1.6 High Voltage Power Supply(HVU)PCB 4.3.2 IOD1 PCB 4.2.6 Video Controller MCTL PCB 4.3.1 DC Power Supply (LVPS)PCB 4.3.8 Fig.7-3 Motor Units Ozone Fan 4.1.15 Fuser Fan 4.4.2 Main Motor 4.1.8 Developer Drive Control...

  • Page 203: Clutches And Solenoids

    Clutches and Solenoids Drum Cleaner Solenoid 4.1.12 Fuser Clutch 4.1.4 Drum Cleaner Clutch 4.1.5 Transfer Solenoid 4.1.14 Registration Clutch 4.1.3 Paper Feeding Clutch 4.1.9 Developer Clutch (K) Developer Clutch (Y) 4.1.10 Developer Clutch (M) Developer Clutch (C) (Developer Solenoids) Fig.7-5 VII-5...

  • Page 204: Sensors

    Sensors Temperature Sensor (Thermistor) Cleaning Roller Sensor Paper Exit Sensor 4.4.3 4.4.6 Drum Jam Sensor Oil Sensor 4.2.13 4.2.14 Interlock Switch (Top) 4.2.8 Toner Detecting Sensor Belt Sensor 4.1.16, 4.3.9 4.2.10 Interlock Switch (Front) Interlock Switch 4.2.15 (Rear) 4.3.3 Developing Photo Sensor Drum Encoder Sensor...

  • Page 205: Disassembly Flow

    3. DISASSEMBLY FLOW 4.PAPER EXIT 6.REAR (Transfer Unit) UNIT 4.4.1 4.6.1 1. RIGHT SIDE Rear Access Cover Rear Cover (U) 2.TOP 3.LEFT SIDE / Transfer Unit 4.1.1 4.2.2 Panel PCB 4.3.1 Side Cover (R) 4.2.1 Upper Side MCTL PCB (LCD inclusive) Cover (LU) 4.6.2 4.4.2...

  • Page 206: Disassembly Procedure

    DISASSEMBLY PROCEDURE Right Side of the Printer 4.1.1 Side Cover (R) 1) Remove the set screw BT4X8 (1 pc.) of side cover (R) at the rear of the printer. Side Cover (R) Fig.7-7 2) Slide the side cover (R) in the direction of the arrows as shown in Fig.7-8. 3) Remove the side cover (R) by releasing the two hooks.

  • Page 207: Base Cover (R)

    4.1.2 Base Cover (R) 1) Remove the set screws BT4X8 (2 pcs.) from the base cover (R). 2) Remove the base cover (R) from the base. Note: If the optional lower tray unit is fitted, it will be necessary to remove the lower tray clamp screw and locking bar to release the base cover (R).

  • Page 208: Iod2 Pcb (With Base)

    Fuser clutch C ring Cleaner clutch C ring C ring Registration clutch Fig.7-10 4.1.6 IOD2 PCB (with base) 1) Disconnect all the harness connectors (13 pcs.) connected to the IOD2 PCB. 2) Remove the set screws ST3X6 (2 pcs.) from the IOD2 PCB base. 3) Remove the IOD2 PCB (with base) from the main body.

  • Page 209: Developer Drive Motor (Dm)

    4.1.7 Developer Drive Motor (DM) CAUTION Take care not to stress the motor drive PCB when removing the connector or handling the motor / PCB assembly. 1) Remove the connector (1 pc.) from the developer drive motor PCB. 2) Remove the set screws ST3X6 (4 pcs.) holding the developer drive motor to the developer drive unit.

  • Page 210: Paper Feeding Clutch (Pclu)

    4.1.9 Paper Feeding Clutch (PCLU) 1) Remove the outer plastic C ring from the shaft. 2) Remove the paper feeding clutch from the shaft. Paper Feeding Clutch C ring Fig.7-14 4.1.10 Developer Clutch (K, Y, M, C) 1) Remove the outer plastic C ring of each developer clutch from the shaft. 2) Pull out the developer clutch from the shaft.

  • Page 211: 4.1.11 Developer Drive Unit

    4.1.11 Developer Drive Unit 1) Open the front cover. 2) Remove the waste toner box. 3) Remove the harness guide. 4) Remove the set screws ST3X6 (4 pcs.) from the developer drive unit. 5) Remove the developer drive unit. Developer Drive Unit Harness guide Fig.7-16 4.1.12 Drum Cleaner Solenoid (FBSOL)

  • Page 212: 4.1.13 Main Gear Unit

    4.1.13 Main Gear Unit 1) Remove the screws ST3X6 (3 pcs.) and loosen the screw BT4X8 (1 pc.) holding the rear plastic cover plate and then remove the stay (R). 2) Remove the upper set screw ST3X6 (1 pc.) from the ozone fan case. 3) Remove the ozone fan duct.

  • Page 213: Ozone Fan (Ozfan)

    4.1.15 Ozone Fan (OZFAN) 1) Remove the lower set screw ST3X6 (1 pc.) from the fan case assembly. (Fig.7-20) 2) Remove the fan case assembly. 3) Remove the ozone fan from the fan case. (Fig.7-21) Ozone Fan Fan case Fig.7-20 Fig.7-21 4.1.16 Toner Sensor Assembly (TPD) 1) Remove the set screws ST3X6 (3 pcs.) from the toner sensor PCB.

  • Page 214: Waste Toner Sensor (Wts)

    PR99077 4.1.17 Waste Toner Sensor (WTS) 1) Lift up the bottle holder. 2) Remove the screws (2 pcs.) from the bottle holder and waste toner sensor assembly. 3) Disconnect the connector from the waste toner sensor. 4) Remove the sensor assembly with the bottle holder. 5) Remove the waste toner sensor by removing the hooked pawl.
  • Page 215 PR99077 CAUTION Be sure to vacuum up waste toner remaining inside the plastic tube with a vacuum cleaner before removing the plastic tube. 4) Remove the set screw ST3x6 (2 pcs.) from the auger spring gear unit. 5) Take the auger spring out of the frame, then remove the auger spring gear unit from the printer inside .

  • Page 216: Top Of The Printer

    Top of the Printer 4.2.1 Upper Side Cover (LU) 1) Open the top cover. 2) Remove the set screw BT4X8 securing the side cover (LU) 3) Press the exterior of the side cover inwards(L) and unlock the hooks (three locations) from the side cover (LU).

  • Page 217: Panel Pcb (Including Lcd)

    4.2.2 Panel PCB (including LCD) 1) Remove the set screw BT4X10 (1 pc.) from the panel case assembly and disconnect the connector. (Refer to Figure 7-26 below.) 2) Remove the set screws BT3X8 (4 pcs.) from the panel PCB and remove the panel shield plate, PCB and LCD from the panel case assembly.

  • Page 218: Base Cover (L)

    4.2.4 Base Cover (L) 1) Remove the set screws TS4X8 (2 pcs.) from the base cover (L). 2) Remove the base cover (L) from the base. Note: If the optional lower tray unit is fitted, it will be necessary to remove the lower tray clamp screw and locking bar to release the base cover (R).

  • Page 219: Iod1 Pcb

    4.2.6 IOD1 PCB 1) Remove the set screws ST3X6 (3 pcs.) from the shield (upper). 2) Disconnect all the harness connectors (14 pcs.) connected to the IOD1 PCB. Note that the DCN3 connector is a link plug and need not be removed unless necessary. 3) Remove the set screws ST3X6 (6 pcs.) from the IOD1 PCB.

  • Page 220: Interlock Switch (Top) (Paper Exit Unit)

    4.2.8 Interlock Switch (Top) (Paper Exit Unit) 1) Remove the set screw BT3X8 (1 pc.) and remove the switch base from the control fan case. 2) Remove the interlock switch from the switch base. CAUTION Since the interlock switch is an important safety item, after installation confirm that the switch operates correctly.

  • Page 221: Waste Toner Feeder Unit / Belt Sensor (Pbs)

    4.2.10 Waste Toner Feeder Unit / Belt Sensor (PBS) 1) Remove the set screws ST3X6 (2 pcs.) from the waste toner feeder unit. 2) Remove the waste toner feeder unit complete with the belt sensor. 3) Disconnect the connector (1 pc.) to the belt sensor. 4) Remove the belt sensor from the waste toner feeder unit.

  • Page 222: 4.2.12 Erase Lamp

    Transfer Drum Fig.7-36 4.2.12 Erase Lamp 1) Disconnect the harness (1 pc.) connected to the erase lamp. 2) Remove the erase lamp from the holder. Holder Harness Erase Lamp Fig.7-37 VII-23...

  • Page 223: Drum Jam Sensor (Dpj)

    4.2.13 Drum Jam Sensor (DPJ) 1) Remove the cover F by lifting the left hand end of the cover and sliding the cover to the right to release the catches. 2) Disconnect the drum jam sensor connector. 3) Remove the drum jam sensor. Cover F Drum Jam Sensor Fig.7-38...

  • Page 224: Interlock Switch (Front) (For Front Cover)

    4.2.15 Interlock Switch (Front) (for Front Cover) 1) Remove the set screw (1 pc.) and washer to remove the switch assembly from the stay U. 2) Remove the connector. 3) Remove the interlock switch from the switch case. Switch case Interlock Switch Stay U Fig.7-40...

  • Page 225: Left Side Of The Printer

    Left Side of the Printer 4.3.1 MCTL PCB CAUTION Remove the Main (Video Controller) PCB before starting this disassembly. 1) Remove the set screws ST3X6 (3 pcs.) from shield cover ‘A’. 2) Remove the shield cover ‘A’. 3) Remove the set screw ST3X6 (1 pc.) from shield cover ‘B’. Slide the cover upwards and remove it 4) Disconnect all the harness connectors (5 pcs.) connected to the MCTL PCB.

  • Page 226: High Voltage Unit

    4.3.2 High Voltage Unit 1) Remove the Main (Video Controller) PCB guide rail (upper). Main PCB guide rail (upper) Fig.7-42 2) Remove the set screws ST3X6 (5 pcs.) from shield case ‘A’ assembly. 3) Remove the fan duct from the power supply. Fan duct Shield case ‘A’...

  • Page 227: Interlock Switch (Rear)

    High Voltage Unit Fig.7-44 CAUTION When disconnecting the connector from the CBV terminal, push both sides of the connector as shown in Fig.7-302. Pulling it hard may cause connector damage. WARNING The high voltage power supply unit generates high voltages of up to 5KV. You can get an electric shock if you touch the unit while it is powered on.

  • Page 228: Drum Encoder Sensor (En)

    4.3.4 Drum Encoder Sensor (EN) 1) Remove the sensor case assembly from the frame (L). 2) Disconnect the connector (1 pc.) to the encoder sensor. 3) Remove the encoder sensor from the sensor holder. Drum Encoder Sensor Fig.7-46 4.3.5 Fuser Connector 1) Remove the PN/PH connectors connected to the DC power supply unit.

  • Page 229: Rear Cover (R)

    4.3.6 Rear Cover (R) 1) Remove the set screw BT4X8 (1 pc.) of rear cover (R). 2) Remove the rear cover (R). Rear Cover (R) Fig.7-48 4.3.7 Power Supply Unit 1) Disconnect the harnesses (4 pcs.) connected to the power supply unit. 2) Remove the power switch key.
  • Page 230 7) Remove the set screw M4X6 (1 pc.) complete with the shakeproof washer to release the earthing harness. 8) Remove the power outlet from the frame. Power outlet Fig.7-50 9) Remove the set screws ST3X6 (2 pcs.) from the power supply unit frame. 10) Remove the power supply unit complete with the frame.

  • Page 231: Paper Size Sensor (Psu)

    4.3.8 Paper Size Sensor (PSU) Note: If the optional lower tray unit is fitted, remove the left hand screw of the front cross rail to release the media cassette guide. 1) Remove the media cassette. 2) Remove the set screws ST3X6 (1 pc.) from the media cassette guide (L) assembly. 3) Pull the media cassette guide toward you while pushing the front catch to release the guide from the plastic catches (4 pcs.).

  • Page 232: Paper Exit Unit

    Paper Exit Unit 4.4.1 Rear Cover (U) 1) Remove the rear cover (R). (Refer to Section 4.3.6 in this chapter.) 2) Remove the set screw BT4X6 (1 pc.) of rear cover (U). 3) Remove the rear cover (U). Rear Cover (U) Rear Cover (R) Fig.7-54 4.4.2...
  • Page 233 6) Remove the paper exit inner cover by removing the set screws BT3X8 (4 pcs.), release arm, hook (R) & (L) and spring. Paper exit inner cover Spring Hook(L) Release arm Hook(R) Fig.7-56 7) Press the sides of the fan case to release the fan motor assembly from the paper exit guide unit.
  • Page 234 9) Remove the set screws BT3X8 (4 pcs.) from the paper exit guide unit. 10) Remove the top cover (paper exit cover) from the paper exit guide unit. Paper exit guide unit Top Cover (Paper Exit Cover) Fig.7-58 Note: • When re-assembling, ensure the hooks are fitted facing in the correct direction on the release arm.

  • Page 235: Cleaning Roller Sensor (Crs)

    4.4.3 Cleaning Roller Sensor (CRS) 1) Disconnect the harnesses connected to the cleaning roller sensor. 2) Remove the cleaning roller sensor from the paper exit guide (paper exit stay). Cleaning Roller Sensor Paper exit guide Fig.7-60 4.4.4 Discharger Brush 1) Remove the set screws BT4X6 (2 pcs.) from the discharger brush. 2) Remove the discharger brush and the plastic retainer.

  • Page 236: Paper Exit Roller

    4.4.5 Paper Exit Roller 1) Remove the C ring, washer, and plastic bush from the left and right hand sides. 2) Remove the shaft support at both sides. 3) Remove the paper exit roller from the paper exit guide. Paper exit guide Paper Exit Roller Fig.7-62 4.4.6...

  • Page 237: Front Of The Printer

    Front of the Printer 4.5.1 Front Cover Unit 1) Open the front cover unit. 2) Remove the set screws BT4X8 (2 pcs.) from the front inner cover. 3) Release the two hooks at the front edge of the inner cover and lift it up. 4) Release the hinge pin lock lever.

  • Page 238: Scanner Unit (Scanner Motor Inclusive)

    4.5.2 Scanner Unit (Scanner Motor inclusive) 1) Cover ‘C’ is fixed by plastic projections and hooks at three locations at the front and three locations at the rear. Release the hooks at the rear. 2) Release the fixings at the front by pulling cover ‘C’ forwards. 3) Remove the harness from the harness holder, and the cover ‘C’...

  • Page 239: Rear Of The Printer

    Rear of the Printer 4.6.1 Rear Access Cover (L) / Transfer Unit 1) Open the rear access cover. 2) Remove the upper screw of the retaining strap supporting the transfer unit to the printer body. 3) Remove the set screw ST3X6 (1 pc.) from the left hand side transfer unit metal retaining plate.

  • Page 240: Transfer Roller

    4.6.2 Transfer Roller 1) Lift the transfer roller lock lever to release the right hand end of the roller. The angle of lifting the lock lever is approx. 80° from the horizontal. 2) Push the tab of the left hand side to remove the shaft from the installation hole at the right side first, then remove the transfer roller.

  • Page 241: Paper Feed Roller / Separator Pad

    4.6.4 Paper Feed Roller / Separator Pad 1) Remove the media cassette. 2) Remove the set screws ST3X6 (2 pcs.) from the paper guide (L). 3) Remove the paper guide (L). 4) Remove the set screws ST3X6 (2 pcs.) from the paper guide (UR). 5) Remove the paper guide (UR).

  • Page 242: Paper Empty Sensor (Pe) / Ohp Sensor (Ohp)

    4.6.5 Paper Empty Sensor (PE) / OHP Sensor (OHP) 1) Remove the sensor connector. 2) Remove the set screws BT3X8 (2 pcs.) from the OHP sensor and remove the (OHP) sensor from the paper guide assembly (UR). 3) Remove the paper empty sensor (PE) from the paper guide assembly (UR) Paper guide assembly (UR) Paper Empty Sensor OHP Sensor...

  • Page 243: Fusing Unit

    Fusing Unit DANGER [Note in Parts Replacement] • The fuser unit consists of important safety parts. Replacement of parts or disassembly and maintenance work should only be done at an appropriate service facility by skilled service personnel acquainted with electrical safety.
  • Page 244 PR98311 Back-up roller Fuser roller Terminal (L) Fuser Lamp (300W) Fuser Lamp (400W) Terminal (L) Fig.7-76 PRECAUTION Do not touch the surface of the heater lamp with your hands, the small traces of oil you leave on the lamp will affect the life of the lamp. The wattage and length of the heater lamp is different between the fuser roller and the back-up roller.

  • Page 245: Chapter Viii Troubleshooting

    CHAPTER VIII TROUBLESHOOTING...
  • Page 246 CONTENTS CHAPTER VIII TROUBLESHOOTING ........VIII-1 1. OUTLINE OF TROUBLESHOOTING ............VIII-2 2. OPERATOR CALL ..................VIII-3 2.1 Video Controller Mode ...................... VIII-3 2.2 Engine Controller Mode ....................VIII-6 3. PAPER TRANSPORT ERROR..............VIII-8 3.1 Feed Jam.......................... VIII-8 3.2 Inner Jam.......................... VIII-9 3.3 Outer Jam......................... VIII-9 3.4 Others ..........................

  • Page 247: Chapter Viii Troubleshooting

    CHAPTER VIII TROUBLESHOOTING This chapter contains troubleshooting information for both the Video Controller Mode and the Engine Controller Mode. If any problem occurs during the normal usage of the printer, which means the printer is being used in the Video Controller Mode, clear the problem by referring to the troubleshooting information in the following sections for the Video Controller Mode or the user’s guide.

  • Page 248: Outline Of Troubleshooting

    OUTLINE OF TROUBLESHOOTING Printer Problem Paper Transport Operator Call Service Call Image Failure Error [Section 2.1] [Section 3] [Section 5] Enter the Engine Controller Mode Turn on the power while holding Turn on the power after turning off the down the Mode, Set and buttons printer.

  • Page 249: Video Controller Mode

    OPERATOR CALL Video Controller Mode The Ready LED is lit and an applicable message appears on the liquid crystal display (LCD) in the following cases; 1) Consumables require to be replenished. 2) Waste toner pack is full of waste toner. 3) Paper jam.
  • Page 250 Display Message Meaning Countermeasure Request to load paper Load the requested size of manually. (The T1 MANUAL FEED paper into the standard message appears ***** SIZE media cassette and press the alternately to show a Select button. particular size.) Turn off the printer, and An error occurred in 19 CHECK FONT reinstall or replace the...
  • Page 251 Display Message Meaning Countermeasure Press the Continue button to start printing the next page. Data which overran the print area on the page cannot be printed. Check your page 31 PRINT OVERRUN Print overrun protection setting with the Mode button. Setting page protection to the correct size could solve this problem.

  • Page 252: Engine Controller Mode

    Display Message Meaning Countermeasure Install SIMMs correctly, Incorrect installation 44 SIMM ERROR referring to the printed error of SIMMs message. Error in 45 MIO ERROR communication with Install the MIO card correctly. the MIO card Use a new card. If the same 47 CARD1(2)R ERROR Card read error error occurs, consult your...
  • Page 253 Countermeasure Display Message Meaning 14 CHK CLEANING Change the fuser Replace with a new fuser ROLLER cleaner cleaner Confirm status of media cassette. 15 MISPRINT Misprinting occurred Confirm correct paper size. PAPER/PRREQ/MEDIA Confirm consistency of media. 16 ALIGN TONER CG Toner cartridge not Confirm the installation of the Y/M/C/K...

  • Page 254: Paper Transport Error

    PAPER TRANSPORT ERROR Paper is transported through the path shown in Fig.8-1. Paper jams at the following locations are easily cleared. • • Paper Feeding Roller Fusing Unit • • Transfer Unit Paper Exit Unit Paper Exit Roller Fusing Unit Oil Bottle Drum Cleaner OPC Belt Cartridge Top Cover...

  • Page 255: Inner Jam

    Inner Jam Table 8-3-2 Problem Item Step Check Item Result Action Open the transfer unit and check. Is there any paper inside the Remove the paper unit? inside. Is the transfer roller firmly Fix the transfer roller locked by the lock lever? with the lock lever.

  • Page 256: Service Call

    SERVICE CALL If errors or failures occurred inside the printer, the applicable error message will be displayed on the control panel, and the printer stops. If errors or failures repeat even after resetting the power button, confirm the error code and then call your Service provider. Error occurs.

  • Page 257: Video Controller Mode

    Video Controller Mode Table 8-4-1 Service Call Message Meaning Countermeasure Program ROM checksum Replace with a new ROM. 61 PROG ERROR error Font ROM checksum error Replace with a new ROM. 62 FONT ERROR D-RAM error Replace with a new SIMM. 63 D-RAM ERROR Replace with a new main 66 NV-W ERROR...
  • Page 258 Service Call Message Description 99 SERVICE D6 HPSI Signal Error (Retract Error of Cyan and Magenta Toner Cartridge) 99 SERVICE E1 Developing Motor Error 99 SERVICE E2 Main Motor Error 99 SERVICE E3 Transfer Drum Rotational Error 99 SERVICE E4 Toner Sensor PCB Error 99 SERVICE E5 Transfer Roller Solenoid Error...

  • Page 259: Engine Controller Mode

    Engine Controller Mode Table 8-4-3 Code Description NVRAM Error (MCTL PCB) Engine Controller MCTL PCB Hardware Error Process Timing Clock Error (Main Motor Clock Error) Clutch Error of the Yellow Developing Unit Clutch Error of the Magenta Developing Unit Clutch Error of the Cyan Developing Unit Clutch Error of the Black Developing Unit HPSI Signal Error (Retract Error of Black and Yellow Toner Cartridge)
  • Page 260 Chart 8-4 Troubleshooting Code Description of Error Cause of Error Clearance Method 1. Failure of MCTL PCB. 1. Turn off and on the power switch. • CPU NVRAM Error 2. If method 1 does not work, carry out the "C3 Error Clearance Procedure". •...
  • Page 261 Description of Error Cause of Error Code Clearance Method 1. Power Feeding Failure 1. Implement the same clearance procedures employed for E2 error. Process Timing Error. 2. MM Failure [Note]: MM stands for OPC Belt Drive Main Motor. 3. MM Input Circuit Failure Implement the same clearance procedures employed for E2 error.
  • Page 262 Error Code Name of Part Developer Clutch (DCLY) Check the Connector. Is the connection between ECN17 of IOD2 and Clutch (DCLY) OK ? Connect the harness. Is the harness of Clutch (DCLY) broken ? Connect the connector properly. Is D1 Error cleared ? Finished Check the voltage at DCLY ON-N.
  • Page 263 Error Code Name of Part Developer Clutch (DCLM) Check the Connector. Connect the harness. Is the connection between ECN16 of IOD2 and Clutch (DCLM) OK ? Connect the connector properly. Is the harness of Clutch (DCLM) broken ? Is D2 Error cleared ? Finished Check the voltage at DCLM ON-N.
  • Page 264 Error Code Developer Clutch (DCLC) Name of Part Check the Connector. Connect the harness. Is the connection between ECN14 of IOD2 and Clutch (DCLC) OK ? Is the harness of Clutch (DCLC) broken ? Connect the connector properly. Is D3 Error cleared ? Finished Check the voltage at DCLC ON-N.
  • Page 265 Error Code Developer Clutch (DCLK) Name of Part Check the Connector. Is the connection between ECN13 of IOD2 and Clutch (DCLK) OK ? Connect the harness. Is the harness of Clutch (DCLK) broken ? Connect the connector properly. Finished Is D4 Error cleared ? Check the voltage at DCLK ON-N.
  • Page 266 Error Code Name of Part Developer Solenoid (PSL YM) Check the Connector. Is the connection between ECN3 of IOD2 and Solenoid (PSL YM) OK ? Connect the harness. Is the harness of Solenoid (PSL YM) broken ? Connect the connector properly Is D5 Error cleared ? Finished Check the voltage at (PSL YM) ON-N.
  • Page 267 Error Code Name of Part Developer Solenoid (PSL KC) Check the Connector. Connect the harness. Is the connection between ECN3 of IOD2 and Solenoid (PSL KC) OK ? Is the harness of Solenoid (PSL KC) broken ? Connect the connector properly. Finished Is D6 Error cleared ? Check the voltage at (PSL KC) ON-N.
  • Page 268 Error Code Concerned Part Developer Motor(DM) Is there any unusual rotation noise while printing ? Replace the toner cartridge. Check the connector. Is the noise cleared ? Finished Is ECN15 of IOD2 properly connected with the connector of DM1? Replace developer gear unit and motor. Is ECN1 of IOD2 properly connected with DCN9 of IOD1? Connect the connectors properly.
  • Page 269 Error Code Concerned Part Main Motor(MM) Does the belt cartridge rotate lightly ? Replace the belt cartridge. Does the fuser unit rotate lightly ? Replace the fuser unit. Is E2 error cleared ? Check the connectors. Finished. Replace developer gear unit and motor. Is ECN12 of IOD2 properly connected with connector DM1 ? Is ECN2 of IOD2 properly connected with DCN9 of IOD1 ? Is ECN1 of IOD2 properly connected with 12CN of MCTL ?
  • Page 270 Error Code Concerned Part Drum HP Sensor Is the belt cartridge properly installed ? Re-install or replace the belt cartridge. Is the encoder plate deformed ? Does the transfer drum rotate lightly ? Replace the transfer drum. Is the rotation torque excessive ? Check the connector.
  • Page 271 Error Code Concerned Part Toner Sensor PCB (LED side) Check the connection of the toner sensor PCB.(LED side) connector. Connect them properly. Is DCN7 of IOD1 properly connected to the toner sensor ? Is E4 error cleared ? Check the voltage(LEDON-N/P) Finished.
  • Page 272 Error Code Concerned Part Transfer Solenoid Check the connection of the transfer solenoid connector. Is ECN8 of IOD2 properly connected with a connector of the solenoid ? Connect them properly. Is ECN2 of IOD2 properly connected with DCN9 of IOD1 ? Is DCN1 of IOD1 properly connected with 11CN of MCTL PCB ? Is E5 error cleared ? Finished.
  • Page 273 Error Code Cleaning Brush Solenoid Concerned Part Check the connection of the cleaning brush solenoid connector. Connect them properly. Is ECN10 of IOD2 properly connected to the solenoid ? Is ECN2 of IOD2 properly connected with DCN9 of IOD1 ? Is E6 error cleared ? Is ECN1 of IOD1 properly connected with 11CN of MCTL PCB ? Finished.
  • Page 274 Error Code Cleaner Clutch Concerned Part Check the connection of the cleaner clutch connector. Connect them properly. Is ECN11 of IOD2 properly connected to the clutch ? Is ECN2 of IOD2 properly connected with DCN9 of IOD1 ? Is ECN1 of IOD1 properly connected with 11CN of MCTL PCB ? Is E7 error cleared ? Finished.
  • Page 275 Error Code Fuser Clutch(FUCL) Concerned Part Check the connection of the fuser clutch connector. Is ECN9 of IOD2 properly connected with a connector of the clutch ? Connect them properly. Is ECN1 of IOD2 properly connected with 11CN of MCTL PCB ? Finished.
  • Page 276 Error Code Concerned Part Belt Sensor (PBS) Is the belt cartridge leaning to one side ? Replace the belt cartridge. Level the printer. Is the belt sensor dirty ? Clean the belt. Is E9 error cleared ? Check the connector. Connect them properly.
  • Page 277 Error Code Erase Lamp (EL) Concerned Part Check the connection of the erase lamp connector. Connect them properly. Is DCN7 of IOD1 properly connected to the erase lamp ? Is DCN1 of IOD1 properly connected with 11CN of MCTL PCB ? Is EL error cleared ? Finished.
  • Page 278 Error Code Concerned Part Fan Motor(Control Cooling) Check the connection of the fan motor connector. Connect them properly. Is DCN13 of IOD1 properly connected to the fan motor ? Is DCN1 of IOD1 properly connected with 11CN of MCTL PCB ? Is F0 error cleared ? Finished.
  • Page 279 Error Code Fan Motor (OZFAN) Concerned Part Check the connection of the fan motor connector. Connect them properly. Is ECN6 of IOD2 properly connected to the fan motor ? Is ECN1 of IOD2 properly connected with 11CN of MCTL PCB ? Is F2 error cleared ? Finished.
  • Page 280 Error Code Concerned Part Heater Fan (HTFAN) Check the connection of the heater fan connector. Connect them properly. Is DCN10 of IOD1 properly connected to the heater fan ? Is DCN1 of IOD1 properly connected with 11CN of MCTL PCB ? Is F4 error cleared ? Finished.
  • Page 281 Error Code Concerned Part High Voltage Unit (HVU) Confirm the status of the charger unit. Is the charger unit properly installed ? Re-install the charger unit. Replace the charger unit or belt cartridge. Is a corona wire cut or shorted ? Confirm the connection of the high voltage wiring.
  • Page 282 H0 (wire cut/ short error of thermistor) Error Code Fusing Unit Concerned Part Check the connection of the fusing unit connector. Re-install the fusing unit. Is the fusing unit properly installed ? Is there any contact failure due to damaged to the fusing unit connector ? Replace the charger unit or belt cartridge.
  • Page 283 Error Code H2,H3,H4 Fusing Unit and Others Concerned Part Confirm that the fusing heater is lit. Is the fusing heater switching on and off. Confirm the wiring and connector of the heater. Confirm the input voltage. Is the line voltage thecorrect value ? Are the connector HP/HN connected ? Connect them properly.
  • Page 284 L1 (Beam Detecting Error) Error Code Scanner Unit Concerned Part Check the connection of the scanner unit connector. Is the connector PDCN properly connected ? Connect the connector properly. Are the connector LCN1 and LCN of MCTL properly connected ? Is L1 error cleared ? Replace the scanner unit.
  • Page 285 Error Code Scanner Unit Concerned Part Connect the connector properly. Is the connector LCN3 properly connected ? Is L2 error cleared ? Replace the scanner unit. Is L2 error cleared ? Replace the MCTL PCB. Finished. MCTL SCMCLK Scanner Unit SCMRDY SCMON +24V-1...
  • Page 286 Error Code Scanner Unit Concerned Part Confirm the connection of the scanner unit connector. Connect the connector properly. Is the connector LCN3 properly connected ? Is the connector PDCN properly connected ? Are the connectors or LCN1 and LCN properly connected ? Is LL error cleared ? Replace the scanner unit.

  • Page 287: Image Failure

    IMAGE FAILURE (9)-a (9)-b (10) (11) (12) (13) (14) VIII-41...
  • Page 288 (15)-a (15)-b (16) (17) (18) (19) (20) (21) (22) (23) (25) (24) (26) (27) (28) (29) 244m/m Fig.8-2 VIII-42...
  • Page 289 Background Phenomenon Background is smeared due to toner spread as shown in print sample (1) of Fig.8-2. Main Causes 1) Too small toner mass and charging level in the developing process. 2) Poor contact of the developer roller’s bias pole. 3) Life expired or failure of the OPC belt cartridge.
  • Page 290 Jitter Phenomenon Uneven optical density appears periodically in the horizontal direction on the printed image as shown in print sample (3) of Fig.8-2. Main Causes Failure of main motor. 1) Irregular rotation of the drive motor. 2) Failure of the gears. 3) Variation of OPC belt running speed due to above reasons.
  • Page 291 Wrinkle / Image Migration Phenomenon Banding shadows of different optical density appear due to wrinkle, image migration and color misregistration occurring on the print paper as shown in print sample (5) of Fig.8-2. Main Causes 1) Print paper other than the recommended paper is being used. 2) The paper discharger unit of the transfer unit is not functioning.
  • Page 292 White Line (1) Phenomenon Vertical white line appears in the specific color area when test-printed in the four color mode (Stripe Mode), as shown in print sample (6) of Fig.8-2. Main Causes 1) Foreign particles adhering to the following places around the developer roller. (Refer to Fig.8-8.) •...
  • Page 293 White Line (2) Phenomenon Vertical white line appears from the leading edge to the trailing edge of the printed image as shown in print sample (7) of Fig.8-2. Main Causes The dustproof glass of the scanner unit is smeared with toner or foreign particles. Countermeasures Clean the dustproof glass.
  • Page 294 Black Line / Blur in the Image Phenomenon Fine black line or blur appears in the printed image as shown in print sample (9) of Fig.8- Main Causes 1) The corona wire of the charger unit is dirty. 2) OPC belt surface is damaged. 3) Foreign particles (paper dust, etc.) are stuck between the cleaning blade and OPC belt.
  • Page 295 I-11 Vertically Staggered Image Phenomenon Printed image staggered in the vertical direction as shown in print sample (11) of Fig.8-2. Main Causes 1) Shock or vibration applied to the printer. 2) Failure of the scanner unit; Vibration from rotation of the scanner motor. Countermeasures 1) Do not apply shock or vibration to the printer body.
  • Page 296 I-13 White Band Phenomenon White banding line appears in the horizontal direction, and consequently causes a missing image as shown in print sample (13) of Fig.8-2. Main Causes 1) Installation failure of the transfer unit, and deformation of the transfer roller. 2) Contact failure of the transfer roller bias pole.
  • Page 297 I-15 White Spot / Black Spot Phenomenon White spots and black spots appear on the print as shown in print sample (15) of Fig.8-2. Main Causes 1) Foreign particles adhering to the OPC belt or transfer drum. 2) The OPC belt or transfer drum is damaged. 3) Foreign particles mixed in the toner.
  • Page 298 I-17 Color Misregistration Phenomenon Color misregistration is caused between two colors as shown in print sample (17) of Fig.8-2. Main Causes 1) The OPC belt cartridge is not properly installed. 2) The OPC belt cartridge is deformed. 3) The cleaning brush of the drum cleaner is unstable in operation. 4) Rotational load on the OPC belt cartridge is excessive.
  • Page 299 I-19 Mottle Phenomenon Variation of the scanning density is found in the image as shown in print sample (19) of Fig.8-2. Main Causes 1) The transfer unit is not fixed in place. 2) Assembly of the transfer roller is inaccurate. 3) THV output of DC high voltage unit is not normal.
  • Page 300 I-21 Insufficient Gloss Phenomenon Gloss of the print is not sufficient as shown in print sample (21) of Fig.8-2. Main Causes 1) The fuser cleaner is stained. 2) The fuser roller is deteriorated. Countermeasures 1) Replace the fuser cleaner with a new one. (See Section 3.3 of Chapter III.) 2) Replace the fusing unit with a new one.
  • Page 301 I-23 White Print Phenomenon A blank page (no print at all) is output or a specific color is missing (not printed) as shown print sample (23) of Fig.8-2. Main Causes 1) Laser light path is blocked by paper or other material stuck at the opening of the scanner unit.
  • Page 302 I-25 Vertical Smear Phenomenon Printed image is smeared vertically as shown in print sample (25) of Fig.8-2. Main Causes 1) Paper dust between the cleaning blade and OPC belt. 2) Debris adhering to the base of a toner cartridge’s developer roller where it contacts with the OPC belt.
  • Page 303 I-27 Color Missing Phenomenon Color is missing in the printed image as shown in print sample (27) of Fig.8-2. Main Causes Fusing failure due to using damp paper or using the printer under high humidity conditions. Countermeasures 1) Use the paper immediately after open the paper bag. 2) Change the NVRAM setting.

  • Page 304: Appendix A

    APPENDIX A SERIAL NO. DESCRIPTIONS The descriptions as below shows how to read labels on each place. < ID for production month of Printer > January September February June October March July November April August December < ID for production month of other parts than the printer > January September February...
  • Page 305 PR98028 Toner Cartridge 1 2 X X X X X X X X X X YEAR MONTH SERIAL NO. <Location> OPC Belt Cartridge 1 2 X X X X SERIAL NO. YEAR MONTH <Location> Fusing Unit XXXX 7 1 2 3 A REV.(-, A - Z) DATE MONTH...
  • Page 306 <Location> Scanner Unit 7 1 2 3 A REV.(-, A - Z) DATE MONTH YEAR <Location> Transfer Drum (Hand-writing) X X X X X X - 7 1 2 3 DATE MONTH YEAR SERIAL NO. <Location>...
  • Page 307 DIAMETER / CIRCUMFERENCE OF ROLLERS The diameter or circumference of each roller is listed below; Parts Name Diameter (Circumference) OPC Belt (380 mm) φ 18 mm Developer Roller (56.52 mm) φ 20 mm Transfer Roller (62.80 mm) φ 40 mm Paper Pick-up Roller (125.60 mm) φ...

  • Page 308: Shelf Life Of Each Consumable

    SHELF LIFE OF EACH CONSUMABLE Each consumable follows has its own shelf life. Shelf life varies whether the package of consumable is unpacked or not. Consumable Before unpacking *1 After unpacking *2 Toner cartridge (all colors) 3 years 1 year OPC belt cartridge 3 years 1 year...

  • Page 309: Consumables Replacement

    CONSUMABLES REPLACEMENT Each consumable follows should be replaced according its own life. Toner Cartridge Life: K = 10,000 pages, CYM = 6,000 pages Condition: Above figures are based on 5% coverage. Life is detected by the toner empty sensor. Note: Life of the starter toner cartridge is half of the above figures.
  • Page 310 <40,020> 3) Add 20 pages Add figure of Figure from <Next care information 32> <Total pages 34> Modified by the addtional life deleted figure <40,000> <40,000> 1) No change This figure is actual <39,990> 2) 10 pages next care time 1) Print 10 pages 2) Print 10 pages This difference is the actual...
  • Page 311 HOW TO RE-ENTER ORIGINAL DATA TO THE MCTL PCB CAUTION Actions 1) and 2) MUST be carried out BEFORE the MCTL PCB is removed or the NVRAM initialized otherwise ALL READINGS WILL BE LOST. Go into the Engine Controller Mode. (Refer to Section 3 “ENGINE CONTROLLER MODE”...
  • Page 312 Re-enter the FC ROLL (NC2) value as follows; i) Enter the value of NC2 - LP2 into the TOTAL PAGE counter. NC2 - LP2 ⇒ 12,050P - 12,000P = 50 (i.e.) Enter the value ‘50’ in the TOTAL PAGE counter. ii) Perform CLEAR CARE 2.
  • Page 313 iii) Check that the value of NEXT CARE is reset correctly. (i.e.) NC8 = 39,684P iv) Reset the LIFE PERIOD counter in FACTORY MODE to 60,100. Re-enter the 120K KIT (NC9) value as follows; i) Enter the value of NC9 - LP9 into the TOTAL PAGE counter. (i.e.) NC9 - LP9 = 120,000 - 120,000 = 0 Enter the value ‘0’...
  • Page 314 RE-PACKING INSTRUCTIONS PRECAUTION When re-packing the printer before shipping, be sure to follow the steps and cautions below. Failure to do so will cause toner or oil spill in the printer and severe damage to the printer. Toner Cartridge 1) Open the front cover and remove all the toner cartridges (K, Y, M, C) from the printer.
  • Page 315 5) Put the OPC belt cartridge into the original starter kit packing. Starter Kit Packing OPC Belt Cartridge CAUTION • Do not directly touch the OPC belt surface with bare hands or gloves. • If the belt is exposed for more than two minutes to a light source of 800 lux, the belt may be damage.
  • Page 316 5) Remove the oil remaining in the fusing unit with the supplied syringe to avoid oil spill in the printer. Note: Re-install the fusing unit into the printer after cleaning the printer as instructed in the following section. For re-install of the fusing unit, see Section 6.6 ‘Packing’.
  • Page 317 2) Drum cleaner Handle i) Remove the cleaner cover by releasing the two hooks. ii) Holding the handle located on the top of the drum cleaner, push it backwards. iii) Remove the drum cleaner by lifting Drum Cleaner it out. iv) Clean the area where the drum cleaner is mounted with a vacuum cleaner and a cloth.
  • Page 318 Packing 1) Re-install the fusing unit into the printer. Fusing Unit i) After setting the fusing unit in place, lightly press down the unit to firmly connect to the connector on the base. ii) Tighten the securing screws while pressing down the fusing unit. Check the metal hook of the screw at the left hand secures the fusing unit correctly.
  • Page 319 6) Fix the four joints, then band the Band carton with two plastic bands. Joint Joint A-16...
  • Page 320 7. Hidden Function Menu Ù 1. Hold down the key and turn the printer ON LINE TEST LCD TEST All LCD segments turned ON SWITCH TEST Press switches to check operation on LCD SENSOR TEST RAM SIZE Shows installed RAM size TRAY 1 SETTING Shows current Tray 1 size TRAY 2 SETTING...
  • Page 321 2. Hold down the following key combinations and turn the printer ON, keep the button(s) pressed until the display changes. FONT prog date..Display PROGRAM DATE press CONTINUE key prog time..font date..font time..version..EngVer LDA VX.X FORM FEED LANG=ENGLISH* Switch LOCAL PROMPT LANG.=FRANCAIS...
  • Page 322 TEST PATTERN = WHITE prints 1 page and exits to ONLINE REPEAT TESTPRINT TEST PATTERN = NORMAL* TEST PATTERN = GRID TEST PATTERN = LINE TEST PATTERN = BLACK TEST PATTERN = WHITE prints continuously, press SEL to stop printing (OFFLINE) press CONT to resume printing (ONLINE) press SHIFT &...
  • Page 323 3B PRIO=HIGH* 300dpi bitmap priority high <3B PRIO=LOW> <3B PRIO=HIGH> 1.DOWNLOAD 600 DOWNLOAD 600 2.DOWNLOAD SCALABLE DOWNLOAD 300 3.CARD 600 DOWNLOAD SCALABLE 4.CARD SCALABLE CARD 600 5.CART 600 CARD 300 6.CART SCALABLE CARD SCALABLE 7.RESIDENT 600 CART 600 8.RESIDENT SCALABLE CART 300 9.DOWNLOAD 300 CART SCALABLE...
  • Page 324 KEEP DTR=OFF* DTR signal is used to show printer status KEEP DTR=ON DTR is kept high except when printer is off-line XOFF TIMING SELECT XOFF TIMING=NORMAL* XOFF TIMING=11K XOFF TIMING=21K XOFFTIMING=101K exit SERIAL LOCAL PROMPT LANG=ENGLISH* LANG.=FRANCAIS SPRAC=DEUTSCH TAAL=NEDERLAND LENG.=ESPANOL LING=ITALIANO REPRINT ON/OFF REPRINT=JOB*...
  • Page 325 DEMO PAGE ON/OFF DEMO PAGE=ON* Display demo page menu in the LCD messages DEMO PAGE =OFF Disable demo page menu DEBUG MODE MENU PANEL DEBUG SELECT OFF* PRINT DEBUG SELECT OFF* exit DEBUG BYPASS MODE SEL BYPASS MODE=OFF* Divert Epson & IBM emulation data BYPASS MODE=ON received on the Parallel or MIO port to the serial Interface APPLETALK AT/PS...
  • Page 326 MIO TIMEOUT MODE MIO TIMEOUT=ON* MIO TIMEOUT=OFF JOB TIMEOUT SEL TIMEOUT=ON* TIMEOUT=OFF MEMORY DEBUG MEMORY DISPLAY MEMORY TEST exit exit MENU Exit the hidden function menu. 4) Go off-line and press the following keys simultaneously CONT TEST PATTERN Test pattern print select STRIPE exit TRAY COMMAND MODE...
  • Page 327 RS-232C MENU REPRINT ON/OFF ROM DATE DISPLAY AUTO HRC ON/OFF APPLETALK AT/PS PS BINARY SELECT PS QUOTE BINARY PS APT MODE PS IMAGE MASK PS CEIL MODE PS STATUS ECHO PROTECT OFF MODE PRO.OFF=AUTO* Virtual page protect process PRO.OFF=NORMAL Controlled as open menu HP ESC E COMMAND HP ESC E=RESET* Normal reset...
  • Page 328 PANEL RESET MODE RESET=NORMAL* RESET=JOB NV-RAM CLEAR TEST MENU LINE TEST ENGINE TEST SINGLE TEST PRINT REPEAT TEST PRINT DRAM CHECK START DRAM ADDRESS FLASH CARD CHECK FLASH CARD CHK2 exit TEST MENU exit MENU Exit the hidden function menu. A-25...

  • Page 329: To Install The Printer Correctly

    PR99010 TO INSTALL THE PRINTER CORRECTLY Please read the installation steps described below carefully. If the printer is not installed correctly, image failures may occur or the life expectancy of the OPC belt cartridge may be shortened. Turn ON the power switch of the printer. After the printer has initialized, open the front cover and then the top cover of the printer and pull up the OPC belt cartridge from the printer.
  • Page 330 PR99010 If the gap is NOT in the range of 5 ± 2 mm, check the following items; Note: If the printer is inclined at 1° as shown in the figures below, the printer is approximately 9mm out of level from one side to the other. i) Is the printer inclined because the table the printer is installed on is unlevel? Level 1°...
  • Page 331 PR99010 iii) Is the printer inclined because it is installed across two or more tables? Level 1° iv) Is there anything under the printer, or is there something stuck to the printer base? After checking these items, initialize the printer again (opening/closing the top cover automatically initializes the OPC belt cartridge), and measure the gap on the OPC belt cartridge again.
  • Page 332 PR99010 If the gap is NOT in the range of 5 ± 2 mm, follow the steps below; i) When the gap is more than 7 mm; (the OPC belt has moved to the right.) Place something 1 cm thick such as a book under the right hand side of Book the printer as shown in the figure on...

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