Brother HL-4200CN Service Manual
Brother HL-4200CN Service Manual

Brother HL-4200CN Service Manual

Color laser printer
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Brother Color Laser Printer

SERVICE MANUAL

MODEL: HL-4200CN
Read this manual thoroughly before maintenance work.
Keep this manual in a convenient place for quick and easy reference at all times.
November 7, 2004
SM-PRN038

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Summary of Contents for Brother HL-4200CN

  • Page 1: Service Manual

    Brother Color Laser Printer SERVICE MANUAL MODEL: HL-4200CN Read this manual thoroughly before maintenance work. Keep this manual in a convenient place for quick and easy reference at all times. November 7, 2004 SM-PRN038...
  • Page 2 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 3 (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-4200CN color laser printer. This manual consists of the following chapters:...
  • Page 4: Table Of Contents

    CONTENTS CHAPTER I SPECIFICATIONS............I-1 1. PRODUCT NAME ..................I-1 2. OPTIONAL PRODUCTS ................I-1 3. DIMENSIONS / WEIGHT (MAIN UNIT)............I-1 4. BASIC CONFIGURATION................I-1 4.1 Engine............................ I-1 4.2 Feeder Unit ..........................I-2 4.3 Tray Feeder Unit........................I-3 5. FUNCTIONAL CONFIGURATION ..............I-3 6.
  • Page 5 10.3 Installation Horizontality..................... I-16 10.4 Ambient Lighting ........................ I-16 11. SAFETY / ENVIRONMENT CONDITIONS..........I-16 11.1 Safety Standard ......................... I-16 11.2 Laser Safety Standard ....................... I-16 11.3 EMI............................. I-17 11.4 Noise..........................I-17 12. PRINT IMAGE QUALITY................I-17 12.1 Image Quality Guarantee Conditions ................I-17 CHAPTER II INSTALLATION............II-1 1.
  • Page 6 5.4 Front ASSY In ........................III-29 5.5 Chute ASSY Out ........................ III-30 5.6 Chute ASSY Exit........................ III-32 5.7 Transfer Roll Cartridge ASSY & Fuser ................III-33 5.8 Xerographics........................III-35 5.9 Toner Cartridge ASSY ....................... III-37 5.10 Frame & Drive........................III-39 5.11 Electrical ..........................
  • Page 7 3.2 Fail Code List ........................V-3 3.3 Error Code FIP........................V-13 4. HOW TO USE DIAG. (C/E) MODE ............V-38 4.1 Roles of the Control Panel in Diag. (C/E) Mode..............V-38 4.2 Entering Diag. (C/E) Mode....................V-38 4.3 Exiting Diag. (C/E) Mode ....................V-38 4.4 Diag. (C/E) Mode Functions ....................V-38 4.5 Operation Procedure ......................V-39 4.6 Diag.
  • Page 8 1.1 How to Use the BSD......................VI-1 1.2 Explanations of Symbols .....................VI-1 1.3 Signal Name/Other description....................VI-4 1.4 DC Voltage...........................VI-4 1.5 Input/Output Test .........................VI-4 2. BSD (BLOCK SCHEMATIC DIAGRAM) 2.1 Standby Power........................VI-5 2.2 Mode Selection ........................VI-7 2.3 Machine Run Control ......................VI-8 2.4 Start Print Power........................VI-11 2.5 OPTICS (Scanner)......................VI-12 2.6 Paper Supplying ........................VI-14 2.7 Paper Transportation ......................VI-19...
  • Page 9 United States. The label shown on the back of the printer indicates compliance with the FDA regulations and must be attached to laser products marketed in the United States. MANUFACTURED: BROTHER INDUSTRIES, LTD. 15-1 Naeshiro-cho, Mizuho-ku, Nagoya, 467-8561 Japan This product complies with FDA radiation performance standards, 21 CFR Subchapter J.
  • Page 10: Internal Laser Radiation

    IEC 60825 SPECIFICATION (FOR 220-240 V MODEL ONLY) This printer is a Class 1 laser product as defined in IEC 60825 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 11 SAFETY To prevent possible accidents during maintenance operation, you should observe strictly the "Warning" and "Caution" information in this manual. Dangerous operations and operations out of range of this manual should be absolutely avoided. Generally various processes not covered by this manual may be required in actual operation, which should be performed carefully always giving attention to safety.
  • Page 12: Driving Units

    Power Source Keep the power supply off during maintenance operation to prevent electric shock, burns and other damages. Keep the power plug disconnected during the maintenance operation. If the power supply should be kept connected for measurement of voltage or other similar reasons, sufficient care should be given to prevent electric shock, by following the procedures of this manual.
  • Page 13 High-temperature Units When servicing high-temperature units (securing unit, etc.), be sure to turn them OFF to prevent burns, injuries and other troubles, remove the power plug and start service processes after they have cooled down enough. WARNING Immediately after completion of operation, they are still hot. Start services after more than 40 minutes.
  • Page 14 Warning/Caution Labels Warning labels and caution labels are attached to this laser printer to prevent accidents check those labels for their peeling or stain when servicing the printer. < Caution label for high-temperature units > Unpacking the Printer WARNING The printer must be carried horizontally by two or more persons. CAUTION Extreme care must be taken to avoid personal injuries.
  • Page 15 ACRONYMS In this manual, the manual specific acronyms are used in addition to the generally used ones. The table below contains typical acronyms that are used throughout this manual. Automatic Density Control Analog Ground AUX. Auxiliary Black and White Bias Charge Roll CART.
  • Page 16: Service Call Procedures

    Service call procedures Notes Before Work 1.1 Safety notes To prevent an accident during maintenance, follow warnings and precautions strictly. Avoid dangerous work. 1. Power supply To prevent an electric shock, burn, or injury, turn off the power and unplug the power cable before maintenance work.
  • Page 17 Be sure to enter the field work contents and the replaced consumables and parts into the Machine Log Book. HL-4200CN weighs 34.9 kg. When moving the equipment, make sure that there are two or more persons carrying it. For details, see the installation procedure on page II-1.
  • Page 18 Workflow in the Field < Initial Actions > 1. Question the Customer for details about the system malfunction. 2. Note down the meter count. 3. Inspect the rejected print and determine the machine condition. 4. Check the Machine Log Book. <...
  • Page 19 Trim Activity Trim activities for HL-4200CN should be made within every SM/UM, mainly for maintaining the machine performance. There is no service call performed only for the trim activity. 3.1 Trim activity procedure 1. Check the overall operation before performing the trim activity.
  • Page 20 3.3 Trim checklist C: Check and if necessary clean, replace, or replenish. A: Always check and clean. R: Replace at specified intervals. * See page V-54 for the test pattern output method. Work item Each 100K Rep & Description time Check before work - Start up the machine to see that no (Mechanical noise...
  • Page 21: Chapter Ispecifications

    CHAPTER I SPECIFICATIONS...
  • Page 22 CONTENTS CHAPTER I SPECIFICATIONS............I-1 1. PRODUCT NAME .................... I-1 2. OPTIONAL PRODUCTS .................. I-1 3. DIMENSIONS / WEIGHT (MAIN UNIT)............I-1 4. BASIC CONFIGURATION ................I-1 4.1 Engine............................ I-1 4.2 Feeder Unit ..........................I-2 4.3 Tray Feeder Unit........................I-3 5. FUNCTIONAL CONFIGURATION ..............I-3 6.
  • Page 23 8.14 Input Properties ......................... I-13 8.14.1 Paper pick-up system ....................I-13 8.14.2 Paper pick-up capacity....................I-13 8.15 Output Properties....................... I-14 8.15.1 Paper delivery system....................I-14 8.15.2 Paper delivery capacity....................I-14 8.15.3 Delivery paper size/mass.................... I-14 8.15.4 Full stack detection ..................... I-14 8.16 Paper ..........................
  • Page 24: Product Name

    CHAPTER I SPECIFICATIONS PRODUCT NAME Product Name Product Code HL-4200CN 54S602 OPTIONAL PRODUCTS Product Name Product Code Remarks 1 x 500 – sheet tray LT-41CL 2 x 500 – sheet tray LT-42CL Hard Disk HD-41CL 20GB DIMENSIONS / WEIGHT (MAIN UNIT)
  • Page 25: Feeder Unit

    Feeder Unit Option Feeder installed under the printer. This printer basically consists of an option feeder and two universal paper tray (500 sheets each). Fig.1-2...
  • Page 26: Tray Feeder Unit

    Tray Feeder Unit Option Feeder installed under the printer. This printer basically consists of an option feeder and a universal paper tray (500 sheets). Fig.1-3 FUNCTIONAL CONFIGURATION Functional configuration of this printer is shown below. Fig.1-4...
  • Page 27: Electrical Properties

    ELECTRICAL PROPERTIES Power Source Two types of power source as follows are available for this printer, which are selected according to the specifications. * 100V/120V printer: Voltage: 100-127VAC ±10% (90 to 140V), frequency: 50/60Hz ± * 220/240V printer: Voltage: 220-240VAC ±10% (198 to 264V), frequency: 50/60Hz ± Power Consumption Power consumption in each operation mode at rated voltage input Operation mode...
  • Page 28 Width: 439mm ± 1% Depth: 509mm ± 1% (with no cassette installed), 563mm ± 1% (with cassette installed) Height: 172mm ± 1% Mass (No cassette installed + (No CRU): 9.3kg ± 1% (No cassette installed + (CRU): 11.8 kg ± 1% Fig.1-6 Width: 439mm ±...
  • Page 29: Dimensions / Mass Of Universal Paper Tray (Standard Paper Supply - 500Sheets

    Dimensions / Mass of Universal Paper Tray (standard paper supply – 500sheets) Width: 321mm ± 1% Depth: 558mm ± 1% Height: 97mm ± 1% Mass: 2.5kg ± 1% Fig.1-8 Dimensions / Mass of Consumables 7.3.1 Print head cartridge Width: 339mm ± 3mm Depth: 146mm ±...
  • Page 30: Installation Space (Min. Installation Space

    7.3.3 Toner cartridge Width Depth Height Mass Black toner cartridge 355mm ± 3mm 51mm ± 3mm 55mm ± 3mm 360g ± 10g Yellow toner cartridge 355mm ± 3mm 51mm ± 3mm 55mm ± 3mm 315g ± 10g Magenta toner cartridge 355mm ±...
  • Page 31: Functions

    FUNCTIONS Recording System OPC drum, 4-tandem cartridges, electro-photographic system using intermediate transfer rolls Exposure System Semiconductor laser, simultaneous scanning by 4 beams Development System Development with dry type 2-component developer Fixing System Heat fusing of the free belt nip system Resolution Two types of resolutions can be switched.
  • Page 32: Process Speed

    *3: Fan status is changed depending on the state (temperature, etc.) of the fixing system. Process Speed The printer prints by switching two levels, Full speed (printing with the highest process speed of the printer) and Half speed (printing with the half of process speed). The controller cannot instruct to change the process speed.
  • Page 33: Paper Mode

    Paper Mode 8 paper modes are available for this printer. Modes are switched over under the instruction from the controller. <Classification of paper mode> (1) Plain paper: Japanese plain paper such as FX-P, L, R, J/JD, and plain paper such as XC-4200 20lb, 24ibs RX-80, 90. (2) Label-L mode: It is mainly selected to run on Japanese labels (V860 etc.).
  • Page 34: Warm-Up Time

    8.10 Warm-up Time When nominal voltage (115/230V) is applied, ready temperature (Fuser Stand-by) is reached within 30 seconds after command is given by the controller. Reference: Measured at 22°C, 55% RH, nominal voltage. 8.11 FPOT (First Print Output Time) FPOT time of the printer is shown in the table below. The time required for the first sheet of paper to be delivered after the START command is given is calculated on the following conditions (rounded to one decimal place).
  • Page 35: Continuous Printing Speed

    8.12 Continuous Printing Speed Assuming the time until the trailing end of the 11th sheet is discharged after the trail end of the 1st sheet is discharged as t seconds, number of printed sheets for a minute given by the equation [60/t ×10] is shown in the table below, excluding, however, the time for which the process control is working and during the Fuse Cool Down are not contained.
  • Page 36: Input Properties

    8.13.3 Guaranteed printing area Area for which the image quality is guaranteed as follows: Area except for 4mm (0.1575 inch) from edges of the paper. Maximum area for which the image quantity is guaranteed as follows: Width: 207.9mm (8.2 inch) × length: 347.6mm (13.7 inch) Fig.1-15 8.14 Input Properties...
  • Page 37: Output Properties

    8.15 Output Properties 8.15.1 Paper delivery system ♦ FACE DOWN delivery Paper can be delivered by the following method. 8.15.2 Paper delivery capacity ♦ FACE DOWN delivery 250 sheets (Letter/A4 standard paper) 8.15.3 Delivery paper size/mass ♦ FACE DOWN delivery All paper sizes applicable to this printer 8.15.4 Full stack detection ♦...
  • Page 38: Consumables

    8.16.3 Paper size Paper size which can be set to each paper pick-up unit is shown in the table below. Cassette Paper size A4 –SEF B5(JIS) –SEF A5 -SEF *1 500 Sheet Paper EXECUTIVE –SEF Universal Tray LETTER –SEF LEGAL(13")-SEF LEGAL(14")-SEF Minimum size Width 88.9mm(3.5inch)×Length139.7mm(5.5inch)
  • Page 39: Parts Requiring Periodical Replacement

    Parts Requiring Periodical Replacement Following parts are replaced when a certain number of sheets are printed (life over) to prevent troubles. Equivalent to about 100,000 prints ♦ Fuser ASSY: Equivalent to about 100,000 prints ♦ Roll ASSY retard: Equivalent to about 45,000 prints *1 ♦...
  • Page 40: Emi

    11.3 ♦ 100V system (JPN) VCCI Class B ♦ 120V system (US) FCC Part 15, Subpart B, Class B (ANSI C63.4) ♦ 220V / 240V system (EC) EN55022 (CISPR Publication 22), Class B 11.4 Noise Noise of printing (including simplex, duplex, with option) is as follows. Option Option Printer...
  • Page 41: 12.1.2 Guaranteed Paper

    12.1.2 Guaranteed paper The print image quality specified here is guaranteed with standard paper fed from the paper tray. The evaluation is performed with A4 or letter size of paper. • FX P paper A4 • Xerox 4200 DP Letter •...
  • Page 42: Chapter Ii Installation

    CHAPTER II INSTALLATION...
  • Page 43 CONTENTS CHAPTER II INSTALLATION............II-1 1. TRANSPORTING THE PRINTER ..............II-1 2. INSTALLATION PROCEDURE...............II-2 2.1 Checking the Packaged Items....................II-3 2.2 Removing the Tapes from the Printer................... II-4 2.3 Removing the Paper Tray Protective Materials ..............II-5 2.4 Mounting the Print Head Cartridge ..................II-7 2.5 Preparing the Toner Cartridges ..................
  • Page 44: Transporting The Printer

    CHAPTER II INSTALLATION TRANSPORTING THE PRINTER Note the following points when transporting the printer into position. At least two people should carry the printer. Note: Because the printer weighs 34.9kg with the tray and consumables installed, at least two people should carry it. To lift the printer, face the front and back of the printer and grip the recessed areas at the bottom left and right with both hands.
  • Page 45: Installation Procedure

    INSTALLATION PROCEDURE Install the printer as follows: Checking the Packaged Items Removing the Tapes from the Printer Removing the Paper Tray Protective Materials Mounting the Print Head Cartridge Preparing the Toner Cartridges Loading Paper Connecting the Power Code Adjusting Color Registrations Note: The printer has various protective materials for protection from vibrations and shocks during move.
  • Page 46: Checking The Packaged Items

    Checking the Packaged Items The printer package contains the items shown below. Before starting installation, make sure that no items are missing. Note: Keep the packaging materials if a future long-distance move of the printer is anticipated. < Printer > Fig.2-3 <...
  • Page 47: Removing The Tapes From The Printer

    Removing the Tapes from the Printer When you first remove the printer from its box, there is packing tape to secure the covers during shipping. Refer to the illustrations below and remove all the packing tape from the printer. < Right side > Fig.2-6 <...
  • Page 48: Removing The Paper Tray Protective Materials

    Removing the Paper Tray Protective Materials Two spacers are installed in the paper tray to protect it from shock and vibrations during shipping. Remove the spacers before using the printer. Follow the procedure below to remove the spacers from the paper tray. Note: Keep the spacers in case you need to transport the printer over long distances in the future.
  • Page 49 Remove the cardboard spacers from the paper tray. Note: Keep the spacers in case you need to transport the printer over long distances in the future. Fig.2-12 Holding the paper tray with both hands, align it with the opening in the printer and gently insert it.
  • Page 50: Mounting The Print Head Cartridge

    Mounting the Print Head Cartridge Follow the procedure below to install the print head cartridge. Fig.2-15 Lift the A button ((1)) and open the front cover ((2)). Fig.2-16 Open the paper outlet cover. Fig.2-17 II-7...
  • Page 51 Open the top of the new print head cartridge box and pull of the top part of the aluminum package. Note: Remove the sheet by working inward from the two notches. Fig.2-18 Grip the handle on top of the print head cartridge and gently lift it. Place the cartridge on a flat surface.
  • Page 52 Take the new print head cartridge out of its package and pull on the longer of the paired seals horizontally toward you. Verify that there is a circle on the leading edge of the tape that you pull out. Do this for another three. Note: If there is no circle on the leading edge of the tape, you cannot use this print head cartridge.
  • Page 53 With the flat part of the cartridge facing the rear, align the orange rollers on both sides of the print head cartridge with the slots in front of the arrows on the printer, and gently lower the cartridge into the printer. Note: Lowering the cartridge into the printer without correctly aligning the rollers with the slots can damage the cartridge.
  • Page 54 12) Close the front cover. Fig.2-27 II-11...
  • Page 55: Preparing The Toner Cartridges

    Preparing the Toner Cartridges Follow the procedure below to prepare the toner cartridges for use. Note: The toner is harmless but should still be washed off immediately if it comes into contact with hands or clothing. Remove the top cover, and then remove the packing sheet covering the toner cartridges.
  • Page 56: Loading Paper

    Loading Paper Follow the procedure below to load paper into the paper tray. Fig.2-31 Pull out the paper tray until it stops. Fig.2-32 Hold the tray with both hands, lift up the front slightly and remove it from the printer. Note: Place the tray on a flat surface.
  • Page 57 Move the side paper guide out so as to align it with the appropriate paper size mark (A4 in this example). Note: Proper guide position differs between A4 and Letter. Align the side guide to the size mark corresponding to the paper size that you want to load. Fig.2-34 Grip the end paper guide with your fingers and gently lift it up.
  • Page 58 Align the four corners of the paper stack and insert the paper (print side up) under the tab. Note: Do not use paper that is folded, creased, or heavily warped. Do not overload the paper tray. Fig.2-36 Make sure that the side guides are aligned with the edges of the paper. Note: Pushing the paper guides too hard against the edges of the paper stack can cause a paper jam.
  • Page 59 Push the paper tray completely back into the printer. Note: Do use excessive force on the paper tray. Doing so could damage the paper tray or the inside of the printer. Fig.2-39 Note: There is an indicator next to the paper tray that tells you how much paper remains in the tray.
  • Page 60: Connecting The Power Code

    To prevent fire or electric shocks, follow the instruction below based on your machine configuration. If in doubt, contact your dealer or authorized Brother service representative. - If your machine is a 220-240 V model, there is no need to attach a separate earth line since the earth connection is incorporated in the power line.
  • Page 61: Adjusting Color Registrations

    Adjusting Color Registrations Follow the procedure below to adjust the color registration when first installing the printer or after moving it to a new location. Use the control panel to print the color registration adjustment chart. From the lines to the right of the Y (yellow), M (magenta), and C (cyan) pattern, find the values of the straightest lines.
  • Page 62: Chapter Iii Structure Of System Components

    CHAPTER III STRUCTURE OF SYSTEM COMPONENTS...
  • Page 63 CONTENTS CHAPTER III STRUCTURE OF SYSTEM COMPONENTS ....III-1 1. PRINTING PROCESS ................... III-1 1.1 Summary of Printing Process ....................III-1 1.2 Schematic Diagram for Printing Processes ................. III-3 1.3 Description of Printing Process Techniques................ III-4 1.3.1 Charging with electricity ....................III-4 1.3.2 Exposure ........................
  • Page 64 5.5.1 Major functions......................III-30 5.5.2 Reference diagram ..................... III-31 5.6 Chute ASSY Exit........................ III-32 5.6.1 Major functions......................III-32 5.6.2 Reference diagram ..................... III-32 5.7 Transfer Roll Cartridge ASSY & Fuser ................III-33 5.7.1 Major functions......................III-33 5.7.2 Reference diagram ..................... III-34 5.8 Xerographics........................
  • Page 65: Printing Process

    CHAPTER III STRUCTURE OF SYSTEM COMPONENTS PRINTING PROCESS Summary of Printing Process This printer is a "Full-color laser printer" which applies the principal of an electrophotographic recording system. The tandem system comprising a drum and developing unit respectively for each color of yellow, magenta, cyan and black (Y, M, C and K) places toner image of each color on paper producing full-color prints finally through 3 intermediate transfer units (IDT 1: 2, IDT 2: 1).
  • Page 66: Primary Transfer (Drum Idt1)

    Drum Y Drum M Drum C Drum K Charged Charged Charged Charged with with with with electricity electricity electricity electricity Exposure Exposure Exposure Exposure Develop- Develop- Develop- Develop- ment ment ment ment Primary transfer Primary transfer ® ® (Drum IDT1) (Drum IDT1) Intermediate...
  • Page 67: Schematic Diagram For Printing Processes

    Schematic Diagram for Printing Processes Outline of printing processes is shown in the figures below. : Laser beam Toner Cartridge ASSY(Y) [(3) Development] Scanner ASSY : Paper transfer [(2) Exposure] Toner Cartridge ASSY(M) Print Head FUSER ASSY [(3) Development] Cartridge ASSY [(10) Fixing] Toner Cartridge ASSY(C) [(3) Development]...
  • Page 68: Description Of Printing Process Techniques

    Description of Printing Process Techniques 1.3.1 Charging with electricity In the charging process, the drum surface rotating at a constant speed is charged uniformly with negative electricity by discharging of RTC (Rubber Tube Charge: Charged film). This process is performed in parallel for yellow, magenta, cyan and black colors. •...
  • Page 69 1.3.2 Exposure In the exposure process, the drum surface charged negatively is scanned by laser beams to form invisible electrostatic latent image on the drum surface. This process is performed in parallel for yellow, magenta, cyan and black colors. • Laser beams are emitted from the laser diode in the scanner ASSY.
  • Page 70 Scanner ASSY : Negative electric charge : Positive electric charge Drum surface (Laser beams) Optical conductor Conductor (Laser beams) Electrostatic latent image Fig.3-9 Drum Fig.3-8 < Drum concept > Electric potential Laser beams on drum (Laser beams) Optical conductor Conductor Fig.3-10 Fig.3-11 III-6...
  • Page 71 1.3.3 Development In the development process, toner is electrically attached to the invisible statistic latent image on the drum surface to form visible toner image on the drum. This process is performed in parallel for yellow, magenta, cyan and black color respectively.
  • Page 72 Toner Cartridge ASSY : Negative electric charge : Positive electric charge Agitator : Toner : Carrier Auger Trimmer Rod Magnet Roll Paddle Auger Auger Drum HVPS Fig.3-12 Dram surface Electric potention on drum Developing bias Toner image Fig.3-13 Fig.3-14 III-8...
  • Page 73 1.3.4 Primary transfer (drum -> IDT 1) In the primary transfer process, toner image formed on the drum surface is transferred onto the surface of the IDT 1 (Intermediate Drum Transfer 1: intermediate transfer roll 1). Two IDT 1 are provided: yellow and magenta, and cyan and black are respectively transferred to their IDT 1.
  • Page 74 Drum surface (Yellow toner image) IDT1 surface Yellow toner image Magenta toner image Drum surface (Magenta toner image) Drum surface (Cyan toner image) IDT1 surface Cyan toner image Drum surface Black (Black toner image) toner image Fig.3-17 III-10...
  • Page 75: Secondary Transfer (Idt 1 -> Idt 2)

    1.3.5 Secondary transfer (IDT 1 -> IDT 2) In the secondary transfer process, the toner image formed on the IDT 1 surface is transferred onto the surface of the IDT 2 (Intermediate Drum Transfer 1: intermediate transfer roll 2). Two color toner image transferred onto the 2 IDT 1 is transferred to the IDT 2. Thus, 4 color toner image are compiled on the IDT 2 as finished toner image.
  • Page 76: Tertiary Transfer (Idt 2 - Paper)

    IDT1 surface Yellow toner image Magenta toner image IDT2 surface Yellow toner image Magenta toner image Cyan toner image IDT1 surface Black toner image Cyan toner image Black toner image Fig.3-19 1.3.7 Tertiary transfer (IDT 2 - paper) In the tertiary transfer process, finished toner image formed on the IDT 2 surface is transferred onto the paper under the voltage supplied to the transfer roll cartridge.
  • Page 77: Cleaning (Idt 2)

    1.3.8 Cleaning (IDT 2) In the cleaning process, toner remaining on the IDT 2 after the toner image is transferred onto the paper is temporarily held at the IDT 2 cleaner. • The IDT 2 cleaner is a conductive roll brush and receives positive high voltage from HVPS.
  • Page 78: 1.3.10 Fixing

    1.3.10 Fixing In the fixing process, toner is fixed on the paper by heat and pressure. • Finished toner image transferred from the belt is easily broken only by touching it with fingers. The toner image is fixed on the paper with the fuser ASSY (fixing unit). The toner melts by heat of the heat roll with the heater lamp as the heat source and is deposited on the paper under pressure given by the belt opposed against the heat roll.
  • Page 79: Cleaning (General)

    1.3.11 Cleaning (general) In the cleaning (general) process, toner stored in the IDT 1 cleaner and IDT 2 cleaner after the finished toner image is transferred onto the paper and the toner remaining on the transfer roll cartridge are removed. •...
  • Page 80 2) Refresher and RTC High voltage of the polarity (negative) reverse to that at the printing transfer is applied to the IDT1, IDT2, and transfer roll cartridge. At this time, the drum surface is charged negatively by negative voltage of the IDT1. The toner (positive polarity) remaining in the Refresher and RTC are move to the drum electrically by transforming the Refresher and RTC to 0V.
  • Page 81: Flow Of Print Data

    FLOW OF PRINT DATA Data Flow Print data (electric signal) from the printer controller flows as shown below to turn to the print image finally. Host (electric signal) Printer controller (electric signal) MCU HL-4200 (electric signal) Scanner ASSY (laser beams) Electrostatic latent on drum (invisible image) Toner image on drum...
  • Page 82: Drive Transmission Route

    DRIVE TRANSMISSION ROUTE Drive ASSY main Rotary power of the drive ASSY main is transmitted through the route below. MAIN DRIVE ASSY GEAR IDLER IN Regi.Clutch CLUTCH ASSY TURN GEAR IDLLER Regi.Roll CHUTE REGI ASSY ROLL ASSY TURN GEAR IDLLER FEED GEAR FEED H1 GEAR FEED1 ROLL ASSY FEED...
  • Page 83: Drive Assy Deve

    Drive ASSY DEVE The rotary power of the Drive ASSY DEVE drives the developers of 4 colors in the print head cartridge ASSY. DEVE DRIVE ASSY Developer (Y) Developer (M) Developer (C) Developer (K) PRINT HEAD CARTRIDGE ASSY Fig.3-26 Holder Toner Cartridge ASSY (Y, M, C, K) Rotary power of the toner motor in the holder toner cartridge ASSY drives the agitator in the toner cartridge ASSY (to supply toner from the toner cartridge ASSY to holder toner cartridge ASSY) and auger in the holder toner cartridge ASSY (to supply toner to...
  • Page 84: Fuser Drive Assy

    Fuser Drive ASSY Rotary power of the fuser drive ASSY drives the fuser ASSY. FUSER DRIVE ASSY Heat Roll Gear Exit Roll Assy Exit FUSER ASSY Fig.3-28 Motor ASSY DUP Rotary power of the motor ASSY DUP is transmitted through the route below. MOTOR ASSY DUP GEAR 48 GEAR 48...
  • Page 85: Gear Layout

    Gear Layout PRINT HEAD CARTRIDGE ASSY CHUTE ASSY OUT TRANSFER ROLL CARTRIDGE ASSY REGI CLUTCH CHUTE REGI ASSY MAIN DRIVE ASSY CLUTCH ASSY TURN GEAR MSI GEAR IDLER FEED HOUSING ASSY RETARD CLUTCH TURN GEAR IDLER IN GEAR FEED1 GEAR IDLER GEAR FEED H1 FRONT PAPER FEEDER (PICK UP ASSY)
  • Page 86: Paper Transfer Route (Without Option)

    PAPER TRANSFER Paper Transfer Route (without option) Paper feed from paper tray (Tray 1) Paper feed from MSI Paper feed by "ROLL ASSY FEED (MSI)" Paper feed by "ROLL ASSY FEED (Pick up ASSY)" and "ROLL ASSY RETARD" Paper feed by "ROLL ASSY (Paper Cassette)" in cassette and "ROLL ASSY (Pick up ASSY)"...
  • Page 87: Layout Of Paper Transfer Route

    Layout of Paper Transfer Route : Laser beam : Paper transfer : Paper sensors ROLL EXIT ROLL MID ROLL PINCH EXIT ROLL PINCH Heat Roll Pinch Roll IDT2 ROLL ASSY EXIT Fuser Belt ROLL DUP ROLL PINCH DUP Transfer Roll Cartridge Metal Roll Regi Roll ROLL ASSY FEED (MSI)
  • Page 88: Functions Of Major Functional Components

    FUNCTIONS OF MAJOR FUNCTIONAL COMPONENTS Major functional components comprising the printer are described below referring to their illustrations. Those components are classified into the following blocks based on the configuration of the printer. • Paper Cassette • Paper Feeder • Housing ASSY Retard •...
  • Page 89: Paper Cassette

    Paper Cassette 5.1.1 Major functions • Side Guide The side guide can move at right angle to the paper transfer direction to align the paper width. • End Guide The end guide can move in the paper transfer direction to determine the paper size. The ON/OFF of switch ASSY size (see 5.2 Paper Feeder) varies according to the end guide position to detect the paper size.
  • Page 90: Paper Feeder

    Paper Feeder 5.2.1 Major functions • Switch ASSY size Switch ASSY size detects paper size and existence or non existence of the paper tray. • Sensor photo (No paper sensor) Detects existence or non existence of paper in the paper tray based on the position of actuator no paper.
  • Page 91 5.2.2 Reference diagram SENSOR PHOTO(No Paper Sensor) ROLL ASSY FEED(PICK UP ASSY) SENSOR HUM TEMP CLUTCH ASSY TURN SWITCH ASSY SIZE GEAR FEED SPRING FEED GEAR IDLER FEED ROLL ASSY TURN SOLENOID FEED ROLL ASSY(PICK UP ASSY) SENSOR PHOTO(Low Paper Sensor) Fig.3-35 III-27...
  • Page 92: Major Functions

    Housing ASSY Retard 5.3.1 Major functions • Clutch turn (MSI) Transmits the drive from the drive ASSY main to the roll turn. • Roll turn The roll turn is rotated by the drive from the drive ASSY main through the clutch turn (MSI) to feed the paper from the manual feed tray to the chute REGI (REGI roll) (refer to "5.8 Xerographics").
  • Page 93: Major Functions

    Front ASSY In 5.4.1 Major functions • Holder ASSY CTD Reads the density of the toner image prepared on the surface of transfer roll cartridge in the transfer roll cartridge unit ASSY (refer to "5.7 Transfer Roll Cartridge ASSY & Fuser") and feeds it back to the process control (refer to "7.4 Process Control").
  • Page 94: Major Functions

    Chute ASSY Out 5.5.1 Major functions • Sensor photo (Full stack sensor) Detects that the prints discharged onto the top cover have accumulated more than specified number of sheets based on the change of position of the actuator. (Full stack: Sensor beam is received) •...
  • Page 95: Reference Diagram

    5.5.2 Reference diagram SENSOR PHOTO(Full Stack Sensor) SENSOR PHOTO(DUP Jam Sensor) ROLL DUP Gear Idier (DRIVE ASSY MAIN) GEAR MSI ROLL ASSY FEED (MSI) SENSOR PHOTO(MSI No Paper Sensor) SOLENOID FEED MSI Fig.3-38 III-31...
  • Page 96: Major Functions

    Chute ASSY Exit 5.6.1 Major functions • Motor ASSY DUP Supplies drive to the roll exist, roll MID, and roll DUP. • Roll exit The roll exit rotates under the drive from the motor ASSY DUP, and feeds fixed prints onto the top cover.
  • Page 97 Transfer Roll Cartridge ASSY & Fuser 5.7.1 Major functions • Fuser ASSY The fuser ASSY fixes toner which was transferred onto the paper but not fixed by the heat and pressure and feeds paper before and after being fixed. The fuser ASSY mainly consists of the following parts: •...
  • Page 98 5.7.2 Reference diagram FUSER ASSY Exit Sensor FAN FUSER Transfer Roll Cartridge ASSY Fig.3-40 III-34...
  • Page 99 Xerographics 5.8.1 Major functions • Scanner ASSY Scanner ASSY (raster output scanner assembly) is an exposure unit to generate laser beams to form electrostatic latent image on the drum surface. In this manual, the scanner ASSY is referred to as scanner ASSY. The scanner ASSY mainly consists of the following parts: •...
  • Page 100 5.8.2 Reference diagram Scanner ASSY Print Head Cartridge ASSY OHP SENSOR SENSOR PHOTO(Regi Sensor) CHUTE REGI(Regi Clutch) Fig.3-41 III-36...
  • Page 101 Toner Cartridge ASSY 5.9.1 Major functions • PWBA CRUM READER The PWB consists of each color toner bottle switch and CRUM. Toner bottle switch: Detects whether toner cartridge (toner bottle) of each color is installed or not. CRUM: Printer specific information is stored. •...
  • Page 102 5.9.2 Reference diagram TONER CARTRIDGE ASSY (Y) PWBA CRUM READER TONER CARTRIDGE ASSY (M) S-HVPS TONER CARTRIDGE ASSY (C) TONER CARTRIDGE ASSY (K) PWBA EEPROM HOLDER ASSY TONER HBN(K) (Toner Motor : K) HOLDER ASSY TONER HBN(C) SENSOR NO TONER(Y) (Toner Motor : C) SENSOR NO TONER(M) HOLDER ASSY TONER HBN(M)
  • Page 103 5.10 Frame & Drive 5.10.1 Major functions • Drive ASSY main Supplies the drive to parts as follows. • Paper feeder • Housing ASSY retard • Chute ASSY out (MSI position) • Chute REGI • Print Head Cartridge ASSY (IDT 2, IDT 1, Drum) •...
  • Page 104 5.11 Electrical 5.11.1 Major functions • Fan Rear Discharges heat out of the printer to prevent too high temperature in the printer. • Harness ASSY AC SW Composed of the main switch and inlet and controls supply of AC power from the power source to LVPS.
  • Page 105 • HDD Optional HDD is used for two uses described below. The space used for each function is divided into partitions by the fixed ratio. The space doesn't have relation each other. The ratio cannot be changed. *Breakdown: (1) Job Log: 2MB (2) PostScript file system: 512MB (It would be the half of the whole HDD if the capacity of HDD is less than 1GB.) (3) Memory sort on HDD: rest of capacity...
  • Page 106: Modes

    MODES Print Mode The printer has four modes, Standard mode, Fine mode, High gloss mode, and Super high gloss mode. Modes are switched over under the instruction from the controller. 1. Standard mode: Used for printing with resolution 600dpi 2. Fine mode: Process direction resolution 1200dpi mode 3.
  • Page 107: Control

    • Error mode Any error was detected in the printer. • Initiglizing mode New parts have been just set to the printer (initializing with a new PHD). • Checking Unit mode Printer is under checking consumable units. CONTROL Control of Paper Size "ON/OFF of paper size switch of switch ASSY size "...
  • Page 108: Process Control

    Process Control For a stable printing, the parameters related to the image forming must be corrected as necessary. The control of entire printing process including parameter correction control is called "process control". Mainly, the following two controls are made: • Potential control •...
  • Page 109 7.4.2 Toner density control The toner density must be kept constant to attain stable printing image. To keep the toner density constant, the toner should be dispensed exactly by the quantity consumed for the printing. This system is the PCDC. However, the system with only the PCDC generates a difference from target toner density, thus requiring the system to correct this error.
  • Page 110: Led Light Quantity Control Of Holder Assy Ctd

    7.4.3 High area coverage mode A continuous printing of the image of area coverage exceeding the toner dispense capability causes the toner density in the developer to be lowered. The high area coverage mode extends the next page feed and dispenses the toner during this time, if the toner dispense time reached the specified value during a continuous printing.
  • Page 111: Color Registration Control

    Color Registration Control The printer uses a tandem system where the drums and developers exclusively for yellow, magenta, cyan, and black are arranged respectively. The images are formed on the drums of respective colors cyan, and black are arranged respectively. The images are formed on the drums of respective colors registration control calculates how much the registration is shifted, and adjusts the scanner write timing.
  • Page 112: Transfer Roll Cartridge Unit Assy Control

    Transfer Roll Cartridge Unit ASSY Control 7.6.1 Detecting the installation of transfer roll cartridge unit ASSY Whether the transfer roll cartridge unit ASSY is installed is detected when the power is turned on, or the front cover is opened and closed. The sensor for detecting the installation is not provided, but judgment is made from the output of the holder ASSY CTD.
  • Page 113: Toner Control

    Toner Control Whether the toner bottle is installed is detected by the switch toner cartridge ASSY, and the presence of toner in the toner bottle is detected by the sensor no toner . These switches and sensors are provided for respective colors, and detection is made for each color.
  • Page 114: Fuser Control

    Fuser Control 7.8.1 Fuser temperature control As for the fuser temperature control, the target temperature is set, then the heat roll surface temperature is controlled so as to be the target temperature by turning on/off the heater lamp. Temperature of individual area of the heat roll is detected by the fuser non-contact sensor (NCS) in the middle of the heat roll and the temp sensor at the edge of it.
  • Page 115 CHAPTER IV ASSEMBLY / DISASSEMBLY...
  • Page 116 CONTENTS CHAPTER IV ASSEMBLY / DISASSEMBLY........ IV-1 ... REPLACING PROCEDURE OF PERIODICAL REPLACEMENT PARTS 1.1 Replacing the Fuser ASSY .....................IV-1 1.2 Replacing the Transfer ASSY ..................IV-4 1.3 Replacing the Roll ASSY ....................IV-6 1.4 Description of Procedures....................IV-6 2. DISASSEMBLY PROCEDURE ..............2.1 Precautions ........................IV-7 2.2 Cover of the Printer ......................IV-8 2.2.1 Cover ASSY front head ....................IV-8...
  • Page 117 2.3.22 Latch R .........................IV-35 2.3.23 Latch L........................IV-36 2.3.24 Fuser drive ASSY ....................IV-36 2.3.25 Chute ASSY REGI....................IV-37 2.3.26 Actuator REGI ......................IV-38 2.3.27 Sensor photo: REGI .....................IV-38 2.3.28 OHP sensor ASSY ....................IV-39 2.3.29 Housing ASSY retard ...................IV-41 2.3.30 Clutch turn ......................IV-41 2.3.31 Roll turn ........................IV-42 2.3.32 Roll ASSY retard ....................IV-42 2.3.33 Stud retard......................IV-44 2.3.34 PWBA ASSY earth ....................IV-44...
  • Page 118 2.6.14 Housing ASSY feeder L ..................IV-76 2.6.15 Sensor HUM temp ....................IV-77 2.6.16 Housing ASSY feeder R..................IV-78 2.6.17 Harness ASSY OPFREC ..................IV-79 2.6.18 Switch ASSY size ....................IV-79 2.6.19 Indicator........................IV-80 2.6.20 Guide indicator .....................IV-81 2.6.21 Lever low paper ....................IV-82 2.6.22 Roll ASSY......................IV-83 2.6.23 Cassette ASSY front.....................IV-83 2.6.24 Holder retard......................IV-84 2.6.25 Actuator exit......................IV-85...
  • Page 119: Chapter Iv Assembly / Disassembly

    CHAPTER IV ASSEMBLY / DISASSEMBLY REPLACING PROCEDURE OF PERIODICAL REPLACEMENT PARTS Periodical replacement parts are the parts to be replaced periodically to maintain product quality. Refer to APPENDIX5. “PERIODICAL REPLACEMENT PARTS” in detail. Replacing the Fuser ASSY WARNING Fuser is high temperature after operation. Be careful when working it not to get burning.
  • Page 120 4) Lift the levers on both sides of the fuser ASSY. Fig.4-4 5) Hold the levers on both sides as you remove the fuser ASSY from the printer carefully. Fig.4-5 6) Unpack a new fuser ASSY and lift the levers on both sides. Grip the lever and install the fuser ASSY into the printer gently placing pin into the guides.
  • Page 121 7) Push down the levers on both sides of the fuser ASSY. Fig.4-7 8) Push and slide backward the switches on both sides of the fuser ASSY. Fig.4-8 9) Close the Paper outlet cover. Fig.4-9 10) Close the chute ASSY. Fig.4-10 - IV-3 -...
  • Page 122: Replacing The Transfer Assy

    Replacing the Transfer ASSY Push up latch A and fully open the chute ASSY. Fig.4-11 Grip the orange tabs at both ends of the transfer roll and gently lift it out of the printer. Fig.4-12 Unpack a new transfer roll cartridge unit ASSY and grip the orange tabs. Fig.4-13 - IV-4 -...
  • Page 123 Insert the pins at both ends of the transfer roll cartridge unit ASSY into the bearings inside the printer, and gently push the roll into the printer. Fig.4-14 To lock the transfer roll cartridge into the printer, push down on the tabs until you hear a click.
  • Page 124: Replacing The Roll Assy

    Replacing the Roll ASSY Release the cover feed secured to the paper tray at one point and open the cover feed. Release the hook securing the roll ASSY to the shaft retard from the paper tray. Pull out the roll ASSY from the shaft retard. Roll ASSY Cover feed Fig.4-16...
  • Page 125: Disassembly Procedure

    DISASSEMBLY PROCEDURE Precautions Note: Parts are controlled as spare parts. When servicing for parts for which no procedures are described, observe their assembling condition before starting the service. Note: For optional parts, refer to the manual for them. Note: Though the optional parts are assumed to be removed, they may not be removed if not required for the purpose of service operation.
  • Page 126: Cover Of The Printer

    2.2 Cover of the Printer 2.2.1 Cover ASSY front head 1) Release latch B of the printer and open the front cover. Note: Do not separate the front cover and cover ASSY front head too far in the following process. 2) Release the 4 hooks securing the cover ASSY front head to the front cover.
  • Page 127: Console Panel Hl-4200

    2.2.2 Console panel HL-4200 1) Release the 3 hooks securing the console panel HL-4200 to the cover ASSY front head. 2) Remove the console panel HL-4200 from the cover ASSY front head. Console panel HL-4200 Cover ASSY front head Bottom view Fig.4-19 - IV-9 -...
  • Page 128: Fan Fuser

    2.2.3 Fan fuser 1) Remove 2 screws securing the holder lever out from the rear of the cover ASSY front head. 2) Remove the fan assembly from the cover ASSY front head. 3) Remove the lever out from the holder lever out. 4) Disconnect of the fan fuser.
  • Page 129: Cover Msi

    2.2.4 Cover MSI 1) Close the front cover. 2) Open the cover MSI. 3) While pulling the left hand side of the cover MSI, release the boss of the tray ASSY base from the slot in the cover MSI. 4) Repeat for the right hand side. 5) Lower the front of the cover MSI unit the cover MSI releases from the printer.
  • Page 130: Strap

    2.2.6 STRAP 1) Release hooks that secure the bottom portion of STRAP, and slide the bottom portion of STRAP toward the right to remove from the chute ASSY out. 2) Turning the top of STRAP secured to the upper right of the chute ASSY IN, meet a convex portion with the key hole in the chute ASSY IN and pull out the top of STRAP to remove the STRAP.
  • Page 131: Cover Assy Front

    2.2.7 Cover ASSY front 1) Release latch B and open the chute ASSY out. 2) Remove the top of the link: L from the leaf spring at the back of the cover ASSY front. 3) Remove 2 screws securing the cover ASSY front to the chute ASSY out. 4) Release the 2 hooks securing the cover ASSY front to the chute ASSY out.
  • Page 132: Cover Assy Front In

    2.2.8 Cover ASSY front IN Note: In the following process, do not separate the cover ASSY front IN and link: R too far. 1) Release latch A and open the chute ASSY IN together with the chute ASSY out. 2) Remove 2 screws securing the cover ASSY front IN to the chute ASSY IN. 3) Pull out the cover ASSY front IN slightly from the chute ASSY IN.
  • Page 133: Cover Top Main

    2.2.9 Cover top main Note: Before removing the cover top main, remove the toner cartridges. 1) Open the Paper outlet cover. 2) Remove 2 screws securing the cover top main to the printer. 3) Release the 4 hooks securing the cover top main to the printer. 4) Raise the cover top main slightly from the printer and extract the left front edge of the cover top main deflecting it leftward.
  • Page 134: Cover Side L

    2.2.10 Cover side L 1) Remove 1 screw securing the rear of cover side L to the printer. 2) Release the hook securing the cover side L at the front edge of the printer. 3) Remove the cover side L from the printer. Cover side L Screw, tapping M3x8 Fig.4-30...
  • Page 135: Cover Side R

    2.2.12 Cover side R 1) Remove 1 screw securing the rear of cover side R to the printer. 2) Release the hook securing the cover side R at the front of the printer. 3) Remove the cover side R from the printer. Cover side R Screw, tapping M3x8 Fig.4-32...
  • Page 136: Link: L

    2.2.14 Link: L 1) Remove the top of spring link: L from the projection on the left side of the printer. 2) Slide the link: L rearward and align the shaft of the printer and hole of the link: L. 3) Remove the link: L from the printer together with the spring link: L.
  • Page 137: Front Of The Printer

    Front of the Printer 2.3.1 Chute ASSY out Note: In the following step, lock the chute ASSY out and chute ASSY IN to the printer with latches A and B. 1) Remove the connectors from the connector bracket on the left side surface of the printer.
  • Page 138 8) Remove the ring E on the right and left shaft pivot securing the bottom portion of the chute ASSY out and chute ASSY IN. CAUTION In the following steps, take care not to hurt your hand with burrs of the plate ASSY bottom MSI.
  • Page 139: Actuator Full

    2.3.2 Actuator full 1) While pulling the center of the actuator full shaft upwards, pull the right hand end of the shaft forwards to clear the sensor and release the right end of the shaft. 2) Move the shaft to the right to release the left end of the shaft and remove it. Actuator full Fig.4-39 2.3.3...
  • Page 140: Actuator Dup

    2.3.4 Actuator DUP 1) Release the 2 hooks securing the cover actuator to the chute ASSY out. 2) Remove the cover actuator from the chute ASSY out. 3) Pushing the front arm of the actuator DUP down, slide the actuator DUP to the right and extract the left side shaft of the actuator DUP from the left side bush.
  • Page 141: Sensor Photo: Dup

    2.3.5 Sensor photo: DUP 1) Remove the sensor photo: DUP cable. 2) Release the 3 hooks securing the sensor photo: DUP to the chute ASSY out. 3) Remove the sensor photo: DUP from the chute ASSY out. Sensor photo: DUP Fig.4-43 2.3.6 Actuator MSI...
  • Page 142: Sensor Photo: Msi

    2.3.7 Sensor photo: MSI 1) Remove the connector on the sensor photo: MSI from the chute ASSY out. 2) Release the 3 hooks securing the sensor photo: MSI to the chute ASSY out. 3) Remove the sensor photo: MSI from the chute ASSY out. Sensor photo: MSI Rear view Fig.4-45...
  • Page 143: Roll Dup

    2.3.9 Roll DUP 1) Release the hook remove the gear 30 from the shaft of the roll DUP. 2) Extract the bush earth securing the left end of the shaft to the chute ASSY out. 3) Remove the E-ring securing the right end of the shaft to the chute ASSY out. 4) Extract the bush securing the right end of the shaft to the chute ASSY out.
  • Page 144: Roll Assy Feed

    2.3.11 Roll ASSY feed 1) Release the hook securing the roll core MSI: right to the shaft MSI on the chute ASSY out and push down the plate bottom MSI slightly to release the nip with the roll ASSY feed. 2) Slide the roll ASSY feed to the right on the shaft MSI and lift out the roll ASSY feed forwards.
  • Page 145: Shaft Assy Roll Feed

    2.3.13 Shaft ASSY roll feed 1) Release the hook of the spring sol from a convex portion on the stopper sol cam from the chute ASSY out. 2) Release the hook securing the stopper sol cam to the left of shaft MSI, and remove the stopper sol cam from the shaft from the chute ASSY out.
  • Page 146: Plate Assy Bottom Msi

    6) Pull off the bush MSI on the shaft MSI toward the inside. 7) Raising the right end of the shaft ASSY roll feed, pull out the shaft ASSY feed from the chute ASSY out. Note: When refitting the cam MSI ensure that it is located connecting on the shaft. When refitting the stopper sol cam, ensure it is in the home position.
  • Page 147: Chute Assy Exit

    2.3.15 Chute ASSY exit 1) Disconnect the connector of the motor ASSY DUP on the chute ASSY out and release the cable from the clips. 2) Remove 2 screws securing the chute ASSY exit to the chute ASSY out. 3) Pull out the chute ASSY exit from the left side surface of the chute ASSY out. Note: When replacing the chute ASSY exit, be careful to avoid the actuator full on the chute ASSY out.
  • Page 148: Roll Exit

    2.3.16 Roll exit 1) Release the hook securing the gear roll to the shaft of the roll exit. 2) Remove the gear roll from the shaft of the roll exit. 3) Remove the E-ring from the shaft of the roll exit. 4) Extract the bush earth from the shaft of the roll exit.
  • Page 149: Roll Mid

    2.3.17 Roll MID 1) Release the hook securing the gear roll to the shaft of the roll MID. 2) Remove the gear roll from the shaft. 3) Remove the E-ring from the shaft of the roll MID. 4) Extract the bush earth from the shaft of the roll MID. 5) Remove the shaft of the roll MID from the chute ASSY exit and pull out the roll exit upwards.
  • Page 150: Motor Assy Dup

    2.3.18 Motor ASSY DUP 1) Release the hook securing the gear roll to the shaft of the roll exit. 2) Remove the gear roll from the shaft of the roll exit. 3) Remove the gear 40/42 from the left side of the chute ASSY exit. 4) Remove the gear 48 from the left side of the chute ASSY exit.
  • Page 151: Chute Assy In

    2.3.19 Chute ASSY IN Note: In the following step, lock the chute ASSY IN to the printer with latch at A to prevent the chute ASSY IN from drop off. 1) Remove the connectors on the S-HVPS from the left side of the printer. 2) Remove the connectors from the connector bracket on the left side of the printer.
  • Page 152: Holder Assy Ctd

    7) Remove 1 screw securing the wire ASSY FSR earth on the right side of the printer. 8) Release the harness of the fuser drive ASSY from the clamp on the drive ASSY main. 9) Shift the harness of the harness ASSY FSR3 (FSR32,FSR4) from the hook of the housing on the right side of the printer.
  • Page 153: Sensor Tnr Full

    2.3.21 Sensor TNR full 1) Release the 2 hooks securing the sensor TNR full to the chute ASSY IN. 2) Remove the connector on the sensor TNR full. 3) Remove the sensor TNR full from the chute ASSY IN. Sensor TNR full Front Fig.4-61 2.3.22...
  • Page 154: Latch L

    2.3.23 Latch L 1) Release the hook securing the latch L to the left side of the chute ASSY IN. 2) Remove the latch L from the chute ASSY IN. Chute ASSY IN Latch L Fig.4-63 2.3.24 Fuser drive ASSY 1) Remove the screw securing the earth of the harness ASSY FSR to the fuser drive ASSY.
  • Page 155: Chute Assy Regi

    2.3.25 Chute ASSY REGI 1) Release the 2 hooks securing the housing ASSY ELEC to the printer and remove the housing ASSY ELEC upward. Housing ASSY ELEC Fig.4-65 2) Disconnect the 2 connectors of the chute ASSY REGI from the printer. 3) Remove 4 screws securing the chute ASSY REGI to the printer.
  • Page 156: Actuator Regi

    2.3.26 Actuator REGI Holding the shielding portion of the actuator REGI move the actuator REGI left and extract the right hand end of the shaft of the actuator REGI from the bush of the chute ASSY REGI. Pull out the actuator REGI from the chute ASSY REGI together with the spring sensor REGI.
  • Page 157: Ohp Sensor Assy

    2.3.28 OHP sensor ASSY Remove the E-ring that secures the gear REGI metal to the chute ASSY REGI, and remove the gear REGI metal. Remove the E-ring that secures the gear REGI rubber to the chute ASSY REGI, and remove the gear REGI rubber. Pull out the bush earth that secures the shaft of the roll REGI rubber.
  • Page 158 Lift the shaft of roll REGI metal, pull out the roll REGI metal together with the bush metal R (white). Roll REGI metal Chute ASSY REGI Fig.4-71 Release the 2 hooks on the bottom of chute ASSY REGI that secure the OHP sensor ASSY.
  • Page 159: Housing Assy Retard

    2.3.29 Housing ASSY retard Remove the connector of the clutch turn from on the PWBA HBN MCU. Remove 3 screws securing the housing ASSY retard to the printer. Remove the housing ASSY retard from the printer. Screw, M3x10 Screw, M3x10 Housing ASSY retard Fig.4-73 2.3.30...
  • Page 160: Roll Turn

    2.3.31 Roll turn Remove the E-ring securing the roll turn to the housing ASSY retard. Pull out the bush earth securing the left side of the roll turn from the housing ASSY retard. Pull out the bush securing the right side of the roll turn from the housing ASSY retard.
  • Page 161 Pull out the holder ASSY retard to left upward from the housing ASSY retard. Release the hook securing the shaft RTD to the holder ASSY retard of the printer. Holder ASSY retard Fig.4-77 Raise the shaft RTD to right upward, and pull out the roll ASSY retard. Holder ASSY retard Roll ASSY retard Fig.4-78...
  • Page 162: Stud Retard

    2.3.33 Stud retard Release the 2 hooks securing the cap retard to the housing ASSY retard. Remove the cap retard from the housing ASSY retard together with the stud retard and spring retard 370. Remove the stud retard from the cap retard. Housing ASSY retard Stud retard Spring retard...
  • Page 163: Top Of The Printer

    Top of the Printer 2.4.1 Holder toner cartridge ASSY unit Note: When removing the holder toner cartridge ASSY unit, remove the toner deposit on the holder toner cartridge ASSY with a vacuum cleaner before starting the removal process. Note: When removing the toner deposit on the holder toner cartridge ASSY with a vacuum cleaner, attach an earth cord to the end of the cleaner to avoid the static electricity.
  • Page 164 Remove the connector (D) on the PWBA EEPROM STD on the left side of the printer. Remove the connector (E) on the S-HVPS on the left side of the printer. From the printer, release the fan harness from the clamps. Remove the connector (F) from the connector block.
  • Page 165 Note: When replacing the gear slide, meet the leading edge of gear rail on the left side. with the vertex of a triangle mark on the rack V. Rack V Fig.4-84 2.4.2 Holder toner cartridge ASSY On the holder toner cartridge ASSY unit, release the hook securing the toner discharging unit of the holder toner cartridge ASSY (1) on the plate ASSY dispenser L with a mini screwdriver.
  • Page 166 <Magenta> Holder toner cartridge ASSY (2) Fig.4-86 <Cyan> Holder toner cartridge ASSY (3) Fig.4-87 - IV-48 -...
  • Page 167: Holder Toner Cartridge Assy

    <Black> Holder toner cartridge ASSY (4) Fig.4-88 - IV-49 -...
  • Page 168 2.4.3 Actuator toner cartridge ASSY Release the 2 hooks securing the actuator toner cartridge ASSY to the holder toner cartridge ASSY with a mini screwdriver. Remove the actuator toner cartridge ASSY from the holder toner cartridge ASSY. A ctuator tone r cartridge ASSY Left Holder toner cartridge ASSY Fig.4-89...
  • Page 169 2.4.5 Sensor no toner Remove the 4 hooks securing the sensor no toner to the holder toner cartridge ASSY. Remove the sensor no toner from the holder toner cartridge ASSY. Holder toner cartridge ASSY Sensor no toner Fig.4-91 2.4.6 Box ASSY CRUM reader Remove the connector on PWBA CRUM reader.
  • Page 170: S-Hvps

    2.4.7 PWBA EEPROM Remove 1 screw securing the PWBA EEPROM. Remove the PWBA EEPROM from the printer. Screw, M3x6 Left PWBA EEPROM Fig.4-93 2.4.8 S-HVPS Remove 4 screws securing the S-HVPS. Remove the S-HVPS from the printer. S-HVPS Screw, M3x6 Screw, M3x6 Screw, M3x6 Left...
  • Page 171: Fan Rear

    2.4.9 Fan rear Remove the connector on the LVPS from the right side surface of the printer. Shift the harness of the fan rear from 3 hooks of the holder toner cartridge ASSY of the printer. Remove 2 screws securing the fan rear from the printer. Remove the fan rear from the printer.
  • Page 172: Right / Left / Pcbs Of The Printer

    Right / Left / PCBs of the Printer 2.5.1 Controller Board Loosen the two screws, and then remove the controller board. Note: In replacing the controller board on the printer, connect the connector at the leading end of controller board to the connector of the MCU HL-4200. Screw, M4x7.5 Controller board Screw, M4x7.5...
  • Page 173: 2.5.2 Hsg Assy Bias

    2.5.2 HSG ASSY BIAS Remove 5 screws securing the HSG ASSY BIAS to the left side surface of the printer. Remove the HSG ASSY BIAS from the printer. Remove 8 contact pads from the printer. HSG ASSY BIAS Screw, M3x10 Screw, M3x10 Fig.4-99 2.5.3...
  • Page 174 Remove the link lever: L from the printer together with the spring lever: 30N and lever drum: L. Remove 4 springs from link lever: L and remove 4 lever drum: L. Note: When replacing the link lever, align the spring IDT L and the bottom of link lever: L with the positions shown in the figure (lever drum: L replacement).
  • Page 175: Drive Assy Main

    2.5.4 Drive ASSY main Remove the connector on the PWBA DRV HBN from the right side of the printer. Remove the connector on the PWBA DRV HBN. Disconnect the connector on the PWBA DRV HBN. Remove 3 screws securing the drive ASSY main to the printer. Remove the drive ASSY main from the printer.
  • Page 176 2.5.5 PWBA DRV HBN Remove the all connectors on the PWBA DRV HBN from the right side of the printer. Remove 4 screws securing the PWBA DRV HBN to the printer. Remove the PWBA DRV HBN from the printer. Screw, M3x6 Screw, M3x6 Screw, M3x6 PWBA DRV HBN...
  • Page 177: Drive Assy Deve

    2.5.6 Drive ASSY DEVE Remove 4 screws securing the Drive ASSY DEVE from the right side of the printer. Remove the Drive ASSY DEVE from the printer. Drive ASSY DEVE Screw, DT M4x10 Screw, DT M4x10 Fig.4-105 2.5.7 Actuator I/R From the right side of the printer, release the hook of the spring I/R from the convex portion of the plate ASSY lever R.
  • Page 178: Lever Drum: R

    2.5.8 Lever drum: R Remove 4 screws securing the plate ASSY lever R from the right side of the printer. Remove the plate ASSY lever R from the printer. Release the hook of the spring lever 30N hitched over the convex portion of the 4 lever drum: R from the right side of the printer.
  • Page 179: Lvps

    Note: When replacing the link lever: R, align the spring IDT R and the bottom of link lever: L with the positions shown in the figure (lever drum: L replacement). Gear IDL. press Link lever: R Gear press R Fig.4-109 2.5.9 LVPS Remove the three connectors from the LVPS.
  • Page 180 Releasing the hooks at 2 positions, and then remove the guide harness SW. Remove the screw, and then release the ground wire. Disconnect the connector on the guide harness SW. Remove the switch part of the guide harness SW. Releasing the hooks at 2 positions, and then remove the inlet part of the guide harness SW.
  • Page 181: Box Assy Mcu/Ess

    2.5.10 Box ASSY MCU/ESS Remove the connector from the right side of the printer. Remove the connector on the scanner ASSY from the right side of the printer. Remove the connector from the left side of the printer. Box ASSY MCU/ESS Fig.4-113 Remove 4 screws securing the box ASSY MCU/ESS to the printer.
  • Page 182: Housing Assy Contact

    2.5.11 Housing ASSY contact Remove the housing ASSY contact from the box ASSY MCU/ESS. Pull out the housing ASSY contact from the box ASSY MCU/ESS and remove it. Housing ASSY contact Fig.4-115 - IV-64 -...
  • Page 183: Mcu Hl-4200

    2.5.12 MCU HL-4200 Remove 4 screws securing the cover MCU to the box ASSY MCU/ESS. Remove the cover MCU from the box ASSY MCU/ESS. Remove the connectors on the MCU HL-4200 from the box ASSY MCU/ESS. Cover MCU Screw, M3x6 Screw, M3x6 Screw, M3x6 Fig.4-116...
  • Page 184: Paper Feed Of The Printer

    Paper Feed of the Printer 2.6.1 Chute ASSY turn Release the 2 hooks at the front securing the chute ASSY turn to the printer feeder. The chute ASSY will hang ertically. Chute ASSY turn Fig.4-118 Release the hook securing the right and left shaft of the chute ASSY turn to the printer feeder.
  • Page 185: Cover Cassette Slide

    2.6.2 Cover cassette slide Right and left of cover cassette slide are pushed, a claw on either side is removed from the projection of housing feeder L and housing feeder R, and cover cassette slide is removed. Cover cassette slide Fig.4-120 - IV-67 -...
  • Page 186: Link Actuator

    2.6.3 Link actuator Shift the bracket of the link actuator from the shaft of the actuator no paper of the printer. Extract the actuator of the link actuator from the hole on the printer and remove the link actuator. Link actuator Actuator no paper Fig.4-121 - IV-68 -...
  • Page 187: Feeder Assy Unit

    2.6.4 Feeder ASSY unit Remove the connector connecting the printer and feeder ASSY unit from the left side of the printer. Remove the 2 connectors connecting the printer and feeder ASSY unit from the right side of the printer. Remove 8 screws securing the feeder ASSY unit to the printer. Remove 4 long screws securing the feeder ASSY unit to the printer.
  • Page 188: Pickup Assy

    2.6.5 Pickup ASSY Remove the harness of the pickup ASSY from the right hook of the feeder ASSY unit. Disconnect the harness from the size switch. Remove 2 screws securing the pickup ASSY to the feeder ASSY unit. Lift the pickup ASSY from the feeder ASSY unit. Pickup ASSY Screw, M3x10...
  • Page 189: Roll Assy Feed

    2.6.6 Roll ASSY feed Rotate the shaft feed 1 (180°) so that the rubber of the roll ASSY feed L and R faces downward from the printer feeder. Release the hook securing the roll ASSY feed L and R to the shaft feed 1 and remove the roll ASSY feeds.
  • Page 190: Actuator No Paper

    2.6.7 Actuator no paper Release the hook securing the actuator no paper to the pickup ASSY and extract the left side shaft of the actuator no paper. Pull out the actuator no paper left and upward from the pickup ASSY. Actuator no paper Rear Front...
  • Page 191: Sensor Photo: No Paper

    2.6.8 Sensor photo: No paper Release the hooks at 3 positions securing the sensor photo: no paper to the pickup ASSY. Remove the connector on the sensor photo: no paper. Remove the sensor photo: no paper from the pickup ASSY. Rear Sensor photo: no paper Front...
  • Page 192: Solenoid Feed

    2.6.10 Solenoid feed Remove 1 screw securing the solenoid feed from the pickup ASSY. Separate the solenoid feed a little from the pickup ASSY and shift the harness of the solenoid feed. Remove the connector of the solenoid feed from the pickup ASSY. Rear Right Solenoid feed...
  • Page 193: Roll Assy

    2.6.12 Roll ASSY turn Release the hook securing the gear feed 2 to the shaft of the pickup ASSY and pull out gear feed 2. Pull out the gear idler from the shaft of pickup ASSY. Pull out the gear idler in from the shaft of the pickup ASSY. Remove the right and left E rings securing the shaft of the roll ASSY turn to the pickup ASSY.
  • Page 194: Housing Assy Feeder L

    2.6.14 Housing ASSY feeder L Remove 4 screws securing the housing ASSY feeder L to the plate bottom. Housing ASSY feeder L Screw, M3x10 Front Screw, M3x10 Left Fig.4-133 Pull down the housing ASSY feeder L inward and extract the 3 hooks out of the hole at the plate bottom.
  • Page 195: Sensor Hum Temp

    2.6.15 Sensor HUM temp Remove the screw securing the sensor HUM temp. Remove the harness ASSY TMPA. Harness ASSY TMPA Screw, M3x10 Sensor HUM temp Left Fig.4-135 - IV-77 -...
  • Page 196: Housing Assy Feeder R

    2.6.16 Housing ASSY feeder R Remove 4 screws securing the support feeder left to the plate bottom. Housing ASSY feeder R Screw, M3x10 Right Screw, M3x10 Front Screw, M3x10 Fig.4-136 Pull down the housing ASSY feeder R inward and extract the 3 hooks out of the hole at the plate bottom.
  • Page 197: Harness Assy Opfrec

    2.6.17 Harness ASSY OPFREC Release the harness ASSY OPFREC from the housing ASSY feeder R of the feeder ASSY unit. Release the 2 hooks securing the harness ASSY OPFREC to the housing ASSY feeder R. Pull out the harness ASSY OPFREC downward from the housing ASSY feeder R. Right Top view Harness ASSY OPFREC...
  • Page 198: Indicator

    2.6.19 Indicator Hold the tip of the indicator with radio pliers and pull the indicator frontward and remove from the housing ASSY feeder R of the feeder ASSY unit. Note: Hold the guide indicator, when replacing the indicator. Guide indicator Indicator Fig.4-140 - IV-80 -...
  • Page 199: Guide Indicator

    2.6.20 Guide indicator Release the 2 hooks securing the holder shaft to the housing ASSY feeder R. Holder shaft indicator Lever low paper Fig.4-141 Pull out the guide indicator from the housing ASSY feeder R together with the spring indicator and shaft indicator. Pull out the guide indicator from the shaft indicator.
  • Page 200: Lever Low Paper

    2.6.21 Lever low paper Turn the housing ASSY feeder R upside down. Push the support pillow to the left and release the lever low paper shaft. Left view Lever low paper Housing ASSY feeder R Fig.4-143 Remove the lever low paper from the housing ASSY feeder R. Lever low paper Fig.4-144 - IV-82 -...
  • Page 201: Roll Assy

    2.6.22 Roll ASSY Release the cover feed secured to the cassette at one point and open the cover feed. Release the hook securing the roll ASSY to the shaft retard from the cassette. Pull out the roll ASSY from the shaft retard. Roll ASSY Cover feed Fig.4-145...
  • Page 202: Holder Retard

    2.6.24 Holder retard Remove the clutch ASSY friction on the shaft retard from the cassette. Release the hook of the spring retard hitched to the bottom groove of the holder retard from the cassette. Release the hook securing the top portion of the holder retard from the cassette and move the holder retard leftward.
  • Page 203: Actuator Exit

    2.6.25 Actuator exit Holding the actuator of the actuator exit from fuser ASSY, pull down the actuator exit rightward an extract the left shaft of the actuator exit. Pull out the actuator exit from the fuser ASSY rightward together with the spring actuator.
  • Page 204 CHAPTER V TROUBLESHOOTING...
  • Page 205 CONTENTS CHAPTER V TROUBLESHOOTING ..........V-1 PROGRESSING WITH THE TROUBLESHOOTING ........V-1 1.1 Flow of Troubleshooting....................V-1 2. LEVEL 1 FIP ....................V-2 2.1 Level 1 FIP ........................V-2 2.2 Flow of Level 1 FIP ......................V-2 3. LEVEL 2 TROUBLESHOOTING ..............V-3 3.1 Level 2 FIP ........................V-3 3.2 Fail Code List ........................V-3 3.3 Error Code FIP ........................V-13 4.
  • Page 206 10. IMAGE QUALITY SPECIFICATIONS ............V-73 10.1 Parallelism........................V-73 10.2 Diagonal ........................V-73 10.3 Skew ..........................V-73 10.4 Straightness ........................V-74 10.5 Magnification Error ......................V-74 10.6 Registration ........................V-74 10.7 Guaranteed Printing Area .....................V-75 11. TEST PRINT ....................V-76 11.1 Test print ........................V-76 12. IMAGE QUALITY FIP................V-77 12.1 Notes on Image Quality Trouble Check................V-77 12.2 Basic Rule of Image Quality Adjustment ..............V-77 12.3 Troubleshooting Table by Trouble Phenomena ............V-78...
  • Page 207: Chapter V Troubleshooting

    CHAPTER V TROUBLESHOOTING PROGRESSING WITH THE TROUBLESHOOTING After making sure of actual condition of a trouble, proceed with the troubleshooting process efficiently making use of the Fault Isolation Procedure (FIP), Operation of Diag., Principles of operation, and BSD (Block Schematic Diagram). Flow of Troubleshooting Flow of the troubleshooting is as follows: Prior check...
  • Page 208: Level 1 Fip

    LEVEL 1 FIP Level 1 FIP The level 1 FIP is the first step for trouble diagnosis. The level 1 FIP isolates the presence of various troubles including error codes, and the level 2 FIP provides a guide for proceeding of the troubleshooting. Flow of Level 1 FIP Ask the operator about trouble status.
  • Page 209: Fail Code List

    LEVEL 2 TROUBLESHOOTING Level 2 FIP The Level 2 FIP is the trouble diagnostic procedure to sort various troubles in addition to the error codes. In the troubleshooting, executing the steps given in the FIP or checking procedure allows you to find out a cause of trouble in a short time. Fail Code List LCD Display <...
  • Page 210: Error Code Fip

    LCD Display < Name of Fail> Action Reference Contents of Trouble 010-350 <IOT Fuser Failure> Power off/on 2.9.1 Turn OFF the Power. See fuser failure FIP 2.9.6 1. Temperature exceeding 235 C detected consecutively 4 times. 2. Temperature below 235 C detected consecutively 4 times. 3.
  • Page 211 LCD Display < Name of Fail> Action Reference Contents of Trouble 016-313 Power off/on <ASIC Fail > 2.3.1 Turn OFF the Power. The controller’s ASIC chip detected this error. 2.3.3 016-314 Power off/on <Video Sync Fail> 2.3.1 Turn OFF the Power. Detected by an incorrect synchronous signal input.
  • Page 212 LCD Display < Name of Fail> Action Reference Contents of Trouble 016-333 <NIC Flash ROM Application Module Checksum Error> Power off/on 2.3.1 Turn OFF the Power. 2.3.3 016-334 <NIC MAC Address Checksum Error> Power off/on 2.3.1 Turn OFF the Power. 2.3.3 016-335 Power off/on...
  • Page 213 LCD Display < Name of Fail> Action Reference Contents of Trouble Transp. Error <IOT Media Type Mismatch> Remove the jammed paper. 2.7.6 Open A-Cover 2.7.7 1. Plain paper detected for a job that is specified transparency. Change paper stock. See media type mismatch 2.
  • Page 214 LCD Display < Name of Fail> Action Reference Contents of Trouble Replace Xxxxx <IOT X Toner Empty> Replace toner cartridge. 2.8.5 Toner (X) Toner empty detected. 2.8.8 See Yellow toner empty FIP, Magenta toner empty FIP, Cyan toner empty FIP or Black toner empty FIP Xxxxx indicates Yellow toner (Y), Cyan toner (C),...
  • Page 215 LCD Display < Name of Fail> Action Reference Contents of Trouble Clean Up <IOT CTD Sensor Dustiness> Clean ADC sensor ASSY. 2.8.7 CTD Sensor ADC sensor ASSY signal level below the specified value. See CTD sensor dustiness 2.8.8 Close <IOT Front Cover Open> Close the front cover.
  • Page 216 LCD Display < Name of Fail> Action Reference Contents of Trouble Upper Cassette Detached> (When auto select is specified) Set the tray 2.6.1 Push in the Tray *Any one of trays upper than the feedable tray is open when auto N indicates the tray No.
  • Page 217 LCD Display < Name of Fail> Action Reference Contents of Trouble Download N/A error <F/W Download Protect Error> Press the Set key. Please Press Set The processing will continue. (Job is cleared.) Erase error <F/W Download erase Error> Press the Set key. Please Press Set The processing will continue.
  • Page 218 LCD Display < Name of Fail> Action Reference Contents of Trouble Ready to Print Need 2.3.2 <Print head cartridge Life Warning> No action required. Replacement Print Head Cart Print head cartridge ASSY is near the end of its life. See print head cartridge life over FIP CRU Warning: Ready to Print...
  • Page 219: Error Code Fip

    Error Code FIP 001-360 Fan Motor Failure FIP Remedy Step Check Initial setting Check the following for evidence of fault. Replace the Go to step [2] Fuser fan replacing condition parts concerned Rear fan replacing condition With tool With tool Isolating faulty fan Go to step [3] Go to step [15]...
  • Page 220 Remedy Step Check Checking drive PWBA HBN DRV for signal Replace PWBA Go to step [14] Print 1 sheet. HBN DRV Is P/J42-29PIN<=>P/J42-14PIN +3.3VDC? Checking MCU HL-4200 for signal Replace harness Replace MCU Print 1 sheet. ASSY DRV2-2 HL-4200 Is P/J12-2PIN<=>P/J12-17PIN +3.3VDC? Checking fuser fan Does fuser fan function normally? Replace MCU...
  • Page 221 003-340 Firmware Error FIP Remedy Step Check Does the error still happen even after Go to step [2] End of work powering Off and On was done? Check whether the value of NVM is Replace MCU Correct the correct. HL-4200 value of NVM.
  • Page 222 010-317 Fuser Detached FIP Remedy Step Check Initial setting Replace the parts Check the following for evidence of fault. Go to step [2] concerned Fuser ASSY replacing condition Checking fuser ASSY Remove fuser measure resistance Replace fuser Go to step [3] value ASSY Is P232-A4PIN<=>P232-A5PIN less than...
  • Page 223 Duplex JAM FIP Remedy Step Check Initial setting Check the following for evidence of fault. With tool Chute ASSY exit replacing condition Replace the parts Go to step [2] DUP motor replacing condition concerned Without tool DUP JAM sensor actuator replacing Go to step [3] condition Chute ASSY out replacing condition...
  • Page 224 Remedy Step Check Checking harness ASSY DRV 2-2 for continuity Check the following for continuity. Replace J12-5PIN<=>J42-26PIN Go to step [12] harness ASSY J12-6PIN<=>J42-25PIN DRV2-2 J12-7PIN<=>J42-24PIN J12-8PIN<=>J42-23PIN J12-29PIN<=>J42-2PIN Checking DUP motor Replace MCU Check if an error occurs though the End of work HL-4200 motor was replaced with a new one.
  • Page 225 Step Check Remedy Step Checking fuser motor Does fuser motor function normally? Replace MCU Go to step [10] Using fuser motor diagnostic tool, check HL-4200 by digital output test. Checking PWBA HBN DRV for signal Replace PWBA Go to step [11] Is P/J52-1PIN<=>P/J60-2PIN +24VDC? HBN DRV Checking harness ASSY DRV 1 for...
  • Page 226 REGI JAM FIP Remedy Step Check Initial setting With tool Check the following for evidence of fault. Replace the parts Go to step [2] REGI sensor actuator replacing condition concerned Without tool chute ASSY REGI replacing condition Go to step [3] Checking REGI sensor Does REGI sensor function normally? Go to step [6]...
  • Page 227 Feed JAM FIP Remedy Step Check Initial setting Check the following for evidence of fault. Paper cassette replacing condition Paper condition in cassette With tool Wear or damage of rolls and gears in Replace the parts Go to step [2] feeder concerned Without tool...
  • Page 228 Remedy Step Check Checking harness ASSY DRV1 for continuity Replace Check the following for continuity. Replace MCU harness ASSY J41-30PIN<=>J11-11PIN HL-4200 DRV1 J41-31PIN<=>J11-10PIN J41-33PIN<=>J11-8PIN Checking clutch ASSY turn for operation With tool Does the turn roll in the feeder run when Go to step [17] Go to step [22] printing 1 sheet?
  • Page 229 Remedy Step Check Checking harness ASSY DRV2-2 for Replace continuity Replace MCU harness ASSY Is J12-10PIN<=>J42-21PIN continuous HL-4200 DRV2-2 normally? Checking clutch ASSY turn MSI for With tool operation Go to step [29] Go to step [31] Does the turn roll in the MSI run when Without tool printing 1 sheet? Go to step [30]...
  • Page 230 Media Type Mismatch FIP Remedy Step Check Initial setting With tool Check the following for evidence of fault. Replace the parts Go to step [2] OHP sensor replacing condition concerned Without tool Chute ASSY REGI replacing condition Go to step [3] Checking OHP sensor Does OHP sensor function normally? Replace MCU...
  • Page 231 Remedy Step Check Checking MCU HL-4200 for signal Replace MCU Is P/J12-27PIN<=>P/12-17PIN of MCU Go to step [9] HL-4200 and HVPS PWBA HBN DRV 0VDC? Checking harness ASSY DRV2-2 for Replace Replace MCU continuity harness ASSY HL-4200 Is J12<=>J42 continuous normally? DRV2-2 Magenta Toner Cartridge Detached FIP Remedy...
  • Page 232 Cyan Toner Cartridge Detached FIP Remedy Step Check Initial setting Check the following for evidence of fault. Cartridge replacing condition With tool Toner cartridge switch ASSY (C) replacing Replace the parts Go to step [2] condition concerned Without tool Toner cartridge switch ASSY (C) actuator Go to step [3] replacing condition Toner cartridge switch ASSY (C)
  • Page 233 Black Toner Cartridge Detached FIP Remedy Step Check Initial setting Check the following for evidence of fault. Cartridge replacing condition With tool Toner cartridge switch ASSY (K) replacing Replace the parts Go to step [2] condition concerned Without tool Toner cartridge switch ASSY (K) actuator Go to step [3] replacing condition Toner cartridge switch ASSY (K)
  • Page 234 Transfer Roll Cartridge Detached FIP Remedy Step Check Initial setting Check the following for evidence of fault. Replace the parts Transfer roll cartridge ASSY replacing Go to step [2] concerned condition ADC sensor ASSY replacing condition Checking harness ASSY CTD for Replace the connection Go to step [3]...
  • Page 235 Yellow Toner Empty FIP Remedy Step Check Initial setting Check the following for evidence of fault. Replace the parts Low toner sensor replacing condition Go to step [2] concerned Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner Go to step [3] End of work...
  • Page 236 Magenta Toner Empty FIP Remedy Step Check Initial setting Check the following for evidence of fault. Replace the parts Low toner sensor replacing condition Go to step [2] concerned Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner Go to step [3] End of work...
  • Page 237 Cyan Toner Empty FIP Remedy Step Check Initial setting Check the following for evidence of fault. Replace the parts Low toner sensor replacing condition Go to step [2] concerned Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner Go to step [3] End of work...
  • Page 238 Black Toner Empty FIP Remedy Step Check Initial setting Check the following for evidence of fault. Replace the parts Low toner sensor replacing condition Go to step [2] concerned Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner Go to step [3] End of work...
  • Page 239 Transfer Roll Cartridge Life Over FIP Remedy Step Check Initial setting With tool Check the following for evidence of fault. Replace the parts Go to step [2] Transfer roll cartridge ASSY replacing concerned Without tool condition Go to step [3] Sensor TNR full replacing condition Checking sensor TNR full Does sensor TNR full function...
  • Page 240 CRUM ID Error FIP (Print Head Cartridge) Remedy Step Check Check the following for failure: Reinstall the Installation of toner cartridge appropriate Go to step [2] Installation of PWB CRUM reader part Check connection of PWB CRUM reader. Is the PWB CRUM reader connector Replace Go to step [3] properly connected to the harness...
  • Page 241 Front Cover FIP Remedy Step Check Initial setting With tool Check the following for evidence of fault. Replace the parts Go to step [2] PWBA HBN DRV replacing condition concerned Without tool Front cover replacing condition Go to step [3] Interlock SW actuator replacing condition Checking interlock SW Does interlock SW function normally?
  • Page 242 Upper Cassette Detached FIP Remedy Step Check Initial setting With tool Check the following for evidence of fault. Replace the parts Go to step [2] Size switch ASSY replacing condition concerned Without tool actuator replacing condition Go to step [3] Paper cassette replacing condition Checking size switch ASSY Does size switch ASSY function normally?
  • Page 243 Tray2 Paper Near Empty FIP Remedy Step Check Initial setting Check the following for evidence of fault. Replace the parts Tray2 low paper sensor replacing Go to step [2] concerned condition Sensor actuator replacing condition Does the error occur even if the paper is With tool added? Go to step [3]...
  • Page 244: How To Use Diag. (C/E) Mode

    HOW TO USE DIAG. (C/E) MODE Roles of the Control Panel in Diag. (C/E) Mode (Note: Control panel display may differ depending upon the machine configuration.) 5.Menu 1. LCD 4. Job Cancel/Back button Menu Form Feed Cancel Ready Alarm Back 2.Up/Down button 3.Form Feed/Set button Fig.5-3...
  • Page 245: Operation Procedure

    Operation Procedure After entering Diag. (C/E) mode, select a diagnostic item with the button and press the Form Feed/Set button to determine the selection. If there is a lower menu, select a diagnostic item with the button and press the Form Feed/Set button to determine the selection.
  • Page 246: Diag. Mode Menu Tree

    Diag. Mode Menu Tree Diag mode ESS Diag Normal Diag CodeROM Test FontROM Test EEPROM Test DRAM Test Centro Test USB Test REMORA Test Cont Panel Test IOT Test HD Test IOT Diag Digital Input Digital Output Power Save Mode NVM Settings NVM Edit Print Info...
  • Page 247 Continued from the up page Test Print CMY 20% [ESS] Gradation [ESS] NIP adjust [ESS] P Regi Adj Chart Parameter PFRegi K to Paper PFRegi 600 K to M PF Regi 600 K to Y PF Regi 600 K to C PF Regi 1200 K to M PF Regi 1200 K to Y PF Regi 1200 K to C...
  • Page 248: Ess Diagnosis

    ESS Diagnosis Function: Executing an ESS related diagnosis. Operation procedure: Enter the Diag. (C/E) mode. Select [CE Maintenance ESS Diag] with the buttons. Press the Form Feed/Set button to advance to diagnostic menu selection in [CE Maintenance ESS Diag]. Select a diagnostic item with the button.
  • Page 249: Iot Diagnosis

    Details of the control panel test For a control panel check, each button is pressed to see whether the three LED indicator lights go on or off and how the LCD panel display changes. The table below lists the relationships between the buttons and the LED indicator lights and LCD panel display.
  • Page 250 4.8.1 Digital input test Function: Displaying a sensor or switch signal level on the LCD panel as "H" or "L" and also the number of changes from "H" to "L" or "L" to "H" Operation procedure: Enter the Diag. (C/E) mode. Select [CE Maintenance IOT Diag] with the buttons.
  • Page 251 Menu Reference Part/signal name Test method TRAY1 NO PAPER SENSOR Block and unblock the sensor DI-11 2.6.1 with an actuator. TRAY2 NO PAPER SENSOR Block and unblock the sensor 2.6.2A DI-12 with an actuator. 2.6.2B TRAY3 NO PAPER SENSOR Block and unblock the sensor DI-13 2.6.3 with an actuator.
  • Page 252 Menu Reference Part/signal name Test method TRAY2 SIZE SWITCH Set the side guide and end (SW2) guide of tray2 to the paper size. Check the sensors signal. 2.6.2A DI-22 When the SW2 is switched on, 2.6.2B displays L (low). Refer to the BSD.
  • Page 253 4.8.2 Digital output test Function: Activating a solenoid, clutch, motor, or other parts. Capable of activating two or more parts simultaneously. (Parallel execution) Operation procedure: Enter the Diag. (C/E) mode. Select [CE Maintenance IOT Diag] with the buttons. Press the Form Feed/Set button to advance to diagnostic menu selection in [CE Maintenance IOT Diag].
  • Page 254 Menu Reference Part/signal name Test method DUP MOTOR ASSY ON <WARNING!> <CAUTION!> (REVERSE DOUBLE Check by hearing and visually that DO-8 2.9.5 SPEED) the motor rotates counterclockwise in double-speed mode. DRIVE ASSY DEVE ON <WARNING!> <CAUTION!> DO-a (NORMAL SPEED) Check by hearing and visually that 2.8.2 the motor rotates in normal mode.
  • Page 255 Menu Reference Part/signal name Test method DUP MOTOR ASSY ON <WARNING> <CAUTION> (FORWARD LOW SPEED) Check by hearing and visually that DO-1a 2.9.5 the motor rotates in Low-speed mode. DUP MOTOR ASSY ON <WARNING> <CAUTION> (REVERSE LOW SPEED) Check by hearing and visually that DO-1b 2.9.5 the motor rotates counterclockwise...
  • Page 256 Menu Reference Part/signal name Test method TRAY1 TURN CLUTCH Check by hearing that the clutch DO-36 2.7.1 operates. TRAY1 FEED SOLENOID Check by hearing that the clutch DO-38 2.7.1 operates. DO-40 CHARGI FILM ON <WARNING><CAUTION> 2.8.1 DO-42 DEVE BIAS AC ON <WARNING><CAUTION>...
  • Page 257 4.8.3 NVM Edit Read/Write Refer to Section 7. NVM LIST. Function: Reading or writing NVM Operation procedure: Enter the Diag. (C/E) mode. Select [IOT Diag] with the buttons and press the Form Feed/Set button. Select [NVM Settings] with buttons and press the Form Feed/Set button. Advance to [NVM Edit] with buttons and press the Form Feed/Set button.
  • Page 258: Nvm Information Print

    4.8.4 NVM Information Print Function: Printing MCU NVM information saved in ESS Operation procedure: Enter the Diag. (C/E) mode. Select [IOT Diag] with the buttons and press the Form Feed/Set button. Select [NVM Settings] with buttons and press the Form Feed/Set button. Advance to [NVM Print Info] with the buttons and press the Form Feed/Set button.
  • Page 259: Installation Setting

    Installation Setting Function: Setting parameters at printer installation and displaying various counter values Operation procedure: Enter the Diag. (C/E) mode. Select [CE Maintenance Installation Set] with the buttons. Press the Form Feed/Set button to advance to setting/display item selection in [CE Maintenance Installation Set].
  • Page 260: Test Print

    *Electronic billing meter (count) function and backup The monochrome and color meters have backup meters. The printer compares the main and backup meters when the power is turned ON. If there is a discrepancy between the main and backup meters, the hardware of both meters is diagnosed by read/write tests.
  • Page 261: Parameter Setting

    4.11 Parameter Setting 4.11.1 Parameter setting/display Function: Setting and displaying parameters held by IOT in NVM Operation procedure: Enter the Diag. (C/E) mode. Select [CE Maintenance Parameter] with the buttons. Press the Form Feed/Set button to advance to setting/display parameter selection in [CE Maintenance Parameter].
  • Page 262: 4.11.2 Parameter List Print

    Select [Parameter Print] with the buttons. Press the Form Feed/Set button to determine the selection. Press the Form Feed/Set button again to print the parameters. HL-4200CN MCU Parameter List Serial No. 000000 Registration Adjust Slow Scan Paper from Black Registration Adjust Slow Scan, 600dpi, Magenta from Black : 6...
  • Page 263: Information Print

    JamHistoryPage Outputs setting jam history information from the control panel. DloadHistoryPage Outputs setting download history information from the control panel. <Config page sample> HL-4200CN MCU Config page Serial No. 000000 Optional Products Status Auxiliary Cassette 1&2&3 ROM Revision NO :V 1.0.1 MVM Revision NO : V 1.0.1...
  • Page 264 <Fail history sample> Fail History HL-4200CN System Serial No. 000000 Total Number of Prints = 6938 No. Print Cnt. Chain-Link ---------------------------------------------------------------------------- 6910 016-370 6872 016-330 6851 016-350 6791 016-314 6656 016-302 0x00000008 0x00000000 200305120950 6647 016-370 6624 016-314 6228 016-370 <Jam history sample>...
  • Page 265: Diagnosis For Standalone Printer

    DIAGNOSIS FOR STANDALONE PRINTER General The test print can be taken place on the standalone printer for operation check. For this purpose, the test print pattern stored in the printer is printed continuously at the continuous printing speed. Printing Method Remove the ESS PWB.
  • Page 266: Test Print Pattern

    Test Print Pattern The test print pattern is lattice patterns composed of black (K), cyan (C), magenta (M), and yellow (Y) patterns in this order every 128 dots in vertical and horizontal directions. lack Yellow Cyan Magenta 128dot Approx.2mm 128dot Approx.2mm Fig.5-9 V-60...
  • Page 267: Transfer Roll Cartridge Adjusting Third Transfer Current Value

    Brother assumes. In this case, the image quality can be improved by changing the transfer current value to the one which corresponding to the paper used actually.
  • Page 268 4. After 2:Maintenace screen (Init NVM) is displayed, press button three times. 2:Maintenance Init NVM 5. After 2:Maintenace screen (Media CurrentAdi) is displayed, press [Form Feed/Set] button. 2:Maintenance BTR CurrentAdj 6. After BTR CurrentAdi screen (Plain paper) is displayed, press button and select the used paper mode (includes front and back sides).
  • Page 269: User Mode Menu Tree

    Check the image error was improved by printing the image caused an error after setting. If it is not improved, repeat 1 to 10. Note: Be careful not to cause other image error by changing the current value to the adjusting value too much.
  • Page 270: Nvm List

    NVM LIST CAUTION Never write the data to the NVM numbers not listed below, as they are for the system areas of the printer. CAUTION Never write the data to the items which address field is hatched, as they are read only. Set value Address Description...
  • Page 271 Set value Address Description Word/ Long 1221 Fuser PV (M) 1222 Fuser PV (H) 1223 M/C PV (L) 1224 M/C PV (M) 1225 M/C PV (H) 122E Counter for long cleaning (L) 122F Counter for long cleaning (H) Transfer roll cartridge full detected 1230 PV1 (L) Transfer roll cartridge full detected...
  • Page 272 Set value Address Description Word/ Long 1614 Fuser Failure(CPU) 2 1615 Fuser Failure(CPU) 3 1616 Firmware Error 1 1617 Firmware Error 2 1618 Firmware Error 3 1619 Fuser Failure(ASIC) 1 161A Fuser Failure(ASIC) 2 161B Fuser Failure(ASIC) 3 0000KCMY:Dispense init 1: Not complete 1680 0: Complete...
  • Page 273 Set value Address Description Word/ Long 1C88 Transparency (=OHP) 1C89 Label-H 1C8A Plain paper-L High Gloss 1C8B 1C8C Label-L 1C8D 1C8E Heavier paper-L Back Face 1C8F Heavier paper-H Back Face 1C90 Envelope Back Face 1C91 Postcard Back Face 1C92 Plain paper-H 1C93 1C94 Plain paper-H High Gloss...
  • Page 274 Set value Address Description Word/ Long 1CCF Heavier paper-H Back Face Coated 1CD0 Envelope Back Face Coated 1CD1 Postcard Back Face Coated 1CD2 Plain paper-H Coated 1CD3 1CD4 Plain paper-H High Gloss Coated 1CD5 1CD6 Plain Paper-L Super High Gloss Coated 1CD7 Plain Paper-H Super High Gloss...
  • Page 275 Set value Address Description Word/ Long User temperature correction Half- setting range: 2556 speed Heavier-2 (0 deg.C) -6 to 6 User temperature correction Half- setting range: 2559 speed Transparency (0 deg.C) -6 to 6 User temperature correction Half- setting range: 255C speed Envelope (0 deg.C) -6 to 6...
  • Page 276: Hex/Dec Conversion Table

    HEX/DEC CONVERSION TABLE Decimal Decimal Decimal Decimal Decimal 0100 0101 0102 0103 0104 V-70...
  • Page 277 Decimal Decimal Decimal Decimal Decimal 0105 0129 014D 0171 0195 0106 012A 014E 0172 0196 0107 012B 014F 0173 0197 0108 012C 0150 0174 0198 0109 012D 0151 0175 0199 010A 012E 0152 0176 019A 010B 012F 0153 0177 019B 010C 0130 0154...
  • Page 278: Image Quality Trouble Entry Chart

    IMAGE QUALITY TROUBLE ENTRY CHART Ask the operator about trouble status. Print internal test pattern. Image quality trouble recurred? Check print instructions Are print instructions correct? Is trouble more than performance Instruct how to submit when compared with standard print job. sample? Acknowledged by operator? Explain to customer.
  • Page 279: Image Quality Specifications

    IMAGE QUALITY SPECIFICATIONS 10.1 Parallelism Fig.5-13 10.2 Diagonal Fig.5-14 10.3 Skew Fig.5-15 V-73...
  • Page 280: Straightness

    10.4 Straightness Fig.5-16 10.5 Magnification Error Fig.5-17 10.6 Registration Fig.5-18 V-74...
  • Page 281: Guaranteed Printing Area

    10.7 Guaranteed Printing Area Fig.5-19 V-75...
  • Page 282: Test Print

    TEST PRINT 11.1 Test Print Function: Printing an internal test pattern of the printer Operation procedure: While pressing the buttons together, turn the power on to enter the Diag. mode. Enter the password. (Password: Press the button twice and the Form Feed/Set button.) Go advance to [Test Print] with the buttons.
  • Page 283: Image Quality Fip

    IMAGE QUALITY FIP 12.1 Notes on Image Quality Trouble Check Image quality troubles are checked and processed according to the troubleshooting table by trouble phenomena. In case of a continuous or abnormal image defect, check the installation environment at the customer, the document, and the consumables. Installation environment •...
  • Page 284 12.3 Toubleshooting Table by Trouble Phenomena <Fogging> Fig.5-20 Condition: Fogging over print. Toner attaches to margin of print. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200, SUB HVPS Item Check...
  • Page 285 <Streak in the process direction> Fig.5-21 Fig.5-22 Condition: Black or white streaks in the process direction. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200, SUB HVPS Item Check...
  • Page 286 <Streak in the shaft direction> Fig.5-23 Fig.5-24 Condition: Black or white streaks in the shaft direction. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200, SUB HVPS Item Check...
  • Page 287 Rolls related with image quality troubles and interval appearing on prints are shown in the table below. Roll Parts Cycle Magnet roll 29 mm Padolle 7.5 mm Drum 63 mm Print head cartridge ASSY 23 mm IDT 1 132 mm IDT 2 132 mm Transfer roll cartridge...
  • Page 288 <All black> Fig.5-25 Condition: Print is wholly black. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200 Item Check...
  • Page 289 <All blank> Fig.5-26 Condition: Print is wholly white. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200, Toner cartridge Item Check...
  • Page 290 <Too light image> Fig.5-27 Condition: Print is wholly light. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200, SUB HVPS Item Check...
  • Page 291 <Black (color) points> Fig.5-28 Condition: Black (color) circles remain on the print. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200, SUB HVPS Item Check...
  • Page 292 <Paper skew> Fig.5-29 Condition: Image is printed in skewed position. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Paper feeder, Chute ASSY REGI, Chute ASSY out, Transfer roll cartridge ASSY, Print head cartridge ASSY, Fuser ASSY, Scanner ASSY Item Check...
  • Page 293 <Crease> Condition: Print on creased paper. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Paper feeder, Chute ASSY REGI, Chute ASSY out, Transfer roll cartridge ASSY, Print head cartridge ASSY, Fuser ASSY Item Check Remedy...
  • Page 294 <Flake> Fig.5-30 Condition: Some parts of image are missing and they become flakes. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Transfer roll cartridge ASSY Item Check Remedy Paper check Change paper.
  • Page 295 <Toner splash> Fig.5-31 Condition: Toner around image splashes. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Transfer roll cartridge ASSY Item Check Remedy Paper check Change paper. The recommended size/type of paper is used? Use the recommended size/type of paper.
  • Page 296 <Whole image has bluish tinge> Fig.5-32 Condition: Whole image has bluish tinge. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Transfer roll cartridge ASSY Item Check Remedy Paper check Change paper.
  • Page 297: Chapter Vi Diagrams

    CHAPTER VI DIAGRAMS...
  • Page 298 CONTENTS CHAPTER VI DIAGRAMS .............. VI-1 1.PREFACE .......................VI-1 1.1 How to Use the BSD......................VI-1 1.2 Explanations of Symbols .....................VI-1 1.3 Signal Name/Other description....................VI-4 1.4 DC Voltage...........................VI-4 1.5 Input/Output Test .........................VI-4 2. BSD (BLOCK SCHEMATIC DIAGRAM) 2.1 Standby Power 2.1.1 AC power on and DC distribution ................VI-5 2.1.2 Monitoring........................VI-6 2.2 Mode Selection 2.2.1 Control panel ......................VI-7...
  • Page 299 2.8.5 Low toner sensing ....................VI-32 2.8.6 Transfer and cleaning....................VI-33 2.8.7 ADC and environment sensing................VI-34 2.8.8 Monitoring........................VI-35 2.9 Fusing and Transportation 2.9.1 Fusing and fuser heat control..................VI-36 2.9.2 Fuser drive control....................VI-37 2.9.3 Fan control.......................VI-38 2.9.4 Exit and invert transportation...................VI-39 2.9.5 Exit and invert mechanism ..................VI-40 2.9.6 Monitoring........................VI-41...
  • Page 300: Preface

    CHAPTER VI DIAGRAMS 1. PREFACE 1.1 How to Use the BSD 1. Enter the chain specified in the chapter of troubleshooting. 2. See the contents to enter the appropriate Chain. 3. Diagnose the failure in the appropriate Chain. 4. If the failure can be isolated, refer to the Parts List No or Adjustment No go to the index of parts or the appropriate adjustment.
  • Page 301 This symbol identifies a signal line is connected in the meet direction. This symbol identifies a signal line is connected in the arrow direction. This symbol indicates that a signal line is connected within the same Function. It shows that the location ZONE to which signal line is connected is marked in Zone (E-3).
  • Page 302 This symbol represents a document or paper as well as its direction. This symbol represents a heat, light or air signal as well as its direction. This symbol represents that the part indicated by an arrow is the information on the duplicator with Tag/Mod.
  • Page 303 1.3 Signal Name/Other description Signal Name Signal name configuration REGI SENSOR SENSED +5VDC Part name Active status Logical value Highest level expected The above example indicates that the signal will be (L) when the registration sensor detected a sheet of paper and that it will be (H) when the sensor has not detected a sheet of paper and that the voltage is +5VDC.
  • Page 341 CHAPTER VII PLUG/JACK (P/J) CONNECTOR LOCATIONS...
  • Page 342 CONTENTS CHAPTER VII PLUG/JACK (P/J) CONNECTOR LOCATIONS..VII-1 1. LIST OF P/J ....................VII-1 2. P/J LAYOUT DIAGRAM ................VII-4...
  • Page 343 CHAPTER VII PLUG/JACK (P/J) CONNECTOR LOCATIONS LIST OF P/J The following tables list the connector (P/J) coordiates corresponding to 2. P/J Layout Diagram. Coordiates Remarks I-37 Connects PWBA Font Card and Controller Board E-43 Connects MCU HL-4200 and PWBA HBN DRV E-43 Connects MCU HL-4200 and PWBA HBN DRV Connects MCU HL-4200, S-HVPS, Harness ASSY FSR3C(FSR32C),...
  • Page 344 Coordiates Remarks Connects Chute ASSY Out (Solenoid Feed MSI) and Harness ASSY Front Connects Chute ASSY Out (DUP JAM Sensor) and Harness ASSY Front 1A Connects Chute ASSY Out (Full Stack Sensor) and Harness ASSY Front 1A Connects Chute ASSY Out (MSI No Paper Sensor) and Harness ASSY Front C-23 Connects Front ASSY In (ADC Sensor ASSY) and Front 1A Harness ASSY Connects Cover ASSY Front Head (Fan Fuser) and PWBA HBN DRV...
  • Page 345 Coordiates Remarks G-54 Connects Solenoid Feed and PWBA HBN DRV H-53 Connects Clutch ASSY Turn and PWBA HBN DRV Connects Holder ASSY MQ-Y (TNR Motor) and PWBA HBN DRV Connects Holder ASSY MQ-M (TNR Motor) and PWBA HBN DRV Connects Holder ASSY MQ-C (TNR Motor) and PWBA HBN DRV Connects Holder ASSY MQ-K (TNR Motor) and PWBA HBN DRV Connects Holder ASSY MQ-Y (Sensor No Toner) and PWBA HBN DRV Connects Holder ASSY MQ-M (Sensor No Toner) and PWBA HBN DRV...
  • Page 346 P/J LAYOUT DIAGRAM VII-4...
  • Page 347 VII-5...
  • Page 348 VII-6...
  • Page 349 VII-7...
  • Page 350 APPENDIX...
  • Page 351 CONTENTS APPENDIX 1 ................APP-1 1.1 When PCB is replaced ......................1.1.1 When Controller Board (ESS) is replaced ..............1.1.2 When MCU PWBA is replaced ..................1.2 Controller Firmware upgrade....................1.2.1 Controller Firmware / NIC Boot program / NIC Firmware upgrade ....... 1.2.2 Controller Boot program / MCU NVM / MCU Firmware upgrade ........
  • Page 352 APPENDIX 1 1.1 When PCB is replaced The information below is stored in NV-RAM (EEPROM) on ESS. If necessary, transfer the data to a new PCB. U8 (Part number) Data set with Control Panel NV-RAM data on MCU that is saved manually Error Log Jam Log Billing Counter...
  • Page 353 1.1.1 When Controller Board (ESS) is replaced Take the EEPROM (U8) out of the Controller Board, then put it in the new U8 on Controller Board. Take out the NIC EXCORD ASSY, then put it on the new Controller Board. 1.1.2 When MCU PWBA is replaced When you replace MCU PWBA, you must temporary save NV-RAM data in EEPROM of Controller Board.
  • Page 354 Controller Firmware upgrade All PCBs are supplied with Firmware written in, however, if there is a problem, you can upgrade PCBs with the following procedures: The following Firmware can be upgraded with the On-demand Downloader Controller firmware NIC Boot program (DIP SW (JP2) of NIC card must be ON.) NIC Firmware The following Firmware must be written in Download mode Controller Boot program...
  • Page 355 1.2.1 Controller Firmware / NIC Boot program / NIC Firmware upgrade Setting up On-demand Downloader Use the [Menu] button to put the machine off line mode. Select [Menu / 2:Maintenance] by pressing the [↓] button, then press the [Set] button. Select [2:Maintenance / F/W Download] by pressing the [↓] button.
  • Page 356 APPENDIX 2 CONSUMABLES REPLACEMENT Printhead Unit The life is 30,000-page (@ C:5%, M:5%, Y:5% , K:5%). The life will change by “Coverage” and “Job”. 1.Coverage If the print coverage increased, the life decreases as below. Coverage[%] vs Life[PV] 30,000-page (Base on Dispense Time) 35,000 30,000 25,000...
  • Page 357 2.Job If each print job increased, the life increases as below. R/L[PV/Job] vs Life[PV] 30,000-page (Based on Work Time) 35,000 30,000 25,000 20,000 Life(PV) 15,000 10,000 15,000-page 5,000 R/L [PV/Job] 1-page 10-page...
  • Page 358 TR-11CL The life is 25,000-page (by printing BW document and Full color document 50%:50%.). The detail is as follows. The life will be 25,000-page when Printing 5% coverage BW document for 12,500-page Printing 20% coverage (C:5%, M:5%, Y:5%, Full color: 20% BK:5%) for 12,500-page Mono: 5% bk 5% each...
  • Page 359 The actual life is over than catalog specification. But as you may know, we are including some margin.
  • Page 360: User Guide

    Print Head Cartridge Cleaning Kit User Guide Thank you for choosing this product. If your printer is printing colored dots at regular intervals like in the diagram below, use the cleaning kit to clean the print head cartridge. Printing colored dots at approx. 25 mm intervals.
  • Page 361 How to clean the print head cartridge Attach this cleaning kit to the printer so the brush directly brushes the dirty parts of the print head cartridge. Follow the following procedures. Lining up the brush with the dirty part of the print head cartridge Remove the dust and dirt from the brush part of the cleaning kit with the brush cleaner provided.
  • Page 362 Push up button A (1) and fully open the front door (2). Push the button as shown and open the paper outlet cover. Grip the handle on top of the print head cartridge and gently lift it out of the printer. Place the print head cartridge on a level surface with its back facing you.
  • Page 363: Printing The Printer Settings List

    Close the paper outlet cover (1), and then close the front door (2). Display will show "Please Wait." The printer will automatically operate to clean the print head cartridge. It'll take about 20 sec. to 2 min. The message changes to "Ready to Print,"...
  • Page 364 APPENDIX 4 MEASURE OF TONER CARTRIDGE WEIGHT Toner Cartridge Weight (approximate weight) Yellow Magenta Cyan Black 315g ± 1 0g 325g ± 1 0g 315g ± 1 0g 360g ± 1 0g Brand new Toner Cartridge Weight 110g 120g 110g 155g Toner Weight at Brand new Toner Cartridge...
  • Page 365 APPENDIX 5 PERIODICAL REPLACEMENT PARTS Periodical replacement parts are the parts to be replaced periodically to maintain product quality. These parts would affect the product quality greatly if they lost their function even if they do not appear to be damaged or there is no change in their appearance. Part number Description LCD Message...
  • Page 366 Note: * A4 or Letter-size single-sided pages at about 5% coverage. The actual number of printed pages may vary depending on the print jobs and paper you use. * Replacement life when converting with utilization ratio CST (Paper Cassette) 85% and MSI (Multi Sheet Inserter) 15%.

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