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Kyocera FS-C5015N Service Manual

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FS-C5015N
FS-C5025N
SERVICE
MANUAL
Published in October 2006
2HK70761
Revision 1

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Summary of Contents for Kyocera FS-C5015N

  • Page 1: Service Manual

    FS-C5015N FS-C5025N SERVICE MANUAL Published in October 2006 2HK70761 Revision 1...
  • Page 2 CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS. It may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for proper disposal. ATTENTION IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE TYPE INCORRECT.

  • Page 3: Revision History

    Revision history Revision Date Replaced pages Remarks October 26, 2006 1-1-1, 1-1-2, 1-1-3, 1-1-4, 1-1-7, 1-3-2, 1-3-3, 1-3-4, 1-3-8, 1-3-13, 1-3-15, 1-3-16, 1-3-17, 1-4-7, 1-4-12, 1-4-13, 1-4-14, 1-4-15, 1-4-27, 1-4-28, 1-4-31, 1-4-32, 1-5-1, 1-5-15, 1-5-22, 1-5-23, 1-5-25, 1-5-32, 1-6-1, 1-6-3, 2-1-26, 2-1-27, 2-1-28, 2-1-29, 2-2-2, 2-2-3, 2-3-1, 2-3-2, 2-3-9, 2-4-1, 2-4-3, 2-4-5...
  • Page 4 This page is intentionally left blank.

  • Page 5: Safety Precautions

    Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.
  • Page 6 Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

  • Page 7: Installation Precautions

    1.Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current....................•...

  • Page 8: Precautions For Maintenance

    2.Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 9 • Do not remove the ozone filter, if any, from the copier except for routine replacement..... • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself...................... •...
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  • Page 11: Specifications

    CONTENTS 1-1 Specifications 1-1-1 Specifications............................1-1-1 1-1-2 Parts names............................1-1-5 (1) Overall ...............................1-1-5 (2) Operation panel..........................1-1-6 1-1-3 Cross section view ..........................1-1-7 1-2 Installation 1-2-1 Drum unit ..............................1-2-1 1-2-2 Developer unit and toner container......................1-2-1 1-2-3 Installation environment ..........................1-2-1 1-2-4 Unpacking and installation ........................1-2-2 (1) Installation procedure ........................1-2-2 1-2-5 Installing expansion memory (optional) ....................1-2-8 1-2-6 Installing a memory card (optional)......................1-2-9...

  • Page 12: Assembly And Disassembly

    (6) Toner drops on the paper conveying path..................1-4-32 (7) Abnormal noise is heard........................1-4-32 1-5 Assembly and Disassembly 1-5-1 Precautions for assembly and disassembly....................1-5-1 (1) Precautions ............................1-5-1 (2) Drum..............................1-5-1 (3) Toner container ..........................1-5-1 1-5-2 Outer covers ............................1-5-2 (1) Detaching and refitting the top cover....................1-5-2 (2) Detaching and refitting the rear cover ....................1-5-3 (3) Detaching and refitting the right cover....................1-5-4 (4) Detaching and refitting the left cover....................1-5-5...

  • Page 13: Electrical Parts Layout

    (1) Drum unit............................2-1-11 (2) Waste toner ejecting mechanism ....................2-1-14 (3) LED print head ..........................2-1-15 (4) Main charger unit..........................2-1-17 2-1-4 Primary transfer section ........................2-1-19 (1) Primary transfer unit ........................2-1-19 (2) Primary transfer cleaning unit......................2-1-21 2-1-5 Secondary transfer and separation section ..................2-1-24 2-1-6 Fuser section ............................2-1-26 (1) Fuser unit (16/17 ppm printer [EUR/USA model]) ................2-1-26 (2) Fuser unit (20/22 ppm printer [EUR/USA model]) ................2-1-28...
  • Page 14 This page is intentionally left blank.
  • Page 15 2HJ/2HK-1 1-1 Specifications 1-1-1 Specifications 16/17 ppm printer (EUR/USA model) Type ..........Desktop Printing system ....... Electrophotographic four color (CMYK) printing using Advanced Beam Array Paper type ........Cassette: Plain, preprinted, bond, recycled, rough, letterhead, color, prepunched, high quality, and custom MP tray: Plain, transparency, preprinted, labels, bond, recycled, vellum, rough, letterhead, color, prepunched, envelope, cardstock, coated, thick, high quality, and custom...
  • Page 16 2HJ/2HK-1 Controller hardware ......CPU: Power PC750CXr (400 MHz) System ROM: 8 MB (32 Mbit × 2) Font ROM: 2 MB (16 Mbit × 1) Main RAM: 128 MB standard (DIMM); expanding up to 640 MB (512 MB × 1) at the maximum by adding optional expansion memory Optional expansion RAM (DIMM): 1 slot 100-pin DIMM (64, 128, 256 or 512 MB)
  • Page 17 2HJ/2HK-1 20/22 ppm printer (EUR/USA model) Type ..........Desktop Printing system ....... Electrophotographic four color (CMYK) printing using Advanced Beam Array Paper type ........Cassette: Plain, preprinted, bond, recycled, rough, letterhead, color, prepunched, high quality, and custom MP tray: Plain, transparency, preprinted, labels, bond, recycled, vellum, rough, letterhead, color, prepunched, envelope, cardstock, coated, thick, high quality, and custom Paper sizes ........
  • Page 18 2HJ/2HK-1 Controller hardware ......CPU: Power PC750CXr (500 MHz) System ROM: 8 MB (32 Mbit × 2) Font ROM: 2 MB (16 Mbit × 1) Main RAM: 128 MB standard (DIMM); expanding up to 640 MB (512 MB × 1) at the maximum by adding optional expansion memory Optional expansion RAM (DIMM): 1 slot 100-pin DIMM (64, 128, 256 or 512 MB)
  • Page 19 2HJ/2HK 1-1-2 Parts names (1) Overall Figure 1-1-1Figure 1-1-1 Top cover 11. Paper gauge 21. Rear cover Magenta toner container 12. Left side cover 22. Fuser cover Cyan toner container 13. Waste toner box 23. Paper feed unit release lever Yellow toner container 14.
  • Page 20 2HJ/2HK (2) Operation panel READY DATA INTERFACE SIZE TYPE ATTENTION Figure 1-1-2Figure 1-1-2 1. Message display [?] key (Right) 2. Interface indicator (INTERFACE) key (Up) 3. Paper size indicator (SIZE) key (Down) 4. Paper type indicator (TYPE) 12. MENU key 5.
  • Page 21 2HJ/2HK-1 1-1-3 Cross section view 20/22 ppm printer [EUR/USA model] 16/17 ppm printer [EUR/USA model] Optional duplexer 16/17 ppm printer [EUR/USA model] optional paper feeder 20/22 ppm printer [EUR/USA model] optional paper feeders Paper path (Main unit) Paper path (Optional unit) Figure 1-1-3Figure 1-1-3 Black drum unit 12.
  • Page 22 2HJ/2HK This page is intentionally left blank. 1-1-8...
  • Page 23 2HJ/2HK 1-2 Installation 1-2-1 Drum unit Note the following when handling or storing the drum (drum unit). Note the following when handling or storing the drum unit. When removing the drum unit, never expose the drum surface to strong direct light. Avoid abrupt changes in temperature and humidity.
  • Page 24 2HJ/2HK 1-2-4 Unpacking and installation (1) Installation procedure Start Unpacking. Installing the toner containers. Installing the waste toner box. Loading paper. Connecting the cables. Printing a status page for test. Completion of the machine installation 1-2-2...
  • Page 25 2HJ/2HK Unpacking. 1. Unpack the printer and components. When carrying the printer, always hold the right and left sides as shown. Printer 2. Pull out the paper feed unit and then remove Printer the filter. 3. Close the paper feed unit. Filter Paper feed unit Figure 1-2-2 Unpacking...
  • Page 26 2HJ/2HK Installing the toner containers. 1. Shake the black toner container several times to loosen the toner inside. Black toner container Figure 1-2-5 2. Open the top cover. 3. Install the black toner container into the printer. The black toner container must be Top cover installed in the front most developer.
  • Page 27 2HJ/2HK 4. Push in the black toner container firmly until it locks in the developer. Black toner container Figure 1-2-7 5. Turn the lock lever backward to the lock position. Lock lever 6. Install other toner containers in the same procedure.
  • Page 28 2HJ/2HK Install the waste toner box. 1. Open the side cover. 2. Install the waste toner box. 3. Close the side cover. Side cover Waste toner box Figure 1-2-9 Loading paper. 1. Remove the paper cassette from the printer. 2. Adjust the paper guides and the paper stop- per according to the paper size to be used.
  • Page 29 2HJ/2HK Connecting the cables. 1. Connect the USB or ethernet cable between the printer and the computer. 2. Connect the power cord to the printer AC inlet. 3. Connect the power cord to the wall outlet. AC inlet Ethernet Power cord Figure 1-2-11 Printing a status page for test.
  • Page 30 2HJ/2HK 1-2-5 Installing expansion memory (optional) <Procedure> 1. Turn off printer power. CAUTION: Do not insert or remove expan- sion memory while printer power is on. Doing so may cause damage to the printer and the expansion memory. 2. If a memory card is currently installed in the memory card slot (See the figure), remove the memory card first.
  • Page 31 2HJ/2HK 1-2-6 Installing a memory card (optional) <Procedure> 1. Turn off printer power. CAUTION: Do not insert or remove memory card while printer power is on. Doing so may cause damage to the printer and the mem- ory card. 2. Insert the memory card into the memory card slot.
  • Page 32 2HJ/2HK 1-2-7 Installing the network interface card (optional) <Procedure> 1. Turn off printer power. Optional interface slot 2. Remove the two screws and then remove the optional interface slot cover. 3. Insert the network interface card into the optional interface slot. 4.
  • Page 33 2HJ/2HK 1-2-8 Installing the hard disk unit (optional) <Procedure> 1. Turn off printer power. Optional interface slot 2. Remove the two screws and remove the optional interface slot cover. 3. Insert the hard disk unit into the optional interface slot. 4.
  • Page 34 2HJ/2HK This page is intentionally left blank. 1-2-12...
  • Page 35 2HJ/2JK-1 1-3 Maintenance Mode 1-3-1 Maintenance mode The printer is equipped with various service mode that can be accessed with the MENU key operation on the operation panel. (1) Executing a maintenance item Message display Ready Press the MENU key. Print Menu Map Press the...

  • Page 36: Toner Coverage

    2HJ/2JK-1 Service items Description Printing a status page for service purpose Description >>Print Prints a status page for service purpose. The status page includes various printing settings Status Page and service cumulatives. Purpose To acquire the current printing environmental parameters and cumulative information. Procedure Enter the service mode [>>Print Status Page].
  • Page 37 2HJ/2JK-1 Service items Description Toner coverage K: Black C: Cyan Number of pages printed coverted M: Magenta in reference to A4 or Letter size. Toner coverage (%) Y: Yellow Toner Coverage / 3.4/Toner Coverage(%) Average K)/13266.4 / 1.1/Toner Coverage(%) Average C)/9277.4 / 1.8/Toner Coverage(%) Average M)/9277.4 / 1.6/Toner Coverage(%) Average Y)/9277.4 / 0.1/ 0.0/ 0.0/ 0.0/(Toner Coverage(%) Last Page /K/C/M/Y/)
  • Page 38 2HJ/2JK-1 Service items Description Service information (20/22 ppm printer [EUR/USA model]) Service information [2F3_1100.001.000/2HK_1000.001.012][2HJ_A000.001.002][2HK_3100.001.004***][01/00] Printed page(s) 9690 /U00/F00/N00/D10:DM0301.DAN:0002001001210052 /0020/0020/1061/0811/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ /AAAAAAA/AAAAAAA/ /AAAAAAA/ /AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ /AAAAAAA/ /AAAAAAA/ /0000/0000/0000/0000/0000/ /0000/0000/0000/0000/ /00000000/00000000/00000000/00000000/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ /[0003-0003]/0/30/88/ 00.00.00.00.00.00 A:1234567890123456 /03030303/03030303/03030303/03000000/00000000/03030303/03030303/ SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E CT01:/0000/0000/0000/0000 CT02:/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000/0000...
  • Page 39 [First byte/second byte (dis- bit 2, 3 (Not used) played in OEM mode only)] bit 4 = 0: Kyocera, 1: OEM bit 5 = 0: For Europe, 1: For US bit 6 = 0: Non MICR mode, 1: MICR mode...
  • Page 40 2HJ/2JK Service items Description Items Description Color print counter Maintenance kit counter Optional unit software version /Paper feeder1/Paper feeder 2/Paper feeder 3/Envelope feeder/Duplexer Drum ID /Black/Cyan/ Magenta/Yellow/ LED print head compensation value Developer refreshing mode /Black/Cyan/Magenta/Yellow/ counter Optional paper feeder/bulk First 2 bytes Second 2 bytes stacker installation...
  • Page 41 2HJ/2JK Service items Description Items Description Calibration information 3 Each 2 bytes in the following order: /450V/400V/350V/Beta/ (CT10 to CT13) CT10: /S-wave background Magenta/ [Measure bias data infor- S-wave background Cyan/ S-wave background Yellow/ mation] S-wave background Black/ CT11: /P-wave background Magenta/ P-wave background Cyan/ P-wave background Yellow P-wave background Black/ CT12: /S-wave patch Magenta/ S-wave patch Cyan/...
  • Page 42 2HJ/2JK-1 Service items Description Media type attribute Paper feed source Paper destination Type Yes/ Type Paper Enve- Face- Face- adjust cas- lope Duplexer down default sette tray feeder tray tray Plain Normal2 Transparency Extra.Thick Preprinted Normal2 Labels Thick1 Bond Normal2 Recycled Normal2 Vellum...
  • Page 43 2HJ/2JK Service items Description Printing an event log (EVENT LOG) Description >>Print Prints the history of paper misfeeds and self-diagnostic errors including up to 16 items from Event Log the latest occurrence of such an error. (If the number of errors exceeds 16, errors will be deleted sequentially from the oldest one.) Purpose To allow machine malfunction analysis based on the frequency of paper misfeeds and self...
  • Page 44 1 = 0: Overseas, 1: Domestic (Japan) [First byte/second byte bit 2, 3 (Not used) (displayed in OEM mode bit 4 = 0: Kyocera, 1: OEM only)] bit 5 = 0: For Europe, 1: For US bit 6 = 0: Non MICR mode, 1: MICR mode...
  • Page 45 2HJ/2JK Service items Description Items Description (a) Cause of paper jam cont. 11: Paper does not pass the registration sensor. [48] 12: Paper remains at the registration sensor when power is turned on. [48] 20: Paper does not arrive at the exit sensor. [48] 21: Paper does not pass the exit sensor.
  • Page 46 2HJ/2JK Service items Description Items Description (c) Detail of paper source (Hexadecimal) cont. 00: MP tray 03: Paper cassette 3 07: Duplexer 01: Paper cassette 1 04: Paper cassette 4 08: Not used 02: Paper cassette 2 05 to 06: Not used 09: Envelope feeder (d) Detail of paper size (Hexadecimal) 00: (indefinite)
  • Page 47 2HJ/2JK-1 Service items Description Items Description Service Call (Self Count. Service Code diagnostic error) Remembers 1 to 8 of The total page count at Example occurrence of self diag- the time of the self diag- nostics error. If the occur- nostics error.
  • Page 48 2HJ/2JK Service items Description Execution of color calibration Description >>Color Executing the density of color using. Calibration Purpose To carry out color calibration manually besides it can be carried out automatically each time the printer is turned on. Procedure Enter the service mode [>>Color Calibration]. Press the OK key twice.
  • Page 49 2HJ/2JK-1 Service items Description Setting the paper feed operation (printer driver priority mode) Description >>Paper feed With printer driver priority mode, when selecting the specific paper feed location (a cassette Special or MP tray) with the printer driver (it is not automatic selection), paper is fed from the selected location.
  • Page 50 2HJ/2JK-1 Service items Description Purpose To reset the life counter for the developer units and drum units included in maintenance kit. Procedure for replacing the maintenance kit Remove the four old drum units (See page 1-5-13). Remove the LED print head from each old drum unit and then refit to the new drum unit (See page 1-5-15).
  • Page 51 2HJ/2JK-1 Service items Description Drum surface refreshing Description >>Drum Rotates the drum approximately 3* minutes with toner lightly applied onto the drum using the high-voltage output control of the engine controller PWB. The cleaning blade in the drum unit scrapes toner off the drum surface to clean it. Purpose To clean the drum surface when image failure occurs due to contamination.
  • Page 52 2HJ/2JK 1-3-2 Maintenance (1) Method of removing the toner soiling which comes in contact with heat roller and press roller/press belt When misfeeding has occurred in the fuser unit, misfeed paper can coil around the heat roller or the press roller/press belt.
  • Page 53 2HJ/2HK 1-4 Troubleshooting 1-4-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the printer immediately stops printing and displays the paper misfeed message on the operation panel. To remove paper misfed in the printer, pull out the paper cassette, pull out the paper feed unit or open the rear cover.
  • Page 54 2HJ/2HK 1-4-2 Self-diagnosis (1) Self-diagnostic function This printer is equipped with self-diagnostic function. When a problem is detected, the printer stops printing and display an error message on the operation panel. An error message consists of a message prompting a contact to service personnel, total print count, and a four-digit error code indicating the type of the error.
  • Page 55 2HJ/2HK (2) Self diagnostic codes Remarks Code Contents Causes Check procedures/corrective measures 0100 EEPROM (U12) write error Defective engine Replace the engine controller PWB (A0004). When it cannot make normal to access controller PWB See page 1-5-41. to the EEPROM (U12) which is installed (A0004).
  • Page 56 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 0951 LED print head 4 (EEPROM) commu- Defective LED print Replace the LED print head 4. See page 1- nication error [black drum unit] head 4. 5-15. The LED print head 4 (EEPROM) of the Installing the LED Install the compatible LED print head to the black drum unit does not communicate...
  • Page 57 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 0952 LED print head 2 (EEPROM) commu- Defective LED print Replace the LED print head 2. See page 1- nication error [cyan drum unit] head 2. 5-15. The LED print head 2 (EEPROM) of the Installing the LED Install the compatible LED print head to the cyan drum unit does not communicate...
  • Page 58 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 0953 LED print head 1 (EEPROM) commu- Defective LED print Replace the LED print head 1. See page 1- nication error [magenta drum head 1. 5-15. The LED print head 1 (EEPROM) the Installing the LED Install the compatible LED print head to the magenta drum unit does communicate...
  • Page 59 2HJ/2HK-1 Remarks Code Contents Causes Check procedures/corrective measures 0954 LED print head 3 (EEPROM) commu- Defective LED print Replace the LED print head 3. See page 1- nication error [yellow drum unit] head 3. 5-15. The LED print head 3 (EEPROM) of the Installing the LED Install the compatible LED print head to the yellow drum unit does not communicate...
  • Page 60 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 5301 Eraser lamp 4 error (black drum unit) Defective eraser Replace the eraser lamp 4 [PWB] (KP- The eraser lamp 4 [PWB] (KP-1090) of lamp 4 [PWB] (KP- 1090). the black drum unit does not communi- 1090).
  • Page 61 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 5302 Eraser lamp 2 error (cyan drum unit) Defective eraser Replace the eraser lamp 2 [PWB] (KP- The eraser lamp 2 [PWB] (KP-1090) of lamp 2 [PWB] (KP- 1090). the cyan drum unit does not communi- 1090).
  • Page 62 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 5303 Eraser lamp 1 error (magenta drum Defective eraser Replace the eraser lamp 1 [PWB] (KP- unit) lamp 1 [PWB] (KP- 1090). The eraser lamp 1 [PWB] (KP-1090) of 1090). the magenta drum unit does not com- Defective engine Replace the engine controller PWB (A0004).
  • Page 63 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 5304 Eraser lamp 3 error (yellow drum Defective eraser Replace the eraser lamp 3 [PWB] (KP- unit) lamp 3 [PWB] (KP- 1090). The eraser lamp 3 [PWB] (KP-1090) of 1090). the yellow drum unit does not communi- Defective engine Replace the engine controller PWB (A0004).
  • Page 64 2HJ/2HK-1 Remarks Code Contents Causes Check procedures/corrective measures 6000 Fuser temperature time-out error Defective installa- Check the installation condition of fuser ther- (heat roller) tion condition of mistor 1, if there is trouble, remedy or Doing the control which turns on the fuser thermistor 1.
  • Page 65 2HJ/2HK-1 Remarks Code Contents Causes Check procedures/corrective measures 6020 Fuser abnormal high temperature Defective engine Replace the engine controller PWB (A0004). error (heat roller) controller PWB See page 1-5-41. Abnormal high fuser temperature of the (A0004). heat roller was detected. Defective fuser Replace the fuser PWB (KP-970* PWB.
  • Page 66 2HJ/2HK-1 Remarks Code Contents Causes Check procedures/corrective measures 6100* Fuser temperature time-out error Defective installa- Check the installation condition of fuser ther- (press roller) tion condition of mistor 2, if there is trouble, remedy or Doing the control which turns on the fuser thermistor 2.
  • Page 67 2HJ/2HK-1 Remarks Code Contents Causes Check procedures/corrective measures 6130* Fuser thermistor 2 broken error Defective engine Replace the engine controller PWB (A0004). (press roller) controller PWB See page 1-5-41. It was judged it has been broken from (A0004). the fact that it is not the input signal from Defective harness Check harness of the fuser PWB (KP-970), of the fuser thermistor 2 which detects...
  • Page 68 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 7002 Toner motor 2 overcurrent detection Defective toner Replace the toner motor 2. See page 1-5- error (cyan toner) motor 2. The engine controller PWB (A0004) Defective engine Replace the engine controller PWB (A0004). detected the overcurrent of toner motor controller PWB See page 1-5-41.
  • Page 69 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 7402 Cyan developer unit non- installing Defective harness Check the damage of harness of the toner error of the toner sensor sensor 2, check the connection of the con- The toner sensor 2 inside the cyan 2, defective con- nector with the cyan developer unit and the developer unit did not output the density...
  • Page 70 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 7404 Yellow developer unit non- installing Defective harness Check the damage of harness of the toner error of the toner sensor sensor 3, check the connection of the con- The toner sensor 3 inside the yellow 3, defective con- nector with the yellow developer unit and the developer unit did not output the density...
  • Page 71 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 7412 Cyan drum unit non- installing error Defective harness Check the connection of the cyan drum unit The EEPROM (U401) on the drum PWB between drum PWB and the printer main unit, check the continu- 2 (KP-972) inside the cyan drum unit 2 (KP-972) and ity of the harness (S03211), if there is trou-...
  • Page 72 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 7413 Magenta drum unit non- installing Defective harness Check the connection of the magenta drum error between drum PWB unit and the printer main unit, check the con- The EEPROM (U401) on the drum PWB 1 (KP-972) and tinuity of the harness (S03211), if there is 1 (KP-972) inside the magenta drum...
  • Page 73 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures 7414 Yellow drum unit non- installing error Defective harness Check the connection of the yellow drum The EEPROM (U401) on the drum PWB between drum PWB unit and the printer main unit, check the con- 3 (KP-972) inside the yellow drum unit 3 (KP-972) and tinuity of the harness (S03211), if there is...
  • Page 74 2HJ/2HK Remarks Code Contents Causes Check procedures/corrective measures D020 Engine firmware error Malfunction of the Turn the power off/on to restart the printer. If Serious status inconsistency that is fatal engine firmware or the error is not resolved, check the update to keep controlling in the engine firm- defective engine information on the engine firmware.
  • Page 75 2HJ/2HK 1-4-3 Image formation problems (1) No image appears (2)No image appears (3)A specific color is (4)The back side gets (5)Image is too light. (entirely white). (entirely black). printed solid. dirty. See page 1-4-24 See page 1-4-24 See page 1-4-24 See page 1-4-25 See page 1-4-25 (6)The background is...
  • Page 76 2HJ/2HK (1) No image appears (entirely white). Print example Causes Check procedures/corrective measures The LED Defective FFC connection Check the FFC connection to the LED print heads relay PWB. print to the LED print heads (Do not attempt to disconnect/connect the FFC while power is head has relay PWB.
  • Page 77 2HJ/2HK-1 (4) The back side gets dirty. Print example Causes Check procedures/corrective measures Dirty secondary transfer roller. Clean the secondary transfer roller. Dirty paper conveying path of the Clean the paper conveying path of the paper feed unit. paper feed unit. Dirty heat roller and press roller* Clean the heat roller and press roller* /press belt*...
  • Page 78 2HJ/2HK (6) The background is colored. Print example Causes Check procedures/corrective measures Defec- Defective developer. Check the four colors of image by using the test page of ser- tive vice mode. If the defect appears on a particular color, replace develop- the developer for that color.
  • Page 79 2HJ/2HK-1 (8) Black streaks are printed vertically. Print example Causes Check procedures/corrective measures Dirty main charger wire. Clean the main charger wire by using main charger wire cleaner. Poor insertion of the main charger Check if the main charger wire cleaner is properly seated. If wire cleaner.
  • Page 80 2HJ/2HK-1 (12) Paper is wrinkled. Print example Causes Check procedures/corrective measures Paper curled. Check the paper storage conditions, replace the paper. Paper damp. Check the paper storage conditions, replace the paper. (13) Offset occurs. Print example Causes Check procedures/corrective measures Deformed or worn cleaning blade in Replace the drum unit.
  • Page 81 2HJ/2HK 1-4-4 Electric problems Problem Causes Check procedures/corrective measures (1) "Close top cover" Right edge of the top cover Close the top cover securely. display is not floating, it is not closed cancelled to completely. closing the top Defective top cover switch Replace the top cover switch 2.
  • Page 82 2HJ/2HK Problem Causes Check procedures/corrective measures (3) "Close paper Defective top cover/paper Replace the sensor PWB (A0001). transfer unit" feed unit switch (SW701) of display is not the sensor PWB (A0001). cancelled to Malfunctioning interlock rod Check to see if the interlock rod malfunctions. If it malfunctions, closing the paper that interfaces between the repair it.
  • Page 83 2HJ/2HK-1 Problem Causes Check procedures/corrective measures (6) The paper size is Defective cassette size Replace the cassette size switch. not recognized as switch. the size set with Defective sensor PWB Replace the sensor PWB (A0001). the paper size (A0001). dial. Defective harness (S03207) Check the continuity of the harness (S03207), check the connec- between cassette size...
  • Page 84 2HJ/2HK-1 1-4-5 Mechanical problems Problem Causes/check procedures Corrective measures (1) No primary paper Check if the surfaces of the following rollers Clean with isopropyl alcohol. See page 1-5- feed. are dirty with paper powder: pickup roller, 7 and 1-5-11. feed roller, retard roller and MP feed roller. Check if the pickup roller, feed roller retard Check visually and replace any deformed roller and MP feed roller are deformed.
  • Page 85 2HJ/2HK-1 1-5 Assembly and Disassembly 1-5-1 Precautions for assembly and disassembly (1) Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly. When handling PWBs, do not touch connectors with bare hands or damage the PWB. Do not touch any PWB containing ICs with bare hands or any object prone to static charge.
  • Page 86 2HJ/2HK 1-5-2 Outer covers (1) Detaching and refitting the top cover Procedure 1. Open the rear cover. 2. Open the top cover. 3. Remove the opening and closing axis from the main unit frame and then remove the top cover. Top cover Figure 1-5-1 1-5-2...
  • Page 87 2HJ/2HK (2) Detaching and refitting the rear cover Procedure 1. Open the rear cover. 2. Remove the opening and closing axis from the main unit frame and then remove the rear cover. Rear cover Figure 1-5-2 1-5-3...
  • Page 88 2HJ/2HK (3) Detaching and refitting the right cover Procedure 1. Remove the top cover (See page 1-5-2). Screw 2. Remove the one screw. Right cover Figure 1-5-3 3. Remove the paper feed unit (See page 1-5- Right cover 4. Using a flat blade screwdriver, unlatch the right cover at the nine positions as shown in the diagram.
  • Page 89 2HJ/2HK (4) Detaching and refitting the left cover Procedure Waste toner box Left cover 1. Remove the top cover (See page 1-5-2). Lock lever 2. Open the left side cover and then remove the one screw. 3. Remove the waste toner box. To remove waste toner box, press the lock lever in.
  • Page 90 2HJ/2HK 1-5-3 Paper feed unit (1) Detaching and refitting the paper feed unit Procedure 1. Pull out the paper feed unit until stop. 2. While pressing the left and right lock release buttons and then remove the paper feed unit. Lock release button Lock release button...
  • Page 91 2HJ/2HK (2) Detaching and refitting the paper feed roller Procedure 1. Remove the paper feed unit (See previous Latches page). 2. Turn over the paper feed unit. 3. While pushing the lock release buttons and then detach the joint. 4. Unlatch the latches and then remove paper feed roller unit.
  • Page 92 2HJ/2HK (3) Detaching and refitting the retard roller Procedure 1. Remove the paper cassette. 2. Unlatch the two latches and then remove Retard roller the retard roller holder. Retard Paper cassette 3. Remove the retard roller from retard roller roller Retard roller holder.
  • Page 93 2HJ/2HK (4) Detaching and refitting the secondary transfer roller Procedure 1. Remove the paper feed unit (See page 1-5- 2. Removing the hook by sliding and then remove the paper chute. 3. Remove the secondary transfer roller. 4. Remove the transfer roller gear. 5.
  • Page 94 2HJ/2HK 1-5-4 MP tray feed unit (1) Detaching and refitting the MP tray feed unit Procedure 1. Remove the paper feed unit (See page 1-5- Latch 2. Remove the paper right cover (See page 1- 5-4). 3. Remove the main high voltage PWB (See page 1-5-45).
  • Page 95 2HJ/2HK (2) Detaching and refitting the MP tray feed roller Procedure 1. Remove the paper feed unit (See page 1-5- 2. Pull up the MP tray holder and then sliding 3. Remove the MP tray feed roller. 4. Check or replace the MP tray feed roller and Paper feed unit then refit all the removed parts.
  • Page 96 2HJ/2HK 1-5-5 Developing section (1) Detaching and refitting the developer unit Procedure 1. Open the top cover. Release lever 2. Remove the one connector. Connector 3. While releasing two release levers and then remove the developer unit. (Use the same Release lever procedure for other developers.) Developer unit...
  • Page 97 2HJ/2HK 1-5-6 Drum section (1) Detaching and refitting the drum unit To replace the drum unit and the engine controller PWB at the same time, turn on the printer after replacing either one. Check that the printer operates properly and then turn off the printer. Replace the other and turn on the printer to check that the printer operates properly.
  • Page 98 2HJ/2HK 5. While releasing two release levers and then Release lever remove the drum unit. (also 4 colors with the Drum unit same procedure, there is no order.) (Yellow) 6. Check or replace the drum unit and then refit all the removed parts. Release lever Drum unit (Magenta)
  • Page 99 2HJ/2HK-1 (2) Replacing the LED print head and drum unit Replacement kit (packing contents) Drum unit kit LED print head kit 16/17 ppm printer 20/22 ppm printer 16/17 ppm printer 20/22 ppm printer DK-511 DK-521 LK-510 LK-520 [EUR/USA model] [EUR/USA model] [EUR/USA model] [EUR/USA model] FFC (white)
  • Page 100 2HJ/2HK 6. Turn the release lever and remove the drum Release lever Drum unit unit. Release lever Figure 1-5-20 7. Remove the three hooks and then remove Hook Hook the LED print head cover from the drum unit. 8. Remove the FFCs form the LED print head Hook cover.
  • Page 101 2HJ/2HK 10. Unlock the connector hook on the LED print head and then pull the white FFC out. 11. Using the same procedure, pull the blue FFC out. FFC (white) White colored LED print head FFC (blue) Blue colored LED print head Connector hook Connector hook Figure 1-5-23...
  • Page 102 2HJ/2HK 13. Turn the connector hook down to lock the new blue FFC. New FFC (blue) 14. Using the same procedure, connect the new white FFC to the connector. Connector hook Contact Connector hook Figure 1-5-25 15. Attach the LED print head into the new drum LED print head unit.
  • Page 103 2HJ/2HK 17. Pass the blue and white FFCs to opening of LED print head cover FFC (white) the LED print head cover. FFC (blue) 18. Store the FFCs in the crevice between LED Hook Hook print head (metal) and sponge. 19.
  • Page 104 2HJ/2HK 21. Refit the drum unit into the printer, and lock Release lever the release levers. Drum unit Release lever Figure 1-5-30 22. Connect one connector. FFC connectors 23. Insert the blue and white FFCs horizontally LED print heads to the FFC connectors (LED print heads relay PWB relay PWB).
  • Page 105 2HJ/2HK 24. Refit the connector cover. 25. Refit the developer units and toner contain- ers to the printer. 26. Close the top cover. (Magenta) Connector cover (Cyan) (Black) (Yellow) Figure 1-5-32 27. Turn the power on. Print a test page selected from the service mode MENU of the operation panel.
  • Page 106 2HJ/2HK-1 1-5-7 Primary transfer section (1) Detaching and refitting the primary transfer unit Procedure 1. Remove the all developer and drum units Primary transfer (See page 1-5-12 and 1-5-13). unit (belt) Handle 2. Place a paper on the primary transfer belt. Handle 3.
  • Page 107 2HJ/2HK-1 (3) Replacing the primary transfer unit Procedure 1. Connect the power cord and then turn on the power switch. 2. Print the status pages (See page 1-3-2). Primary transfer 3. Turn off the power switch and then remove unit (belt) the power cord.
  • Page 108 2HJ/2HK (4) Detaching and refitting the primary transfer cleaning unit Procedure 1. Remove the primary transfer unit (See page1-5-6). 2. Pull out the primary transfer cleaning unit from the main unit frame a little with under- neath the right (1). 3.
  • Page 109 2HJ/2HK-1 1-5-8 Fuser unit (16/17 ppm printer [EUR/USA model]) (1) Detaching and refitting the fuser unit Procedure 1. Remove the rear cover (See page 1-5-3). 2. Remove the right cover and left cover (See page 1-5-4 and1-5-5). 3. Remove the two screws and then remove the fuser unit.
  • Page 110 2HJ/2HK (2) Detaching and refitting the fuser thermistor 1 and 2, fuser thermostat 1 and 2, fuser heater lamp 1 and 2, heat roller, and press roller Procedure 1. Remove the fuser unit (See previous page). 2. While two latches unlatching, remove the fuser bottom cover by making slide.
  • Page 111 2HJ/2HK 5. Remove the three connectors from the fuser PWB. 6. Remove the one tab. 7. While unlatching the latches and then remove the fuse unit connector. 8. Remove the terminal. Latch Fuser PWB Connectors Latch Fuser unit connector Connector Terminal Figure 1-5-41 9.
  • Page 112 2HJ/2HK 10. Remove the one screw and then remove the fuser right cover. 11. Remove the fuser heater lamp 1 and 2. Fuser heater lamp 1 (Heat roller: 500 W) Fuser heater lamp 2 (Press roller: 350 W) Screw Fuser right cover Figure 1-5-43 12.
  • Page 113 2HJ/2HK 15. Remove the two screws and then remove Screws the fuser thermostat 1. 16. Remove the one screw and then remove the fuser thermistor 1. Fuser thermostat 1 Fuser upper cover Fuser thermistor 1 Screw Figure 1-5-45 17. Remove the user lower guide. Screws 18.
  • Page 114 2HJ/2HK 21. Remove the one C-ring, fuser gear, one C- ring, one bush and, one bearing. 22. Remove the one C-ring, one bush and, one bearing. 23. Remove the heat roller. C-ring Fuser gear C-ring Heat roller Bush Bearing Bearing Bush C-ring Figure 1-5-47...
  • Page 115 2HJ/2HK 24. Remove the two bushes and two bearings. 25. Remove the right stay, left stay and press roller. 26. Check or replace the fuser thermistor 1 and 2, fuser thermostat 1 and 2, fuser heater lamp 1 and 2, heat roller and, press roller then refit all the removed parts.
  • Page 116 2HJ/2HK-1 1-5-9 Fuser unit (20/22 ppm printer [EUR/USA model]) (1) Detaching and refitting the fuser unit Procedure 1. Remove the rear cover (See page 1-5-3). 2. Remove the right cover and left cover (See page 1-5-4 and 1-5-5). 3. Remove the two screws and then remove the fuser unit.
  • Page 117 2HJ/2HK (2) Detaching and refitting the fuser thermistor 1, fuser thermostat 1, fuser heater lamp, heat roller, and press belt Procedure 1. Remove the fuser unit (See previous page). 2. Remove the one screw and then the termi- nal and nut. Screw Terminal Figure 1-5-50...
  • Page 118 2HJ/2HK 6. Remove the one tab from the terminal. 7. Remove the Lamp hold seal L. 8. Remove the wire form the two wire clamps. 9. Remove the one screw. 10. While unlatching the latch and then detach the fuser R cover. 11.
  • Page 119 2HJ/2HK 14. Remove the one tab from the terminal. Screws 15. While removing the fuser UP cover and then remove the wire. 16. Remove the one screw and then remove the fuser thermistor 1. 17. Remove the two screws and then remove the fuser thermostat 1.
  • Page 120 2HJ/2HK 18. While sliding [direction of the arrow (1)] the exit guide and then detach the axis. 19. While detaching the axis and then remove the exit guide. Axis hole Axis Spring Axis hole Axis Exit guide Spring Figure 1-5-54 20.
  • Page 121 2HJ/2HK 22. Remove the two press plates and two pres- suresprings. Press plate Pressure spring Press plate Pressure spring Figure 1-5-56 23. Remove the two screws and then remove Screw the fuser B stay. 24. Remove the two screws and then remove Screw the fuser C stay.
  • Page 122 2HJ/2HK 25. Remove the press belt assembly. Press belt assembly Figure 1-5-58 26. Remove the two roller holders with pitch plates. 27. Remove the belt roller A and belt roller. 28. Remove the each two bearings. Roller holder Pitch plate Bearing Belt roller A Belt roller...
  • Page 123 2HJ/2HK 29. Remove the two screws and then remove the exit UP guide. 30. Remove the two C-rings. 31. Remove the stopper ring and heat Z43S gear. 32. Remove the two bearings. 33. Remove the heat roller with bushes. 34. Remove the two bushes from heat roller. Bush Heat roller C-ring...
  • Page 124 2HJ/2HK 1-5-10 PWBs (1) Detaching and refitting the main controller PWB Procedure 1. Turn off the power switch and then remove the power cord. 2. When the optional memory card has been installed in the memory card slot already, remove that. 3.
  • Page 125 2HJ/2HK (2) Detaching and refitting the engine controller PWB and power supply PWB To replace the engine controller PWB and the drum unit at the same time, turn on the printer after replacing either one. Check that the printer operates properly and then turn off the printer. Replace the other and turn on the printer to check that the printer operates properly.
  • Page 126 2HJ/2HK 8. Remove the six screws and then remove the Screws controller box cover. Controller box cover Screws Figure 1-5-64 9. Remove the five screws. Connector 10. Remove the two connectors and then removing the connection with the power supply PWB, remove the engine controller PWB.
  • Page 127 2HJ/2HK 11. The EEPROM (U12) removing from the EEPROM (U12) EEPROM (U12) socket of the old engine controller PWB, it does again to install in the socket of the new engine controller PWB. Engine controller PWB Figure 1-5-66 12. Remove the three screws, one terminal, one Screw washer and then remove the power supply Power supply PWB...
  • Page 128 2HJ/2HK (3) Detaching and refitting the LED print heads relay PWB Procedure 1. Remove the left cover (see page 1-5-5). 2. Remove the one screw. 3. Remove the two connectors and two tabs. 4. Unlatch the four latches and then remove the LED print heads relay PWB.
  • Page 129 2HJ/2HK (4) Detaching and refitting the main high voltage PWB Procedure 1. Remove the right cover (See page 1-5-4). 2. Unlatch the four latches and remove the one connector and then remove the main high voltage PWB. 3. Check or replace the main high voltage PWB and then refit all the removed parts.
  • Page 130 2HJ/2HK (5) Detaching and refitting the bias high voltage PWB Procedure 1. Remove the right cover (See page 1-5-4). 2. Unlatch the five latches and remove the two connectors and then remove the bias high voltage PWB. 3. Check or replace the bias high voltage PWB and then refit all the removed parts.
  • Page 131 2HJ/2HK 1-5-11 1 Others (1) Detaching and refitting the main drive unit Procedure 1. Remove the right cover (See page 1-5-4). 2. Remove the nine connectors from the main drive unit. 3. Remove the one connector. 4. Remove the six screws and four terminals then remove the main drive unit.
  • Page 132 2HJ/2HK (2) Detaching and refitting the paper feed drive unit Procedure 1. Remove the right cover (See page 1-5-4). Connectors 2. Remove five connectors. 3. Remove the harness from the two wire hooks. Wire hooks Connectors Figure 1-5-72 4. Remove the three screws and then remove the paper feed drive unit.
  • Page 133 2HJ/2HK (3) Detaching and refitting the fuser drive unit Procedure 1. Remove the right cover (See page 1-5-4). 2. Remove the main drive unit (See page 1-5- 47). 3. Remove the one connector. Fuser drive unit 4. Remove the two screws and the remove the fuser drive unit.
  • Page 134 2HJ/2HK (4) Detaching and refitting the toner motor 1, 2, 3 and 4 Procedure 1. Remove the right cover (See page 1-5-4). 2. Remove the one connector. Toner motor 3. Remove the hole which is inserted into the (Black) Hooks projection of main unit frame side, slide toner motor 4 to up in order to remove the hook.
  • Page 135 2HJ/2HK (5) Detaching and refitting the ozone filters Procedure 1. Open the top cover. 2. Remove the ozone filters from the ozone fan motor 1 and 2. Ozone filters 3. Check or replace the ozone filters and then refit all the removed parts. Ozone fan motor 2 Ozone fan motor 1 Figure 1-5-76...
  • Page 136 2HJ/2HK (6) Detaching and refitting the waste toner duct Procedure 1. Remove the primary transfer unit (See page 1-5-22). 2. Remove the primary transfer cleaning unit (See page 1-5-24) 3. Unlatch the three latches and then remove the waste toner duct. 4.
  • Page 137 2HJ/2HK-1 1-6 Firmware 1-6-1 Downloading firmware The system firmware can be update by downloading new firmware. Downloading can be made by using a memory card that contains the new firmware. Firmware file name example Software ID Compression S 2 H K _ 1 0 0 0 0 0 1 0 2 1 . c m p Product code Pause (period) 2HJ: 16/17 ppm printer...
  • Page 138 2HJ/2HK (1) Downloading the firmware from the memory card The procedure below provides how to download firmware from a memory card. Note that you can download both the sys- tem and engine firmware at a time. Procedure 1. Turn printer power off. 2.
  • Page 139 2HJ/2HK-1 10. Confirm that the printer's power switch is set to off. 11. Insert the memory card into the printer's memory card slot. Memory card slot Memory card Memory card slot Figure 1-6-5 12. Turn printer power on. Power switch: On 13.
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  • Page 141 2HJ/2HK 2-1 Mechanical construction 2-1-1 Paper feed section There is paper feed from the paper cassette which can load paper 500 and paper feed from the MP tray which can load paper 100 in paper feed method of this printer. The paper feed section is composed of paper cassette, paper feed unit, paper feed drive unit, MP tray and, MP tray feed unit.
  • Page 142 2HJ/2HK The paper size dial has predetermined patterns of activating the paper size switches using concaves and convexes according to paper sizes. SW1, SW2, and SW3 produce corresponding signals for paper sizes. Engine controller PWB Sensor PWB CAS0 CAS0 CAS1 CAS1 CAS2 Paper size dial...
  • Page 143 2HJ/2HK Paper gauge sensing circuit The actuator which has a light reflector at one end keeps tracking of the height of the paper stack in the paper cassette. The angle of the reflector varies according to the actuator angle which means the amount of paper remaining. As the reflector moves across the detecting surface of paper gauge sensor (photo interrupter) 1 and 2, the on and off states of these sensors vary in combination as shown in the table below, allowing to determine the amount of remaining paper in the cassette.
  • Page 144 2HJ/2HK Secondary Upper transfer roller registration roller Lower registration roller Guide rollers To fuser unit From paper cassette Feed roller Pickup roller Figure 2-1-5Paper feed unit Engine controller PWB Feed clutch FEDCLDR YC11-6 Registration clutch REGCLDR YC11-4 Feed motor STFDA YC11-14 STFDAN YC11-15...
  • Page 145 2HJ/2HK Paper feeding from MP tray The MP tray bottom which is driven by the MP feed solenoid press the paper against the MP feed roller. The sheet is rewound to the MP feed roller, then forward to the registration roller by means of the MP middle roller. Figure 2-1-7MP tray paper feed section MP frame MP middle tray...
  • Page 146 2HJ/2HK Engine controller PWB MP feed solenoid MPSOLDR YC11-8 Feed motor STFDA YC11-14 STFDAN YC11-15 STFDB YC11-16 STFDBN YC11-17 Figure 2-1-9MP tray paper feed section block diagram 2-1-6...
  • Page 147 2HJ/2HK-1 2-1-2 Developing section (1) Developer unit Developing section is composed of mixer screw, developing blade, developing magnet roller and, developing sleeve. Figure 2-1-10Developer unit Developing sleeve Mixer screw A Developing magnet roller Developer case Doctor blade Developer lid Mixer screw B Developer case Toner sensor Mixer screw B...
  • Page 148 2HJ/2HK Black : Developing magnet roller developer : Developing sleeve : Toner sensor Output* Output* Output* Engine controller PWB Developing Yellow HVCLK1 magnet bias YC5-2 developer HVCLK2 output circuit YC5-3 HVCLK3 YC5-4 HVCLK4 Output* YC5-5 Output* HVBDATD YC5-6 HVBCLKD converter Cyan YC5-7 HVBLATD...
  • Page 149 2HJ/2HK (2) Touch down developing method Touchdown development system is a development system having the best of both mono-component system and dual component system. Dual component developer which is a powder of mixture of toner and carrier powder is continuously agitated by mixer screws A and B in the toner hopper in the developer unit.
  • Page 150 2HJ/2HK (3) Developer drive stop mechanism Developer drive stop mechanism detaches the drive transmission of developers other than black developer at the time of monochrome printing and makes stop, drives only black developer due to the movable part and the operation of developer drive stop motor with idle plate lever, cam lever, cam gear and idle arm plate etc.
  • Page 151 2HJ/2HK 2-1-3 Drum section The drum unit includes a photoconductive drum, eraser lamp, LED print head, cleaning blade and, a main charger unit. The drum unit is removable with the main charger unit. (1) Drum unit The tandem development system uses four drum units which are isomorphic to each other, in cyan, magenta, yellow, and black colors.
  • Page 152 2HJ/2HK Eraser lamp [PWB] LED print head Waste toner exit screw Cleaning blade Drum : Waste toner flow To waste toner duct Figure 2-1-16Drum unit 2-1-12...
  • Page 153 2HJ/2HK LED print heads relay PWB : LED print head (LPH PWB) 1, 2, 3, 4 LVDSP0 to 11 : Eraser lamp [PWB] 1, 2, 3, 4 Main LVDSN0 to 11 : Drum PWB 1, 2, 3, 4 YC2-1 to 32 controller ADATA10 to 19 YC3-9 to 18...
  • Page 154 2HJ/2HK (2) Waste toner ejecting mechanism The waste toner which is ejected from the drum units drops on the waste toner conveyer through a duct. The waste toner is conveyed towards the primary transfer cleaning unit, finally stored in the waste toner box. Primary transfer cleaning unit From...
  • Page 155 2HJ/2HK (3) LED print head The LED print head is comprised of SELFOC lens array, and an LPH PWB. The LPH PWB arrays 5184 of LED chips in line. It also includes the driver circuit for the LED chips. The light which is switched on and off depending on video data irradiate the drum through the SELFOC lens, to form an image.
  • Page 156 2HJ/2HK Data to print is processed by the main controller PWB and transferred to the LED print head relay PWB in synchronization with VIDEO signal through the engine controller PWB. VIDEO signal is sent from ASIC (U22) on the mail controller PWB to ASIC (U1) on the LED print head relay PWB using LVDS method.
  • Page 157 2HJ/2HK (4) Main charger unit Main charger unit is comprised of the main charger wire, main charger grid, main charger shield, and the main charger cleaner which are modularized and fitted to the drum unit. Figure 2-1-21 Main charger wire Main charger grid Main charger shield Main charger cleaner...
  • Page 158 2HJ/2HK Main high voltage PWB Main charger unit Output* Shield Wire Grid Engine controller PWB Zener PWB 1 Drum MCH1DR YC1-2 YC6-2 MCH2DR YC1-3 YC6-3 MCH3DR YC6-4 YC1-4 Magenta drum unit MCH4DR YC1-5 YC6-5 Main charger unit Output* Main high Shield voltage Wire...
  • Page 159 2HJ/2HK 2-1-4 Primary transfer section Primary transfer section is composed of the primary transfer unit and primary transfer cleaning unit. (1) Primary transfer unit The primary transfer unit is comprised of the primary transfer belt, tension rollers, and four primary transfer rollers of col- ors.
  • Page 160 2HJ/2HK Figure 2-1-26Primary transfer section block diagram Tension roller Primary transfer roller (black) Backup roller Primary transfer belt Drive base Backup gear 29H Primary transfer roller (magenta) 10. Image gear 22H Primary transfer roller (cyan) 11. Image gear 28S Primary transfer roller (yellow) 12.
  • Page 161 2HJ/2HK (2) Primary transfer cleaning unit The primary transfer cleaning unit is composed of the fur brush, brush cleaning roller, cleaning blade and, cleaning screw. After secondary transferring is done, the toner which remains in the primary transfer belt is collected back in the waste toner box.
  • Page 162 2HJ/2HK Fur brush Brush cleaning roller Cleaning frame Engine controller PWB Main high voltage PWB YC1-7 Fur brush HVADATD YC6-6 Output 500 V DC YC1-8 HVACLKD bias output converter YC6-7 YC1-9 HVALATD circuit (IC501) YC6-8 Figure 2-1-29Primary transfer cleaning unit block diagram From waste toner duct : Waste toner flow...
  • Page 163 2HJ/2HK A full color image is developed by recoating four colors on the primary transfer belt. If the density of each color is not kept constant, the resultant color image will be deteriorated. The toner ID sensor mounted on the primary transfer belt to the printer main unit side maintains the constant color fidelity.
  • Page 164 2HJ/2HK 2-1-5 Secondary transfer and separation section The secondary transfer and separation section includes the secondary transfer roller which is installed on the paper feed unit. The secondary transfer roller is applied by the bias high voltage PWB of DC bias. The image constituted by toner on the primary transfer belt is transferred on paper by means of the difference in potential.
  • Page 165 2HJ/2HK The primary transfer roller bias is triggered by a serial data which is generated by the engine controller PWB and derived from the bias high voltage PWB. The engine controller PWB converts current and voltage into serial data and applies it to the bias high voltage PWB.
  • Page 166 2HJ/2HK-1 2-1-6 Fuser section (1) Fuser unit (16/17 ppm printer [EUR/USA model]) The fuser unit is composed of the heat roller, press roller, fuser heater lamp 1, fuser heater lamp 2, and the change guide. Paper sent from the secondary transfer and separation section is applied with heat and pressure to permanently fuse toner on paper.
  • Page 167 2HJ/2HK-1 To face-down tray Change guide Upper exit roller To optional duplexer or face-up tray Lower exit roller From paper feed unit Heat roller Press roller Figure 2-1-36Fuser unit (16/17 ppm printer [EUR/USA model]) Engine controller PWB Power supply PWB Fuser PWB FUSOLDR FUDR...
  • Page 168 2HJ/2HK-1 (2) Fuser unit (20/22 ppm printer [EUR/USA model]) The fuser unit is composed of the heat roller, press belt, fuser heater lamp 1, and the change guide. Paper sent from the secondary transfer and separation section is applied with heat and pressure to permanently fuse toner on paper. The change guide switches the destination of paper to the face-down tray or optional face-up tray.
  • Page 169 2HJ/2HK-1 Change guide face-down tray face-down tray To optional duplexer or face-up tray Exit pulley Exit roller From paper feed unit Press belt roller Heat roller Press belt Press belt roller Figure 2-1-39Fuser unit (20/22 ppm printer [EUR/USA model]) Engine controller PWB Power supply PWB Fuser PWB FUDR...
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  • Page 171 2HJ/2HK 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) Main frame and controller box CONTROLLER BOX Figure 2-2-1Main frame and controller box Main controller PWB ........Controls the software such as the print data processing and provides the interface with computers. Engine controller PWB.........
  • Page 172 2HJ/2HK-1 Engine relay PWB........Interconnects the engine controller PWB and the electrical parts. Sensor PWB ..........Consists the top cover/paper feed unit switch, side cover switch, top cover switch 1, paper gauge switch 1/2, registration sensor, and, wiring relay circuit. Operation panel PWB ........
  • Page 173 2HJ/2HK-1 (2) Drum unit, developer unit and fuser unit FUSER UNIT 16/17 ppm printer [EUR/USA model] DRUM UNIT DEVELOPER UNIT FUSER UNIT 20/22 ppm printer [EUR/USA model] Figure 2-2-2Drum unit, developer unit and fuser unit Drum PWB 1, 2, 3, 4 ........Drum PWB 1 (magenta), drum PWB 2 (cyan), drum PWB 3 (yellow), drum PWB 4 (black) wiring relay circuit inside each color drum unit.
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  • Page 175 2HJ/2HK-1 2-3-1 Operation of the PWBs (1) Power supply PWB Power supply PWB Engine Power Current controller fuse switch input Transformer Rectifier (T1) circuit Noise +24V1 filter 24 V DC circuit rectifier/ smoothing (Q1) circuit (Q2) +5V1 5 V DC rectifier/ smoothing circuit...
  • Page 176 2HJ/2HK-1 Connector Pin No. Signal Voltage Description AC (LIVE) 220 -240 V AC AC power input 120 V AC Connected Frame ground to the AC AC (NEUTRAL) 220 -240 V AC AC power input inlet 120 V AC YC901 Analog Fuser thermistor 1 detection voltage output Connected Analog...
  • Page 177 2HJ/2HK-1 2-3-2 Engine controller PWB Engine controller PWB Operation Sensors/switches signals Sensor panel Reset IC RESET (U10) Data/Address Micro RESET multiplex bus controller Address bus (U8) Main controller Flash memory Address bus (U9) LED print heads control EEPROM (U12) EEPROMs control Paper full sensor signal Face up/down solenoid control print...
  • Page 178 2HJ/2HK-1 Connector Signal Voltage Description +24V1 24 V DC 24 V DC power output Connected +24V1 24 V DC 24 V DC power output to the sen- +24V1 24 V DC 24 V DC power output sor PWB +24V1 24 V DC 24 V DC power output Ground Ground...
  • Page 179 2HJ/2HK Connector Signal Voltage Description LVDSP14 Analog LED print head control video data signal (LVDS) Connected LVDSN14 Analog LED print head control video data signal (LVDS) to the LED LVDSP15 Analog LED print head control video data signal (LVDS) print heads LVDSN15 Analog LED print head control video data signal (LVDS)
  • Page 180 2HJ/2HK Connector Signal Voltage Description +24V2 24 V DC 24 V DC power output (via top cover/paper feed unit switch) Connected HVCLK1 3KHz rectangular wave Developing sleeve (magenta) output to the bias HVCLK2 3KHz rectangular wave Developing sleeve (cyan) output high voltage HVCLK3 3KHz rectangular wave Developing sleeve (yellow) output...
  • Page 181 2HJ/2HK Connector Signal Voltage Description VTXCLKP 0/3.3 V DC (pulse) LED print head control clock signal Connected VTXDP7 Analog LED print head control video data signal (LVDS) to the main VTXDP6 Analog LED print head control video data signal (LVDS) controller VRXDP0 Analog...
  • Page 182 2HJ/2HK Connector Signal Voltage Description YC10 +5V1 5 V DC 5 V DC power output Connected PDATA I/O 0/3.3 V DC (pulse) Operation panel PWB control data signal to the opera- FPDIR 0/3.3 V DC Operation panel PWB communication direction control signal tion panel FPCLK 0/3.3 V DC (pulse) Operation panel PWB control data synchronizing clock signal...
  • Page 183 2HJ/2HK-1 Connector Signal Voltage Description YC12 Analog Fuser thermistor 1 detection voltage input Connected Analog TH2* Fuser thermistor 2* detection voltage input to the power FDSOLDR 0/24 V DC (pulse) Face up/down solenoid control signal supply PWB +5V2 5 V DC 5 V DC power input RCOVOPN 0/5 V DC...
  • Page 184 2HJ/2HK 2-3-3 Main controller PWB CPUD[31-0] ASIC PPC750CXr CPUDH [31-0] [31-0] [23-2] MA [12-0] MDQ [31-0] MCSN [4:1], MCKE [4:0] EXTBOEN Transceiver Latch MRASN, MCASN, MWEN, MBA [1:0], MDQS [3:0] DM [3:0], MCKP [6,4:3,1:0] SDRAM MCKN [6,4:3,1:0] FPCLK, FPDIR, FPDAT, MREFOUTP, MREFOUTN, FPRSTN, SCLKN, SO, SI, Engine...
  • Page 185 2HJ/2HK-1 2-4 Appendixes 2-4-1 Appendixes (1) Wiring diagram (16/17 ppm printer [EUR/USA model]) 2-4-1...
  • Page 186 2HJ/2HK 2-4-2...
  • Page 187 2HJ/2HK-1 (2) Wiring diagram (20/22 ppm printer [EUR/USA model]) 2-4-3...
  • Page 188 2HJ/2HK 2-4-4...
  • Page 189 2HJ/2HK-1 (3) Repetitive defects gauge First occurrence of defect 31.16 mm [Upper registration roller] 33.28 mm [Developing sleeve] 51.21 mm [Lower registration roller] 59.33 mm [Secondary transfer roller] 94.4 mm [Drum] 113.04 mm [Heat roller Press roller, 16/17 ppm printer (EUR/USA model)] 114.61 mm [Heat roller, 20/22 ppm printer (EUR/USA model)] 2-4-5...
  • Page 190 2HJ/2HK This page is intentionally left blank. 2-4-6...

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