Triumph Adler CLP3316, Service Manual

Page 1: ...Service Manual Color Printer CLP 3316 CLP 3520 X First Edition Date 24 10 2006 2HKSM060 ...

Page 2: ...Service Manual Color Printer CLP 4316 CLP 4520 X First Edition Date 24 10 2006 2HKSM060 ...

Page 3: ... The back side gets dirty 1 4 25 5 Image is too light 1 4 25 6 The background is colored 1 4 26 7 White streaks are printed vertically 1 4 26 8 Black streaks are printed vertically 1 4 27 9 Streaks are printed horizontally 1 4 27 10 Spots are printed 1 4 27 11 The leading edge of image begins to print too early or too late 1 4 27 12 Paper is wrinkled 1 4 28 13 Offset occurs 1 4 28 14 Part of image...

Page 4: ...ress roller 1 5 26 1 5 9 Fuser unit 20 ppm printer 1 5 32 1 Detaching and refitting the fuser unit 1 5 32 2 Detaching and refitting the fuser thermistor 1 fuser thermostat 1 fuser heater lamp heat roller and press belt 1 5 33 1 5 10 PWBs 1 5 40 1 Detaching and refitting the main controller PWB 1 5 40 2 Detaching and refitting the engine controller PWB and power supply PWB 1 5 41 3 Detaching and re...

Page 5: ...1 1 Main frame and controller box 2 2 1 2 Drum unit developer unit and fuser unit 2 2 3 2 3 1 Operation of the PWBs 2 3 1 1 Power supply PWB 2 3 1 2 3 2 Engine controller PWB 2 3 3 2 3 3 Main controller PWB 2 3 10 2 4 Appendixes 2 4 1 Appendixes 2 4 1 1 Wiring diagram 16 ppm printer 2 4 1 2 Wiring diagram 20 ppm printer 2 4 3 3 Repetitive defects gauge 2 4 5 ...

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Page 7: ...rsonnel to ensure the safety of their customers their machines as well as themselves during maintenance activities Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities ...

Page 8: ... this symbol CAUTION Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol Symbols The triangle symbol indicates a warning including danger and caution The specific point of attention is shown inside the symbol General warning Warning of risk of electric shock Warning of high temperature indicates a prohibited ...

Page 9: ... or dusty place This may cause fire or electric shock Do not install the copier near a radiator heater other heat source or near flammable material This may cause fire Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool as possible Insufficient ventilation may cause heat buildup and poor copying performance Always handle the machine by the correct l...

Page 10: ... carefully Always check that the copier is correctly connected to an outlet with a ground connection Check that the power cable covering is free of damage Check that the power plug is dust free If it is dirty clean it to remove the risk of fire or electric shock Never attempt to disassemble the optical unit in machines using lasers Leaking laser light may damage eyesight Handle the charger section...

Page 11: ...r trapped wire and missing screws Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling Replace with new ones if necessary Handle greases and solvents with care by following the instructions below Use only a small amount of solvent at a time being careful not to spill Wipe spills off completely Ventilate the room wel...

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Page 13: ...Standby mode 16 seconds or less A4 Sleep mode 96 seconds or less A4 Warm up time Sleep mode 80 seconds or less room temperature 22 C 71 6 F 60 RH Power on 80 seconds or less room temperature 22 C 71 6 F 60 RH Paper feed system One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m2 0 11 µm MP tray 100 sheets 80 g m2 0 11 µm Paper eject system Face down 250 sheets ...

Page 14: ...ne dimensional bar code 45 types Two dimensional bar code 1 type PDF 417 d Connectivity plug play Windows 95 98 ME NT4 0 2000 XP SNMP KM NET viewer Resolution 600 dpi Dimensions Main unit 345 470 385 mm 13 5 8 18 1 2 15 1 4 W D H Weight Main unit 24 kg 52 15 16 lbs not including toner containers Power source 220 240 V AC 50 60 Hz European countries 120 V AC 60 Hz U S A Canada Power consumption Max...

Page 15: ...al 13 pages minutes First print time Standby mode 13 seconds or less A4 Sleep mode 81 seconds or less A4 Warm up time Sleep mode 68 seconds or less room temperature 22 C 71 6 F 60 RH Power on 68 seconds or less room temperature 22 C 71 6 F 60 RH Paper feed system One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m2 0 11 µm MP tray 100 sheets 80 g m2 0 11 µm Pap...

Page 16: ...ode 45 types Two dimensional bar code 1 type PDF 417 d Connectivity plug play Windows 95 98 ME NT4 0 2000 XP SNMP KM NET viewer Resolution 600 dpi Dimensions Main unit 345 470 385 mm 13 5 8 18 1 2 15 1 4 W D H Weigh Main unit 25 kg 55 1 8 lbs not including toner containers Power source 220 240 V AC 50 60 Hz European countries 120 V AC 60 Hz U S A Canada Power consumption Maximum 1037 W 220 240 V m...

Page 17: ...ize window 10 Paper size dial 11 Paper gauge 12 Left side cover 13 Waste toner box 14 Power switch 15 Magenta main charger unit 16 Cyan main charger unit 17 Yellow main charger unit 18 Black main charger unit 19 Main charger wire cleaner 20 Lens cleaner 21 Rear cover 22 Fuser cover 23 Paper feed unit release lever 24 Memory card slot 25 AC inlet 26 Optional interface slot 27 USB interface connecto...

Page 18: ...NTERFACE 1 Message display 2 Interface indicator INTERFACE 3 Paper size indicator SIZE 4 Paper type indicator TYPE 5 Ready indicator READY 6 Data indicator DATA 7 Attention indicator ATTENTION 8 W key Left 9 X key Right 10 S key Up 11 T key Down 12 MENU key 13 OK key 14 CANCEL key 15 GO key ...

Page 19: ...Yellow drum unit 3 Cyan drum unit 4 Magenta drum unit 5 Black developer unit 6 Yellow developer unit 7 Cyan developer unit 8 Magenta developer unit 9 Black toner container 10 Yellow toner container 11 Cyan toner container 12 Magenta toner container 13 Primary transfer unit 14 Primary transfer cleaning unit 15 MP tray 16 MP tray feed unit 17 Feed unit 18 Fuser unit 19 Controller box 20 Face down tr...

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Page 21: ...void direct sunlight or bright lighting Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams Avoid extremes of temperature and humidity abrupt ambient temperature changes and hot or cold air directed onto the machine Avoid dust and vibration Choose a surface capable of supporting the weight of the machine Place the machine on a level ...

Page 22: ...g 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 ...

Page 23: ...t Figure 1 2 2 Unpacking 4 Check parts and components Printer Document and software Installation guide operation guide CD ROMs Magenta toner container Cyan toner container Yellow toner container Black toner container Waste toner boxes one is a spare Power cord Figure 1 2 3 5 Open the top cover and remove the packing item Figure 1 2 4 Unpacking Filter Printer Printer Paper feed unit Top cover Packi...

Page 24: ...the toner inside Figure 1 2 5 2 Open the top cover 3 Install the black toner container into the printer The black toner container must be installed in the front most developer Figure 1 2 6 Installing the toner containers Black toner container Black toner container Top cover ...

Page 25: ...firmly until it locks in the developer Figure 1 2 7 5 Turn the lock lever backward to the lock position 6 Install other toner containers in the same procedure 7 Close the top cover Figure 1 2 8 Black toner container Magenta Lock lever Yellow Cyan Black ...

Page 26: ...tte from the printer 2 Adjust the paper guides and the paper stop per according to the paper size to be used 3 Turn the dial so that the size of the loaded paper is indicated in the paper size indica tion window Figure 1 2 10 Install the waste toner box Waste toner box Side cover Loading paper Paper size window Paper cassette ...

Page 27: ... the following key operation to print a status page for test Press the MENU key when Ready is dis played Press the T or S key to display Print Sta tus Page Press the OK key to display Print Status Page Press the OK key Processing will be dis played and the status page will be printed When printing is complete Ready will appear again 2 Check to see if the status page is properly printed Connecting ...

Page 28: ...gure 1 2 12 4 Open the stoppers of the memory socket 5 Insert the memory so that the two notches of the memory are engaged with the projec tions of the memory socket 6 Close the stoppers of the memory socket 7 Reattach the main controller PWB in the printer 8 Print a status page to check the memory expansion If memory expansion has been properly performed information on the installed memory is pri...

Page 29: ...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 3 Format the memory card before use Refer to the operation guide Figure 1 2 14 Memory card slot Memory card slot Memory card ...

Page 30: ...lot cover 3 Insert the network interface card into the optional interface slot 4 Use the two screws to secure the network interface card Figure 1 2 15 5 Connect the network cable 6 Configure the network interface card See the IB 2x quick configuration guide Figure 1 2 16 Optional interface slot Screws Cover Network interface card Network interface card Network cable ...

Page 31: ...emove the two screws and remove the optional interface slot cover 3 Insert the hard disk unit into the optional interface slot 4 Use the two screws to secure the hard disk unit 5 Format the hard disk unit Refer to the operation guide Figure 1 2 17 Cover Optional interface slot Screws Hard disk unit ...

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Page 33: ... an event log EVENT LOG Displayed when FRPO I1 is set to 1 To execute color calibration To print a test page To set paper feed operation as printer driver priority mode To reset the counter after replacing the maintenance kit To perform developer refreshing To perform drum surface refreshing Press the or key several times until Others is displayed Service mode items Press the key Press the key Pre...

Page 34: ...eleased 25 Apr 2006 2F3_1100 001 001 2HJ_1000 001 003 2HJ_A000 001 002 2HJ_3100 001 004 03 03 Printed page s 9690 U00 F00 N00 D10 DM0301 DAN 0002001001210052 0020 0020 1061 0811 0 0 0 0 0 0 0 0 0 AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA 0000 0000 0000 0000 0000 0000 00000000 00000000 00000000 00000000 AAAAAAA AAAAAAA AAAAAAA AAAAAAA 00...

Page 35: ...3100 001 004 03 03 Printed page s 9690 U00 F00 N00 D10 DM0301 DAN 0002001001210052 0020 0020 1061 0811 0 0 0 0 0 0 0 0 0 AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA 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 0303...

Page 36: ...0 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 DN SPL9200007 SPL9200007 SPL9200007 SPL9200007 SN SPL9200010 CT01 0000 0000 0000 0000 CT02 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT03 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT04 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 00...

Page 37: ... lock NVRAM error displayed only when any error has occurred 01 ID error 02 Version error 03 Checksum error 04 NVRAM crush error NVRAM download 00 Normal bit0 Font data bit1 Host data bit2 Macro data bit3 Program data bit4 Operation panel message data download file name displayed bit5 OEM data bit6 Web template data version displayed bit7 Error occurred Printable area setting Top offset Left offse...

Page 38: ...t temperature Current humidity MAC address Fixed asset number Media type attributes Media type setting value from 1 to 28 paper weight unused media type are always 0x00 Memory SPD information slot 1 Calibration information 1 CT01 Average background S wave Average background P wave Dark potential S wave Dark potential P wave Calibration information 2 CT02 to CT09 I O output data information Each 2 ...

Page 39: ...ge 1 byte Calibration information 5 CT15 Relative compensation for toner 2 bytes Each 2 bytes in the following order Magenta 450 400 350 Beta Cyan 450 400 350 Beta Yellow 450 400 350 Beta Black 450 400 350 Beta Calibration information 6 CT16 Total number of times Number of cancellation Number of retries E10 error E11 error E12 error Calibration result IO 1 Calibration result bias 2 1 E00 Completed...

Page 40: ...13 Cardstock YES Thick2 NO YES YES NO YES YES 14 Coated YES Normal2 NO YES YES NO YES YES 15 2 nd Side NO 16 Thick YES Thick1 NO YES YES NO NO YES 17 Fine YES Normal2 YES YES YES YES YES YES 18 Reserved 19 Reserved 20 Reserved 21 Custom1 YES Normal2 YES YES YES YES YES YES 22 Custom2 YES Normal2 YES YES YES YES YES YES 23 Custom3 YES Normal2 YES YES YES YES YES YES 24 Custom4 YES Normal2 YES YES Y...

Page 41: ...SPL6400142 DN SPL6401106 Firmware version 2HK_30000 001 018 11111 10 48 01 88 01 01 10000 10 48 01 88 01 01 9999 10 48 01 88 01 01 9998 10 48 01 88 01 01 9997 10 48 01 88 01 01 9996 10 48 01 88 01 01 9995 10 48 01 88 01 01 9994 10 48 01 88 01 01 9993 10 48 01 88 01 01 9992 10 48 01 88 01 01 9991 10 48 01 88 01 01 9990 10 48 01 88 01 01 9989 10 48 01 88 01 01 9979 10 48 01 88 01 01 9969 10 48 01 88...

Page 42: ...e If the occur rence of the previous paper jam is less than 16 all of the paper jams are logged When the occur rence exceeds 16 the oldest occurrence is removed The total page count at the time of the paper jam Log code 2 digit hexadecimal 6 cate gories a Cause of a paper jam b Position of paper jam c Paper source d Paper size e Paper type f Paper exit Refer to the next page for the details of eac...

Page 43: ...sor when power is turned on 33 50 Paper does not arrive at the paper feeder 3 paper sensor 34 Cassette 4 51 Paper does not pass the paper feeder 3 paper sensor 34 52 Paper remains at the paper feeder 3 paper sensor when power is turned on 34 A1 Paper does not arrive at the vertical path sensor 48 duplexer A2 Paper does not arrive at the switchback sensor 49 duplexer A3 Paper does not pass the dupl...

Page 44: ...xadecimal 01 Plain 02 Transparency 03 Preprinted 04 Labels 05 Bond 06 Recycle 07 Vellum 08 Rough 09 Letter head 0A Color 0B Prepunched 0C Envelope 0D Cardstock 0E Coated 0F 2nd side 10 Media 16 11 High quality 15 Custom 1 16 Custom 2 17 Custom 3 18 Custom 4 19 Custom 5 1A Custom 6 1B Custom 7 1C Custom 8 f Detail of paper exit location Hexadecimal 01 Face down output tray FD 02 Face up output tray...

Page 45: ...er is not precisely detectable Code of maintenance replac ing item 1 byte 2 category 01 Toner container First byte Replacing item 01 Toner container Second byte Type of replac ing item 00 Black 01 Cyan 02 Magenta 03 Yellow First byte Replacing item 02 Maintenance kit Second byte Type of replac ing item 00 Fixed Counter Log Comprised of three log counters including paper jams self diagnos tics erro...

Page 46: ... check the activation of the developer and drum units of four colors Procedure 1 Enter the service mode Printing Test Page 2 Press the OK key twice The test page is printed Completion 1 Since focusing in yellow is hardly readable yellow is mixed with cyan for more readability resulting in green 2 Each portion of colors has three different magnitude of halftones bands If focus is excessively lost d...

Page 47: ...er the service mode Paper feed 2 Press the OK key Message Paper feed will be displayed 3 Select the mode Special or Normal pressing the T key or S key 4 Press the OK key Completion Counter reset for the maintenance kit Description The Install MK message means that maintenance kit should be replaced at 200 000 images of printing 20 ppm printer only The interval counter must be manually reset using ...

Page 48: ...enance is displayed 2 Press the OK key twice The counter for each component is reset immediately Completion NOTE Occurrences of resetting the maintenance kits are recorded on the service status page and event log in number of pages or images at which the maintenance kit was replaced See page 1 3 2 and 1 3 9 This may be used to determine the possibility that the counter was erroneously or unintenti...

Page 49: ...e 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 This mode is useful when dew condensation on the drum occurs Procedure 1 Enter the service mode Drum 2 Press the OK key Message Drum will be displayed 3 Press the OK key Drum surface refreshing will start and finish after approximately 3 ...

Page 50: ...he toner soiling from the heat roller or the press roller press belt 1 Remove the misfed paper Cancel misfeed by opening and closing a cover wait until the message display shows Ready 2 Press MENU key and set paper type to Transparency and paper source to MP tray 3 Set the a sheet transparency sheet 3M CG3700 or thick paper with the of more than weight above 135 g m2 to MP tray 4 Press MENU key an...

Page 51: ...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 Figure 1 4 1 2 Paper misfeed detection Figure 1 4 2Paper misfeed detection Paper Jam MP tray Paper misfeed location Paper misfeed message Paper path Paper full sensor Registration sensor Exit sensor MP paper sensor ...

Page 52: ... 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 The display varies depending on the type of the error Figure 1 4 3Error message display Call service 7600 0123456 Call service F020 Error power off F030 Error codes 0100 to 9530 Error codes D020 F000 F010 and F020 Error codes F000 F030 F040 and F226...

Page 53: ...erface connec tor or poor contact of the connector terminals Check the continuity of the harness S03202 Check the insertion of YC7 of the engine controller PWB A0004 if there is trouble remedy or replace 0460 Duplexer communication error When turning on power the ASIC of the engine controller PWB A0004 recog nized the optional duplexer but when it becomes not be able to communicate from the middle...

Page 54: ...D print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the con nector terminals Check the continuity of the harness S03214 check the insertion of YC3 of the engine controller PWB A0004 if there is trouble remedy or replace Defective FFCs S03011 betw...

Page 55: ...Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the con nector terminals Check the continuity of the harness S03214 check the insertion of YC3 of the engine controller PWB A0004 if there is trouble remedy or replace Defective FFCs S03011 between LED print head 2 and LED p...

Page 56: ...ce the LED print heads relay PWB A0176 See page 1 5 44 Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the con nector terminals Check the continuity of the harness S03214 check the insertion of YC3 of the engine controller PWB A0004 if there is trouble remedy or replace Defective FFCs S03011 between LED print head 1 and LED print ...

Page 57: ...ce See page 1 5 15 1200 Side registration motor error The duplexer PWB of the optional duplexer cannot detect the home posi tion of the adjust guide Defective duplexer Refer to the duplexer s service manual Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 2610 Paper feed motor error top The notification that was received the motor clock sensor cannot de...

Page 58: ...PWB 4 KP 972 and eraser lamp 4 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 4 KP 972 if there is trouble remedy or replace Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the con nector terminals Check the continuity of the harness S03214 check the connection...

Page 59: ...B 2 KP 972 and eraser lamp 2 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 2 KP 972 if there is trouble remedy or replace Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the con nector terminals Check the continuity of the harness S03214 check the connection Y...

Page 60: ...um PWB 1 KP 972 and eraser lamp 1 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 1 KP 972 if there is trouble remedy or replace Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the con nector terminals Check the continuity of the harness S03214 check the connect...

Page 61: ...m PWB 3 KP 972 and eraser lamp 3 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 3 KP 972 if there is trouble remedy or replace Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the con nector terminals Check the continuity of the harness S03214 check the connecti...

Page 62: ...m printer Defective harness S03204 220 240 V AC model S03205 120 V AC model between fuser unit connec tor and fuser heater lamp 1 Check the continuity of the harness S03204 220 240 V AC model S03205 120 V AC model check the connection YC694 connector of the fuser PWB KP 970 1 A0003 2 if there is trouble remedy or replace YC694 connector of the fuser PWB KP 970 1 A0003 2 if there is trouble remedy ...

Page 63: ... poor contact of the con nector terminals Check harness of the fuser PWB KP 970 1 A0003 2 check the connection YC694 con nector of the fuser PWB KP 970 1 A0003 2 if there is trouble remedy or replace Defective harness S03203 between fuser PWB and fuser connector or poor contact of the connector termi nals Check the continuity of the harness S03203 check the connection YC691 con nector of the fuser...

Page 64: ...replace Defective fuser heater lamp 2 Replace the fuser heater lamp 2 See page 1 5 26 Defective harness S03204 220 240 V AC model S03205 120 V AC model between fuser unit connec tor and fuser heater lamp 2 Check the continuity of the harness S03204 220 240 V AC model S03205 120 V AC model check the connection YC693 connector of the fuser PWB KP 970 if there is trouble remedy or replace Defective h...

Page 65: ...e connection YC902 con nector of the power supply PWB if there is trouble remedy or replace Defective fuser PWB KP 970 Replace the fuser PWB KP 970 Defective power supply PWB Replace the power supply PWB See page 1 5 41 Defective installa tion condition of fuser thermistor 2 Check the installation condition of fuser ther mistor 2 if there is trouble remedy or replace See page 1 5 26 6400 Zero cros...

Page 66: ...er motor 3 Defective toner motor 3 Replace the toner motor 3 See page 1 5 50 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Lump of toner inside yellow toner container or defec tiveness of toner replenishment drive system Replace the yellow toner container 7401 Black developer unit non installing error The toner sensor 4 inside the black developer uni...

Page 67: ...ective engine relay PWB A0009 Replace the engine relay PWB A0009 7403 Magenta developer unit non install ing error The toner sensor 1 inside the magenta developer unit did not output the density detection signal judged the engine con troller PWB A0004 the magenta devel oper unit is not installed Defective harness of the toner sensor 1 defective con nection of the con nector between magenta develop...

Page 68: ... KP 972 inside the black drum unit does not communicate normally The incompatible drum unit is installed to the printer Defective harness between drum PWB 4 KP 972 and printer main unit or poor contact of the connector terminals Check the connection of the black drum unit and the printer main unit check the continu ity of the harness S03211 if there is trou ble remedy or replace Installing the dru...

Page 69: ...incompatible with the printer specifi cation Install the compatible drum unit to the printer Defective drum PWB 2 KP 972 Replace the drum PWB 2 KP 972 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness S03214 between engine controller PW...

Page 70: ... is incompatible with the printer specifi cation Install the compatible drum unit to the printer Defective drum PWB 1 KP 972 Replace the drum PWB 1 KP 972 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness S03214 between engine controlle...

Page 71: ...or replace 7600 Toner ID sensor error The detection signal of the toner ID sen sor was abnormal value Defective toner ID sensor Replace the toner ID sensor Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective harness S03195 between engine controller PWB A0004 and toner ID sensor or poor contact of the connector termi nals Check the continuity of t...

Page 72: ...s not resolved replace the main controller PWB A0171 See page 1 5 40 Defective expand ing memory If the expanding memory is installed after removing or replacing the expanding mem ory do the operation check If operation is normal replace the expanding memory See page 1 3 8 F030 Main controller PWB system error The error which is related to the system other than the error code F000 F010 and F020 oc...

Page 73: ...d 7 White streaks are printed vertically 8 Black streaks are printed vertically 9 Streaks are printed horizontally 10 Spots are printed See page 1 4 26 See page 1 4 26 See page 1 4 27 See page 1 4 27 See page 1 4 27 11 The leading edge of image begins to print too early or too late 12 Paper is wrinkled 13 Offset occurs 14 Part of image is missing 15 Fusing is loose See page 1 4 27 See page 1 4 28 ...

Page 74: ...gh voltage PWB See page 1 5 45 Defec tive sec ondary transfer bias out put Defective engine control ler PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective bias high volt age PWB Replace the bias high voltage PWB See page 1 5 46 Malfunction of the developer installa tion Reinstall the developer See page 1 5 12 Print example Causes Check procedures corrective measures No main char...

Page 75: ...ct appears on a particular color replace the developer for that color See pages 1 3 14 and 1 5 12 Defective bias high volt age PWB Replace the bias high voltage PWB See page 1 5 46 Defective engine control ler PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective main controller PWB Replace the main controller PWB A0171 See page 1 5 40 Defective drum unit Replace the drum unit See ...

Page 76: ...es Check procedures corrective measures Defec tive LED print head output Poor insertion of LED cleaner Check if the LED cleaner unit is properly seated If necessary reseat it properly Dirty SELFOC lens of LED print head Clean the SELFOC lens of LED print head by using lens cleaner Focus is lost with the LED print head Check the four colors of image by using the test page of ser vice mode If the de...

Page 77: ... of main charger unit Insert the main charger unit properly Poor contact of grounding terminal of drum unit Replace the drum unit See page 1 5 13 Poor contact of developing bias termi nal of developer Replace the developer See page 1 5 12 Print example Causes Check procedures corrective measures Dirty or flawed drum Perform the drum surface refreshing See page 1 3 17 Deformed or worn cleaning blad...

Page 78: ... 1 3 17 Flawed drum Replace the drum unit See page 1 5 13 Flawed primary transfer belt Replace the primary transfer unit See page 1 5 22 Print example Causes Check procedures corrective measures Wrong types of paper Check if the paper meets specifications replace paper Defective pressure for the heat roller and press roller 1 press belt 2 Check the fuser pressure springs See page 1 5 26 1 5 33 Fla...

Page 79: ...Defective harness S03197 between engine controller PWB A0004 and sensor PWB A0001 or poor con tact of the connector termi nals Check the continuity of the harness S03197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace 2 Close side cover display is not cancelled to cl...

Page 80: ...3197 between engine controller PWB A0004 and sensor PWB A0001 or poor con tact of the connector termi nals Check the continuity of the harness S03197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace Defective engine controller PWB A0004 Replace the engine controller P...

Page 81: ...ontinuity of the harness S03197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace Defective exit sensor Replace the fuser PWB KP 970 1 A0003 2 Defective harness S03197 between fuser PWB KP 970 1 A0003 2 and fuser connector or poor contact of the connector terminals Che...

Page 82: ...r Check if the surfaces of the following rollers are dirty with paper powder pickup roller feed roller retard roller and MP feed roller Clean with isopropyl alcohol See page 1 5 7 and 1 5 11 Check if the pickup roller feed roller retard roller and MP feed roller are deformed Check visually and replace any deformed rollers See page 1 5 7 and 1 5 11 Deformed guides along the paper conveying path Che...

Page 83: ...nect 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 Use only the specified parts to replace the fuser unit thermostat Never substitute electric wires as the printer may be seri ously damaged ...

Page 84: ...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 Figure 1 5 1 Top cover ...

Page 85: ...HJ 2HK 1 5 3 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 Figure 1 5 2 Rear cover ...

Page 86: ...he top cover See page 1 5 2 2 Remove the one screw Figure 1 5 3 3 Remove the paper feed unit See page 1 5 2 4 Using a flat blade screwdriver unlatch the right cover at the nine positions as shown in the diagram Figure 1 5 4 Right cover Screw Right cover Frame Right cover Latch ...

Page 87: ...e screw 3 Remove the waste toner box To remove waste toner box press the lock lever in Figure 1 5 5 4 Remove the paper feed unit See page 1 5 6 5 Using a flat blade screwdriver unlatch the right cover at the nine positions as shown in the diagram Figure 1 5 6 Left cover Screw Left side cover Lock lever Waste toner box Left cover Frame Latch Left cover ...

Page 88: ... 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 Figure 1 5 7 Paper feed unit Lock release button Lock release button ...

Page 89: ...atches and then remove the feed bracket cover 6 Remove the feed roller and pickup roller The one way clutch is built in to the pickup gear Z32S When the pickup gear Z32S is installed again the surface of one way clutch side is directed to feed bracket cover side 7 Check or replace the feed roller and then refit all the removed parts Figure 1 5 9 Paper feed roller unit Lock release button Lock rele...

Page 90: ...cassette 2 Unlatch the two latches and then remove the retard roller holder 3 Remove the retard roller from retard roller Retard roller holder 4 Check or replace the retard roller and then refit all the removed parts Figure 1 5 10 Retard roller holder Retard roller Latches Paper cassette ...

Page 91: ...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 Check or replace the secondary transfer roller and then refit all the removed parts Figure 1 5 11 Secondary transfer roller Transfer roller gear Paper chute Hook Hook Hook Paper feed unit ...

Page 92: ...t cover See page 1 5 4 3 Remove the main high voltage PWB See page 1 5 45 4 Remove the paper feed drive unit See page 1 5 48 5 While pushing the two latches from inside the main unit frame and then remove the MP tray feed unit 6 Check or replace the MP tray feed unit and then refit all the removed parts Figure 1 5 12 MP tray feed unit MP tray feed unit Latch Latch ...

Page 93: ...ve the paper feed unit See page 1 5 6 2 Pull up the MP tray holder and then sliding do 3 Remove the MP tray feed roller 4 Check or replace the MP tray feed roller and then refit all the removed parts Figure 1 5 13 Paper feed unit MP tray feed roller MP tray holder MP tray feed unit ...

Page 94: ...oper unit Procedure 1 Open the top cover 2 Remove the one connector 3 While releasing two release levers and then remove the developer unit Use the same procedure for other developers Figure 1 5 14 Release lever Release lever Connector Developer unit Black Cyan Magenta Yellow ...

Page 95: ...printer to check that the printer operates properly Be sure to replace one by one Refer to self diagnostic code 9530 See page 1 4 21 Procedure 1 Remove the developer unit See previous page 2 Remove the each connector cover 3 Remove the FFC a and FFC b from the FFC connectors 4 Remove the one connector Figure 1 5 15 FFC a Connector cover Black Connector cover Cyan Connector cover Magenta Connector ...

Page 96: ...s no order 6 Check or replace the drum unit and then refit all the removed parts NOTE When refitting the drum unit insert the FFC straightly to the FFC connector when connecting the FFC Figure 1 5 16 Drum unit Yellow Release lever Release lever FFC FFC connector Contact Drum unit Drum unit Cyan Drum unit Black Drum unit Magenta ...

Page 97: ...its 4 Remove the drum unit connector cover for the color to be replaced Figure 1 5 18 5 Remove two Flexible Flat Cables FFCs and one connector Figure 1 5 19 Drum unit LED print head FFC white FFC white FFC blue FFC blue DK 511 16 ppm printer DK 521 20 ppm printer Drum unit kit LK 510 16 ppm printer LK 520 20 ppm printer LED print head kit Connector cover Black Yellow Cyan Magenta FFC white FFC blu...

Page 98: ...d cover Figure 1 5 21 9 Remove the LED print head from the drum unit CAUTION When handling the LED heads discharge the body of static electricity by using an anti static wrist strap band or anti static globes NOTE Do not touch the pins painted red Figure 1 5 22 Drum unit Release lever Release lever FFC Hook Hook Hook Drum unit LED print head cover LED print head Drum unit Pin painted red Pin paint...

Page 99: ...rocedure pull the blue FFC out Figure 1 5 23 12 Insert the new blue FFC vertically into the connector Ensure the FFC is in line with the connector and not slanted Figure 1 5 24 FFC white FFC blue White colored Blue colored LED print head LED print head Connector hook Connector hook New FFC blue Blue colored Connector ...

Page 100: ...ew white FFC to the connector Figure 1 5 25 15 Attach the LED print head into the new drum unit Figure 1 5 26 16 Attach the LED print head cover into the new drum unit Figure 1 5 27 New FFC blue Connector hook Connector hook Contact LED print head New drum unit FFC blue FFC white LED print head cover New drum unit ...

Page 101: ...hold the three hooks Figure 1 5 28 20 Check that the press springs on both sides of the LED print head are not buckling NOTE If the press springs are buckling pushdown on the central part of the LED print head cover to correct the buckle Figure 1 5 29 Drum unit rim Sponge Opening Hook Hook Hook FFC blue FFC blue FFC white LED print head metal LED print head cover LED print head cover Press spring ...

Page 102: ...r 23 Insert the blue and white FFCs horizontally to the FFC connectors LED print heads relay PWB NOTE Ensure the FFCs are not inserted at a slant to the connectors Figure 1 5 31 Release lever Release lever Drum unit FFC connectors FFC connector Contact Drum unit FFC white FFC blue FFC Connector LED print heads relay PWB ...

Page 103: ...the printer needs to download the data stored in the EEPROM mounted on the LED print head for optimizing the LED print head performance CAUTION If there is a fault with the test page or a fault is displayed on the self diagnostic display check the following If the test print image is partly missing or a fault is displayed The FFC connection to the LED print head Step 12 The FFC connection to the p...

Page 104: ...ry transfer unit Procedure 1 Remove the all drum units See page 1 5 13 2 Pull two handles and raise 3 Remove the primary transfer unit with the handles 4 Check or replace the primary transfer unit and then refit all the removed parts Figure 1 5 33 Handle Handle Primary transfer unit ...

Page 105: ...o handles 3 Remove the paper chute 4 Remove the two screws and then make the primary transfer unit two fold 5 Remove the primary transfer belt 6 Check or replace the primary transfer belt and then refit all the removed parts Figure 1 5 34 Primary transfer unit Primary transfer unit Paper chute Primary transfer belt Handle Handle Screw Screw ...

Page 106: ...unit from the main unit frame a little with under neath the right 1 3 Pull out the waste toner outlet 2 which is on the left side of the primary transfer clean ing unit from the main unit frame 4 Remove the primary transfer cleaning unit 5 Check or replace the primary transfer clean ing unit and then refit all the removed parts Figure 1 5 35 Primary transfer cleaning unit 1 2 ...

Page 107: ...r 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 4 Check or replace the fuser unit and then refit all the removed parts Figure 1 5 36 Screw Screw Fuser unit ...

Page 108: ...mp 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 3 Remove the one tab Figure 1 5 37 4 Remove the two screws form the terminals Figure 1 5 38 Tab Latch Fuser bottom cover Latch Screws Terminals ...

Page 109: ...ab 7 While unlatching the latches and then remove the fuse unit connector 8 Remove the terminal Figure 1 5 39 9 Remove the one screw and then remove the fuser left cover Figure 1 5 40 Fuser unit connector Latch Latch Tab Terminal Connectors Fuser PWB Connector Screw Fuser left cover ...

Page 110: ...he two pressure springs 13 Remove the fuser upper cover right pres sure lever and left pressure lever 14 Remove the fuser stay Figure 1 5 42 Fuser heater lamp 2 Press roller 350 W Fuser right cover Screw Fuser heater lamp 1 Heat roller 500 W Fuser stay Pressure spring Pressure spring Left pressure lever Upper fuser cover Right pressure lever ...

Page 111: ...Figure 1 5 43 17 Remove the user lower guide 18 Remove the one tab 19 Remove the two screws and then remove the fuser thermostat 2 20 Remove the one screw and then remove the fuser thermistor 2 Figure 1 5 44 Fuser thermistor 1 Fuser upper cover Screw Fuser thermostat 1 Screws Tab Fuser thermistor 2 Screws Fuser thermostat 2 Screws lower guide ...

Page 112: ...ve 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 Figure 1 5 45 C ring Bush Bearing Heat roller Bush Bearing C ring C ring Fuser gear ...

Page 113: ...tay 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 Figure 1 5 46 C ring Bush Bearing Press roller Right stay C ring Bush Bearing Left stay ...

Page 114: ...r 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 4 Check or replace the fuser unit and then refit all the removed parts Figure 1 5 47 Screw Screw Fuser unit ...

Page 115: ...dure 1 Remove the fuser unit See previous page 2 Remove the one screw and then the termi nal and nut Figure 1 5 48 3 Remove the two connectors 4 Remove the wire from wire clamp 5 While unlatching the latch and then remove the fuser L cover Figure 1 5 49 Nut Terminal Screw Connector Connector Screw Fuser L cover Latch Wire clamp Wire ...

Page 116: ...unlatching the latch and then detach the fuser R cover 11 Unhook the projection and then remove the fuser R cover 12 Remove the wire from the fuser R cover and Fuser gear sleeve 13 Remove the heater lamp Figure 1 5 50 Fuser R cover Fuser R cover Wire clamp Wire clamp Terminal Tab Wire Latch Latch Lamp hold seal L Screw Projection Heater lamp Fuser gear sleeve ...

Page 117: ...ng 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 Figure 1 5 51 Wire Terminal Tab Fuser UP cover Screw Screws Fuser thermistor 1 Fuser thermostat 1 ...

Page 118: ... the axis 19 While detaching the axis and then remove the exit guide Figure 1 5 52 20 Turn the fuser unit bottom side up 21 While unlatching the two latches and then remove the entrance guide Figure 1 5 53 1 Axis hole Axis hole Axis Axis Spring Exit guide Spring Latch Latch Entrance guide ...

Page 119: ...suresprings Figure 1 5 54 23 Remove the two screws and then remove the fuser B stay 24 Remove the two screws and then remove the fuser C stay Figure 1 5 55 Pressure spring Press plate Press plate Pressure spring Screw Screw Screw Screw Fuser B stay Fuser C stay ...

Page 120: ...emove the two roller holders with pitch plates 27 Remove the belt roller A and belt roller 28 Remove the each two bearings Figure 1 5 57 Press belt assembly Roller holder Pitch plate Bearing Roller holder Pitch plate Bearing Bearing Press belt Belt roller Belt roller A ...

Page 121: ...he 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 Figure 1 5 58 Bush Bush Bearing Bearing Heat Z43S gear C ring C ring Stopper ring Screw Exit UP guide Screw Heat roller ...

Page 122: ...ure 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 Remove the two screws and then remove the main controller PWB Figure 1 5 59 Memory card slot Main controller PWB Screw Screw ...

Page 123: ... self diagnostic code 9530 See page 1 4 21 Procedure 1 Remove the main controller PWB See pre vious page 2 Remove the right cover left cover and rear cover See page 1 5 4 1 5 5 and 1 5 3 3 Remove the one screw and then remove the wire clamp and terminal 4 Remove the all machine left five machine right four connectors Figure 1 5 60 5 Remove three screws 6 Loose the one screw A 7 Remove the main uni...

Page 124: ...r box cover Figure 1 5 62 9 Remove the five screws 10 Remove the two connectors and then removing the connection with the power supply PWB remove the engine controller PWB Figure 1 5 63 Screws Screws Controller box cover Engine controller PWB Connector Connector Screws ...

Page 125: ...the socket of the new engine controller PWB Figure 1 5 64 12 Remove the three screws one terminal one washer and then remove the power supply PWB 13 Check or replace the engine controller PWB and power supply PWB then refit all the removed parts Figure 1 5 65 EEPROM U12 Engine controller PWB Power supply PWB Screw Screws Terminal ...

Page 126: ...ge 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 5 Check or replace the LED print heads relay PWB and then refit all the removed parts Figure 1 5 66 LED print heads relay PWB Connector Connector Tab Tab Latches Screw ...

Page 127: ...re 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 Figure 1 5 67 Main high voltage PWB Connector Latches ...

Page 128: ...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 Figure 1 5 68 Latches Latch Connector Connector Bias high voltage PWB Latch ...

Page 129: ... 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 5 Check or replace the main drive unit and then refit all the removed parts Figure 1 5 69 Connectors nine Screw Screw and terminals Main drive unit Screw and terminal Screw Screw Screw and terminal Connector ...

Page 130: ... 5 4 2 Remove five connectors 3 Remove the harness from the two wire hooks Figure 1 5 70 4 Remove the three screws and then remove the paper feed drive unit 5 Check or replace the paper feed drive unit and then refit all the removed parts Figure 1 5 71 Wire hooks Connectors Connectors Screws Paper feed drive unit ...

Page 131: ...ight cover See page 1 5 4 2 Remove the main drive unit See page 1 5 47 3 Remove the one connector 4 Remove the two screws and the remove the fuser drive unit 5 Check or replace the fuser drive unit and then refit all the removed parts Figure 1 5 72 Fuser drive unit Screw Screw Connector ...

Page 132: ...nserted into the projection of main unit frame side slide toner motor 4 to up in order to remove the hook 4 Remove the toner motor 4 5 Check or replace the toner motor 4 and then refit all the removed parts Also four toner motors with the same procedure there is no order Figure 1 5 73 Hooks Hooks Connector Toner motor Black Holes Bihind view Yellow Cyan Projections Magenta ...

Page 133: ...e ozone filters Procedure 1 Open the top cover 2 Remove the ozone filters from the ozone fan motor 1 and 2 3 Check or replace the ozone filters and then refit all the removed parts Figure 1 5 74 Ozone filters Ozone fan motor 2 Ozone fan motor 1 ...

Page 134: ...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 Check or replace the waste toner duct and then refit all the removed parts Figure 1 5 75 Latches Waste toner duct ...

Page 135: ...y using a memory card that contains the new firmware Figure 1 6 1 S2HK_1000001021 cmp Firmware file name example Product code 2HJ 16 ppm printer 2HK 20 ppm printer Pause under bar Pause period Build number Compression Software ID Version up history 0 Normal E Corrective Firmware description supplement Firmware description 10 Engine 30 System ...

Page 136: ...matting is complete turn printer power off Figure 1 6 3 6 Remove the formatted memory card from the memory card slot 7 Insert the memory card to the PC s slot or to the adaptor 8 Copy the firmware file to download to the root directory of the memory card 9 Remove the memory card from the PC s slot or the adaptor Figure 1 6 4 Memory card slot Memory card slot Memory card Message display Operation p...

Page 137: ...card slot 18 Turn printer power on 19 Confirm that message display 4 is dis played after warm up 20 Print the status page Print the status page to check that the firmware version has been updated Figure 1 6 6 Memory card slot Memory card slot Memory card 2 1 4 Ready Supervisor mode CF card reading Supervisor mode 3 2HK_3000 001 021 06 04 26 E1F9 Power switch On Power switch On Power switch Off Mes...

Page 138: ...2HJ 2HK 1 6 4 This page is intentionally left blank ...

Page 139: ... and sent to the paper feed roller which forward the paper in the printer In order to pre vent paper misfeed during feeding the retard roller which is positioned face to face with the paper feed roller acts to pre vent feeding more than one sheet at a turn of the pick up roller The paper cassette has an opening at the front side This opening is a loophole for the paper that is fed by the optional ...

Page 140: ...ing signals for paper sizes Figure 2 1 3 Engine controller PWB Sensor PWB H H H H H L H L H H L L L H H A4 L H L A5 L L H B5 L L L SW1 SW2 SW3 CAS0 CAS0 105 106 107 CAS1 CAS1 CAS2 CAS2 SW2 SW3 SW1 ASIC U13 Cassette size switch Cassette size switch Paper size Paper size dial Paper size dial Paper cassette Other Legal Letter Cassette not installed Concave Function Off Convex Function On ...

Page 141: ...ctor 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 Figure 2 1 4 Paper feed unit Sensor PWB Paper gauge sensor 1 PH702 Paper gauge sensor 2 PH703 Actuator Reflecting mirror PH702 PH703 1 to 1 3 1 3 to 2 3 2 3 ...

Page 142: ...user unit Secondary transfer roller Upper registration roller Lower registration roller Guide rollers Pickup roller Feed roller From paper cassette Engine controller PWB Feed clutch Registration clutch Feed motor 1 2 3 4 REGCLDR FEDCLDR STFDA STFDAN STFDB STFDBN YC11 14 YC11 4 YC11 15 YC11 16 YC11 17 YC11 6 ...

Page 143: ...ewound 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 Figure 2 1 8 1 MP frame 2 MP feed roller 3 MP middle roller 4 Multi bottom 5 MP middle tray 6 MP base 7 Separator 8 MP tray cover To fuser unit MP feed roller MP middle roller MP tray feed unit MP tray Paper feed unit ...

Page 144: ...2HJ 2HK 2 1 6 Figure 2 1 9MP tray paper feed section block diagram MPSOLDR STFDA STFDAN STFDB STFDBN YC11 14 YC11 8 YC11 15 YC11 16 YC11 17 1 2 3 4 MP feed solenoid Engine controller PWB Feed motor ...

Page 145: ...magnet roller and developing sleeve Figure 2 1 10Developer unit Figure 2 1 11Developer unit 1 Developing sleeve 2 Developing magnet roller 3 Doctor blade 4 Mixer screw B 5 Mixer screw A 6 Developer case 7 Developer lid Developer case Toner sensor Mixer screw B Mixer screw A Developing magnet roller Developing sleeve Doctor blade ...

Page 146: ...ay PWB YC5 6 YC5 7 YC5 8 YC4 25 YC4 21 YC4 11 YC4 10 YC5 2 YC5 3 YC5 4 YC5 5 TNSEN1 TNSEN2 TNSEN3 TNSEN4 HVBDATD HVBCLKD HVBLATD HVCLK1 HVCLK2 HVCLK3 HVCLK4 Output 1 Output 2 Output 2 Output 1 Output 2 Output 1 Output 2 Output 1 Output 1 Output 2 6 7 8 2 3 4 5 CN4 CN8 CN5 CN10 CN9 CN11 CN6 CN7 D A converter IC501 Black developer Yellow developer Cyan developer Magenta developer Developing magnet r...

Page 147: ...constant length of height approximately 0 5 to 0 55 millimeters as they pass under the doctor blade The developing magnet roller lies along the developing sleeve at the distance of 0 40 millimeters As the developing magnet roller revolves the brushes formed at pole N1 sweep the developing sleeve and the toner is transferred to the developing sleeve as it is attracted by the difference in potential...

Page 148: ...ar K3 and a black development unit always drives But idle gear which transmits drive to developer of the other colors Y2 C2 M2 because in idle arm plate which mobility it does it is installed the idle gear Y2 C2 M2 with developer gear Y3 C3 M3 connection leaves due to the mobility of idle arm plate the mechanism where drive is separated According to this mechanism although all developers are drive...

Page 149: ...he light emitted by LED hits the charged drum the electrostatic latent image is developed on the drum The electro static latent image is developed by toner applied by the developer unit and transferred onto the primary transfer belt in four colors The toner remaining on the drum is scraped off by the cleaning blade and driven outside by the spiral screw The residual potential on the drum is discha...

Page 150: ...2HJ 2HK 2 1 12 Figure 2 1 16Drum unit LED print head Cleaning blade Waste toner exit screw To waste toner duct Drum Waste toner flow Eraser lamp PWB ...

Page 151: ... YC401 7 YC401 4 YC401 5 YC401 2 YC401 1 YC402 1 YC401 7 YC401 4 YC401 5 YC401 2 YC401 1 YC402 1 Magenta drum unit Drum Cyan drum unit Drum Yellow drum unit Drum Black drum unit Drum EEDATA DA0 DA1 EECLK ERS2DR EEDATA DA0 DA1 EECLK ERS3DR EEDATA DA0 DA1 EECLK ERS4DR EEDATA DA0 DA1 EECLK YC2 6 YC2 5 YC2 4 YC2 2 YC2 1 YC2 1 to 32 EECLK ERAS1DR ERS2DR ERS3DR ERS4DR YC3 8 YC3 6 YC3 5 YC3 3 YC3 2 Engin...

Page 152: ...gh a duct The waste toner is conveyed towards the primary transfer cleaning unit finally stored in the waste toner box Figure 2 1 18Waste toner ejecting mechanism Waste toner duct Waste toner box Waste toner Waste toner flow From yellow drum unit From black drum unit Primary transfer cleaning unit From magenta drum unit From cyan drum unit ...

Page 153: ...ched on and off depending on video data irradiate the drum through the SELFOC lens to form an image The LED print head is of 600 dpi therefore the exposure of the light is as dense as 600 dots per a inch The EEPROM on the LPH PWB stores data for compensation of fluctuation of luminosity over all LED chips in the array Figure 2 1 19LED print head SELFOC lens array LED chips 5184 pieces LPH PWB EEPR...

Page 154: ... the flash memory on the main controller PWB In a subsequent power up the main controller PWB refers the flash memory to obtain the compen sating data and the EEPROM is checked with its checksum only If the LED print head or the main controller PWB is replaced checksum becomes error The compensating data is trans ferred to the main controller PWB again from the EEPROM In case of failure with EEPRO...

Page 155: ...hield and the main charger cleaner which are modularized and fitted to the drum unit Figure 2 1 21 Figure 2 1 22 Main charger unit 1 Main charger wire 2 Main charger grid 3 Main charger shield 4 Main charger cleaner Main charger cleaning knob Main charger shield Main charger cleaning pad Main charger grid Main charger wire ...

Page 156: ...R Main charger unit Main high voltage PWB Main high voltage output circuit Engine controller PWB Shield Wire Grid Zener PWB 1 Magenta drum unit Drum Main charger unit Shield Wire Grid Zener PWB 2 Cyan drum unit Drum Main charger unit Shield Wire Grid Zener PWB 3 Yellow drum unit Drum Main charger unit Shield Wire Grid Zener PWB 4 Black drum unit Drum Output 1 Output 1 Output 1 Output 1 Output 1 32...

Page 157: ...on the primary transfer belt Figure 2 1 24Primary transfer unit The primary transfer belt is made of stratum fluorine coat stratum elastic and stratum resin in the order from the surface to the bottom These substances ensure smooth paper travel as well as the durability of the belt itself Figure 2 1 25Primary transfer unit Primary transfer cleaning unit 1 Tension roller 2 Backup roller 3 Drive rol...

Page 158: ...Primary transfer roller black 8 Primary transfer belt 9 Backup gear 29H 10 Image gear 22H 11 Image gear 28S 12 Toner ID sensor mounted on the main frame 7 8 9 Magenta Yellow Cyan Black Toner ID sensor Engine controller PWB Primary transfer roller D A converter IC501 HVADATD HVACLKD HVALATD IDSW IDPW IDREF YC6 7 YC6 8 YC6 9 YC11 11 YC11 12 YC11 13 Output Output Output Output Output Output 600 V DC ...

Page 159: ...he conductive cleaning frame from the main high voltage PWB The voltage at the fur brush is approximately 300 V DC The toner remaining on the primary transfer belt is transferred onto the fur brush that is biased and continuously revolving It is then scraped off of the fur brush by the metal brush cleaning roller in the cleaning frame The brush cleaning roller has the cleaning blade which scrapes ...

Page 160: ...sh cleaning roller Cleaning frame Fur brush bias output circuit D A converter IC501 Main high voltage PWB Engine controller PWB 500 V DC Output YC1 7 YC1 8 YC1 9 HVADATD HVACLKD HVALATD YC6 6 YC6 7 YC6 8 From waste toner duct To waste toner box Waste toner flow 1 Fur brush 2 Brush cleaning roller 3 Cleaning blade 4 Cleaning screw ...

Page 161: ...ght from the LED to S wave and P wave S wave oscillates vertically in ref erence to the entrance plane whereas P wave oscillates horizontally in reference to the entrance plane S wave reaches the photo diode PD1 and acts to stabilize the luminosity of the LED by means of the feed back circuit P wave is irradi ated to toner then it produces scattered light wave S and reflection wave P which bounced...

Page 162: ...of DC bias The image constituted by toner on the primary transfer belt is transferred on paper by means of the difference in potential The paper is separated from the transfer belt as the curvature radius of the secondary transfer roller is considerably small Figure 2 1 32 Figure 2 1 33Secondary transfer unit Feed base Paper feed unit Secondary transfer roller Paper chute Feed base Paper feed unit...

Page 163: ...The bias high voltage PWB then uses D A converter IC501 and revert it into analog voltage The analog voltage is applied to the high voltage output circuit which in turn applies the secondary transfer roller with the bias accordingly Figure 2 1 34Secondary transfer unit block diagram 6 7 8 HVBDATD HVBCLKD HVBLATD YC5 6 YC5 7 YC5 8 Secondary transfer roller Secondary transfer roller bias 40 µA Bias ...

Page 164: ...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 It also sends paper to the duplexer Figure 2 1 35Fuser unit 16 ppm printer 1 Upper fuser frame 2 Lower fuser frame 3 Upper exit roller 4 Lower exit roller 5 Heat roller 6 Press roller 7 Fuser heater lamp 1 8 Fuser heater lamp 2 9 Lower fuser cover 10 Lower e...

Page 165: ...12 10 YC12 1 YC12 2 YC12 5 YC12 7 YC12 6 YC12 3 YC12 9 YC12 11 Engine controller PWB YC11 18 YC11 19 YC11 20 YC11 21 HEAT1DR HEAT2DR ZCROSS YC901 10 YC901 9 YC901 11 COM Fuser thermostat 1 Fuser thermostat 2 Fuser thermistor 1 Fuser motor STFSA STFSAN STFSB STFSBN Face up down solenoid Fuser PWB FDSOLDR EXITPAPN RCOVOPN TH2 TH1 FUSOLDR FUDR FDDR Fuser heater lamp 1 Fuser heater lamp 2 Fuser thermi...

Page 166: ...r The change guide switches the destination of paper to the face down tray or optional face up tray It also sends paper to the duplexer Figure 2 1 38Fuser unit 20 ppm printer 1 Fuser UP cover 2 Entrance guide 3 Exit guide 4 Exit UP guide 5 Fuser A stay 6 Fuser B stay 7 Fuser C stay 8 Separator plate 9 Change guide 10 Press plate 11 Exit roller 12 Exit pulley 13 Press belt rollers 14 Heat roller 15...

Page 167: ...ed unit Heat roller Press belt roller Press belt roller FUDR FDDR Fuser motor Fuser PWB Face up down solenoid Power supply PWB Engine controller PWB Exit sensor Rear cover open sensor FDSOLDR EXITPAPN RCOVOPN TH1 LIVE COM FUSOLDR Fuser heater lamp 1 Fuser thermostat 1 Fuser thermistor 1 HEAT1DR ZCROSS STFSA STFSAM STFSB STFSBN YC12 10 YC12 2 YC12 1 YC12 5 YC12 7 YC12 6 YC12 3 YC12 9 YC11 18 YC11 1...

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Page 169: ...terface with computers 2 Engine controller PWB Controls printer hardware such as high voltage bias output control paper conveying system control and fuser temperature control etc 3 Power supply PWB Generates 3 3 V DC 5V DC and 24 V DC power source Controls the fuser heater lamp 1 and 2 1 4 LED print heads relay PWB Consists the LED print head control circuit and wiring relay circuit between engine...

Page 170: ...e cover switch Shuts off 24 V power line when the left side cover is opened 25 Power switch Turns ON OFF the AC power source 26 Cassette size switch Detects the paper size dial setting of the paper setting dial 27 Feed motor Drives the paper feed section 28 Fuser motor Drives the primary transfer cleaning unit fuser unit and exit section 29 Primary transfer motor Drives the primary transfer unit 3...

Page 171: ...the temperature of the heat roller 7 Fuser thermistor 2 1 Detects the temperature of the press roller 1 8 Exit sensor Detects paper misfeed in the fuser unit 9 Rear cover open close sensor Detects the rear cover open 10 Face up down solenoid Switches the output stack between face up and face down 11 LED print head 1 2 3 4 LED print head 1 magenta LED print head 2 cyan LED print head 3 yellow LED p...

Page 172: ...2HJ 2HK 2 2 4 This page is intentionally left blank ...

Page 173: ... FET Q1 Q2 Transformer T1 Zero cross signal generation circuit Switching control circuit IC1 Fuser thermostat 1 Fuser thermostat 2 Fuser thermistor 1 Fuser thermistor 2 Fuser heater lamp 1 Fuser heater lamp 2 Triac TRA1 Triac TRA2 Photo coupler PC4 Photo coupler PC5 Photo coupler PC3 Photo coupler PC1 Photo coupler PC2 DC DC converter circuit Over voltage current detection circuit 3 3V1 ZCROSS GND...

Page 174: ...utput 17 GND Ground 18 GND Ground 19 GND Ground 20 GND Ground 21 GND Ground 22 GND Ground 23 GND Ground 24 GND Ground 25 3 3V1 O 3 3 V DC 3 3 V DC power output 26 3 3V1 O 3 3 V DC 3 3 V DC power output 27 3 3V1 O 3 3 V DC 3 3 V DC power output 28 3 3V1 O 3 3 V DC 3 3 V DC power output 29 5V1 O 5 V DC 5 V DC power output 30 5V1 O 5 V DC 5 V DC power output YC902 1 GND Ground Connected to the fuser ...

Page 175: ... driver IC U21 Clutch driver circuit Q39 Sleep mode circuit Abnormal temperature detection circuit U1 Zero cross signal Exit sensor signal Face up down solenoid control Fuser heater lamps control Fuser thermistor signals Sleep signal Address bus Micro controller U8 Flash memory U9 Address bus Data Address multiplex bus Operation panel PWB Reset IC U10 LED print heads control Main controller PWB LE...

Page 176: ...t head control video data signal LVDS 13 LVDSP1 O Analog LED print head control video data signal LVDS 14 LVDSN1 O Analog LED print head control video data signal LVDS 15 LVDSP2 O Analog LED print head control video data signal LVDS 16 LVDSN2 O Analog LED print head control video data signal LVDS 17 LVDSP3 O Analog LED print head control video data signal LVDS 18 LVDSN3 O Analog LED print head con...

Page 177: ...ection voltage input 11 TNSEN3 I Analog Toner sensor 3 yellow detection voltage input 12 ST3BN O 0 24 V DC pulse Drum motor 3 yellow energization pulse 13 TNM3DR O 0V 24V DC Toner motor 3 yellow On Off 14 ST3AN O 0 24 V DC pulse Drum motor 3 yellow energization pulse 15 24V2 O 24 V DC 24 V DC power output 16 ST3B O 0 24 V DC pulse Drum motor 3 yellow energization pulse 17 24V2 O 24 V DC 24 V DC po...

Page 178: ...t control signal Cyan On Off 4 MCH3DR O 0 24 V DC Main charger output control signal Yellow On Off 5 MCH4DR O 0 24 V DC Main charger output control signal Black On Off 6 5V1 O 5 V DC 5 V DC power output 7 HVADATD O 0 5 V DC pulse Output control D A converter serial signal 8 HVACLKD O 0 5 V DC pulse Output control D A converter clock signal 9 HVALATD O 0 5 V DC pulse Output control D A converter da...

Page 179: ...3 V DC power output 35 3 3V O 3 3 V DC 3 3 V DC power output 36 VTXDN11 I Analog LED print head control video data signal LVDS 37 VTXDN10 I Analog LED print head control video data signal LVDS 38 VTXDN9 I Analog LED print head control video data signal LVDS 39 VTXDN8 I Analog LED print head control video data signal LVDS 40 VTXCLKN I 0 3 3 V DC pulse LED print head control clock signal 41 VTXDN7 I...

Page 180: ... V DC Feed clutch On Off 7 24V2 O 24 V DC 24 V DC power output via top cover paper feed unit switch 8 MPSOLDR O 0 24 V DC MP tray feed solenoid On Off 9 5V1 O 5 V DC 5 V DC power 10 Ground 11 IDSW I Analog Toner ID sensor detection voltage S wave input 12 IDSW I Analog Toner ID sensor detection voltage P wave input 13 IDREF O Analog Toner ID sensor LED light emitting control signal 14 STFDA O 0 24...

Page 181: ...ser heater lamp 1 On Off 11 ZCROSS I 0 5 V DC pulse Zero cross signal input 12 N C 13 24V1 I 24 V DC 24 V DC power input 14 24V1 I 24 V DC 24 V DC power input 15 24V1 I 24 V DC 24 V DC power input 16 24V1 I 24 V DC 24 V DC power input 17 GND Ground 18 GND Ground 19 GND Ground 20 GND Ground 21 GND Ground 22 GND Ground 23 GND Ground 24 GND Ground 25 3 3V1 I 3 3 V DC 3 3 V DC power input 26 3 3V1 I 3...

Page 182: ...ALID UTXREADY URXACTIVE URXERR UOPMODE 1 0 ULSTATE 1 0 USUSPPEND UTERMSELUTXVALID USBDATA 15 0 UXCVRSEL VTXCLKP VTXCLKN VTXDP 11 0 VTXDN 11 0 VRXCLKP VRXCLKN VRXDP 1 0 VRXDN 1 0 DBCLK DBTXD DBRXD ECRS ECOL ETXEN ETXCLK ETXD 3 0 ERXER ERXDV ERXCLK ERXDV 3 0 EMDIO EMDC PHYIR MACLED ROMA 4 2 ROMK ROMCSN 1 0 ROMEON 0 ROMWEN 0 ROMB ROMRB ROMA 1 ROMCSN 2 ROMOEN 1 KUIOCSN 0 KUIOIORN 0 KUIOIOWN 0 KKUIORDY...

Page 183: ...Toner ID sensor Feed motor Fuser motor Operation panel PWB A0007 Engine controller PWB A0004 Drum motors cooling fan motor TCOVOP2 GND Top cover switch 2 24V2 REGCLDR 24V2 FEDCLDR 24V2 MPSOLDR Registration clutch Feed clutch MP tray feed solenoid YC462 YC461 YC460 YC463 24VF2 TNSEN2 GND 24VF2 TNSEN3 GND 24VF2 TNSEN4 GND 24VF2 TNSEN1 GND Toner sensor 2 Yellow Toner sensor 3 Cyan Toner sensor 4 Mage...

Page 184: ...VDSP4 LVDSN3 LVDSP3 LVDSN2 LVDSP2 LVDSN1 LVDSP1 LVDSN0 LVDSP0 YC401 YC402 YC651 YC17 YC3 YC1 YC2 YC5 YC11 YC4 YC6 YC9 YC15 YC8 YC12 YC13 YC10 YC16 YC7 YC14 OP24V GND OP5V PFSEL OPSCLK OPSEL0 OPSDI OPSEL1 OPSDO OPSEL2 OPRDY GND ERS1DR GND EEDATA EECLK 5V1 DA0 DA1 1 31 2 32 3 33 4 34 5 35 6 36 7 37 8 38 9 39 10 40 11 41 12 42 13 43 14 44 15 45 16 46 17 47 18 48 19 49 20 50 21 51 22 52 23 53 24 54 25...

Page 185: ...n motor 2 Ozone fan motor 1 Toner ID sensor Feed motor Fuser motor Operation panel PWB A0007 Engine controller PWB A0004 Drum motors cooling fan motor TCOVOP2 GND Top cover switch 2 24V2 REGCLDR 24V2 FEDCLDR 24V2 MPSOLDR Registration clutch Feed clutch MP tray feed solenoid YC462 YC461 YC460 YC463 24VF2 TNSEN2 GND 24VF2 TNSEN3 GND 24VF2 TNSEN4 GND 24VF2 TNSEN1 GND Toner sensor 2 Yellow Toner senso...

Page 186: ...erface KUIO LV Memory card slot YC1 YC8 YC7 GND GND GND GND 5V1 5V1P 5V1 FDPFUL 5V1 5V1P LVDSN15 LVDSP15 LVDSN14 LVDSP14 LVDSN13 LVDSP13 LVDSN12 LVDSP12 LVDSN11 LVDSP11 LVDSN10 LVDSP10 LVDSN9 LVDSP9 LVDSN8 LVDSP8 LVDSN7 LVDSP7 LVDSN6 LVDSP6 LVDSN5 LVDSP5 LVDSN4 LVDSP4 LVDSN3 LVDSP3 LVDSN2 LVDSP2 LVDSN1 LVDSP1 LVDSN0 LVDSP0 YC401 YC402 YC651 YC17 YC3 YC1 YC2 YC5 YC11 YC4 YC6 YC9 YC15 YC8 YC12 YC13 ...

Page 187: ...currence 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 114 61 mm Heat roller 20 ppm printer 113 04 mm Heat roller Press roller 16 ppm printer ...

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