magicolor 2300 Series

Service Manual

1750058-001A

Trademarks
The following are registered trademarks of MINOLTA-QMS, Inc.: QMS and the MINOLTA-QMS logo. Minolta, and PagePro are trademarks of Minolta Co., Ltd. Other product names mentioned in this guide may also be trademarks or registered trademarks of their respective owners.

Proprietary Statement
The digitally encoded software included with your printer is Copyrighted 2002 by MINOLTA-QMS, Inc. All Rights Reserved. This software may not be reproduced, modified, displayed, transferred, or copied in any form or in any manner or on any media, in whole or in part, without the express written permission of MINOLTA-QMS, Inc.

Copyright Notice
This manual is Copyrighted 2002 by MINOLTA-QMS, Inc., One Magnum Pass, Mobile, AL 36618. All Rights Reserved. This document may not be copied, in whole or part, nor transferred to any other media or language, without written permission of MINOLTA-QMS, Inc.

Manual Notice
MINOLTA-QMS, Inc. reserves the right to make changes to this manual and to the equipment described herein without notice. Considerable effort has been made to ensure that this manual is free of inaccuracies and omissions. However, MINOLTA-QMS, Inc. makes no warranty of any kind including, but not limited to, any implied warranties of merchantability and fitness for a particular purpose with regard to this manual. MINOLTA-QMS, Inc. assumes no responsibility for, or liability for, errors contained in this manual or for incidental, special, or consequential damages arising out of the furnishing of this manual, or the use of this manual in operating the equipment, or in connection with the performance of the equipment when so operated.

SAFETY .......................................................................7
Safety Precautions for Inspection and Service .................................................... 9 Warning ......................................................................................................... 9 Caution ........................................................................................................ 11 Used Batteries Precautions ......................................................................... 13 Other Precautions ........................................................................................ 14 Precautions for Service ................................................................................ 14 Safety information ........................................................................................ 18 Laser Safety Label ....................................................................................... 21 Laser Caution Label ..................................................................................... 21 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ................... 22

GENERAL ..................................................................23
Product Specifications ........................................................................................ 25 Installation Precautions ...................................................................................... 28 Installation environment ............................................................................... 28 Installation power supply ............................................................................. 28 Space requirements ..................................................................................... 29 Operation Precautions ....................................................................................... 30 Ensuring the optimum performance of this unit ........................................... 30 Operating environment ................................................................................ 30 Power supply requirements ......................................................................... 30 Other precautions ........................................................................................ 30 Parts Identification ....................................................................................... 31

MECHANICAL/ ELECTRICAL ...................................33

CROSS-SECTIONAL VIEW ............................................................................... 35 ELECTRICAL COMPONENTS LAYOUT ........................................................... 36 OPERATING SEQUENCE ................................................................................. 39 IMAGE STABILIZATION CONTROL ................................................................. 40 AIDC Detection ............................................................................................ 40 Outline of AIDC Control ............................................................................... 41 Operation Timing ......................................................................................... 42 Temperature/Humidity Sensor ..................................................................... 43 DRUM CARTRIDGE .......................................................................................... 44 PC Drum ...................................................................................................... 44 PC Drum Charging ...................................................................................... 45 LASER EXPOSURE .......................................................................................... 46 DEVELOPING UNIT .......................................................................................... 48 Developing Position ..................................................................................... 50 Toner Cartridge ............................................................................................ 51 IMAGE TRANSFER ........................................................................................... 55 Image Transfer Belt Unit .............................................................................. 55 Second Image Transfer Roller Cleaning ...................................................... 58 Image Transfer Belt Cleaning Mechanism ................................................... 59 Waste Toner Bottle ...................................................................................... 61 Waste Toner Bottle Detection ...................................................................... 61 FUSING SECTION ............................................................................................. 62 Fusing Unit ................................................................................................... 62

Fusing Temperature Control ....................................................................... 64 PAPER TAKE-UP SECTION ............................................................................. 66 Manual Feed Tray ....................................................................................... 66 Second Cassette (Option) ........................................................................... 67 OTHER MECHANISMS ..................................................................................... 68 Duplex Unit (Option) .................................................................................... 68

DISASSEMBLY/ASSEMBLY .....................................75
Disassembly/Assembly Precautions .................................................................. 77 Precautions for disassembly and assembly ................................................ 77 Parts that must not be touched ................................................................... 77 Precautions for transporting or storing PWBs ............................................. 77 Precautions for replacing PWBs .................................................................. 77 Precautions for inspecting PWBs ................................................................ 77 Precautions for transporting or storing the PC drum (drum cartridge) ........ 78 Precautions for handling the PC drum (drum cartridge) .............................. 78 Maintenance Schedule ...................................................................................... 79 Disassembly Procedures ................................................................................... 80 Pre-disassembly preparation ....................................................................... 82 Disassembly ...................................................................................................... 84 Removing the controller control board ........................................................ 84 Replacing the Second image transfer roller ................................................ 84 Removing the top-front cover and the top cover ......................................... 85 Removing the front door .............................................................................. 85 Removing the rear cover ............................................................................. 86 Removing the master board (PWB-A) ......................................................... 86 Power supply cooling fan motor (M4) .......................................................... 86 Removing the ventilation fan motor (M6) .................................................... 87 Removing the left-side cover ....................................................................... 87 Removing the power unit (PU) .................................................................... 87 Removing the AIDC sensor (AIDC) ............................................................. 88 Removing the high voltage unit (HV) ........................................................... 88 Remove the Belt cleaner separation solenoid (SL4) ................................... 89 Remove the Rack motor (M2) ..................................................................... 90 Removing the main motor assembly (M1) ................................................... 91 Removing the Manual feed tray .................................................................. 92 Removing the paper empty sensor ............................................................. 92 Removing the front cover ............................................................................ 93 Removing the right-side door ...................................................................... 93 Removing the fusing unit ............................................................................. 94 Disassembling the fusing unit...................................................................... 95 Removing the fusing cooling fan motor (M5) ............................................... 97 Replacing the paper take-up roller .............................................................. 97 Replacing the paper-separating roller ......................................................... 98 Removing the print head unit (PH) .............................................................. 99 Remove the Manual feed take-up solenoid (SL1) ..................................... 100 Replacing the Second paper take-up roller of the Second paper cassette (optional) 101

Removing the relay control board (PWB-A) for the Second paper cassette 101 Removing the relay control board (PWB-A) for the duplex unit (optional) . 102 Removing the transport sensor .................................................................. 102 Removing the turnover motor and the transport motor .............................. 103 Others .............................................................................................................. 104 Replacing the EEPROM ............................................................................ 104 Cleaning the paper take-up roller .............................................................. 105 Cleaning the paper Second paper take-up roller for the Second paper cassette 105 Cleaning the laser lens cover .................................................................... 105

CONTROL PANEL / SERVICE MODE DESCRIPTIONS 107

Control Panel Descriptions ............................................................................... 109 Names of control panel parts and their functions ...................................... 109 Display screens ......................................................................................... 110 Menu Contents ................................................................................................. 113 Print menu over view ................................................................................. 113 Settings menus .......................................................................................... 114 Service Mode ................................................................................................... 116 Service mode displays ............................................................................... 116 Entering the service mode ......................................................................... 116 Service mode options ................................................................................ 116

TROUBLESHOOTING .............................................117
Introduction ...................................................................................................... 119 Checking the electrical components .......................................................... 119 Paper Misfeeds ................................................................................................ 122 Perform initial check procedures ............................................................... 122 Paper misfeed displays .............................................................................. 123 Wiring diagram of misfeed-detecting sensors ............................................ 124 Misfeed detection timing and remedies ..................................................... 125 Malfunctions and Warnings .............................................................................. 129 Malfunction detection timing and remedies ............................................... 130 Power supply malfunctions ........................................................................ 135 Image Quality Troubleshooting ........................................................................ 136

INDEX ......................................................................139

SAFETY

1.

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. Depending on the model, some of the precautions given in the following do not apply. Different markings are used to denote specific meanings as detailed below.

WARNING
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION
The following graphic symbols are used to give instructions that need to be observed. Used to call the service technician attention to what is graphically represented inside the marking (including a warning). Used to prohibit the service technician from doing what is graphically represented inside the marking. Used to instruct the service technician to do what is graphically represented inside the marking.

1-1.

Warning

WARNING
1. Always observe precautions. Parts requiring special attention in this product will include a label containing the mark shown on the left plus precautionary notes. Be sure to observe the precautions. Be sure to observe the Safety Information given in the Operators Manual. 2. Before starting the procedures, be sure to unplug the power cord. This product contains a high-voltage unit and a circuit with a large current capacity that may cause an electric shock or burn. The product also contains parts that can jerk suddenly and cause injury. If this product uses a laser, laser beam leakage may cause eye damage or blindness.

WARNING
3. Do not throw toner or the toner bottle into a fire. Do not throw toner or the Toner Bottle (Imaging Cartridge, Toner Cartridge) into a fire. Toner expelled from the fire may cause burns. 4. Use the specified parts. For replacement parts, always use the genuine parts specified in the manufacturers parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possible electric shock or fire. Replace a blown electrical fuse or thermal fuse with its corresponding genuine part specified in the manufacturers parts manual. Installing a fuse of a different make or rating could lead to a possible fire. If a thermal fuse blows frequently, the temperature control system may have a problem and action must be taken to eliminate the cause of the problem. 5. Handle the power cord with care and never use a multiple outlet. Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock. Do not use a multiple outlet to which any other appliance or machine is connected. Be sure the power outlet meets or exceeds the specified capacity. 6. Be careful with the high-voltage parts. A part marked with the symbol shown on the left carries a high voltage. Touching it could result in an electric shock or burn. Be sure to unplug the power cord before servicing this part or the parts near it. 7. Do not work with wet hands. Do not unplug or plug in the power cord, or perform any kind of service or inspection with wet hands. Doing so could result in an electric shock. 8. Do not touch a high-temperature part. A part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is energized. Touching them may result in a burn. Wait until these parts have cooled down before replacing them or any surrounding parts.

10

WARNING
9. Maintain a Grounded Connection at all times. Connect the power cord to an electrical outlet that is equipped with a grounding terminal. 10. Do not remodel the product. Modifying this product in a manner not authorized by the manufacturer may result in a fire or electric shock. If this product uses a laser, laser beam leakage may cause eye damage or blindness. 11. Restore all parts and harnesses to their original positions. To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed. To promote safety, make sure that all tubing and other insulating materials are returned to their original positions. Make sure that floating components mounted on the circuit boards are at their correct distance and position off the boards.

1-2.

Caution

CAUTION
1. Precautions for Service Jobs. A star washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire. When reassembling parts, make sure that the correct screws (size, type) are used in the correct places. Using the wrong screw could lead to stripped threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury. Take great care to avoid personal injury from possible burrs and sharp edges on the parts, frames and chassis of the product. When moving the product or removing an option, use care not to injure your back or allow your hands to be caught in mechanisms.

11

CAUTION
2. Precautions for Servicing with Covers and Parts Removed. Wherever feasible, keep all parts and covers mounted when energizing the product. If energizing the product with a cover removed is absolutely unavoidable, do not touch any exposed live parts and use care not to allow your clothing to be caught in the moving parts. Never leave a product in this condition unattended. Never place disassembled parts or a container of liquid on the product. Parts falling into, or the liquid spilling inside, the mechanism could result in an electric shock or fire. Never use a flammable spray near the product. This could result in a fire. Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors. Always use the interlock switch actuating jig to actuate an interlock switch when a cover is opened or removed. The use of folded paper or some other object may damage the interlock switch mechanism, possibly resulting in an electric shock, injury or blindness. 3. Precautions for the Working Environment. The product must be placed on a flat, level surface that is stable and secure. Never place this product or its parts on an unsteady or tilting workbench when servicing. Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time. Avoid dusty locations and places exposed to oil or steam. Avoid working positions that may block the ventilation ports of the product. 4. Precautions for Handling Batteries. (Lithium, Nickel-Cadmium, etc.) Replace a rundown battery with the same type as specified in the manufacturers parts manual. Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst. Dispose of used batteries according to the local regulations. Never dispose of them at the users premises or attempt to try to discharge one. 5. Precautions for the Laser Beam. (Only for Products Employing a Laser) Removing the cover marked with the caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover. If removing this cover while the power is ON is unavoidable, be sure to wear protective laser goggles that meet specifications. Make sure that no one enters the room when the machine is in this condition. When handling the laser unit, observe the Precautions for Handling Laser Equipment. 6. Precautions for storing the toner or imaging cartridge. Be sure to keep the toner or imaging cartridge out of the reach of children. Licking the imaging cartridge or ingesting its contents is harmful to your health.

12

1-3.

Used Batteries Precautions

ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturers instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ. Entsorgung gebrauchter Batterien nach Angaben des Herstellers. France ATTENTION Il y a danger dexplosion sil y a remplacement incorrect de la batterie. Remplacer uniquement avec une batterie du mme type ou dun type quivalent recommand par le constructeur. Mettre au rebut les batteries usages conformment aux instructions du fabricant. Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering. Udskiftning m kun ske med batteri af samme fabrikat og type. Levr det brugte batteri tilbage til leverandren. Finland, Sweden VAROlTUS Paristo voi rjht, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hvit kytetty paristo valmistajan ohjeiden mukaisesti. VARNING Explosionsfara vid felaktigt batteribyte. Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera anvnt batteri enligt fabrikantens instruktion. Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri. Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten. Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

13

1-4.

Other Precautions

When handling circuit boards, observe the HANDLING of PWBs. The PC Drum is a very delicate component. Observe the precautions given in HANDLING OF THE PC DRUM because mishandling may result in serious image problems. Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.

1-5.

Precautions for Service

When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply. 1. Precautions Before Service When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads. Never disturb the LAN by breaking or making a network connection, altering termination, installing or removing networking hardware or software, or shutting down networked devices without the knowledge and express permission of the network administrator or the shop supervisor. 2. How to Use this Book DIS/REASSEMBLY, ADJUSTMENT To reassemble the product, reverse the order of disassembly unless otherwise specified. TROUBLESHOOTING If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit. All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions. The procedures preclude possible malfunctions due to noise and other external causes. 3. Precautions for Service Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged. After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions. Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged motor or locking mechanism. If the product is to be run with the front door open, make sure that the toner hopper is in the locked position. Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit.

14

4. Precautions for Dis/Reassembly Be sure to unplug the copier from the outlet before attempting to service the copier. The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears. Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet. Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed. While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses. Never use flammable sprays near the copier. A used battery should be disposed of according to the local regulations and never be discarded casually or left unattended at the users premises. When reassembling parts, make sure that the correct screws (size, type) and toothed washer are used in the correct places. 5. Precautions for Circuit Inspection Never create a closed circuit across connector pins except those specified in the text and on the printed circuit. When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the GND wire. 6. Handling of PWBs During Transportation/Storage During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature. When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity. Do not touch the pins of the ICs with your bare hands. Protect the PWBs from any external force so that they are not bent or damaged. During Inspection/Replacement Avoid checking the IC directly with a multimeter; use connectors on the Board. Never create a closed circuit across IC pins with a metal tool. Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet. When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board. When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB. Note that replacement of a PWB may call for readjustments or resetting of particular items. 7. Handling of Other Parts The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.

15

8. Handling of the PC Drum Only for Products Not Employing an Imaging Cartridge. During Transportation/Storage Use the specified carton whenever moving or storing the PC Drum. The storage temperature is in the range between 20C and +40C. In summer, avoid leaving the PC Drum in a car for a long time. Handling Ensure that the correct PC Drum is used. Whenever the PC Drum has been removed from the copier, store it in its carton or protect it with a Drum Cloth. The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. Do not scratch the surface of the PC Drum. Do not apply chemicals to the surface of the PC Drum. Do not attempt to wipe clean the surface of the PC Drum. If, however, the surface is contaminated with fingerprints, clean it using the following procedure. A. Place the PC Drum into one half of its carton.

1076D001

1076D002

B. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. Turn the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum. Turn the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned. At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping.

16

C. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times. Never move the Pad back and forth.
1076D003

D. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropriate for cleaning.

1076D004

NOTES Even when the PC Drum is only locally dirtied, wipe the entire surface. Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. If dirt remains after cleaning, repeat the entire procedure from the beginning one more time.

9. Handling of the Imaging Cartridge Only for Products Employing an Imaging Cartridge. During Transportation/Storage The storage temperature is in the range between 20 C and +40 C. In summer, avoid leaving the Imaging Cartridge in a car for a long time. Handling Store the Imaging Cartridge in a place that is not exposed to direct sunlight. Precautionary Information on the PC Drum Inside the Imaging Cartridge Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. Do not scratch the surface of the PC Drum. Do not attempt to wipe clean the surface of the PC Drum.

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1-6.
(1)

Safety information
Laser Safety

This is a digital machine certified as a class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual. (2) Internal Laser Radiation semiconductor laser Maximum average radiation power(*) Wavelength *:Laser power in surface of the PC Drum This product employs a Class 3b laser diode that emits an invisible laser beam. The laser diode and the scanning polygon mirror are incorporated in the print head unit. The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit should not be opened under any circumstances. 4.68 W 770-795 nm

Laser Aperture of the Print Head Unit

C4131o001AA

This figure shows the view inside the Top Cover with the Toner Cartridge and the Drum Cartridge removed.

18

the U.S.A., Canada (CDRH Regulation) This machine is certified as a Class I Laser product under Radiation Performance Standard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of the U.S. Department of Health and Human Services (DHHS). This means that the device does not produce hazardous laser radiation. The label shown to page 13 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States.
.

CAUTION Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. semiconductor laser Maximum power of the laser diode Wavelength All Areas CAUTION Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. semiconductor laser Maximum power of the laser diode Wavelength Denmark ADVARSEL Usynlig laserstrling ved bning, nr sikkerhedsafbrydere er ude af funktion. Undg udsttelse for strling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene. halvlederlaser Laserdiodens hjeste styrke blgelngden 5 mW 770-795 nm 5 mW 770-795 nm 5 mW 770-795 nm

19

Finland, Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT

VAROITUS! Laitteen kyttminen muulla kuin tss kyttohjeessa mainitulla tavalla saattaa altistaa kyttjn turvallisuusluokan 1 ylittvlle nkymttmlle lasersteilylle. puolijohdelaser Laserdiodin suurin teho aallonpituus 5 mW 770-795 nm

VARNING! Om apparaten anvnds p annat stt n i denna bruksanvisning specificerats, kan anvndaren utsttas fr osynlig laserstrlning, som verskrider grnsen fr laserklass 1. halvledarlaser Den maximala effekten fr laserdioden vglngden 5 mW 770-795 nm

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttomlle lasersteilylle. l katso steeseen.

VARNING! Osynlig laserstrining nr denna del r ppnad och sprren r urkopplad. Betrakta ej strien. Norway ADVERSEL Dersom apparatet brukes p annen mte enn spesifisert i denne bruksanvisning, kan brukeren utsettes fr unsynlig laserstrlning, som overskrider grensen for laser klass 1. halvleder laser Maksimal effekt till laserdiode blgelengde 5 mW 770-795 nm

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1-7.

Laser Safety Label

A laser safety label is attached to the outside of the machine as shown below.

for 120V

for 220 - 240V

4131o003AA

1-8.

Laser Caution Label

A laser caution label is attached to the inside of the machine as shown below.

C4131s005AA

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1-9.

PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the printer OFF. If the job requires that the printer be left ON, take off your watch and ring and wear laser protective goggles. A highly reflective tool can be dangerous if it is brought into the laser beam path. Use utmost care when handling tools on the users premises.

22

GENERAL

23

1.
(1)
Type

Product Specifications
Printer
Desktop full-color laser beam printer Electrophotographic (two-part imaging cartridge) Laser diode and polygon mirror scanning 600 dpi (dots/inch) A5T, B5T, A4, Letter, Legal Plain paper (60-90 g/m2), recycled paper, overhead projector transparencies, letterheads, envelopes (Monarch, Com-10, DL, C5, C6, Youkei -0, Youkei -1, Youkei -4, Youkei -6), label sheets, thick paper (91-163 g/m2), government-standard postcards, postcard sheets, and return postcards Black-and-white printing: 14 sec. Color printing: 25 sec. Black-and-white printing: 16 pages/min. (for A4- or Letter-size pages) Color printing: 4 pages/min. (for A4- or Letter-size pages) Within 180 seconds (at a room temperature of 23 C and at the rated voltage) 101.78 mm/sec. 1-way system (maximum 2-way)*1 Manual feed tray (200 sheets of plain paper) 2nd paper cassette (500 sheets of plain paper) *1Expandable to 2-way system by installing the optional 2nd paper cassette

Printing method Exposure method Print resolution Media sizes

Media types

First-page print time

Multi-page print speed

Warm-up time System speed Paper feed-in method

Paper feed-out method Drum-charging method Developing method Image transfer method PC drum PC drum cleaning method Paper separation method Fusing method Dimensions Weight Weight (consumables) Rated power supply voltage Frequency Maximum power consumption Operating noise

Face-down (tray capacity: 200 sheets) Comb electrode scorotron charger Single-element developing system Transport image transfer system OPC (Organic Photoconductor) Blade system Curvature separation + charge-neutralizing system Heated roller fusing system 356 mm (W) x 500 mm (D) x 392 mm (H) 25 kg (without drum cartridge and toner cartridges) 2.8 kg (drum cartridge and toner cartridges) 100 V / 120V / 220-240 V 50/60 Hz 1100 W or less (100/120 V) 1100 W or less (220-240 V) During stand-by: 39 dB (A) or less During printing: 54 dB (A) or less (color printing) 54 dB (A) or less (black-and-white printing)

Operating environment

10-35 C 15 - 85%

25

Drum cartridge life Toner cartridge life (purchased separately) Toner cartridge life (enclosed cartridge) Options

45,000 pages (black/white ratio=5%) 4,500 pages (black/white ratio=5%) 1,500 pages (black/white ratio=5%) Black: 1,500 pages (black/white ratio=5%) Color: 1,500 pages (color/white ratio for each color=5%) Second paper cassette Duplex unit

(2)

Second paper cassette (Option)

Second paper cassette Plain paper (16 to 24 lbs.; 60-90 g/m2), recycled paper (16 to 24 lbs., 60-90 g/m2) A4, Letter 500 sheets Paper separator system Supplied by main unit (DC24 V 10%) Supplied by main unit 380 mm (W) x 511 mm (D) x 176 mm (H) (including the height of the right-side door) 5.3 kg

Name Paper Media sizes Paper cassette capacity Paper separation mechanism Power source Drive source Dimensions Weight

(3)

Duplex unit
Duplex unit Plain paper (16 to 24 lbs.; 60-90 g/m2) A4, Letter Color printing: 2.0 pages/min. (A4- or Letter-size pages) Black-and-white printing: 5.0 pages/min. (A4- or Letter-size pages) A4/LetterT: 2 pages (including the paper path of the paper feedout section) Center baseline Supplied by main unit (DC24 V 10%) Supplied by main unit 97 mm (W) x 340 mm (D) x 330 mm (H) (including the height of the right-side door) 2.0 kg

Name Paper Media sizes Print speed (double-sided printing)

Document feeding capacity Paper transfer baseline Power source Drive source Dimensions Weight

26

(4)
CPU

Controller (PWB-P)
D8405 200MHz Standard ROM: 4MB Standard RAM: 32MB Ethernet (10/100BASE-TX, RJ-45) IEEE1284 (Compatible/Nibble/ECP/EPP) USB Type B connector

Memory configuration Standard I/F

Network protocol Network print service

TCP/IP DHCP, ARP/ICMP, BOOTP, SLP, IPP, HTTP, SNMP, LPR RAW Port Printing (9100) IPP1.0 (http://Printer IP address/ipp.cgi) LPD (Queue Name: lp, LP, default, DEFAULT)

Resolution Printer Driver

600 x 600 dpi, 1200 x 600 dpi, 2400 x 600 dpi OS: Windows 95/98/Me, Windows NT4.0, Windows 2000, Windows XP

Compatible clients: PC CPU Hard disk free space IBM PC or compatible CPU clock of 300 MHz or more recommended Minimum 36 MB 20 MB: Printer drive/Status display 16 MB: Image processing area RAM At least 16 MB (Windows 95/98/NT4.0) At least 32 MB (Windows Me) At least 64 MB (Windows 2000 Professional) At least 128 MB (Windows XP Home Edition/Professional) browser Either of the following browsers is required to use PageScope Light. Netscape Navigator Ver. 4.7 or later Internet Explorer ver5.0

27

2.
2-1.

Installation Precautions
Installation environment

To ensure safety and prevent possible malfunctions, install the unit in a location that meets the following requirements. A location that is not exposed to extremely high or low temperatures and not exposed to extremely high or low humidity. A location that is not exposed to extreme changes in temperature or humidity. A location that is not exposed to direct sunlight. A location out of the direct airflow of an air conditioner, heater or ventilation opening. A well-ventilated location that is not extremely dusty. A stable and level location that is not subjected to undue vibrations. A location that is not near room heaters or any other heat-generating appliances. A location away from volatile, combustible material (such as paint thinner or gasoline). A location that is not exposed to water or other liquids and where a short circuit of the unit is not likely. A location that does not put people in the direct airflow of exhaust from the unit. A location where ammonia gases are not generated.

2-2.

Installation power supply

If other electrical equipment are plugged into the same electrical outlet, make sure that the current capacity is not exceeded. Use a power source with as little voltage fluctuations as possible. Only use an outlet expander or a table tap; never use extension cords. Be careful that the unit does not pinch or is not placed on top of power or transmission cords of other electrical equipment. Periodically check that the following conditions are met. The power supply plug does not feel unusually warm. The power supply cord is free of cracks and scratches. The power supply plug is securely inserted into the electrical outlet. Pressure is not applied to the power supply cord.

28

2-3.

Space requirements

In order to reduce the risk of electric shock in the event of a short circuit, the ground wire must be connected. Attach the ground wire to the ground terminal of the electrical outlet or to a ground connection that complies with local electrical standards. Never connect the ground wire to a gas pipe, a telephone ground connection, a lightning rod or a water pipe, otherwise a fire or electric shock may occur.

20.2 in. (512 mm)

14.1 in. (357 mm) 27.8 in. (705 mm)

4131o103AA

5.9 in. (150 mm)

19.7 in. (500 mm)

11.8 in. (300 mm)

27.6 in. (700 mm)

29

28.0 in. (712 mm)

C4131o105AA

3.
3-1.

Operation Precautions
Ensuring the optimum performance of this unit

Never place heavy objects on the unit or subject it to shocks. Make sure that the power supply plug is securely inserted into the electrical outlet. Never remove secured panels or open doors of the unit while it is printing. Never turn off the unit while it is printing. Always provide good ventilation when using the unit for a long period of time within a confined area. Never use combustible sprays near the unit. If the unit becomes unusually warm or generates an unusual noise, immediately turn it off, and then unplug the power supply cord. Never turn on the unit at the same time that the power supply cord is being plugged in. When unplugging the power supply cord, always grasp the plug, not the cord. Never bring magnetized objects near the unit. Never place vases or other containers filled with water on the unit. Be sure to turn off the unit if it is not to be used for a long period of time or if a power outage occurs. Never allow metal objects such as paper clips or staples to fall into the unit or any of its openings.

3-2.

Operating environment

In order to ensure proper operation of the unit, make sure that the operating environment meets the following conditions. Temperature: 10-35 C Humidity: 15-85%Rh Temperature fluctuation: 10 C per hour Humidity fluctuation: 20%Rh per hour

3-3.

Power supply requirements

In order to ensure proper operation of the unit, make sure that the power supply meets the following conditions. Voltage fluctuation 10% of the specified voltage Frequency fluctuation 3 Hz%

3-4.

Other precautions

When servicing a machine equipped with a laser beam, observe the following precautions. When servicing parts in the path of the laser beam (near the print head or PC drum), be sure to first unplug the power supply cord of the unit. When you are required to service the unit with the power supply cord plugged in, be sure to strictly observe the following precautions. 1. Before performing any service procedures, be sure to remove any reflective accessories such as watches and rings, and wear laser protective goggles. 2. Be sure that nobody is nearby while you perform the service operations. 3. Do not bring highly reflective tools into the path of the laser beam.

30

3-5.

Parts Identification

4131o001AA

4 2

4131o106AA

1 5

4131g002AA

4131g003AA

6 7

8
4131g004AA 4131o107AA

1. 2. 3. 4. 5. 6. 7. 8. 9.

Manual feed tray Power switch Image transfer belt unit Waste toner bottle Drum cartridge Toner cartridge Right-side door release lever Duplex unit (optional) Second paper cassette (optional)

31

32

MECHANICAL/ ELECTRICAL

33

1.

CROSS-SECTIONAL VIEW
3 4 5 2 6

7 1

C M

K Y

10
4131M001AA

1. 2. 3. 4. 5. 6.

Toner Cartridge Rack PC Drum Image Transfer Belt Unit Exit Roller Fusing Roller Second Image Transfer Roller 7. Synchronizing Roller

8. Transport Roller 9. Paper Take-Up Roll 10. Second Paper Take-Up Roll

Paper Path The printer has a Multi-Purpose (MP) Cassette capable of holding up to 200 sheets of paper. The paper feeding becomes a two-way system by mounting an optional Second Cassette. The paper taken up by the Paper Take-Up Roll is transported by the Transport Roller, Synchronizing Roller, Second Image Transfer Roller, Fusing Roller, and the Exit Roller and fed out of the printer.

35

2.
(1)

ELECTRICAL COMPONENTS LAYOUT

Printer

36 35 33 31 30 29 28 27 26 32 34

37 38 1

5 6

7 8 9 10 11 12

25 24 23 13 21 20 14 19 18 17 16 15
4131D002AA

22

36

1. Fusing Roller Heater Lamp (H1) 2. Fusing Pressure Roller Heater Lamp (H2) 3. Thermistor (TH1) 4. Thermostat (TS1) 5. Second Image Transfer Roller Pressure Contact Solenoid (SL5) 6. Fusing Cooling Fan Motor (M5) 7. Synchronizing Roller Solenoid (SL3) 8. Fusing Paper Loop Detecting Sensor (PC11) 9. Transport Roller Solenoid (SL2) 10. Right Door Switch (S3) 11. Paper Transport Sensor (PC12) 12. Waste Toner Bottle Set Switch (S5) 13. Second Image Transfer Roller Pressure Positioning Sensor (PC7) 14. Waste Toner Full Detecting Sensor (PC6) 15. OHP Detecting Sensor (PC3A) 16. Synchronizing Roller Sensor (PC2) 17. Laser Safety Switch (S4) 18. Front Door Switch (S2) 19. Manual Feed Paper Empty Sensor (PC1) 20. Manual Feed Paper Take-Up Solenoid (SL1) 21. Temperature/Humidity Sensor (HS1) 22. Power Unit (PU) 23. Power Switch (S1) 24. Toner Cartridge Detecting Sensor (PC8) 25. High Voltage Unit (HV) 26. Rack Home Position Sensor (PC4) 27. Belt Cleaner Separation Solenoid (SL4) 28. Rack Clutch (CL1)

29. Belt Cleaner Positioning Sensor (PC9) 30. Rack Motor (M2) 31. AIDC Sensor (AIDC) 32. Main Motor (M1) 33. Master Board (PWB-A) 34. Power Supply Cooling Fan Motor (M4) 35. Ventilation Fan Motor (M6) 36. Fusing Paper Loop Solenoid (SL6) 37. Print Head Unit (PH) 38. Exit Sensor (PC10)

37

(2)

Controller

4131M039AA

Symbol U18 U26, U27, U28, U29 CON4 CN1 U3 CN3 U12 CN5 U21 U6 U5 CON1 CN2 CPU

Item

Explanation Destiny D8405 200 MHz controller control CPU 8-MB memory chip, a total of 32 MB standard memory 68-pin SD-RAM add-on memory (128, 256 MB, PC100/ 133 CL3) 10/100Base-T Ethernet RJ45 connector Ethernet Controller USB connector USB Controller IEEE1284 Parallel Connector Parallel buffer System data storage ROM (4 MB) JBIG compressed image processing Controller Panel expansion connector Engine Controller connector 1. Not Used (Always OFF) Not Used (Always OFF) ON: A4, OFF: Letter ON: A4, OFF: Letter 2. 3. 4.

SDRAM Expansion slot Connector IC Connector IC Connector IC IC ASIC Connector Connector

SW1

Dip SW

CR7 CR10 CN6

LED LED Connector

For 5 V voltage check For 3.3 V voltage check Video signal connector

38

3.

1 2
Print Request

3 1

Polygon Motor (M3)

Image Transfer Belt Positioning Sensor (PC5)

FD Scanning Signal (/TOD)

Main Motor (M1)

Rack Motor (M2)

PC Drum Charge Output

Exposure Output

Synchronizing Roller Sensor (PC2)

Conditions: A4 plain paper, full color printing

OPERATING SEQUENCE

39
Retraction Pressure Retraction Pressure Retraction

Synchronizing Roller Solenoid (SL3)

Transport Roller Solenoid (SL2)

First Image Transfer Output

Second Image Transfer Output Pressure

Second Image Transfer Roller Pressure Contact Solenoid (SL5)

Belt Cleaner Separator Solenoid (SL4)

4131M043AA

Manual Feed Paper Take-Up Solenoid (SL1)

1. Outside image area illumination 2. Y development 3. M development

4. C development 5. Bk development 6. Paper trailing edge voltage

4.

IMAGE STABILIZATION CONTROL

he printer provides the image stabilization control as detailed below to ensure stabilized print image.
Purpose Control AIDC control Control (Sensor) AIDC Sensor (AIDC detection)

To stabilize image density To stabilize gradation

To stabilize image transTemperature/Humidity SenImage transfer output control sor fer

4-1.

AIDC Detection

The amount of toner sticking to the Image Transfer Belt is measured and color reproducibility is stabilized.
Amount of Toner Sticking Large Small Intensity of Light Reflected Low High Output Small Great

1. A light-emitting diode is used to emit infrared rays that illuminate the toner pattern on the Image Transfer Belt. 2. The photo receiver detects the intensity of the infrared light reflected off the toner pattern on the Image Transfer Belt. 3. A voltage corresponding to the intensity of the reflected light is output to the Master Board (PWB-A).

AIDC Sensor

4004M532AA 4131M002AA

40

4-2.

Outline of AIDC Control

The following AIDC controls are provided to ensure image stabilization.

Control Description

Ds correction control LED intensity adjustment control

Sets the developing bias. Adjusts the intensity of the LED light.

Belt surface (on which no Used for corrections for the laser intensity and cortoner sticks) reflection factor rection control. measurement control Solid image toner amount control Laser intensity adjustment control correction control (1) Ds correction control Maintains a given amount of toner sticking to the surface of the PC Drum. Ensures constant reproduction of black and white lines. Adjusts the intensity of the laser light to ensure a constant amount of toner consumed. Makes a gradation correction by means of the controller

Sets a developing bias optimum for not producing a fog or uneven density. (2) LED intensity adjustment control Adjusts the intensity of the LED light to ensure a constant output value provided by the AIDC Sensor for a surface of the Image Transfer Belt, to which no toner sticks, thereby controlling variations in characteristics caused by change with time and contamination of the sensor. (3) Belt surface (on which no toner sticks) reflection factor measurement control Measures variations in the reflection factor caused by change with time of the Image Transfer Belt for use for corrections in the laser intensity control and correction control. (4) Solid image toner amount control Adjusts the pulse width ratio of the developing bias to keep constant the amount of toner sticking to the surface of the PC Drum for a 100% solid image. (5) Laser intensity adjustment control Adjusts the intensity of the laser light to ensure constant reproduction of black and white lines and constant toner consumption characteristics with changes in characteristics of PC Drum, developing, and drum charging and in durability. (6) correction control Makes a gradation correction by producing a pattern on the Image Transfer Belt, measuring the image density of the pattern with the AIDC Sensor, and sending the measurement results to the controller.

41

4-3.

Operation Timing

A specific function of image stabilization control is carried out as required according to the situation.
Operating Timing Processing

When a new Image Transfer Belt is detected When a new Drum Cartridge or Toner Cartridge is detected When the environment changes When 1,000 printed pages have been produced*1 When 200 printed pages have been produced*2 When the processing is commanded from the Control panel

Ds correction control -> LED intensity adjustment control -> Belt surface reflection factor measurement control -> Solid image toner amount control -> Laser intensity adjustment control -> correction control Solid image toner amount control -> Laser intensity adjustment control -> correction control

correction control

1: When 1,000 printed pages have been produced after A has been performed last. 2: When 200 printed pages have been produced after A and B have been performed last.

42

4-4.

Temperature/Humidity Sensor

The output voltage is determined based on the value calculated through ATVC control by the Temperature/Humidity Sensor (environment).

Temperature/Humidity Sensor (HS1)

4131M038AA

Temperature Data

ATVC Control

Humidity Data

Master Board (PWB-A)

4131m029AA

High Voltage Unit (HV)

Second Image Transfer Bias

43

5.
5-1.

DRUM CARTRIDGE
PC Drum

The photoconductive drum used in this printer is the organic photo conductor (OPC) type. This is the PC Drum consisting of the Charge Generating Layer and the Charge Transport Layer applied to an aluminum alloy base. Handling Precaution The PC Drum exhibits light fatigue after being exposed to light for a long time, which results in its sensitivity being changed.Always wrap the drum, therefore, in the PC Drum Cloth or a soft cloth immediately after it has been removed from the printer. Use utmost care to protect the surface of the PC Drum from contamination. Charge Transport Layer Charge Generating Layer Aluminum

1167M007AA 1139M007AA

Grounding of the PC Drum The PC Drum ground point is located inside, and in the rear of, the PC Drum. It is in constant contact with the Drum Holding Shaft. When the Drum Cartridge is installed in the printer, the Drum Holding Shaft contacts the ground plate in the printer. This provides for assured grounding of the PC Drum through the ground point, Drum Holding Shaft, and ground plate to the frame of the printer. Ground Plate Ground Plate PC Drum

4131M044AA

Drum Holding Shaft

44

5-2.

PC Drum Charging

The PC Drum Charge Corona employs a comb electrode Scorotron charger system. It generates corona emission to deposit a charge evenly across the surface of the PC Drum through a grid mesh. he comb electrode ensures that a charge is concentrated on the grid mesh, thus reducing the amount of ozone produced.

Comb Electrode Charger

PC Drum

Grid Mesh

4131M004AA

Drum Charge Corona Bias

Charge Bias

4131M045AA

45

6.

LASER EXPOSURE

An electrostatic latent image is formed on the surface of the PC Drum by a laser light emitted from the print head.

Polygon Motor (M3)

PC Drum

4131M005AB

(1)

FD Direction (vertical scanning direction)

The Polygon Motor and Main Motor are energized by the PRINT signal, which starts a paper take-up sequence. The printing action in the FD direction is started when the Image Transfer Belt Positioning Sensor is activated. (2) CD Direction (horizontal scanning direction)

The printing action in the CD direction is started by the SOS signal sent from the Laser Control Board.

46

(3)

Print Area

The figure below shows the print area in the FD and CD direction.

/HSYNC /VIDEO Void Image Width: 4 mm /VIDEO /TOD

CD Direction: 208 mm 80 ms

Void Image Width: 4 mm

4131M046AA

FD Direction: 345 mm

47

7.
(1)

DEVELOPING UNIT
Toner Cartridge Rack

When printing in each of the four different colors of toner, the Toner Cartridge Rack is rotated to bring the Toner Cartridge of the corresponding color of toner (K, Y, M, or C) to the developing position. (2) Drive for the Toner Cartridge Rack The Toner Cartridge Rack is driven by the Rack Motor (M2) and Rack Clutch. Toner Cartridge Rack Toner Cartridge PC Drum

Direction of Rotation

Developing Roller

4131M047AA

Developing Roller Drive Gears

4131M048AA

48

(3)

Drive for the Developing Roller

The Developing Roller is driven by the Rack Motor (M2) and the Developing Roller Drive Gears. When the Toner Cartridge Rack is stopped at the developing position, the Developing Roller is rotated by a drive from the Rack Motor (M2) transmitted with the Developing Roller Drive Gears.
Rack Motor (M2) Developing Roller

Rack Clutch (CL1)

4131M022AA

49

7-1.
(1)

Developing Position
Toner Cartridge Rack Stop Position for Development

The stop position for development of each Toner Cartridge is determined by the Rack Lock Lever and the Rack Home Position Sensor (PC4). The Toner Cartridge Rack rotates and the Rack Lock Lever drops into a stopping cutout. This unblocks the Rack Home Position Sensor (PC4), thus determining the stop position for the Toner Cartridge for the current use. (2) Toner Cartridge Rack Standby Position The standby position (reference position) of the Toner Cartridge Rack is 20 ahead of the developing stop position of the black Toner Cartridge. When the Toner Cartridge Rack rotates and the Rack Lock Lever moves past the black position detection cutout (PC4: blocked -> unblocked), the rotating speed of the rack is decelerated. Rack Home Position Sensor (PC4)

Rack Lock Lever

Rack Home Position Sensor (PC4) Rack Lock Lever Black Stopping Cutout

Yellow Stopping Cutout

PC Drum

Magenta Stopping Cutout

Black Position Detection Cutout

4131M049AA

Cyan Stopping Cutout

50

7-2.
(1)

Toner Cartridge
Construction

The Toner Cartridge is constructed as illustrated below. 4 5

4131M050AA

4131M051AA

1. 2. 3. 4. 5.

Toper Hopper Toner Agitating Plate Toner Transport Roller Developing Roller PC Drum

6. First Regulator Blade 7. Second Regulator Blade 8. Bias Seal

51

(2)

First Regulator Blade / Second Regulator Blade

Regulates the amount of toner supplied to the Developing Roller. (3) Developing Roller Carries toner, whose amount has been regulated by the Regulator Blades. (4) Developing Bias Applied to the Developing Roller to ensure that an adequate amount of toner is fed to the PC Drum. (5) Toner Empty Detection Toner consumption is calculated from image data for toner empty detection. When a toner-empty condition is detected, the corresponding message is displayed on the control panel. (6) Bias Seal Recovers toner that has not stuck to the PC Drum. 2 1 6 7

7 5 6

4131m010

3 1 4 8

4131M007AA

4
4131M008AA

1. 2. 3. 4. 5.

Developing Roller PC Drum First Regulator Blade Second Regulator Blade Regulator Blade Bias

6. Developing Bias 7. Developing Seal Bias 8. Bias Seal

52

(7)

Toner Cartridge Installation Detection

Toner Cartridge installation detection is made with the Toner Cartridge Detection Sensor (PC8) and the Reflector in the Toner Cartridge.
Intensity of Light Reflected

Detection Method

No Cartridge installed Cartridge installed

NO YES

Reflector

Reflector
VCC

CPU GND
4131M039AA

PC8

4131M040AA

53

(8)

Detection of a brand new Cartridge 1. A brand new Cartridge is installed.

2. The Front Door is closed. Then, the Power Switch is turned ON. 3. The Toner Cartridge Rack is rotated to bring the Toner Cartridge at the developing position. 4. The Toner Cartridge Detection Sensor(PC8) detects whether or not the Toner Cartridge is installed. 5. The Toner Cartridge Detection Sensor judges that no Toner Cartridge is installed, since no light reflection is made with the Reflector placed under the Cover in the brand new Toner Cartridge. 6. Toner Cartridge, which is detected as not installed, is stopped at the developing position. Then, the Developing Roller is rotated. 7. The Reflector placed under the Cover is pushed out in the Toner Cartridge with a rotation of the Developing Roller. The Toner Cartridge Detection Sensor detects that the Toner Cartridge is installed with the light reflection from the Reflector 8. Other Toner Cartridges are stopped at the developing position respectively. If the Cartridge is a brand new, sequences from 4 through 7 are repeated for each Color Toner Cartridge. According to the above-mentioned sequential operation, the Toner Cartridge is detected as a brand new one.

No Toner Cartridge Installed

Toner Cartridge Installed Reflector

4131M041AA

4131M042AA

54

8.
8-1.
(1)

IMAGE TRANSFER
Image Transfer Belt Unit
Construction 1

4131M053AA

3 1. 2. 3. 4. (2) Image Transfer Belt Cleaning Blade Waste Toner Conveying Coil First Image Transfer Roller

5. Drive Roller 6. Second Image Transfer Roller

Drive Train 1

4131M009AA

1. Main Motor (M1)

2. Drive Roller

55

(3)

First Image Transfer

The first image transfer bias is applied to the First Image Transfer Roller to transfer the toner image on the surface of the PC Drum onto the Image Transfer Belt.
First Image Transfer Roller Image Transfer Belt First Image Transfer Bias

4131M054AA

PC Drum

(4)

Second Image Transfer

The second image transfer bias is applied to the Second Image Transfer Roller to transfer the toner image on the Image Transfer Belt onto the paper. The residual charge left on the paper is neutralized by the Charge Neutralizer.
Drive Roller Charge Neutralizing Bias (Self Bias) Charge Neutralizer

4131M055AA

Second Image Transfer Roller

Second Image Transfer Bias

56

(5)

Second Image Transfer Roller Pressure/Retraction

The Second Image Transfer Roller is pressed against, and retracted from, the Image Transfer Belt by a cam on the printer side that is turned as the Second Image Transfer Roller Pressure Contact Solenoid (SL5) is energized or de energized. When the Second Image Transfer Roller Pressure Contact Solenoid (SL5) is energized, the cam on the printer side turns, causing the Pressure Lever to move the Second Image Transfer Roller away from the Image Transfer Belt. The pressure and retracted positions are detected by the Second Image Transfer Roller Pressure Positioning Sensor (PC7).

Second Image Transfer Roller Pressure Contact Solenoid (SL5) Second Image Transfer Roller

Drive Roller Second Image Transfer Roller Spring Pressure Lever Second Image Transfer Roller Pressure Positioning Sensor Cam

4131M010AA

When Retracted

4131M056AA

When Pressed
4131M057AA

(6)

Second Image Transfer Roller Pressure/Retraction Timing

Pressed Retracted Before the paper reaches the Second Image Transfer Roller After the trailing edge of the paper has moved past the Second Image Transfer Roller

57

8-2.

Second Image Transfer Roller Cleaning

A reverse bias is applied to the Second Image Transfer Roller to remove any residual toner left on the roller. The residual toner is transferred onto the Image Transfer Belt and then recovered by the Cleaning Blade. (1) Operating Timing After the lapse of a given period of time during pre drive. After the paper moves past the Second Image Transfer Roller when a media error occurs. Before the second image transfer ATVC

4131M037AA

58

8-3.
(1)

Image Transfer Belt Cleaning Mechanism

Image Transfer Belt Cleaning Blade

The Cleaning Blade is used to scrape any residual toner off the surface of the Image Transfer Belt.
Image Transfer Belt Positioning Sensor (PC5) Cam

Belt Cleaner Separation Solenoid (SL4)

4131M011AA

Cleaning Blade Opposing Roller

Cleaning Blade

4131M058AA

59

(2)

Image Transfer Belt Cleaning Blade Retraction

The Image Transfer Belt Cleaning Blade is retracted from the Opposing Roller by a cam on the printer side that turns as the Belt Cleaner Separation Solenoid (SL4) is energized or de energized. The cam on the printer side is made into direct contact with the Cleaning Blade housing so that the Cleaning Blade is retracted. The Image Transfer Belt Cleaning Blade is detected at its retracted position when the cam turns to deactivate the Belt Cleaner Positioning Sensor (PC9).

4131M059AA

Main Motor (M1) Belt Cleaner Positioning Sensor

ON OFF

Pressure Pressure
ON OFF

Belt Cleaner Separation Solenoid (SL4)

Retraction * In color printing

4131M030AA

60

8-4.

Waste Toner Bottle

Waste toner on the PC Drum and the Image Transfer Belt is collected. The waste toner sticking to the surface of the PC Drum is scraped off by the Cleaning Blade and conveyed by the Waste Toner Conveying Coil. The waste toner left on the surface of the Image Transfer Belt is scraped off by the Image Transfer Belt Cleaning Blade and conveyed by the Waste Toner Conveying Coil.
Cleaning Blade Waste Toner Conveying Coil

4131M012AA

4131M013AA

Waste Toner Bottle

8-5.
(1)

Waste Toner Bottle Detection

Waste Toner Bottle Detection

The Waste Toner Bottle Set Switch (S5) detects whether or not the Waste Toner Bottle is installed in the printer. (2) Waste Toner Full Detection The Waste Toner Full Detecting Sensor (PC6) detects that the Waste Toner Bottle is full of waste toner. A waste toner full condition is detected when waste toner in the Waste Toner Bottle blocks the sensor.

Waste Toner Full Detecting Sensor (PC6)

Waste Toner Bottle Set Switch (S5)

4131M014AA

61

9.
9-1.
(1)

FUSING SECTION
Fusing Unit
Overview

Toner transferred onto the paper through the image transfer process is permanently fixed onto the paper. The fusing system employed in the printer is a heat roller method, in which the Fusing Roller heated by a heater lamp is pressed against the Fusing Pressure Roller and, by feeding the paper between these two rollers, toner is fused onto the paper.

4 3 7

5
4131M015AA

1. 2. 3. 4. 5.

Fusing Roller Fusing Pressure Roller Thermistor (TH1)) Thermostat (TS1) Fusing Roller Heater Lamp (H1)

6. Fusing Pressure Roller Heater Lamp (H2) 7. Pressure Spring

62

(2)

Drive

The Fusing Unit is driven by the Main Motor (M1).

Main Motor (M1)

4131M016AA

(3)

Fusing Roller Pressure

The Fusing Roller and the Fusing Pressure Roller are pressed against each other at all times. They are released for maintenance service or replacement of parts. hen a paper misfeed occurs in the Fusing Unit, the Fusing Misfeed Clearing Levers are pulled upward to release pressure between the two rollers.

Fusing Misfeed Clearing Levers

4131M017AA

63

9-2.
(1)

Fusing Temperature Control

Fusing Temperature Control Circuit

The resistance of the Thermistor (TH) mounted to the Fusing Roller varies with temperature. The higher the temperature, the smaller the resistance value. The output from the Thermistor (TH) is applied to the analog port of the CPU. When the temperature increases and the resistance of the Thermistor (TH) decreases, the input voltage to the analog port becomes smaller. The CPU monitors the output from the Thermistor and turns ON or OFF the Heater Lamp as necessary to control the temperature of the Fusing Roller. To energize the Fusing Roller Heater Lamp (H1), the CPU turns ON (LOW) the Heater Remote output signal. This turns ON the triac in the Power Unit, which allows an AC voltage to be applied to the Fusing Roller Heater Lamp (H1) to heat it. When the temperature of the Fusing Roller runs inordinately high, the Abnormal Heater Temperature Detecting Circuit is activated to shut down power to the Fusing Roller Heater Lamp (H1).
PWB-A (Main Board)

CPU A/D Main Switch AC Input Abnormal Heater Temperature Detecting Circuit

H1 H2

Power Unit

Heater Remote On/Off

4131M060AA

64

(2)

Fusing Temperature Control

The temperature control as detailed below is provided by means of the Fusing Roller Heater Lamp (H1) and the Fusing Pressure Roller Heater Lamp (H2). The surface temperature of the Fusing Roller is converted by the Thermistor (TH1) to a corresponding electrical signal. 1. Warm-up Control The temperature during the warm-up cycle is set at 170. When the temperature of the Fusing Roller reaches this set temperature, both the Fusing Roller Heater Lamp (H1) and the Fusing Pressure Roller Heater Lamp (H2) are turned OFF. 2. Temperature Control in Standby State The temperature in the standby state is set at 171. 3. Temperature Control during Printing (monochrome printing) The temperature during printing is set as follows.
Plain paper Set temperature 157 Thick paper postcards 157 OHP transparencies 157 Envelopes 166 Small size* 152

Small size paper: Plain paper whose length is 226 mm or less 4. Temperature Control during Printing (color printing) The temperature during printing is set as follows.
Plain paper Set temperature 174 Thick paper postcards 174 OHP transparencies 166 Envelopes 166 Small size* 169

Small size paper: Plain paper whose length is 226 mm or less

180 170 160

In Standby

During Printing

Plain paper (color)

Plain paper (monochrome)

Warm-up: approx. 180 sec.

4131M061AA

65

10. PAPER TAKE-UP SECTION

10-1.
(1)

Manual Feed Tray

Paper Take-Up Mechanism

The Manual Feed Tray consists of a Paper Take-Up Roll, Paper Lifting Plate, and the Manual Feed Paper Take-Up Solenoid (SL1). When the Manual Feed Paper Take-Up Solenoid (SL1) is energized, the cam turns. At the same time, the Paper Lifting Plate raises the tray and the paper on the tray is taken up by the Paper Take-Up Roll and fed into the printer. (2) Paper Empty Detection There is the Manual Feed Paper Empty Sensor (PC1) provided on the underside of the Manual Feed Tray. It detects a paper-empty condition of the Manual Feed Tray. When there is paper, the actuator is lowered to unblock the sensor. When there is no paper, the actuator is raised to block the sensor.
Manual Feed Paper Take-Up Solenoid (SL1)

4131M019AA

Manual Feed Paper Empty Sensor (PC1)

Main Motor Image Transfer Belt Positioning Sensor

ON OFF

Manual Feed Paper Take-Up Solenoid (SL1)

ON OFF
4131m031AA

* In color printing

66

10-2.
(1)

Second Cassette (Option)

Paper Take-Up Mechanism

Since there is no drive motor installed, the drive for paper take-up and transport (supplied from M1) is transmitted through a drive coupling gear from the printer. The same paper take-up mechanism is employed as that of the Multi-Purpose Cassette, except that paper separator fingers are used, instead of the separator roll with a torque limiter, for paper separation. The 2nd Drawer Take-Up Solenoid (SL7) is controlled from the printer through the 2nd Drawer Control Board (PWB-A) of the Second Cassette. (2) Paper Empty Detection A paper-empty condition is detected by the 2nd Drawer Paper Empty Sensor (PC16). When there is paper, the actuator is raised to block the sensor. When there is no paper, the actuator is lowered to unblock the sensor.
2nd Drawer Paper Near-Empty Sensor (PC14)

2nd Drawer Take-Up Solenoid (SL7)

4131M020AA

2nd Drawer Paper Empty Sensor (PC16)

(3)

2nd Drawer Paper Near-Empty Sensor (PC14)

A paper near-empty condition is detected by the 2nd Drawer Paper Near-Empty Sensor. A paper near-empty condition is equivalent to the following number of sheets of paper left in the cassette.
Specifications Near-empty detection 50 +/- 25 sheets

67

11. OTHER MECHANISMS

11-1.
(1)

Duplex Unit (Option)

Drive

Drive for the Duplex Unit works as follows. The paper having a printed image on its one side is temporarily fed toward the Exit Tray and, as soon as the trailing edge of the paper moves past the guide plate before the Exit Roller, the Exit Roller is turned backward so that the paper is fed into the Duplex Unit. Drive for the Exit Roller is disconnected from the printer when the Duplex Unit is mounted on the printer and, instead, it is provided by the Duplex Unit Turnover Motor of the Duplex Unit. The Transport Rollers of the Duplex Unit are driven by the Duplex Unit Transport Motor. The paper is transported to the printer by the Transport Rollers.

Duplex Unit Turnover Motor (M8)

Duplex Unit Transport Motor (M7)

Transport Rollers

Duplex Unit Transport Sensor (PC17)

4131M021AA

68

(2)

Paper Feeding Method

1. Operations in 2-sided printing with a single sheet of paper resident in, and circulated through, the system (1) Paper is taken up and fed in and the image on page 2 of the original is printed.

4657M521AA

(2)

The paper is temporarily fed toward the exit section and, immediately before the paper leaves the Exit Roller, the direction of rotation of the Exit Roller is switched.

2
(3)

The paper is transported into the Duplex Unit.

4657M522AA

(4)

The paper in the Duplex Unit is temporarily stopped at the Duplex paper take-up position.

4657M523AA

69

(5)

The image on page 1 of the original is printed on the paper that is taken up from the Duplex Unit.

(6)

The first paper is fed out of the printer.

4657M524AA

Steps from (2) to (6) are hereafter repeated.

70

2. Operations in 2-sided printing with two sheets of paper resident in, and circulated through, the system (1) The first sheet of paper is taken up and fed in and the image on page 2 of the original is printed.

4657M515AA

(2)

The first sheet of paper is temporarily fed toward the exit section and, immediately before the paper leaves the Exit Roller, the direction of rotation of the Exit Roller is switched.

2
(3) (4)
4657M516AA

The first sheet of paper is transported into the Duplex Unit. At the same time, the second sheet of paper is taken up and fed in.

(5)

The first sheet of paper in the Duplex Unit is temporarily stopped at the Duplex paper takeup position.

4 2
(6)

The image on page 4 of the original is printed on the second sheet of paper.

4657M517AA

(7)

The first sheet of paper is taken up from the Duplex Unit. The second sheet of paper is temporarily fed toward the Exit Tray and, immediately before the paper leaves the Exit Roller, the direction of

(8)

rotation of the Exit Roller is switched.

4657M518AA

71

(9)

The image on page 1 of the original is printed on the first sheet of paper.

(10) The second sheet of paper is transported into the Duplex Unit.

2
4657M519AA

(11) At the same time that the first sheet of paper is

2 1

fed out of the printer, the image on page 3 is printed on the second sheet of paper.

4
4657M526AA

(12) At the same time that the second sheet of

4 2 1 3 3

paper is fed out of the printer, the third sheet of paper is taken up and fed in and the image on page 6 is printed on the third sheet of paper.

4657M527AA

Steps from (2) to (12) are hereafter repeated.

72

3. Operations in 2-sided printing with two sheets of paper resident in the system and with a new sheet of paper taken up when a printed page with images printed on both sides is fed out (1) The first sheet of paper is taken up and fed in and the image on page 2 of the original is printed. (2) The first sheet of paper is temporarily fed toward the exit section and, immediately before the paper leaves the Exit Roller, the direction of rotation of the Exit Roller is switched. (3) (4)
4657M528AA

The first of paper is fed in the duplex unit. At the same time that the second sheet of paper is taken up and page4 is printed.

(5)

The first sheet of paper is stopped at take-up position. The second sheet of paper is fed in exit section.

(6)

4657M529AA

(7)

The image on page1 of the original is printed on the first sheet of paper. The second sheet of paper is immediately before the paper leaves the Exit Roller, the direction of rotation of the Exit Roller is switched.

(8)

2
4657M530AA

(9)

The second sheet of paper fed in the duplex unit.

73

2 1

(10) The first sheet of paper fed out in exit tray. (11) At the same time the third sheet of paper is taken up and fed in. (12) The second of sheet of paper stopped at takeup position.

4 6

4657M531AA

(13) The image on page3 is printed on the second sheet of paper.

2 1

(14) The third sheet of paper is immediately before the paper leaves the Exit Roller the direction of rotation of the Exit Roller is switched. (15) The third sheet of paper fed in the Duplex Unit.

4
4657M532AA

(16) The second sheet of paper fed out in Exit Tray.

4 2 1 8 6 3

(17) At the same time the fourth sheet of paper is taken up and red in. (18) The third sheet of paper stopped at take-up position.

4657M532AA

Steps from (13) to (18) are hereafter repeated.

74

DISASSEMBLY/ASSEMBLY

75

19971

12. Disassembly/Assembly Precautions

12-1. Precautions for disassembly and assembly
Be sure to unplug the power cord from the electrical outlet before attempting to service the printer. To reassemble the unit, reverse the order of disassembly unless otherwise instructed. If it is necessary to run the unit with its covers removed, use extreme care not to allow your fingers or clothing to be caught in drive or rotating parts (such as gears, rollers or motors). Never touch the terminals of electrical components or high-voltage parts (such as the power unit or the high voltage unit). Be careful when working around the fusing unit since it remains hot for a while after the unit is turned off. Wait until the unit has cooled before starting to disassemble it. Be sure that the unit is turned off before plugging in or unplugging connectors. Never plug in or unplug a connector that is energized. In addition, when plugging in or unplugging connectors, be sure to grasp the connector housing. Never pull on the wires, otherwise faulty contacts may result. Be sure to use fuses of the specified rating. To ensure electrical conduction, be sure to attach the ground wire or ground plate. In addition, be sure to use the indicated screws with toothed washers as instructed.

12-2.

Parts that must not be touched

Removal, disassembly or adjustment of the parts listed below must not performed. Print head unit (disassembly or adjustment) Parts with mounting screws that are painted red.

12-3.

Precautions for transporting or storing PWBs

The following precautions must be observed when handling circuit boards. During transportation or while in storage, circuit boards must be placed in conductive cases or on conductive mats and must not be unnecessarily removed. (Do not wrap the circuit boards in plastic or paper bags.) Do not store or place circuit boards in a location where it will be exposed to direct sunlight. When it becomes necessary to remove a circuit board from its conductive case or mat, do not place where it can easily be subjected to static electricity (such as on carpet or on plastic or vinyl bags).

12-4.

Precautions for replacing PWBs

Generally, the unit or the assembly should be replaced. When unplugging connectors from the circuit board, make sure that the power supply cord has been unplugged from the electrical outlet. When removing a circuit board from its conductive bag or case or when replacing the circuit board, be sure to hold the board by its edges, making sure not to touch pins of the ICs or the printed pattern.

12-5.

Precautions for inspecting PWBs

Avoid checking ICs directly with a multimeter; use connectors on the circuit board. Never create a closed circuit across IC pins with a metal tool. When it is necessary to touch ICs and other electrical components on the circuit board, be sure to first ground yourself.

77

12-6.

Precautions for transporting or storing the PC drum (drum cartridge)

Use the specified carton when transporting or storing the drum cartridge. Do not store or place drum cartridges in a location where it will be exposed to direct sunlight. The storage temperature should be between -20 C to +40 C.

12-7.

Precautions for handling the PC drum (drum cartridge)

Since the PC drum is extremely sensitive to light fatigue and takes a long time to recover its sensitivity, never leave the protective cover open or expose the PC drum to direct sunlight for long periods of time. Be very careful not to contaminate the surface of the PC drum with fingerprints, oil or chemicals. Do not allow the surface of the PC drum to be scratched.

78

13. Maintenance Schedule

Replacement cycle(Continuous printing) Approx. 45,000 pages*1(black and white) Approx. 11,250 pages*1(color) Approx. 4,500pages Approx. 1,500 pages Replacement cycle(Intermittent printing) Approx. 15,000 pages*1(black and white) Approx. 7,500 pages*1(color) Approx. 4,500 pages Approx. 1,500 pages Approx. 1,500 pages Reference page

Part name

Cleaning cycle

Drum cartridge

None

D-6

Toner cartridge (purchased separately) Toner cartridge (enclosed) Second image transfer roller

None

D-7

None None

Approx. 1,500 pages Approx. 120,000 pages Approx. 210,000 pages*1(black and white) Approx. 52,500 pages*1(color) Approx. 120,000 pages Approx. 25,000 pages(black and white)

D-7 D-8

Image transfer belt unit

None

Approx. 70,000 pages*1(black and white) Approx. 35,000 pages*1(color)

D-6

Fusing unit

None

D-16

Waste toner bottle Paper take-up roller Paper take-up roller of the Second paper cassette Laser lens cover

None

D-6

When a paper feed-in error occurs Perform as necessary

Replace if an error occurs.

D-19, 23

D-27

The drum cartridge, toner cartridge and waste toner bottle can generally be replaced by the user.

79

14. Disassembly Procedures

(1) Disassembly procedure chart (3-2) Waste toner bottle Drum cartridge Toner cartridge Image transfer belt unit

(4-3) Top-front cover, top cover (4-4) Front door (4-5) Rear cover

(4-2) Second image transfer roller

(4-1) Controller control board

(4-6) Master Board (PWB-A) (4-7) Power supply cooling fan (4-8) Ventilation fan motor

(4-9) Left-side cover

(4-10) Power unit (4-11) AIDC sensor

(4-18) Front cover

(4-12) High voltage unit (4-15) Main motor (4-16) Manual feed Tray

(4-13) Belt cleaner separation solenoid (4-14) Rack motor (4-17) Paper empty sensor (PC1) (4-21) Fusing Roller Fusing Pressure Roller Heater lamps (H1 & H2) Thermostat (TS1) (4-24) Paper-separating roller

(4-19) Right-side door

(4-20) Fusing unit (4-22) Fusing cooling fan motor (4-23) Paper take-up roller (4-25) Print head Unit (4-26)

Manual feed paper take-up solenoid

80

Second Paper Cassette

(4-27) Second Paper Take-up roller

(4-28) Master Board (PWB-A)

Duplex unit (4-29) Master Board(PWB-A) (4-30) Transport sensor (4-31) Turnover motor (4-32) Transport motor

81

14-1.

Pre-disassembly preparation

Before disassembling the machine, the following units need to be removed. Waste toner bottle Drum cartridge Toner cartridges (4 colors) Image transfer belt unit

1. Open the front door. 2. Remove the waste toner bottle.

4131o023AA

3. Remove the drum cartridge.

4131o027AA

4. Remove the image transfer belt unit. (2 screws) Note When replacing the transport image transfer belt unit, be sure to remove the packing material. Do not touch the image transfer belt with your bare hands.

4131D061AA, 4131D062AA

82

5. Remove all toner cartridges. (1) From the display, select the menu Engine. (2) (3) Select Replacing Toner. Select the toner color of the cartridge to be removed, and then press the Select key to move the cartridge to the removal position.
4131o017AA

4131D003AA

4131D064AA 4131D063AA

1 Toner cartridge 2 Drum cartridge

3 Waste toner bottle 4 Image transfer belt unit

83

15. Disassembly
15-1. Removing the controller control board
1. Loosen the 9 screws for the protective cover of the controller control board, and then remove the protective cover. (2 screws)

4131D057AA

2. Unplug connector CN6 from the controller control board. Unplug the video interface (PJ45) from the controller. 3. Remove the controller control board (PWB-P). (7 screws)

4131D055AB

15-2.

Replacing the Second image transfer roller

1. Open the right-side door. 2. While opening the bushing levers (white) on both ends of the Second image transfer roller to the outside, pull the image transfer roller toward you, and then remove it from the Second image transfer roller holder.

4131D004AA

84

15-3.

Removing the top-front cover and the top cover

1. Open the front door and the right-side door. 2. Remove the top-front cover. (loosen 3 screws)

4131D006AA

3. Remove the top cover. (5 screws)

4131D007AB

15-4.

Removing the front door

1. Remove the top-front cover. 2. Remove the front door.

4131D008AA

85

15-5.

Removing the rear cover

1. Loosen the 9 screws for the protective cover of the controller control board, and then remove the protective cover. (2 screws) 2. Remove the rear cover. (8 screws). Note: If the top cover has been removed, 6 screws will be removed in step 2.

4131D005AB

15-6.

Removing the master board (PWB-A)

1. Remove the rear cover. (8 screws) 2. Remove the wiring from the cable holders. 3. Unplug all 27 connectors, and then remove the master board (PWB-A). (5 screws).

4131D009AA

To replace the Master board, refer to page D-26.

15-7.

Power supply cooling fan motor (M4)

1. Open the right-side door. 2. Remove the top-front cover, top cover and the rear cover. 3. Unplug connector PJ5 from the master board (PWB-A), and then remove the wiring from the cable holders. 4. Remove the power supply cooling fan motor. (2 screws).

4131D010AA

86

15-8.

Removing the ventilation fan motor (M6)

1. Open the right-side door. 2. Remove the top-front cover, top cover and the rear cover. 3. Unplug connector PJ6 from the master board (PWB-A), and then remove the wiring from the cable holders. 4. Remove the ventilation fan motor. (2 screws)

4131D012AA

15-9.

Removing the left-side cover

1. Open the right-side door. 2. Remove the top-front cover and the top cover. 3. Remove the left-side cover. (3 screws)

4131D011AA

15-10. Removing the power unit (PU)

1. Open the right-side door. 2. Remove the top-front cover, top cover and the leftside cover. 3. Remove the protective cover. (3 screws)

4131D013AA

4. Remove the wiring from the 3 cable holders. 5. Remove the power unit. (3 screws, 5 connectors and 3 holders)

4131D014AB

87

15-11. Removing the AIDC sensor (AIDC)

1. Remove the top-front cover, top cover, left-side cover and the power unit. 2. While keeping away from the seal, remove the AIDC sensor. (2 screws and 1 connector)

4131D015AA

15-12. Removing the high voltage unit (HV)

1. Open the right-side door. 2. Remove the top-front cover, top cover, rear cover, left-side cover, controller protective cover and the controller control board. 3. Remove the controller box. (7 screws)

4131D016AA

4. Remove the high voltage unit (HV). (4 screws, 3 connectors and 2 holders)

4131D017AA

88

15-13. Remove the Belt cleaner separation solenoid (SL4)

1. Open the right-side door. 2. Remove the top-front cover, top cover, rear cover, left-side cover, controller protective cover, controller box, and the high voltage unit. 3. Remove the belt cleaner separation solenoid. (1 screw and 1 connector)

4131D068AA

89

15-14. Remove the Rack motor (M2)

1. Open the right-side door. 2. Remove the top-front cover, top cover, rear cover, left-side cover, controller protective cover, controller box, high voltage unit, and the belt separation solenoid. Use a permenant marker to scribe both the plug and jack for easy reinstallation. 3. Remove the inside of the cam (1 E-clip) them remove the rack drive assy. (5 screws)
4131D069AA

4. Disconnect the electrical connections to the rack clutch, belt cleaner positioning sensor, and the rack home position sensor. 5. Remove the rack clutch shaft them remove the drive gear. (1 E-clip)

4131D070AA

6. Remove the rack motor. (2 screws)

4131D071AA

Note: Manually turn the misfeed clearing dial counterclockwise if the image transfer belt unit does not fully seat after this procedure is completed. Sometimes the belt cleaning separation cam can be out of place, thus blocking full seating of the image transfer belt unit.
C4131O065AA

90

15-15. Removing the main motor assembly (M1)

1. Remove the rear cover, master board (PWB-A) and the controller box. 2. Remove the wiring from the cable holders, and then remove the assembly cover. (2 screws)

4131D018AA

3. Remove the fusing paper loop solenoid (SL6). (1 screw)

4131D019AA

4. Remove the main motor assembly. (4 screws)

4131D020AA

91

15-16. Removing the Manual feed tray

1. Remove the top-front cover, top cover, front door and the left-side cover. 2. Remove the switch box. (3 screws)

4131D021AA

3. Remove the manual feed tray. (1 E-clip)

4131D022AB

15-17. Removing the paper empty sensor

1. Remove the top-front cover, top cover, front door, left-side cover, switch box and and the manual feed tray. 2. Use a mini screwdriver to remove the trays lower cover. (2 screws)

4131D023AA

3. Remove the sensor mounting bracket, and then unplug the connector (1). 4. Remove the paper empty sensor.

4131D024AA

92

15-18. Removing the front cover

1. Remove the top-front cover, top cover and the front door. 2. Remove the top cover. (9 screws)

4131D026AA

15-19. Removing the right-side door

1. Remove the front door, controller protective cover, rear cover and the front cover. 2. Remove the right-rear cover. (2 screws)

4131D025AA

3. Unplug the connectors (PJ16, PJ17 and PJ29) from the master board (PWB-A), and then remove the wiring from the cable holders. 4. Open the right-side door, and then while supporting it with your hand, remove the screw and the 2 E-clips.

4131D027AA

5. Remove the shaft, and then remove the right-side door.

4131D028AA

93

15-20. Removing the fusing unit

1. Remove the top-front cover, top cover, and then open the right-side door. 2. Remove the fusing unit cover. (2 screws)

4131D014AB

3. Unplug the connectors from the power unit, and then remove the wiring from the cable holders. 4. Remove the fusing unit. (2 screws and 2 connectors)

4131D033AA

94

15-21. Disassembling the fusing unit

1. Remove the cover. (2 screws)

4131D050AB

2. Remove the Fusing roller heater lamps (H1) and Fusing Pressure roller heater lamp(H2). (6 screws) Notes for installation Be sure to install the screws securing the leads in the correct locations.

4131D051AA

3. Remove the release lever, the pre-fusing guide plate and the post-fusing guide plate. (2 screws)

4131D052AA

4. Remove the thermostat (TS1). (2 screws)

4131D053AB

95

5. Remove the fusing roller and the fusing pressure roller. (1 screw, 1 E-clip and 1 C-clip)

4131D054AA

Notes for installation When installing the fusing roller and the fusing pressure roller, install them with the specified misalignment. Standard: 3 mm or less

3mm or less

3mm or less

Fusing pressure roller Fusing roller

4131D060AA

96

15-22. Removing the fusing cooling fan motor (M5)

1. Remove the rear cover. 2. Unplug the connectors (PJ16, PJ17 and PJ29) from the master board (PWB-A), and then remove the wiring from the cable holders. 3. Remove the right-side door. 4. Remove the right-side door cover. (2 screws) 5. Remove the right-front cover. (1 screw)
4131D029AA

6. Remove the paper output unit. (6 screws)

4131D030AA

7. Remove the wiring from the cable holders. 8. Remove the fusing cooling fan motor. (4 screws)

4131D031AA

15-23. Replacing the paper take-up roller

1. Remove the right-side door. 2. Remove the knob, and then replace the paper take-up roller.

4131D058AA,

4131D034AA

97

15-24. Replacing the paper-separating roller

1. Remove the right-side door. 2. Remove the paper-separating roller assembly

4131D058AA,

4131D035AB

98

15-25. Removing the print head unit (PH)

1. Remove the top-front cover, top cover, rear cover, front door, front cover and the right-side door. 2. Unplug the connectors (PJ23 and PJ24) from the master board (PWB-A), and then remove the wiring from the cable holders. 3. Remove the drum units slide cover. (2 screws)

4131D037AA

4. Remove the laser lens cover. (1 screw)

4131D038AA

5. Remove the print head cover. (2 screws)

4131D039AA

6. Remove the print head unit (PH). (3 screws)

4131D040AA,

4131D041AA

99

15-26. Remove the Manual feed take-up solenoid (SL1)

1. Remove the top-front cover, top cover, rear cover, left-side cover, controller protective cover, controller box, high voltage unit and the master board. 2. Remove the Lower base plate. (11 screws)

4131D065AA

3. Remove the manual feed Assy. (5 screws)

4131D066AA

4. Remove the manual feed paper take-up solenoid. (1 screw)

4131D067AA

100

15-27. Replacing the Second paper take-up roller of the Second paper cassette (optional)
1. Separate the Second paper cassette from the printer. 2. Remove the paper take-up roller as shown in fig. 1. (c) (a). Raise the lever for the paper take-up roller. (b). Slide the paper take-up roller to the right. (c). Remove the paper take-up roller. 3. Install the new paper take-up roller by reversing the operations described in step 2

(a) (b)

Figure 1
4131D042AA, 4131D063AA

15-28. Removing the relay control board (PWB-A) for the Second paper cassette
1. Unplug the connector, and then remove the relay control board assembly for the 2nd paper cassette. (3 screws)

4131D043AA

2. Remove the cover. (1 screw) 3. Remove the relay control board for the Second paper cassette. (2 screws)

4131D044AA

101

15-29. Removing the relay control board (PWB-A) for the duplex unit (optional)
1. Separate the duplex unit from the printer. 2. Remove the protective cover for the control board. (2 screws)

4131D045AA

3. Remove the relay control board for the duplex unit. (1 screw and 3 connectors)

4131D046AA

15-30. Removing the transport sensor

1. Separate the duplex unit from the printer. 2. Remove the protective cover for the control board and the relay control board. 3. Remove the sensor mounting bracket and the transport sensor. (1 connector)

4131D047AA

102

15-31. Removing the turnover motor and the transport motor

1. Separate the duplex unit from the printer. 2. Remove the protective cover for the control board. 3. Unplug connector PJ1 from the relay control board (PWB-A) for the duplex unit. 4. Remove the cover for the duplex unit (1 screws), and then remove the wiring from the cable holders.

4131D048AA

5. Remove the turnover motor and the transport motor. (2 screws each)

4131D049AA

103

16. Others
16-1. Replacing the EEPROM

Note When replacing the master board, be sure to move the EEPROM from the old master board to the new one. 1. Remove the rear cover and the master board. 2. Replace the EEPROM.

4131D056AA

Note Be sure to install the EEPROM so that it faces the correct direction.

4131d001AA

104

16-2.

Cleaning the paper take-up roller

1. Open the right-side door. 2. Clean the paper take-up roller at the bottom of the printer by wiping it with a soft, dry cloth.

C4131o067AA,

C4131D073AA

16-3.

Cleaning the paper Second paper take-up roller for the Second paper cassette
1. Remove the Second paper cassette. 2. Clean the paper take-up roller of the Second paper cassette by wiping it with a soft, dry cloth.

4131D047AA

16-4.

Cleaning the laser lens cover

1. Open the front door, and then remove the waste toner bottle. 2. Pull out the laser lens cover.

4131o042AA

3. Clean the laser lens cover by wiping it with a soft, dry cloth.

4131o043AA

105

106

CONTROL PANEL / SERVICE MODE DESCRIPTIONS

107

1.
1-1.

Control Panel Descriptions

Names of control panel parts and their functions
1 4 5

For details, refer to the Operators Manual supplied with the unit.

6 2

C4131o015AA

9
Name Green LED indicator Orange LED indicator Cancel Key Prev. Key Up key Next Key Down Key Menu Select Key Display

7
Function/details

No. 1 2 3 4 5 6 7 8 9

Lights up to indicate that the printer is ready to print Lights up to indicate that an error has occurred Press to cancel the print job. The initial screen is displayed. Press to scroll through the menus. Press to apply the currently selected setting. Displays the status of the printer

109

1-2.
(1)

Display screens
Basic screen

The basic screen is the initial screen that appears after the unit is finished warming up and after a menu setting is cancelled.

IDLE MAGICOLOR 2300DL

C4131o001AA

(2)

Warning screen

The following appear in the warning screen according to the condition of the printer. <Malfunction display> This generally appears when a malfunction that cannot be corrected by the user has occurred. Example: Malfunction that can be indicated with malfunction code

FATAL ERROR CODE: 04H

C4131o002AA

<Error display> This appears when an error has occurred. Example: When there is a paper misfeed or a door is open

MEDIA JAM FUSER

C4131o003AA

<Caution display> This appears if printing is possible, but an error in the near future is expected. Example: The toner is empty.

TONER EMPTY BLACK

C4131o004AA

110

(3)

Message status
Message

IDLE PROCESSING PRINTING WARMING UP CALIBRATING

The printer is ready to accept data, and no jobs are in progress. The printer is processing data. The printer is printing. The printer is warming up. After 200 one-sided pages are continuously printed the printer automatically pauses to do an Auto-Image Density Control (AIDC) cycle. The printer is in energy saver mode to reduce power consumption during periods of inactivity. The media tray X (specified tray) is out of media. The optional media tray is almost out of media. Media type XXXX specified with the printer driver is different from the type of media loaded into Tray1 (multipurpose tray). The media detected in tray X (specified tray) doesnt match the media size setting. Change the media in the tray to YYYY (specified size) or change the media size setting. Media type XXXX specified with the printer driver is different from the type of media loaded into Tray1 (multipurpose tray). During printing, the specified tray YYYY has run out of the specified type of media XXXX. A misfeed occurred while media was fed from tray X (specified tray). A misfeed occurred after between the print engine and the output tray. A misfeed occurred after fuser section. A misfeed occurred in the transfer roller section. A misfeed occurred near the feeder of the duplex unit. A misfeed occurred near the media holding area of the duplex unit. The printers front door and/or right-side door are open and must be closed. The cover of the optional duplex unit is open and must be closed. The media tray is not fully inserted into the optional media feed unit (Tray2). The right-side door of the optional media feed unit (Tray2) is open. The waste toner bottle is nearly full.

ENERGY SAVER TRAYX EMPTY TRAY2 LOW SIZE MISMATCH

PUT MEDIA TRAY YYYY

PUT XXXX TRAY1

PUT XXXX YYYY MEDIA JAM TRAYX MEDIA JAM EXIT MEDIA JAM FUSER MEDIA JAM TRANSFER ROLLER MEDIA JAM DUPLEX LOWER MEDIA JAM DUPLEX UPPER

PRINTER COVER OPEN

DRAWER OPEN TRAY2 COVER OPEN TRAY2 WASTE: NEAR FULL

111

WASTE TONER BOX FULL The waste toner bottle is full. X TONER LOW DRUM LOW TONER EMPTY XXXX DRUM CARTRIDGE END OF LIFE WASTE TONER BOX NOT ATTACHED DRUM CARTRIDGE NOT ATTACHED XXXX NOT INSTALLED TRAY2 NOT ATTACHED DUPLEX UNIT NOT ATTACHED ERROR MEMORY OVERFLOW ERROR VIDEO UNDERRUN ERROR AIDC SENSOR FATAL ERROR CODE: XX ERROR COMMUNICATION ERROR RAM ERROR DIMM ERROR ROM ERROR CONTROLLER

Toner cartridge X (specified color) is low. The OPC drum cartridge is low. Toner cartridge XXXX (specified color) is empty. The drum cartridge has reached the end of its service life. The waste toner bottle is not installed. The OPC drum cartridge is not installed. Toner cartridge XXXX (specified color) is not installed properly. Tray2 was specified with the printer driver for printing, but Tray2 is not attached to the printer. Duplex printing was specified with the printer driver, but the duplex unit is not attached to the printer. The printer has received more data than can be processed by its internal memory. The amount of data to be printed exceeds the printer's internal data transmission speed. An AIDC sensor error occurred. An error has been detected with the code (X) indicated in the service message. A communication error occurred in the parallel, USB or Ethernet interface. An RAM writing/reading error occurred. A SDRAM DIMM error occurred. A ROM error occurred. An internal controller error occurred.

112

2.
2-1.

Menu Contents
Print menu over view

The following settings appear in the menus. The settings that appear in bold are the default settings.
IDLE

Select key Down key

Up key

Up key

Select key Down key

English, French, German, Italian, Portuguese, Spanish, Czech, Japanese

LANGUAGE

Prev. key Next key

SPECIAL PAGES

STATISTIC PAGE DEMO PAGE MENU MAP

A4, Letter

ENGINE

ENERGY SAVER AUTO CONTINUE CHAINING TRAY REPLACE TONER CHANGE TONER SZ ENGINE SERVICE*1

15 min, 30 min, 1 hour, 2 hour On, Off On, Off Black, Yellow, Magenta, Cyan

FACE COUNT CONTROLLER VER. ENGINE VER. DIMM TEST SDRAM TEST POWER ON TEST TRANSFER UNIT USER DEFAULT

NETWORK

IP ADDRESS SUBNET MASK GATEWAY HW ADDRESS DHCP/BOOTP HTTP SNMP

113

CONSUMABLE USAGE

BLACK TONER YELLOW TONER MAGENTA TONER CYAN TONER DRUM UNIT

1: When displayed in service mode, the Prev. key can be used to scroll through the options.

2-2.
(1)

Settings menus
Language menu

The language in which messages are displayed can be changed. (2) Special pages
Statistic Page Demo Page Menu Map A configuration page can be printed. A demonstration page can be printed. A menu chart page can be printed

(3)

Engine menu
Set the length of time until the printer enters energy saver mode after it no longer receives print jobs or is not operated. If a print job is received while the printer is in energy saver mode, the printer warms up, then returns to normal print mode before starting to print. When set to On, the printer continues printing even if the specified tray is not loaded with paper of the correct size. When set to Off, the printer stops and displays a message indicating that paper of the correct size should be loaded into the specified tray if the specified tray does not contain paper of the correct size. The Auto Continue setting can also be changed while printing. If this is done, the setting will remain valid for future print jobs. When set to On, the printer automatically switches to a different media tray containing paper of the same size and type and continues printing if the specified tray runs out of paper. When set to Off, the printer stops and displays a message indicating that paper should be loaded into the specified tray if the specified tray runs out of paper. The Chaining Tray setting can also be changed while printing. If this is done, the setting will remain valid for future print jobs. This is used when replacing the toner cartridge. By selecting the color of the toner cartridge that you wish to replace (remove), the carousel automatically stops so that the selected toner cartridge can be removed.

Energy Saver

Auto Continue

Chaining Tray

Change Toner

114

(4)

Service menu
Page Count Controller Ver. Engine Ver. DIMM Full Test SDRAM Full Test Power On Test A six-digit number indicating the number of pages that have been printed until now with this printer is displayed. The controller firmware version is displayed. The printer engine firmware version is displayed. A complete DIMM test is performed, allowing you to check that there are no errors in the DIMM. A complete SDRAM test is performed, allowing you to check that there are no errors in the SDRAM. A Power On test is performed. Wait until the test is finished and Ready is displayed. The settings for Energy Saver, Auto Continue and Chaining Tray are returned to their defaults. The default settings are listed below. Energy Saver: 30 minutes Auto Continue: On Chaining Tray: On

User Default

(5)

Network menu

If the printer is connected and used on a network, the following settings should be specified. For details about each setting, contact your network administrator.
IP Address Subnet Mask Gateway HW Address HTTP SNMP Set the IP address of this printer on the network. Using the Up, Down, Prev. and Next keys, enter the value. Set the subnet mask value of the network. Using the Up, Down, Prev. and Next keys, enter the value. If a router is used on the network, enter the IP address of the router. Using the Up, Down, Prev. and Next keys, enter the value. The Ethernet hardware address for this printer can be seen. (It cannot be changed.) This specifies whether or not PageScopeLight can be accessed. This specifies the access privileges for the MIB file. DHCP: If there is a DHCP server on the network, set whether or not the IP address is automatically assigned by the DHCP server and other network information is loaded. BOOTP: Set whether or not the IP address is automatically assigned by BOOTP and other network information is loaded. Either can be set to On or both can be set to Off.

DHCP/BOOTP

115

3.
3-1.

Service Mode
Service mode displays
FACE CONUT CONTROLLER VER. ENGINE VER. DIMM FULL TEST SDRAM FULL TEST POWER ON TEST USER DEFAULT SERVICE SERVICE PERSON RESTORE FACTORY DEFAULT SERVICE PERSON SRU USAGE RESET CONTROLLER RESET COUNTER FUSER UNIT

This mode is used to check and specify service functions.

Service

3-2.

Entering the service mode

<Procedure> 1. With the menu ENGINE selected, press the Down key. 2. Press the Prev. key until ENGINE SERVICE is displayed. 3. Press both the Select and the Down keys at the same time for at least 2 seconds. 4. With SERVICE PERSON displayed, press the Down key. <Cancelling procedure> Press the Cancel key.

3-3.
(1)

Service mode options

RESTORE FACTORY DEFAULT

Select this option to restore all settings to their defaults.

Language, Energy Saver, Auto Continue, Chaining Tray, IP Address, Subnet Mask, Gateway, DHCP/ BOOTP, All toner max life=1500, All remaining=100%, All counters, CPU counters for service, PSL admin password.

(2)

SERVICE PERSON SRU USAGE

Select this option to display the remaining service life for the image transfer belt unit and the drum unit. (3) RESET CONTROLLER Select this option to reset the controller. (4) RESET COUNTER FUSER UNIT

Select this option to reset the counter for the fusing unit.

116

TROUBLESHOOTING

117

1.

Introduction

Information required for troubleshooting and steps that must be performed are described in this chapter.

1-1.

Checking the electrical components

If a paper misfeed or malfunction occurs, perform the following operation to check the condition of the electrical components. (1)
Step 1

Sensor
Check Does the input signal of the master board change (HL, LH) when the sensor light is interrupted? Result NO YES Remedy Replace the sensor. Replace the master board.

4025T520AA

4025T521AA

(2)
Step 1

Switch
Check Does the input signal (NO) of the master board change from L to H when the switch is turned on? Result NO YES Remedy Replace the switch. Replace the master board.

COM Not Use NO

4025T523AA

119

(3)
Step

Solenoid
Check Does the output signal of the master board change from H to L when the solenoid is turned on? Result NO YES Remedy Replace the master board. Replace the solenoid.

1 2

2 1

1 2

4025T522AA

(4)
Step 1

Clutch
Check Does the output signal of the master board change from H to L when the clutch is activated? Result NO YES Remedy Replace the master board. Replace the clutch.

4025T528AA

120

(5)
Step 1

Motor
Check Does the LOCK signal switch to H when the machine goes into standby? Does the REM signal of the master board change from H to L when the motor is turned on? Result NO YES NO Remedy Replace the master board.Replace the motor. Replace the motor. Replace the master board.

GND 1 LOCK REM 2 3

4025T526AA

Step 1

Check Does the input signal of the master board change from H to L when the motor is turned on?(The input signal differs depending on the rotation direction.)

Result YES NO

Remedy Replace the motor. Replace the master board.

4025T525AA

Step

Check

Result YES

Remedy Replace the motor or the master board. Connect the connector or the print jack.

Are the relay connector of the motor and the print jack on the master board correctly connected?

NO

4025T527AA

121

2.
2-1.

Paper Misfeeds
Perform initial check procedures

If a paper misfeed occurs, first check for the following conditions. If the answer is No, perform the remedy described.
Condition to be checked Is paper within the product specifications being used? Is the paper curled, wrinkled or humid? Are there foreign objects in the transport path or is it dirty or deformed? Are the rollers dirty, deformed or scratched? Are the paper guides adjusted to the size of the paper? Is the actuator operating correctly? Remedy Change the paper. Change the paper. Instruct the user on how to store paper. Clean or replace the transport path. Clean or replace the rollers. Adjust the guides. Repair or replace the actuator.

122

2-2.

Paper misfeed displays

If a paper misfeed occurs, a message indicating the location of the misfeed appears in the display.

Control Panel Display

C4131o015AA

Display Media Jam Tray1 Madia Jam Transfer Roller Media Jam Fuser Media Jam Exit Media Jam Tray2 Media Jam Duplex Lower Media Jam Duplex Upper

Location of misfeed or location of paper Paper feed-in section of manual feed tray Second image transfer section Fusing section Paper feed-out section of main unit Feed-in section of expansion paper cassette unit Feed-in section of duplex unit Turnover section of duplex unit Storage section of duplex unit

Remedy page reference T-7 T-8 T-8 T-8 T-9 T-9 T-9 T-9

<Display reset procedure>

Paper misfeed in the main unit Paper misfeed in optional equipment Open the appropriate door, remove the misfed paper and any remaining paper, and then close the door. (For optional equipment, after removing the paper, load it again.)

123

2-3.

Wiring diagram of misfeed-detecting sensors

If the duplex unit and 2nd paper cassette are installed Exit sensor (PC10) Fusing paper loop detecting sensor (PC11)

4131M036AA

Synchronizing roller sensor (PC2)

Duplex unit transport sensor (PC17)

124

2-4.
(1)

Misfeed detection timing and remedies

Paper misfeed in the paper feed-in section of the manual feed tray (Tray1)

<Detection timing>
Category Paper misfeed detected in the paper feed-in section of the manual feed tray Paper size error detected in the manual feed tray Details If the end of the paper does not interrupt the synchronizing roller sensor (PC2) when a set amount of time has passed after the manual feed paper take-up sensor (SL1) is activated If PC2 does not pass through when a set amount of time has passed after the paper interrupts the synchronizing roller sensor (PC2)

<Remedy>
Electrical components for detection of the paper misfeed Synchronizing roller sensor (PC2) Manual feed paper take-up solenoid (SL1) Master board (PWB-A)

Step

Remedy Perform initial check procedures. Check PC2 operation. Check SL1 operation. Replace PWB-A

Reference page T-4 T-1 T-2 -

WARNING DIAGRAM Control signal PC2_ON SL1_REM Location(electrical component) 5-D 8-G -

1 2 2 3

125

(2)

Paper misfeed in the Second image transfer section

<Detection timing>
Category Details If PC2 does not pass through when a set amount of time has passed after the paper interrupts the synchronizing roller sensor (PC2) If the light is not interrupted even after the paper has passed the interruption position for the fusing paper loop detecting sensor (PC11) If the synchronizing roller sensor (PC2) is interrupted when the machine is turned on, doors and covers are opened, then closed, and paper misfeeds and malfunctions are corrected

Paper misfeed detected in the Second image transfer section

Remaining paper detected in the Second image transfer section

<Remedy>
Electrical components for detection of the paper misfeed Synchronizing roller sensor (PC2) Fusing paper loop detecting sensor (PC11) Master board (PWB-A)

Step

Remedy Perform initial check procedures. Check PC2 operation. Check PC11 operation. Replace PWB-A.

Reference page T-4 T-1 T-1 -

WARNING DIAGRAM Control signal PC2_ON PC11_ON Location(electrical component) 5-D 9-B -

1 2 3 4

(3)

Paper misfeed in the fusing section or the paper feed-out section

<Detection timing>
Category Paper misfeed detected in the paper feed-out section Remaining paper detected in the paper feed-out section Details If PC10 does not pass through when a set amount of time has passed after the paper interrupts the exit sensor (PC10) If the exit sensor (PC10) is interrupted when the machine is turned on, doors and covers are opened, then closed, and paper misfeeds and malfunctions are corrected

<Remedy>
Electrical components for detection of the paper misfeed Exit sensor (PC10) Master board (PWB-A) WARNING DIAGRAM Control signal PC10_ON Location(electrical component) 3-D -

Step 1 2 3

Remedy Perform initial check procedures. Check PC10 operation. Replace PWB-A.

Reference page T-4 T-1 -

126

(4)

Paper misfeed in the paper feed-in section of the Second paper cassette (Tray2)

<Detection timing>
Category Paper misfeed detected in the paper feed-in section Remaining paper detected in the Second paper cassette <Remedy> Electrical components for detection of the paper misfeed 2nd drawer take-up solenoid (SL7) Synchronizing roller sensor (PC2) 2nd drawer control board (PWB-A) Details If the end of the paper does not interrupt the synchronizing roller sensor (PC2) when a set amount of time has passed after the 2nd drawer take-up solenoid (SL7) is activated If the synchronizing roller sensor (PC2) is interrupted when the machine is turned on, doors and covers are opened, then closed, and paper misfeeds and malfunctions are corrected

Step

Remedy Perform initial check procedures. Check PC2 operation. Check SL7 operation. Replace PWB-A.

Reference page T-4 T-1 T-2 -

WARNING DIAGRAM Control signal PC2_ON SL7_REM Location(electrical component) 5-D 7-F -

1 2 4 5

(5)

Paper misfeed in the transport section, turnover section or storage section of the duplex unit

<Detection timing>
Category Paper misfeed detected in the turnover, storage or transport section Remaining paper detected in the transport section Details If the paper does not interrupt the duplex unit transport sensor (PC17) when a set amount of time has passed If the duplex unit transport sensor (PC17) is interrupted when the machine is turned on, doors and covers are opened, then closed, and paper misfeeds and malfunctions are corrected

<Remedy>
Electrical components for detection of the paper misfeed Duplex unit transport sensor (PC17) Duplex unit control board (PWB-A) WARNING DIAGRAM Control signal PC17_ON Location(electrical component) 7-C

Step

Remedy Perform initial check procedures. Check PC17 operation.

Reference page T-4 T-1

1 2

127

Replace PWB-A.

128

3.

Malfunctions and Warnings

The CPU performs a self-diagnosis on the condition of the unit, and if a malfunction is detected, the malfunction appears on the display. Malfunction cancelling procedure For malfunctions other than those described above, open, then close the front door or turn the unit off, then on.
Malfunction code FATAL ERROR CODE: 04H FATAL ERROR CODE: 08H FATAL ERROR CODE: 0BH FATAL ERROR CODE: 0CH FATAL ERROR CODE: 0EH FATAL ERROR CODE: 10H Detection timing Reference page T-11 T-11 T-11 T-12 T-12 T-12 T-13 T-13 T-13 T-14

If abnormal transmissions are detected in the master board (PWB-A) If the main motor (M1) does not rotate when the unit is turned on If the ventilation fan motor (M6) does not rotate when the unit is turned on If the power supply cooling fan motor does not rotate when the unit is turned on If the fusing cooling fan motor does not rotate when the unit is turned on If the polygon motor does not rotate

If there is no pressure by or separation from the FATAL ERROR CODE: 14H Second image transfer roller
FATAL ERROR CODE: 15H FATAL ERROR CODE: 16H FATAL ERROR CODE: 17H

If there is no pressure by or separation from the transfer belt cleaner If the transfer belt of the transport image transfer belt unit does not rotate If the toner cartridge does not rotate

If the unit does reach 80 C within 100 seconds from the time that warm-up begins FATAL ERROR CODE: 18H If the temperature of the fusing roller falls below FATAL ERROR CODE: 19H 70 C in 10 seconds during standby If the temperature of the fusing roller increases to 220C in 0.1 second If the temperature of the fusing roller when the fusing unit begins warming up does not remain FATAL ERROR CODE: 1AH increased by 5C for 1 second within the 40 to FATAL ERROR CODE: 1BH 50 seconds after the fusing roller begins warming up
FATAL ERROR CODE: 21H

T-14

T-15

If a overhead projector transparency is not detected

T-15

FATAL ERROR CODE: 29H FATAL ERROR CODE: 2AH If the EEPROM malfunctioned FATAL ERROR CODE: 2BH FATAL ERROR CODE: 2CH

T-15

129

3-1.
(1)

Malfunction detection timing and remedies

FATAL ERROR CODE 04H: Malfunction of the master board

If the problem cannot be corrected by the user, a service code is displayed.

<Remedy>
Components for display of the warning Master board (PWB-A) WARNING DIAGRAM Control signal Location(electrical component) -

Step 1

Remedy Replace PWB-A.

Reference page -

(2)

FATAL ERROR CODE 08H: Malfunction of the main motor

<Remedy>
Components for display of the warning Main motor (M1) Master board (PWB-A) Power unit (PU) Controller control board (PWB-P) WARNING DIAGRAM Control signal M1_REM Location(electrical component) 5-A -

Step 1 3 4 5

Remedy Check M1 operation. Replace PU. Replace PWB-A. Replace PWB-P.

Reference page T-3 -

(3)

FATAL ERROR CODE 0BH: Malfunction of the ventilation fan motor

<Remedy>
Components for display of the warning Ventilation fan motor (M6) Master board (PWB-A) Power unit (PU) Controller control board (PWB-P) WARNING DIAGRAM Control signal M6_REM Location(electrical component) 3-E -

Step 1 2 3 4

Remedy Check M6 operation. Replace PU. Replace PWB-A. Replace PWB-P.

Reference page T-3 -

130

(4)

FATAL ERROR CODE 0CH: Malfunction of the power supply cooling fan motor

<Remedy>
Components for display of the warning Power supply cooling fan motor (M4) Master board (PWB-A) Power unit (PU) Controller control board (PWB-P) WARNING DIAGRAM Control signal M4_REM Location(electrical component) 3-D -

Step 1 2 3 4

Remedy Check M4 operation. Replace PU. Replace PWB-A. Replace PWB-P.

Reference page T-3 -

(5)

FATAL ERROR CODE 0EH: Malfunction of the fusing cooling fan motor

<Remedy>
Components for display of the warning Fusing cooling fan motor (M5) Master board (PWB-A) Power unit (PU) Controller control board (PWB-P) WARNING DIAGRAM Control signal M5_REM Location(electrical component) 11-E -

Step 1 2 3 4

Remedy Check M5 operation. Replace PU. Replace PWB-A. Replace PWB-P.

Reference page T-3 -

(6)

FATAL ERROR CODE 10H: Malfunction of the polygon motor

Electrical components for detection of the malfunction

<Remedy>
Master board (PWB-A) Power unit (PU) Controller control board (PWB-P) WARNING DIAGRAM Control signal Location(electrical component) -

Print head unit

Step 1 2 3 4

Remedy Replace the print head unit. Replace PU. Replace PWB-A. Replace PWB-P.

Reference page -

131

(7)

FATAL ERROR CODE 14H: Incorrect pressure by or separation from the Second image transfer roller

<Remedy>
Electrical components for detection of the malfunction Image transfer roller pressure contact solenoid (SL2) Image transfer roller pressure positioning sensor (PC7) Master board (PWB-A) Controller control board (PWB-P) WARNING DIAGRAM Control signal PC7_ON SL2_REM Location(electrical component) 5-C 5-E -

Step 1 2 3 4 5

Remedy Check PC7 operation. Replace the Second image transfer roller pressure/separation mechanisms. Check SL2 operation. Replace PWB-A. Replace PWB-P.

Reference page T-1 T-2 -

(8)

FATAL ERROR CODE 15H: Incorrect pressure by or separation from the transfer belt cleaner

<Remedy>
Electrical components for detection of the malfunction Belt cleaner pressure contact solenoid (SL4) Belt cleaner positioning sensor (PC9) Master board (PWB-A) Controller control board (PWB-P) WARNING DIAGRAM Control signal PC9_ON SL4_REM Location(electrical component) 3-G 2-H -

Step 1 2 3 4 5

Remedy Check PC9 operation. Replace the belt cleaner pressure/separation mechanisms. Check SL4 operation. Replace PWB-A. Replace PWB-P.

Reference page T-1 T-2 -

(9)

FATAL ERROR CODE 16H: Incorrect transfer belt rotation

Electrical components for detection of the malfunction WARNING DIAGRAM Control signal Location(electrical component) -

<Remedy>

Step

Remedy Replace the image transfer belt unit.

Reference page -

132

(10) FATAL ERROR CODE 17H: Incorrect developing rack rotation <Remedy>
Electrical components for detection of the malfunction Rack motor (M2) Rack clutch (CL1) Rack home position sensor (PC4) Master board (PWB-A) Controller control board (PWB-P)

Step 1 2 3 4 5

Remedy Check PC4 operation. Check M2 operation. Check CL1 operation. Replace PWB-A. Replace PWB-P.

Reference page T-1 T-2 T-3 -

WARNING DIAGRAM Control signal PC4_ON CL1_REM Location(electrical component) 3-F 2-F 3-E -

(11) FATAL ERROR CODE 18H: Faulty warm-up detected (12) FATAL ERROR CODE 19H: Incorrect fusing roller low temperature <Remedy>
Electrical components for detection of the malfunction Fusing roller heater lamp (H1) Fusing pressure roller heater lamp (H2) Thermostat (TS1) Master board (PWB-A) Power unit (PU)

WARNING DIAGRAM Step Check Check for continuity at H1 and H2. Check for continuity at TS1. Is the resistance at TH1 infinite? (between CN18-1 and -2 on the thermistor) Result Remedy Replace H1 and H2. Replace TS1. Clean TH1 or replace the fusing unit. Replace PU. Replace PWB-A. Control signal Location(electrical component) 2-B, 2-C 2-C

1 2

NO NO YES

HEATER

2-D

NO

133

(13) FATAL ERROR CODE 1AH: Incorrect fusing roller high temperature (14) FATAL ERROR CODE 1BH: Disconnection at thermistor <Remedy>
Electrical components for detection of the malfunction Thermistor (TH1) Master board (PWB-A) Controller control board (PWB-P) WARNING DIAGRAM Step Check Result Remedy Clean TH1. 1 Is there a short circuit at TH1? (between CN18-1 and -2 on the thermistor) YES Replace the fusing unit. Replace PU. Replace PWB-A HEATER 2-D Control signal Location(electrical component)

NO

(15) FATAL ERROR CODE 21H: Malfunction of the OHP detecting sensor <Remedy>
Electrical components for detection of the malfunction OHP detecting sensor (PC3A) Master board (PWB-A) Controller control board (PWB-P) WARNING DIAGRAM Control signal PC3_REM Location(electrical component) 5-D -

Step 1 2 3

Remedy Check PC3A operation. Replace PWB-A. Replace PWB-P.

Reference page T-1 -

(16) FATAL ERROR CODE 29H: Malfunction of the EEPROM (memory counter error) (17) FATAL ERROR CODE 2AH: Malfunction of the EEPROM (memory data error) (18) FATAL ERROR CODE 2BH: Malfunction of the EEPROM (memory access error) (19) FATAL ERROR CODE 2CH: Malfunction of the EEPROM (memory recognition error) <Remedy> Electrical components for detection of the malfunction
EEPROM Master board (PWB-A) WARNING DIAGRAM Control signal Location(electrical component) -

Step 1 2

Remedy Replace the EEPROM. Replace PWB-A.

Reference page -

134

3-2.
(1)

Power supply malfunctions

No power

<Remedy>
Electrical components for detection of the malfunction Power unit (PU) Power switch (S1) Master board (PWB-A)

Step

Remedy Check if the power supply cord is connected to the main unit. Check S1 operation. Replace the power unit. Replace PWB-A.

Reference page -

WARNING DIAGRAM Control signal Location(electrical component) 2-A -

1 2 3 4

135

4.

Image Quality Troubleshooting

f an image quality problem occurs, replace the toner cartridge and drum cartridge with new ones, and then determine whether the cause of the problem is due to one of the cartridges or another part of the main unit.
Symptom Blank print Cause Faulty PC drum Remedy

Replace the drum cartridge. Replace the print head unit. Replace the master board (PWB-A). Replace the controller control board. Replace the master board (PWB-A).

Improper laser exposure

Poor developing bias

Replace the controller control board. Replace the print head. Replace the controller control board. Replace the master board (PWB-A).

0951o211 Black print Improper laser exposure

Improper charging

Replace the controller control board

0951o213 White spots Damp paper

Change the paper. Replace the Second image transfer roller. Replace the master board (PWB-A). Replace the transport image transfer belt unit.

Poor image transfer

Replace the controller control board.

0951o220

136

Symptom Toner smudges on backside of paper

Cause Dirty fusing roller Dirty image transfer roller

Remedy Replace the fusing roller. Replace the Second image transfer roller.

Dirty paper transport path

Clean the paper transport path.

0951o226 No toner in toner cartridge Low image density Faulty PC drum (end of service life) Replace the toner cartridge. Replace the drum cartridge. Replace the master board (PWBA). Replace the controller control board. Replace the Second image transfer roller. Replace the master board (PWBA). Replace the transport image transfer belt unit. Replace the controller control board. Replace the master board (PWBA). Replace the controller control board.

Poor developing bias

Poor image transfer

0951o214 Foggy background Poor developing bias

Faulty PC drum (end of service life)

Replace the drum cartridge.

0951o218

137

Symptom White/Black lines and bands

Cause Scratched PC drum

Remedy Replace the drum cartridge. Replace the print head unit. Replace the master board (PWBA).

Defective print head Replace the controller control board.

0951o222 Offset image Defective fusing roller Replace the fusing roller. Replace the Second image transfer roller.

Faulty image transfer roller

Replace the image transfer belt unit.

0951o219

138

INDEX

139

A
AIDC Control 41 AIDC Detection 40

B
Belt Cleaning 59 Belt Cleaning Blade 59 Belt Cleaning Blade Retraction 60 Belt Unit 55 Black print 136 Blank print 136

C
CDRH Regulation 19 Charging 45 Cleaning laser lens cover 105 paper take-up roller 105 Second paper take-up roller 105 Comb electrode 45 Control Panel Description Cancel Key 109 Menu Select Key 109 Control Panel Descriptions 109 Controller 38

D
DEVELOPING UNIT 48 Developing Unit Developing Position 50 Developing Roller 49 Drive 48 Rack Standby Position 50 Rack Stop Position 50 Toner Cartridge 51 Toner Cartridge Installation Detection 53 Toner Cartridge Rack 48 Dimensions 25 Disassembling the fusing unit 95 Disassembly Procedures 80 AIDC sensor 88 Belt cleaner separation solenoid 89 controller 84 front cover 93 front door 85 fusing cooling fan motor (M5) 97 fusing unit 94 high voltage unit 88 left-side cover 87 main motor assembly (M1) 91 Manual feed take-up solenoid (SL1) 100 Manual feed tray 92

paper empty sensor 92 paper take-up roller 97 paper-separating roller 98 Power supply cooling fan motor (M4) 86 power unit 87 Pre-disassembly 82 print head unit (PH) 99 PWB-A 86 Rack motor 90 rear cover 86 relay control board (PWB-A) 101 relay control board (PWB-A) for the duplex unit 102 Replacing the EEPROM 104 right-side door 93 Second image transfer roller 84 Second paper take-up roller 101 top cover 85 top-front cover 85 transport motor 103 transport sensor 102 turnover motor 103 ventilation fan motor (M6) 87 Disassembly/Assembly 77 Disassembly/Assembly Precautions 77 Disconnection at thermistor 134 Display screens 110 Drum Cartridge 44 Drum cartridge life 26 Duplex Unit 68 Drive 68 Paper Feeding Method 69

E
ELECTRICAL COMPONENTS 36 environment 28 Error Codes 04H 130 08H 130 0BH 130 0CH 131 0EH 131 10H 131 14H 132 15H 132 16H 132 17H 133 18H 133 19H 133 1AH 134 1BH 134 21H 134

141

29H 134 2AH 134 2BH 134 2CH 134

F
Faulty warm-up detected 133 First Image Transfer 56 Foggy background 137 Fusing Roller Pressure 63 Fusing Section 62 Drive 63 Fusing Temperature Control 64

133 Incorrect pressure 132 Incorrect transfer belt rotation 132 Installation environment 28 power supply 28 Space requirements 29 Installation Precautions 28

J
Jam sensors 124 Jams 122

G
Grid 45

L
Laser Caution Label 21 Laser Exposure 46 CD Direction 46 FD Direction 46 Print Area 47 Laser Safety Label 21 Low image density 137

H
Handling of the Imaging Cartridge 17 High-temperature Part 10 High-voltage Parts 10 How to Use this Book 14 Humidity Sensor 43

M
Main motor malfunction 130 Maintenance Schedule 79 Drum cartridge 79 Fusing unit 79 Image transfer belt unit 79 Laser lens cover 79 Paper take-up roller 79 Second image transfer rolle 79 Toner cartridge 79 Waste toner bottle 79 Malfunction of the EEPROM 134 Malfunction of the fusing cooling fan motor 131 Malfunction of the main motor 130 Malfunction of the master board 130 Malfunction of the OHP detecting sensor 134 Malfunction of the polygon motor 131 Malfunction of the power supply cooling fan motor 131 Malfunction of the ventilation fan motor 130 Malfunctions and Warnings 129 Manual Feed Tray 66 Paper Empty Detection 66 Take-Up 66 Media sizes 25 Media types 25 Memory configuration 27 Menu 113 Misfeed detection timing 125

I
Image Quality Black print 136 Blank print 136 Foggy background 137 Low image density 137 Offset image 138 Toner smudges on backside of paper 137 White spots 136 White/Black lines and bands 138 Image Quality Troubleshooting 136 Image Stabilization Control 40 AIDC Control 41 AIDC Detection 40 Operation Timing 42 Temperature/Humidity Sensor 43 Image Transfer 55 Belt Cleaning 59 Belt Cleaning Blade Retraction 60 Belt Unit 55 Drive Train 55 First Image Transfer 56 Roller Cleaning 58 Roller Pressure/Retraction 57 Second Image Transfer 56 Waste Toner Bottle 61 Incorrect developing rack rotation 133 Incorrect fusing roller high temperature 134 Incorrect fusing roller low temperature

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Misfeed-detecting sensors 124

N
Near-Empty Sensor 67 No power 135 Noise 25

O
Offset image 138 Operating environment 25, 30 Operating noise 25 Operating Sequence 39

P
Paper cassette capacity 26 Paper Empty Detection 66 Paper Misfeeds 122 Paper Path 35 Paper Take-up Section 66 Manual Feed Tray 66 PC Drum 44 Charging 45 Grounding 44 Handling Precaution 44 Scorotron 45 PC drum specifications 25 polygon motor 131 Power consumption 25 Power Cord 10 Power supply 28 Power supply requirements 30 Precautions for Dis/Reassembly 15 Precautions for Service 14 Print resolution 25 Product Specifications 25

R
Rack 48 Rack Standby Position 50 Rack Stop Position 50 RAM 27 Replacing the EEPROM 104 Roller Cleaning 58 Roller Pressure/Retraction 57

Handling of the Imaging Cartridge 17 Handling of the PC Drum 16 High-temperature Part 10 High-voltage Parts 10 Laser Beam 12 Power Cord 10 Service Jobs 11 Specified Parts 10 Storing toner 12 Scorotron 45 Second Cassette 67 Near-Empty Sensor 67 Paper Empty Detection 67 Take-Up 67 Second Image Transfer 56 Service Mode 116 Service mode options 116 Space requirements 29 Specifications 25 CPU 27 Dimensions 25 Drum cartridge life 26 Maximum power consumption 25 Media sizes 25 Media types 25 Memory configuration 27 Operating environment 25 Operating noise 25 Paper cassette capacity 26 PC drum 25 Print resolution 25 RAM 27 Rated power supply voltage 25 Toner cartridge life 26 Warm-up time 25 Weight 25 Specified Parts 10

T
Temperature Control 64 Temperature/Humidity Sensor 43 Toner Cartridge Installation Detection 53 Toner cartridge life 26 Toner smudges 137 Troubleshooting 119 Checking the electrical components 119 Clutch 120 Fatal Error Codes 129 Image Quality 136 Jams 122 Misfeed detection timing 125 Misfeed-detecting sensors 124

S
Safety Information Internal Laser Radiation 18 Laser Safety 18 Safety information 18 Safety Precautions 9 Covers and Parts Removed 12 Grounded Connection Grounded Connections 11 Handling of PWBs 15

143

Motor 121 No power 135 paper curled, wrinkled or humid 122 Sensor 119 Solenoid 120 Switch 119

W
Warm-up time 25 Warnings 129 Waste Toner Bottle 61 Waste Toner Bottle Detection 61 Waste Toner Full Detection 61 Weight 25 White spots 136 White/Black lines 138

144