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FS-C5016N Service Manual

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2. Triac thermistor 1 TRA2 Engine controller Rectifier Transf PWB ransformer circuit T1 Enargy Saving 24V1 24 V DC circuit AA at FET rectifier Q101 po smoothing TO circuit GND Los SLEEP ki 5V1 5 VDC rectifier smoothing Switching control circuit GND circuit IC1 Over voltage current detection circuit Photo coupler Proto PCS L coupler ZCROSS PCS r oto coupler HEAT1DR Proto PON coupler HEAT2DR PC2 TH1 TH2 EXITPAP FUDR FDDR gt E Fuser Exit sensor thermistor 2 Fuser PWB Ll AE Figure 2 3 1 Power supply PWB block diagram gt 3 Face up down solenoid 2 3 1 CLP Connector Connected to the AC inlet AC100V 120 V AC 220 240 V AC 120 V AC Description AC power input Ground AC power output CN2 Connected to the AC inlet fuser heater lamp 1 and 2 fuser ther mostat 1 and2 HEATER LIVE NC HEATER COM NC HEATER LIVE 220 240 V AC 120 V AC 220 240 V AC 120 V AC 220 240 V AC 120 V AC Fuser heater lamp 1 output Not Connected Fuser heater lamps output common Not Connected Fuser heater lamp 2 output YC901 Connected to the engine con troller PWB TH1 TH2 FDSOLDR 5V2 RCOVOP F
3. 1 6 25 3 Detaching and refitting the LED print heads relay PWB seme 1 6 28 4 Detaching and refitting the main high voltage DW 1 6 29 b Detaching and refitting the bias high voltage PWB AA 1 6 30 A Ee ie Deen eege eege e eeh ee E EE 1 6 31 1 Detaching and refitting the main drive unt eee ce ceece cen conoser rana 1 6 31 2 Detaching and refitting the paper feed drive unit ee mee 1 6 32 3 Detaching and refitting the fuser drive unit ss mmm 1 6 33 4 Detaching and refitting the toner motor 1 2 3 and A 1 6 34 b Detaching and refitting the ozone filters irsini neoan a aa enne 1 6 35 6 Detaching and refitting the waste toner duct ssseeee meme 1 6 36 1 7 Firmware 1 7 1 Downloading fg ecc rr herr ER ARA 1 7 1 1 Format of the firmware Tiles eccentric eta a rr ndn tat cde caved Een eed e esa nu ede engen 1 7 1 2 Downloading firmware via the parallel interface AA 1 7 2 3 Downloading firmware using the memory card seseen em meme 1 7 3 4 Downloading the message data cocinar o rtt rk e iere tei Ri e gens UE Ra ERR 1 7 5 2 1 Mechanical construction 2 1 1 2 1 2 2 1 3 2 1 4 2 1 5 2 1 6 Paper feed Section eu 2 1 1 1 Paper feeding from paper cassette risia sinira A o cc 2 1 1 2 Paper feeding from MP tray ei ecc in e ae EEEE ewes dened EE 2 1 5 Developing
4. 1 4 1 1 Executing SERVICE ModE EE 1 4 1 1 4 2 Maintenance 2 ea 1 4 14 1 Method of removing the toner soiling which comes in contact with heat roller and Press roller 1 4 14 1 5 Troubleshooting E WEE Re e 1 5 1 Cl Paper mistesd Indica EE 1 5 1 2 Paper misfeed message display ooooconcccnnnniconnccoonnncccnn nece 1 5 1 1 5 2 Self diagnosis REENEN 1 5 2 1 Self diagnostiC Une le EE 1 5 2 EAR ele Ee 1 5 3 1 5 9 Electrical reel EE 1 5 18 1 5 4 Image formation ele E 1 5 21 1 6 Assembly and Disassembly 1 6 1 Precautions for assembly and disassembly AA 1 6 1 CPPCC AUTO INS earn iconos 1 6 1 1 6 2 QUIEN COVENS osten cn meer ee es tei te de eec ae teretes tre ie nea aed 1 6 2 1 Detaching and refitting the top COVER sissies ienirt idirek dineo nnne nnne nennen 1 6 2 2 Detaching and refitting the rear COVEN visiini praene penna EREE AEE EE EE 1 6 2 3 Detaching and refitting the right Cover 1 6 3 4 Detaching and refitting the left cover eseesssesesseeeeeeeeee nennen nennen nnne nnne 1 6 4 UE e GER m 1 6 5 1 Detaching and refitting the paper feed Unit eee ce ceeeeeeeceeeeeeee ee eeeeeeeeeaeeseeeeeeeeeeeeecaeesneneerseeeees 1 6 5 2 Detaching and refitting the paper feed roller sssm mem 1 6 6 3 Detaching and refitting the retard roller eseesseeeeeseeennneeeennnnen nnne 1 6 7 4 Detaching and refitting the secondary transfer ro
5. driver IC U22 Clutches Feed motor Fuser motor Dr Optional paper Transfer charger control Y feeder duplexer Bias Sensor signals high D A converter voltage U28 Analog Switches U24 U25 Figure 2 3 2 Engine controller PWB block diagram PWB Toner ID Sensor 2 3 3 CLP 1 Fuser heater lamps control circuit Engine controller PWB Power supply PWB AC input Zero Ge cross IL gt 39 signal ZCROSS detection circuit ASIC HEAT1DR U13 3 Fuser heater lamp 1 FEST ON circuit Edi ge 95 HEATION HEAT2DR 4 rH pad annormal emparature 5V1 detection H1HTEMP if circuit U1 1 Fuser HEAT2ON thermisotor 1 m H2HTEMP 3 Q50 Fuser heater lamp 2 ON circuit Micro Fuser Fuser Fuser abnormal controller heater heater temparature U8 lamp 1 lamp 2 detection circuit U1 2 TH1 dt Fuser thermisotor 2 TH2 Figure 2 3 3 The ON OFF action of the fuser heater lamp 1 and 2 are controlled by the fuser heater lamp 1 and 2 lighting ON signals HEAT1ON HEAT2ON output from the No 35 and 36 pin of ASIC U13 of the engine controller PWB When the HEAT1ON and HEAT2ON signals reach the H level the photocouplers PC1 PC2 and triacs TRA1 TRA2 turn on because the transistors Q47 Q50
6. U32 SDD15 0 SDD31 16 SDRAM Data bus SDD31 0 Figure 2 3 5 Main controller circuit block diagram 2 3 11 CLP This page is intentionally left blank 2 3 12 CLP ize hart No 1 Paper cassette A4 s iming c 2 4 1 Appendixes 1 T LL OL 9 WS g9zz Sm ee el eR a ee E E zb A SECH 2866 J 80ZzL LU a LU soez EA ee AE 2 SE90L 0266 96601 6101 AAA 2 8bv6 L KL LL lr Z9 04 1196 0z8s 68 2 l J S209 vroz S a e a a S a a ee a LM Lrge EZ J ft AN 99901 Dez 99901 Des e E n ee E E 1266 SC M 411 1266 ZSL 9 16 0645 08 SIE 9 16 0648 082 TT o T 0 E gt e T e v n ver ll el 1 esezl 6LeS epes _ dB 06vL th 9 0601 Sv l 8SLOL EI LL OL 9 S s o Uuojnjo pasy Josuas NZ piouajos umop dn aoe4 seq Jaysuesy repuodas yoynjo uoneysibay y seq saysued Are A seq 18jsue1 Ae 2 seiq 1ejsuea Anew IN seig 19Jsuea Arewiid 01 peeu juud q31 A Peay juud q31 9 peeu uud q31 W peeu 1uud q31 01 seiq e eejs Buidoje eq y seiq 1euBeui Buidoje eq A seiq anaa s Buidojo eq A Seiq 1euBeui Buidojo eq 9 seiq e ee s Burdojaneg 9 serq joub
7. lona hart No 7 Opt SL L 9 S v s o 1884 y 262 M Oso 98 oe o gt el 1 i a em em ae vier 9867 Ud pP odo obo CPFLLILCIL IZ rr PA PA D LOLL 8689 S98 vier L m s oT 9984 690 bell J zz 96 9 Ud SSES SS d p pb Pb LLL 9 9 1699 629z l 01 Z 62cv pe ti a pe a its leez 9989 ITT ITT d IT A 1 9899 ege 682z Les vvOZ S405 SZ08 _ Frai DEN EN O82 6989 0422 o_o E eel eb rF TI TT O82 6989 Des SES9 SZS ooo E L 1 cec er Gest LLL ST ee ee ee ee ee vci9 0615 082 IT Gent 087 Lp 6468 gezz TL 06p1 LIII I I M A enn Sy Lo p qp LLL iming c 7 T SL S0 do1 09 4d 1epeej Jee 0 0u paa jedeg UD paay sodeq Josus 13 piouejos umop dn eoe4 seq 1ejsueJ 1epuodas yoynjo uonejsi amp eud M seig 19Jsue Hewnd A serq Jajsues Are 2 seg 1ejsuea Mewud IN Seiq 1ejsuean Are 01 peeu uud q37 A peeu juud q31 9 peeu 1uud q31 IN peeu quid q31 y Seiq anaajs Buido e eq y seiq 1euDeui Buidoje eq A Setq e ee s Buido auer A Seq jouBbew Buidojansq 2 seiq e eers Budo e eg 9 serq jouBeu Buidoje eq IN Seiq e eejs Burdo GI IN Seiq 1euBeui Buidojaneg y 1e81euo ureiw A saBreyo ug 9 1eB1euo ure IN 1
8. B Defective main high voltage PWB Replace the main high voltage PWB KP 978 See page 1 6 29 C Poor contact of output terminal of main high voltage PWB Check the installation of the main high voltage PWB KP 978 If it instal lation incorrectly reinstall it See page 1 6 30 D Defective engine controller PWB 2 Defective LED print heads relay PWB 1 5 22 Replace the engine controller PWB KP 1054 See page 1 6 25 Replace the LED print heads relay PWB KP 1048 See page 1 6 28 CLP 3 A specific color is printed solid Causes 1 Defective main charger unit which corresponds to the color causing the prob lem 2 Disconnected main charger wire Causes Check procedures corrective measures 1 Defective main charger unit which corre Check if the main charger unit is properly seated If necessary reseat it sponds to the color causing the problem properly 2 Disconnected main charger wire Replace main charger unit 4 The back side gets dirty Causes 1 Dirty secondary transfer roller 2 Dirty paper conveying path of the paper feed unit 3 Dirty heat roller and press roller Causes Check procedures corrective measures 1 Dirty secondary transfer roller Clean the secondary transfer roller 2 Dirty paper conveying path of the paper Clean the paper conveying path of the paper feed unit feed unit 3 Dirty heat roller and press roller Clean the heat roller an
9. Connected to the optional paper feeder duplexer o Joo P Go GND OPRDY OPSEL2 OPSDO OPSEL1 OPSDI OPSELO OPSCLK NC OP5V GND OP24V OO O00 O 1 0 5 V DC 0 5 V DC 0 5 V DC pulse 0 5 V DC 0 5 V DC pulse 0 5 V DC 0 5 V DC pulse 5V DC 24 V DC Ground Optional unit ready signal Ready Not ready Optional unit select signal bit2 Optional unit serial communication data output Optional unit select signal bit1 Optional unit serial communication data input Optional unit select signal bitO Optional unit serial communication clock signal Not connected 5 V DC power output via fuse Ground 5 V DC power output via fuse Connected to the main controller PWB 2 3 8 3 3V1 3 3V1 2 5V1 2 5V1 GND LVDSN15 LVDSN14 LVDSN13 LVDSN12 LVDSN11 LVDSN10 LVDSN9 LVDSN8 LVDSN7 LVDSN6 LVDSN5 LVDSN4 LVDSN3 LVDSN2 LVDSN1 LVDSNO RD GND SCLKIN SYSRES SIOUT GND GND 3 3 V DC 3 3 V DC 3 3 V DC 3 3 V DC Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog 0 5 V DC 0 5 V DC pulse 0 5 V DCC 0 5 V DC pulse 3 3 V DC power output 3 3 V DC power output 3 3 V DC power output 3 3 V DC power output Ground LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data s
10. 6 Toner sensor TON Output a GNA Output 2 Output ong Engine controller PWB av rae Developing Yellow 1 developer sleeve bias ycgo1 2 HVCLK1 ec i output circuit vcgo1 3 HVCLK2 vog 4 YC801 4 HVCLKS Leg 4 Output YC801 5 HVCLK4 ep CN5 Output CN9 D A YC801 6 HVBDATD o c converter YC801 7 HVBCLKD YC5 7 Si IC501 L YC801 8 HVBLATD eg Output CN6 Output Developing CN10 magnet bias output circuit i Output CN7 CN11 Bias high voltage PWB YC406 2 YC401 2 YC402 2 SR YC403 2 Output Approximately 400 V DC Output 100 V DC and 1 6kV p p rectangular wave 3 kHz Figure 2 1 12 Developing section block diagram CLP 2 Touch down developing method Touchdown development system is a development system having the best of both mono component system and dual component system Dual component developer which is a powder of mixture of toner and carrier powder is continuously agitated by mixer screws A and B in the toner hopper in the developer unit The toner and carrier powder are adsorbed to each other by means of electrostatic charge developed by the friction when they are stirred The developing magnet roller is comprised of a magnet and a sleeve which revolves coaxially with the magnet The developer powder forms brushes of toner and carrier on the magnet sleeve along the magnetic field centering the magnet The brushes are truncated to a constant length of height appr
11. Lock release button Paper feed roller unit Figure 1 6 8 One way clutch Latch 5 Unlatch the three latches and then remove the feed bracket cover 6 Remove the feed roller and pickup roller The one way clutch is built in to the pickup Pickup roller gear Z32S When the pickup gear Z32S is installed again the surface of one way clutch side is directed to feed bracket cover side 7 Check or replace the feed roller and then PB refit all the removed parts e i a Latches Feed bracket cover Pickup gear Z32S Feed roller Figure 1 6 9 1 6 6 3 Detaching and refitting the retard roller Procedure 1 2 3 Remove the paper cassette Unlatch the two latches and then remove the retard roller holder Remove the retard roller from retard roller holder Check or replace the retard roller and then refit all the removed parts Retard Retard roller Figure 1 6 10 CLP Paper cassette 1 6 7 CLP 4 Detaching and refitting the secondary transfer roller Procedure 1 Remove the paper feed unit see page 1 6 5 2 Removing the hook by sliding and then remove the paper chute 3 Remove the secondary transfer roller 4 Remove the transfer roller gear 5 Check or replace the secondary transfer roller and then refit all the removed parts Secondary transfer roller d Transfer roller gear Paper chute Paper feed unit Hook Figure 1 6 11 1 6
12. 4 Detaching and refitting the toner motor 1 2 3 and 4 Procedure 1 Remove the right cover see page 1 6 3 2 Remove the one connector 3 Remove the hole which is inserted into the projection of main unit frame side slide toner motor 4 to up in order to remove the hook Remove the toner motor 4 5 Check or replace the toner motor 4 and then refit all the removed parts Also four toner motors with the same procedure there is no order B 1 6 34 Toner motor Projections Figure 1 6 46 CLP 5 Detaching and refitting the ozone filters Procedure 1 Open the top cover 2 Remove the ozone filters from the ozone fan motor 1 and 2 3 Check or replace the ozone filters and then refit all the removed parts Ozone filters Ozone fan motor 1 Figure 1 6 47 1 6 35 CLP 6 Detaching and refitting the waste toner duct Procedure 1 Remove the primary transfer unit see page 1 6 15 2 Unlatch the three latches and then remove the waste toner duct 3 Check or replace the waste toner duct and then refit all the removed parts Latches Waste toner conveying duct Figure 1 6 48 1 6 36 CLP 1 7 1 Downloading firmware The system firmware can be update by downloading new firmware Downloading can be made either by directly sending the new firmware from PC via the parallel interface or using a memory card that contains the new firmware The message data for the oper
13. KP 1040 which is attached to the LED print head 3 of the yellow drum unit does not communicate with the engine controller PWB KP 1054 nor mally head memory PWB 3 KP 1040 drum unit See page 1 6 13 Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 KP 1054 Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness S02866 between engine controller PWB KP 1054 and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Check the continuity of the harness S02866 check the insertion of YC3 of the engine controller PWB KP 1054 if there is trouble remedy or replace Defective harness S02866 between LED print head memory PWB 3 KP 1040 and LED print heads relay PWB KP 1048 or poor con tact of the connec tor terminals Check the connection of the connector with the yellow drum unit and the printer main unit check the continuity of the harness S02866 check the connection of the LED print head memory PWB 3 KP 1040 if there is trouble remedy or replace 1 5 5 CLP Code Contents EES Causes Check procedures corrective measures 1200 Side registration motor error Defective duplexer Refer to the duplexer DU 300 s service man The duplexer PWB of the optional DU 300 ual e d
14. 1 Turn on the printer power switch The mes sage will change from Self test to Ready when initialization is complete Use the following key operation to print a status page for test Press the MENU key when Ready is dis played Press the V key to display Print Status Page Press the ENTER key to display Print Sta tus Page Press the ENTER key Processing will be displayed and the status page will be printed When printing is complete Ready will appear again Check to see if the status page is properly printed Completion of the machine installation 1 3 6 df USB 11111 Mil Parallel AC inlet Power cord Figure 1 3 11 1 3 2 Installing expansion memory optional lt Procedure gt 1 Turn off printer power Caution Do not insert or remove expan sion memory while printer power is on Doing so may cause damage to the printer and the expansion memory 2 If a memory card is currently installed in the memory card slot See the figure remove the memory card first 3 Remove two screws and then remove the main controller PWB 4 Open the stoppers of the memory socket 5 Insert the memory so that the two notches of the memory are engaged with the projec tions of the memory socket 6 Close the stoppers of the memory socket 7 Reattach the main controller PWB in the printer 8 Print a status page to check the memory expansion If memory
15. Defective harness Check the continuity of the harness 802865 between 802865 check the connection YC11 con engine controller nector of the engine controller PWB KP PWB KP 1054 1054 if there is trouble remedy or replace and toner ID sen Sor or poor contact of the connector terminals FO Operation panel PWB communica Defective main Replace the main controller PWB KP 957 F000 tion error controller PWB See page 1 6 24 The operation panel PWB KP 962 KP 957 does not communicate to the main 8 controller PWB KP 957 normally 30 Defective operation Replace the operation panel PWB KP 962 seconds panel PWB KP 962 F010 System DIMM PWB checksum error Defective system Replace the system DIMM PWB KP 893 The system DIMM PWB KP 893 DIMM PWB KP which stores the program checksum 893 dianar coincide Defective main Replace the main controller PWB KP 957 controller PWB See page 1 6 24 KP 957 F020 Main controller PWB memory check Defective main Replace the main controller PWB KP error controller PWB 1054 See page 1 6 24 t could not access to the standard KP 957 memory or the optional expanding a memory which are mounted on the Defective expand If the ecak A is EE after main PWB KP 957 normally ing memory removing or replacing the expanding mem ory do the operation check If operation is normal replace the expanding memory See page 1 3 7 F030 Main controller PWB syst
16. MP tray feed solenoid On Off 5 V DC power Ground Toner ID sensor detection voltage S wave input Toner ID sensor detection voltage P wave input Toner ID sensor LED light emitting control signal Feed motor energization pulse Feed motor energization pulse Feed motor energization pulse 2 3 9 CLP YC11 STFDB 0 24 V DC pulse Feed motor energization pulse Connected STFSA Fuser motor energization pulse to the regis STFSA pulse Fuser motor energization pulse tration STFSB pulse Fuser motor energization pulse clutch feed STFSB Fuser motor energization pulse clutch MP GND Ground tray feed solenoid toner ID sensor feed motor and fuser motor YC12 Connected to the power supply PWB TH1 TH2 FDSOLDR 5V2 RCOVOP FUSOLDR EXITPAP 24V2 HEAT2DR HEAT1DR ZCROSS SLEEP 24V1 24V1 Analog Fuser thermistor 1 detection voltage input Analog Fuser thermistor 2 detection voltage input 0 24 V DC pulse Face up down solenoid control signal 5VDC 5 V DC power input 0 5 V DC Rear cover open close sensor rear cover open close 0 24 V DC Face up down solenoid control signal 0 5 V DC Exit sensor On Off 24V DC 24 V DC power output 0 24 V DC Fuser heater lamp 1 On Off 0 24 V DC Fuser heater lamp 2 On Off 0 5 V DC pulse Zero cross signal input 0 24 V DC Eco mode control signal output Normal Eco mode 24V DC 24 V DC power input 24V DC 24 V DC power input 24V1 24VDC 24 V DC power inp
17. 1 defective con nector with the magenta developer unit and developer unit did not output the den nection of the con the printer main unit if there is trouble rem sity detection signal judged the nector between edy or replace engine controller PWB KP 1054 the magenta devel magenta developer unit is not oper unit and the installed printer main unit or poor contact of the connector termi nals Defective toner Replace the magenta developer unit See sensor 1 page 1 6 11 Defective engine Replace the engine controller PWB KP controller PWB 1054 See page 1 6 25 KP 1054 Defective engine Replace the engine relay PWB KP 966 relay PWB KP 966 7403 Cyan developer unit non installing Defective harness Check the damage of harness of the toner error of the toner sensor sensor 2 check the connection of the con The toner sensor 2 inside the cyan 2 defective con nector with the cyan developer unit and the developer unit did not output the den nection of the con printer main unit if there is trouble remedy sity detection signal judged the nector between or replace engine controller PWB KP 1054 the cyan developer unit cyan developer unit is not installed and the printer main unit or poor contact of the con nector terminals Defective toner Replace the cyan developer unit See page sensor 2 1 6 11 Defective engine Replace the engine controller PWB KP controller PWB 1054 See page 1 6 25 KP 10
18. Cyan developer unit DV 500C Part No 2D993080 Magenta developer unit DV 500M Part No 2D993070 Yellow developer unit DV 500Y Part No 2D993060 Black developer unit DV 500K Part No 2D993050 Fuser unit FK 500 E Part No 2D993150 Paper feed unit FE 500 Part No 2D993140 Primary transfer set TR 500 Part No 2D993130 Primary transfer unit and primary transfer cleaning unit Part No 2D993250 Ozone filters x 2 Part No 2D902530 Feed roller set Retard roller Part No 5AAVROLL 052 MP tray feed roller Part No 5AAVROLL 051 MK 502 For 120 V AC model Drum unit DK 500 DRUM UNIT Part No 2D993040 Cyan developer unit DV 502C DLP C UNIT Part No 2D993290 Magenta developer unit DV 502M DLP M UNIT Part No 2D993280 Yellow developer unit DV 502Y DLP Y UNIT Part No 2D993270 Black developer unit DV 502K DLP K UNIT Part No 2D993260 Fuser unit FK 500 U FUSER UNIT Part No 2D993220 Paper feed unit FE 500 Part No 2D993140 Primary transfer set TR 500 Part No 2D993130 Primary transfer unit and primary transfer cleaning unit Part No 2D993250 Ozone filters x 2 Part No 2D902530 Feed roller set Retard roller Part No 5AAVROLL 052 MP tray feed roller Part No 5AAVROLL 051 Purpose To reset the life counter for the developer units and drum units included in maintenance kit Procedure for replacing the maintenance kit 1 Remove the
19. 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Sensor PWD AA Consists the top cover paper feed unit switch side cover switch top cover switch 1 paper gauge switch 1 2 registration sensor and wiring relay circuit Operator panel DWD Indicates the LCD message display and LED indicators Controls key inputs Bias high voltage DW Generates the developing magnet roller bias developing sleeve bias and secondary transfer bias Main high voltage DWD Generates the main charger high voltage and primary transfer rollers bias System DIMM PWB sssssoseeeeseeeneeseeseereeee System program firmware Waste toner full sensor PWB Detects the waste toner box being full Waste toner full sensor Section of LED light emitting for waste toner detection MP tray paper sensor Detects paper misfeed in the MP tray Humidity sensor Detects the ambient humidity Temperature sensor Detects the ambient temperature Registration sensor Detects the timing of primary feeding Paper gauge sensor 1 Detects the paper remaining amount level Paper gauge sensor 3 Detects the paper remaining amount level Paper full sensor Detects whether the face down tray is full Toner ID Sensor uere Measures image density for color calibration Envelope feeder install sensor Installing detection of opt
20. B Loose connection with the LED print head connector Check CN2 LED print head connector for connection If necessary secure the connection Do not attempt to disconnect connect the con nector while power is on C Defective main controller PWB Replace the main controller PWB KP 957 See page 1 6 24 D Defective LED print heads relay PWB See page 1 6 26 2 Defective developing sleeve bias or devel oping magnet bias output Replace the LED print heads relay PWB KP 1048 See page 1 6 28 A Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 B Defective main high voltage PWB 3 Defective secondary transfer bias output Replace the main high voltage PWB KP 978 See page 1 6 30 A Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 B Defective bias high voltage PWB 4 Malfunction of the developer installation 2 No image appears entirely black Replace the bias high voltage PWB KP 980 See page 1 6 30 Reinstall the developer See page 1 6 11 Causes 1 No main charging 2 Defective LED print heads relay PWB Causes 1 No main charging Check procedures corrective measures A Poor contact of output terminal of main high voltage PWB Check the installation of the main high voltage PWB KP 978 If it instal lation incorrectly reinstall it See page 1 6 29
21. ENTER key CANCEL key GO key CLP 1 1 3 Cross section view B 000 0606 P 7 see zz 1 on 8 Je Optional Duplexer Optional Paper feeders Paper path 3 Main unit Paper path gt Optional unit 1 Black drum unit 12 Magenta toner container 2 Yellow drum unit 13 Primary transfer unit 3 Cyan drum unit 14 Primary transfer cleaning unit 4 Magenta drum unit 15 MP tray 5 Black developer unit 16 MP tray feed unit 6 Yellow developer unit 17 Feed unit 7 Cyan developer unit 18 Fuser unit 8 Magenta developer unit 19 Controller box 9 Black toner container 20 Face down tray unit vertical path 10 Yellow toner container 21 Paper cassette 11 Cyan toner container CLP This page is intentionally left blank CLP 1 2 1 Drum unit Note the following when handling or storing the drum unit D D D D When removing the drum unit never expose the drum surface to strong direct light Avoid abrupt changes in temperature and humidity Avoid exposure to any substance which is harmful to or may affect the quality of the drum Do not touch the drum surface wi
22. ane YC12 1 l Pu Fuser thermistor 1 1 Fuserheater m y lamp O S LIVE j Get cda eon ene A yc12 9 M wen al EAT2DR vc45 49 Pasaia ZCROSS ea L LIVE YC901 11 YC12 12 Y L Fuser H S thermostat 2 i Fuser l es Fuser motor heater 2 Safer amp A 1 STFSA YC11 14 STFSA es 2 YC11 15 SC Fuser thermistor 1 O 3 STFSB YC11 16 beri e red a STFSB MC Ie 2 1 26 Figure 2 1 36 Fuser unit block diagram CLP 2 2 1 Electrical parts layout 1 Main frame and controller box CONTROLLER BOX Figure 2 2 1 Main frame and controller box Main controller DW Controls the software such as the print data processing and provides the interface with computers Engine controller PWB sss Controls printer hardware such as high voltage bias output control paper conveying system control and fuser temperature control etc Power supply PWB AAA Generates 24 V DC and 5 V DC power source Controls the fuser heater lamp 1 and 2 LED print head relay PWB Consists the LED print head control circuit and wiring relay circuit between engine controller PWB and drum units Engine relay PWB sssss Interconnects the engine controller PWB and the electrical parts 2 2 1 CLP 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
23. cover switch 2 or poor con tact of the connector termi nals Check the continuity of the harness S02846 check the connec tion YC11 connector of the engine controller PWB KP 1054 if there is trouble remedy or replace Malfunctioning interlock rod that interfaces between the top cover and the top cover paper feed unit switch SW701 Check to see if the interlock rod malfunctions If it malfunctions repair it Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective harness 802849 between engine controller PWB KP 1054 and sensor PWB KP 982 or poor con tact of the connector termi nals Check the continuity of the harness S02849 check the connec tion YC2 connector of the engine controller PWB KP 1054 check the connection YC701 and YC702 connectors of the sensor PWB KP 982 if there is trouble remedy or replace 2 Close side cover display is not cancelled to closing the top cover Defective side cover switch SW702 of the sensor PWB KP 982 Replace the sensor PWB KP 982 The actuator of the side cover switch SW702 of the sensor PWB KP 982 is bent Check the bending of the actuator of the side cover switch if there is trouble remedy or replace Defective sensor PWB KP 982 Replace the sensor PWB KP 982 Defective engine controller PWB KP 1054 Replace the engine controller
24. e lt swe lt 4 E Cassette size switch Paper size dial n Paper cassette Cassette size switch Cassette not installed Legal Letter A4 Paper size See note below Note Color calibration cancellaton signal Figure 2 1 3 Paper size dial Concave Function Off Convex EM Function On CLP Paper gauge sensing circuit The actuator which has a light reflector at one end keeps tracking of the height of the paper stack in the paper cassette The angle of the reflector varies according to the actuator angle which means the amount of paper remaining As the reflector moves across the detecting surface of paper gauge sensor photo interrupter 1 and 2 the on and off states of these sensors vary in combination as shown in the table below allowing to determine the amount of remaining paper in the cassette Paper feed unit Sensor PWB Acutuator Reflecting mirror Paper gauge sensor 1 PH702 Sensing input Paper gauge sensor 2 PH703 PH702 PH703 1 3 to 2 3 2 3 to full Figure 2 1 4 2 1 3 CLP Secondary transfer roller Upper registration roller Lower registration roller Guide rollers To fuser unit Feed roller Pickup roller Figure 2 1 5 Paper feed unit Engine controller PWB Feed clutch FEDCLDR _ ye44 Registration clutch REGCLDR Le Feed motor S
25. hexadeci mal 01 Paper feed sensor 32 Paper feed sensor 33 Paper feed sensor 34 Registration sensor 48 Vertical path sensor 49 02 Eject sensor 47 Switchback sensor 47 03 Duplexer refeed sen sor 49 99 Not determined Values within indicate paper misfeed locations Printer Rear cover Duplexer Envelope M 33 vi MP tray feeder 1 Paper i feeder 2 Paper feeder 3 Cause of paper mis feed hexa decimal 01 Paper did not pass within a specified time 02 Paper did not arrive within a specified time 09 Paper remains longer than a specified time other than 01 and 02 11 Paper misfeed occurred when paper is being transported 91 Paper remains when power is turned on 99 Others Paper stopped due to an external cause such as opening of a cover during printing Paper source hexadeci mal 00 MP tray 01 Cassette 1 in the printer 02 Cassette 2 03 Cassette 3 04 Cassette 4 09 Duplexer 99 Envelope feeder Paper size hexadeci mal 01 02 03 04 05 06 07 Monarch Business International DL International D5 Executive Letter size Legal size 08 A4 09 B5 13 A5 14 A6 15 B6 16 Commercial 9 17 Commercial 6 18 ISO B5 19 Custom size 31 Postcard 32 Reply paid 33 Oficio Il 34 216 x 310 mm 35 216 x 305 mm 1 4 8 CLP Service items Code d
26. transfer roller D A converter IC501 Engine controller PWB YC801 6 HVBDATD YC801 7 HVBCLKD LE YC801 8 HVBLATD LUES Figure 2 1 33 Secondary transfer unit block diagram 2 1 24 2 1 6 Fuser section 1 Fuser unit CLP The fuser unit is composed of the heat roller press roller fuser heater lamp 1 fuser heater lamp 2 and the change guide Paper sent from the secondary transfer and separation section is applied with heat and pressure to permanently fuse toner on paper The change guide switches the destination of paper to the face down tray or optional face up tray It also sends paper to the duplexer Figure 2 1 34 1 Upper fuser frame 8 Fuser heater lamp 2 2 Lower fuser frame 9 Lower fuser cover 3 Upper exit roller 10 Lower entrance guide 4 Lower exit roller 11 Stay plate 5 Heat roller 12 Change guide 6 Press roller 13 Exit guide 7 Fuser heater lamp 1 14 Fuser frame 2 1 25 CLP To face down tray Change guide To optional duplexer or x face up tray gt Lower exit roller From paper feed unit Figure 2 1 35 Fuser unit Engine controller PWB Petit pe Fuser PWP Power supply PWB i FUDR FUSOLDR YC12 4 BEL ee i Rear oe gt YC12 8 cover RCOVOP YC12 6 Face up down open vc i solenoid SENSON TH1 Kg Keren
27. 11 of developer 10 Spots are printed Causes Dirty or flawed drum Deformed or worn cleaning blade in the drum unit Defect fur brush of the primary transfer cleaning unit Flawed developing sleeve roller Dirty heat roller and press roller arwon gt Causes Check procedures corrective measures 1 Dirty or flawed drum Perform the drum surface refreshing See page 1 4 13 2 Deformed or worn cleaning blade in the Replace the drum unit See page 1 6 12 drum unit 3 Defect fur brush of the primary transfer Replace the primary transfer cleaning unit See page 1 6 16 cleaning unit 4 Flawed developing sleeve roller Replace the developer See page 1 6 11 5 Dirty heat roller and press roller Perform the heat roller and press roller cleaning See page 1 4 14 11 The leading edge of image begins Causes to print too early or too late 1 Registration clutch operating incorrectly 2 Defective engine controller PWB 3 Defective main controller PWB Check procedures corrective measures 1 Registration clutch operating incorrectly Check the installation of the registration clutch If it operates incorrectly replace it 2 Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 3 Defective main controller PWB Replace the main controller PWB KP 957 See page 1 6 24 1 5 26 CLP 12 Paper is wrinkled Causes 1 Paper curle
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29. 3 YC557 4 YC557 5 YC557 2 YC557 1 YC554 10 to 36 YC554 42 YC554 43 YC558 7 YC551 5 YC558 4 YC558 5 YC558 2 YC558 1 YC555 10 to 36 YC555 42 YC555 43 YC559 7 YC551 6 YC559 4 YC559 5 YC559 2 YC559 1 YC556 10 to 36 YC556 42 YC556 43 YC560 7 YC560 4 YC560 5 YC560 2 YC560 1 YC551 8 LVDSNO to 15 LVDSPO to 15 EECLK ERAS1DR ERAS2DR ERAS3DR ERAS4DR Figure 2 1 16 Drum section block diagram Main controller PWB YC1 6 to 21 Engine controller PWB CLP 2 Waste toner ejecting mechanism The waste toner which is ejected from the drum units drops on the waste toner conveyer through a duct The waste toner is conveyed towards the primary transfer cleaning unit finally stored in the waste toner box Primary transfer SS cleaning unit ND BN 2 2 Le dan From From From dum mii yellow black drum unit drum unit magenta drum unit Lo Waste toner conveying duct Waste toner Ha o Skee ee de e e E Figure 2 1 17 Waste toner ejecting mechanism 2 1 13 CLP 3 LED print head The LED print head is comprised of an LED array SELFOC lens array and an LED print head memory PWB The LED array arrays 5120 of LED chips in line It also includes the driver circuit for the LED array The light which is switched on and off depending on video data irradiate the drum through the SELFOC lens to form an image The LED head is of 600 dpi therefore
30. 8 1 6 4 MP tray feed unit 1 Detaching and refitting the MP tray feed unit Procedure 1 2 3 Remove the paper feed unit see page 1 6 5 Remove the paper right cover see page 1 6 3 Remove the main high voltage PWB see page 1 6 29 Remove the paper feed drive unit see page 1 6 32 While pushing the latch from inside the main unit frame and then remove the MP tray feed unit Check or replace the MP tray feed unit and then refit all the removed parts Figure 1 6 12 CLP CLP 2 Detaching and refitting the MP tray feed roller Procedure 1 Remove the MP tray feed unit see previous page MP tray feed roller 2 Pull up the MP tray holder and then sliding do 3 Remove the MP tray feed roller 4 Check or replace the MP tray feed roller and then refit all the removed parts MP tray feed unit Figure 1 6 13 1 6 10 1 6 5 Developing section 1 Detaching and refitting the developer unit Procedure 1 Open the top cover 2 Remove the one connector 3 While releasing two release levers and then remove the developer unit Use the same procedure for other developers CLP Release lever ict vex Release lever Developer unit Cyan Black Figure 1 6 14 1 6 11 CLP 1 6 6 Drum section 1 Detaching and refitting the drum unit Procedure Connector cover 1 Remove the developer unit see previous Magenta page Connector cover 2 Remove the each con
31. B AF C AG C AD D 69 03030303 03030303 03030303 03000000 00000000 03030303 03030303 SPD1 0203040508090A0B0C0D0F101112131415161718191A1B1C1D1 1F202122235E G SPD2 0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E G 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 DN SPL9200007 SPL9200007 SPL9200007 SPL9200007 SN SPL9200010 G3 Items Description Engine ROM information Flash ROM version 2 Operation panel PWB information Operation panel PWB mask ROM version 3 Boot ROM information Boot ROM version Software jumper switch information First byte second byte displayed in OEM mode only hexadecimal First byte Bit 0 1 Fixed Bit 1 0 Overseas 1 Domestic Japan Bit 2 3 Not used Bit 4 0 Kyocera 1 OEM Bit 5 0 For Europe 1 For US Bit 6 0 Non MICR mode 1 MICR mode Bit 7 2 0 Kyocera 1 Kyocera Mita Second byte Displayed in OEM mode only 1 4 3 CLP Service items Description Items Description Total page Total print page count Parallel UO information Serial I O error code 00 Normal Bit 0 Framing error Bit 1 Overrun error Bit 2 Parity error Operation panel lock status dis
32. CLP 5 Push in the black toner container firmly until it locks in the developer Black toner container A Figure 1 3 7 6 Turn the lock lever backward to the lock position 7 Install other toner containers in the same procedure 8 Close the top cover Magenta Yellow Cyan Figure 1 3 8 1 3 4 Installing the waste toner box 1 2 3 Open the side cover Install the waste toner box Close the side cover a Loading paper Remove the cassette from the printer 2 Adjust the paper guides and the paper stop per according to the paper size to be used 3 Turn the dial so that the size of the loaded paper is indicated in the paper size indica tion window CLP Side cover Rs Waste toner box Figure 1 3 9 ja Z 9E Na Cy ca Paper size window Paper cassette Figure 1 3 10 CLP Connecting the cable Connect the USB ethernet or parallel cable between the printer and the computer Connect the power cord to the printer AC inlet Connect the power cord to the wall outlet Printing a status page for test
33. D Code Code Q identifies an error and codes 2 to 9 indicate the details The value 02 of code 1 means a paper misfeed See code table 1 The value 99 of code 1 means a self diagnostic error See code table 2 Description Prints the history of paper misfeeds and self diagnostic errors including up to 16 items from the latest occurrence of such an error If the number of errors exceeds 16 errors will be deleted sequentially from the oldest one Purpose To allow machine malfunction analysis based on the frequency of paper misfeeds and self diagnostic errors Procedure 1 Enter the service mode gt gt Print Event log 2 2 Press the ENTER key gt gt Print Event Log will be displayed 3 3 Press the ENTER key A sheet of event log will be printed CR KYOCERA mila Ecosrs FS C5016 Page Printer A003 C1 22 00A 03 03 Firmware version 88 00 Released 18 Feb 2003 Total page 522 SN SPL2700012 02 11 48 02 09 01 88 21 73 FA A8 CO Paper jam Printer unit 02 11 48 01 09 01 88 11 73 FA A8 CO Paper jam Printer unit 02 11 48 01 09 01 88 11 73 FA A8 CO Paper jam Printer unit 02 11 48 02 09 01 88 21 73 FA A8 CO Paper jam Printer unit 02 11 48 01 09 01 88 11 73 FA A8 CO Paper jam Printer unit 02 11 32 01 91 00 88 32 74 04 A8 CO Paper jam Cassette 2 02 11 32 01 91 00 88 32 74 04 A8 C0 Paper jam Cassette 2 Events Figure 1 4 3 Event log EVENT LOG Details of events The event list includes t
34. HD 4 network interface card IB 20 10 BASE T 100BASE TX 10BASE 2 network interface card IB 21E 10BASE T 100BASE TX wireless LAN card IB 22 compatible to IEEE802 11b serial interface board IB 11 Maximum 115 kbps paper feeder PF 60 500 sheets 60 to 105 g m x 1 cassette A4 A5 B5 legal letter custom duplexer DU 300 face up output tray PT 300 250 sheets envelope feeder EF 60A 1 1 2 1 1 2 Parts names 1 Overall USA Canada European countries 120V 220 240V 60Hz 9 1A 50 60Hz 4 5A KYOCERA MITA CORPORATION KYOCERA MITA CORPORATION Hess KM c US LISTED BCC TE ENELICY Tes y wi FOR HOME OR OFFICE USE C ACN003852444 This device complies with Part 15 of the FCC Rules REMOVE POWER CORD BEFORE SERVICE wing Wwe Operation is subject ta the following two conditions 1 This device may not cause harmful AND FUSE REPLACEMENT interference and 2 this device must acc san VORSICHT addu VOR WARTUNG UND cuernos m Sech ial apparatus complies WECHSEL NETZSTECKER ZIEHEN with Canadian ICES 003 Cet appareil num rique de la classe B est ATTENTION confor POUR PREVENIR LES CHOCS ELECTRIQUES COUPER L ALIMENTATION CAUTION AVANT DE REMPLACER LE FUSIBLE REMOVE POWER CORD BEFORE SERVICE AND FUSE REPLACEMENT ATTENTION DESENCHUFE EL CORDON up PR VENIR LES CH interference received may cause undesired me la norme NMB 003 du Canada s DE ALIMENTACI N ANTES DEL SERVICIO Y LECTRIQ
35. LED cleaner Check if the LED cleaner unit is properly seated If necessary reseat it properly Dirty SELFOC lens of LED print head Clean the SELFOC lens of LED print head by using LED cleaner C Focus is lost with the LED print head Check the four colors of image by using the test print of service mode If the defect appears on a particular color replace the LED print head for that color See page 1 4 13 Defective LED print head Defective main charging output Check the four colors of image by using the test print of service mode If the defect appears on a particular color replace the LED print head for that color See page 1 4 13 Adhesion of oxide to main charger wire Clean the main charger wire by using main charger wire cleaner Dirty main charger grid Clean the main charger wire by using main charger grid cleaner Dirty main charger shield Foreign object in one of the developers Replace the main charger unit Check the image by using the test print of service mode If the white line appears on a particular page replace the developer for that color See page 1 4 11 1 6 11 4 Adhesion of soiling to primary transfer belt Replace the primary transfer unit See page 1 6 14 Causes Dirty main charger wire Poor insertion of the main charger wire cleaner Dirty or flawed drum Deformed or worn cleaning blade in the drum unit Defect fur bru
36. Service Press the H P key Service mode items gt gt Print Status Page gt gt Print Event L tion To scroll gt gt Color these items Calibra press the gt gt Print repeatedly Test Pa ge gt gt Maint enance Vor Akey To print a status page for service purpose See page 1 4 2 To print an event log EVENT LOG Displayed when FRPO 11 is set to 1 See page 1 4 7 To execute color calibration See page 1 4 10 To print a test page See page 1 4 11 To reset the counter after replacing the maintenance kit See page 1 4 12 To perform drum surface refreshing See page 1 4 13 1 4 1 CLP Service items Description Printing a status page for service purpose Description gt gt Print Prints a status page for service purpose The status page includes various printing settings Status Page and service cumulatives Purpose To acquire the current printing environmental parameters and cumulative information Procedure 1 Enter the service mode gt gt Print Status Page 2 Press the ENTER key Print Status Page will be displayed 3 Press the ENTER key Two pages will be printed The second page includes service information Service information Main controller PWB Refer to next page firmware version Release date of the firmware Firmware version 132 00 PAGE PRINTER STATUS PAGE FS C501 Firmwa
37. as possible Insufficient ventilation may cause heat buildup and poor copying performance Always handle the machine by the correct locations when moving H Always use anti toppling and locking devices on copiers so equipped Failure to do this may cause the copier to move unexpectedly or topple leading to injury seeeeese SOO Avoid inhaling toner or developer excessively Protect the eyes If toner or developer is accidentally ingested drink a lot of water to dilute it in the stomach and obtain medical attention immediately If it gets into the eyes rinse immediately with copious amounts of water and obtain Q MECICAl AMS MTOM mesada a Advice customers that they must always follow the safety warnings and precautions in the copier s Q instruction MAMODOOK asmina m 2 Precautions for Maintenance AAWARNING Always remove the power plug from the wall outlet before starting machine disassembly Always follow the procedures for maintenance described in the service manual and other related lee ina Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits esessssessesesesseseeennee ennemis Always use parts having the correct specifications oooononncncnnniciccnnnnconnnnnnnnnancnnnnnn nn enne Always use the thermostat or thermal fuse specified in the service manual or other rela
38. controller CIFCUll viii Ao 2 3 11 2 4 Appendixes ET ANC ar an 2 4 1 1 Timing chart No 1 Paper cassette A4 size sssssssseeem emm eere 2 4 1 2 Timing chart No 2 Paper cassette Legal size sesesseeeeeeneeen nennen 2 4 2 3 Timing chart No 3 Paper cassette Letter size seessssssseeeneneeeeennneen nennen 2 4 3 4 Timing chart No 4 MP tray E 2 4 4 5 Timing chart No 5 MP tray Legal SIZE eerie easet dent ai ente quas 2 4 5 6 Timing chart No 6 MP tray Letter SIZe nite e ada 2 4 6 7 Timing chart No 7 Optional paper feeder A4 size meme 2 4 7 8 Timing chart No 8 Paper cassette A4 size Slow mode Io 2 4 8 9 Timing chart No 9 Paper cassette A4 size Slow mode 2 55 96 sssse 2 4 9 10 Timing chart No 10 MP tray A4 size Transparency eem 2 4 10 11 Wiring diagram cc a aaa a a NGE R EEEE OTATKO ANEAN ARAE 2 4 11 12 Hepelitive defecis gauge derer nas Eire m A E e rar need A eben RO S 2 4 13 CLP This page is intentionally left blank CLP 1 1 1 Specifications Pes casonas Desktop Printing system ss Electrophotographic printing tandem Paper type iens Cassette Plain paper 60 to 90 g m Recycled paper 60 to 90 g m Thick paper 90 to 105 g m MP tray Plain paper 60 to 90 g m Recycled paper 60 to 90 g m Thick paper 90 to 200 g m Special paper Transparencies labels envelopes postca
39. expansion has been properly per formed information on the installed memory is printed with the total memory capacity has been increased Standard memory capacity 96 MB Stopper C CLP Main controller PWB ues Screw Figure 1 3 12 Figure 1 3 13 1 3 7 CLP 1 3 3 Installing a memory card optional lt Procedure gt 1 Turn off printer power Caution Do not insert or remove memory card while printer power is on Doing so may cause damage to the printer and the mem ory card 2 Insert the memory card into the memory card slot 3 Format the memory card before use Refer to the operation guide PA Memory card slot huc Memory card Figure 1 3 14 1 3 4 Installing the network interface card optional lt Procedure gt 1 2 3 Turn off printer power Remove the two screws and then remove the optional interface slot cover Insert the network interface card into the optional interface slot Use the two screws to secure the network interface card Connect the network cable IB 20 and IB 21E Configure the network interface card See the IB 2x quick configuration guide SN 2 Optional interface slot CLP Network interface card Screws Network interface cards avilable Part number Remarks Specifications IB 20 10 Base TX 100 Base TX 10 Base2 IB 21E 10 Base TX 100 Base TX IB 22 Compatible to IE
40. is not cancelled to closing the paper cassette Defective cassette size switch Replace the cassette size switch Defective sensor PWB KP 982 Replace the sensor PWB KP 982 Defective harness S02861 between cassette size switch and sensor PWB KP 982 or poor contact of the connector terminals Check the continuity of the harness S02861 check the connec tion YC703 connector of sensor PWB KP 982 if there is trouble remedy or replace Defective harness 802849 between engine controller PWB KP 1054 and sensor PWB KP 982 or poor con tact of the connector termi nals Check the continuity of the harness S802849 check the connec tion YC2 connector of the engine controller PWB KP 1054 check the connection YC701 and YC702 connectors of the sensor PWB KP 982 if there is trouble remedy or replace Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 5 Check waste toner box display is not cancelled to replacing the waste toner box The waste toner full sensor or the waste toner full sen sor PWB KP 974 the sensor section is dirty Replace the waste toner full sensor or the waste toner full sensor PWB KP 974 Defective harness S02863 between bias high voltage PWB KP 980 and waste toner full sensor PWB KP 974 or poor contact of the connector terminals Check the continuity of the harness
41. ks ADC Service Manual CLP 3516 VERSION 15 07 03 B Triumph Adier Service Manual CLP 4516 Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers their machines as well as themselves during maintenance activities Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property These symbols are described below AADANGER High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol A WARNING Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol CAUTION Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol Symbols The triangle symbol indicates a warning including danger and caution The specific point of attention is shown inside the symbol NM General warning WM Warning of risk of electric shock ZN warning of high temperature Q indicates a prohibited action The specific prohibi
42. leuez TI 235 amp o 235 2 y Gq I c of la Stol E l zz Ee x E lee wars l l 5 ke Il s Goo 5 ui 898Z0S Ai 22 SE a 125 l za 9 1159 II ES ES l HOH Ss 15 gt 11 22 lg D l LIHIS o l o lla a Q c BE HI ue l r EE E E l l es Lu 5 r J P ke n S War a e i m Jog oval e lel ER LAS amp ao aa ea 419 Cie 910 910 sX S vivas E GS anol j 9 yarsua B e alos 19820 e 98208 eer E vov Sm Ir ONO bre es e Zb evo e E gt ole OV kd 698Z0S 2005 LAS DEX GS 31033 PER z be LUS Wg ug logiya Pr orl or LENTZ el em sa gg HQ SUJ IVIVOH3 s 9 So Ae TT UOS gg Ai 48 L t smsars ee 6 0L 601 L QLAS LAS HQYSU3 501 gro else o aLAst au 2 TONASH LEZE ELUOLE LEZE LEZE ele palpa 3 OdSGAVONSGAT BHOHIS E CUurLIEUEL CUrLUIEUEL rlrt aoer EE 7 91 91 161 91 LdSOACHULNSOAT evilevet 00 na yun xajdng S S anol See Y Zuei Lue 4SGAVENSGAT S Ua FURL 09 4d Jopoo sedeg 9 9 GT pte gt EdSGAVENSGAT jeuondo oL 12H Eno tbejoz m 61 02 61 02 61 03 61 02 i VE Le zz 12 22 e LZ ZZ Lage Tao rn ro HE v z vz ez vz z e aras pror E Ss SC 9dSCAVONSGAT gz 9z 92 98 eje EE o E ZdSGAVZNSGA 323 2593051193950 v y IND gelse T 10 72 82 22 92 22 82 Z2 82 gt a ziulduelusiuaz QNS o 8 8dSQAT 8NSQA1 a AS c o o 9 om O s same vee 8 Zeie ez oe 6z oe amp S om aepo y 9 9 eero pepe S zerme zerze BHSGAVENSOAT __ zezelzeyze E
43. press roller then refit all the removed parts Right stay Sd Press roller Left stay C ring Bush Bearing K a Bearing 4 Bush C ring Figure 1 6 31 1 6 23 CLP 1 6 9 PWBs 1 Detaching and refitting the main controller PWB Procedure 1 Turn off the power switch and then remove the power cord 2 When the optional memory card has been installed in the Memory card slot already remove that 3 Remove the two screws and then remove the main controller PWB Screw Figure 1 6 32 1 6 24 CLP 2 Detaching and refitting the engine controller PWB and power supply PWB Procedure 1 Remove the main controller PWB see pre Connectors vious page 2 Remove the right cover left cover and rear cover see pages 1 6 2 3 4 3 Remove the all machine left five machine right four connectors Machine right Connectors Connectors SN Sy X ed Figure 1 6 33 A Remove three screws 5 Loose the one screw 6 Remove the main unit frontal projections and remove the controller box Figure 1 6 34 1 6 25 CLP 7 Remove the six screws and then remove the controller box cover Screws Controller box cover Screws Figure 1 6 35 8 Remove the five screws 9 Remove the two connectors and then Connecotor removing the connection with the power supply PWB remove the engine controller PWB Figur
44. printer power off 14 Remove the memory card from memory card slot 15 Turn printer power on 16 Confirm that message display 3 is dis played after warm up 17 Print the status page See page 1 4 2 18 Print the status page to check that the firm ware version has been updated 1 7 4 I is When a some key is pushed indication changes 1 1 1 1 1 1 1 1 1 1 1 1 1 1 d y To PC Memory card P aw Adapter Memory card reader writer Figure 1 7 8 Figure 1 7 9 Message display zr Product code 80 FS C5016N Version 88 00 System Engine 234 2 YS Release date Checksum Plural data Release date Memory card slot C UE Ee Memory card Figure 1 7 10 Version A005 s A gid A 80 r 02 06 07 1 03703 07 1234 2 GER Checksum Plural data 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CLP 4 Downloading the message data To download the new message data progress the following procedures 1 Turn off the power switch to the printer and PC 2 Connect the parallel printer cable between the PC and printer Parallel interface connector RS Parallel printer cable Figure 1 7 11 3 Turn on the power to the printer 4 Check that the message indication 1 is indicated O 5 Input the command 2 following the DOS prompt indication PC DOS display E
45. remove the fuser right cover 11 Remove the fuser heater lamp 1 and 2 Fuser heater lamp 1 Heat roller 500 W Ly Oy Lv SE Sen gt ees GE Fuser heater lamp 2 Press roller 350 W Fuser right cover Screw Figure 1 6 26 12 Remove the two pressure springs 13 Remove the fuser upper cover right pres sure lever and left pressure lever 14 Remove the fuser stay Fuser stay Right pressure lever Pressure CA Left pressure lever Figure 1 6 27 1 6 20 CLP 15 Remove the two screws and then remove the fuser thermostat 1 16 Remove the one screw and then remove the fuser thermistor 1 Fuser thermostat 1 Fuser upper cover Fuser thermistor 1 Screw Figure 1 6 28 17 Remove the user lower guide Screws 18 Remove the one tab 19 Remove the two screws and then remove the fuser thermostat 2 20 Remove the one screw and then remove the fuser thermistor 2 Fuser lower guide Figure 1 6 29 1 6 21 CLP 21 Remove the one C ring fuser gear one C ring one bush and one bearing 22 Remove the one C ring one bush and one bearing 23 Remove the heat roller Heat roller 1 6 22 C ring Fuser gear C ring Figure 1 6 30 CLP 24 Remove the two bushes and two bearings 25 Remove the right stay left stay and press roller 26 Check or replace the fuser thermistor 1 and 2 fuser thermostat 1 and 2 fuser heater lamp 1 and 2 heat roller and
46. the drum surface when image failure occurs due to contamination This mode is use ful when dew condensation on the drum occurs Procedure 1 Enter the service mode gt gt Drum 2 Press the ENTER key Message gt gt Drum will be displayed 3 Press the ENTER key Drum surface refreshing will start and finish after approximately 3 minutes 1 4 13 CLP 1 4 2 Maintenance 1 Method of removing the toner soiling which comes in contact with heat roller and Press roller When misfeeding has occurred in the fuser unit misfeed paper can coil around the heat roller or the press roller Remov ing the misfed paper will cause there are times when the toner soiling remains in the heat roller or the press roller Follow the procedure below in this case and remove the toner soiling from the heat roller or the press roller 1 2 3 1 4 14 Remove the misfed paper Cancel misfeed by opening and closing a cover wait until the message display shows Ready Press MENU and set paper type to Transparency and paper source to MP tray Set the a sheet transparency sheet 3M CG3700 or thick paper with the of more than weight above 135 g m to MP tray Press MENU and print a status page The toner soiling which comes in contact with the heat roller and the press roller will be transferred onto paper Until the toner soiling is cleared repeat Usually when 4 5 it prints the soiling goes out the above proced
47. the home poste Defective engine Replace the engine controller PWB KP Ig controller PWB 1054 See page 1 6 25 KP 1054 2610 Paper feed motor error top Defective paper Refer to the paper feeder PF 60 s service The notification that was received the feeder PF 60 manual motor clock Sensor cannot detect the Defective engine Replace the engine controller PWB KP revolution of the paper feed motor of the optional paper feeder top controller PWB 1054 See page 1 6 25 KP 1054 2620 Paper feed motor error middle Defective paper Refer to the paper feeder PF 60 s service The notification that was received the feeder PF 60 manual motor clock Sensor CANNOT detechthe Defective engine Replace the engine controller PWB KP revolution of the paper feed motor of the optional paper feeder middle controller PWB 1054 See page 1 6 25 i KP 1054 2630 Paper feed motor error bottom Defective paper Refer to the paper feeder PF 60 s service The notification that was received the feeder PF 60 manual molar clock sensor cannot detect the Defective engine Replace the engine controller PWB KP revolution of the paper feed motor of the optional paper feeder third controller PWB 1054 See page 1 6 25 i KP 1054 5301 Eraser lamp 4 error black drum unit Defective eraser Replace the eraser lamp 4 PWB KP 976 The eraser lamp 4 PWB KP 976 of the black drum unit does not communi cate with the engine controller
48. the sensor PWB KP 982 Defective sensor PWB KP 982 Replace the sensor PWB KP 982 Defective harness 802849 between engine controller PWB KP 1054 and sensor PWB KP 982 or poor con tact of the connector termi nals Check the continuity of the harness S02849 check the connec tion YC2 connector of the engine controller PWB KP 1054 check the connection YC701 and YC702 connectors of the sensor PWB KP 982 if there is trouble remedy or replace Defective exit sensor Replace the fuser PWB KP 970 Defective harness S802849 between fuser PWB KP 970 and fuser connector or poor contact of the connec tor terminals Check the continuity of the harness S02849 check the connec tion YC691 connector of the fuser PWB KP 970 if there is trou ble remedy or replace Defective harness 802853 between power supply PWB and fuser connector or poor contact of the con nector terminals Check the continuity of the harness S802853 check the connec tion YC902 connector of the power supply PWB if there is trouble remedy or replace Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective power supply PWB Replace the power supply PWB See page 1 6 25 1 5 20 1 5 4 Image formation problems 1 No image 2 No image 3 A specific color 4 The back side appears appears is printed solid gets dirt
49. when second sheet remains Duplexer drive signal output from the printer while paper is transported turns Paper remains in the duplexer when power is turned on Paper misfeed occurs due to forced stop when an error occurs during printing such as opening of a cover FO to FF Paper misfeed caused by a reason excluding above a Misfed paper width hexadeci mal 0000 to FFFF in 0 1 mm Example 73FA hexadecimal 29690 decimal 296 9 mm b Misfed paper length hexadeci mal 0000 to FFFF in 0 1 mm Example A8CO hexadecimal 43200 decimal 432 0 mm 1 4 9 CLP Service items Code digit and Details of code description Identifica tion code hexadeci mal Description Table 1 4 4 Code table 2 Details of code Self diagnostic error Self diag nostic error code Upper digit of former 2 dig its hexa decimal Self diag nostic error code Lower digit of former 2 dig its hexa decimal D T rm O OQ U o o NO oR WMO to Remarks Self diagnostic error codes EO and FO to F2 are not recorded gt gt Color Calibration Execution of color calibration Description Executing the density of color using Purpose To carry out color calibration manually besides it can be carried out automatically each time the printer is turned on Start Enter the service mode gt gt Color Calibration P
50. 07 1969 J A Seiq saysuesy feug 28001 0614 9129 veee 9 seiq 19Jsue1 Mewud Lee6 Svv9 vs KS IN sp 19Jsue AIEUUd 96601 Sv18 0814 ead 01 peey und On LSZOL 00v S8E9 vese l J A peeu uud OT 9096 S999 Ov9S 684Z TE PT 9 peeu uud q31 19 8 DLG S687 voz l J IN peay 1uud q31 00 LL veog verz Sloe x seiq e eejs Buidoje eq 00 LL t608 FER SLOE y seiq 1euBeui Buidoje eq SSSOL 6reZ_ 6899 D A Seiq e eejs Buidoje eq SSS0L 6rvEZ_ 6899 ozz AH APA A rr A serg youBew Buidojaneq 0196 099 preg zs ize l I 9 seig anaas Buidoje eq 0186 v099 hes Seet ET Th 9 seiq 1euBeui Buidoje eq S906 6989 084 1 IN sp e eejs Buidoje egq 661S S906 6989 084 IN sp jouBew Burdoje eg 1eset m gezz y 1361249 Urey 98 11 Dk SS LM A AGA PANA A A 1361249 ure MOL are m 9 1e81euo ureyy 96201 1 a IN 1351249 ure hart No 6 MP tray Letter s e6Vv L iming c CLP 6 T due Josey 94 SL FL EL Zk LL OL 6 8 L 9 S v 4 L 90 2 4 6 CLP ize paper feeder A4 s
51. 54 Defective engine Replace the engine relay PWB KP 966 relay PWB KP 966 7404 Yellow developer unit non installing Defective harness Check the damage of harness of the toner error The toner sensor 3 inside the yellow developer unit did not output the den sity detection signal judged the engine controller PWB KP 1054 the yellow developer unit is not installed of the toner sensor 3 defective con nection of the con nector between yellow developer unit and the printer main unit or poor contact of the con nector terminals sensor 3 check the connection of the con nector with the yellow developer unit and the printer main unit if there is trouble remedy or replace Defective toner sensor 3 Replace the yellow developer unit See page 1 6 11 Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective engine relay PWB KP 966 Replace the engine relay PWB KP 966 1 5 14 CLP Code Contents asas Causes Check procedures corrective measures 7411 Black drum unit non installing error Defective harness Check the connection of the black drum unit The EEPROM U401 on the drum between drum and the printer main unit check the continu PWB 4 KP 972 inside the black drum PWB 4 KP 972 ity of the harness 802867 if there is trou unit does not communicate normally and printer main b
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53. 8 c 470mm18 5 Figure 1 2 1 Installation dimensions 1 2 1 CLP This page is intentionally left blank 1 2 2 CLP 1 3 1 Unpacking and installation 1 Installation procedure C Start y Unpacking y Installing the toner containers Y Installing the waste toner box Y Loading paper Y Connecting the cables Y Printing a status page for test Y Completion of the machine installation Figure 1 3 1 1 3 1 CLP Unpacking 1 3 2 oo gt O N Figure 1 3 3 Unpacking 7 8 9 1 1 Printer Black toner container Yellow toner container Cyan toner container Magenta toner container Power cord Waste toner box x 2 Operation guide Quick reference guide Kyocera mita software library CD ROM Kyocera mita document library CD ROM CLP Installing the toner containers 1 Remove the protective seal from the black toner container Black toner container 2 Shake the black toner container several times to loosen the toner inside Black toner container Figure 1 3 5 3 Open the top cover 4 Install the black toner container into the printer The black toner container must be q installed in the front most developer Top cover Black toner container Lo Figure 1 3 6 1 3 3
54. Check the continuity of the harness S02854 between S02854 check the connection YC691 con fuser PWB KP nector of the fuser PWB KP 970 if there is 970 and fuser trouble remedy or replace connector or poor contact of the con nector terminals Defective harness Check the continuity of the harness 802853 power 802853 check the connection YC902 con supply PWB and nector of the power supply PWB if there is fuser connector or trouble remedy or replace poor contact of the connector termi nals Defective fuser Replace the fuser PWB KP 970 PWB KP 970 Defective power Replace the power supply PWB See page supply PWB 1 6 25 Defective installa Check the installation condition of fuser ther tion condition of mistor 2 if there is trouble remedy or fuser thermistor 2 replace See page 1 6 18 6400 Zero cross signal error Defective power Replace the power supply PWB See page The zero cross signal which from the supply PWB 1 6 25 POWER SUBpy PWB i outputted to Defective engine Replace the engine controller PWB KP the engine controller PWB KP 1054 w s hot detected controller PWB 1054 See page 1 6 25 KP 1054 7001 Toner motor 4 overcurrent detection Defective toner Replace the toner motor 4 See page 1 6 error black toner The engine controller PWB KP 1054 detected the overcurrent of toner motor 4 motor 4 34 Defective engine controller PWB KP 1054 Replace the engi
55. EE 802 11b Wireless LAN Figure 1 3 15 interface card d Network cable Network configuration ex IB 22 Wireless LAN Mode Ad hoc 802 11 Ad hoc Infrastruccture Automatic SSID Any string up to 32 characters Channel Depends on the environment Encryption WEP DISABLE 64 bit 128 bit WEP key Hexadecimal setting 00 FF 64 bits 10 digits 128 bits 26 digits Figure 1 3 16 1 3 9 CLP 1 3 5 Installing the hard disk unit optional lt Procedure gt 1 2 3 Turn off printer power Remove the two screws and remove the optional interface slot cover Insert the hard disk unit into the optional interface slot Use the two screws to secure the hard disk unit Format the hard disk unit Refer to the oper ation guide 1 3 10 MY mi Optional interface slot Screws 1 NY ND Sa EN GH UM N Hard disk unit HD 4 Screws Cover 7 Figure 1 3 17 1 4 1 Service mode CLP The printer is equipped with various service mode that can be accessed with the MENU key operation on the operation panel 1 Executing service mode Message display Ready A4 PLAIN 0 Press the MENU key 2 Press the VorA key several times until Other gt is displayed gt MSG Language Engl ish 3 Press the ENTER key Press the york key several times until gt Service gt is displayed gt
56. IEDA YC11 14 STFDA YC11 15 SRD YC11 16 STFDB YC11 17 Figure 2 1 6 Paper cassette paper feed section block diagram 2 1 4 CLP 2 Paper feeding from MP tray The MP tray bottom which is driven by the MP feed solenoid press the paper against the MP feed roller The sheet is rewound to the MP feed roller then forward to the registration roller by means of the MP middle roller Figure 2 1 7 MP tray paper feed section 1 MP frame 5 MP middle tray 2 MP feed roller 6 MP base 3 MP middle roller 7 Separator 4 Multi bottom 8 MP tray cover MP Tesairollor MP tray feed unit To fuser unit MP middle roller Figure 2 1 8 2 1 5 CLP Engine controller PWB MP feed solenoid G Feed motor MPSOLDR Figure 2 1 9 MP tray paper feed section block diagram 2 1 2 Developing section 1 Developer CLP Developing section is composed of mixer screw developing blade developing magnet roller and developing sleeve PON gt Figure 2 1 10 Developing sleeve 5 Mixer screw A developing magnet roller 6 Developer case Doctor blade 7 Developer lid Mixer screw B 2 1 7 CLP Developer case Toner sensor Mixer screw B Developing magnet roller Figure 2 1 11 Developer unit D Developing magnet roller 3 developer Gi Developing sleeve
57. LLL LJ LL LL LaL Lg vZELL Evtl OvSLL LES oo OvSZL LESOL Err 9v66 J 68v c Dirt LLLZZ 0862 ESA 06vl J Seel LE ges le O 6c 82 Le 92 Sc ve amp ce L OC 6l 8L Lt DL SL vl EL eL LL OL 6 8 9 S v L elo yan pee Josuas 1x3 piouejos umop dn eoe serq 1ejsueJ tepuosas uoinj uoneusibeu x seiq 1ejsuen reu Lig A serq 1ejsuen Arewnd 2 seig Jajsue Areuiugd IN Seq 19Jsue Aewnd 01 peeu jud q31 A peeu juud qa1 9 peeu puud q31 IN peay 1uud q31 y Seiq onge Buido e eg x seiq 1euBeui Buidoje eq A Seiq e eejs Buido e eg A Seiq 1euBeui Buridoje eq 9 seiq a ajs Dudo Ger 9 seiq joubeu Buidojaneq IN Seq anaa s Buido auer IN seig 1euBeui Buidoje eq 9 1eB1euo ureyy A 1eB1euo uen 9 1e81euo urea IN 1351299 urew due J9selg 2 4 9 le O 6c 82 Le 92 Sc ve ce L O 6b DL Z OF GL ve EL ct LL OL 6 8 9 S v e L feig t6284 oZoSL 2962 DIr plougjos paa e dN LZZLE Lptboc Glee SE vZlL JOSUOS yxy EIS EE U U plougjos umop dn eoe S9vec 6SvSI parse spree 8Sv0c Pot LU seiq 1ejsueJ repuodas S v9c 128403 63p8L bezel LE ES pp i es yoynjo uo Mee DC 60691 c8Svt 068 A a AAA ot O 9 seg Jaysue Ueuuud Olele Less POS seg WU o N A serg Jaysue Arewiid ZE86L esto 9Z8LL v19 2 Seq Jejsue Areuiugd vSv8l 7AA 8vtOL 697v IN Seq 1e
58. MM PWB bit6 Erasing to the system DIMM PWB bit7 Writing to the system DIMM PWB bit8 Checking the blank after erasing to the system DIMM PWB bit9 Verifying after writing to the system DIMM PWB 1 4 4 CLP Service items Description Items Description 3 Serial interface information RS2 RS 232C RS4 RS 422A G Optional unit information Upper 2 bytes Bit 0 MPF Bits 1 to 6 Feeders 1 to 6 6 is not supported Bit 7 Duplexer Bit 9 Envelope feeder Bits 10 to 15 Reserved Lower 2 bytes Bit 0 Face up Bit 1 Face down Bits 2 to 15 Reserved 25 Operation panel message language PMSG command setting decimal C Current temperature 0 to 60 C in 1 C increment Humidity temperature sensor is abnormal Current humidity 10 to 9096 RH in 296 increment Average printing ratio 2 digits for integer part 1 digit for decimal part Cyan Magenta Yellow Black Printing ratio for the total period from shipping displayed in 9 Media type attributes Media type setting value from 1 to 28 fixing temperature paper thickness duplex printing refer to next page 14 to 20 are unused and always 0x00 Memory SPD information slot 1 Bus error if all digits are E 6 Memory SPD information slot 2 Bus error if all digits are E 62 Engine parameter setting Hexadecimal 128 bytes 256 digits 63 Drum se
59. PWB KP 1054 normally lamp 4 PWB KP 976 Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective drum PWB 4 KP 972 Replace the black drum unit See page 1 6 12 Defective harness between drum PWB KP 972 and eraser lamp 4 PWB KP 976 or poor contact of the connector termi nals Check the connection of the YC401 connec tor of the drum PWB KP 972 if there is trouble remedy or replace Defective harness S02869 between engine controller PWB KP 1054 and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Check the continuity of the harness S02869 check the connection YC3 con nector of the engine controller PWB KP 1054 if there is trouble remedy or replace Defective LED print heads relay PWB KP 1048 Replace the LED print heads relay PWB KP 1048 See page 1 6 28 1 5 6 CLP Code Contents Remarks Causes Check procedures corrective measures 5302 Eraser lamp 2 error cyan drum unit Defective eraser Replace the eraser lamp 2 PWB KP 976 The eraser lamp 2 PWB KP 976 of lamp 2 PWB KP the cyan drum unit does not communi 976 ie eae den SORINONSHENVS Defective engine Replace the engine controller PWB KP controller PWB 1054 See page 1 6 25 KP 1054 Defective drum Replace the cyan drum unit See page 1 6
60. PWB KP 1054 See page 1 6 25 Defective harness S02849 between engine controller PWB KP 1054 and sensor PWB KP 982 or poor con tact of the connector termi nals Check the continuity of the harness S02849 check the connec tion YC2 connector of the engine controller PWB KP 1054 check the connection YC701 and YC702 connectors of the sensor PWB KP 982 if there is trouble remedy or replace 1 5 18 Problem Causes CLP Check procedures corrective measures 3 Close paper transfer unit display is not cancelled to closing the paper feed unit Defective top cover paper feed unit switch SW701 of the sensor PWB KP 982 Replace the sensor PWB KP 982 Malfunctioning interlock rod that interfaces between the top cover and the top cover paper feed unit switch SW701 Check to see if the interlock rod malfunctions If it malfunctions repair it Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective harness 802849 between engine controller PWB KP 1054 and sensor PWB KP 982 or poor con tact of the connector termi nals Check the continuity of the harness S02849 check the connec tion YC2 connector of the engine controller PWB KP 1054 check the connection YC701 and YC702 connectors of the sensor PWB KP 982 if there is trouble remedy or replace 4 Cassette 1 not loaded display
61. PWB 2 KP 972 12 Defective harness Check the connection of the YC401 connec between drum tor of the drum PWB 2 KP 972 if there is PWB 2 KP 972 trouble remedy or replace and eraser lamp 2 PWB KP 976 or poor contact of the connector termi nals Defective harness Check the continuity of the harness 802869 between 802869 check the connection YC3 con engine controller nector of the engine controller PWB KP PWB KP 1054 1054 if there is trouble remedy or replace and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 5303 Eraser lamp 1 error magenta drum Defective eraser Replace the eraser lamp 1 PWB KP 976 unit The eraser lamp 1 PWB KP 976 of the cyan drum unit does not communi cate with the engine controller PWB KP 1054 normally lamp 1 PWB KP 976 Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective drum PWB 1 KP 972 Replace the magenta drum unit See page 1 6 12 Defective harness between drum PWB 1 KP 972 and eraser lamp 1 PWB KP 976 or poor contact of the connector termi nals Check the connection of the YC401 connec tor of the drum PWB 1 KP 972 if there is trouble remedy or replace Defective harness S02869 b
62. Rear cover open close sensor rear cover Open Close Fuser thermistor 1 detection voltage output Fuser thermistor 2 detection voltage output 2 3 2 Engine controller PWB Main controller PWB Reset IC U10 Engine controller PWB LED print heads relay PWB box fan motor Main high voltage PWB Engine relay PWB 3 3V LED print heads control EEPROMs control Sensors switches signals CLP Sensor Data Address multiplex bus N Address bus controller Micro U8 Address bus Paper full sensor signal Eraser driver circuit Q13 Controller Q12 EEPROM U11 EEPROM U12 Face up down solenoid control PWB Q11 Controller box fan motor driver circuit Q39 Main charger control Exit sensor signal Zero cross signal Power Fuser heater lamps control supply Toner motor driver circuit Q14 Q16 Q15 Q17 Drum motor driver IC U14 Intermediate transfer belt motor driver IC U18 Fan motor driver circuit Q27 Toner sensors signals a ka Abnormal temperature detection circuit U1 Fuser thermistor signals PWB Clutch driver 5V 24V lt circuit Q39 Q40 Fuser motor Feed motor driver IC U21
63. S02863 check the connec tion of YC802 connector of the bias high voltage PWB KP 980 check the connection of YC682 connector of the waste toner full sensor PWB KP 974 if there is trouble remedy or replace Defective harness 802862 between waste toner full sensor and waste toner full sensor PWB KP 974 or poor contact of the connec tor terminals Check the continuity of the harness S02862 check the connec tion YC681 connector of the waste toner full sensor PWB KP 974 if there is trouble remedy or replace Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 1 5 19 CLP Problem Causes Check procedures corrective measures 6 The paper size is not recognized as the size set with the paper size dial Defective cassette size switch Replace the cassette size switch Defective sensor PWB KP 982 Replace the sensor PWB KP 982 Defective harness S02861 between cassette size switch and sensor PWB KP 982 or poor contact of the connector terminals Check the continuity of the harness S02861 check the connec tion YC703 connector of sensor PWB KP 982 if there is trouble remedy or replace Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 7 Paper misfeed dis play is not cancelled Defective registration sen Sor Replace
64. SECCION corran 2 1 7 abge A A A leona AA 2 1 7 2 Touch down developing method eese ennemis 2 1 9 illu m 2 1 10 LOOP LU a PET OO OE M 2 1 10 2 Waste toner ejecting mechanism cccecceeecence esses ee eeeeeeeeeeee sees nennen nennen tenen a 2 1 13 SLED Orit Le P Rm 2 1 14 4 O Ee tera e 2 1 16 Primary iransterSeclOn oot en epe et 2 1 18 1 Primary transfer Unit tedesco etre herede eter A lea revue duit eet cadens 2 1 18 2 Primary transfer cleaning Uhlil 3 3 rr r EXER E ERAS RUE rela Re E eege instead HAS 2 1 20 Secondary transfer and separation Section nennen 2 1 23 ele le M 2 1 25 aS eee 2 1 25 2 2 Electrical Parts Layout 2 2 1 Electrical PariSlayOut ci e E 2 2 1 1 Main frame and controller DOX icr rient eet a a ede ndi da 2 2 1 2 Drum unit developer unit and fuser unit nennen enne 2 2 8 CLP 2 3 Operation of the PWBs 2 8 1 Power supply PWB sce cstv death winds ey eit ened edita dde dee Eel e eut enone 2 3 1 2 3 2 Engine controller PWB ci ia 2 3 3 1 Fuser heater lamps control circuit sissen cere eera ee aa ED EOE AE NETE 2 3 4 2 Interlock and 24 V DC power supply circuit seeeeenennenm nennen 2 3 5 2 9 9 Main
65. T S d Pa S ES 9b 91 90 9 S4SGAT SNSGAT o E E 2 opgi Lengt 9ASOAVINSCA o 5 a ve vl tvivl ZASGAVZNSGAT 5 E WE gt o ev el Eb l S4SGAV SNSGAT z S 22 allas o ev et Zb 21 GaSQA V6NSOAT ui 8 SEILER E Lb LL LULL OLdSGAT OLNSGAT 5 cla sje se ont 09 01 LLdSGAT ELNSGAT h hi 66 6 6 6 ZLdSGAV ZLNSGAT 88 8 88 8 LdSGAV ELNSGAT g ZEIL Z lZ vLASOAVYENSCAT o 96 9 98 9 SLdSGAVSLNSGAT 38 ei 8 he S 83 25 S S SE 8 AND OND ER ER Sg S86 EK velv vere LASZ HLASZ ER So 25 B95 5 a see EE LAS Z HLAS e _ E _ 2 _ OFZ _ S zen zere LAS Z HLAE E SE N ee m 8 8 8 S 8 Len i LAS LAE E we CN LE lt Lo Z 1 M AA Xy SSS a y d _ I 2 4 12 _ CLP 12 Repetitive defects gauge First occurrence of defect y 31 16 mm Upper registration roller n 33 28 mm Developing sleeve 191 21 mm Lower registration roller 159 33 mm Secondary transfer roller y 94 4 mm Drum 1 115 6 mm Heat roller Press roller 2 4 13 CLP 2 4 14
66. UES COUPER L ALIMENTATION DEL REEMPLAZO DEL FUSIBLE AVANT DE REMPLACER LE FUSIBLE PRECAUZIONE PRECAUZIONE PRIMA DI CAMBIARE FIESIBILI O PRIMA DI CAMBIARE FIESIBILI O DI ESEGUIRE RIPARAZIONI DI ESEGUIRE RIPARAZIONI ou STACCATE IL CADO DI ALIMENTAZIONE gt ABS lt YM MADE IN JAPAN gt ABS lt MADE IN JAPAN Top cover Magenta toner container Cyan toner container Yellow toner container Black toner container Paper feed unit MP tray Paper cassette Paper size window 10 Paper size dial 11 Paper gauge 12 Left side cover 13 Waste toner box 14 Power switch 15 Magenta main charger unit OONDARWN Figure 1 1 1 16 17 18 19 20 21 22 23 24 25 26 2 28 29 30 CLP Cyan main charger unit Yellow main charger unit Black main charger unit Main charger wire cleaner Lens cleaner Rear cover Fuser cover Paper feed unit release lever Memory card slot AC inlet Optional interface slot Parallel interface connector USB interface connector Network interface connector Rating label CLP 2 Operation panel DNOARWN Message display Interface indicator INTERFACE Paper size indicator SIZE Paper type indicator TYPE Ready indicator READY Data indicator DATA Attention indicator ATTENTION lt key Left Figure 1 1 2 gt key Right A key Up V key Down MENU key
67. USOLDR EXITPAP 24V2 HEAT1DR HEAT2DR ZCROSS SLEEP 24V1 24V1 24V1 24V1 GND GND GND GND GND GND GND GND 3 3V1 3 3V1 3 3V1 3 3V1 5V1 5V1 o0o 00 0000 0 00 Analog Analog 0 24 V DC 5V DC 0 5 V DC 0 24 V DC 0 5 V DC 24 V DC 0 24 V DC 0 24 V DC 0 5 V DC pulse 0 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 3 3 V DC 3 3 V DC 3 3 V DC 3 3 V DC 5V DC 5V DC Fuser thermistor 1 detection voltage output Fuser thermistor 2 detection voltage output Face up down solenoid control signal 5 V DC power output Rear cover open close sensor rear cover Open Close Face up down solenoid control signal Exit sensor On Off 24 V DC power output Fuser heater lamp 1 On Off Fuser heater lamp 2 On Off Zero cross signal output Eco mode control signal input Normal Eco mode 24 V DC power output 24 V DC power output 24 V DC power output 24 V DC power output Ground Ground Ground Ground Ground Ground Ground Ground 3 3 V DC power input 3 3 V DC power input 3 3 V DC power input 3 3 V DC power input 5 V DC power output 5 V DC power output Connected to the fuser PWB 2 3 2 GND 24V2 FDDR EXITPAP FUSOLDR 5V1 RCOVOP TH1 TH2 24 V DC 0 24 V DC 0 5 V DC 0 24 V DC 5VDC 0 5 V DC Analog Analog Ground 24 V DC power output Face up down solenoid control signal Exit sensor On Off Face up down solenoid control signal 5 V DC power output
68. VDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS 5 V DC power output Paper full sensor On Off 5 V DC power output 5 V DC power output Ground Ground Ground Ground Connected to the engine relay PWB ST4A STMIDB ST4B STMIDA ST4A STMIDB ST4B STMIDA TNM4DR TNSEN4 TNSEN3 ST3B TNM3DR ST3A 24V2 ST3B 24V2 ST3A GND GND TNSEN2 HFANDR TNM2DR OZFANDR TNSEN1 TNM1DR ST2A ST1B ST2B ST1A ST2A ST1B ST2B ST1A O O O O O O O O O O O O O O O O OOO 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC Analog Analog 0 24 V DC pulse DCOV 24V 0 24 V DC pulse 24V DC 0 24 V DC pulse 24V DC 0 24 V DC pulse Analog 0 24 V DC 0 24 V DC 0 24 V DC Analog 0 24 V DC 0 24 V DC pulse 24 V DC 0 24 V DC pulse 24 V DC 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse Drum motor 4 black energization pulse Primary transfer motor energization pulse Drum motor 4 black energization pulse Primary transfer motor energization pulse Drum motor 4 black energization pulse Primary transfer motor energization pulse Drum motor 4 black energization pulse Primary transfer motor energization pulse Toner motor 4 black On Off Toner sens
69. YI ESN z duer sayeay Josny 10 S1W19U J9SNY 046 dM lu OV 28994 191104 iq n amd 1esn4 e S19 O4 Jejsuen LHL v69 Fall sersass _jeubew repuodas ysniq_ c JOIS LUISUl 168n3 mar 1220690 a ZHL r a E z Ende e Buidojeneq Buidoje eg si9jjo1 Bujueajo TIT E6991 ale His E E THL 8 n o SjoD1euo Jajsuen ejsueg ZHL 3 donou donoou 4 O Ox uey ewig Jeuwud LAS CE rage LE S8 y THS 9 ZS OA OA Yyoums 109099 i s s ama S v iw s s ezis asojouado y y Of foy lev z Ohl y Oo oo 13A09 Ee dyd 1X3 Vd LIX ez ayesseg Y jeje ev ev ele S 33 On ON z e ay y y LSD le SEE PONA C dr ZAvet zweit Dg rere meee Sie 108098 193 aNg LE V sv S QNS En EA i yada 1699 20694 NES olololo o umop dn z omo vS8c0S S820S Roo 086 4M aleiza E pei SES Y 26994 Jo1oeuuo2 amd Ajddns 160g zogoA 40Sues preoq 2 m yun Jeer yeysul obeyon ufiu seig 826 43 Jepeej NOA g 10sues L youms U9iMS yms 2 or doj9Au3 car A a c e A EOLOA oo e8ne6 jedeq J9 02 J9 02 jun pooj 9 m m LOGIA 1osues D I xr A doma EOZHd y iosuas GOL 9PIS Jour dol zge qy 10J0U 35 JB e jeded CLIT g 8 d Za Eo e6ne6 sadeg Y an al ae UE xoq SKEEEER Be Aen din Gosa LOZOA E josuas Z0ZHd ous Lozms S j omoo Dg zossoo99 29 ete 9nG E Kb EK Erde BUBDHAEBDNHASOMNANAWN SONDAN r E EE uoneusiDe GIS O5lr SS Soo ce uomerogoc oo oosromw SONDAN WT 20 04 poo No o LOLA E 3 520m2299995605 Ol l lt l
70. ase 2 IB 21E 10 Base TX 100 Base TX wireless LAN card IB 22 must be installed Controller software a Emulation PCL6 PCL5e PCLXL KPDL3 PostScript 3 compatible b Fonts Bitmap font 1 Line Printer bitmap font Outline fonts 80 PCL fonts 136 KPDL3 fonts c Graphic 1 Raster graphic 75 100 150 200 300 600 dpi 200 dpi is supported when the resolution is 600 dpi 2 Vector graphic Line Box Circle Arc Fill pattern etc 3 Bar code One dimensional bar code 45 types Two o dimensional bar code 1 type PDF 417 d Connectivity plug amp play Windows 95 98 ME NT4 0 2000 XP SNMP KM NET viewer Ftesolution csi 600 x 600 dpi multi 4 bit NIE Main unit 385 x 345 x 470 mm 15 16 x 13 58 x 18 5 W x D x H WIG dioe ec ene te taie Main unit 22 kg 48 6 Ibs not including toner containers Power source 220 240 V AC 50 60 Hz European countries 120 V AC 60 Hz U S A Canada Power consumption Maximum 991 W 220 240 V model 1037 W 120 V model Normal operating 483 W 220 240 V model 491 W 120 V model Ready 202 W 220 240 V model 199 W 120 V model EcoPower 26 W 220 240 V model 22 W 120 V model G ne MEE 4 5 A 220 240 V model 9 1 A 120 V model Neee d e Printing 53 dB A Ready 39 dB A ODItiORlS 2 niet rient petes Expansion memory 32 64 128 256 MB 100 pin DIMM memory card CompactFlash hard disk unit
71. at from the drum motors Controller box fan motor eenen Dissipates heat from the controller box MP tray feed solenoid AAA Controls the primary paper feed from the MP tray Registration clutch Controls the second paper feed Feed clutch Controls the paper cassette paper feed AC inlet emere Connects the AC power source Expanding memory optional For expanding main RAM Expanding memory card optional Expands the print job function Expanding board optional Expands the interface network interface card or serial interface board 2 2 2 CLP 2 Drum unit developer unit and fuser unit 13 14 15 16 DRUM UNIT DEVELOPER UNIT FUSER UNIT Figure 2 2 2 Drum unit developer unit and fuser unit Drum PWB 1 2 3 Aint Drum PWB 1 magenta drum PWB 2 cyan drum PWB 3 yellow drum PWB 4 black wiring relay circuit inside each color drum unit Drum individual information in EEPROM storage Zener PWB 1 2 3 4 Adjusts the main charger grid electrostatic potential F ser PWB ele p terre c Relays wirings from electrical components on the fuser unit LED print head memory PWB 1 2 3 4 LED print head memory PWB 1 magenta LED print head memory PWB 2 cyan LED print head memory PWB 3 yellow LED print head memory PWB 4 black storage of compensation data of each color LED print head of each d
72. ation panel display is also downloadable so that a new message language is appended for the operation panel The message data should be downloaded directly from PC 1 Format of the firmware files The file names for the firmware files have the following formats System firmware file name example a80k9100PS3 bcmp Compression L Boot program attached PSS version Version code Version 91 00 Kyocera Mita ID code Product code 80 FS C5016N System firmware Engine firmware file name example E80KA001 x Version code Version A001 Kyocera Mita ID code Product code 80 FS C5016N Engine firmware Operation panel message data file name example dm8002 spa Language code __ jpn Japanese dan Dutch swe Swedish ita Italian spa Spanish Product code 80 FS C5016N por Portuguese rus Russian pol Polish L cze Czech Version code Version A02 L Operation panel massage data Figure 1 7 1 1 7 1 CLP 2 Downloading firmware via the parallel interface To download the system firmware using the parallel interface use the procedure below Note that you can download both the system and engine firmware at a time 1 Turn printer and PC power off 2 Connect the parallel printer cable between the PC and the printer Parallel interface connecto
73. ba mas 5 uoneJado Bees M S8S33 SS gs el 0 S3 on 8 eng ow S ow S 2228 zk g ee 28326 g SASS 2222 22822 Ze E SESS aaa duda E ESOS g sl 25 lev 3 IS 3 on g Qv S S555 SS S SSS SSS BS X Ee o Qo col y D 10 OUJ JOJOUI Josues 23 ea es ENS 53 oma sem son kon EEE 2 3 y RON S wxg pee4 aruo 53 328 133 188 38 Cera usen ueko mole JOJOUI SAS AIS eweDew eI moja B gt S m gs Josuas y Josuas Josuas Z Josues jejsuen IS IS Bg Jojow y 100W J010UJ S Sg 1euo 13u01 Jeuo jeuo ege Ss Ro wng wnq wng KS B ES ILI 2 4 11 CLP pale aan 71 l l e _ l mo a Ge Emo ER Eme L ama
74. bias high voltage PWB 3 Check or replace the bias high voltage PWB and then refit all the removed parts Latches Latch Connector Bias high volatage PWB Figure 1 6 41 1 6 30 CLP 1 6 10 Others 1 Detaching and refitting the main drive unit Procedure 1 2 3 4 Remove the right cover see page 1 6 3 Remove the seven connectors Remove the six screws and then remove the main drive unit Check or replace the main drive unit and then refit all the removed parts Connectors 2 Screws m gef EJ a W Lal A Main drive unit Screws Figure 1 6 42 1 6 31 CLP 2 Detaching and refitting the paper feed drive unit Procedure 1 Remove the right cover see page 1 6 3 2 Remove five connectors 3 Remove the harness from the two wire Connectors hooks Wire hooks 4 Remove the three screws and then remove the paper feed drive unit 5 Check or replace the paper feed drive unit and then refit all the removed parts Paper feed drive unit Screws Figure 1 6 44 1 6 32 3 Detaching and refitting the fuser drive unit Procedure 1 Remove the right cover see page 1 6 3 2 Remove the one connector 3 Remove the two screws and the remove the fuser drive unit 4 Check or replace the fuser drive unit and then refit all the removed parts Figure 1 6 45 CLP Connector 1 6 33 CLP
75. can download both the sys tem and engine firmware at a time 1 Turn printer power on 2 Insert the memory card into the printer s memory card slot 3 Press MENU key on the printer s operation panel and carry out the memory card for matting procedure 1 4 When formatting is complete turn printer power off 5 Remove the formatted memory card from the memory card slot Memory card slot Figure 1 7 4 Message display Ready Operation panel keys Press the MENU key Press the V or A key Y Memory Card E Press the ll key Press the Vor Akey gt Format O Press the ENTER key Y gt Format i Press the ENTER key Y Processing Format information is automatically printed Ready i i Figure 1 7 6 Memory card slot m Memory card Figure 1 7 7 1 7 3 CLP 6 Insert the memory card to the PC s slot or to the adaptor 7 Copy the firmware file to download to the root directory of the memory card 8 Remove the memory card from the PC s slot or the adaptor 9 Confirm that the printer s power switch is set to off 10 Insert the memory card into the printer s memory card slot 11 Turn printer power on The firmware file in the memory card will be automatically down loaded 12 Message display 4 is displayed during downloading When message display 2 is displayed to indicate downloading is fin ished 13 Turn
76. ck the connection YC3 con nector of the engine controller PWB KP 1054 if there is trouble remedy or replace Defective LED print heads relay PWB KP 1048 Replace the LED print heads relay PWB KP 1048 See page 1 6 28 1 5 8 CLP Code Contents Remarks Causes Check procedures corrective measures 6000 Fuser temperature time out error Defective installa Check the installation condition of fuser ther heat roller tion condition of mistor 1 if there is trouble remedy or Doing the control which turns on the fuser thermistor 1 replace See page 1 6 18 fuser heater lamp 1 which is built in to the heat roller of the fuser unit the oe 1 ids the Fuser thermostat 1 See page fuser temperature which fuser ther operarea mistor 1 detects stipulated tempera Defective engine Replace the engine controller PWB KP ture did not rise within stipulated time controller PWB 1054 See page 1 6 25 KP 1054 Defective power Replace the power supply PWB See page supply PWB 1 6 25 Defective fuser Replace the fuser PWB KP 970 PWB KP 970 Defective harness Check the harness of the fuser thermistor 1 of the fuser ther check the connection YC694 connector of mistor 1 or poor the fuser PWB KP 970 if there is trouble contact of the con remedy or replace nector terminals Defective fuser Replace the fuser heater lamp 1 See page heater lamp 1 1 6 18 Defective harne
77. connection CN2 con fuser unit connec nector of the power supply PWB if there is tor and power sup trouble remedy or replace ply PWB 6120 Fuser abnormal high temperature Defective engine Replace the engine controller PWB KP error press roller Abnormal high fuser temperature of the press roller was detected controller PWB KP 1054 1054 See page 1 6 25 Defective fuser PWB KP 970 Replace the fuser PWB KP 970 Defective power supply PWB Replace the power supply PWB See page 1 6 25 Defective installa tion condition of fuser thermistor 2 Check the installation condition of fuser ther mistor 2 if there is trouble remedy or replace See page 1 6 18 1 5 11 CLP Code Contents Remarks Causes Check procedures corrective measures 6130 Fuser thermistor 2 broken error Defective engine Replace the engine controller PWB KP press roller controller PWB 1054 See page 1 6 25 It was judged it has been broken from KP 1054 a faoi May it iS nor me input signal Defective harness Check harness of the fuser PWB KP 970 rom of the fuser thermistor 2 which e detects the fuser temperature of the of the fuser PWB check the connection YC693 connector of KP 970 between the fuser PWB KP 970 if there is trouble press roller fuser thermistor 2 remedy or replace or poor contact of the connector ter minals Defective harness
78. ctive color calibration Causes Check procedures corrective measures Defective developing sleeve bias output Defective developer Check the four colors of image by using the test print of service mode If the defect appears on a particular color replace the developer for that color See pages 1 4 11 1 6 11 Defective bias high voltage PWB Replace the bias high voltage PWB KP 980 See page 1 6 30 Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 Defective main controller PWB Replace the main controller PWB KP 957 See page 1 6 24 Defective drum unit Replace the drum unit See page 1 6 12 Defective primary transfer cleaning unit Replace the primary transfer cleaning unit See page 1 6 16 Defective color calibration Dirty sensing surface of the toner ID sensor Clean the sensing surface of the toner ID sensor The printer environment considerably Perform the color calibration of service mode See page 1 6 17 changed since an automatic calibration was made 1 5 24 7 White streaks are printed vertically CLP Causes 1 Defective LED print head output 2 Defective main charging output Causes Defective LED print head output 3 Foreign object in one of the developers 4 Adhesion of soiling to primary transfer belt Check procedures corrective measures Poor insertion of
79. d 2 Paper damp Check procedures corrective measures 1 Paper curled Check the paper storage conditions replace the paper 2 Paper damp Check the paper storage conditions replace the paper 13 Offset occurs Causes 1 Deformed or worn cleaning blade in the drum unit 2 Wrong types of paper Causes Check procedures corrective measures 1 Deformed or worn cleaning blade in the Replace the drum unit See page 1 6 12 drum unit 2 Wrong types of paper Check if the paper meets specifications Replace paper 14 Part of image is missing Causes 1 Paper damp 2 Paper creased 3 Drum condensation 4 5 Flawed drum Flawed primary transfer belt Causes Check procedures corrective measures 1 Paper damp Check the paper storage conditions replace the paper 2 Paper creased Replace the paper 3 Drum condensation Perform the drum surface refreshing See page 1 4 13 4 Flawed drum Replace the drum unit See page 1 6 12 5 Flawed primary transfer belt Replace the primary transfer unit See page 1 6 14 1 5 27 CLP 15 Fusing is loose Causes 1 Wrong types of paper 2 Defective pressure for the heat roller and press roller 3 Flawed heat roller or press roller Causes Check procedures corrective measures 1 Wrong types of paper Check if the paper meets specifications replace paper 2 Defective pressure for the heat rol
80. d press roller See page 1 4 14 1 5 23 CLP 5 Image is too light Causes 1 Defective developing bias output 2 Dirty drum 3 Dirty SELFOC lens of LED print head Causes Check procedures corrective measures 1 Defective developing bias output A Defective developer Check the four colors of image by using the test print of service mode If the defect appears on a particular color replace the developer for that color See pages 1 4 11 1 6 11 B Defective bias high voltage PWB Replace the bias high voltage PWB KP 980 See page 1 6 30 A Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 B Defective main controller PWB Replace the main controller PWB KP 957 See page 1 6 24 C Defective drum unit Replace the drum unit See page 1 6 12 2 Dirty drum Perform the drum surface refreshing See page 1 4 12 3 Defective color calibration A Dirty sensing surface of the toner ID sen Clean the sensing surface of the toner ID sensor sor B The printer environment considerably Perform the color calibration of service mode See page 1 4 10 changed since an automatic calibration was made 4 Dirty SELFOC lens of LED print head Clean the SELFOC lens of LED print head by using LED cleaner 6 The background is colored Causes 1 Defective developing sleeve bias output 2 Defective primary transfer cleaning unit 3 Defe
81. diagram 2 1 19 CLP 2 Primary transfer cleaning unit The primary transfer cleaning unit is composed of the fur brush brush cleaning roller cleaning blade and cleaning screw After secondary transferring is done the toner which remains in the primary transfer belt is collected back in the waste toner box The brush cleaning roller and the fur brush are applied with the DC bias of approximately 500 V DC through the conductive cleaning frame from the main high voltage PWB The voltage at the fur brush is approximately 300 V DC The toner remaining on the primary transfer belt is transferred onto the fur brush that is biased and continuously revolving It is then scraped off of the fur brush by the metal brush cleaning roller in the cleaning frame The brush cleaning roller has the cleaning blade which scrapes off the waste toner The waste toner scraped off of the brush cleaning roller falls onto the cleaning screw then driven outward from the cleaning frame Fur brush Brush cleaning roller Cleaning blade Cleaning screw Cleaning frame 1 2 3 4 5 Figure 2 1 27 Primary transfer cleaning unit 2 1 20 CLP Fur brush Brush cleaning roller Cleaing frame Engine controller PWB Main high voltage PWB Fur brush D A YC801 6 HVBDATD 500 V DC Output pias output converter YC801 7 HVBCLKD eee circuit IC501 vC801 8 HVBLATD es Figure 2 1 28 Pri
82. e 1 6 36 1 6 26 10 The EEPROM U12 removing from the socket of the old engine controller PWB it does again to install in the socket of the new engine controller PWB 11 Remove the three screws one terminal one washer and then remove the power supply PWB 12 Check or replace the engine controller PWB and power supply PWB then refit all the removed parts CLP EEPROM U12 Engine controller PWB Figure 1 6 37 Screw Power supply PWB Terminal Im Screws Figure 1 6 38 1 6 27 CLP 3 Detaching and refitting the LED print heads relay PWB Procedure 1 Remove the left cover see page 1 6 4 2 Unlatch the four latches and remove the two connectors and then remove the LED print heads relay PWB 3 Check or replace the LED print heads relay PWB and then refit all the removed parts Latches LED print head relay PWB Figure 1 6 39 1 6 28 4 Detaching and refitting the main high voltage PWB Procedure 1 Remove the right cover see page 1 6 3 2 Unlatch the four latches and remove the one connector and then remove the main high voltage PWB 3 Check or replace the main high voltage PWB and then refit all the removed parts Latches Figure 1 6 40 CLP 1 6 29 CLP 5 Detaching and refitting the bias high voltage PWB Procedure 1 Remove the right cover see page 1 6 3 2 Unlatch the five latches and remove the two connectors and then remove the
83. e LED print head memory PWB time of 30 seconds is required CLP Connecotors Harness Connecotor LED print head Drum unit fl Hooks es Hook LED print head cover A Hook Figure 1 6 17 1 6 13 CLP 1 6 7 Primary transfer section 1 Detaching and refitting the primary transfer unit Procedure Handle Primary transfer unit 1 Remove the all drum units see page 1 6 12 2 Pull two handles and raise 3 Remove the primary transfer unit with the handles 4 Check or replace the primary transfer unit and then refit all the removed parts Handle Figure 1 6 18 1 6 14 2 Detaching and refitting the primary transfer belt Procedure 1 Remove primary transfer unit see previous page Remove the two handles 3 Remove the two screws and then make the primary transfer unit two fold Remove the primary transfer belt 5 Check or replace the primary transfer belt and then refit all the removed parts N B CLP 7h aN Primary transfer belt B cm Handle o Primary transfer unit Figure 1 6 19 1 6 15 CLP 3 Detaching and refitting the primary transfer cleaning unit Procedure 1 Remove the primary transfer unit see page 1 6 14 2 Pull out the primary transfer cleaning unit from the main unit frame a little with under neath the right 1 3 Pull out the waste toner outlet 2 which is on the left side of the primary transfer cleaing un
84. e socket of the engine controller PWB KP 1054 The total counter serial number and engine parameter etc are stored in the EEPROM U12 Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 EEPROM U12 installing malfunc tion Check the bending of the lead pin and float ing of the IC there is trouble if there is trou ble remedy or replace EEPROM U11 write error When it cannot make normal to access to the EEPROM U11 which is mounted on the engine controller PWB KP 1054 Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 raper feeder communication error When turning on power the ASIC of the engine controller PWB KP 1054 recognized the optional paper feeder PF 60 but when it becomes not be able to communicate from the middle After the error occurring when power Source is turned on off there are times when the paper feeder is not recognized Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective paper feeder PF 60 After removing or replacing the paper feeder PF 60 do the operation check If operation is normal replace the paper feeder PF 60 Defective duplexer DU 300 If the duplexer DU 300 is installed after removing or replacing the duplexer DU 300 do the operation check If operat
85. eck the connection of the LED KP 1040 and print head memory PWB 4 KP 1040 if LED print heads there is trouble remedy or replace relay PWB KP 1048 or poor con tact of the connec tor terminals 0952 LED print head memory PWB 2 com Defective LED print Replace the LED print head 2 of cyan drum unit See page 1 6 13 Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 KP 1054 Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness 802866 between engine controller PWB KP 1054 and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Check the continuity of the harness 802866 check the insertion of YC3 of the engine controller PWB KP 1054 if there is trouble remedy or replace Defective harness 802866 between LED print head memory PWB 2 KP 1040 and LED print heads relay PWB KP 1048 or poor con tact of the connec tor terminals Check the connection of the connector with the cyan drum unit and the printer main unit check the continuity of the harness 802866 check the connection of the LED print head memory PWB 2 KP 1040 if there is trouble remedy or replace 1 5 4 CLP Code Contents aad Causes Check procedures corrective measures 0953 LED print head memory PWB 1 com De
86. ed to the controller PWB again from the EEPROM In case of failure with EEPROM on the LED print head memory PWB or with compensating data the printer displays service call 0951 0952 0953 or 0954 within approximately 30 sec onds LED print heads relay PWB Engine Main controller controller STREQ1 STROBE1 PWB PWB HSYNC1 STBCLK1 D110 to 119 D120 to 129 LVDSNO to 15 LVDS 2000000000 LVDSPO to 15 Drum unit EEDATA Serial communication Micro controller Serial communication c aS yyy Drum unit Drum unit ped LVDS Low Voltage Differential Signaling prin head LED memory print PWB head o Figure 2 1 19 LED print head block diagram 2 1 15 CLP 4 Main charger unit Main charger unit is comprised of the main charger wire main charger grid main charger shield and the main charger cleaner which are modularized and fitted to the drum unit L Main charger unit Main charger grid Main charger shield Main charger cleaner Bom Figure 2 1 20 Main charger grid Main charger cleaning pad Main charger shield Main charger cleaing knob Figure 2 1 21 Main charger unit 2 1 16 Main charger unit Main high voltage PWB Output Shield N Wire pe DT e X e _ j PWB 1 Drum p
87. eee eee OZLOL v849 ses Ao y Ll vci9 OZLOL v9 9 DCL velo Seve 6ZES 082 6 09 34 E Seve 6809 6LES 084 SY a gt IESEL meee O6rL 9vLcL LOVE Sy Un 99904 eS8el oz GL SL Di 9r St FL EL ZL LL OL 6 8 9 S E zZ s 0 plouajos paaj Aen dN Josuas 1X3 plouajos umop dn a9e 4 seiq Jaysuey repuodas yayo uonesibay x se q 19 sue Aewnd A seq saysuesy Arewnd 9 seq 19Jsue1 Ae IN Seq 1ejsuea Aaeuiud 01 peeu quud q31 A peeu 1uud qan 9 peeu uud q31 W peeu 1uud q31 x Seiq e eejs Buidojo eq x seiq jouBew Buidoje eg A serq e eejs Buidojo eq A serq 1euBeui Buidojo eq 2 seig e eejs Burdojanag 9 seq joubeu Buidojansq IN seiq e eejs Buidoje eq IN Seiq 1euBeuu Buidoje eq y seBseyo urea A JoBseyo ure 9 1e81euo ure IN 1e81euo ure due 19se13 2 4 4 CLP Ize hart No 5 MP tray Legal s iming c 5 T Zi 9L SL bl L et LL OL 6 8 L 9 S v 4 L s o 28011 90 v ESCH 2408 piouajos peo Ken dN SE 9zovL oo c9c6 JOSU8S 4x3 90561 96v8 plougjos umop dn e2e4 SH BIEN oeee Stott 828 936 FAT seq Jajsue1 repuodas Z9LSL Z8vLL 8LSOL 8689 yoynjo uoneasib
88. eiq joubew Buidojo eq A Seiq e eejs Buidoje eq A Seiq joubew Buidoje eq 9 seiq e eejs Buidoje eq 9 serq joubew Buidojansq IN Seq ansajs Burdoje eq IN Seiq joubeu Buidoje eq y 1e81euo uen A 19B1eyo uen 9 1eB1euo uen IN 1961ey9 uen due 1 se13 2 4 2 CLP ize hart No 3 Paper cassette Letter s iming c 3 T D GL 8L LL DL SL vl L cL LL DL 6 8 L 9 S v 4 L s o 6108 90 v E yoynjo pee4 DE 66621 2866 Jezel Josues 1x3 82431 9ez8 DE P P o 4 n QQ YAA ATA piouajos umop dn ade tSv 82921 cogi zesor gere Leer seq Jajsue Aepuooag ZSEE SSvOL 06 9 89 yayo uoyensibay EZELL Lerg 9022 vi8v l J x seiq 19jsuen Arewnd 82301 9894 Jaen 6906 _ oc le 2 1 1 A serq 1ejsuem Aled 86 9129 veee Je 2 seiq 19Jsue1 Ae 8806 9619 LL 6LS mm gt al Fi IN seiq saysued Are DZ 9682 6 2v ol Lil peey uud qan 20001 Seco vege LL ys Ll OS A peeu uud G37 2926 90v9 orgs 68 2 9 peeu unid qa zise 1995 S687 vv0z J A A od pP LE e ew bl e E b FU IN peeu 1uud q31 LSOLL vEVL SLOE y seiq e eejs Buidoje eq vez LSOLL tet SLOE TTD e TTT TTF 9 seiq j
89. em error Defective main Replace the main controller PWB KP The error which is related to the sys controller PWB 1054 See page 1 6 24 tem other than the error code FO KP 957 F010 and F020 occurred F040 Engine controller PWB communica Defective engine Replace the engine controller PWB KP tion error controller PWB 1054 See page 1 6 25 The main controller PWB KP 957 KP 1054 does not communicate to the engine F 8 Defective main Replace the main controller PWB KP 957 controller PWB KP 1054 normally controller PWB See page 1 6 24 KP 957 F050 Engine controller PWB flash ROM Defective engine Replace the engine controller PWB KP error Abnormality occurring in the flash ROM which is mounted on the engine controller PWB KP 1054 the main controller PWB KP 957 received notification controller PWB KP 1054 1054 See page 1 6 25 1 5 17 CLP 1 5 3 Electrical problems Problem Causes Check procedures corrective measures 1 Close top cover display is not cancelled to closing the top cover Right edge of the top cover floating it is not closed completely Close the top cover securely Defective top cover switch 2 Replace the top cover switch 2 Defective top cover paper feed unit switch SW701 of the sensor PWB KP 982 Replace the sensor PWB KP 982 Defective harness S02846 between engine controller PWB KP 1054 and top
90. emperature in the software system by the input voltage of the TH1 and TH2 signals that are input to the No 3 and 4 pin of micro controller U8 therefore the circuit operates the control to turn off the fuser heater lamps before the mentioned circuit is activated and stops the machine and then indicates the error code 6020 or 6120 that shows the fuser high temperature failure according to the self diagnosis function 2 3 4 2 Interlock and 24 V DC power supply circuit Power supply PWB 24 V DC output circuit Main high voltage PWB 24V3 Fuser PWB RCOVOP cover Engine controller PWB CLP Sensor PWB Top cover Side cover feed unit switch switch 24V2 24V3 FEEDOP SCOVOP ASIC TOPCOVP Top cover switch 1 7 7 TOPCOVP2 BS Top cover switch 2 TTF D Power supply to main fan motor 2 Power supply to eraser lamp drum motor 1 2 3 4 primary transfer motor feed motor i fuser motor ozone fan motor 1 2 bias high voltage PWB feed clutch registration clutch Figure 2 3 4 The 24 V DC power source line is shut off by the top cover feed unit switch or the side cover switch that is turned OFF when the top cover or the side cover is opened At the same time the 24 V DC power supply is stopped to the motor and clutch and it is also output to the ASIC of the engine controller PWB as the cover open d
91. ercurrent of toner motor 3 controller PWB 1054 See page 1 6 25 i KP 1054 Lump of toner Replace the yellow toner container inside yellow toner container or defec tiveness of toner replenishment drive system 7401 Black developer unit non installing Defective harness Check the damage of harness of the toner error The toner sensor 4 inside the black developer unit did not output the den sity detection signal judged the engine controller PWB KP 1054 the black developer unit is not installed of the toner sensor 4 defective con nection of the con nector between black developer unit and the printer main unit or poor contact of the con nector terminals sensor 4 check the connection of the con nector with the black developer unit and the printer main unit if there is trouble remedy or replace Defective toner sensor 4 Replace the black developer unit See page 1 6 11 Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective engine relay PWB KP 966 Replace the engine relay PWB KP 966 1 5 18 CLP Code Contents ene Causes Check procedures corrective measures 7402 Magenta developer unit non install Defective harness Check the damage of harness of the toner ing error of the toner sensor sensor 1 check the connection of the con The toner sensor 1 inside the magenta
92. etection signal The 24 V DC power is divided into five groups of 24V1 24V2 and 24V3 as figure 2 3 4 and the loads that supply the 24 V DC power source or the cover open detection signals are different In the Eco power mode the circuit shuts off the 24V power source that is used by the printer unit in order to reduce the power consumption In the Eco power mode the sleep signal SLEEP becomes L level which is output from the CPU of the engine controller PWB The signal at this level turns off the transistors Q101 of the Eco circuit accordingly the supply of 24V1 to the power line is shut off and the operation of connected load will stop 2 3 5 CLP Connector Pin No Signal VO Voltage Description YC2 1 24V1 O 24VDC 24 V DC power output Connected 2 24V1 O 24VDC 24 V DC power output to the sen 3 24V1 O 24VDC 24 V DC power output sor PWB 4 24V1 O 24V DC 24 V DC power output 5 GND Ground 6 GND j Ground 7 24V2 O 24VDC 24 V DC power output via top cover paper feed unit switch 8 24V2 O 24VDC 24 V DC power output via top cover paper feed unit switch 9 24V2 O 24VDC 24 V DC power output via top cover paper feed unit switch 10 5V2 O 5VDC 5 V DC power output 11 REGPAP 0 5V DC Registration sensor On Off 12 PAPVOLO 0 5V DC Paper gauge sensor 1 On Off 13 PAPVOL1 0 5V DC Paper gauge sensor 2 On Off 14 TCOVOP 0 5V DC Top cover switch 1 Top cover Close Open 15 CASO 0 5V DC Cassette size
93. etween engine controller PWB KP 1054 and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Check the continuity of the harness S02869 check the connection YC3 con nector of the engine controller PWB KP 1054 if there is trouble remedy or replace Defective LED print heads relay PWB KP 1048 Replace the LED print heads relay PWB KP 1048 See page 1 6 28 1 5 7 CLP Code Contents Remarks Causes Check procedures corrective measures 5304 Eraser lamp 3 error yellow drum unit Defective eraser Replace the eraser lamp 3 PWB KP 976 The eraser lamp 3 PWB KP 976 of the yellow drum unit does not commu nicate with the engine controller PWB KP 1054 normally lamp 3 PWB KP 976 Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective drum PWB 3 KP 972 Replace the yellow drum unit See page 1 6 12 Defective harness between drum PWB 3 KP 972 and eraser lamp 3 PWB KP 976 or poor contact of the connector termi nals Check the connection of the YC401 connec tor of the drum PWB 3 KP 972 if there is trouble remedy or replace Defective harness 802869 between engine controller PWB KP 1054 and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Check the continuity of the harness 802869 che
94. etween engine controller PWB KP 1054 and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Check the continuity of the harness 802869 check the connection YC3 con nector of the engine controller PWB KP 1054 if there is trouble remedy or replace 1 5 15 CLP Code Contents Remarks Causes Check procedures corrective measures 7413 Magenta drum unit non installing Defective harness Check the connection of the magenta drum error between drum unit and the printer main unit check the con The EEPROM U401 on the drum PWB 1 KP 972 tinuity of the harness S02867 if there is PWB 1 KP 972 inside the magenta and printer main trouble remedy or replace drum unit does not communicate nor unit or poor contact mally of the connector terminals Defective drum Replace the drum PWB 1 KP 972 PWB 1 KP 972 Defective engine Replace the engine controller PWB KP controller PWB 1054 See page 1 6 25 KP 1054 Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness Check the continuity of the harness S02869 between 802869 check the connection YC3 con engine controller nector of the engine controller PWB KP PWB KP 1054 1054 if there is trouble remedy or replace and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals 7414 Yellow dr
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97. fective LED print Replace the LED print head 1 of magenta munication error magenta drum unit head memory drum unit See page 1 6 13 The LED print head memory PWB 2 PWB 1 KP 1040 vm Gees a EM Defective engine Replace the engine controller PWB KP unit does not communicate with the AA PME 1054 See page 1 6 25 engine controller PWB KP 1054 nor KP mally Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness Check the continuity of the harness 802866 between 802866 check the insertion of YC3 of the engine controller engine controller PWB KP 1054 if there is PWB KP 1054 trouble remedy or replace and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Defective harness Check the connection of the connector with 802866 between the magenta drum unit and the printer main LED print head unit check the continuity of the harness memory PWB 1 802866 check the connection of the LED KP 1040 and print head memory PWB 1 KP 1040 if LED print heads there is trouble remedy or replace relay PWB KP 1048 or poor con tact of the connec tor terminals 0954 LED print head memory PWB 3 com Defective LED print Replace the LED print head 3 of yellow munication error yellow drum unit LED print head memory PWB 3 com munication error yellow drum unit The LED print head memory PWB 3
98. four old drum units See page 1 6 12 2 Remove the LED print head from each old drum unit and then refit to the new drum unit See page 1 6 13 Install the four new drum units Replace the four developer units See page 1 6 11 Replace the fuser unit See page 1 6 18 Replace the paper feed unit See page 1 6 5 Replace the primary transfer unit See page 1 6 14 Replace the primary transfer cleaning unit See page 1 6 16 Replace the two ozone filters See page 1 6 35 10 Replace the retard roller See page 1 6 7 11 Replace the MP tray feed roller See page 1 6 10 o nO Or BG Start Enter the service mode gt gt Maintenance Press the ENTER key gt gt Maintenance is displayed Press the ENTER key twice The counter for each component is reset immediately Completion Note Occurrences of resetting the maintenance kits are recorded on the service status page in number of pages or images at which the maintenance kit was replaced See page 1 4 4 This may be used to determine the possibility that the counter was errorneously or uninten tionally reset 1 4 12 CLP Service items Description Drum surface refreshing gt gt Drum Description Rotates the drum approximately 5 minutes with toner lightly applied onto the drum using the high voltage output control of the engine controller PWB The cleaning blade in the drum unit scrapes toner off the drum surface to clean it Purpose To clean
99. grease or solvents Allow applied solvents to evaporate completely before refitting the covers or turning the main Switch on Always wash hands afterwards Never dispose of toner or toner bottles in fire Toner may cause sparks when exposed directly to S tire INGA TUPNACE etC csu codi idee dere e eene teur eta Due mua e ek a dea sh a dia Should smoke be seen coming from the copier remove the power plug from the wall outlet lunii 3 Miscellaneous WARNING Never attempt to heat the drum or expose it to any organic solvents such as alcohol other than S the specified refiner it may generate toxic Oase This page is intentionally left blank CLP CONTENTS 1 1 Specifications EE Wee e e aos ia ira 1 1 1 1 1 2 EE 1 1 3 Overall cascada NIE 1 1 3 PARS curl 1 1 4 151 9 Ne Een 1 1 5 1 2 Handling Precautions 1 221 DRUM UNM ie ceased See ee 1 2 1 1 2 2 Installation enviroriment eor dis 1 2 1 1 3 Installation 1 31 Unpacking and installation er rer Ges dance eer dete vanes Hides A det adipex deed 1 3 1 1 Installation procedute torre poa 1 3 1 1 3 2 Installing expansion memory optional 1 3 7 1 3 3 Installing a memory Card optional sssi sannin seniai nennt en a EE 1 3 8 1 3 4 Installing network interface card optional emm emen 1 3 9 1 3 5 Installing hard disk unit optional mono 1 3 10 1 4 Service Mode I EE rupe
100. gure 2 1 30 Toner ID sensor 2 1 22 CLP 2 1 5 Secondary transfer and separation section The secondary transfer and separation section includes the secondary transfer roller which is installed on the paper feed unit The secondary transfer roller is applied by the bias high voltage PWB of DC bias The image constituted by toner on the primary transfer belt is transferred on paper by means of the difference in potential The paper is separated from the transfer belt as the curvature radius of the secondary transfer roller is considerably small Paper chute Feed base Paper feed unit Secondary transfer roller Figure 2 1 31 Secondary Transfer roller gear transfer roller To fuser unit Feed base Paper feed unit Figure 2 1 32 Secondary transfer unit 2 1 23 CLP The primary transfer roller bias is triggered by a serial data which is generated by the engine controller PWB and derived from the bias high voltage PWB The engine controller PWB converts current and voltage into serial data and applies it to the bias high voltage PWB The bias high voltage PWB then uses D A converter IC501 and revert it into analog voltage The analog voltage is applied to the high voltage output circuit which in turn applies the secondary transfer roller with the bias accordingly Bias high voltage PWB Secondary transfer roller bias PEE High ned 40 uA voltage output Ge j circuit Secondary
101. he following information A Number Prints a list of errors occurred 1 to 16 A smaller number means an older event Number of pages Number of pages printed when an error occurred Description Indicates the description of error Paper jam Cassette 2 Number Page Count Code 519 11 48 02 09 01 A jam Printer d n6 515 02 11 48 01 09 01 88 11 73 FA A8 C0 4 i D n Paper jam Printer unit i EE 5 166 02 11 48 01 09 01 88 11 73 FA A8 C0 E 1 M Paper jam Printer unit Fi b E r 4 71 02 11 48 02 09 01 88 21 73 FA A8 CO 1 1 Fi E Paper jam Printer unit A D 5 3 71 02 11 48 01 09 01 88 11 73 FA A8 C0 4 i r Paper jam Printer unit ee D n 2 64 02 11 32 01 91 00 88 32 74 04 A8 C0 14 m Fi i Paper jam Cassette 2 Dx d ri 1 5 02 11 32 01 91 00 88 32 74 04 A8 C0 che e i m b va 1 VEG AUR NS 09 01 88 21 73 FA A8 C0 D Paper jam Printer unit 19 02 dd 43402 Figure 1 4 4 Understanding events 1 4 7 CLP Service items Code digit and Details of code description Identifica tion code Description Table 1 4 3 Code table 1 02 Paper misfeed Code table Error type hexadeci mal 11 Paper misfeed Paper mis feed loca tion ASCII 31 Cassette 1 in the printer 32 Cassette 2 33 Cassette 3 34 Cassette 4 35 Envelope feeder 42 MP tray 47 Rear cover 48 Inside the printer 49 Duplexer Paper mis feed loca tion
102. igit and Details of code description Main cause of paper mis feed hexadeci mal 10 11 21 A1 off A9 EO Description Details of code Paper does not arrive at the registration sensor Paper does not pass the registration sensor 12 20 Paper remains at the registration sensor when power is turned on Paper does not arrive at the eject sensor Paper does not pass the eject sensor 22 30 31 32 40 41 42 50 51 52 Paper remains at the eject sensor when power is turned on Paper does not arrive at the paper feeder 1 feed sensor Paper does not pass the paper feeder 1 feed sensor Paper remains at the paper feeder 1 feed sensor when power is turned on Paper does not arrive at the paper feeder 2 feed sensor Paper does not pass the paper feeder 2 feed sensor Paper remains at the paper feeder 2 feed sensor when power is turned on Paper does not arrive at the paper feeder 3 feed sensor Paper does not pass the paper feeder 3 feed sensor Paper remains at the paper feeder 3 feed sensor when power is turned on Paper does not arrive at the vertical path sensor A2 A3 A4 Ab A6 AT A8 Paper does not arrive at the switchback sensor Paper does not pass the vertical path sensor Paper does not arrive at the duplexer refeed sensor Paper does not pass the switchback sensor Paper does not pass the duplexer refeed sensor Duplexer overflow Third sheet is commanded
103. ignal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control video data signal LVDS LED print head control signal Ground Serial communication synchronizing clock signal System reset signal Serial communication data output Ground Ground CLP Connector Pin No Signal VO Voltage Description FPRST 5V DC Connected to the main controller PWB GND 5V1 2 5V1 2 5V1 2 5V1 GND LVDSP15 LVDSP14 LVDSP13 LVDSP12 LVDSP11 LVDSP10 LVDSP9 LVDSP8 LVDSP7 LVDSP6 LVDSP5 LVDSP4 LVDSP3 LVDSP2 LVDSP1 LVDSPO BDMASK GND SIIN SDIR SBSY EGIR FPCLK FPDATA FPDIR 2 5 V DC 2 5V DC 2 5V DC Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog 0 3 3 V DC pulse 0 3 3 V DC 0 3 3 V DC 0 3 3 V DC 0 3 3 V DC pulse 0 3 3 V DC pulse 0 3 3 V DC Operation panel PWB reset signal Ground 5 V DC power outp
104. in the paper cassette is raised by the lifter mechanism The sheet at top is rewound to the pick up roller and sent to the paper feed roller which forward the paper in the printer In order to pre vent paper misfeed during feeding the retard roller which is positioned face to face with the paper feed roller acts to pre vent feeding more than one sheet at a turn of the pick up roller The paper cassette has an opening at the front side This opening is a loophole for the paper that is fed by the optional paper feeder or the duplexer which feeds paper into the printer Figure 2 1 1 Paper cassette 1 Guide roller 6 Feed base 11 Bottom plate 2 Paper guide 7 Registration sensor actuator 12 Feed pulley 3 Upper registration roller 8 Pickup roller 13 Retard roller 4 Lower registration roller 9 Feed roller 5 Secondary transfer roller 10 Cassette base Bottom plate To p Retard roller registration roller Feed pulley Bottom springs From optinal paper feeder or duplexer Figure 2 1 2 2 1 1 CLP The paper size dial has predetermined patterns of activating the paper size switches using concaves and convexes according to paper sizes SW1 SW2 and SW3 produce corresponding signals for paper sizes Engine controller PWB CASO CAS1 CAS2 ASIC U13 Sensor PWB 105 CASO 106 l CAS1 _107 l CAS2 sui mmm e CUSTOM A5 A4
105. ion is nor mal replace the duplexer DU 300 Defective harness 802852 between engine controller PWB KP 1054 and interface con nector or poor contact of the con nector terminals Check the continuity of the harness 802852 Check the insertion of YC7 of the engine controller PWB KP 1054 if there is trouble remedy or replace Duplexer communication error When turning on power the ASIC of the engine controller PWB KP 1054 recognized the optional duplexer DU 300 but when it becomes not be able to communicate from the middle After the error occurring when power Source is turned on off there are times when the duplexer is not recognized Defective engine controller PWB KP 1054 Replace the engine controller PWB KP 1054 See page 1 6 25 Defective duplexer DU 300 After removing or replacing the duplexer DU 300 do the operation check If operation is normal replace the Duplexer DU 300 Defective paper feeder PF 60 If the optional paper feeder PF 60 is installed after removing or replacing the paper feeder PF 60 do the operation check If operation is normal replace the paper feeder PF 60 Defective harness 802852 between engine controller PWB KP 1054 and interface con nector or poor contact of the con nector terminals Check the continuity of the harness 802852 Check the insertion of YC7 of the engine controller PWB if there is trouble re
106. ional envelope feeder Top cover feed unit switch Shuts off 24 V power line when the top cover is opened Top cover switch 1 Detects the top cover open Top cover switch 2 Detects the top cover right side open Side cover switch AAA Shuts off 24 V power line when the side cover is opened Power switch oooooonocccccnnnnococccnccnononococcnnnannnnos Turns ON OFF the AC power source Cassette size switch Detects the paper size dial setting of the paper setting dial Feed motor Drives the paper feed section Fuser motor Drives the fuser unit and paper exit section Primary transfer motor sssse Drives the primary transfer unit and primary transfer cleaning unit Drum motor 1 Drives the magenta drum unit Drum motor 2 Drives the cyan drum unit Drum motor 3 Drives the yellow drum unit Drum motor 4 Drives the black drum unit Toner motor 1 Replenishes the magenta developer with toner Toner motor 2 Replenishes the cyan developer with toner Toner motor 3 Replenishes the yellow developer with toner Toner motor 4 inerenti tts Replenishes the black developer with toner Ozone fan motor 1 The exhaust gas of ozone Ozone fan motor 2 The exhaust gas of ozone Maint fan motor aeree Dissipates heat from the fuser unit Drum motor cooling fan motor Dissipates he
107. it from the main unit frame 4 Remove the primary transfer cleaning unit Check or replace the primary transfer clean ing unit and then refit all the removed parts Primary transfer cleaing unit a Figure 1 6 20 1 6 16 1 6 8 Fuser unit 1 Detaching and refitting the fuser unit Procedure 1 Remove the rear cover see page 1 6 2 2 Remove the right cover and left cover see pages 1 6 4 5 3 Remove the two screws and then remove the fuser unit 4 Check or replace the fuser unit and then refit all the removed parts Figure 1 6 21 CLP Fuser unit 1 6 17 CLP 2 Detaching and refitting the fuser thermistor 1 and 2 fuser thermostat 1 and 2 fuser heater lamp 1 and 2 heat roller and press roller Procedure 1 Remove the fuser unit see previous page 2 While two latch unlatching remove the fuser bottom cover by making slide 3 Remove the one tab 4 Remove the two screws form the terminal Terminals Screws Figure 1 6 23 1 6 18 5 Remove the three connectors from the fuser PWB Remove the one tab While unlatching the latches and then remove the fuse unit connector 8 Remove the terminal NO Fuser PWB Connectors Connector Terminal Figure 1 6 24 9 Remove the one screw and then remove the fuser left cover Fuser left cover Figure 1 6 25 1 6 19 CLP 10 Remove the one screw and then
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109. le remedy or replace unit or poor contact of the connector terminals Defective drum Replace the drum PWB 4 KP 972 PWB 4 KP 972 Defective engine Replace the engine controller PWB KP controller PWB 1054 See page 1 6 25 KP 1054 Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness Check the continuity of the harness S02869 between 802869 check the connection YC3 con engine controller nector of the engine controller PWB KP PWB KP 1054 1054 if there is trouble remedy or replace and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals 7412 Cyan drum unit non installing error Defective harness Check the connection of the cyan drum unit The EEPROM U401 on the drum PWB 2 KP 972 inside the cyan drum unit does not communicate normally between drum PWB 2 KP 972 and printer main unit or poor contact of the connector terminals and the printer main unit check the continu ity of the harness 802867 if there is trou ble remedy or replace Defective drum PWB 2 KP 972 Replace the drum PWB 2 KP 972 Defective engine controller PWB Replace the engine controller PWB KP 1054 See page 1 6 25 KP 1054 Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness 802869 b
110. ler and Check the fuser pressure springs press roller 3 Flawed heat roller or press roller Replace the heat roller or press roller See page 1 6 18 16 Colors are printed offset to each Causes other 1 The drum unit is not properly seated in its position Causes Check procedures corrective measures 1 The drum unit is not properly seated in its Perform the color registration to correct Refer to user s manual position 1 5 28 CLP 1 6 1 Precautions for assembly and disassembly 1 Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly When handling PWBs printed wiring boards do not touch parts with bare hands The PWBs are susceptible to static charge Do not touch any PWB containing ICs with bare hands or any object prone to static charge Use the following circuit testers when measuring voltages Hioki 3200 Sanwa MD 180C Sanwa YX 360TR 1 6 1 CLP 1 6 2 Outer covers 1 Detaching and refitting the top cover Procedure 1 Open the rear cover 2 Open the top cover 3 Remove the opening and closing axis from the main unit frame and then remove the upper cover 2 Detaching and refitting the rear cover Procedure 1 Open the rear cover 2 Remove the opening and closing axis from the main unit frame and then remove the rear cover Rear cover Figure 1 6 2 CLP 3 Detaching and
111. ller AAA 1 6 8 1 64 MP tray teed Unt uico a eie td esr ito 1 6 9 1 Detaching and refitting the MP tray feed unit ssssse emm 1 6 9 2 Detaching and refitting the MP tray feed roller seeeseeeeeeeeennneeneneen 1 6 10 1 6 5 Developing le EE 1 6 11 1 Detaching and refitting the developer unit 1 6 11 CLP 1 6 6 1 6 7 1 6 8 1 6 9 1 6 10 bu M S 1 6 12 1 Detaching and refitting the drum unit esee entm nre 1 6 12 2 Detaching and refitting the LED print heads eeeeeee eene 1 6 13 Primary transfer Section ione a Ee det E 1 6 14 1 Detaching and refitting the primary transfer unit 1 6 14 2 Detaching and refitting the primary transfer belt 1 6 15 3 Detaching and refitting the primary transfer cleaning unit se 1 6 16 ell 1 6 17 1 Detaching and refitting the fuser unit esseeeseeeeeneeneemenenn nennen nnne nene 1 6 17 2 Detaching and refitting the fuser thermistor 1 and 2 fuser thermostat 1 and 2 fuser heater lamp 1 and 2 heat roller and press roller isisisi iienaa rna ar i eE 1 6 18 dulce 1 6 24 1 Detaching and refitting the main controller DW 1 6 24 2 Detaching and refitting the engine controller PWB and power supply PWB
112. mary transfer cleaning unit block diagram From waste toner conveying duct waste toner box Figure 2 1 29 Primary transfer cleaning unit Fur brush Brush cleaning roller Cleaning blade Cleaning screw Boo 2 1 21 CPL A full color image is developed by recoating four colors on the primary transfer belt If the density of each color is not kept constant the resultant color image will be deteriorated The toner ID sensor mounted on the primary transfer belt to the printer main unit side maintains the constant color fidelity The toner ID sensor includes a LED deflection beam splitters of BS1 and BS2 photo diode PD2 and PD3 that scale toner density and associated components The deflection beam splitter 1 BS1 splits the light from the LED to S wave and P wave S wave oscillates vertically in ref erence to the entrance plane whereas P wave oscillates horizontally in reference to the entrance plane S wave reaches the photo diode PD1 and acts to stabilize the luminosity of the LED by means of the feed back circuit P wave is irradi ated to toner then it produces scattered light wave S and reflection wave P which bounced on the primary transfer belt They reach the deflection beam splitter 2 BS2 where they are distinguished as P wave and S wave respectively then detected by photo diode 2 PD2 and photo diode 3 PD3 Primary transfer belt Beam spliter 2 spliter 1 BS2 BS1 Toner ID sensor Fi
113. medy or replace 1 5 3 CLP munication error cyan drum unit The LED print head memory PWB 2 KP 1040 which is attached to the LED print head 2 of the cyan drum unit does not communicate with the engine controller PWB KP 1054 normally head memory PWB 2 KP 1040 Code Contents Remarks Causes Check procedures corrective measures 0951 LED print head memory PWB 4 com Defective LED print Replace the LED print head 4 of black drum munication error black drum unit head memory unit See page 1 6 13 The LED print head memory PWB 4 PWB 4 KP 1040 Ee WEE Defective engine Replace the engine controller PWB KP print head 4 of the Black drum ller PWB 1054 S 1 6 25 unit does not communicate with the pol CH See page engine controller PWB KP 1054 nor KP mally Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness Check the continuity of the harness S02866 between S502866 check the insertion of YC3 of the engine controller engine controller PWB KP 1054 if there is PWB KP 1054 trouble remedy or replace and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Defective harness Check the connection of the connector with 802866 between the black drum unit and the printer main unit LED print head check the continuity of the harness memory PWB 4 802866 ch
114. n Primary transfer roller yellow Primary transfer roller black Primary transfer belt Drive base 0 Tension base gi d o mc SP OND Figure 2 1 23 Primary transfer unit The primary transfer belt is made of stratum fluorine coat stratum elastic and stratum resin in the order from the surface to the bottom These substances ensure smooth paper travel as well as the durability of the belt itself 2 1 18 BM Primary transfer belt I gt Stratum fluorine coated Y Stratum resin Stratum elasticity Figure 2 1 24 Primary transfer unit PGS og Tension roller Tension roller Drive base Primary transfer roller magenta Primary transfer roller cyan Primary transfer roller yellow Figure 2 1 25 7 Primary transfer roller black 8 Primary transfer belt 9 Backup gear 29H 10 Backup gear 29H 11 Image gear 22H 12 Image gear 28S 13 Toner ID sensor mounted on the main frame Toner ID sensor CLP Q Primary transfer roller Engine controller PWB Bias high voltage PWB IDSW IDPW IDREF YC11 11 Output Primary trasfer bias output circuit D A converter IC501 YC801 6 HVBDATD YC11 12 YC11 13 YC5 6 YC801 7 HVBCLKD YC5 7 YC801 8 HVBLATD YC5 8 Output 600 V DC variable Figure 2 1 26 Primary transfer section block
115. nal LVDS 22 LVDSN5 O Analog LED print head control video data signal LVDS 23 LVDSP6 O Analog LED print head control video data signal LVDS 24 LVDSN6 O Analog LED print head control video data signal LVDS 25 LVDSP7 O Analog LED print head control video data signal LVDS 26 LVDSN7 O Analog LED print head control video data signal LVDS 27 LVDSP8 O Analog LED print head control video data signal LVDS 28 LVDSN8 O Analog LED print head control video data signal LVDS 29 LVDSP9 O Analog LED print head control video data signal LVDS 30 LVDSN9 O Analog LED print head control video data signal LVDS 31 LVDSP10 O Analog LED print head control video data signal LVDS 32 LVDSN10 O Analog LED print head control video data signal LVDS 33 LVDSP11 O Analog LED print head control video data signal LVDS 34 LVDSN11 O Analog LED print head control video data signal LVDS 35 LVDSP12 O Analog LED print head control video data signal LVDS 36 LVDSN12 O Analog LED print head control video data signal LVDS 37 LVDSP13 O Analog LED print head control video data signal LVDS 38 LVDSN13 O Analog LED print head control video data signal LVDS 2 3 6 Connector Connected to the LED print head relay PWB LVDSN14 LVDSP15 LVDSN15 5V1 FDPFUL 5V1 5V1 GND GND GND GND Voltage Analog Analog Analog Analog 5VDC 0 5 V DC 5VDC 5V DCV CLP Description LED print head control video data signal L
116. ne controller PWB KP 1054 See page 1 6 25 Lump of toner inside black toner container or defec tiveness of toner replenishment drive system Replace the black toner container 1 5 12 CLP Code Contents Remarks Causes Check procedures corrective measures 7002 Toner motor 2 overcurrent detection Defective toner Replace the toner motor 2 See page 1 6 error cyan toner motor 2 34 The engine controlar PWE F 10548 Defective engine Replace the engine controller PWB KP detected the overcurrent of toner motor 2 controller PWB 1054 See page 1 6 25 i KP 1054 Lump of toner Replace the cyan toner container inside cyan toner container or defec tiveness of toner replenishment drive system 7003 Toner motor 1 overcurrent detection Defective toner Replace the toner motor 1 See page 1 6 error magenta toner motor 1 34 Tne engine com alan PWE RPS Defective engine Replace the engine controller PWB KP detected the overcurrent of toner motor controller PWB 1054 See page 1 6 25 i KP 1054 Lump of toner Replace the magenta toner container inside magenta toner container or defectiveness of toner replenish ment drive system 7004 Toner motor 3 overcurrent detection Defective toner Replace the toner motor 3 See page 1 6 error yellow toner motor 3 34 The engine ponmalar TANA E Wed Defective engine Replace the engine controller PWB KP detected the ov
117. nector cover Connector cover Black Connector cover Yellow Figure 1 6 15 3 Remove the two connectors 4 While releasing two release levers and then i remove the drum unit also 4 colors with the Connectors alow Release lever Black Figure 1 6 16 1 6 12 2 Detaching and refitting the LED print heads Procedure 1 2 Remove the drum unit see previous page Remove the hook and the opening and clos ing axis and then remove the LED print head cover Before removing the LED print head suffi ciently do to let escape the static electricity which is electrified in the human body con cerning the metal part and the like of the aqueduct faucet after that do that work Remove the LED print head Do not attempt turn the focal adjustment pins At the time of handling have the metal based part the both ends do not touch the SELFOC lens part Remove the four connectors and then remove the harness Check or replace the LED print head and then refit all the removed parts When replacing to the new LED print head peel the protection seal blue color of the SELFOC lens Caution When refitting the LED print head in the drum unit make sure that the print head is properly seated in the drum unit 6 Print the test print and check the image After replacing to the new LED print head when making the printer restart in order again to read the LED compensation data from th
118. nstalla Check the installation condition of fuser ther press roller tion condition of mistor 2 if there is trouble remedy or Doing the control which turns on the fuser thermistor 2 replace See page 1 6 18 fuser heater lamp 2 which is built in to the press roller of the fuser unit the ees 2 Mes the Fuser thermostat 2 See page fuser temperature which fuser ther operarea mistor 2 detects stipulated tempera Defective engine Replace the engine controller PWB KP ture did not rise within stipulated time controller PWB 1054 See page 1 6 25 KP 1054 Defective power Replace the power supply PWB See page supply PWB 1 6 25 Defective fuser Replace the fuser PWB KP 970 PWB KP 970 Defective harness Check the harness of the fuser thermistor 1 of the fuser ther check the connection YC693 connector of mistor 2 or poor the fuser PWB KP 970 if there is trouble contact of the con remedy or replace nector terminals Defective fuser Replace the fuser heater lamp 2 See page heater lamp 2 1 6 18 Defective harness Check the continuity of the harness S802857 220 240 802857 220 240 V AC model S802858 V AC model 120 V AC model check the connection S02858 120 V AC YC693 connector of the fuser PWB KP model between 970 if there is trouble remedy or replace fuser unit connec tor and fuser heater lamp 2 Defective harness Check the continuity of the harness S02856 between 802856 check the
119. nter BOOST SPR in capitals gt echo R BOOT SPR gt PRN 6 Check that the message indication 3 is indicated 7 Input the command 2 following the DOS prompt indication and copy the message data file to the printer e g dm8002 spa 8 The message indication 5 is indicated while downloading the data file When the message indication 6 is indicated which shows the end of downloading turn off the power switch once and then turn it on again 9 Check that the message indication 7 is indicated after warming up the printer 10 Print the status page See page 1 4 2 11 Print the status page to check that the firm AE Message display i Language Version 04 y ware version has been updated i N i A Spanish 04 AS X Release date Check sum S Power switch Off On X O Ready Figure 1 7 12 1 7 5 CLP This page is intentionally left blank 1 7 6 CLP 2 1 1 Paper feed section There is paper feed from the paper cassette which can load paper 500 and paper feed from the MP tray which can load paper 100 in paper feed method of this printer The Paper feed section is composed of paper cassette paper feed unit paper feed drive unit MP tray and MP tray feed unit 1 Paper feeding from paper cassette The paper cassette is fit underneath the paper feed unit The paper stored in the paper cassette is lifted up so that it is pressed against the pickup roller as the bottom plate
120. o evenly charge the drum When the light emitted by LED hits the charged drum the electrostatic latent image is developed on the drum The electro static latent image is developed by toner applied by the developer unit and transferred onto the primary transfer belt in four colors The toner remaining on the drum is scraped off by the cleaning blade and driven outside by the spiral screw The residual potential on the drum is discharged by the exposure to the eraser lamp Thus the drum becomes ready for the next main charging Figure 2 1 14 Waste toner exit screw Eraser lamp PWB Drum frame Lens cleaner Main charger unit LED print head Drum Cleaning blade Romo ONDI 2 1 10 Figure 2 1 15 Drum unit 2 1 11 CLP 2 1 12 LED print head E Elaser lamp PWB LED print head memory PWB 2 Drum PWB g O vc631 6 SEEK i o YC631 5 j Qe e ERAS1DR EECLK pee 3 Yce31 6 E l d io YC631 5 j Wa YC401 7 b YC401 7 ERAS2DR COMMUN 2 YC401 5 Baa YC401 2 hag Cyan drum unit YC401 1 77 9 YC631 6 E i ER YC631 5 j l Wa YC401 7 ERR YC401 7 ERASSDR vow EE 9 YC401 5 5 AB YC401 2 t 5a Yellow drum unit YC401 1 Y YC401 7 ERAS4DR m YC401 7 voto Eso YC401 5 DAO YC401 2 DAT Black drum unit YC401 1 LED print head relay PWB YC551 11 to 42 j YC553 10 to 36 YC553 42 YC553 43 YC551 2 YC557 7 YC551
121. or 4 black detection voltage input Toner sensor 3 yellow detection voltage input Drum motor 3 yellow energization pulse Toner motor 3 yellow On Off Drum motor 3 yellow energization pulse 24 V DC power output Drum motor 3 yellow energization pulse 24 V DC power output Drum motor 3 yellow energization pulse Ground Ground Toner sensor 2 cyan detection voltage input Main fan motor On Off Toner motor 2 cyan On Off Ozone fan motor 1 ozone fan motor 2 and drum motors cooling fan motor On Off Toner sensor 1 magenta detection voltage input Toner motor 1 magenta On Off Drum motor 2 cyan energization pulse Drum motor 1 magenta energizatione pulse Drum motor 2 cyan energization pulse Drum motor 1 magenta energization pulse Drum motor 2 cyan energization pulse Drum motor 1 magenta energization pulse Drum motor 2 cyan energization pulse Drum motor 1 magenta energization pulse Connected to the bias high voltage PWB 24V2 HVCLK1 HVCLK2 HVCLK3 HVCLK4 HVADATD HVACLKD HVALATD GND 000 0 0 O OOOOOOOOOOOo 24V DC 3KHz rectangular wave 3KHz rectangular wave 3KHz rectangular wave 3KHz rectangular wave 0 5 V DC pulse 0 5 V DC pulse 0 5 V DC pulse 24 V DC power output via top cover paper feed unit switch Developing sleeve magenta output Developing sleeve cyan output Developing sleeve yellow output Developing sleeve black output Outpu
122. os fa eU Magenta drum unit YC701 2 YC701 3 YC701 4 YC701 5 l Main charger unit Output Shield b D Wire IN _ Eet S f A Zenner i PWB 2 Drum ZA Main charger unit Main high voltage output circuit D A YC801 6 CLP Engine controller PWB MCH1DR MCH2DR MCH3DR MCHADR HVBDATD converter YC801 7 HVBCLKD IC501 YC801 8 HVBLATD Output Shield Pas Wire M S Grid 4 MENGE upto t uso SN N Drum d Ss TIT Main charger unit Output Shield NS Wire T N 1 WE EE AS Be PWB4 i i E i m N i Drum 4 e Output 320 uA 7 kV variable Figure 2 1 22 Main charger output block diagram 2 1 17 CLP 2 1 4 Primary transfer section Primary transfer section is composed of the primary transfer unit and primary transfer cleaning unit 1 Primary transfer unit The primary transfer unit is comprised of the primary transfer belt tension rollers and four primary transfer rollers of col ors Color image is transferred on the transfer belt as the four layers different colors The toner ID sensor mounted on the main frame monitors the density of the toner on the primary transfer belt Primary transfer 6 cleaning unit Tension roller Tension roller Drive roller Primary transfer roller magenta Primary transfer roller cya
123. oubew Buidoje eq 90 01 aves 7174 l 0017 6899 A Seiq e eejs Buidoje eg 90 01 7174 l 0012 6899 A serq youbew Buidojanaq 1996 og vv6S Seet TTT LL py y 9 seig e eojs Buidoje eq 1996 ESCH i EE E EEN EN Kee mE PEOR 9 seiq joubew 8uidoje eq 9188 WIER 08 IN serq easels Buidoje eq 6615 9188 orgs 087 T_T Ww serq 1eu8eu Buidoje eq 6618 SE sezz y 1351249 UE 88ZLL 06pL l A 1361249 Uew vS0L SL 9 1e81euo urew 9646 IN 19861euo urew Sp ro du asp 0c 6L 8L LL 9L SL vl L eL EL OL 6 8 L 9 S v 4 L s o 2 4 3 CLP Ize hart No 4 MP tray A4 s iming c 4 T oz GL SL 21 94 SL FL EL gt LL OL 6 8 Z 9 S D z s 0 68v0L 8vv8 90Er ER l J vss9L Bevel 80ScI 2826 m gt gt E 1 DOC 9 v8 Lauer LI E 90SL e 0cL ZLOLL BEER 9864 996 v880L 0c66 8689 Poo q 4 e 6ll 0988 9884 vier 28LLL GILLS 47A 690v Ul qj p TTT TTT E I 1 2vvOL DEI 969 erg EIERE EEN RER KEE EE oa EE ENT KE I 1696 KH Loo 6283 q Ml E gt EN e 1 QSELL Gees OLEZ 6Ler p A A eee eas AAA LL9OL 0894 S999 pese 9986 GEO 0z8s 16843 1316 0609 S408 vvOc Wo 09911 FER vio SLOE J l 099LL v128 F i SLOE DW o omo 0m o WR cb w cp c 1 1 SL60L KD 6989 WIES l SL6OL 6392 6989 0222 Lf a ee ees
124. oximately 0 5 to 0 55 millimeters as they pass under the doctor blade The developing mag net roller lies along the developing sleeve at the distance of 0 40 millimeters As the developing magnet roller revolves the brushes formed at pole N1 sweep the developing sleeve and the toner is transferred to the developing sleeve as it is attracted by the difference in potential between them The toner on the developing sleeve is approximately 70 micrometer in thickness The developing sleeve is located 0 23 millimeter from the drum The toner is transferred to the drum by means of the DC AC bias applied to the developing sleeve Developer unit S y A 0 50 to 0 55 mm Q Doctor blade 8 0 40 mm Toner hopper 0 23 mm Main charger LED print head Mixer scr Developing magnet roller Developing magnet roller 3 y i Developing sleeve C CT Developing Developing sleeve Magnetic sleeve brush Figure 2 1 13 CLP 2 1 3 Drum section The drum unit includes a photoconductive drum eraser lamp LED print head cleaning blade and a main charger unit The drum unit is removable with the main charger unit 1 Drum unit The tandem development system uses four drum units which are isomorphic to each other in cyan magenta yellow and black colors In the drum unit the main charger disperses charging potential over the drum t
125. played only 01 Partial lock when locked 02 Full lock 9 NVRAM error displayed only when any error 01 ID error has occurred 02 Version error 03 Checksum error 04 NVRAM crash error NVRAM downloading status 00 Normal not downloaded Bit 0 Font data Bit 1 Host data Bit 2 Macro data Bit 3 Program data Bit 4 Operation panel message data file name dis played Bit 5 OEM data file name displayed Bit 6 Reserved Bit 7 Error occurred Printable area setting Top offset Left offset Page length Page width 2 Left offset for each paper source MP tray Cassette 1 Cassette 2 Cassette 3 Cassette 4 Cassette 5 Duplexer 3 Optional paper feeder life counter Paper feeder 1 Paper feeder 2 Optional paper feeder life counter Paper feeder 3 9 Optional paper eject unit life counter Duplexer Drum life counter Cyan drum unit Magenta drum unit Yellow drum unit Black drum unit 2 Pixel counter Cyan Magenta Yellow Black Maintenance kit counter Optional unit software version Paper feeder1 Paper feeder 2 Paper feeder S Envelope feeder Duplexer GO Drum ID Cyan Magenta Yellow Black 3 LED print head compensation value 22 LED print head compensation data handling 0 Normal error bitO to 3 LED print head compensation data in the LED print head memory PWB 0 Black 1 Yellow 2 Cyan 3 Magenta bit4 Consistency and legitimacy check bit5 Type of system DI
126. pre Lor inre t AEA AAE NA Do not remove the ozone filter if any from the copier except for routine replacement S Do not pull on the AC power cord or connector wires on high voltage components when removing S them always hold the plug isal enren O Do not route the power cable where it may be stood on or trapped If necessary protect it with a S cable cover or other appropriate item sccrercenann naina R Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks o Remove toner completely from electronic components oooocccccconoccnononanancnnnnnnnn cnn n nano enn NM e Run wire harnesses carefully so that wires will not be trapped or damaged ooocccccnooccccccnnncccccnnnnnns O After maintenance always check that all the parts screws connectors and wires that were removed have been refitted correctly Special attention should be paid to any forgotten connector trapped wire and missing Screws oocccconoocccccnononcnnncnanoncnnnnnnnn enne nenne enne Check that all the caution labels that should be present on the machine according to the Q instruction handbook are clean and not peeling Replace with new ones if necessary Handle greases and solvents with care by following the instructions below Use only a small amount of solvent at a time being careful not to spill Wipe spills off completely Ventilate the room well while using
127. r TRE Parallel printer cable Figure 1 7 2 Message display Turn printer power on Confirm that display 1 is displayed e At the DOS prompt enter command 2 Enter UPGR SYS in capitals Confirm that message display 3 is dis played 7 Atthe DOS prompt enter command 4 so that the system firmware example s80K9100 bcmp and the engine firmware 0 RO PC DOS display UPGR SYS PRN o gt echo R example E80KA005 x are copied to the printer 8 Message display 5 is displayed during downloading When message display 6 is Peery Jb 580K9100 bemp prn 1 en doas b E80K005 displayed to indicate downloading is fin gt Copy TORUM ished turn printer power off and then turn on Y 9 Confirm that message display 7 is dis Downloading A eae played after warm up f When a some key is pushed indication changes 10 Print a status page See page 1 4 2 O LEPOREM 11 Check that the status page shows the Version 88 00 y System Engine A i i Version A005 8800 A go A005 02 06 07 1234 2 03 03 07 1234 2 Tusc mE A ZS updated firmware version Release date Checksum Plural data Release date Checksum Plural data J Power switch Off On Y Figure 1 7 3 1 7 2 3 Downloading firmware using the memory card CLP The procedure below provides how to download firmware from a memory card Note that you
128. r 1 which detects the fuser temperature of the heat roller controller PWB KP 1054 1054 See page 1 6 25 Defective harness of the fuser PWB KP 970 between fuser thermistor 1 or poor contact of the connector ter minals Check harness of the fuser PWB KP 970 check the connection YC694 connector of the fuser PWB KP 970 if there is trouble remedy or replace Defective harness 802854 between fuser PWB KP 970 and fuser connector or poor contact of the con nector terminals Check the continuity of the harness 802854 check the connection YC691 con nector of the fuser PWB KP 970 if there is trouble remedy or replace Defective harness 802853 power supply PWB and fuser connector or poor contact of the connector termi nals Check the continuity of the harness 802853 check the connection YC902 con nector of the power supply PWB if there is trouble remedy or replace Defective fuser PWB KP 970 Replace the fuser PWB KP 970 Defective power supply PWB Replace the power supply PWB See page 1 6 26 Defective installa tion condition of fuser thermistor 1 Check the installation condition of fuser ther mistor 1 if there is trouble remedy or replace See page 1 6 18 1 5 10 CLP Code Contents Remarks Causes Check procedures corrective measures 6100 Fuser temperature time out error Defective i
129. rds tracing paper Paper Size ee ein Rhine A4 210 x 297 mm B5 182 x 257 mm A5 148 x 210 mm Letter 8 x 11 Legal 8 x 14 Non standard size 148 to 216 mm x 210 to 356 mm cassette 70 to 216 mm x 148 to 297 mm MP tray Print speee eree Cassette Values within are for duplex printing using the duplexer DU 300 A4 16 pages minutes 16 pages minutes B5 17 pages minutes 16 pages minutes Ab 17 pages minutes 16 pages minutes Letter R 17 pages minutes 16 pages minutes Legal 14 pages minutes 14 pages minutes MP tray in cassette mode A4 16 pages minutes 16 pages minutes B5 17 pages minutes 16 pages minutes A5 17 pages minutes 16 pages minutes Letter 17 pages minutes 16 pages minutes Legal 14 pages minutes 14 pages minutes First print time Standby mode 16 seconds or less A4 Sleep mode 76 seconds or less A4 Warm up time esse Sleep mode 80 seconds or less room temperature 23 C 60 RH Power on 80 seconds or less room temperature 23 C 60 RH Paper feed system One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m 0 11 um MP tray 100 sheets 80 g m 0 11 um Paper eject system Face down 250 sheets 80 g m 0 11 um equipped with a face down paper full sen sor Face up 250 sheets Optional face up tray PT 300 mu
130. re version 132 00 Released 18 Feb 2003 Service Information A003 C1 22 00 03 03 Total page 200 S00 F00 N00 D10 DM0301 DAN 0020 0020 1061 0811 0 0 AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 00000000 00000000 00000000 00000000 00 RS2 0003 0003 0 30 8 AE B AF C AG C AD D 03030303 03030303 03030303 03000000 00000000 03030303 03030303 SPD1 0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E SPD2 0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 DN SPL9200007 SPL9200007 SPL9200007 SPL9200007 SN SPL9200010 Figure 1 4 1 1 4 2 CLP Service items Description Service information A003 C1 22 00A 03 03 Total page 000 0 P00 S00 F00 N00 D10 DM0301 DAN 0000 0020 0020 1061 0811 0 0 Q3 AAAAAAA AAAAAAA AAAAAAA g AAAAAAA RAAAAAA AAAAAAA AAAAAAA AAAAAAA Q2 AAAAAAA AAAAAAA 0000 0000 0000 0000 0000 9 0000 0000 0000 0000 0000 00000000 00000000 00000000 00000000 00 a RS2 0003 0003 0 30 8 G9 a ODD AE
131. refitting the right cover Procedure 1 Remove the top cover see page 1 6 2 2 Remove the one screw Right cover Figure 1 6 3 3 Remove the paper feed unit see page 1 6 5 4 Using a flat blade screwdriver unlatch the right cover at the nine positions as shown in the diagram Figure 1 6 4 CLP 4 Detaching and refitting the left cover Procedure 1 Remove the top cover see page 1 6 2 2 Open the side cover and then remove the one screw Left cover L A Waste toner box 3 Remove the waste toner box To remove waste toner box press the lock lever in Side cover Figure 1 6 5 4 Remove the paper feed unit see page 1 6 5 5 Using a flat blade screwdriver unlatch the right cover at the nine positions as shown in the diagram Figure 1 6 6 1 6 4 CLP 1 6 3 Paper feed unit 1 Detaching and refitting the paper feed unit Procedure 1 Pull out the paper feed unit until stop 2 While pressing the left and right lock release buttons and then remove the paper feed unit Lock release button Lock release button er feed unit Pap Figure 1 6 7 CLP 2 Detaching and refitting the paper feed roller Procedure 1 Remove the paper feed unit see previous page Latches m Turn over the paper feed unit 3 While pushing the lock release buttons and then detach the joint 4 Unlatch the latches and then remove paper feed roller unit
132. ress the ENTER key twice The color calibration starts and automatically finishes Completion 1 4 10 CLP Service items Description Printing a test page gt gt Print Test Page Description Four colors are printed respectively with halftones of three different levels Purpose To check the activation of the developer and drum units of four colors Start Enter the service mode gt gt Printing Test Page Press the ENTER key twice The test page is printed Completion 16 256 Density 24 256 Black 32 256 I Cyan Magenta Green Yellow 1 Since focusing in yellow is hardly readable yellow is mixed with cyan for more readability resulting in green 2 Each portion of colors has three different magnitude of halftones bands If focus is excessively lost dots are not recognizable with the 16 256 band resulting in uneven density It also results in vertical streaks in the 24 256 and or 32 256 bands Figure 1 4 5 Test page 1 4 11 CLP Service items gt gt Maintenance Description Counter reset for the maintenance kit Description The Install MK message means that maintenance kit should be replaced at 200 000 images of printing The interval counter must be manually reset using this service item MK 500 MK 502 Maintenance kit includes the following units MK 500 For 220 240 V AC model Drum unit DK 500 Part No 2D993040
133. rial number Cyan Magenta Yellow Black Machine serial number Code conversion 1 4 5 CLP Service items Description Table 1 4 1 Media type attribute Paper feed source Paper destination Type Paper Enve Face Face adjust cassette MP lope Duplexer down up default tray feeder tray tray Plain Normal2 Transparency Extra Thick Preprinted Normal2 Labels Thick1 Bond Normal2 Recycled Normal2 Vellum Thin Rough Normal2 Letter Head Normal2 Color Normal2 Prepunched Normal2 Envelope Thick1 Cardstock Thick2 Coated Normal2 2 nd Side Thick Thick1 Fine Normal2 Reserved Reserved Reserved Custom1 Normal2 Custom2 Normal2 Custom3 Normal2 Custom4 Normal2 Custom5 Normal2 Custom6 Normal2 Custom7 Normal2 Custom8 Normal2 Table 1 4 2 Type adjust setting Speed line Speed in gloss mode Type 1 3 4 1 2 1 3 4 1 2 Normal1 Normal2 Normal3 Thick1 Thick2 Thick3 Extra Thick TE Note that a half speed is 55 of the normal speed Since the speed of printing in gross mode gets slower than normal printing in media types including Thick2 Thick3 and Extra Thick is not possible in gloss mode 1 4 6 CPL Service items Description Printing an event log EVENT LOG gt gt Print Event Log
134. rum unit Eraser lamp 1 2 3 4 Eliminates the residual electrostatic charge on the drum Toner sensor 1 2 3 4 Measures the toner concentration in the toner hopper Fuser thermistor 1 seseessss Detects the temperature of the heat roller Fuser thermistor 2 eese Detects the temperature of the press roller EXIL SONS OM cai dere Detects paper misfeed in the fixing unit Rear cover open close sensor Detects the rear cover open Face up down Solenoid Switches the output stack between face up and face down LED print head 1 2 3 A LED print head 1 magenta LED print head 2 cyan LED print head 3 yellow LED print head 4 black lighting of dot light to drum of each color drum unit Fuser heater lamp 1 Heats the heat roller Fuser heater lamp 2 esee Heats the press roller Fuser thermostat 1 5 eee Disable power for the fuser heater lamp 1 in emergency Fuser thermostat 2 2 ees Disable power for the fuser heater lamp 2 in emergency 2 2 3 CLP This page is intentionally left blank 2 2 4 2 3 1 Power supply PWB Power Current switch fuse Power supply PWB oH I Noise filter circuit YY Zero cross signal generation circuit Triac TRA1 CLP
135. sh of the primary transfer cleaning unit Worn primary transfer belt 8 Black streaks are printed vertically OO P GO A Causes Check procedures corrective measures 1 Dirty main charger wire Clean the main charger wire by using main charger wire cleaner 2 Poor insertion of the main charger wire cleaner Check if the main charger wire cleaner is properly seated If necessary reseat it properly 3 Dirty or flawed drum A Dirty drum Perform the drum surface refreshing See page 1 4 13 B Flawed drum Replace the drum unit See page 1 6 12 4 Deformed or worn cleaning blade in the drum unit Replace the drum unit See page 1 6 12 5 Defect fur brush of the primary transfer cleaning unit Replace the primary transfer cleaning unit See page 1 6 16 6 Worn primary transfer belt Replace the primary transfer unit See page 1 6 14 1 5 25 CLP 9 Streaks are printed horizontally Causes 1 Poor contact of output terminal of main charger unit 2 Poor contact of grounding terminal of drum unit 3 Poor contact of developing bias terminal of developer Causes Check procedures corrective measures 1 Poor contact of output terminal of main Insert the main charger properly charger unit 2 Poor contact of grounding terminal of Replace the drum unit See page 1 6 12 drum unit 3 Poor contact of developing bias terminal Replace the developer See page 1 6
136. ss Check the continuity of the harness S802857 220 240 802857 220 240 V AC model 802858 V AC model 120 V AC model check the connection S02858 120 V AC YC694 connector of the fuser PWB KP model between 970 if there is trouble remedy or replace fuser unit connec tor and fuser heater lamp 1 Defective harness Check the continuity of the harness S02856 between 802856 check the connection CN2 con fuser unit connec nector of the power supply PWB if there is tor and power sup trouble remedy or replace ply PWB 6020 Fuser abnormal high temperature Defective engine Replace the engine controller PWB KP error heat roller Abnormal high fuser temperature of the heat roller was detected controller PWB KP 1054 1054 See page 1 6 25 Defective fuser PWB KP 970 Replace the fuser PWB KP 970 Defective power supply PWB KP 1054 Replace the power supply PWB See page 1 6 25 Defective installa tion condition of fuser thermistor 1 Check the installation condition of fuser ther mistor 1 if there is trouble remedy or replace See page 1 6 18 1 5 9 CLP Code Contents Remarks Causes Check procedures corrective measures 6030 Fuser thermistor 1 broken error heat Defective engine Replace the engine controller PWB KP roller It was judged it has been broken from the fact that it is not the input signal from of the fuser thermisto
137. st be installed 100 sheets when the duplexer DU 300 is installed Photoconductor tns OPC drum diameter 30 mm Charging eystem seeen Scorotron positive charging Light Source LED Developing system Touch down development method Developer Two component magnetic toner Toner replenishing Automatic from the toner container Transfer system Primary transfer Transfer belt negative charged Secondary transfer Transfer roller negative charged Separation system Small radius curvature separation Fixing System entes Heat roller system Oil less Heat roller diameter 35mm 500 W halogen heater lamp Pressure roller diameter 35mm 350 W halogen heater lamp Charge erasing system Exposure by eraser lamp LED Cleaning system Drum Counter blade Primary transfer belt Fur brush Controller hardware CPU Power PC750CXe 400 MHz System ROM 4 MB 32 Mbit x 2 Font ROM 4 MB 32 Mbit x 1 Main RAM 96 MB standard on board expanding up to 608 MB standard 96 MB 256 MB x 2 at the maximum by adding optional expansion memory Optional expansion RAM DIMM 2 slot 100 pin DIMM 32 64 128 or 256 MB 1 1 1 CLP JEE Parallel High speed bi directional IEEE 1284 Nibble ECP mode USB Full Speed USB2 0 Optional interface KUIO LV x 1 Network interface card IB 20 10 Base TX 100 Base TX 10 B
138. switch lower button On Off 16 CAS1 0 5V DC Cassette size switch middle button On Off 17 CAS2 0 5V DC Cassette size switch upper button On Off 18 24V3 24V DC 24 V DC power output via side cover switch YC3 1 GND l Ground Connected 2 EECLK O 0 5V DC pulse Clock for EEPROM data reading and writing to the LED 3 ERS1DR O 0 24V DC Eraser lamp 1 black On Off print head 4 EEDATA UO 0 5 V DC pulse EEPROM data signal relay PWB 5 ERS2DR O 0 24V DC Eraser lamp 2 yellow On Off 6 ERS3DR O 0 24 V DC Eraser lamp 3 cyan On Off 7 5V1 O 5VDC 5 V DC power output 8 ERS4DR O 0 24 V DC Eraser lamp 4 magenta On Off 9 5V1 O 5VDC 5 V DC power output 10 RD O 0 5V DC LED print head control signal 11 LVDSPO O Analog LED print head control video data signal LVDS 12 LVDSNO O Analog LED print head control video data signal LVDS 13 LVDSP1 O Analog LED print head control video data signal LVDS 14 LVDSN1 O Analog LED print head control video data signal LVDS 15 LVDSP2 O Analog LED print head control video data signal LVDS 16 LVDSN2 O Analog LED print head control video data signal LVDS 17 LVDSP3 O Analog LED print head control video data signal LVDS 18 LVDSN3 O Analog LED print head control video data signal LVDS 19 LVDSP4 O Analog LED print head control video data signal LVDS 20 LVDSN4 O Analog LED print head control video data signal LVDS 21 LVDSP5 O Analog LED print head control video data sig
139. t control D A converter serial signal Output control D A converter clock signal Output control D A converter data latch signal Ground 2 3 7 CLP Connector Connected to the bias high voltage PWB MPFSENS1 MPFSENS2 WTLEDDR WTSENS AIRTEMP WETCK1 WETCK2 o o Voltage 5V DC 0 5 V DC 0 5 V DC 0 5 V DC pulse 0 5 V DC pulse Analog 0 5 V DC pulse Analog Description 5 V DC power output MP tray paper sensor On Off Envelope feeder install sensor Installed Not installed Waste toner full sensor emitter drive output Waste toner full sensor receiver input Full at voltage above the 2 V DC Temperature sensor detection voltage input Humidity sensor control signal 1 KHz Temperature sensor detection signal Connected to the main high voltage PWB E Ab Do JO om Fo o IS o 24V3 MCH1DR MCH2DR MCH3DR MCH4DR 5V1 HVADATD HVACLKD HVALATD GND 00000000 O 24VDC 0 24 V DC 0 24 V DC 0 24 V DC 0 24 V DC 5V DC 0 5 V DC pulse 0 5 V DC pulse 0 5 V DC pulse 24 V DC power input via side cover switch Main charger output control signal Magenta On Off Main charger output control signal Cyan On Off Main charger output control signal Yellow On Off Main charger output control signal Black On Off 5 V DC power output Output control D A converter serial signal Output control D A converter clock signal Output control D A converter data latch signal Ground
140. t szE z OIC Ole le e D N INIJU O000 oo c sa o EE SEZESIESBE 2 S RRE g m enue eee cour ns OO rr Fri mila EogoECtrEEsm HI EE ek Ces 21213 19 S SR amp OGII IOSu dg tgm x to BhEESmTEP nE ess 9 BIS SSSise 2 o SIZ3I3I3NNBNNDO PP Ree PPS 2 SSS SEI Z Saona ocesouson mm E JE SISTE VPI SOONONAUN 2 2oo xoorom SE EE EEGEN n N59 ob5pEOoSNERDANG o od j9QvsigoooNSD o GtrIIIINNNND D GOA 90A 20A 194 TE cea ew RD ee xDD 00 en Li ZLOA A t94 N FS0L dM AMA 19110 U09 euiBu3 LERSEBSIASARERE SS sisoro s5 c ooodoosrowv A LERBSSSISARBRN SO BUSHESGBN ASOWDNOMNAWN n L 40 0W S e J010u1 m ka ea ea en en nen e E rz De e 21525 2 2 2 2229929822292 e 40 0W uejeuozo j 3 wjeuvo B Seer BeSSeSSEGOo Presses K ue uen SZ SS SS 2255 sel E si 9x9 E S CH T 019A LLOA Ma Da SARONUASOCBNOOAON SGSHRONAISODNOT AON CS J l 95 5ow S9S2s ez opo on on FW N gt y y SIRUNAISOONDARONA SBUISHRESGRESOMVAM AWN y NIS e og EEEE OY On AW N zlz S9791 OLv9A 992A 99594 p9vOA 2 om BL E o 8 Y e9YDA 090A L9YIDA z9VOA 996 dy amd feje1 euibu3 X 25 a Lon n om n E NV AOO ROMs ason w2 w w los oz orig owas Goo L an th S USYA zap aporn v v w 69 SS ebk BARS Spe 2S368 Lou 6spOA Ser LSPOA BSOA PSVOA LSPA zSvOA E9794 G i o 296 dM A le co g 5 m m y BRS MBAR ms Bl Es Bom Da m wi iw ARON RON ROM ROD S DEE gaga fsgeas Be De Bel So Le leg Fy le wee bake 8 bodo Bam ab
141. ted Q brochure when replacing them Using a piece of wire for example could lead to fire or other ee UEa eelo a ET T When the service manual or other serious brochure specifies a distance or gap for installation of a o part always use the correct scale and measure carefully sss Always check that the copier is correctly connected to an outlet with a ground connection Check that the power cable covering is free of damage Check that the power plug is dust free If it is dirty clean it to remove the risk of fire or electric shock Never attempt to disassemble the optical unit in machines using lasers Leaking laser light may damage eyesiQht D Handle the charger sections with care They are charged to high potentials and may cause electric shock if handled improperly ooooconccccc nnnoccconnnoncccnnononnccnn E EE ACAUTION Wear safe clothing If wearing loose clothing or accessories such as ties make sure they are NM safely secured so they will not be caught in rotating sections eesseessseesssesrrssrerrresrrrrrnsrrerssnns Use utmost caution when working on a powered machine Keep away from chains and belts A Handle the fixing section with care to avoid burns as it can be extremely hot ooooonocococaciccccanananos A Check that the fixing unit thermistor heat and press rollers are clean Dirt on them can cause Q abnormally high temperatures ecrit
142. th any object Should it be touched by hands or stained with oil clean it Developer unit and toner container Store the toner container in a cool dark place Avoid direct light and high humidity 1 2 2 Installation environment gi de o mc Temperature 10 32 5 C 50 90 5 F Humidity 20 80 RH Power supply 120 V AC U S A Canada 220 240 V AC European countries Power source frequency 50 Hz 2 60 Hz 2 installation location Avoid direct sunlight or bright lighting Ensure that the photo conductor will not be exposed to direct sunlight or other strong light when removing paper jams Avoid extremes of temperature and humidity abrupt ambient temperature changes and hot or cold air directed onto the machine Avoid dust and vibration Choose a surface capable of supporting the weight of the machine Place the machine on a level surface maximum allowance inclination 1 Avoid air borne substances that may adversely affect the machine or degrade the photo conductor such as mer cury acidic of alkaline vapors inorganic gasses NOx SOx gases and chlorine based organic solvents Select a room with good ventilation Allow sufficient access for proper operation and maintenance of the machine Machine front 600 mm 26 6 Machine rear 250 mm 9 84 Machine right 250 mm 9 84 Machine left 400 mm 15 7 Machine top 750 mm 29 5 a a 385mm 15 16 b 345mm13 5
143. the exposure of the light is as dense as 600 dots per a inch The LED print head memory PWB stores data for compensation of fluctuation of luminosity over all LED chips in the array LED print head memory PWB LED print head LED chips 5120 pieces LED array 7 7 SELFOC lens array 600 dot inch Drum Figure 2 1 18 LED print head 2 1 14 CLP Data to print is processed by the main controller PWB and transferred to the LED print head relay PWB in synchronization with VIDEO signal through the engine controller PWB VIDEO signal is sent from ASIC U22 on the mail controller PWB to ASIC U551 on the LED print head relay PWB using LVDS method LVDS stands for Low Voltage Differential Signaling which uses 16 pairs of signal lines 32 in all The main controller PWB converts VIDEO signal into a unique format using LVDS depending on compensating data stored in a flash DIMM The LED print head has an LED print head memory PWB mounted The PWB includes data for compensating the fluctua tion of luminosity of every LED chip At power up the compensating data in EEPROM are cached in the flash DIMM on the main controller PWB In a subsequent power up the main controller PWB refers the flash DIMM to obtain the compensat ing data and the EEPROM is checked with its checksum only If the LED print head or the main controller PWB is replaced checksum becomes error The compensating data is trans ferr
144. tion is shown inside the symbol General prohibited action eo Disassembly prohibited indicates that action is required The specific action required is shown inside the symbol General action required Remove the power plug from the wall outlet Always ground the copier Gag 1 Installation Precautions AAWARNING e Do not use a power supply with a voltage other than that specified Avoid multiple connections to one outlet they may cause fire or electric shock When using an extension cable always check that it is adequate for the rated current NEEN Connect the ground wire to a suitable grounding point Not grounding the copier may cause fire or electric shock Connecting the earth wire to an object not approved for the purpose may cause explosion or electric shock Never connect the ground cable to any of the following gas pipes e lightning rods ground cables for telephone lines and water pipes or faucets not approved by the proper authorities c ed ACAUTION S Do not place the copier on an infirm or angled surface the copier may tip over causing injury Do not install the copier in a humid or dusty place This may cause fire or electric shock SO Do not install the copier near a radiator heater other heat source or near flammable material EU MILENA IN In Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
145. turn on and then the AC voltage is loaded to the fuser heater lamps The HEAT1ON and HEAT2ON signals turn ON OFF the photocouplers PC1 PC2 and triacs TRA1 TRA2 being synchronized with the zero cross signal ZCROSS that is detected by the zero cross signal detection circuit on the power supply PWB The ZCROSS signal detects the zero cross point OV where the AC power source changes between positive negative domains and it is input to the No 39 pin of the ASIC U13 of the engine high voltage PWB Since the ON OFF operation of the photocouplers PC1 PC2 and triacs TRA1 TRA2 are performed at the zero cross point OV it can avoid the sharp change of current and restrain noises generated from the AC power source The fuser thermistor detection voltages TH1 TH2 are input to the micro controller U8 and branched to input to the comparator U1 1 U1 2 The comparator U1 1 U1 2 compares the TH1 and TH2 signals voltage with the unusually high temperature voltage If the voltage TH1 and TH2 signals voltage are higher than unusually high temperature voltage the output level is L For the HEAT1ON and HEAT2ON signals the circuit that forcibly turns off the fuser heater lamps by the hardware based method and forcibly makes the HEAT1ON and HEAT2ON signals to L level regardless of controls by ASIC U13 is provided fuser heater lamp ON signals HEAT1ON HEAT2ON This circuit is provided for the purpose of fail safe it usually monitors the unusual high t
146. um unit non installing error Defective harness Check the connection of the magenta drum The EEPROM U401 on the drum PWB 3 KP 972 inside the yellow drum unit does not communicate nor mally between drum PWB 3 KP 972 and printer main unit or poor contact of the connector terminals unit and the printer main unit check the con tinuity of the harness 802867 if there is trouble remedy or replace Defective drum PWB 3 KP 972 Replace the drum PWB 3 KP 972 Defective LED print Replace the engine controller PWB KP heads relay PWB 1054 See page 1 6 25 KP 1048 Defective LED print Replace the LED print heads relay PWB heads relay PWB KP 1048 See page 1 6 28 KP 1048 Defective harness S02869 between engine controller PWB KP 1054 and LED print heads relay PWB KP 1048 or poor contact of the con nector terminals Check the continuity of the harness S02869 check the connection YC3 con nector of the engine controller PWB KP 1054 if there is trouble remedy or replace 1 5 16 CLP Code Contents Remarks Causes Check procedures corrective measures 7600 Toner ID sensor error Defective toner ID Replace the toner ID sensor The detection signal of the toner ID sensor sensor was abnetmal value Defective engine Replace the engine controller PWB KP controller PWB 1054 See page 1 6 26 KP 1054
147. uo ure LO9EL hart No 8 Paper cassette A4 size Slow mode 1 75 IN 1351249 urew 16821 ec iming c CLP 8 T l due 19selg L D 6L 8l AL 9L SL tl L eL LL DL 6 8 9 S D e L s o 2 4 8 CLP hart No 9 Paper cassette A4 size Slow mode 2 55 iming c 9 T le Oe 6c 8c e 9c Sc vc E cd L Oe 6L 8l ZL OL SL vl L eb LL DL 6 8 9 S v t So v648L ozost Z96L EU he RE Krk KE Ab h CA ff L 1 6080 mee sizez SCH L o Lp eszez SEH LI U ere gsosz 8906 epee 8svoz vs8bL Eege sze0z H 7141 po AAA AAA 94122 16v9L 2z8svi 068 l 96402 6LLSL vozeL seg ai e e lr o o E o e fre ees Ocv6L WZEL 9z8LL Art ee L zv08L 982 8tV0L 692v A a A gt i 17 gt or d I 7 1 LLLLS 80991 8LSEL FI l J l veel OELbL Oriel 9S9 geg EZE 29 01 ssis 82691 HELL v8 6 084 SNC Td SE a r NHS EE H eweg v1912 LZ9pL z499 vz9LZ M m l J Ol 96202 Md 62 120721 66i 96202 62el 20 2 661v UW LLL LLL PS y y IE ER LLL FR RO O O E SL6LL 1282 K _ Oo Q_ 81081 r4 vert 81681 SL6LE bese LLL LLL
148. ure CLP 1 5 1 Paper misfeed detection 1 Paper misfeed indication When a paper misfeed occurs the printer immediately stops printing and displays the paper misfeed message on the operator panel To remove paper misfed in the printer pull out the paper cassette pull out the paper feed unit or open the rear cover Paper misfeed message Paper misfeed location 2 Paper misfeed message display Paper full sensor Paper path Figure 1 5 1 Paper misfeed detection 1 5 1 CLP 1 5 2 Self diagnosis 1 Self diagnostic function This printer is equipped with self diagnostic function When a problem is detected the printer stops printing and display an error message on the operator panel An error message consists of a message prompting a contact to service personnel total print count and a four digit error code 2 digits for FO only indicating the type of the error The display varies depending on the type of the error 1 5 2 service Error codes 0100 to 7600 10123456 Error code Call service Error codes F000 to F050 F050 A Error code Call service Error code FO person FO Error code Figure 1 5 2 Error message display 2 Self diagnostic code Contents CLP Remarks Causes Check procedures corrective measures EEPROM U12 write error When it cannot make normal to access to the EEPROM U12 which is installed in th
149. ut 2 5 V DC power input 2 5 V DC power input 2 5 V DC power input Ground Ground Serial communication data output Control signal Control signal Control signal Operation panel PWB control data synchronizing clock signal Operation panel PWB control data signal Operation panel PWB communication direction control signal Connected to the opera tion panel PWB 3 3V1 FPDATA FPDIR FPCLK GND FPRST 3 3V DC 0 3 3 V DC pulse 0 3 3 V DC 0 3 3 V DC pulse DCOV 5V 3 3 V DC power output Operation panel PWB control data signal Operation panel PWB communication direction control signal Operation panel PWB communication direction control signal Ground Operation panel PWB reset signal Connected to the regis tration clutch feed clutch MP tray feed solenoid toner ID sensor feed motor and fuser motor TCOVOP2 GND 24V2 REGCLDR 24V2 FEDCLDR 24V2 MPSOLDR 5V1 GND IDSW IDSW IDREF STFDA STFDA STFDB 0 OO OO 000 Ooooo DCOV 5V 24V DC 0 24 V DC 24V DC 0 24 V DC 24V DC 0 24 V DC 5VDC Analog Analog Analog 0 24 V DC pulse 0 24 V DC pulse 0 24 V DC pulse Top cover switch Top cover Close Open Ground 24 V DC power via top cover paper feed unit switch Registration clutch On Off 24 V DC power output via top cover paper feed unit switch Feed clutch On Off 24 V DC power output via top cover paper feed unit switch
150. ut 24V1 24V DC 24 V DC power input GND Ground GND Ground GND Ground GND Ground GND Ground GND Ground GND Ground GND Ground 3 3V1 3 3V DC 3 3 V DC power output 3 3V1 3 3 V DC 3 3 V DC power output 3 3V1 3 3 V DC 3 3 V DC power output 3 3V1 3 3 V DC 3 3 V DC power output 5V1 5V DC 5 V DC power input 5V1 5V DC 5 V DC power input BFANDR 0 5 V DC Controller box fan motor On Off Connected GND Ground to the con troller box fan motor OD Joo P Go O O O O O O oj O000 2 3 10 2 3 3 Main controller circuit U25 SDRAM U28 SDRAM N_A 23 1 sora Em EN N_D 31 0 U05 U07 09 U11 CPUD31 0 CPUA22 2 Local Data bus CLP LD31 0 PowerPC 750C Xe 400MHz U19 U20 wn By LA20 LA11 2 ci p 5 o a 3 YS1 System E DIMM LD31 0 o 9 slot Bont on LD15 0 25 0MHz 4 125MHz SE YC4 mask SEE U12 U14 gem X tal USB ABI HO X4 socket Yc3 x4 p LD15 0 Parallel PPDATAT 0 centro l PDTA7 0 UO2 KUIOLV 3 3V Y S VF nics trans ceiver YS2 YC11 Option SDRAM Address bus SDA12 0 8 SDD31 0 serial I F Lon zs d rc IB 11E UE ES YC7 SDRAM 256Mb YS3 Engine UF VIDEO P15 00 VIDEO N15 00 UT E SDRAM sDA12 0 2 X tal SSCG U3 128Mb e SDD31 0 rc SSCG 52 16 6667MHz 2 5V Regulator 45V 2 5V gt gt U31 1 8V Regulator 3V2 1 8V 1 8V 3 3 8
151. y entirely white entirely black ed 4 E P 1 5 23 P 1 5 22 P 1 5 22 P 1 5 23 6 The background is colored 7 White streaks are printed ver tically 8 Black streaks are printed ver tically 9 Streaks are printed horizon tally P 1 5 24 P 1 5 25 P 1 5 25 P 1 5 26 11 The leading edge of image begins to print too early or too late 12 Paper is wrin kled 13 Offset occurs 14 Part of image is missing P 1 5 26 P 1 5 27 P 1 5 27 P 1 5 27 16 Colors are printed offset to each other CLP 5 Image is too light P 1 5 24 10 Spots are printed P 1 5 26 15 Fusing is loose P 1 5 28 1 5 21 CLP Causes 1 The LED print head has not done functioning 2 Defective developing sleeve bias or developing magnet bias output 3 Defective secondary transfer bias output 4 Malfunction of the developer installation 1 No image appears entirely white Causes Check procedures corrective measures 1 The LED print head has not done func tioning A Loose connection with drum connectors Check connection between the drum unit and the unit frame If neces Sary secure the connection Do not attempt to disconnect connect the connector while power is on

FS-C5016N Service Manual

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