Brother HL-4000cn Service Manual

Brother Color Laser Printer

SERVICE MANUAL

MODEL: HL-4000CN

Read this manual thoroughly before maintenance work.

Keep this manual in a convenient place for quick and easy reference at all times.

January 2002

SM-PRN027

© Copyright Brother 2002 All rights reserved.

No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher.

Specifications are subject to change without notice.

Trademarks:

The brother logo is a registered trademark of Brother Industries, Ltd.

Apple, the Apple Logo, and Macintosh are trademarks, registered in the United States and other countries, and True Type is a trademark of Apple computer, Inc.

Epson is a registered trademark and FX-80 and FX-850 are trademarks of Seiko Epson Corporation.

Hewlett Packard is a registered trademark and HP Laser Jet is a trademark of Hewlett Packard Company.

IBM, IBM PC and Proprinter are registered trademarks of International Business Machines Corporation.

Microsoft and MS-DOS are registered trademarks of Microsoft Corporation.

Windows is a registered trademark of Microsoft Corporation in the U.S. and other countries.

PREFACE

This service manual contains basic information required for after-sales service of the color laser printer (here-in-after referred to as "this machine" or "the printer"). This information is vital to the service technician to maintain the high printing quality and performance of the printer.

This service manual covers the HL-4000CN color laser printer.

This manual consists of the following chapters:

CHAPTER I : SPECIFICATIONS

Specifications, etc.

CHAPTER II : INSTALLATION

Installation conditions and installation procedures.

CHAPTER III : STRUCTURE OF SYSTEM COMPONENTS

Basic operation of the mechanical system, the electrical system and the electrical circuits and their timing information.

CHAPTER IV : ASSEMBLY / DISASSEMBLY

Procedures for replacement of the mechanical system parts.

CHAPTER V : TROUBLESHOOTING

Description of error messages on the control panel, troubleshooting image failure, etc.

CHAPTER VI : DIAGRAMS

CHAPTER VII : PLUG / JACK (P/J) CONNECTOR LOCATIONS

Information in this manual is subject to change due to improvement or re-design of the product. All relevant information in such cases will be supplied in service information bulletins (Technical Information).

A thorough understanding of this printer, based on information in this service manual and service information bulletins, is required for maintaining its print quality performance and for improving the practical ability to find the cause of problems.

CONTENTS

CHAPTER I SPECIFICATIONS ........................................................		I-1
1. PRODUCT NAME ............................................................................................		I-1
2. DIMENSIONS / WEIGHT (MAIN UNIT)............................................................		I-1
3. SPACE REQUIREMENTS ...............................................................................		I-1
4. PRINTER SYSTEM CONFIGURATION ...........................................................		I-2
4.1. Outline of the Printer .............................................................................................................		I-2
4.2. IOT Function Outline.............................................................................................................		I-3
4.3. ESS Standard Configuration.................................................................................................		I-4
5. OPTIONAL PRODUCTS ..................................................................................		I-5
6. SYSTEM CHARACTERISTICS........................................................................		I-6
6.1	Operation Modes ...................................................................................................................	I-6
6.2	Throughput.............................................................................................................................	I-7
6.3	FPOT .....................................................................................................................................	I-7
6.4	Continuous Printing Speed ....................................................................................................	I-7
6.5	Warm-up Time .......................................................................................................................	I-8
7. PRINT FUNCTION ...........................................................................................		I-8
7.1	Image Area ............................................................................................................................	I-8
7.2	Internal Fonts .........................................................................................................................	I-8
7.3	True Type Fonts...................................................................................................................	I-11
8. IMAGE PROCESSING FUNCTIONS .............................................................		I-12
8.1	Color/Monochrome Specification .........................................................................................	I-12
8.2	Paper Type Selection...........................................................................................................	I-12
8.3	Toner Save ..........................................................................................................................	I-12
8.4	Color Matching.....................................................................................................................	I-12
8.5	Image Adjustment ................................................................................................................	I-12
8.6	Color Adjustment .................................................................................................................	I-12
8.7	Automatic Image Quality Correction ....................................................................................	I-12
8.8	Recommended Image Quality Modes..................................................................................	I-12
8.9	Profile Specification .............................................................................................................	I-13
9. IMAGE ADDITION FUNCTION ......................................................................		I-14
9.1	Watermark ...........................................................................................................................	I-14
10. PAGE LAYOUT FUNCTIONS ......................................................................		I-14
10.1 Reverse Print .....................................................................................................................		I-14
10.2 Zoom..................................................................................................................................		I-14
10.3 Multiple Page .....................................................................................................................		I-14
10.4 Margin Shift........................................................................................................................		I-14
10.5 Poster.................................................................................................................................		I-14
10.6 Booklet Printing..................................................................................................................		I-14

11. PAGE OUTPUT SEQUENCE CONTROL FUNCTIONS ..............................		I-14
11.1	Stacking .............................................................................................................................	I-14
11.2	Collating .............................................................................................................................	I-14
12. SEPARATOR ...............................................................................................		I-15
12.1	Banner Sheet .....................................................................................................................	I-15
13. JOB CONTROL ............................................................................................		I-15
13.1	Print Abortion .....................................................................................................................	I-15
13.2	Forced Ejection ..................................................................................................................	I-15
13.3	Job Timeout .......................................................................................................................	I-15
13.4	Job Recovery .....................................................................................................................	I-15
14. OTHER FUNCTIONS ...................................................................................		I-15
14.1	User Job Registration Function..........................................................................................	I-15
14.2	Billing Count Function ........................................................................................................	I-15
14.3	Toner Level Display ...........................................................................................................	I-15
14.4	Job Log Function ...............................................................................................................	I-16
14.5	Reception Limit (IP Filter Function)....................................................................................	I-16
15. UTILITY PRINT ............................................................................................		I-16
15.1	Printer Setting List..............................................................................................................	I-16
15.2	Panel Setting List ...............................................................................................................	I-16
15.3	Font List .............................................................................................................................	I-16
15.4	Job Log Print......................................................................................................................	I-16
15.5	Color Registration Correction Chart...................................................................................	I-16
16. HOST INTERFACE ......................................................................................		I-17
16.1	Client Hardware .................................................................................................................	I-17
16.2	Client OS............................................................................................................................	I-17
16.3	Server OS ..........................................................................................................................	I-17
17. IEEE1284 .....................................................................................................		I-17
17.1	Connector ..........................................................................................................................	I-17
17.2	IEEE1284 Support .............................................................................................................	I-17
18. ETHERNET ..................................................................................................		I-17
18.1	Connector ..........................................................................................................................	I-17
18.2	Printing Protocols...............................................................................................................	I-18
18.3	Management Protocols ......................................................................................................	I-19
18.4	USB....................................................................................................................................	I-20
19. UTILITY SOFTWARE...................................................................................		I-20
19.1	Printer Drivers/Installers.....................................................................................................	I-20
19.2	BLP (LPR)..........................................................................................................................	I-20
19.3	BNT (NetBIOS) ..................................................................................................................	I-20
19.4	BRAdmin Pro .....................................................................................................................	I-20
20. PAPER HANDLING......................................................................................		I-21
20.1	Paper Feed ........................................................................................................................	I-21
20.2	Output Tray ........................................................................................................................	I-22

20.3	Duplex................................................................................................................................	I-22
20.4	Handling of Other Paper ....................................................................................................	I-22
20.5	Summary of Prohibited Conditions ....................................................................................	I-22
21. OPERATING SUPPLY VOLTAGE ...............................................................		I-23
22. RATED POWER CONSUMPTION ...............................................................		I-23
23. NOISE ..........................................................................................................		I-24
24. FIRMWARE UPDATE FUNCTION ...............................................................		I-24
25. TOOLS AND SERVICE CONSUMABLES....................................................		I-24
25.1	Tools ..................................................................................................................................	I-24
25.2	Service Consumables ........................................................................................................	I-24
26. CONSUMABLES ..........................................................................................		I-24
27. SOFTWARE RELATED INFORMATION......................................................		I-25
27.1	Menu Tree (User Mode).....................................................................................................	I-25

CHAPTER II INSTALLATION ..........................................................	II-1
1. INSTALLATION PROCEDURE .......................................................................	II-1
1.1. Checking the Packaged Items .............................................................................................	II-2
1.2. Removing the Tapes from the Printer ..................................................................................	II-3
1.3. Removing the Paper Tray Protective Materials ...................................................................	II-4
1.4. Mounting the Print Head Cartridge ......................................................................................	II-6
1.5. Mounting the Toner Cartridge ..............................................................................................	II-9
1.6. Mounting the Transfer Roll Cartridge.................................................................................	II-12
1.7. Loading Paper....................................................................................................................	II-14
1.8. Connecting the Power Cable .............................................................................................	II-18
1.9. Correcting the Color Registrations.....................................................................................	II-20

CHAPTER III STRUCTURE OF SYSTEM COMPONENTS		.............III-1
1. PRINTING PROCESS....................................................................................		III-1
1.1	Summary of Printing Process ..............................................................................................	III-1
1.2	Schematic Diagram for Printing Process .............................................................................	III-3
1.3	Description of Printing Process Techniques ........................................................................	III-4
2. FLOW OF PRINT DATA...............................................................................		III-17
2.1	Data Flow...........................................................................................................................	III-17
3. DRIVE TRANSMISSION ROUTE.................................................................		III-18
3.1	Main Drive ASSY ...............................................................................................................	III-18
3.2	DEVE Drive ASSY .............................................................................................................	III-19
3.3	Holder Toner Cartridge ASSY (Y, M, C, K)........................................................................	III-19
3.4	Fuser Drive ASSY..............................................................................................................	III-20
3.5	Motor ASSY DUP...............................................................................................................	III-20
3.6	Gear Layout .......................................................................................................................	III-21

4. PAPER TRANSFER .....................................................................................		III-22
4.1	Paper Transfer Route (without option)...............................................................................	III-22
4.2	Layout of Paper Transfer Route.........................................................................................	III-23
5. FUNCTIONS OF MAJOR FUNCTIONAL COMPONENTS...........................		III-24
5.1	Paper Cassette ..................................................................................................................	III-25
5.2	Paper Feeder .....................................................................................................................	III-26
5.3	Housing ASSY Retard .......................................................................................................	III-28
5.4	Front ASSY In ....................................................................................................................	III-29
5.5	Chute ASSY Out ................................................................................................................	III-30
5.6	Chute ASSY Exit................................................................................................................	III-32
5.7	Transfer Roll Cartridge ASSY & Fuser ..............................................................................	III-33
5.8	Xerographics......................................................................................................................	III-35
5.9	Toner Cartridge ASSY .......................................................................................................	III-37
5.10 Frame & Drive..................................................................................................................		III-39
5.11 Electrical ..........................................................................................................................		III-40
6. MODES ........................................................................................................		III-42
6.1	Print Mode..........................................................................................................................	III-42
6.2	Operation Modes ...............................................................................................................	III-42
7. CONTROL....................................................................................................		III-43
7.1	Control of Paper Size.........................................................................................................	III-43
7.2	Selective Control on Paper Pick-up Unit............................................................................	III-43
7.3	Scanner Light Quantity Control..........................................................................................	III-43
7.4	Process Control .................................................................................................................	III-43
7.5	Color Registration Control..................................................................................................	III-47
7.6	Transfer Roll Cartridge Unit ASSY Control ........................................................................	III-48
7.7	Toner Control .....................................................................................................................	III-49
7.8	Fuser Control .....................................................................................................................	III-50

CHAPTER IV ASSEMBLY / DISASSEMBLY.................................		IV-1
1. BEFORE STARTING DISASSEMBLY ...........................................................		IV-1
1.1	Precautions .........................................................................................................................	IV-1
1.2	Fuser ASSY Removal .........................................................................................................	IV-2
1.3	Transfer ASSY Removal.....................................................................................................	IV-3
1.4	Controller Board Removal...................................................................................................	IV-4
1.5	Description of Procedures...................................................................................................	IV-5
2. DISASSEMBLY PROCEDURE ......................................................................		IV-6
2.1	Cover of the Printer.............................................................................................................	IV-6
2.2	Front of the Printer ............................................................................................................	IV-16
2.3	Top of the Printer ..............................................................................................................	IV-40
2.4	Right / Left / PCBs of the Printer.......................................................................................	IV-47
2.5	Paper Feed of the Printer..................................................................................................	IV-58

CHAPTER V TROUBLESHOOTING...............................................		V-1
1. PREFACE .......................................................................................................		V-1
1.1	Troubleshooting Procedure..................................................................................................	V-1
1.2	Note on Troubleshooting......................................................................................................	V-1
2. LEVEL 1 TROUBLESHOOTING .....................................................................		V-3
2.1	Level 1 FIP...........................................................................................................................	V-3
3. LEVEL 2 TROUBLESHOOTING .....................................................................		V-4
3.1	Fail Code List .......................................................................................................................	V-4
3.2	Fail FIP...............................................................................................................................	V-14
4. HOW TO USE DIAG. (C/E) MODE................................................................		V-39
4.1	Roles of the Control Panel in Diag. (C/E) Mode ................................................................	V-39
4.2	Entering Diag. (C/E) Mode.................................................................................................	V-39
4.3	Exiting Diag. (C/E) Mode ...................................................................................................	V-39
4.4	Diag. (C/E) Mode Functions...............................................................................................	V-39
4.5	Operation Procedure..........................................................................................................	V-40
4.6	Diag. Mode Menu Tree ......................................................................................................	V-41
4.7	ESS Diagnosis ...................................................................................................................	V-43
4.8	IOT Diagnosis ....................................................................................................................	V-44
4.9	Installation Setting..............................................................................................................	V-51
4.10 Test Print..........................................................................................................................		V-52
4.11 Parameter Setting ............................................................................................................		V-53
4.12 Information Print...............................................................................................................		V-55
5. DIAGNOSIS FOR STANDALONE PRINTER ................................................		V-56
5.1	General ..............................................................................................................................	V-56
5.2	Printing Method..................................................................................................................	V-56
5.3	Test Print Pattern ...............................................................................................................	V-57
6. NVM LIST......................................................................................................		V-58
7. HEX/DEC CONVERSION TABLE .................................................................		V-67
8. IMAGE QUALITY TROUBLE ENTRY CHART ..............................................		V-69
9. IMAGE QUALITY SPECIFICATIONS............................................................		V-70
9.1	Parallelism .........................................................................................................................	V-70
9.2	Diagonal.............................................................................................................................	V-70
9.3	Skew ..................................................................................................................................	V-70
9.4	Straightness .......................................................................................................................	V-71
9.5	Magnification Error.............................................................................................................	V-71
9.6	Registration........................................................................................................................	V-71
9.7	Guaranteed Printing Area ..................................................................................................	V-72
10. TEST PRINT ...............................................................................................		V-73

10.1 Test print ..........................................................................................................................

V-73

11. IMAGE QUALITY FIP ..................................................................................		V-74
11.1	Notes on Image Quality Trouble Check ...........................................................................	V-74
11.2	Basic Rule of Image Quality Adjustment..........................................................................	V-74
11.3	Troubleshooting Table by Trouble Phenomena...............................................................	V-75

CHAPTER VI DIAGRAMS..............................................................		VI-1
1.PREFACE .......................................................................................................		VI-1
1.1	How to Use the BSD ...........................................................................................................	VI-1
1.2	Explanations of Symbols.....................................................................................................	VI-1
1.3	Signal Name .......................................................................................................................	VI-4
1.4	DC Voltage..........................................................................................................................	VI-4
1.5	Input/Output Test ................................................................................................................	VI-4
2. BSD (BLOCK SCHEMATIC DIAGRAM)

CHAPTER VII PLUG/JACK (P/J) CONNECTOR LOCATIONS ....		VII-1
1. LIST OF P/J...................................................................................................		VII-1
1.1	Base Engine.......................................................................................................................	VII-1
1.2	2 Tray Module ....................................................................................................................	VII-3
2. P/J LAYOUT DIAGRAM ................................................................................		VII-4
2.1	IOT Top..............................................................................................................................	VII-4
2.2	IOT Front/RH .....................................................................................................................	VII-5
2.3 MCU and HVPS PWB/ESS PWB.......................................................................................		VII-6
2.4	Tray 1.................................................................................................................................	VII-7
2.5	2 Tray Module ....................................................................................................................	VII-8

REGULATIONS

LASER SAFETY (FOR 120 V MODEL ONLY)

This printer is certified as a Class I laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation.

Since radiation emitted inside the printer is completely confined within protective housings and external covers, the laser beam cannot escape from the machine during any phase of user operation. However, the machine contains 5-milliwat, 700-800 nanometer wavelength, GaAIAs laser diodes. Direct (or indirect reflected) eye contact with the laser beam might cause serious eye damage. Safety precautions and interlock mechanisms have been designed to prevent any possible laser beam exposure to the operator.

FDA REGULATIONS (FOR 120 V MODEL ONLY)

U.S. Food and Drug Administration (FDA) has implemented regulations for laser products manufactured on and after August 2, 1976. Compliance is mandatory for products marketed in the United States. The label shown on the back of the printer indicates compliance with the FDA regulations and must be attached to laser products marketed in the United States.

MANUFACTURED: BROTHER INDUSTRIES, LTD.

15-1 Naeshiro-cho, Mizuho-ku, Nagoya, 467-8561 Japan

This product complies with FDA radiation performance standards, 21 CFR Subchapter J.

Caution:

Use of controls, adjustments or the performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

i

IEC 60825 SPECIFICATION (FOR 220-240 V MODEL ONLY)

This printer is a Class 1 laser product as defined in IEC 60825 specifications. The label shown below is attached in countries where required.

CLASS 1LASER PRODUCT

APPAREIL Å LASER DE CLASSE 1

LASER KLASSE 1 PRODUKT

This printer has a Class 3B Laser Diode which emits invisible laser radiation in the Scanner Unit. The Scanner Unit should not be opened under any circumstances.

Caution: Use of controls, adjustments or the performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

For Finland and Sweden

LUOKAN 1 LASERLAITE

KLASS 1 LASER APPARAT

Varoitus! Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

Varning – Om apparaten används på annat sätt än i denna Bruksanvisning specificerats, kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass 1.

Internal laser radiation

Max. Radiation Power	10 mW
Wave Length	770 nm-808 nm
Laser Class	Class IIIb (Accordance with 21 CFR Part 1040.10)
	Class 3B (Accordance with IEC60825)

ii

SAFETY

To prevent possible accidents during maintenance operation, you should observe strictly the "Warning" and "Caution" information in this manual.

Dangerous operations and operations out of range of this manual should be absolutely avoided.

Generally various processes not covered by this manual may be required in actual operation, which should be performed carefully always giving attention to safety.

Caution

Use of controls or adjustment or performance of procedures other than those specified in this manual might result in hazardous radiation exposure.

Disconnect device

This printer must be installed near a power outlet that is easily accessible. In case of emergencies, you must disconnect the power cord from the power outlet to shut off the power completely.

Caution for batteries

Do not replace the battery. There is a danger of explosion if the battery is incorrectly replaced. Do not disassemble, recharge or dispose of inby fire. Used batteries should be disposed of according to local regulations.

iii

Power Source

Keep the power supply off during maintenance operation to prevent electric shock, burns and other damages. Keep the power plug disconnected during the maintenance operation.

If the power supply should be kept connected for measurement of voltage or other similar reasons, sufficient care should be given to prevent electric shock, by following the procedures of this manual.

WARNING

While the printer is ON, never touch live parts if not required absolutely.

WARNING

Power is supplied to the power switch / inlet (LVPS ASSY) even while the printer is off. Never touch its live components.

WARNING

Do not touch live parts unless otherwise specified.

Driving Units

When servicing gears or other driving units, be sure to turn them OFF and plug off. Drive them manually when required.

WARNING

Never touch the gears or other driving units while the printer is running.

iv

High-temperature Units

When servicing high-temperature units (securing unit, etc.), be sure to turn them OFF to prevent burns, injuries and other troubles, remove the power plug and start service processes after they have cooled down enough.

WARNING

Immediately after completion of operation, they are still hot. Start services after more than 40 minutes.

Laser Beams

WARNING

N If your eyes are exposed to laser beams, you may lose your eyesight.

N Never open the cover if warning label for laser beams is attached there.

N Before disassembling and reassembling this laser printer, be sure to turn it OFF.

N When servicing this laser printer while it is running, be sure to follow the procedures specified in this manual.

N You should understand the features of the laser beams which are capable of having an injurious action on the human body, not to extend the danger over the workers as well as other people around the printer.

Note:

I Laser beams have features as follows:

NFrequencies are smaller in width than other beams (sun and electric bulbs) and phases are uniform so that high monochromatic and convergence performance can be obtained and thin beams of light can reach places at a long distance.

NDue to the high convergence, beams are concentrated in high density and high temperature, which is dangerous to human body.

Reference: Laser beams of this laser printer is invisible rays which you cannot see.

Scanner ASSY

Print Head Cartridge ASSY

v

Warning/Caution Labels

Warning labels and caution labels are attached to this laser printer to prevent accidents check those labels for their peeling or stain when servicing the printer.

< Caution label for high-temperature units >

Unpacking the Printer

WARNING

The printer must be carried horizontally with two or more persons.

CAUTION

Extreme care must be taken to avoid personal injuries.

Check visually the printer for evidence of any damages.

Peel all tapes off the printer.

Remove protection parts (2 pieces) from the paper tray.

vi

ACRONYMS

In this manual, the manual specific acronyms are used in addition to the generally used ones. The table below contains typical acronyms that are used throughout this manual.

ADC	Automatic Density Control
AUX.	Auxiliary
BCR	Bias Charge Roll
BUR	Back Up Roll
CCW	Counter Clock Wise
CLN	Cleaning (or Cleaner)
CR	Charge Roll
CRUM	CRU Monitor
DB	Developing Bias
FG	Frame Ground
Hex	Hexadecimal
IDT	Intermediate Drum Transfer
L/H	Left Hand
LD	Laser Diode
MSI	Multi Sheet Inserter
N/P	No Paper
OPC	Organic Photo Conductor
PCDC	Pixel Count Dispense Control
Pixel	Picture Cell
PV	Print Volume
R/H	Right Hand
SEF	Short Edge Feed
SNR	Sensor
SOS	Start Of Scan
SYNC.	Synchronous
TC	Toner Concentration
TR	Transfer
WDD	Wide Range Dynamic Damper
XERO.	Xerographic

AG	Analog Ground
B/W	Black and White
CART.	Cartridge
CL.	Clutch
CLK	Clock
CRU	Customer Replaceable Unit
CW	Clock Wise
DTS	Detack Saw
FDR	Feeder
FRU	Field Replaceable Unit
I/F	Interface
ID	Image Density
	(or Identification)
L/P	Low Paper
LEF	Long Edge Feed
N/F	Normal Force
NVM	Non Volatile Memory
P/H	Paper Handling
PPM	Prints Per Minute
PWB	Printed Wiring Board
REGI.	Registration
RTN	Return
SG	Signal Ground
SOL.	Solenoid
SPI	Scans Per Inch
T/A	Take Away
TEMP.	Temperature
TRANS.	Transport
YMCBk	Yellow, Magenta, Cyan, Black

vii

Service call procedures

1.Notes Before Work

1.1 Safety notes

To prevent an accident during maintenance, follow warnings and precautions strictly. Avoid dangerous work.

1.Power supply

To prevent an electric shock, burn, or injury, turn off the power and unplug the power cable before maintenance work. If it is inevitable to keep the power on for voltage measurement, take the greatest care not to receive an electric shock.

2.Drive

Never inspect or lubricate drive components such as gears when the machine is in operation.

3.Heavy parts

The machine weighs 35.3 kg. When lifting the machine, get a firm footing and bend your knees to avoid possible injuries to your back.

4.Safety devices

Ensure the safety functions of safety devices for preventing mechanical accidents (fuses, circuit breakers, and interlock switches) and for safe user operations (panels and covers). Do not make mechanical alterations that may impair the safety functions.

5.Parts mounting and removal

Parts and covers may have sharp edges. Do not touch the edges readily. If your fingers or hands become greasy, wipe off the grease well. Do not pullout a part cable forcibly but gradually.

6.Specified tool

Follow instructions if a tool is specified.

7.Organic solvents

Use the drum cleaner and other organic solvents carefully with the following notes in mind:

N Keep the room well ventilated not to breathe in vapor a lot or continuously.

NThe solvents are inflammable liquids. Do not put them close to or into a fire or do not heat their containers.

NAvoid storing the solvents near a naked fire or sparks because they may catch fire.

8.Irregular use of machine

When altering the machine, submit an application for irregular use in advance.

viii

1.2Other notes

Do maintenance work correctly and efficiently with the following notes in mind:

1.Reference materials

Read the related technical information (SB, FTI, FTO and so on) well and do maintenance work systematically.

2.Disassembling

Before removing parts for disassembling, check the normal mounting status in advance.

3.Mounting and adjustment

Do not start up the machine immediately after finishing part mountings and adjustments. Check that there are no tools or parts left inside the machine or on assy.

4.Handling of replaced parts and consumables

Do not discard of replaced parts and consumables at the customer site. After replacing the following consumables, be sure to attach the U tag to the replaced one and recover.

Drum cartridge

Color toner cartridges

As to parts to be recycled, enter necessary data into the U tag and recover the parts.

5.General Notes

Be careful not to disturb the customer's daily work.

Color toner dropped on the floor is hardly cleaned. Place the drop cloth on the floor when maintaining the inside of the machine to protect carpets and floors. Puts wastes, consumables, and replaced parts into a plastic or paper bag and obtain the permission of the customer to throw them away.

Be sure to enter the field work contents and the replaced consumables and parts into the Machine Log Book.

HL-4000CN weighs 35.3 kg.

When moving the equipment, make sure that there are two or more persons carrying it. For details, see the installation procedure on page II-1.

ix

2.Workflow in the Field

<Initial Actions >

1.Question the Customer for details about the system malfunction.

2.Note down the meter count.

3.Inspect the rejected print and determine the machine condition.

4.Check the Machine Log Book.

<For UM visit >

1.Perform the Level 1 troubleshooting.

2.Perform the troubleshooting.

3.Print any Internal Test Pattern to check the print quality. (See page V-51)

4.Feed paper from each tray, and clean or replace the feed role as required.

5.Repair any secondary problems that would prevent the machine from running.

6.Perform the trim activities.

<For SM visit >

1.Print any Internal Test Pattern to check the print quality. (See page V-51)

2.Feed paper from each tray, and clean or replace the feed role as required.

3.Repair any secondary problems that would prevent the machine from running.

4.Perform the trim activities.

<Final Actions >

1.Check the machine overall operation and function.

2.Check the machine appearance and consumables.

3.Perform the operator training as required.

4.Record the performed action in the Machine Log Book and Service Report.

5.Store the sample printouts in the Machine Log Book.

x

3.Trim Activity

Trim activities for HL-4000CN should be made within every SM/UM, mainly for maintaining the machine performance. There is no service call performed only for the trim activity.

3.1Trim activity procedure

1.Check the overall operation before performing the trim activity.

Print any Internal Test Pattern to output three patterns: all colors of 20 % each, halftone and grid.

All colors of 20 % each: IBT belt, scratches on the drum surface, and fusing problem are checked.

Halftone pattern: Low density area reproduction problem, color balance and fusing problem are checked.

Grid pattern: Color registration problem and fusing problem are checked.

*See page V-51 for test pattern output method.

2.Clean the interior of the machine.

Clean toner contamination and paper dust in the paper path area. (Operator area should be cleaned carefully.)

3.Check the periodic replacement parts(consumable parts). Replace as required.

4.Safety check.

Check the Power Cord for damage or loose connection.

5.After 1 to 4 above completes, do the following overall operation checks. Machine operation

Print quality Meter reading

3.2Mechanical consumables and periodic replacement parts

A mechanical consumable should be replaced after checking the printed sheets count during trim action.

<Mechanical consumables>

Consumable	Product Code	Number of sheets that can be
		printed*1
Black Toner Cartridge	TN-11BK	8.5K
Cyan Toner Cartridge	TN-11C	6K
Magenta Toner Cartridge	TN-11M	6K
Yellow Toner Cartridge	TN-11Y	6K
Print Head Cartridge	PH-11CL	30K
Transfer Roll Cartridge	TR-11CL	25K
(with Toner Collector Bottle)
*1: Condition

Paper size: A4 or LETTER

Toner coverage: 5%

Ratio of B/W to color: 1: 1

Average number of sheets printed at onetime: 4 sheets

<Parts for periodic replacement>

Consumable	Replacement interval	Remarks
Fuser Unit	100K prints
Retard Roll	100K prints

xi

3.3Trim checklist

C:Check and if necessary clean, replace, or replenish.

A:Always check and clean.

R:Replace at specified intervals.

*See page V-51 for the test pattern output method.

No.	Work item	Each	100K	Rep &	Description
		time		Adj No.
1.1	Check before work	C			- Start up the machine to see that no
	(Mechanical noise				abnormal noise occurs
	check)
1.2	Check before work	C			- Output the internal test patterns to check
	(Test pattern output)				the print quality.
					(Check uneven darkness, deletion, and
					drum of belt damage with each 20%
					pattern and reproducibility of low darkness
					with the document reproducibility pattern.)
2	Cleaning inside the	C	R		- Clean any loose toner and paper dust from
	machine				the paper transport path and jam sensors.
	(Paper transport				- Clean especially the operator area.
	system cleaning)				- Check and clean the MSI field roll.
	Retard Roll
3.1	Fuser ASSY	A	R		- Check that the H. Roll and P. Roll are not
					scratched.
					Replace them when necessary.
3.2	Print Head Cartridge	A	30K		- Visual check only. Do not touch.
3.3	Transfer Roll	C	18K		- Visual check only. Do not touch.
	Cartridge Unit ASSY
4	Safety check	A			- Check the power plug for loose connection.
					- Check the power cable for crack or
					explosion of its conductor.
					- Check that the extension cable of an
					insufficient capacity or a nonstandard
					power cable (ex. table tap) is not used.
					- Check that the power cable is not
					connected to the same outlet as some
					other cables.
5.1	Check after work	C			- Output the internal test patterns to see that
	(Print quality check)				the print quality satisfies the standards.
5.2	Check after work	C			- Check paper feed and noise.
	(Machine operation
	check)
5.3	Check after work	C			- Create Machine Log Book and a service
					report.

CAUTION

Do not touch the print head cartridge or transfer roll cartridge unit directly by hand.

Do not use a drum cleaner or other solvents. (It will take time for the machine to recover.)

xii

CHAPTER I

SPECIFICATIONS

CONTENTS

CHAPTER I SPECIFICATIONS........................................................		I-1
1. PRODUCT NAME............................................................................................		I-1
2. DIMENSIONS / WEIGHT (MAIN UNIT) ...........................................................		I-1
3. SPACE REQUIREMENTS...............................................................................		I-1
4. PRINTER SYSTEM CONFIGURATION ..........................................................		I-2
4.1	Outline of the Printer ..............................................................................................................	I-2
4.2	IOT Function Outline..............................................................................................................	I-3
4.3	ESS Standard Configuration..................................................................................................	I-4
5. OPTIONAL PRODUCTS..................................................................................		I-5
6. SYSTEM CHARACTERISTICS .......................................................................		I-6
6.1	Operation Modes ...................................................................................................................	I-6
6.2	Throughput.............................................................................................................................	I-7
6.3	FPOT .....................................................................................................................................	I-7
6.4	Continuous Printing Speed ....................................................................................................	I-7
6.5	Warm-up Time.......................................................................................................................	I-8
7. PRINT FUNCTION...........................................................................................		I-8
7.1	Image Area ............................................................................................................................	I-8
7.2	Internal Fonts .........................................................................................................................	I-8
7.3	True Type Fonts...................................................................................................................	I-11
8. IMAGE PROCESSING FUNCTIONS.............................................................		I-12
8.1	Color/Monochrome Specification .........................................................................................	I-12
8.2	Paper Type Selection...........................................................................................................	I-12
8.3	Toner Save ..........................................................................................................................	I-12
8.4	Color Matching.....................................................................................................................	I-12
8.5	Image Adjustment................................................................................................................	I-12
8.6	Color Adjustment .................................................................................................................	I-12
8.7	Automatic Image Quality Correction ....................................................................................	I-12
8.8	Recommended Image Quality Modes..................................................................................	I-12
8.9	Profile Specification .............................................................................................................	I-13
9. IMAGE ADDITION FUNCTION......................................................................		I-14
9.1	Watermark ...........................................................................................................................	I-14
10. PAGE LAYOUT FUNCTIONS......................................................................		I-14
10.1 Reverse Print .....................................................................................................................		I-14
10.2 Zoom..................................................................................................................................		I-14
10.3 Multiple Page .....................................................................................................................		I-14
10.4 Margin Shift........................................................................................................................		I-14

10.5	Poster.................................................................................................................................	I-14
10.6	Booklet Printing..................................................................................................................	I-14

11. PAGE OUTPUT SEQUENCE CONTROL FUNCTIONS..............................		I-14
11.1	Stacking .............................................................................................................................	I-14
11.2	Collating .............................................................................................................................	I-14
12. SEPARATOR...............................................................................................		I-15
12.1	Banner Sheet .....................................................................................................................	I-15
13. JOB CONTROL............................................................................................		I-15
13.1	Print Abortion .....................................................................................................................	I-15
13.2	Forced Ejection ..................................................................................................................	I-15
13.3	Job Timeout .......................................................................................................................	I-15
13.4	Job Recovery .....................................................................................................................	I-15
14. OTHER FUNCTIONS ..................................................................................		I-15
14.1	User Job Registration Function..........................................................................................	I-15
14.2	Billing Count Function ........................................................................................................	I-15
14.3	Toner Level Display ...........................................................................................................	I-15
14.4	Job Log Function ...............................................................................................................	I-16
14.5	Reception Limit (IP Filter Function)....................................................................................	I-16
15. UTILITY PRINT............................................................................................		I-16
15.1	Printer Setting List..............................................................................................................	I-16
15.2	Panel Setting List ...............................................................................................................	I-16
15.3	Font List .............................................................................................................................	I-16
15.4	Job Log Print......................................................................................................................	I-16
15.5	Color Registration Correction Chart...................................................................................	I-16
16. HOST INTERFACE......................................................................................		I-17
16.1	Client Hardware .................................................................................................................	I-17
16.2	Client OS............................................................................................................................	I-17
16.3	Server OS ..........................................................................................................................	I-17
17. IEEE1284.....................................................................................................		I-17
17.1	Connector ..........................................................................................................................	I-17
17.2	IEEE1284 Support .............................................................................................................	I-17
18. ETHERNET..................................................................................................		I-17
18.1	Connector ..........................................................................................................................	I-17
18.2	Printing Protocols...............................................................................................................	I-18
18.3	Management Protocols ......................................................................................................	I-19
18.4	USB....................................................................................................................................	I-20
19. UTILITY SOFTWARE ..................................................................................		I-20
19.1	Printer Drivers/Installers.....................................................................................................	I-20
19.2	BLP (LPR)..........................................................................................................................	I-20
19.3	BNT (NetBIOS) ..................................................................................................................	I-20

19.4 BRAdmin Pro .....................................................................................................................

I-20

20. PAPER HANDLING .....................................................................................		I-21
20.1	Paper Feed ........................................................................................................................	I-21
20.2	Output Tray ........................................................................................................................	I-22
20.3	Duplex................................................................................................................................	I-22
20.4	Handling of Other Paper ....................................................................................................	I-22
20.5	Summary of Prohibited Conditions ....................................................................................	I-22
21. OPERATING SUPPLY VOLTAGE...............................................................		I-23
22. RATED POWER CONSUMPTION ..............................................................		I-23
23. NOISE..........................................................................................................		I-24
24. FIRMWARE UPDATE FUNCTION ..............................................................		I-24
25. TOOLS AND SERVICE CONSUMABLES ...................................................		I-24
25.1	Tools ..................................................................................................................................	I-24
25.2	Service Consumables ........................................................................................................	I-24
26. CONSUMABLES .........................................................................................		I-24
27. SOFTWARE RELATED INFORMATION.....................................................		I-25
27.1	Menu Tree (User Mode).....................................................................................................	I-25

CHAPTER I SPECIFICATIONS

1.PRODUCT NAME

Product Name	Product Code	Model

2.DIMENSIONS / WEIGHT (MAIN UNIT)

Width (mm)	Depth (mm)		Height (mm)	Weight (kg)
439	590*		445	35.5kg or less (with CRU)
*: with the manual tray folded

3.SPACE REQUIREMENTS

The printer has vents on the sides and the rear. Install the printer with clearances of 150 cm on the right, 100 cm on the left, and 200 cm on the rear.

600mm	100mm	200mm
	150mm

I-1

4.PRINTER SYSTEM CONFIGURATION

4.1Outline of the Printer

1)Host computer

The target host is a personal computer (PC98, IBM PC-AT compatible, or Macintosh) connected directly and also through a network.

2)ESS

The ESS interprets print information (control code data, character code data, graphics data, and image data) sent from the host computer into video data and sends it to the IOT.

3)IOT

The ESS prints received video data for viewing. This unit uses the A4-size 600/1200 dpi laser xerography system.

Host

Computer

Network

IEEE1284 or USB1.1

	ESS				IOT

Control Panel

Power Source

AC

I-2

4.2IOT Function Outline

Configuration	Contents
Recording section	- Color 16PPM, Monochrome 16PPM
	- 600dpi (standard speed), 1200dpi (half speed)
Recording System	- OPC drum, 4-tandem cartridges , electro-photographic system
	using intermediate transfer rolls
Developer	- 2-component
Toner	- Chemical toner (black, yellow, magenta, cyan)
Exposure System	- Semiconductor laser, simultaneous scanning by 4 beams
Fusing System	- Heat fusing of the free belt nip system
CRU	- Black toner cartridge
(consumables)	- Yellow toner cartridge
	- Magenta toner cartridge
	- Cyan toner cartridge
	- Drum cartridge
	- Transfer roll cartridge
Paper Source	- Internal 500 sheets feeder unit
	- MSI unit (100 sheets)
	- 500 sheets x 2 feeder unit (optional)
Paper Exit	- Face down output tray (250 sheets)
Duplex	- Internal Duplex
Control Panel	- LCD: 16 digits x two rows
	- Button: 8
	- LED: 5
	- MIMIC: supported
LVPS	- 100/120/220 VAC, 50/60Hz power source

I-3

4.3ESS Standard Configuration

Item	Contents
CPU	QED RM5261A 350MHz
Memory	RAM: Standard 64MB, 320MB max
	One 144pin SO-DIMM slot installed
	ROM: 4MB Flash ROM (On Board) (for program)
	8MB Mask ROM (On Board) (for fonts)
	HDD: For electronial sorting: 10GB or more IDE HDD (optional)
External Interface	- Parallel connection interface
	: IEEE1284-compliant (compatible, nibble, ECP)
	- USB1.1
	- Network connection interface
	: 100BASE-TX supported (10BASE-T compatible)
Network Protocol	- LPD
	- Port9100
	- IPP
	- FTP (only for firmware update)
	- NetWare (SPX/IPX)
	(with optional network expantion card installed)
	- Apple Talk (Ether Talk)
	(with optional network expantion card installed)
	- SMB over TCP/IP
	(with optional network expantion card installed)
	- SMB over NetBEUI
	(with optional network expantion card installed)
	- DHCP
	- HTTP (EWS)
	- SNMP

I-4

5.OPTIONAL PRODUCTS

No.	Product Name	Product Code	Remarks
1	2 Tray Module	LT-40CL
2	Hard Disk	HD-40CL
3
4
5
6
7
8
9

I-5