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:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
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.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
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.
1. Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. ............................................................................................
• 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,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
• 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. ..............
• Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. ..........................................................................................................................
• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........
• Always handle the machine by the correct locations when moving it. ..............................................
• 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..................................................
• 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
medical attention. ..............................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
• Under no circumstances attempt to bypass or disable safety features including safety
mechanisms and protective circuits. .................................................................................................
• Always use parts having the correct specifications. ..........................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related
brochure when replacing them. Using a piece of wire, for example, could lead to fire or other
Charging system ............................ Single positive corona charging
Developing system ......................... Single element reversing process
Transfer system ............................. Transfer roller
Fixing system ................................. Heat roller
Heat source: halogen heaters (750 W)
Control temperature: 180°C/356°F (at normal ambient temperature)
Abnormally high temperature protection device: thermal cutout
Charge erasing system .................. Exposure by eraser lamp (LED array)
Cleaning system ............................ Cleaning blade
Controller hardware ....................... CPU: Power PC405 (266 MHz)
System ROM: 4 MB
Font ROM: 2 MB (16 Mbit × 1)
Main RAM: 16 MB standard (on-board); expanding up to 272 MB (standard 16 MB
+256 MB) at the maximum by adding optional expansion memory
Optional expansion RAM (DIMM): 1 slot
2
[thick paper mode: 90 - 105 g/m2])
2
[thick paper mode: 90 - 163 g/m2])
2
, 0.11 µm)
2
, 0.11 µm)
2
, 0.11 µm)
2FM
1-1-1
2FM
Controller software ......................... a) Emulation
Cassette, MP tray
Optional paper feeder
Switch back and refeed (duplex printing)
4
3
Figure 1-1-2
1 Cassette
2 Paper feed unit
3 MP tray
4 MP tray paper feed unit
5 Process unit
6 Toner container
7 Transfer section
8 Fuser unit
9 Face-down output tray
0 Switch back/conveying section
! Refeed unit
1-1-5
2FM
1-2-1 Process unit (drum)
Note the following when handling or storing the drum.
• When removing the process unit, never expose the drum surface to strong direct light.
• Keep the drum at an ambient temperature between 10°C/50°F and 32.5°C/90.5°F and at a relative humidity not higher
than 80% RH. 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 with any object. Should it be touched by hands or stained with oil, clean it.
1-2-2 Installation environment
1. Temperature: 10 - 32.5°C/50 - 90.5°F
2. Humidity: 20 - 80%RH
3. Power supply: 120 V AC, 7.1 A
4. Power source frequency: 50 Hz ±0.3%/60 Hz ±0.3%
5. Installation location
• Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or other
strong light when removing paper jams.
• Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directed onto
the machine.
• Avoid dust and vibration.
• Choose a surface capable of supporting the weight of the machine.
• Place the machine on a level surface (maximum allowance inclination: 1° ).
• Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor, such as
mercury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.
• Select a room with good ventilation.
6. Allow sufficient access for proper operation and maintenance of the machine.
Machine front: 50 mm/19
Machine right: 25 mm/9
Machine above: 30 mm/11
3. Remove the protective packing from inside the
cassette.
Protective packing
Cassette
Figure 1-3-3
1-3-3
2FM
Install a toner container.
1. Open the front top cover.
2. Move the lock lever until it is in its unlocked
position (marked “UNLOCK”).
3. Shake the toner container horizontally back
and forth five or six times so that the toner
inside of it becomes evenly distributed.
Lock lever
Front top cover
Figure 1-3-4
4. Remove the orange protective seal.
Toner container
Figure 1-3-5
Protective seal
Figure 1-3-6
1-3-4
2FM
5. Set the toner container into the process unit.
6. Push in on the areas of the toner container marked
“PUSH HERE” until the container clicks into place in
the process unit.
Toner container
Process unit
Figure 1-3-7
Toner container
7. Push the lock lever back into its locked position.
8. Close the front top cover.
Figure 1-3-8
Lock lever
Front top cover
LOCK
UNLOCK
Figure 1-3-9
1-3-5
2FM
Connect the printer cable and power cord.
1. Connect the printer cable (parallel or USB).
Parallel interface
connector
Parallel
printer cable
2. Connect the power cord.
USB interface
connector
USB cable
Figure 1-3-10
Power cord
1-3-6
AC inlet
Figure 1-3-11
Load paper.
1. Pull the cassette out of the copier.
2. Set the paper in the cassette.
2FM
Cassette
Initializing the printer and make test print.
1. Turn on the printer’s power switch. Upon turning
on the power, the printer’s 4 indicators flash in
sequence until printer initialization is complete,
then the indicator ( [on line]) lights steadily.
2. The printer can print two different types of status
page standard and service-purpose. A servicepurpose status page contains more detailed
information about printer settings than a standard
status page.
• To print a standard status page, press
the GO key for at least 3 seconds and
the indicators light in sequence from
top to bottom.
• To print a service-purpose status
page, press the GO key for more than
10 seconds and the indicators light in
sequence twice from top to bottom.
Figure 1-3-12
Power switch
GO key
Completion of machine installation.
Figure 1-3-13
1-3-7
2FM
1-3-2 Installing the expanding memory (option)
The main board of the printer is equipped with one
socket for memory expansion. Expansion memory is
available in the form of DIMM (Dual In-line Memory
Module).
CAUTION
Take precautions that no foreign substances such as
metal chips or liquid get inside the printer during the
installation process. Operation of the printer during the
presence of a foreign substance may lead to fire or
electric shock.
WARNING
Turn the printer’s power switch off. Unplug the printer’s
power cable.
Clip
Memory socket
Procedure
1. Remove the one screw and then remove the
memory cover.
2. Open the clips on both ends of the DIMM socket.
3. Insert the DIMM into the DIMM socket so that the
notches on the DIMM align with the corresponding
protrusions in the slot.
4. Close the clips on the DIMM slot to secure the
DIMM.
DIMM
Memory cover
Figure 1-3-14 Inserting the DIMM
Clip
Screw
1-3-8
1-3-3 Installing the memory card (option)
The main board of the printer is equipped with one
slot for memory card.
CAUTION
Take precautions that no foreign substances such as
metal chips or liquid get inside the printer during the
installation process. Operation of the printer during the
presence of a foreign substance may lead to fire or
electric shock.
2FM
WARNING
Turn the printer’s power switch off. Unplug the
printer’s power cable and disconnect the printer from
the computer or the network. Never insert or remove a
memory card while the printer power is ON.
Failure to turn the power switch OFF will immediately
halt the printer with a [Memory card err20]
message (this message may not always appear). It
also could result in any damage to the printer’s
electronic parts or the memory card. Turn the power
switch ON again to restart the printer.
Procedure
1. Remove the two screws and then remove the
option interface slot cover (or network interface
card/serial interface board).
2. Insert the memory card in the slot. Push it in all
the way.
3. Secure the option interface slot cover (or network
interface card/serial interface board) by using two
screws.
Memory card
Option interface
slot cover
Screws
Figure 1-3-15 Inserting the memory card
1-3-9
2FM
1-3-4 Installing the network interface card (option)
If the serial interface board kit is installed, remove it to use the network interface card.
CAUTION
Take precautions that no foreign substances such as
metal chips or liquid get inside the printer during the
installation process. Operation of the printer during the
presence of a foreign substance may lead to fire or
electric shock.
WARNING
Turn the printer’s power switch off. Unplug the printer’s
power cable.
Procedure
1. Remove the two screws and then remove the option
interface slot cover (or the serial interface board).
2. Insert the network interface card in the slot. Push it in
all the way.
3. Secure the network interface card by using two
screws.
Network interface card
Screws
Option interface
slot cover
Screws
Figure 1-3-16 Inserting the network interface card
1-3-10
2FM
1-4-1 Paper misfeed detection
(1) Paper misfeed indication
If a paper jam occurs while printing, the printer notifies it by the following combination of the four indicators. Remove the
jammed paper as described below. After removal, open and close the top cover once to initialize the jam sensing.
Off
Lit
Fast flashing
Off
(2) Paper misfeed detection
Paper path
Exit sensor
Figure 1-4-1 Paper misfeed indication
MP paper sensor
Registration
sensor
Cassette, MP tray
Optional paper feeder
Switch back and refeed (duplex printing)
Paper sensor
Figure 1-4-2
1-4-1
2FM
1-4-2 Self-diagnosis
(1) Self-diagnostic function
Service errors are represented by the alternating flashing of the indicators (LEDs). Each error is represented by the notation
of four digits code and can be monitored on the Remote Operation Panel utility. e.g. Call service 2000 is for the main motor
error.
(2) Self diagnostic inidication
Call service 2000
(Lit)
(Lit)
(Lit)
(Off)
(Off)
(Off)
(Off)
(Lit)
Figure 1-4-1 Self diagnostic inidication
Red
Green
1-4-2
CodeError indicationsContents
2000
Main motor error
Check procedures/corrective measures
START
Remove and check
harness (2DC2711)
between engine board
(KP-1046) and main
motor at pins 6 to 9 on
both ends.
2FM
No
No
Replace harness (2DC2711)
between engine board (KP-
1046) and main motor.
OK?
Yes
+24 V DC at
pin 9 of CN1 on
main motor?
Yes
Connect circuit tester to
pin 8 (MOTORN) of
YC04 on engine board
(KP-1046) and ground.
Turn printer power off,
then on.
Print status page.
Does
pin 8 (MOTORN)
of YC04 on engine board
(KP-1046) goes high,
then low?
No
Replace engine board
(KP-1046). See page 15-9.
Connect oscilloscope to
pin 8 (MOTORN) and
pin 7 (MRDYN) of CN1
on main motor.
Turn power switch off,
then on.
Yes
No
Print status page.
Does
pin 7 (MRDYN)
of CN1 on main motor goes
high, then low, within 3 seconds
from pin 8 (MOTORN)
goes low?
Yes
Replace main motor. See
page 1-5-15. If not solved,
check or replace drive unit.
See page 1-5-15.
1-4-3
2FM
CodeError indicationsContents
4000Laser scanner unit [Polygon motor] error
Check procedures/corrective measures
START
+24 V DC at pin 5 of
YC06 on engine board
(KP-1046) ?
Yes
Connect oscilloscope to
pin 1 (PLGCLK) and pin
3 (PLGDRN) of YC06 on
engine board (KP-1046).
Turn power switch off,
then on.
Does
pin 3 (PLGDRN) of
YC06 on engine board
(KP-1046) goes high,
then low?
Yes
Does
pin 1 (PLGCLK) of
YC06 on engine board
(KP-1046) output
square-wave*
signal?
Yes
Connect oscilloscope to
pin 2 (PLGRDYN) and
pin 3 (PLGDRN) of
YC06 on engine board
(KP-1046).
No
No
No
*: 1417 Hz
(705 µs)
Continued
to next page.
Replace engine board
(KP-1046). See page 5-
11.
Replace engine board
(KP-1046). See page 15-9.
Turn power switch on.
A
OK?
End.
No
Yes
Does pin 2
(PLGRDYN) of YC6 on
engine board (KP-1046) goes
high, then low, within 8 seconds
after pin 3 (PLGDRN)
goes high, then
low?
No
Replace laser scanner
unit. See page 5-29.
Turn power switch on.
OK?
No
Replace laser scanner
unit. See page 1-5-28.
Turn power switch on.
OK?
End.
Replace harness (2DC2714)
between engine board and
laser scanner unit.
Yes
Replace engine board
(KP-1046). See page 15-9.
No
Yes
1-4-4
Turn power switch off,
then on.
End.
Yes
Replace harness (2DC2714)
between engine bard and
laser scanner unit.
Check procedures/corrective measures
Continued
from previous page.
A
Replace engine board
(KP-1046). See page 15-9.
Turn power switch on.
2FM
OK?
End.
Yes
No
Replace main board
(KP-1050). See page 15-10.
Turn power switch on.
OK?
End.
No
Yes
Replace harness
(2FM2602) between engine
board and main board.
1-4-5
2FM
CodeError indicationsContents
4200Laser scanner unit [Pin photo diode] error
Check procedures/corrective measures
START
+5 V DC at pin 6 of
YC07 on main board
(KP-1050) ?
Yes
Connect oscilloscope to
pin 4 (OUTPEN) of
YC07 on main board
(KP-1050).
Turn power switch off,
then on.
Does
pin 4 (OUTPEN) of
YC06 on main board (KP-
1050) goes high, then low
before "4200"
error?
Yes
Connect oscilloscope to
pin 4 (OUTPEN) and
pin 8 (PDN) of YC07 on
main board (KP-1050).