Olivetti d-Color P116 Service Manual

COLOUR PRINTER

d - C o l o r P 1 1 6

SERVICE MANUAL

Y110260-4

PUBLICATION ISSUED BY:

Olivetti S.p.A.
77, via Jervis – 10015 Ivrea (TO)
Italy

Copyright2009, Olivetti
All rights reserved

Preface

This manual explains the maintenance methods of d_Color P116.
This manual is prepared for the maintenance person. In regard to the handling methods of d_color P116,

please refer to the User’s Manual.

Note!

• Contents of this manual is subject to change without notice.

• While all reasonable efforts have been made to make this document as accurate
and helpful as possible, we make no warranty of any kind, expressed or implied,
as to the accuracy of the information contained herein. Oki Data assumes no
responsibility to the damages caused or claimed to have been caused by the user
as a result of repair, adjustment and/or change using this manual.

• Parts of this product are delicate and can be damaged unless properly handled. We
strongly recommend the user to maintain the product at the hand of the registered
maintenance person of our company.

• Before starting the maintenance work, please neutralize the static electricity.

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3

Table of contents

1 CONFIGURATION ................................................................................................ 7

1.1 System Configuration ........................................................................................................ 7

1.2 Structure of Printer ............................................................................................................ 8

1.3 Offer of Options ................................................................................................................. 9

1.4 Specifications ................................................................................................................... 10

1.5 Interface Specification ..................................................................................................... 13

1.5.1 USB Interface Specification (d-Color P116)........................................................ 13

1.5.1.1 Outline of USB Interface..................................................................... 13

1.5.1.2 USB Interface Connector and Cable .................................................. 13

1.5.1.3 USB Interface Signal .......................................................................... 13

1.5.2 Network Interface Specification (d-Color P116) ................................................. 14

1.5.2.1 Outline of Network Interface............................................................... 14

1.5.2.2 Network Interface Connector and Cable ............................................ 14

1.5.2.3 Network Interface Signal .................................................................... 14

2. OPERATION DESCRIPTION ............................................................................15

2.1 Electrophotographic Process Mechanism ....................................................................... 15

2.2 Printing Process .............................................................................................................. 20

3. PRINTER INSTALLATION ................................................................................30

3.1 Precautions and Prohibition ............................................................................................ 30

3.2 Printer Unpacking Procedure .......................................................................................... 32

3.3 Printer Installation Instructions ........................................................................................ 33

3.4 Packed Units and Attachments ...................................................................................... 34

3.5 Assembly Procedure ....................................................................................................... 35

3.5.1 Printer Main Body ............................................................................................... 35

3.5.2 Power Cable Connection .................................................................................... 41

3.5.3 Installation of Optional Components................................................................... 43

3.5.4 Confirmation of recognition of optional items ..................................................... 47

3.6 Menu Map print ............................................................................................................... 48

3.7 Network Information Print ............................................................................................... 49

3.8 Connection Procedures ................................................................................................... 50

3.9 Checking of User Paper ................................................................................................. 52

4. REPLACEMENT OF PARTS ............................................................................53

4.1 Precautions on the replacement of parts ....................................................................... 53

4.2 Part replacement methods .............................................................................................. 55

4.2.1 Left side cover .................................................................................................... 55

4.2.2 Right side cover .................................................................................................. 56

4.2.3 Rear cover (Top/Bottom)..................................................................................... 57

4.2.4 Front cover.......................................................................................................... 58

4.2.5 Top cover assembly ............................................................................................ 59

4.2.6 Top cover ............................................................................................................ 60

4.2.7 LED assembly/ LED assembly spring ................................................................ 61

4.2.8 RFID assembly ................................................................................................... 62

4.2.9 Control pane assembly ....................................................................................... 63

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4.2.10 WHP board ....................................................................................................... 64

4.2.11 Feeder unit ........................................................................................................ 65

4.2.12 Manual feeder unit ............................................................................................ 66

4.2.13 Face up tray...................................................................................................... 67

4.2.14 Guide eject assembly ....................................................................................... 68

4.2.15 Eject roller......................................................................................................... 69

4.2.16 Plate shield front ............................................................................................... 70

4.2.17 Color registration assembly .............................................................................. 71

4.2.18 Plate shield rear................................................................................................ 72

4.2.19 PRS board (toner sensor board)/ Gear idle dram............................................. 73

4.2.20 Main motor/ Solenoid........................................................................................ 74

4.2.21 Belt motor/ High voltage board/ Cover open switch ......................................... 76

4.2.22 Low voltage power supply/ Low voltage fan ..................................................... 77

4.2.23 TB3 Board (Main Board)................................................................................... 78

4.3 Lubricating points ............................................................................................................ 79

5. MAINTENANCE MENUS .................................................................................. 92

5.1 System maintenance menu (For maintenance personnel) ............................................ 92

5.2 Maintenance utility ........................................................................................................... 95

5.3 Self-diagnostic mode ...................................................................................................... 95

5.3.1 Operator panel.................................................................................................... 95

5.3.2 Normal self-diagnostic mode (Level 1) ............................................................. 98

5.3.2.1 Activation method for self-diagnostic mode (Level 1)....................... 99

5.3.2.2 Deactivation of self-diagnostic mode................................................ 99

5.3.3 Switch scan test................................................................................................ 99

5.3.4 Motor clutch test ............................................................................................... 102

5.3.5 Test print ........................................................................................................... 104

5.3.6 Color registration adjustment test......................................................................109

5.3.7 Print density adjustment test .............................................................................110

5.3.8 Indication of consumable part counters.............................................................112

5.3.9 Indication of printed page counters ...................................................................113

5.3.10 Factory/Shipping switching ..............................................................................113

5.3.11 Setup of self-diagnostic function ......................................................................114

5.3.12 Indication of LED head serial number .............................................................115

5.3.13 Details of panel indications ............................................................................. 116

5.4 Settings after Parts Replacement ................................................................................. 126

5.4.1 Notes when replacing Main Board TB3 ........................................................... 126

5.5 About the manual setting of density correction ........................................................... 130

6. REGULAR MAINTENANCE .......................................................................... 131

6.1 Recommended substitutes ............................................................................................ 131

6.2 Cleaning ......................................................................................................................... 131

6.3 Cleaning LED lens array .............................................................................................. 131

6.4 Cleaning the pick-up roller ............................................................................................ 133

6.5 Cleaning the inside of the printer ................................................................................. 134

7. TROUBLESHOOTING PROCEDURES ..........................................................136

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7.1 Precautions prior to repair ............................................................................................ 136

7.2 Items to be checked prior to taking action on abnormal images ............................... 136

7.3 Precautions when taking action on abnormal images ................................................. 136

7.4 Troubleshooting method ................................................................................................ 136

7.4.1 LCD Message List ............................................................................................ 137

7.4.2 Preparing for troubleshooting ........................................................................... 150

7.4.2.(1) LCD Display Malfunction................................................................ 152

7.4.2.(2) Irregular Operation of the device after turning on the power ......... 153

7.4.2.(3) Paper Feed Jam (Error 391:1st tray) ............................................. 162

7.4.2.(4) Paper Feed Jam (Error 390: Multipurpose tray) ............................ 164

7.4.2.(5) Paper transport jam (Error 381) ..................................................... 166

7.4.2.(6) Paper Exit Jam (Error 382) ............................................................ 171

7.4.2.(7) Paper Size Error (Error 400) .......................................................... 174

7.4.2.(8) ID Unit Up-Down Error (Service Call 140-143) .............................. 175

7.4.2.(9) Fuser Error (Error 170-177) ........................................................... 176

7.4.2.(10) Motor Fan Error(Error 127) .......................................................... 177

7.4.2.(11) Print Speed is Slow (Low Performance) ...................................... 178

7.4.2.(12) LED head is not recognized(Error 131,132,133,134) .................. 178

7.4.2.(13) Toner cartridge is not recognized (Error 540, 541, 542, 543) ...... 179

7.4.2.(14) Fuse Cut Error (Error 150-155).................................................... 180

7.4.2.(15) Dew Condensation Errors (Error 123) ......................................... 181

7.4.2.(16) RFID Related Error (Error 610-613).............................................. 182

7.4.3 Image Problem Troubleshooting....................................................................... 183

7.4.3.(1) Color is totally pale (Figure 7.2 A ) ................................................. 184

7.4.3.(2) Background is dirty (Figure 7.2 B ) ................................................ 185

7.4.3.(3) Blank Print (Figure 7.2 C ) ............................................................. 186

7.4.3.(4) Vertical lines are printed................................................................. 187

7.4.3.(5) Cyclic Print Trouble (Refer to Figure 7.2 E ) .................................. 188

7.4.3.(6) Color drift is wide. .......................................................................... 189

7.4.3.(7) Solid Black Print............................................................................. 190

7.4.4 Response after Flash compulsive initialization ................................................. 191

7.4.5 Network Troubleshooting.................................................................................. 192

7.5 Fuse Checking .............................................................................................................. 193

8. CONNECTION DIAGRAMS ............................................................................ 194

8.1 Check of resistance values .......................................................................................... 194

8.2 Component layout ........................................................................................................ 197

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Figure 1-1-1

1 CONFIGURATION

1.1 System Configuration
d-Color P116

The system configuration of this product is shown in Figure 1-1-1.

JST12

4

FLASH

8M

Stand-by

FAN

CU

CC1 ASIC

CiF2 ASIC

PPC750CL(400Mz)

JST3

Network I/F

DCON I/F

LSYNC

LEISUS

Command I/F

OPTION

RAM

DIMM

slot x 1

3

4

PU

1st

P.E

5V, 24V

0VL,0VP

14

Color Blur,

Density,

Thermistor signal

EEPROM

20MHz

5V→3.3V

5V→1.5V

Regulator

JST14

ELC12

ASIC(ARMORED)

75Ω

12

Environment Temoerature/

Humidity Signal,

High Pressure I/F, Cover Open

Belt Unit

BELT

FUSE

ELC10

ELC10

10

ELC5

JST5

5

RFID

Operator

Panel

ELC7

JST7

7

High Voltage Power Unit

Cover

Open Sw

ENV Sensor

UP/DOWN

Sensor

AMP2

3333

K-ID Y-ID M-ID C-ID

LED

FUSE

LED

FUSE

LED

FUSE

LED

FUSE

222 2

Toner Sensor PCB

ID Fuse-Cut terminal

C Toner

Sensor

M Toner

Sensor

Y Toner

Sensor

K Toner

Sensor

RFID

PCB

222

2

K-

Tag

Y-

Tag

M-

Tag

C-

Tag

K-

ANT

Y-

ANT

C-

ANT

M-

ANT

Operation Panel PCB

K LED HEAD

ELC24

ELC24

Y LED HEAD

ELC24

ELC24

M LED HEAD

ELC24

ELC24

C LED HEAD

ELC24

ELC24

24

24

24

24

FAN

AC

HRS2-10

AC-SW

2

2

2

3

Low Voltage Power Unit

JST3

JST3 JST3

AC Inlet

Fuser Unit

Heater Thermistor x 4

Consumable Fuse

JST17

EL

17

Density

Sensor

5

MOLEX10

HRS2-10

FUSE

10

Temperature

Sensor

LOW-TH

FRM-TH

UP-TH

SIDE-TH

EXIT

Sensor

Rear Sensor Relay PCB

Reg-R

Sensor

AMP3

AMP3

HOP

Solenoid

JST4

AMP4AMP4

BELT

M

4

4

MOLEX6

HEAT

M

IDUP

M

AMP4

AMP5

4

JST2

2

AMP10

10

AMP4

4

ID

M

HOP

M

Reg-L

Sensor

3

MOLEX5

MOLEX5

AMP4

AMP10

AMP5

IN1

Sensor

IN2

Sensor

WR

Sensor

Front Sensor PCB

AMP5

5

USB 2.0

Belt Consumable Fuse

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Figure 1-2

1.2 Structure of Printer

The insides of d-Color P116 printers are composed of the following parts.

• Electronic photography process part

• Paper path

• Control part (CU part/PU part)

• Operation panel

• Power supply parts (high voltage part/low voltage part)

Figure 1-2 shows the composition of the printer.

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1.3 Offer of Options

This product can be installed with the following option.

(1) Additional memory board 256/512MB 200pin DDR RAM

DIMM Installation of the additional memory board is
recommended for banner-sheet printing.

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1.4 Specifications

d-Color P116Category Item

Exterior
Dimension

Width of print
Engine
speed(A4)
Fast print time
(A4)

Resolution

CPU

RAM

ROM
Power
Consumption

Operating
Environment
(temperature)

Operating
Environment
(humidity)

Width
Depth
Height
Weight
Width of print
Monochrome
Color
Monochrome
Color
Warm-up time
Low noise mode
LED head
Maximum input resolution
Output resolution

Step
Economic mode
Core
Level 1 cache
Level 2 cache
Clock
Bus width
Resident
Option
Program
Power input

Power saving mode
Idle
Normal operation
Peak
In operation

At stand-by
In storage (1 year max.)
At transport (1 month max.)
At transport (1 month max.)
In operation

At stand-by
In storage
At transport

372mm
478mm
290mm

about 21kg

A4
20ppm
16ppm

10sec
12sec
80sec

Unavailable

600dpi

600 × 1200dpi

True 600 × 1200dpi

True 600 × 600dpi

4 steps 600 × 600dpi

toner saving by lowering light

PowerPC750

32KB

256KB

400MHz

64bit

128MB

256/512MB DIMM

64MB+2MB

100-127VAC (Range 99-140VAC) /

220-240VAC (Range 198-264VAC)

Below 14W

100W(average)

400W
980W

10°C-32°C,17°C-27°C

(temperature at full color printing with quality guaranteed)

0°C-43°C, power off

-10°C-43°C with drum and toner

-29°C-50°C with drum and without toner

-29°C-50°C with drum and toner
20%-80%, 50%-70%

(humidity at fullcolor printing with quality guaranteed)

Max. wet bulb temperature : 25°C

10%-90%, Max. wet bulb temperature : 26.8°C with power off

10%-90%, Max. wet bulb temperature : 35°C
10%-90%, Max. wet bulb temperature : 40°C

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d-Color P116Category Item

Life

Operation
noise

Paper handling

Paper size

Min. paper size

Printer life
Duty cycle (M=L/12,A=L/12/5)

MTBF (2.3% duty)
MTBF
MTTR
Toner life
(5% duty)

Image drum life

Transcript belt life
Fuser life

In operation (ISO 7779 front)
Printing on one side

At stand-by (ISO 7779 front)
Power saving mode
Paper feeding capacity (1st tray)
Paper feeding capacity

(manual feeder)
Paper output

Legal/universal or A4 cassette/
Universal cassette

Manual feeder

1st tray
Manual feeder

50,000pages (size A4)

Automatic counter reset

6.5B (A)

legal 13/13.5/14, letter,
executive, A4, A5, B5, A6, C5, DL, Com-9, com-10,monarch,
custom size, government postcard, reply paid postcard, end-

opening envelope, banner up to 1200mm (In case length is

over 356, width would be up to 210 to 215.9)

about 2,500pages (black)

AOS about 2,000pages (color)

ODA/OEL about 2,500pages (color)

about 1,700pages (black)

AOS about 1,200pages (color)

ODA/OEL about 1,700pages (color)

OEL about 1,500pages (black)
AOS about 1,000pages (black)
AOS about 1,500pages (color)

OEL about 1,000pages (color)

OEL about 700pages (black)
AOS about 500pages (black)
AOS about 500pages (color)
OEL about 700pages (color)

starter toner

(Appended)

Standard

New drum 1st one

S type

New drum 1st one

300,000 pages or 5 years

350,000 pages per month max.

5,000 pages per month average

6,000 hours

35,000 pages

20 minutes

ODA about 1,000 pages (black)

OEL/AOS about 500pages (black)

ODA about 1,000 pages (color)

OEL/AOS about 500pages (color)

15,000 pages approx.(3 pages/ job)

9,000 pages approx.(1 page/ job)

20,000 pages approx.(at continuous print)

Automatic drum counter reset

50,000pages (size A4, 3 pages/job) Automatic counter reset

3.7B (A)

back grand level

legal/universal cassette 250 sheets (70kg)

1 sheet

150 sheets (70kg) face down/

one sheet (10 postcards) face up tray

1st cassette: legal13/13.5/14, letter, executive, A4, A5, B5,

A6, postcard

100mm × 148mm

100mm × 148mm

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d-Color P116 Category Item

Paper
thickness

Operation
panel

Status
switch/Sensor

Communication
Interface

Emulation

Font

Shipping set­up

Others

1st tray
Manual feeder
duplex (manual)
LCD
LED (color)
Switch
Paper tray empty
Paper low
Toner low
Cover open
Fuser temp.
Paper size
Stacker full
Standard (on circuit board)

Option for OEM user
On/off switch
Standard

Option (Removable)
Emulation switch
Bit map

Type face
Scalable 1

Type face
Scalable 2

Type face
Scalable 3

Type face
Rasterizer
Barcode

OCR
Japanese PCL font
Japanese PS font
Japan

USB-IF logo
Windows logo
Operation by UPS

Hi-Speed USB

64-120gsm
64-203gsm

64-105gsm

16 characters in 2 line(Roman alphabet) No paper size indicated

2 (Green × 1, dark amber × 1)

6

Available

N/A

Available (Y.M.C.K)

Available
Available

N/A
N/A

Ethernet

N/A

Automatic

PCL 6 (XL3.0 and PCL5c)

PostScript 3 (clone), SIDM (IBM-PPR,EPSON-FX)

N/A

Auto

MonoType

1

MonoType MicroType

80

MonoT ype TrueType

10

Adobe T ype 1

80

MonoType UFST 4.0

USPS, UPC-A, UPC-E, EAN/JAN-8, EAN/JAN-13,

Iinterleaved2of5, Code39, Code128, EAN/UCC-128,

CODABAR, ZIP+4 POSTNE

OCR-A,B

N/A
N/A
N/A

Available
Available

Operation by UPS (outage free power supply) is not

guaranteed. (Do not use UPS)

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2

34

1

Name of Signal Function
1 Vbus Power Supply (+5V) (red)
2 D - Data transmission (white)
3 D + Data transmission (green)
4 GND Signal ground (black)

Shell Shield

1.5 Interface Specification

1.5.1 USB Interface Specification (d-Color P116)

1.5.1.1 Outline of USB Interface

(1) Basic Specification

USB (d-Color P116 supports Hi-Speed USB )

(2) Transmission Mode

Hi speed (480Mbps±0.05% max.)

(3) Power Control

Self power device

1.5.1.2 USB Interface Connector and Cable

(1) Connector

• Printer side: B receptacle
Upstream port
Equivalent of UBR24-4K5C00 (made by ACON)

Connector pin arrangement

• Cable side: B plug (off)

(2) Cable

Cable length: Specification Cable of USB2.0 spec. of less than 5m.(less than 2m is

recommended)
(Shielded cable is used here.)

1.5.1.3 USB Interface Signal

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18

1.5.2 Network Interface Specification (d-Color P116)

1.5.2.1 Outline of Network Interface

Table1.5.2 Basic Specification of Network Interface (d-Color P116)
Protocol Family Network Protocol Application

TCP/IP TCP,UDP, IPv4/v6,

LPR, RAW, IPP,FTP

ICMP, ARP, IGMP

HTTP, Telnet

SNMPv1/v3

DHCP/BOOTP

DNS, DDNS

WINS, UPnP, Bonjour

SMTP
SNTP

WindowsRally

(WSD Print, LLTD)

NetBEUI NetBIOS SMB

1.5.2.2 Network Interface Connector and Cable

(1) Connector

100 BASE-TX/10 BASE-T (automatic switch, no simultaneous use)

Pin No. Signals Signal Direction Functions

1 TXD+ FROM PRINTER Send Data +
2 TXD- FROM PRINTER Send Data ­3 RXD+ TO PRINTER Received Data +
4 - - Unassigned
5 - - Unassigned
6 RXD- TO PRINTER Received Data ­7 - - Unassigned
8 - - Unassigned

Connector pin arrangement

(2) Cable

Unshielded twist pair cable with RJ-45 connector (Category 5 is recommended.)

1.5.2.3 Network Interface Signal

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-

-

-

-

-

-

Electrification roller

OPC drum

Power
supply

unit

2. OPERATION DESCRIPTION

2.1 Electrophotographic Process Mechanism

(1) Electronic photography Process

Electronic photography process is outlined as follows:

1. Electrification
Electric voltage is impressed on CH roller and the surface of CPC drum is electrified.

2. Exposure
LED head radiates light on the electrified surface of OPC drum following the image
signal. Electric charge on the radiated OPC drum surface abates depending on the
intensity of light and static latent image is formed on the OPC drum surface.

3. Development
Electrified toner is adhered to the static latent image on the OPC drum by static electric­ity and a visible image is formed on the OPC drum surface.

4. Transcript
A sheet of paper is put upon the OPC drum surface and the toner image is transferred
on the paper by impressing electric charge on its back side by the transcript roller.

5. Drum Cleaning
Drum cleaning blade eliminates the remaining toner on the OPC drum after transfer.

6. Belt Cleaning
Belt cleaning blade eliminates the remaining toner on the belt.

7. Fusing
The toner image on the paper is fused by adding heat and pressure.

(2) Electrification

Electric voltage is impressed on electrification roller touching on the OPC drum surface and
thus the OPC drum surface is electrified.

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15

-

-

-

-

-

-

-

-

-

LED head

Electrified roller

OPC drum

OPC drum

Paper

Power
supply

unit

LED head

-

-

-

-

-

-

-

-

-

-

-

-

Electrified roller

Development roller

Sponge roller

OPC drum

(3) Exposure

The light emanated from the LED head is radiated on the OPC drum surface. The electric
charge on the radiated portion of the OPC drum surface abates by intensity of the light and a
static latent image is formed on the OPC drum surface.

(4) Development

Adhere the toner to the static latent image on the drum surface and change it to the toner image.

1. The sponge roller let the toner adhere to the development roller.

2. The static latent image on the OPC drum surface is changed to a visible image by the toner.

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-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

+

-

+

-

+

-

+

-

+

-+-+-+-+-+-

+

-+-

+

-+-

+

-+-

+

OPC drum

Transcript roller

Paper

Transport belt

Power

supply

unit

(5) Transcript

A sheet of paper is placed under the OPC drum surface and is given electric charge from the
back side by the transcript roller. When a high voltage is impressed on the transcript roller, the
electric charge generated by the transcript roller moves over to the paper surface at the
interfacing part of the transcript roller and the toner is absorbed to the paper surface from the
OPC drum surface.

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17

d-Color P116 (belt fusing method)

Thermostat

Thermistor

Heat roller

Halogen lamp

Paper

Pad

Thermistor

Backup roller

Belt

Paper Type Setting

Light

Medium

Heavy

U.Heavy

Paper Thickness

Thin

Thick

Temperature Setting

Middle temp.

High temp.

Middle temp.

Low temp.

Setting of Fusing Temperature

(6) Fusing

The toner image transferred on the paper is impressed with heat and pressure and is fused to
the paper when the paper passes through the heat roller and the back-up roller.
Further, a thermostat is equipped for the safety’s sake and if the temperature of the heat roller
rises above a certain degree, the thermostat opens and shuts the power supply to the heater.

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Waste toner area

Drum cleaning blade

ID unit

Toner cartridge

Belt waste toner box

Belt cleaning blade

Transport belt

(7) Drum Cleaning

The toner not transferred and remaining on the OPC drum is scraped away by the drum
cleaning blade and is collected in the waste toner area of the toner cartridge.

(8) Belt Cleaning

The toner remaining on the transcript belt is scraped away by the belt cleaning blade and is
collected in the waste toner box of the transcript belt unit.

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19

Transport belt

Belt

Heat roller

Backup roller

Halogen lamp

Paper feeding roller

Sub roller

Resist roller L

Resist roller U

Face down stacker

Face up stacker

Manual feeder

2.2 Printing Process

The paper feeded from tray 1 is transported by the resist roller L and transport roller. When the
paper is feeded by the manual feeder, it is transported by the resist roller U. Then, the paper
transported is developed into a toner image not yet fused on the paper through electronic
photography process in the order of KYMC. After that, the image is fused by heat and pressure
while passing through the fusing unit. After fusing, the paper is discharged on the face up or face
down stacker through the discharge method opted by opening or shutting of the face up stacker.

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Resist roller U

(drive)

Hopping roller

(drive)

Paper

Sub roller

(drive)

Hopping motor

(counterclockwise turn)

Resist roller L

(stop)

WR sensor

Solenoid lever

(solenoid on)

IN2 sensor

IN1 sensor

IN1 sensor

Resist roller U

(drive)

Hopping roller

(stop)

Paper

Sub roller

(stop)

Hopping motor

(counterclockwise turn)

Resist roller L

(drive)

WR sensor

Solenoid lever

(solenoid off)

IN2 sensor

Figure 2-1 Figure 2-2

Resist roller U

(drive)

Hopping roller

(stop)

Sub roller

(stop)

Hopping motor

(counterclockwise turn)

Resist roller L

(drive)

WR sensor

Solenoid lever

(solenoid off)

IN 2 sensor

IN 1 sensor

Paper

Figure 2-3

(1) Paper Feeding from the 1st Tray

1. As shown in Figure 2-1, while the solenoid is on and the resist motor turns counterclockwise,
a sheet of paper is transported until the IN1 sensor is on. (When the solenoid is on, the paper
feeding roller operates.)

2. When the paper turns the IN1 sensor on, a certain more sheets of paper are transported
and thrusted against the resist roller. (This process corrects the paper skew.)

3. As shown in Figure 2-2, turn the solenoid off and transport the paper by the resist roller L.
(When the solenoid is off, the resist roller operates.)

(2) Paper Feeding from Manual Feeder

1. Thrust the paper against the resist roller U. (This process corrects the paper skew.)

2. As shown in Figure 2-3, the resist motor turns counterclockwise and the paper is
transported by the resist roller U. (When the resist roller turns counterclockwise, the resist
roller U drives.)

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Figure 2-4

Transport belt

Transport rollers

Transport belt motor

Drums

KYMC

(3) Transport Belt

1. When the transport belt motor turns in the direction of the arrow, the transport belt starts
to operate. The belt unit is composed of drums of each color above and the transport rollers
immediately below them with the transport belt in-between. When a certain voltage is
impressed, the transport belt and the transport rollers send the paper on the transport belt
to the fuser while transferring the toner images on the drums of each color.

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Movement of each ID unit at the time of color printing

C-ID unit

C-ID unit down
M-ID unit down
Y-ID unit down
K-ID unit down

M-ID unit

Y-ID unit K-ID unit

C-ID unit

M-ID unit

Y-ID unit K-ID unit

Lift-up motor

(counterclockwise turn)

Lift-up motor

(clockwise turn)

Movement of each ID unit at the time of monochrome printing

C-ID unit lift-up
M-ID unit lift-up
Y-ID unit lift-up
K-ID unit down

Figure 2-5

Figure 2-6

(4) Up and Down Movements of ID Units

1. The up and down movements of the ID units are performed by the drive of the lift-up motor.

2. Figure 2-5 shows movements of each ID unit at the time of printing. When the lift-up motor
turns clockwise, the lift-up link slides to the left and each ID unit is in the state of down as
shown in Figure 2-6. That condition enables color printing.

3. Figure 2-6 shows movements of each ID unit at the time of monochrome printing. When the
lift-up motor turns counterclockwise, the lift-up link slides to the right and the units other than
K-ID are in the state of up as shown in Figure 2-7. That condition enables monochrome
printing.

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Fuser motor

(counterclockwise turn)

Output roller

(drive)

Heat roller (drive)

Fuser unit

Figure 2-7

Figure 2-8

Fuser motor

(clockwise turn)

Output roller

(stop)

Heat roller (stop)

Cover open gear

Fuser unit

(5) Fusing Unit and Paper Output

1. As shown in Figure 2-7, the fuser unit and output roller are driven by the pulse motor. When
the fuser motor turns counterclockwise, the heat roller turns. This roller fuses the toner
image ‘on the paper with heat and pressure.

2. At the same time, the output roller turns and ‘sends out the paper.

(6) Cover Open Operation of Color Registration Sensor and Density Sensor

1. As shown in Figure 2-8, when the fuser motor turns clockwise, the cover open gear also
turns and the covers of the color registration sensor and the density sensor will open.

2. When the fuser motor turns counterclockwise, interlocking of the cover open gear is
released and the covers of the color registration sensor and the density sensor will close.

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Belt waste toner box

Belt cleaning blade

Transport belt

Color Registration sensor

Belt motor

Color Registration sensor

Color Registration sensor

Sensor shutter

Right color registration pattern

Left color registration pattern

Outline of Color registration Method

Color registration is performed by reading the correction pattern printed on the belt using the sensor
placed in the sensor shutter equipped under the belt unit. The correction is made by identifying the
pattern using this sensor.
Timing of automatic activation of color registration:

• At the time of switching the power on

• At the time of closing the cover after opening it over 5 seconds

• When over 400 sheets are printed after a color registration was made previously

Correction errors can be caused by the amount of toner which generates the pattern, toner stain
on the sensor, malfunction of shutter opening and closing. However, as an error may not be
displayed on the operation panel, it may be necessary to confirm the error display by forcible
execution of the color registration test function (2.4.1.5.3) using the maintenance utility.

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Error Confirmation Method and Countermeasure
Errors should be confirmed by using the color registration test function of the maintenance utility

(2.4.1.5.3).
Countermeasures to each error are:

• SNS CARIBRATION(L or R), DYNAMICRANGE(L or R)
Confirmation 1 When the above is displayed, check the connection of the sensor cable

(FFC). If the connection is found abnormal, correct it to the normal state.

Confirmation 2 Check the surface of the sensor to confirm if it is stained by the toner,

paper dust, etc. If stained, wipe the surface neatly.

Confirmation 3 Confirm adequacy of opening and shutting of the sensor shutter by

MOTOR& CLUTCH TEST of the maintenance utility. If a malfunction is
found, replace the shutter unit .

• BELT REFLEX ERR
Confirmation 4 When the above is displayed, confirm the cleaning state of the toner

remaining on the belt surface besides the above confirmations 1, 2 and

3. Remove the belt unit and confirm if the belt surface is cleaned neatly
by turning the drive gear placed in the left rear side.
Replace the belt unit if the toner remains on the belt surface and the
surface is not cleaned despite of turning of the drive gear.

• (Y or M or C) LEFT. (Y or M or C) RIGHT, (Y or M or C) HORIZONTAL
Confirmation 5 When the above is displayed, confirm if it is the toner insufficiency that has

caused NG color generation and replace the cartridge if necessary.

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Density sensor

Density correction pattern

Belt waste toner box

Belt cleaning blade

Transport belt

Belt motor

Sensor shutter

Outline of Density Correction Method

Density correction is made by identifying the correction pattern printed on the belt using the sensor
installed in the sensor shutter under the belt unit.
Timing of automatic activation of density correction

• When the circumstance is significantly different from the previous work performance at the
time when the power is to be switched on.

• When at least one of the 4 ID count values is almost new at the time when the power is to
be switched on.

• When the ID count value is over 500 after the previous work performance.

Correction error can be caused by the amount of toner which generates the pattern, toner stain on
the sensor, malfunction of shutter opening and closing. However, as an error may not be displayed
on the operation panel, it may be necessary to confirm the error display by forcible execution of
the density correction test function (2. 4. 1. 5. 3) using the maintenance utility.
Error Confirmation Method and Countermeasure

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Errors should be confirmed by using the density correction test function of the maintenance utility
(2.4.1.5.4).

Countermeasures to each error are:

• CALIBRATION ERR, DENS SENSOR ERR
Confirmation 1 When the above is displayed, check connection of the sensor cable. If the

connection is found abnormal, correct it to the normal state.

Confirmation 2 Check the surface of the sensor to confirm if it is stained by the toner,

paper dust, etc. If stained, wipe the surface neatly.

• DENS SHUTTER ERR
Confirmation 3 Confirm adequacy of the opening and shutting of the sensor shutter by

MOTOR&CLUTCH TEST of the maintenance utility. If a malfunction is
found, replace the shutter unit.

• DENS ID ERR
Confirmation 4 Remove the ID unit to confirm if the surface of the drum is covered with

abnormal amount of toner. Then, replace the LED head if the focus blurs
or replace the ID unit.
When a new ID unit is to be used for trial, attach a treatment device to the
ID unit lest the fuse breaks ( refer to p.132).

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Shading board

Shutter

Toner sensor

(light reception sensor)

Luminous LED

Toner cartridge lever

Toner stir

Toner Sensor Detection Principle

Detection of the low toner is performed by the toner sensor (light reception sensor) installed inside
the equipment and the luminous LED installed inside the cartridge. The shading board is installed
inside the ID and rotates synchronizing with the toner stir. A shutter is attached to the ID. The
shutter synchronizes with the cartridge operation lever and the toner sensor can detect whether
the cartridge is installed properly. If the toner sensor is stained by the toner, etc., or the ID unit and
the toner sensor are not facing each other as specified due to improper setting of the ID unit or for
other reason, the detection may not be executed normally, resulting in a toner sensor error.

Toner Counter Principle

After the image data is developed into 2 value data to enable printing using the printer, the print
dot number is counted by the LSI. The amount of the toner used is counted from the above count
value and the remaining amount is displayed. On the other hand, detection of the low toner by the
toner sensor is physically made when the amount of the toner remaining in the cartridge comes
to be under certain amount.

Principles of ID, Belt and Fusing Counter

ID Counter : 1 count is the value of one third of the amount of drum rotation when three A4

sheets of paper are continuously printed.

Belt Counter : 1 count is one third of the amount of the belt rotation when three A4 sheets of

paper are continuously printed.

Fusing Counter : Standard is the length of Legal 13 inches sheet of paper. 1 count is the sheet of

paper under that length and when the length is more than that, the number of
count is decided by multiples of Legal 13 inches.(Number under the decimal
point is rounded up.)

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3. PRINTER INSTALLATION

3.1 Precautions and Prohibition

• Do not install the printer in the vicinity of high temperature or fire.

• Do not install the printer at the place where a chemical reaction may take place (laboratory, etc.).

• Do not install the printer near flammable solution like alcohol, thinner, etc.

• Do not install the printer at the place where a small child can reach.

• Do not install the printer at an unstable place (unsteady frame, tilted place, etc.).

• Do not install the printer at a highly humid or dusty place or under the direct sunshine.

• Do not install the printer under the environment of sea breeze or caustic gas.

• Do not install the printer at a highly vibrating place.

• When you drop the printer or damage the cover, remove the power plug from the outlet and contact
the Customers’ Service Center.
Electric shock, fire or injury may occur.

• Do not connect the power cord, printer cable and earth wire as otherwise directed by the Manual.
A fire may break out.

• Do not insert a thing in the vent hole.
Electric shock, fire or injury may occur.

• Do not place a cup with water on the printer.
Electric shock or fire may occur

• Do not touch the fuser unit when you open the printer cover.
Burn may occur.

• Do not throw the toner cartridge or image drum cartridge into fire.
Burn may occur by the dust explosion.

• Do not use a highly flammable spray near the printer.
Fire may break out as there are high temperature parts inside the printer.

• When the cover becomes abnormally hot, a smoke arises or a strange odor comes out, remove
the power plug from the outlet and contact the Customers’ Service Center.
Fire may break out.

• When liquid like water drops inside the printer, remove the power plug from the outlet and contact
the Customers’ Service Center.
Fire may break out.

• When a thing like a clip drops inside the printer, remove the power plug from the outlet and take
out that thing.

• Do not operate or disassemble the printer as otherwise directed in the Manual.
Electric shock, fire or injury may occur.

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• Do not install the printer at the place where the vent hole is blocked.

• Do not install the printer on the shaggy carpet.

• Do not install the printer at the place with little draught or without ventilation like a room with no
window.

• Install the printer away from the monitor TV.

• When the printer is to be moved, hold both ends of the printer.

• This printer weighs about 21kg and should be lifted by 2 or more persons.

• When to switch the power on or while printing, do not come near the paper exit of the printer.
Injury may occur.

As regards the items of caution, explain to the customer showing the items of caution of the User’s
Manual. Particularly, explain fully about the power supply cord and earth cable.

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3.2 Printer Unpacking Procedure

• Open the upper lid.

• Take out accessories.

• Remove the upper buffer material.

• Take out the equipment

This printer weighs about 21kg. So lift it up with 2 or more persons.

Personal injuries may occur.

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30cm

20cm

20cm

100cm

50cm

3.3 Printer Installation Instructions

• Install the printer at a place under the following temperature and humidity:
Ambient Temperature : 10 to 32°C
Ambient Humidity : 20 to 80% relative humidity
Maximum Wet-Bulb Temperature : 25°C

• Be careful not to be bedewed.

• When the printer is to be installed at a place where the humidity is less than 30%, use a humidifier

or a static electricity prevention mat.

Installation Space

• Place the printer on a flat desk with enough space for the legs of the printer.

• Secure enough space around the printer.

Top View

Side View

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3.4 Packed Units and Attachments

• Confirm whether there are scratches, stains, etc. on the exterior of the machine.

• Confirm whether there are lacking items, damages, etc. among the accessories.

• If anything unusual is found, contact the user’s section in charge and follow its instruction.

This printer weighs about 21kg and should be lifted by 2 or more persons.

Personal injuries may occur.

■ ■ Printer (main body)

d-Color P116

■ ■ Image Drum Cartridges with Starter Toner Cartridges (4 sets) (installed in the printer)

Explain to customers that the toner cartridge and the image drum cartridge are separable.

■ ■ Printer Software CD-ROM

■ ■ Power Cord

■ ■ Warranty and Registration Card

■ ■ Users Manual (Setup Guide)

■ ■ Users Manual on CD-ROM

■ ■ Quick Guide

■ ■ Quick Guide Bag

Note!

The printer cable is not included in the accessories.

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3.5 Assembly Procedure

3.5.1 Printer Main Body
Remove Protective Equipment

(1) Remove front protection tapes (4 places) and back protection tapes (2 places) of the printer.

Protection tapes

Protection tapes

(2) Pull out the paper cassette.
(3) Press the open button and open the top cover.

Paper Cassette

Open Button

(4) Remove the stopper release (orange color) while pushing down the lever (blue) of the fuser unit

in the direction of arrow 1.

Note!

Explain to the customer that the stopper release must be kept as it would be used at the
time of transporting the printer.

Stopper release (orange)

Lever of the fuser unit (blue)

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Install Image Drum Cartridges

(1) Pull out the image drum cartridge (4 pieces) gently with the toner cartridge attached.

Note!

• Handle the image drum (green tube portion) very carefully as it is quite easily injured.

• Do not expose the image drum cartridge to direct sunshine or bright light (approximately

1,500 lux or more) . Do not leave it more than 5 minutes under the room light.

• Do not move the blue lever of the cartridge at this stage.

Starter T oner Cartridge

Image Drum Cartridge

(2) Place the image drum cartridge on a flat desk, remove the tape which fastens the protection

sheet and pull it out in the direction of arrow.

Note!

Do not work on the image drum off the desk top.

(3) Pull out protection sheet 2 from the image drum cartridge in the direction of arrow.

Tape

Protection sheet

Protection sheet

Protection sheet

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(4) Conform the label color of the image drum cartridge to the label color of the printer.
(5) Return the 4 image drum cartridges gently.

Labels

Label

(6) Turn the 4 blue levers of the toner cartridges fully in the direction of arrow.

Note!

• The starter toner (the toner cartridge attached to the product at the time of purchase)
can print approximately 1,000 sheets of A4 paper in case of 5% coverage.
(Approximately 500 sheets in case of OEL/AOS specification)

• If the error message [CHECK TONER CARTREGE] stays permanently on the
operator panel,check to make sure that the levers of the toner cartridges have fully
been moved in the direction of the arrow.

• If normal starter toner cartridges have been used, the starter toners can no longer be

used. First use the starter toners, and use normal toners after the starter toners are
exhausted.

• Make sure to change the starter toners only after [REPLACE TONER] is indicated.

If the starter toners are replaced before the above message appears, the correct toner
remaining level will not be able to be indicated.

Blue Lever

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Load Paper in Paper Cassette

(1) Pull out the paper cassette.

Note!

Do not remove the cork on the plate.

(2) Conform the paper guide to the paper size and fix it firmly.

Plate

Cork

Paper Guide

(3) Shuffle the sheets of paper and arrange up, down, left and right properly.

(4) Make the printable side down and set the paper.

Note!

• Place the paper in front of the paper cartridge.

• Set the paper not to exceed “▼▼”mark of the paper guide. (250 sheets weighing 70kg)

(5) Fix the paper by the paper stopper.
(6) Return the paper cassette to the printer.

Printing face down

Paper Stopper

Paper life display

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Load Paper in the Manual Feed Opening

(1) Put a finger in the dent at the center of the manual feed opening and pull forward.

Manual Feed Opening

(2) Conform the manual feeding guide to the size of the paper.
(3) Arrange the left and right of the paper.

Manual Feeding Guide

Manual feeding opening

Manual Feeding Guide

(4) Make the printing side up and insert the paper straight to the rear end along the manual feed

guide.

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Preserve the Quick Guide

Paste the quick guide case to the printer and put in the quick guide.

(1) Turn around the quick guide case and remove the covers of the Double faced adhesive tapes

(2 places).

Double faced adhesive tapes

(2) Paste the case to the printer.

Note!

Paste the case so as not to block the vent hole on the back of the printer.

Quick Guide

Quick Guide Bag

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3.5.2 Power Cable Connection
Conditions for Power Supplies

• Observe the following conditions:
Alternate Current (AC) : 110 ~127VAC(Range 99~140VAC)/220 ~240VAC(Range

198~264VAC)

Power Supply Frequency: 50Hz or 60Hz±2%

• Use a voltage regulator when the power supply is not stable.

• The maximum power consumption of this printer is 980W. Confirm that the power supply has

sufficient extra capacity.

• Never fail to switch off the power supply at the time of connection or removal of the electric cord
and earth cable.

• Always connect the earth cable to the earth terminal equipped only for that purpose. Never
connect the earth cable with water pipe, gas pipe, telephone cable earth terminal, lightening rod,
etc.

• Always grasp the power plug at the time of connection and removal of the electric cord.

• Always make sure that the electric plug is inserted fully into the outlet.

• Do not connect or disconnect the electric plug with the wet hand.

• Do not install the electric cord at the place liable to be stepped on and do not put things on the

electric cord.

• Do not bundle up or tie up the electric cord

• Do not use the damaged electric cord.

• Do not put many loads on one electric outlet.

• Do not connect this printer to the same outlet with other electric machines. Particularly, erroneous

operation may occur by electric noise when the same outlet is shared by the air conditioner,
duplicator, shredder, etc. at the same time. When the same outlet had to be used, use a noise filter
or noise cut transformer on the market.

• Use the attached electric cord only.

• Do not use an extension cord. Use the cord of over rating 15A if you had to use one.

• When you use the extension cord, the printer may not operate normally due to the drop of AC

voltage.

• Do not shut down the power supply or remove the power plug while printing.

• Disconnect the power cord when the printer would not be used for some long while due to

consecutive holidays or journey.

It may expose you to electric shocks or cause a fire.

As to the connection of the electric cord and earth cable, explain fully to the customer showing the
User’s Manual.

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Connect Power Supply Cord

Note!

Be certain the power switch is placed in the OFF (O) position.

(1) Insert the electric cord in the printer.
(2) Insert the plug in the outlet after connecting the earth cable with the earth cable terminal of the

outlet.

Earth Terminal

Earth Cable

2

1

Press ON (I) of Power Switch

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3.5.3 Installation of Optional Components
(1) Extension Memory Installation

Memory Capacity (Total Memory)

128MB (128MB)
+256MB (384MB)
+512MB (640MB)

Type

resident (mandatory)

256MB
512MB

d_color P116 Additional Memory

Note!

• You must use genuine Oki Original. Otherwise, the memory will not work.

• For banner-sheet printing, use of additional memory of more than 256MB is

recommended.

• The slot for memory is one slot.

• d-Color P116 additional memory (256MB/512MB) is interchangeable with the memory of

other PDL (C9650/C6150/C5950/C710/etc ) .

Switch the power supply of the printer off and pull out the electric cord.

Note!

If installed with the switch on, an electric shock or a trouble to the printer may occur.

OI

Open the top cover.

Top cover

Open Button

Screw

Eliminate static electricity by touching a screw.

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3.4 Packed Units and Attachments

• Confirm whether there are scratches, stains, etc. on the exterior of the machine.

• Confirm whether there are lacking items, damages, etc. among the accessories.

• If anything unusual is found, contact the user’s section in charge and follow its instruction.

This printer weighs about 21kg and should be lifted by 2 or more persons.

Personal injuries may occur.

■ ■ Printer (main body)

d-Color P116

■ ■ Image Drum Cartridges with Starter Toner Cartridges (4 sets) (installed in the printer)

Explain to customers that the toner cartridge and the image drum cartridge are separable.

■ ■ Printer Software CD-ROM

■ ■ Power Cord

■ ■ Warranty and Registration Card

■ ■ Users Manual (Setup Guide)

■ ■ Users Manual on CD-ROM

■ ■ Quick Guide

■ ■ Quick Guide Bag

Note!

The printer cable is not included in the accessories.

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Open the memory cover.

(1) Release the lock by pushing the knob of the memory cover in the direction of arrow and open

the memory cover.

Install the memory.

Note!

Do not touch electronic parts and connector terminal.

(1) Neutralize static electricity by letting the bag touch the metal part before taking out the memory

from the bag.

(2) Pay attention to the direction of the memory. There is a cut on the terminal part of the memory

to fit it into the connector of the slot.

(3) Insert the memory in the empty slot and bring it down to the circuit board side.

2

1

Memory Cover

Knob

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Memory Cover

Lever (blue)

Belt Unit

Belt Unit

Lock Lever (blue)

Lock Lever (blue)

Close the memory cover.

(1) Close the memory cover. Confirm that it is firmly locked.

Install the belt unit.

(1) Hold the belt unit lever (blue) and install the belt unit.

(2) Turn the lock lever(blue, 2) in the direction of and confirm that the belt unit is firmly fixed.

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Image Drum Cartridge

Install the image drum cartridge.

(1) Restore the 4 image drum cartridges to the original place.

Install the electric cord and printer cable to the printer and set the switch on.

3.5.4 Confirmation of recognition of optional items

To check to see whether or not the optional items have been installed properly, execute the Menu
Map print by referring to "3.6 Menu Map print.

(1) Confirmation of recognition of expansion memory

Checking the contents of the Menu Map.
Check the total memory volume indicated in "Total Memory Size" of the header.

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3.6 Menu Map print

This print is intended to ensure that the printer operates normally.

(1) Press the MENU + key several times to cause "INFORMATION MENU" to be displayed.
(2) Press the ENTER key to cause "PRINT MENU MAP/EXECUTE" to appear.
(3) Press the ENTER key.
The Menu Map print will get under way.

(Sample) d-Color P116

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3.7 Network Information Print
Confirm the network information print.

(1) Press the MENU + Key several times to cause "INFORMATION MENU" to be displayed.
(2) Press the ENTER Key to cause "NETWORK/EXECUTE" to be displayed.
(3) Press the ENTER Key.

Or, press the TEST switch which is at the side of network connector on the back of the
printer for 5 seconds, then release it.

(Sample) d-Color P116

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3.8 Connection Procedures
<USB Connection>
Prepare a USB Cable.

Note!

• The cable of the printer is not attached. Users should buy seperately.

• Obtain the cable of USB specification by yourself.

• Use the USB cable of Hi-Speed specification in case the connection is to be made

using “HI-Speed” mode of USB2.0.

Switch off the power of the printer and computer.

Memo

Although the USB cable can be connected or removed with the switch of the computer
and printer on, switch off the power of the printer at this step in order to ensure installation
of the printer driver and USB driver later.

Connect the printer with the computer.

(1) Plug the USB cable into the USB interface connector of the printer.
(2) Plug the USB cable into the USB interface connector of the computer.

Note!

Be careful not to insert the USB cable into the network interface connector.
Or else it may cause troubles.

USB Interface Connector

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<LAN Cable Connection>
Prepare the LAN cable.
Switch off the power of the printer and computer.
Connect the computer and printer.

(1) Plug the Ethernet cable into the network interface connector of the printer.
(2) Plug the Ethernet cable into the hub.

Network Interface Connector

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3.9 Checking of User Paper

Set the medium the user uses, set up media type/weight, conduct menu map/demo print and
confirm that the toner does not peel off.

Media type *

1

Media weight

55-64kg (64-74g/m

2

)

65-89kg (75-104g/m

2

)

90-103kg (105-120g/m

2

)

104-172kg (121-200g/m

2

)

-

-

Less than 0.1-0.17mm

0.17-0.2mm

WeightTypes

Setting *

2

for

[Media weight] of the

printer driver

Light

Madium

Heavy

Ultra Heavy

-

­Label paper 1
Label paper 2

Light

-

-

Label paper

Setting values of

the printer menu setting

Light

Madium

Heavy

Ultra Heavy

-

-

Heavy

Ultra Heavy

Regular
paper*

3

Postcard*

4

Envelope*

4

Label paper

*1

: The set-up of the media type at the time of shipment from the factory is “Light”.

*2

: Thickness and type of paper can be set up by the printer driver. When they are set up by

the printer driver, the printer driver set-up has priority. When “Automatic Selection” is
selected by “Paper Feed Method” of the printer driver or when “Printer Set-up” is selected
by “Paper Thickness”, printing is made by the set-up of the printer menu setting.

*3

: Thickness of paper for both side printing is 65~90kg in weight (75~105g/m2).

*4

: Set-up of media weight and media type is not necessary for postcards and envelopes.

Memo

When “Heavy” and “Ultra Heavy” of Media Weight and “Label Paper” of Media Type are
set up, the printing speed becomes slow.

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(2) Do not disassemble the printer as long as it is operating normally.

(3) Limit disassembly to a necessary minimum. Do not remove other parts than those specified

in the part replacement procedure.

(4) Use the designated maintenance tools.

(5) Conduct disassembly by following the specified sequential order. Failure to observe this order

could damage the parts.

(6) Screws, collars and other small parts should be attached provisionally to their original

positions, since they are liable to be lost.

(7) When handling a microprocessor, ROM, RAM and other ICs and circuit boards, do not wear

gloves that tend to generate static electricity.

(8) Printed-circuit boards should not be placed directly on an equipment or floor.

4. REPLACEMENT OF PARTS

This section explains the field replacement procedures for parts, assemblies and component units.
While those replacement procedures refer to the disassembling of parts, follow the same
procedures inversely for reassembling them.
The part numbers (1, 2, etc.) employed in this manual are different from those assigned in the
corresponding configuration diagrams of Disassembly for Maintenance (44004601TL) and RSPL
(44004601TR).

4.1 Precautions on the replacement of parts

(1) Prior to replacing a part, be sure to disconnect the AC cord and interface cable.

(a) To disconnect the AC cord, always follow the procedure described below:

1 Turn off ("O") the power switch of the printer.
2 Pull out the AC plug of the AC cord from the AC power outlet.
3 Unplug the AC cord and interface cable from the printer.

(b) To reconnect the printer, always follow the procedure described below:

1 Plug the AC cord and interface cable into the printer.
2 Insert the AC plug into the AC power outlet.
3 Turn on ("|") the power switch of the printer.

Disconnect

Connect

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[Maintenance Tools]

Clawle 4-1-1 indicates the tools necessary to replace printed-circuit boards and component units.

Clawle 4-1-1 Maintenance Tools

No. Q’ ty Place of use RemarksService Tools

1

2

3

4

5

6

7

9

No. 2-200 Philips
screwdriver, Magnetized

No. 3-100 screwdriver

No. 5-200 screwdriver

Digital multimeter

Pliers

E-ring pliers

Handy cleaner

LED Head cleaner
P/N 4PB4083-2248P001

1

1

1

1

1

1

3~5

Cleans LED head

1

8

1

1 2-2.5 mm screws

No. 1-100 Philips

screwdriver

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4.2 Part replacement methods

This subsection explains the replacement methods for the parts and assemblies illustrated in the
disassembly system diagram below.

4.2.1 Left side cover

(1) Open the top cover.
(2) Open the front cover.
(3) Remove a screw (silver) 1 four claws A and a claw B to detach the left side cover 2.

Figure 4-2-1 Left side cover

2

1

Top cover

Front-cover

ClawA

ClawB

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4.2.2 Right side cover

(1) Open the top cover.
(2) Open the front cover.
(3) Remove a screw (silver) 1 four claws A and a claw B to detach the right side cover 2.

Figure 4-2-2 Right side cover

ClawB

1

2

ClawA

Top cover

Front-cover

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Figure 4-2-3 Rear cover

1

2

3

ClawA

ClawA

ClawB

HoleA

HoleA

HoleA

HoleA

Hole

4.2.3 Rear cover (Top/Bottom)

(1) Remove the left side cover. (See Subsection 4.2.1)
(2) Remove the right side cover. (See Subsection 4.2.2)
(3) Remove two screws (silver) 1.
(4) As shown in the drawing, put the flat-blade screwdriver into a hole A to remove

two claws A.
(5) Remove tow claws B by hand and then, remove the rear cover assembly 2.
(6) Lift the rear cover bottom 3 upward to detach it.

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4.2.4 Front cover

(1) Remove the Shaft-Cover 1 and the stay 2 and then, remove the Shaft-Cover 3, and the

Front-Cover 4.

Figure 4-2-4 Front cover

1

4

3

2

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4.2.5 Top cover assembly

(1) Open the top cover.
(2) Remove the left side cover. (See Subsection 4.2.1)
(3) Remove the right side cover. (See Subsection 4.2.2)
(4) Detach the rear cover. (See Subsection 4.2.3)
(5) Remove the plate heat. (See Subsection 4.2.18)
(6) Remove the plate shield front. (See Subsection 4.2.16)
(7) Remove a screw (silver) 1.
(8) Remove the TB3-PCB (main board) (See Subsection 4.2.23), and then, remove the head

cable (FFC) and the RFID cable.

(9) Remove two E-type retaining rings 2 two spring torsions 3 and the top cover assembly 4.

Figure 4-2-5 Top cover assembly

1

4

ViewA

ViewA

4

3

2

3

2

1

RFID

K

Y

M

C

Head cable(FFC)

TB3-PCB
(Main circuit board PCB)

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4.2.6 Top cover

(1) Remove the top cover assembly. (See Subsection 4.2.5)
(2) Remove nine screws (black) 1 to remove the top cover 2.

Figure 4-2-6 Top cover

2

1

× 9

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4.2.7 LED assembly/ LED assembly spring

(1) Open the top cover.
(2) After removing the head cable (FFC), apply force in the direction of the arrow ‘X’ as shown

in Figure (2). Remove a hook A first and then a hook B to remove the LED assembly 1.

(3) Remove the spring 2.

Figure 4-2-7 LED assembly/ LED assembly spring

X

1

2

Top cover

Hook A

Hook B

Figure(2)

Figure(1)

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4.2.8 RFID assembly

(1) Remove the top cover assembly. (See Subsection 4.2.6)
(2) Remove the top cover. (See Subsection 4.2.7)
(3) Remove two screws (silver) 1 and all connectors to detach the LUM board (RFID reader

writer) 2.

(4) Detach six claws A and two claws B engaging with the plate-inner 3 to remove RFID

assembly 4.

Figure 4-2-8 RFID assembly

2

1

3

4

Claw A

Claw B

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4.2.9 Control pane assembly

(1) Open the top cover.
(2) Open the front cover.
(3) Remove the right side cover (See Subsection 4.2.2)
(4) Remove the plate shield front and cable (See Subsection 4.2.16)
(5) Detach FFC which connects the control panel assembly with the control panel PCB.
(6) Remove four screws (silver) 1 to remove the control panel assembly 2.

Figure 4-2-9 Control pane assembly

1

2

OP cable

1

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4.2.10 WHP board

(1) Remove the control panel assembly (See Subsection 4.2.9)
(2) Remove a claw A to remove the frame OP 1.
(3) Remove a claw B and the button lock 2 to detach the lever lock 3.
(4) Remove a spring 4.
(5) Remove nine claws C and the cover assembly OP 5.
(6) Remove the cover-LCD 6 and lens-LED 7.
(7) Remove two screws 9 (M2,Tool No.1) and the button-Key 8 to remove the WHP board

(operation panel) 0.
(8) Remove a spring A.

Figure 4-2-10 WHP board

Claw A

Claw A

8

9

0

A

7

6

5

4

3

2

1

Claw C

Claw C

Claw B

Claw B

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4.2.11 Feeder unit

(1) Open the top cover.
(2) Open the front cover. (See Subsection 4.2.4)
(3) Remove the Lever_Lock_Assembly 1.
(4) Remove the left side cover. (See Subsection 4.2.1)
(5) Remove the right side cover. (See subsection 4.2.2)
(6) Detach the plate shield front. (See Subsection 4.2.16)
(7) Remove a connector 3 connecting to the feeder unit 2 from the TB3 board (main board).
(8) Remove four screws (silver) 4 to remove the feeder unit 2.
(9) Remove claws to remove the cover sensor 5.
(10) Remove the MIP board (front sensor board) 6.

Figure 4-2-11 Feeder unit

1

2

3

3

4

5

6

× 4

HOP

TB3-PCB
(Main circuit board PCB)

TB3-PCB (Main circuit board PCB)

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4.2.12 Manual feeder unit

(1) Open the top cover.
(2) Open the manual feeder 1 .
(3) Hold both ends of the manual feeder 1 and pull it in the direction of the arrow to remove it.

Figure 4-2-12 Manual feeder unit

1

about 45°

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4.2.13 Face up tray

(1) Remove the left side cover. (See Subsection 4.2.1)
(2) Remove the right side cover. (See Subsection 4.2.2)
(3) Remove the rear cover. (See Subsection 4.2.3)
(4) Remove the supporting points of the face up tray 1 with a flat blade screwdriver.

Figure 4-2-13 Face up tray

1

Support point (2 places)

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2.14 Guide eject assembly

(1) Remove the left side cover. (See Subsection 4.2.1)
(2) Remove the right side cover. (See Subsection 4.2.2)
(3) Remove the rear cover. (See Subsection 4.2.3)
(4) Remove the top cover assembly. (See Subsection 4.2.5)
(5) Remove the color registration assembly. (See Subsection 4.2.17)
(6) Detach two latches at the lower part of the guide eject assembly 1 to remove the guide eject

assembly 1.

Figure 4-2-14 Guide eject assembly

1

Latch

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4.2.15 Eject roller

(1) Remover the guide eject assembly 1. (See Subsection 4.2.14)
(2) Remove two claws A to divide them into the guide eject lower 2 and the guide eject upper

3.

(3) Detach a claw B, three gear idle ejects 4. Remove the shaft assembly eject (FD) 5 and the

shaft assembly eject (FU) 6.

(4) Remove the eject sensor 7, and the lever eject sensor 8 from the guide eject lower 2.

Figure 4-2-15 Eject roller

1

5

6

8

7

3

4

2

View A

View A

Claw B

Claw A

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4.2.16 Plate shield front

(1) Remove three screws (silver) and remove the plate shield front 2.

Figure 4-2-16 Plate shield front

1

2

Claw

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4.2.17 Color registration assembly

(1) Remove two screws (silver) 1 to remove the plate heat.
(2) Remove two screws (silver) 3 to detach two connectors and one FFC. Then remove the color

registration assembly 4.
(3) Detach two supporting points to remove the frame shutter 5.
(4) Remove two screws (silver) 6 to remove the color registration sensor board 7.
(5) Remove a screw (silver) 8 to remove the density sensor board 9.

Figure 4-2-17 Color registration assembly

7

6

9

8

4

2

3

1

1

3

5

Fulcrums

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4.2.18 Plate shield rear

(1) Remove the left side cover. (See Subsection 4.2.1)
(2) Remove the right side cover. (See Subsection 4.2.2)
(3) Remove the rear cover. (See Subsection 4.2.3)
(4) Remove the top cover assembly. (See Subsection 4.2.5)
(5) Remove the color registration assembly. (See Subsection 4.2.17)
(6) Remove the plate shield front. (See Subsection 4.2.16)
(7) Remove the low voltage power supply. (See Subsection 4.2.22)
(8) Remove the TB3 board (main board.) (See Subsection 4.2.23)
(9) Remove two screws (silver) 1 to remove the plate heat 2.
(10) Remove latches of the gear lift up 3 to detach a shaft 4.
(11) Remove three screws (silver) 5 to remove the plate shield rear 6.

Figure 4-2-18 Plate shield rear

6

2

1

3

5

4

5

5

3

1

3

Rear

Link-LiftUp-L

*Precautions for assembly
Gear lift up

shall be assembled after
Link-LiftUp-L and Link-LiftUp-R are slided
to the rear direction until bumping.

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4.2.19 PRS board (toner sensor board)/ Gear idle dram

(1) Remove the right side cover. (See Subsection 4.2.2)
(2) Remove seven screws (silver) 1 and remove bracket outer 2.
(3) Remove the drum idle gears 3, 4, 5 and 6.
(4) Remove the idle gear 0, C.
(5) Remove ID lift-up gears 7 and 8.
(6) Remove the cover plate 9 by sliding back the latch A.
(7) Remove the latch B to remove the Board-PRS A and the spring contact B.

7

2

8

4

3

5

6

1

× 7

0

C

9

A

B

× 8

LatchB

LatchA

Toner sensor
cable

Front

34 5 6

Figure 4-2-19 PRS board/ Gear idle dram

*Precautions for assembly
Make sure that the triangle directions at
the sides of the gears match the arrow
directions of the cover plate on completion
of assembling drum idle gears 3 to 6 .

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4.2.20 Main motor/ Solenoid

(1) Remove the left side cover. (See Subsection 4.2.1)
(2) Remove the right side cover. (See Subsection 4.2.2)
(3) Remove the rear cover. (See Subsection 4.2.3)
(4) Remove the front cover (See Subsection 4.2.4)
(5) Remove the plate shield front. (See Subsection 4.2.16)
(6) Remove the top cover assembly. (See Subsection 4.2.5)
(7) Remove the control panel assembly. (See Subsection 4.2.9)
(8) Remove the feeder unit assembly. (See Subsection4.2.11)
(9) Remove the guide eject assembly. (See Subsection4.2.14)
(10) Remove the color registration assembly. (See Subsection 4.2.17)
(11) Remove the plate shield rear. (See Subsection 4.2.18)
(12) Remove two screws (silver) 1 to remove the part A and the side plate R assembly 2.
(13) Remove a screw (silver) 3 to remove the plate lockout ID 4.
(14) Remove five screws (silver) 5 to remove the part B and the bracket inner 6.
(15) Remove two screws (silver) 7 to remove the Fuser- motor 8.
(16) Remove two screws (silver) 9 to remove the DC motor 0.
(17) Remove two screws (silver) A to remove the ID lift up motor B.
(18) Remove two screws (black) C to remove the hopping motor D.
(19) Remove two screws (black) E to remove a claw C and the Gear-HP-assembly F.
(20) Remove a spring G, a screw H and solenoid I.
(21) Remove a spring J, a claw D of the hopping roller K, claw E of the gear L , bushing M,

hopping roller N and frame hopping O.

(22) Remove the lever end P.

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Figure 4-2-20 Main motor/ Solenoid

J

P

3

4

5

A

1

5

1

9

6

2

B

5

0

F

L

N

O

M

G

D

C

I

H

E

K

9

7

8

A

A

B

Claw C

Claw E

Claw D

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4.2.21 Belt motor/ High voltage board/ Cover open switch

(1) Remove the left side cover. (See Subsection 4.2.1)
(2) Remove the connector and claw A to remove the cover open switch1.
(3) Remove a screw (silver) 2 and a screw (black) 3, and then remove seven claws B to detach

the high voltage board 3.

(4) Remove a screw (silver) 4 to remove belt motor 6.

Figure 4-2-21 Belt motor/ High voltage board/ Cover open switch

1

6

5

3

2

4

1

CN4

TR-KTR-M TR-YTR-C

High-voltage power supply

Cover-open switch

Claws A

Claw A

Claw A

Claws B

Cover opening switch cable route chart

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4.2.22 Low voltage power supply/ Low voltage fan

(1) Remove the left side cover (See Subsection 4.2.1)
(2) Remove the right side cover (See Subsection 4.2.2)
(3) Remove the plate shield front (See Subsection 4.2.16)
(4) Remove a cable connecting the TB3 board (main board) with the Low voltage power

supply.
(5) Detach the rear cover. (See Subsection 4.2.3)
(6) Remove the two (silver-colored) screws 1, release claw engagement at the two places, and

pull out the low-voltage power supply 2 to the position at which the AC switch connector and

the fuser interface connector can be removed.
(7) Remove the AC switch connector and the fuser interface connector and detach the low-

voltage power supply 2.
(8) Pull out a connector of the FAN in the direction of the arrow to extract the FAN 3.

Figure 4-2-22 Low voltage power supply/ Low voltage fan

1

2

1

3

3

CN5

2

CN5

1

CN101

CN102

CN2

PRN PCB
POWER connector

Short-circuit plug for CN5

Claw

Notes!
CN5 : Switching connector for AC input voltage setting
Short-circuit plug to be equipped for 100-V system/Short-circuit plug
not to be equipped for 230-V system

AC switch

Fuser unit I/F connector

Low-voltage power supply

Low-voltage fan

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4.2.23 TB3 Board (Main Board)

(1) Remove the left side cover (See Subsection 4.2.1)
(2) Remove the right side cover (See Subsection 4.2.2)
(3) Remove the plate shield front (See Subsection 4.2.16)
(4) Remove all connectors connecting to the TB3 board (main board).
(5) Remove the rear cover. (See Subsection 4.2.3)
(6) Remove the low voltage power supply (See Subsection 4.2.22)
(7) Remove five screws (silver) 1 and two screws (silver) 2 to remove the TB3 board (main

board) 3.

Figure 4-2-23 TB3 Board

View A

View A

2

1

× 5

3

3

2

HEAT

IDUP

HOP

HSOL

FSNS

DCID

SSNS

OPE

BELT

HVOLT

RSNS

DIMMB

POW1

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4.3 Lubricating points

This subsection indicates the lubricating points of the printer. Conversely, it means that any other
parts than the specified lubricating points must not be lubricated.
There is no need to lubricate in the midst of a disassembling job. However, if lubricating oil has been
wiped off, supply the specified oil.

Lubricating work

(1) Symbols and names of oils

EM-30L: MOLYKOTE EM-30L
HP-300: MOLYKOTE HP-300
PM : Pan Motor Oil 10W-40 or ZOA 10W-30

(2) Boundary samples of grease

Class

Amount of grease(cc)

W(mm)

Sample

SABCDEF

0.0005 0.003 0.005 0.01 0.03 0.05 0.1

1.24 2.25 2.67 3.37 4.86 5.76

W

7.26

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1 43192202 Plate-Assy.-Base

Stopper-Z45-48-HP

Holder-Planet

Bearing portion

EM-30L Class A

Bearing portion

EM-30L Class A

Both side

EM-30L Class A

Post

EM-30L Class A

End face

EM-30L Class C

Both side

EM-30L Class A

Gear-Planet-HP

Stopper-HP

Gear-Z24-50-HP

The side of groove

EM-30L Class C

Gear tooth surface

and end surface

EM-30L Class C

Shaft-Hopping

Gear bottom surface

EM-30L Class C

Ratch portion (Hatching portion)

EM-30L Class C

Guide-Cassette-L

Apply MOLYKOTE (EM-30L)

to the hatched areas.

EM-30L Class C

Guide-Cassette-R

Apply MOLYKOTE (EM-30L)

to the hatched areas.

EM-30L Class C

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2 43192602 Cassette-Assy.

3 43197301 Gear-Assy.-HP

Frame-Separation

The MOLYKOTE (EM-30L) should be applied to the hatched areas
portions shown in the figure below before assembly. (At both sides)

Fulcrum of rotation and side
The application of grease protruding over
on the paper carriage surface is not
permitted.

Class C

Holder-Gear-A

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

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4-1 43194101 Plate-Assy.-Side-R (PX732)

Bracket-Inner (Caulking)

Gear-Idle-Heat

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

Apply MOLYKOTE (EM-30L)

to the inside of a gear.

EM-30L Class C

Grease is not applied to a metal shaft.

Gear-Idle-Drum-Z24-117

Gear-Idle-Drum-Z55

Apply MOLYKOTE (EM-30L) to the gear tooth surface

EM-30L Class F

Apply MOLYKOTE (EM-30L) to the gear tooth surface

EM-30L Class F

Apply MOLYKOTE (EM-30L)

to the end face

EM-30L Class C

Apply MOLYKOTE (EM-30L)

to the end face

EM-30L Class C

Gear-Idle-Drum-Z55

Gear-Idle-Drum-Z24-117

4-2 43194101 Plate-Assy.-Side-R (PX732)

Link-Liftup-R

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class A

Apply MOLYKOTE (EM-30L)

to the gear tooth surface.

EM-30L Class A

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class A

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5 43200101 Plate-Assy.-Side-L (PX732)

Link-Liftup-L

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class A

Apply MOLYKOTE (EM-30L)

to the gear tooth surface.

EM-30L Class A

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class A

Class S

OR-Board-PRS

After palish the terminals to luster with BEMCOT M-3 Tetfa
(C-9300) is soaked cotton swab a little (Class:S).
and it coated on terminals. (32 places)

4-3 43194601 Cover-Ass.-Plate-R

Plate-Side-R(Caulking)

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

4-4 43194101 Plate-Assy-Side-R(PX732)

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6 43209701 Holder Assy.-Regist-L

7 43210301 Holder Assy.-Regist-R

Holder-Regist-L

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

Holder-Regist-R

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

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8 43217001 Fuser-Assy.

9-1 43206503 Guide-Assy.-Eject-U

Apply MOLYKOTE (HP-300) to the hatched areas.

HP-300 Class C

Cam-Release

Lever-Release

Not allowed to stain

the area with grease

Apply MOLYKOTE (EM-30L) to the sliding portions (hatching portions).

EM-30L Class S

The application of grease protruding over
on the paper carriage surface is not permitted.

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9-2 43206503 Guide-Assy.-Eject-U

Apply MOLYKOTE (EM-30L)

to the gear tooth surface.

EM-30L Class C

Gear-Idle-Exit (Z19)

Gear-Idle-Exit (Z19)

Gear-Idle-Exit (Z21)

Bearing-Eject (FD.FU)

(2 points)

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

Apply MOLYKOTE (EM-30L) to the hatched areas.

(In gear bearing part)

EM-30L Class C

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0-1 43192008 Printer-Unit-PX742

Apply MOLYKOTE (EM-30L) to the terminal tip areas.

EM-30L Class C

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

Apply MOLYKOTE (EM-30L) to the end face.

EM-30L Class C

Apply areas to grease (4 points)

Plate-Shield-Rear (Caulking)

Gear-Idle-Belt

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0-2 43192008 Printer-Unit-PX742

Spring-Torsion-L

Spring-Torsion-R

Apply PM with a brush to the portion of the slot

of solid coiling of this torsion-spring.

(2 places, Both Sides)

PM Class C

Apply MOLYKOTE (EM-30L) to the hatched areas.

EM-30L Class C

Plate-Assy.-Side-R

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A-1 43216001 Belt-Unit (PX732)

Apply MOLYKOTE (EM-30L) to the hatched area.

EM-30L Class C

Guide-R

Guide-L

Apply MOLYKOTE (EM-30L) to the hatched area.

EM-30L Class C

Bracket-CL-Assy.

Not applying grease to a part of a metal plate.

Bracket-CL-L

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A-2 43216001 Belt-Unit (PX732)

Apply MOLYKOTE (EM-30L)

to an end face of Gear-Drive-Z36.

EM-30L Class C

Bearing-TR(Belt)

Roller-Transfer

Frame Assy.-Belt

Bearing-GSB

Gear-Drive-Z36

Apply MOLYKOTE (EM-30L) to all inside of Bearing-TR(Belt).

EM-30L Class A

Apply MOLYKOTE (EM-30L) to

all inside of Bearing-TR(Belt).

EM-30L Class A

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OR-Board-TB3

Class S

Polish the two terminals clean with fine-grade wipers
(e.g. BEMCOT_M-3 or equivalent),
then put lubricant (e.g. TETRA_C-9300 or equivalent) on them.

B 44017501 Borad-Assy PX742 PDL

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5. MAINTENANCE MENUS

The adjustment of this printer can be implemented using the maintenance utility and also by key
input through the operator panel.
This printer provides maintenance menus, apart from the normal menus. Select the menu that best
suits the purpose of your intended adjustment.

Used to set the destination.
JPOEM1: Japan OEM
OEMA: Overseas OEM for A4 default
OEML: Overseas OEM for Letter
default
When the menu is dismissed, the
printer is automatically rebooted.
Default is OEL.

Do not use.
Initializes the Flash ROM.
When this item is executed, the menu
is dismissed, and formatting of the
flash device mounted in the Resident
(Onboard) begins. (CAUTION! NIC
F/W will be erased.see section 7.4.4)

Resets the EEPROM contents to the
factory defaults. After the settings
have been changed, the printer is
automatically rebooted.
* Certain special items are not
initialized.

Function

ENTER
PASSWORD

OKIUSER

FLASH FORMAT

MENU RESET

Item(1st Line)

xxxxxxxxxxxxxxx

ODA
OEL
APS
JP1
JPOEM1
OEMA
OEML

EXECUTE

EXECUTE

Value(2nd Line)

000
000

*

-

-

DF

SYSTEM MAINTE

OKIUSER

MAINTENANCE
MENU

Category

5.1 System maintenance menu (For maintenance personnel)

This menu is activated when the power is turned with the MENU+ and MENU- keys held down.
The menu indications are given in English only, irrespective of the destination of the printer.

Note!

Since this menu is likely to be changed depending on the destination or for other

reason, it is not disclosed to the end users.

Table 5-1. Maintenance menu indication table (1/3)

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FunctionItem(1st Line) Value(2nd Line) DFCategory

Function
This menu is displayed on the printers
for all destinations.
TYPE1: Does not indicate Russian/
Greek.
TYPE2: Indicates Russian/Greek.
When the menu is dismissed, the
printer is automatically rebooted.
For destinations of OEL/APS/OEMA,
TYPE2 is the default value, and for the
rest of destinations, TYPE1 is the
default value.

Setting is made here to select either to
display or not to display "PRT ID CHK
PATN" and "ENG STATUS IPRINT"
under "USER MENU" - "PRINT
INFORMATION" category. If this item
is set to "DISABLE," "PRT ID CHK
PATN" and "ENG STATUS PRINT" will
not be displayed at all. When the menu
is dismissed after changing the setting,
the printer is restarted.

Pressing the ENTER key issues a
command from CU to PU, making the
printer ONLINE.
A consumable part is replaced with a
new one with the power switched on
and the operation is checked (in this
condition, the new consumable fuse is
not cut, and the operation count is not
added to the value of the old
consumable part).
Turning off the power terminates the
check mode, and the mode becomes
invalid next time the power is turned
on.

CODESET

TEST PRINT MENU

FUSE KEEP MODE

TYPE1
TYPE2

ENABLE
DISABLE

EXECUTE

*J

*E

*

-

CONFIG MENU

TEST PRINT MENU

FUSE KEEP MODE

Table 5-1. Maintenance menu indication table (2/3)

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93

PERSONALITY

CHANGE
PASSWORD

ENGINE DIAG
MODE

Changes the default of support PDL
language for each destination.

The PDL language disabled in this
menu will no longer be displayed in
"USER MENU" - "SYS CONFIG
MENU" - "PERSONALITY." If print data
in the PDL language set to "DISABLE"
is received, the printer displays
INVALID DATA and discards the
received data.

(HP-GL/2 is an item now under
development.)

If IBM PPR III XL and EPSON FX are
set to ENABLE on a printer for
domestic market, its operation is not
guaranteed.

Activates the self-diagnostic mode of the
engine.

FunctionItem(1st Line) Value(2nd Line) DFCategory

Operations of the switches and LCD indications produced during the self-diagnostic mode are
different from the specifications for operation of the printer.
See 5.3.2 Self-diagnostic mode.

IBM5577

IBM PPR III XL

EPSON FX

HP-GL/2

NEW PASSWORD
VERIFY P ASSWORD

Table 5-1. Maintenance menu indication table (3/3)

ENABLE
DISABLE

ENABLE
DISABLE

ENABLE
DISABLE

ENABLE
DISABLE

xxxxxxxxxxxxxxx
xxxxxxxxxxxxxxx

*

*E

*J

*E

*J

*

-

-

-

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5.3 Self-diagnostic mode

Individual explanation of LEVEL0 and LEVEL1.

5.3.1 Operator panel
The explanation of the operations relating to the self-diagnosis presupposes the

(1) Transition of menu items

Level transition is possible only when a part is displayed.
Transition of is activated with [MENU-] or [MENU+].

xxxxx
xxxxx

Hold down [MENU+] and [MENU-], until the system
maintenance menu is displayed.
Then, select ENGINE DIAG MODE and press [ENTER].

Not pressed

LEVEL0-engine status indication

LEVEL1-ENGINE DIAG MODE XX.XX

Engine status indication

SWITCH SCAN

(Heater temperature)

MOTOR & CLUTCH TEST

(Environmental temperature
& humidity indication)

TEST PRINT

Indication of each voltage
(TR, CH, DB, SB) during printing

REG ADJUST TEST

Toner sensor

DENS ADJ TEST

RFID internal noise monitoring

MOTOR INFORMATION

Error detail

CONSUMABLE STATUS

Press [MENU+] and [ONLINE]
simultaneously.(3seconds)

PRINTER STATUS

FACTORY MODE SET

SENSOR SETTING

LED HEAD DATA

Self-diagnostic Self-diagnostic
mode layout (Overall)mode layout (Overall)

Normal operation mode

POWER ON

Press [MENU-], [MENU+], [ENTER] and
[BACK] simultaneously.(6seconds)

5.2 Maintenance utility

The maintenance utility is esclusively used to perform the adjustments in boards repair laboratory.

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LEVEL0

[BACK](2seconds)

Engine status indication

Heater temperature

Environmental temperature & humidity

Setup table

Transfer voltage

Transfer-OFF voltage *Belt temperature

Side thermistor

[ONLINE](2seconds)

[MENU-] [MENU-]

[MENU-]

Indication of each voltage during printing

Toner sensor

RFID internal noise monitoring

Error detail

Transfer (TR) voltage(1)*1
Transfer (TR) voltage(2)*1

[MENU+]

Toner sensor status monitoring indication

[MENU+]

[MENU+]

Error code indication, etc.

Charge (CH) voltage
Supply (SB) voltage
Development (DB) voltage
Environmental level

Noise detection count indication . Toner K error
Noise detection count indication . Toner Y error
Noise detection count indication . Toner M error
Noise detection count indication . Toner C error

MOTOR INFORMATION

Regist MOTOR
Exit MOTOR
ID MOTOR
BELT MOTOR

*1: A color is changed pressing the [CANCEL] key while it is indicated.

(1) Switchover of menu items
The transition of xxxxx is activated when [BACK] or [ONLINE] is pressed and held down, or [MENU+] or [MENU-] is pressed briefly.
The transition of xxxxx is activated with [MENU+] or [MENU-].

The item selection screen is restored when [BACK] is pressed and held down.

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(1) Transition of menu items

Transition of is selected with [MENU+] or [MENU-] and executed pressing [ENTER].

Transition to is executed with [ENTER] or [BACK].

Select an item with [MENU+] or [MENU-] following the transition.

Pressing [ENTER] executes the test, and pressing [BACK] terminates it.

LEVEL1

LEVEL1

xxxxx

xxxxx

[MENU+] [MENU+] [MENU+] [MENU+] [MENU+] [MENU+]

SWITCH SCAN MOTOR & CLUTCH TEST TEST PRINT REG ADJUST TEST

ENGINE DIAG LEVEL1 [MENU-] [MENU-] [MENU-] [MENU-]

PAPER ROUTE : PU ID MOTOR [MENU-] PRINT EXECUTE [MENU-] REG ADJ EXECUTE DENS ADJ EXECUTE

TONER SENS BELT MOTOR TEST PATTERN REG ADJ RESULT *2

CVO UP_LU_FU FUSER MOTOR TEST CASSETTE *1 DENS ADJ RESULT *4

REG L/R_OHP_WG REGIST MOTOR PAGE BLT REFLECT RSLT *3 AUTO CALIBRATION

HT THERMISTER T1 HOPPING MOTOR COLOR

HUM_TEMP_DEN FRONT MOTOR DUPLEX *1

<Indication items of color drift correction test result>

Items of *2.

<Indication items of density correction test result>

Items of *4.

REGIST SHUTTER MONO SPEED REG ADJ RSLT DENS ADJ RESULT

ID UP/DOWN

EXIT SOLENOID COLOR SPEED SNS CARIBRAT (L)

RFID COLOR

DUPLEX MOTOR *1: TRAY2 and DUPLEX are displayed only

when these are mounted.

SNS CARIBRAT (R)

DUPLEX CLUTCH D-RANGE (L) Y,M,C LEV0 V/D OUT RD

T1 PE_PNE_CVO

T2 HOPPING MOTOR D-RANGE (R) Y,M,C

H_DUTY DENS-K

LEVO V/D OUT K

LEVO V/D OUT YMC

T2 FEED CLUTCH CRSE ADJ Y L,R,X

H_DUTY DENS-Y

ID UP/DOWN CRSE ADJ M L,R,X

H_DUTY DENS-M

LV FAN TEST CRSE ADJ C L,R,X

H_DUTY DENS-C

FUSER FAN TEST FINE ADJ Y L,R,X

L_DUTY DENS-K

DUPLEX FAN TEST FINE ADJ M L,R,X

L_DUTY DENS-Y

FINE ADJ C L,R,X

L_DUTY DENS-M

REG ADJ Y L,R,X

L_DUTY DENS-C

REG ADJ M L,R,X

FINAL DENS-K

REG ADJ C L,R,X

FINAL DENS-Y

CRSE ADJ Y [Y-L]

FINAL DENS-M

CRSE ADJ Y [Y-R]

FINAL DENS-C

CRSE ADJ Y [X]

DB DENS VALUE

CRSE ADJ M [Y-L]

DELTA-K 01=#***

CRSE ADJ M [Y-R]

DELTA-K 04=#***

CRSE ADJ M [X]

DELTA-K 07=#***

CRSE ADJ C [Y-L]

DELTA-Y 01=#***

CRSE ADJ C [Y-R]

DELTA-Y 04=#***

CRSE ADJ C [X]

DELTA-Y 07=#***

FINE ADJ Y [Y-L]

DELTA-M 01=#***

FINE ADJ Y [Y-L]

DELTA-M 04=#***

FINE ADJ Y [Y-R]

DELTA-M 07=#***

FINE ADJ Y [Y-R]

DELTA-C 01=#***

FINE ADJ Y [X-L]

DELTA-C 04=#***

FINE ADJ Y [X-R]

DELTA-C 07=#***

FINE ADJ M [Y-L]

DENS-K

FINE ADJ M [Y-L]

DENS-Y

FINE ADJ M [Y-R]

DENS-M

FINE ADJ M [Y-R]

DENS-C

FINE ADJ M [X-L]

BEFORE STD=***H

FINE ADJ M [X-R]

AFTER STD=***H

FINE ADJ C [Y-L]

FINE ADJ C [Y-L]

FINE ADJ C [Y-R]

FINE ADJ C [Y-R]

FINE ADJ C [X-L]

FINE ADJ C [X-R]

<Indication items of color drift correction belt reflectivity test result> Items of *3.

L-SIDE

R-SIDE

[MENU+]

[MENU+]

[MENU+]

[MENU+]

[MENU+]

CONSUMABLE STATUS PRINTER STATUS FACTORY MODE SET

SENSOR SETTING

LED HEAD DATA

[MENU-] [MENU-]

[MENU-]

[MENU-]

[MENU-]

K-ID UNIT K-IMPRESSIONS FACTORY MODE *5

TONER SENSOR

K

Y-ID UNIT Y-IMPRESSIONS FUSE INTACT *6

BELT UNIT CHECK

Y

M-ID UNIT M-IMPRESSIONS ID UNIT CHECK

M

C-ID UNIT C-IMPRESSIONS

<FACTORY MODE setting items. Items of *5

C

FUSER UNIT TOTAL SHEETS CNT FACTORY MODE

REG ADJUST ERROR

TR BELT UNIT FACTORY MODE

Factory work mode

DRUM OVER LIFE

WR POINT REV

BOTTOM WRT POINT

<Indication of LED header serial number>

K-TONER (FULL)

SHIPPING MODE

Factory work mode

cleared

n 01 23 45 6789

Y-TONER (FULL)

<FUSE INTACT items> Item of *6

1234567890123

M-TONER (FULL)

FUSE INTACT

n:K,Y,M,C

C-TONER (FULL)

BELT UNIT INTACT: Not cut yet/BLOWN:Cut already

M-WASTE TNR CNT

FUSE UNIT INTACT: Not cut yet/BLOWN:Cut already

C-WASTE TNR CNT

K-ID UNIT INTACT: Not cut yet/BLOWN:Cut already

K-STC MODE CNT

Y-ID UNIT INTACT: Not cut yet/BLOWN:Cut already

Y-STC MODE CNT

M-ID UNIT INTACT: Not cut yet/BLOWN:Cut already

M-STC MODE CNT

C-ID UNIT INTACT: Not cut yet/BLOWN:Cut already

C-STC MODE CNT

K OVER RIDE CNT

Y OVER RIDE CNT

M OVER RIDE CNT

C OVER RIDE CNT

A

B

B

A

DENS ADJ RAR-SET

DENS ADJ TEST

BLT REFLECT TEST

LEV0 V/D OUT YMC

LEV0 V/D OUT K

Note: The motor keeps rotating if holding

down the [ENTER] key for two

seco when determining the choice

of the motor. (The motor stops when

the [CANCEL] key is pressed.)

Note: Press and hold down (3 sec) the [ENTER] key to

define a parameter.

Note: Press and hold down (3 sec) the [ENTER]

key to define a parameter.

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5.3.2 Normal self-diagnostic mode (Level 1)

The menus of the normal self-diagnostic mode are indicated below.

Table 5-3 Maintenance Utility Adjustment Items

Maintenance Utility

1

2

3

4

5

6

7

8

9

10

No.19

No.20

Not operable

No.21

No.21

No.14

No.14

No.3

No.25

No.26

ML3600n

(With a Panel)

Item AdjustmentSelf-diagnosis Menu

Switch scan
test

Motor clutch
test

Execution of
test print

Color drift
correction test

Density
correction test

Indication of
consumable
part counter

Indication of
consumable
part
continuance
counter

Factory/
Shipping mode
switching

Check of Fuse
status

Engine
parameter setup

SWITCH SCAN

MOTOR&CLTCH
TEST

TEST PRINT

REG ADJUST TEST

DENS ADJ TEST

CONSUMABLE
STATUS

PRINTER STATUS

FACTORY MODE

SET

SENSOR SETTING

Checking of inlet sensor and switch

Operation test of motor and clutch

Print of test patterns built in PU

Judgment of good/bad color drift
correction mechanism.

Judgment of good/bad density
correction mechanism.

Indication of consumed state of
consumables

Indication of lifetime consumed state
of consumables

Switching between Factory mode
and Shipping mode

Indication of the status of each fuse

Setup of Enable/Disable of error
detection by various sensors

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5.3.2.1 Activation method for self-diagnostic mode (Level 1)

1. The system maintenance menu mode is activated when the power is turned on with the MENU+
and MENU- keys held down simultaneously

2. Press the MENU+ or MENU- key several times, until "ENGINE DIAG MODE" is displayed.
Pressing the ENTER key causes "DIAGNOSTIC MODE" to appear.

DIAGNOSTIC MODE
XX.XX.XX FACTORY/SHIPPING

SWITCH SCAN

PAPER ROUTE:PU

1=H 2=L 3=H 4=L

3. XX.XX.XX of "DIAGNOSTIC MODE XX.XX.XX" which is displayed in the LCD section is the
version of the PU firmware. The set value of FACTORY WORKING MODE is indicated in the
lower line to the right. Normally, S-MODE for "SHIPPING" is displayed.

4. Pressing the MENU+ or MENU- key takes you to each self-diagnostic step. (The menu items
rotate as the MENU+ or MENU- key is pressed.)

5.3.2.2 Deactivation of self-diagnostic mode

1. Turn the power off, and on again after ten seconds.

5.3.3 Switch scan test

This self-diagnosis is practiced to check the inlet sensors and switches.

1. Activate the self-diagnostic mode (Level 1), press and hold down the MENU+ or MENU- key,
until "SWITCH SCAN" appears in the upper line of the display section, and then, press the
ENTER key. (The MENU+ key increments a test item, and the MENU- key decrements a test
item.)

2. Press and hold down the MENU+ or MENU- key, until the item corresponding to the unit of
Table 5-3 now to be tested appears in the lower line of the display section. (The MENU+ key
increments a test item, and the MENU- key decrements a test item.)

3. Pressing the ENTER key initiates the test, and the name and current status of the corresponding
unit are displayed.

Note)

Pressing and holding down (2 sec) the [ENTER] key when a motor is decided causes
the motor to keep running.

Conduct this operation on each unit (Figure 5-1). The indications are produced in the
corresponding LCD display. (The indications vary from one sensor to another. See Table 5-3
for details).

4. Pressing the CANCEL key restores the status of Item 2 above.

5. Repeat Items 2 to 4, as needed.

6. To end the test, press the BACK key. (The status of Item 1 will be restored).

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Write sensor

Exit sensor

Paper-end sensor

Inlet sensor 1

Temperature/Humidity
sensor

Inlet sensor 2

Hopping solenoid

Hopping motor

Belt motor

Fuser motor

ID Up/Down motor

ID Up/Down sensor

ID motor

Toner sensor K

Toner sensor Y

Toner sensor M

Toner sensor C

RFID antenna M

RFID antenna C

RFID antenna K

RFID antenna Y

Color registration sensor (L)
Color registration sensor (R)

Density sensor

Fuser thermistor
lower

Fuser thermistor upper/
Compensation thermistor

Figure 5-1 Switch Sensor Positions

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