Olivetti PG L2130, PG L2135 Service Manual

SERVICE

MANUAL

PG L2130 / PG L2135

CAUTION

RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF
USED BATTERIES ACCORDING TO THE INSTRUCTIONS.

It may be illegal to dispose of this battery into the municipal waste stream. Check with your local
solid waste officials for details in your area for proper disposal.

ATTENTION

IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE
TYPE INCORRECT. METTRE AU REBUT LES BATTERIES UTILISEES SELON LES INSTRUC­TIONS DONNEES.

Il peut être illégal de jeter les batteries dans des eaux d’égout municipales. Vérifiez avec les fonc­tionnaires municipaux de votre région pour les détails concernant des déchets solides et une mise
au rebut appropriée.

This page is intentionally left blank.

Safety precautions

This booklet provides safety warnings and precautions for our service personnel t o ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

Safety warnings and precautions

Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:

DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance

with warning messages using this symbol.

CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

Symbols

The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.

General warning.

Warning of risk of electric shock.

Warning of high temperature.

indicates a prohibited action. The specific prohibition is shown inside the symbol.

General prohibited action.

Disassembly prohibited.

indicates that action is required. The specific action required is shown inside the symbol.

General action required.

Remove the power plug from the wall outlet.

Always ground the copier.

1.Installation Precautions

WARNING

• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check

that it is adequate for the rated current. .............................................................................................

• Connect the ground wire to a suitable g rou nding point. Not grounding the copier may cause fire o r
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the follo wing: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not ap proved by the

proper authorities. ............................................................................................................................

CAUTION:

• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .......

• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ................

• Do not install the copier near a radiator, heater, other heat source or near flammable material.

This may cause fire. .........................................................................................................................

• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool

as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ...........

• Always handle the machine by the correct locations when moving it. ...............................................

• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause

the copier to move unexpectedly or topple, leading to injury. ...........................................................

• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is acciden­tally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immedi­ately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical

attention. ......................................................................................................................................

• Advice customers that they must always follow the safety warnings and precautions in the copier’s

instruction handbook. .....................................................................................................................

2.Precautions for Maintenance

WARNING

• Always remove the power plug from the wall outlet before starting machine disassembly. ...............

• Always follow the procedures for maintenance described in the service manual and other related

brochures. ....................................... ... ... ... .... ... ... .......................................... ... .... ... ... ......................

• Under no circumstances attempt to bypass or disable safety features inclu ding safety mechanisms

and protective circuits. .......................................... .... ... ... ... ... .... .......................................................

• Always use parts having the correct specifications. ..........................................................................

• Always use the thermostat or thermal fuse specified in the service manual or other related bro­chure when replacing them. Using a piece of wire, for example, could lead to fire or other serious

accident. ..........................................................................................................................................

• When the service manual or other serious brochure specifies a distance or ga p for inst alla tion of a

part, always use the correct scale and measure carefully. ................................................................

• Always check that the copier is correctly connected to an outlet with a ground connection. .............

• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it

is dirty, clean it to remove the risk of fire or electric shock. ..............................................................

• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may

damage eyesight. ....................................... ... .... ... ... ... ... .......................................... .... ... ................

• Handle the charger sections with care. They are charged to hig h potentials and ma y cause electric

shock if handled improperly. ............................................................................................................

CAUTION

• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are

safely secured so they will not be caught in rotating sections. ..........................................................

• Use utmost caution when working on a powered machine. Keep away from chains and belts. ........

• Handle the fixing section with care to avoid burns as it can be extremely hot. ..................................

• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause

abnormally high temperatures. ........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement. ....................

• Do not pull on the AC power cord or connector wires on high-voltage components when removing

them; always hold the plug itself. ................................... .... ... ... ... .......................................... ...........

• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a

cable cover or other appropriate item. .............................................................................................

• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ........

• Remove toner completely from electronic components. ...................................................................

• Run wire harnesses carefully so that wires will not be trapped or damaged. ....................................

• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special atte ntion sh ould b e p aid to any forgo tten con nector,

trapped wire and missing screws. ...................................................................................................

• Check that all the caution labels that should be present on the machine according to the instruction

handbook are clean and not peeling. Replace with new ones if necessary . ......................................

• Handle greases and solvents with care by following the instructions below: .....................................

· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely .

· Ventilate the room well while using grease or solvents.

· Allow applied solvents to evaporate completely before refitting the covers or turning the power
switch on.

· Always wash hands afterwards.

• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to

fire in a furnace, etc. .......................................................................................................................

• Should smoke be seen coming from the copier, remove the power plug from the wall outlet imme-

diately. ............................................................................................................................................

3.Miscellaneous

WARNING

• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the

specified refiner; it may generate toxic gas. .....................................................................................

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CONTENTS

1-1 Specifications

1-1-1 Specifications..........................................................................................................................................1-1-1

1-1-2 Parts names............................................................................................................................................1-1-3

(1) Overall...............................................................................................................................................1-1-3

(2) Operation panel.................................................................. ... ............................................................1-1-4

1-1-3 Machine cross section ............................................................................................................................1-1-5

1-2 Installation

1-2-1 Installation environment..........................................................................................................................1-2-1

1-2-2 Unpacking...............................................................................................................................................1-2-2

(1) Removing the tapes..........................................................................................................................1-2-3

1-2-3 Installing the expanded memory (option)................................................................................................1-2-4

1-2-4 Installing the memory card (option).........................................................................................................1-2-5

1-2-5 Installing the network interface card (option) ..........................................................................................1-2-6

1-3 Maintenance Mode

1-3-1 Maintenance mode .................................................................................................................................1-3-1

(1) Executing a service mode.................................................................................................................1-3-1

1-4 Troubleshooting

1-4-1 Paper misfeed detection.........................................................................................................................1-4-1

(1) Paper misfeed indication................................................. ... ...............................................................1-4-1

(2) Paper misfeed detection condition....................................................................................................1-4-2

1-4-2 Self-diagnostic function...........................................................................................................................1-4-3

(1) Self-diagnostic function.....................................................................................................................1-4-3

(2) Self diagnostic codes indication ........................................................................................................1-4-4

(3) Self diagnostic codes ........................................................................................................................1-4-5

1-4-3 Image formation problems......................................................................................................................1-4-9

(1) Completely blank printout................................................................................................................1-4-10

(2) All-black printout..............................................................................................................................1-4-10

(3) Dropouts..........................................................................................................................................1-4-11

(4) Black dots........................................................................................................................................1-4-11

(5) Black horizontal streaks..................................................................................................................1-4-11

(6) Black vertical streaks.......................................................................................................................1-4-12

(7) Unsharpness...................................................................................................................................1-4-12

(8) Gray background.............................................................................................................................1-4-12

(9) Dirt on the top edge or back of the paper........................................................................................1-4-13

(10) Undulated printing at the right edge (scanning start position).........................................................1-4-13

1-4-4 Electric problems ..................................................................................................................................1-4-14

1-4-5 Mechanical problems............................................................................................................................1-4-16

1-5 Assembly and Disassembly

1-5-1 Precautions for assembly and disassembly............................................................................................1-5-1

(1) Precautions .......................................................................................................................................1-5-1

(2) Drum..................................................................................................................................................1-5-1

(3) Toner container.................................................................................................................................1-5-1

1-5-2 Outer covers ...........................................................................................................................................1-5-3

(1) Detaching and refitting the top cover.................................................................................................1-5-3

(2) Detaching and refitting the right and left covers................................................................................1-5-4

1-5-3 Paper feed section..................................................................................................................................1-5-6

(1) Detaching and refitting the paper feed assembly (paper feed roller and pickup roller).....................1-5-6

(2) Detaching and refitting the retard roller assembly.............................................................................1-5-8

(3) Detaching and refitting the MP paper feed roller.............................................................................1-5-10

1-5-4 Developing section................................................................................................................................1-5-11

(1) Detaching and refitting the developing unit.....................................................................................1-5-11

1-5-5 Drum section.........................................................................................................................................1-5-12

(1) Detaching and refitting the drum unit ..............................................................................................1-5-12

(2) Detaching and refitting the main charger unit..................................................................................1-5-13

1-5-6 Transfer/separation section ..................................................................................................................1-5-14

(1) Detaching and refitting the transfer roller........................................................................................1-5-14

1-5-7 Fuser section ............................................... ... ......................................................................................1-5-16

(1) Detaching and refitting the fuser unit...............................................................................................1-5-16

(2) Switching the fuser pressure...........................................................................................................1-5-18

1-5-8 PWBs....................................................................................................................................................1-5-19

(1) Detaching and refitting the control PWB .........................................................................................1-5-19

(2) Detaching and refitting the power source PWB...............................................................................1-5-22

(3) Detaching and refitting the operation panel PWB ...........................................................................1-5-24

(4) Detaching and refitting the high voltage PWB.................................................................................1-5-25

1-5-9 Others...................................................................................................................................................1-5-29

(1) Detaching and refitting the main motor ...........................................................................................1-5-29

(2) Detaching and refitting the laser scanner unit.................................................................................1-5-30

(3) Detaching and refitting the eraser lamp ..........................................................................................1-5-32

(4) Direction of installing the left and right cooling fan motors..............................................................1-5-33

1-6 Firmware

1-6-1 Downloading firmware ............................................................................................................................1-6-1

(1) Downloading the firmware from the memory card.............................................................. ... ............1-6-2

2-1 Mechanical Construction

2-1-1 Paper feed/conveying section.................................................................................................................2-1-1

(1) Cassette paper feed section..............................................................................................................2-1-1

(2) MP tray paper feed section ...............................................................................................................2-1-2

(3) Paper conveying section........................... ... .....................................................................................2-1-3

2-1-2 Drum section...........................................................................................................................................2-1-4

(1) Drum section.....................................................................................................................................2-1-4

(2) Main charger unit...............................................................................................................................2-1-5

2-1-3 Expose section........................................................................................................................................2-1-6

(1) Laser scanner unit................................................................. ............................................................2-1-6

2-1-4 Developing section..................................................................................................................................2-1-8

2-1-5 Transfer/separation section ....................................................................................................................2-1-9

2-1-6 Cleaning section ...................................................................................................................................2-1-10

2-1-7 Fuser section ............................................... ... ......................................................................................2-1-11

2-1-8 Paper exit section .................................................................................................................................2-1-13

2-1-9 Duplex/conveying section.....................................................................................................................2-1-15

2-2 Electrical Parts Layout

2-2-1 Electrical parts layout..............................................................................................................................2-2-1

(1) PWBs ................................................................................................................................................2-2-1

(2) Switches and sensors .......................................................................................................................2-2-2

(3) Other electrical components..............................................................................................................2-2-3

2-3 Operation of the PWBs

2-3-1 Power source PWB.................................................................................................................................2-3-1

2-3-2 Control PWB....................... ... .................................................................................................................2-3-3

2-4 Appendixes

2-4-1 Appendixes.............................................................................................................................................2-4-1

(1) Wiring diagraml .................................................................................................................................2-4-1

(2) Repetitive defects gauge...................................................................................................................2-4-2

(3) Self diagnostic codes indication (Animation).....................................................................................2-4-3

(4) Maintenance parts list .......................................................................................................................2-4-5

1-1-1

1-1 Specifications

1-1-1 Specifications

Type................................................Desktop

Printing method...............................Electrophotography, laser scan

Paper weight...................................Cassette: 60 to 120 g/m

2

(Duplex: 60 to 105 g/m2)

MP tray: 60 to 220 g/m

2

Paper type ......................................Cassette:

Plain, Preprinted, Bond, Recycled, Rough, Letterhead, Color (Colour), Prepunched,
High quality, Custom 1 to 8

MP tray:

Plain, Transparency, Preprinted, Labels, Bond, Recycled, Rough, Vellum,
Letterhead, Color (Colour), Prepunched, Envelope, Cardstock, Thick paper,
High quality, Custom 1 to 8

Paper size ........................................Cassette:

A4, JIS B5, A5, Follio, Legal, Letter, Oficio II, Statement, Executive, A6, B6, ISO B5,
Envelope C5, 16K, Custom (105 × 148 to 216 × 356 mm/4

1/8

× 5

13/16

" to 8

1/2

× 14")

MP tray:

A4, JIS B5, A5, Follio, Legal, Letter, Oficio II, Statement, Executive, A6, B6, ISO B5,
Envelope C5, Envelope #10, Envelope #9, Envelope #6-

3/4

, Envelope Monarch,

Envelope DL, Hagaki, Ofuku Hagaki, 16K, Yokei 2, Y okei 4, Custom (70

×

148 to 216 ×

356 mm/2

13/16

× 5

13/16

" to 8

1/2

× 14")

Zoom level......................................25 to 400%, 1% increments

Printing speed.................................30/32 ppm model (A4/Letter)

Simplex printing Duplex printing
A4: 30 ppm A4: 17 ppm
Letter: 32 ppm Letter: 18 ppm
A5: 17 ppm

35/37 ppm model (A4/Letter)

Simplex printing Duplex printing
A4: 35 ppm A4: 19 ppm
Letter: 37 ppm Letter: 20 ppm
A5: 20 ppm

First print time.................................30/32 ppm model (A4/Letter)

6 s or less (A4, feed from cassette)

35/37 ppm model (A4/Letter)

7 s or less (A4, feed from cassette)

Warm-up time.................................Room temperature 22

°C/71.6°F, 60% RH

120 V AC model

Power on: 20 s or less
Sleep mode:15 s or less

220 - 240 V AC model

Power on: 19 s or less
Sleep mode:14 s or less

Paper capacity................................Cassette:250 sheets (80 g/m

2

, Letter/A4 or smaller)

MP tray: 50 sheets (80 g/m

2

, Letter/A4 or smaller)

Output tray capacity........................Simplex printing: 250 sheets (80 g/m2)

Duplex printing: 200 sheets (80 g/m

2

)

Continuous printing.........................1 to 999 sheets

Photoconductor...............................OPC drum (diameter 30 mm)

Image write system .........................Semiconductor laser (1 beam)

Charging system.............................Scorotron (positive charging)

Developing system .........................Mono component dry developing method

Toner replenishing: Automatic from the toner container

Transfer system..............................Transfer roller (negative-charged)

Separation system..........................Small diameter separation, discharger brush

Cleaning system.............................Drum: Counter blade

Charge erasing system...................Exposure by eraser lamp (LED)

Fusing system.................................Heat roller system

Resolution .......................................30/32 ppm model (A4/Letter)

Fast 1200 mode, 600 dpi, 300 dpi

35/37 ppm model (A4/Letter)

Fine 1200 mode, Fast 1200 mode, 600 dpi, 300 dpi

Y 112480 - 6 Service Manual

Operating environment...................Temperature: 10 to 32.5

°C/50 to 90.5 °F

Humidity: 15 to 80%

Altitude: 2,500 m/8,202 ft maximum

Brightness: 1,500 lux maximum

Controller........................................PowerPC 405F5/360 MHz

Supported OS.................................Microsoft Windows 2000/XP/Vista/7, Windows Server 2003/2008, Mac OS X 10.x

Interface..........................................Standard: Hi-Speed USB × 1

Option: Network interface card × 1 (10BASE-T/100BASE-TX)

PDL.................................................PRESCRIBE

Memory...........................................Standard: 32 MB

Maximum: 544 MB

Dimension (W × D × H)...................375 × 393 × 250 mm

14 3/4 × 15 1/2 × 9 7/8"

Weight (without toner container).....12 kg/26.5 lb

Power source..................................120 V AC, 60 Hz, 8.0 A/220 to 240 V AC, 50 Hz, 4.2 A

Power consumption........................30/32 ppm model (A4/Letter)

[Standard]

120 V AC model 220 - 240 V AC model
Maximum: 911 W 976 W
During printing: 555.1 W 524.1 W
During standby: 6.6 W (EcoF user ON) 7.3 W (EcoFuser ON)

79.8 W (EcoFuser OFF) 82.0 W (EcoFuser OFF)

Sleep mode: 4.3 W 4.4 W
[Full options]

120 V AC model 220 - 240 V AC model
Maximum: 921 W 986 W
During printing: 559.2 W 527.1 W
During standby: 9.2 W (EcoF user ON) 9.2 W (EcoFuser ON)

81.1 W (EcoFuser OFF) 80.8 W (EcoFuser OFF)

Sleep mode: 6.4 W 6.5 W

35/37 ppm model (A4/Letter)

[Standard]

120 V AC model 220 - 240 V AC model
Maximum: 917 W 981 W
During printing: 573.9 W 543.6 W
During standby: 6.5 W (EcoF user ON) 7.2 W (EcoFuser ON)

76.5 W (EcoFuser OFF) 80.1 W (EcoFuser OFF)

Sleep mode: 4.2 W 4.3 W
[Full options]

120 V AC model 220 - 240 V AC model
Maximum: 933 W 995 W
During printing: 592.9 W 561.1 W
During standby: 9.9 W (EcoF user ON) 10.0 W (EcoFuser ON)

81.1 W (EcoFuser OFF) 82.9 W (EcoFuser OFF)

Sleep mode: 6.6 W 6.6 W

Options ...........................................30/32 ppm model (A4/Letter)

Expanded memory, Paper feeder (250-sheet × 1), Network interface card (IB-23)

35/37 ppm model (A4/Letter)

Expanded memory, Paper feeder (250-sheet × 2), Network interface card (IB-23)

NOTE: These specifications are subject to change without notice.

1-1-2

Service Manual Y 112480 - 6

1-1-3

1-1-2 Parts names

(1) Overall

Figure 1-1-1

2

3

4

1

7

9

6

10

11

12

13

14

8

5

1. Top cover

2. Paper stopper

3. Top tray

4. Operation panel

5. Right side cover

6. Cassette

7. Front cover

8. MP tray

9. Sub tray

10. Optional interface slot cover

11. USB interface connector

12. Rear cover

13. Power cord connector

14. Power switch

Y 112480 - 6 Service Manual

1-1-4

(2) Operation panel

Figure 1-1-2

1

2

3

4

5

6

7

8

1. Ready indicator

2. Attention indicator

3. Toner indicator

4. Data indicator

5. Paper indicator

6. Jam indicator

7. Cancel key

8. GO key

Service Manual Y 112480 - 6

1-1-5

1-1-3 Machine cross section

l

Figure 1-1-3

13

2

456811

12

9

10 13

7

Paper path

Light path

Paper path

(option)

1. Cassette

2. MP tray

3. Paper feed/conveying section

4. Toner container

5. Developing unit

6. Main charger unit

7. Drum unit

8. Laser scanner unit

9. Transfer/separation section

10. Fuser section

11. Exit section

12. Top tray

13. Duplex/conveying section

Y 112480 - 6 Service Manual

1-1-6

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Service Manual Y 112480 - 6

1-2-1

1-2 Installation

1-2-1 Installation environment

1. Temperature: 10 to 32.5°C/50 to 90.5°F

2. Humidity: 15 to 80%RH

3. Power supply: 120 V AC, 8.0 A
220 - 240 V AC, 4.2 A

4. Power source frequency: 50 Hz ±0.3%/60 Hz ±0.3%

5. Installation location

Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or
other strong light when removing paper jams.
Avoid locations subject to high temperature and high humidity or low temperature and low humidity; an abrupt
change in the environmental temperature; and cool or hot, direct air.
Avoid places subject to dust and vibrations.
Choose a surface capable of supporting the weight of the machine.
Place the machine on a level surface (maximum allowance inclination: 1

°).

Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor, such as mer­cury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.
Select a well-ventilated location.

6. Allow sufficient access for proper operation and maintenance of the ma chine.

Machine front: 500 mm/19

11/16"

Machine rear: 200 mm/7 7/8"
Machine right: 300 mm/11

13/16"

Machine left: 300 mm/1113/16"
Machine top: 400 mm/15 3/4"

Figure 1-2-1

300 mm
11

13/16"

300 mm
11 13/16"

200 mm
7 7/8"

500 mm
19 11/16"

400 mm
15

3/4"

Y 112480 - 6 Service Manual

1-2-2

1-2-2 Unpacking

Figure 1-2-2

1

2

6

8

9

7

10

11

3

5

4

12

120 V AC model220 - 240 V AC model

14

14

13

16

18

19

17

15

15

1. Printer

2. Outer case

3. Bottom pad L

4. Bottom pad R

5. Machine cover

6. Top pad L

7. Top pad R

8. Spacer

9. Toner container

10. Plastic bag

11. Power cord

12. Pad

13. Plastic bag

14. Installation guide

15. Panel GFIS sheet

16. EEA information leaflet

17. Operation guide

18. Energy star leaflet

19. CD-ROM

Service Manual Y 112480 - 6

1-2-3

(1) Removing the tapes

Procedure

1. Remove three tapes.

Figure 1-2-3

Tape

Tape

Tape

Y 112480 - 6 Service Manual

1-2-4

1-2-3 Installing the expanded memory (optio n)

Procedure

1. Turn off printer po w e r switch.

Caution: Do not insert or remove expanded
memory while printer power is on.
Doing so may cause damage to the printer
and the expanded memory.

2. Remove the right side cover.

3. Remove the tape.

Figure 1-2-4

4. Open the memory slot cover.

5. Open clamps on both ends of the memory

socket on the control PWB.

6. Insert the expanded memory into the mem-

ory socket so that the notches on the mem­ory align with the corresponding protrusions
in the slot.
The memory module is secured to the mem­ory socket with the clamps.

7. Close the memory slot cover.

8. Refit the right side cover.

9. Print a status page to check the memory

expansion (See page P.1-3-2).
If memory expansion has been properly per­formed, information on the installed memory
is printed with the total memory capacity has
been increased. Standard memory capacity
32 MB.

Figure 1-2-5

Right side cover

Tape

Memory slot cover

Expanded memory

Clamp

Clamp

Memory socket

Service Manual Y 112480 - 6

1-2-5

1-2-4 Installing the memory card (option)

Procedure

1. Turn off printer po w e r switch.

Caution: Do not insert or remove memory
card while printer power is on.
Doing so may cause damage to the printer
and the memory card.

2. Open the rear cover.

Figure 1-2-6

3. Remove two screws and then remove the

optional interface slot cover.

4. Insert the memory card into the memory

card slot. Push it in all the way.

5. Secure the optional interface slot cover by

using two screws.

6. Format the memory card before use.

To format the memory card:
Send the following PRESCRIBE command
sequence from the PC to the printer.

!R! RWER F, A; EXIT;

Note: To send a PRESCRIBE command
sequence to the printer, use COMMAND
CENTER (the printer's embedded web)
while the printer is connected to the PC via
its network interface.

Figure 1-2-7

Rear cover

Screw

Optional interface
slot cover

Screw

Memory card

Memory card slot

Y 112480 - 6 Service Manual

1-2-6

1-2-5 Installing the network interface card (option)

Procedure

1. Turn off printer po w e r switch.

Caution: Do not insert or remove network
interface card while printer power is on.
Doing so may cause damage to the printer
and the network interface card.

2. Open the rear cover.

Figure 1-2-8

3. Remove two screws and then remove the

optional interface slot cover.

4. Insert the network interface card into the

network interface slot. Push it in all the way.

5. Secure the network interface card by using

two screws.

Figure 1-2-9

Rear cover

Screw

Screw

Optional interface
slot cover

Network
interface slot

Network interface
card

Service Manual Y 112480 - 6

1-3-1

1-3 Maintenance Mode

1-3-1 Maintenance mode

The product incorporates several service modes which are activated by using the keys on the operation panel or by com­manding from a PC.

(1) Executing a service mode

Printing a status page for service purpose...................................See page 1-3-2.

Printing an event log (EVENT LOG)............................................See page 1-3-6.

Toner install mode........................................................................See page 1-3-12.

Y 112480 - 6 Service Manual

1-3-2

Service items Description

Printing a status page
for service purpose

Description

Prints a status page for service purpose. The status page includes various printing settings
and service cumulative.

Purpose

To acquire the current printing environmental parameters and cu mulative information.

Procedure

1. Press the GO key for 10 seconds or more.
Two pages will be printed. (The second page includes service information.)

Figure 1-3-1 Service status page

Released: 20/January/2010

Firmware version: 2LZ_3000.001.024

Firmware version: 132.00

Service Information

Released: 20/January/2010

[XXXXXXXX][XXXXXXXX][01/00] Printed Page(s) 9690
/t/U00/F00/N00
/0020/0020/1061/0811/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/

/0000/0000/

/00/300/81/31/81/31/

A:1234567890123456

/02870284/03028003/83030286/86000086/02000000/02020202/02020202/
/03030303/03030303/03030303/03030303/03000000/03030303/03030303/
SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E

/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/

/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
XXXXXXXX
/00000000/00000000/00000000000000000000000000000000/00000000000000000000000000000000/0000/00/00

SN:SPL9200010

Service information
(Refer to next page) Control PWB firmware version Firmware release date

Service Manual Y 112480 - 6

1-3-3

Detail of service information

Figure 1-3-2 Detail of service information

Service items Description

[XXXXXXXX][XXXXXXXX][01/00]

/t/U00/F00/N00

/0020/0020/1061/0811/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/

/0000/0000/

/00/300/81/31/81/31/

A:1234567890123456

/02870284/03028003/83030286/86000086/02000000/02020202/02020202/
/03030303/03030303/03030303/03030303/03000000/03030303/03030303/
SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E

/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
/8088808880808000/8088808880808000/8088808880808000/8088808880808000
XXXXXXXX
/00000000/00000000/00000000000000000000000000000000/00000000000000000000000000000000/0000/00/00

SN:SPL9200010

Service information

(2) (3)

(4)

(1)

(6)

(7)

(8)

(9)

(13)

(20)

(21)
(23)

(22)

(24)

(25)

(26)
(27)

(28)

(14)(15)(16)(17)(18)(19)

(5)

(10) (11) (12)

Total page 9690

Y 112480 - 6 Service Manual

1-3-4

Service items Description

Code conversion

ABCDEFGHI J

0123456789

No. Items Description

(1) Engine ROM information [Flash ROM version]
(2) Boot ROM information [Boot ROM version]
(3) Software jumper switch

information
(hexadecimal)
[First byte/Second byte
(displayed in OEM model
only)]

First byte
bit 0 = 1: (Fixed)
bit 1 = 0: Overseas, 1: Domestic (Japan)
bit 2, 3 (Not used)
bit 4 = 0: Kyocera, 1: OEM
bit 5 = 0: For Europe, 1: For US
bit 6 = 0: Non MICR mode, 1: MICR mode
bit 7 (Not used)

Second byte: Displayed in OEM model only
(4) Total page ­(5) Toner install information ­(6) USB information 00: Not connected

01: Full-Speed

02: Hi-Speed
(7) Operation panel lock sta-

tus (displayed only when
locked)

01: Partial lock

02: Full lock

(8) NVRAM error (displayed

only when any error has
occurred)

01: ID error

02: Version error

03: Checksum error

04: NVRAM crush error
(9) Printable area setting /Top offset/Left offset/Page length/Page width

(10) Left offset for each paper

source

/MP tray/Cassette1/Cassette 2/Cassette 3/Duplex

(1/600 inches unit)

(11) Top offset for each paper

source

/MP tray/Cassette 2/Cassette 3/Duplex

(1/600 inches unit)

(12) Offset for rotation /Top offset/Left offset/

(1/600 inches unit)

(13) Optional paper feeder ver-

sion

/Paper feeder 1/Paper feeder 2/

(14) Calibration table setting Setting value (FRPO I4), Hexadecimal
(15) Resolution Current value of bit-per-pixel
(16) Copy quantity ­(17) Installed device/function

information

bit0: HDD

bit1: Optional ROM

bit2: Memory card

bit3: USB memory

bit4: HDD security

(18) Operation panel message

language

PMSG command setting (decimal)

(19) Current temperat ure

0 to 50 °C/32 to 122 °F (in 1 °C/1.8 °F increment, “-” = Temperature sensor

is abnormal.)

Service Manual Y 112480 - 6

1-3-5

Service items Description

No. Items Description

(20) Fixed asset number (Maximum 16 characters)
(21) Paper type attributes Paper type setting value from 1 to 28 (fuser, weight, duplex)

(unused paper type are always 0x00.)

(22) Paper type attributes Paper type setting value from 1 to 28 (density)

(unused paper type are always 0x00.)

(23) Memory SPD information (slot 1)2 to 6 bytes, 8 to 36 bytes, 94 to 95 bytes (total 32 bytes)

(24) DRT correction coefficient 4 bytes × 11 × 23 groups
(25) Engine parameter Hexadecimal, 256 bytes
(26) RFID reader/writer version

information

-

(27) RFID information ­(28) Machine serial number -

NOTE:

Code conversion

ABCDEFGH I J

0123456789

Y 112480 - 6 Service Manual

1-3-6

Printing an event log
(EVENT LOG)

Description

Prints a history list of occurrences of paper jam, self-diagnostics, toner replacements, etc.

Purpose

To allow machine malfunction analysis based on the frequency of paper misfeeds, self diag­nostic errors and replacements.

Procedure

1. Connect the USB cable between printer and PC.

Figure 1-3-3

2. Connect the power cord.

3. Turn printer power on. Make sure the printer is ready.

4. At the DOS prompt, send the following command to the printer:
echo !R! ELOG;EXIT;>prn
Event log will be printed.

Service items Description

To PC

USB cable

USB interface
connector

Service Manual Y 112480 - 6

1-3-7

Figure 1-3-4Event log (EVENT LOG)

Service items Description

[EB20MA001/2LZ_1000.001.019] [40.00SFLB] [01]

Printed page(s) 12345

SN:SPL0000000

Firmware version: 2LZ_30000.001.024

10.48.01.80.01.01

10.48.01.80.01.01

10.48.01.80.01.01

10.48.01.80.01.01

10.48.01.80.01.01

10.48.01.80.01.01

10.48.01.80.01.01

10.48.01.80.01.01

J10: 0 C:6000: 4 T00: 1
J11: 0 C:6020: 1
J12: 0
J20: 0
J21: 0
J22: 0
J30: 0
J31: 0
J32: 0
J40: 0
J41: 0
J42: 0

Released: 20/January/2010

# Count. Event # Count. Service Code

8 11234 01.6000
7 10000 01.6000
6 9999 01.6000
5 9998 01.6000
4 9997 01.6000
3 9996 01.6000
2 9995 01.6000
1 9994 01.6000

8 11234 01.00
7 10000 01.00
6 9999 01.00
5 9998 01.00
4 9997 01.00
3 9996 01.00
2 9995 01.00
1 9994 01.00

# Count. item

(1)

(6)

(7)

(2)

(9)(8)

(12)

(10)

(11)

5 9800 01.00
4 9700 01.00
3 9600 01.00
2 9500 01.00
1 9400 01.00

# Count. item

(3) (4)

(5)

(i)

8 9993
7 9992
6 9991
5 9990
4 9989
3 9979
2 9969
11

(h)

(g)

Unknown Toner Log

Counter Log

Maintenance Log

Service Call LogPaper Jam Log

EVENT LOG

10.48.01.80.01.01

(a) (b) (c) (d) (e) (f)

Y 112480 - 6 Service Manual

1-3-8

Detail of event log (EVENT LOG) information

Service items Description

No. Items Description

(1) Control PWB mask version [Engine mask version/Engine software version]
(2) BROM version ­(3) Software jumper switch informa-

tion
(hexadecimal)
[First byte/Second byte (dis­played in OEM mode only)]

First byte
bit 0 = 1: (Fixed)
bit 1 = 0: Overseas, 1: Domestic (Japan)
bit 2, 3 (Not used)
bit 4 = 0: Kyocera, 1: OEM
bit 5 = 0: For Europe, 1: For US
bit 6 = 0: Non MICR mode, 1: MICR mode
bit 7 (Not used)

Second byte: Displayed in OEM mode only
(4) Control PWB firmware version ­(5) Control PWB firmware release

date

-

(6) Total page counter ­(7) Printer serial number ­(8) Paper Jam Log # Count. Event

Remembers 1 to 8 of

occurrence. If the occur-

rence of the previous

paper jam is less than 8,

all of the paper jams are

logged. When the occur-

rence excesseds 8, the

oldest occurrence is

removed.

The total page count
at the time of the
paper jam.

Log code (2 digit,
hexadecimal, 6
categories)

(a) Cause of a

paper jam

(b) Position of

paper jam
(c) Paper source
(d) Paper size
(e) Paper type
(f) Paper exit

Refer to the next
page for the details
of each log code.

Service Manual Y 112480 - 6

1-3-9

Service items Description

No. Items Description

(8)

cont.

Paper Jam
Log

(a) Cause of paper jam
10: Paper does not arrive at the registration sensor. (MP tray) [42]

10: Paper does not arrive at the registration sensor. (Cassette 1) [31]
10: Paper does not arrive at the registration sensor. (Cassette 2) [31]
10: Paper does not arrive at the registration sensor. (Cassette 3) [31]
10: Paper does not arrive at the registration sensor. (Duplex conveying) [49]
11: Paper does not pass the registration sensor. [48]
12: Paper remains at the registration sensor when power is turned on. [48]
20: Paper does not arrive at the exit sensor. [48]
21: Paper does not pass the exit sensor. [47]
22: Paper remains at the exit sensor when power is turned on. [47]
30: Paper does not arrive at the paper feeder 1’s PF paper feed sensor. (Cassette 2) [32]
30: Paper does not arrive at the paper feeder 1’s PF paper feed sensor. (Cassette 3) [33]
31: Paper does not pass the paper feeder 1’s PF paper feed sensor. (Cassette 2) [32]
32: Paper remains at the paper feeder 1’s PF paper feed sensor when power is turned on.

(Cassette 2) [32]
40: Paper does not arrive at the paper feeder 2’s PF paper feed sensor. (Cassette 3) [33]
41: Paper does not pass the paper feeder 2’s PF paper sensor. (Cassette 3) [33]
42: Paper remains at the paper feeder 2’s PF paper feed sensor when power is turned on.

(Cassette 3) [33]
A1: Paper does not arrive at the exit sensor. [47]
A3: Paper does not pass the exit sensor. [49]
E0: Paper misfeed occurs due to forced stop when an error occurs during printing. (such as

opening of a cover) [00]
F0 to FE: Paper misfeed by another cause. [00]

Note:
Values (hexadecimal) within [ ] indicate paper misfeed locations.

(b) Detail of jam location

Paper feeder 1

Paper feeder 2

Printer

[42]

[32]

[31]

[48]

[47]

[33]

(c)

(b)

(a)

(e)

(f)

(e)

(f)

(d)

(a) Registration sensor
(b) Paper sensor
(c) MP paper sensor
(d) Paper exit sensor
(e) PF paper sensor
(f) PF paper feed sensor

Sensors

[49]

[31] Cassette 1
[32] Cassette 2
[33] Cassette 3
[42] MP tray
[47] Fuser/Exit section
[48] Printer inside
[49] Duplex section

Paper jam location

Y 112480 - 6 Service Manual

1-3-10

Service items Description

No. Items Description

(8)

cont.

Paper Jam Log

(c) Detail of paper source (Hexadecimal)
00: MP tray

01: Cassette 1 (printer)
02: Cassette 2 (paper feeder 1)
03: Cassette 3 (paper feeder 2)
07: Duplex

(d) Detail of paper size (Hexadecimal)
00: (Undefined)

01: Monarch
02: Business
03: International DL
04: International C5
05: Executive
06: Letter-R
07: Legal
08: A4R

09: B5R
0D: A5R
0E: A6
0F: B6
10: Commercial #9
11: Commercial #6
12: ISO B5
13: Custom
1F: Post card

20: Reply-paid postcard
21: Oficio II
28: 16K-R
32: Statement-R
33: Folio
34: Western type 2
35: Western type 4

(e) Detail of paper type (Hexadecimal)
01: Plain

02: Transparency
03: Preprint
04: Labels
05: Bond
06: Recycle
07: Vellum
08: Rough

09: Letterhead
0A: Color
0B: Prepunched
0C: Envelope
0D: Cardstock
10: Thick
11: High quality
15: Custom 1

16: Custom 2
17: Custom 3
18: Custom 4
19: Custom 5
1A: Custom 6
1B: Custom 7
1C: Custom 8

(f) Detail of paper exit location (Hexadecimal)
01: Top tray

(9) Service Call

(Self diagnostic
error) Log

# Count. Service Code
Remembers 1 to 8 of occur-

rence of self diagnostics error.
If the occurrence of the previ-

ous diagnostics error is less
than 8, all of the diagnostics
errors are logged.

The total page count at
the time of the self diag­nostics error.

Self diagnostic error
code (See page 1-4-5)

Example

01.6000
01 means a self-diag-

nostic error; 6000
means a self diagnos­tic error code.

(10) Maintenance

Log
NOTE:

It is not logged if
100 or more
counts are not
added to the
count at the last
occurrence of
replacement.

# Count. Item
Remembers 1 to 8 of occur-

rence of replacement. If the
occurrence of the previous
replacement of toner con­tainer is less than 8, all of the
occurrences of replacement
are logged.

The total page count at
the time of the replace­ment of the toner con­tainer.

This is virtually logged as
the occurrence of the
“Toner Empty” condition
since the replacement of
the toner container is not
precisely detectable.

Code of maintenance
replacing item (1 byte, 2
categories)

First byte (Replacing
item)

01: Toner container

Service Manual Y 112480 - 6

1-3-11

Service items Description

No. Items Description

(11) Unknown Toner

Log
NOTE:

It is not logged if
100 or more
counts are not
added to the
count at the last
error.

# Count. Item
Remembers 1 to 5 of occur-

rence of unknown toner
detection.

If the occurrence of the previ­ous unknown toner detection
is less than 5, all of the
unknown toner detection are
logged.

The total page count at
the time of the “Toner
Empty” condition with
using an unknown toner
container.

Unknown toner log code
(1 byte, 2 categories)

First byte
01: Fixed (Toner con­tainer)

Second byte
00: Fixed (Black)

(12) Counter Log

Comprised of
three log counters
including paper
jams, self diag­nostics errors, and
replacement of
the toner con­tainer.

NOTE:
It is not logged if
100 or more
counts are not
added to the
count at the last
error.

(g) Paper jam (h) Self diagnostic error (i) Maintenance item

replacing

Indicates the log counter of
paper jams depending on
location.

Refer to (8) Paper Jam Log.
All instances including those

are not occurred are dis­played.

Indicates the log counter
of self diagnostics errors
depending on cause.
(See page 1-4-5)

Example
C6000: 4

Self diagnostics error
6000 has happened four
times.

Indicates the log counter
depending on the mainte­nance item for mainte­nance.

T: Toner container
00: Black

Example
T00: 1

The (black) toner con­tainer has been replaced
once.

Y 112480 - 6 Service Manual

1-3-12

Toner install mode Description

Replenishes toner rapidly from the toner container into the developing unit.

Purpose

To execute after replacing the developing unit to replenish toner rapidly into the developing
unit.

Procedure

Toner install mode is performed by simultaneously pressing and holding the GO and Cancel
keys for more than 5 seconds. To abort toner install mode, turn power on while pressing and
holding the GO and Cancel keys.

Service items Description

Service Manual Y 112480 - 6

1-4-1

1-4 Troubleshooting

1-4-1 Paper misfeed detection

(1) Paper misfeed indication

If paper jams in the paper conveying system, or no paper sheets are fed at all, the printer automatically goes offline, and
the jam indicator will flash rapidly. Status Monitor or COMMAND CENTER can indicate the location of the paper jam (the
component where the paper jam has occurred). After removing the jammed paper, the printer will resume printing.

Figure 1-4-1

Jam indicator

(Amber, Lit)

Y 112480 - 6 Service Manual

1-4-2

(2) Paper misfeed detection condition

Figure 1-4-2

Peper feeder 1
(Option)

Peper feeder 2
(Option)

Printer

(1) Registration sensor
(2) Paper sensor
(3) MP paper sensor
(4) Paper exit sensor
(5) PF paper sensor
(6) PF paper feed senso

r

(1)

(2)

(3)

(4)

(5)

(6)

(5)

(6)

Service Manual Y 112480 - 6

1-4-3

1-4-2 Self-diagnostic function

(1) Self-diagnostic function

The printer is equipped with self-diagnostic function which automatically halts the printer when an error is detected. The
four indicators (Jam, Paper, Attention, Toner) are simultaneously lit, then indicate a specific error by the combination of the
four indicators.

Figure 1-4-3

Jam indicator

(Amber, Lit)

Paper indicator

(Amber, Lit)

Attention indicato

r

(Amber, Lit)

Toner indicator

(Amber, Lit)

Y 112480 - 6 Service Manual

1-4-4

(2) Self diagnostic codes indication

Self diagnostic codes indication (Animation). See page 2-4-3.

Figure 1-4-4

0

1Code

Indicator

Code

Indicator

2345

67890F

2

6

1

1.6 s

1.6 s

0.8 s

0.8 s

0.8 s

0.8 s

0.8 s

0.8 s

Repeat

Example of self-diagnostic code: 2610
(Refer to the following code conversion table)

Code conversion table

Indicates the
occurrence of a self
diagnostics error.

Sequence of display

Lit (Green)

Lit (Amber)

Lit (Amber)

Off (Amber)

Off (Amber)

Off (Green)

Indication example

Service Manual Y 112480 - 6

1-4-5

(3) Self diagnostic codes

Code Contents

Remarks

Causes Check procedures/corrective measures

0150 Control PWB EEPROM error

Detecting control PWB EEPROM
(U300) communication error.

Improper installation
control PWB EEPROM
(U300).

Check the installation of the EEPROM
(U300) and remedy if necessary (See page
1-5-19).

Defective control
PWB.

Replace the control PWB (See page 1-5-

19).

0420 Paper feeder communication error

Communication error between con­trol PWB and optional paper feeder.

Improper installation
paper feeder.

Follow installation instruction carefully again.

Defective harness
between control PWB
(YC318) and paper
feeder interface con­nector, or improper
connector insertion.

Reinsert the connector. Also check for conti­nuity within the connector harness. If none,
remedy or replace the harness.

Defective control
PWB.

Replace the control PWB (See page 1-5-

19).

Defective harness
between PF main
PWB (YC5) and paper
feeder interface con­nector, or improper
connector insertion.

Reinsert the connector. Also check for conti­nuity within the connector harness. If none,
remedy or replace the harness (Refer to the
service manual for the paper feeder).

Defective PF main­PWB.

Replace the PF main PWB (Refer to the ser­vice manual for the paper feeder).

2000 Main motor error

The main motor ready input is not
given for 2 s during the main motor is
ON.

Defective harness
between main motor
(CN1) and control
PWB (YC305), or
improper connector
insertion.

Reinsert the connector. Also check for conti­nuity within the connector harness. If none,
remedy or replace the harness.

Defective drive trans­mission system of the
main motor.

Check if the rollers and gears rotate
smoothly. If not, grease the bushings and
gears. Check for broken gears and replace if

any.
Defective main motor. Replace the main motor (See page 1-5-29).
Defective control

PWB.

Replace the control PWB (See page 1-5-

19).

Y 112480 - 6 Service Manual

1-4-6

2610 PF paper feed motor error (Paper

feeder 1)

The PF paper feed motor of paper
feeder 1 ready input is not given for 2
s during the PF paper feed motor is
ON.

Defective harness
between PF paper
feed motor and PF
main PWB (YC4), or
improper connector
insertion.

Reinsert the connector. Also check for conti-

nuity within the connector harness. If none,

remedy or replace the harness (Refer to the

service manual for the paper feeder).

Defective drive
transmission system of
the PF paper feed
motor.

Check if the gears rotate smoothly. If not,

grease the bushings and gears. Check for

broken gears and replace if any.

Defective PF main
motor.

Replace the PF main motor (Refer to the

service manual for the paper feeder).
Defective control

PWB.

Replace the control PWB (See page 1-5-

19).

2620 PF paper feed motor error (Paper

feeder 2)

The PF paper feed motor of paper
feeder 2 ready input is not given for 2
s during the PF paper feed motor is
ON.

Defective harness
between PF paper
feed motor and PF
main PWB (YC4), or
improper connector
insertion.

Reinsert the connector. Also check for conti-

nuity within the connector harness. If none,

remedy or replace the harness (Refer to the

service manual for the paper feeder).

Defective drive
transmission system of
the PF paper feed
motor.

Check if the gears rotate smoothly. If not,

grease the bushings and gears. Check for

broken gears and replace if any.

Defective PF main
motor.

Replace the PF main motor (Refer to the

service manual for the paper feeder).
Defective control

PWB.

Replace the control PWB (See page 1-5-

19).

4000 Polygon motor (laser scanner unit)

error

The polygon motor ready input is not
given for 6 s during the polygon
motor is ON.

Defective harness
between polygon
motor and control
PWB (YC319), or
improper connector
insertion.

Reinsert the connector. Also check for conti-

nuity within the connector harness. If none,

remedy or replace the harness.

Defective laser scan­ner unit.

Replace the laser scanner unit (See page 1-

5-30).
Defective control

PWB.

Replace the control PWB (See page 1-5-

19).

Code Contents

Remarks

Causes Check procedures/corrective measures

Service Manual Y 112480 - 6

1-4-7

6000 Broken fuser heater lamp wire

The fuser temperature does not rise
after the fuser heater lamp has been
turned on.

Poor contact in the
fuser thermistor con­nector terminals.

Reinsert the connector (See page 1-5-16).

Poor contact in the
fuser heater lamp con­nector terminals.

Reinsert the connector (See page 1-5-16).

Fuser thermistor
installed incorrectly.

Replace the fuser unit (See page 1-5-16).

Fuser thermal cutout
triggered.

Replace the fuser unit (See page 1-5-16).

Fuser heater lamp
installed incorrectly.

Replace the fuser unit (See page 1-5-16).

Broken fuser heater
lamp wire.

Replace the fuser unit (See page 1-5-16).

6020 Abnormally high fuser thermistor

temperature

Fuser thermistor detects abnormally
temperature.

Shorted fuser ther­mistor.

Replace the fuser unit (See page 1-5-16).

Defective control
PWB.

Replace the control PWB (See page 1-5-

19).

6030 Broken fuser thermistor wire

Input from fuser thermistor is 0 (A/D
value).

Poor contact in the
fuser thermistor con­nector terminals.

Reinsert the connector (See page 1-5-16).

Broken fuser ther­mistor wire.

Replace the fuser unit (See page 1-5-16).

Fuser thermistor
installed incorrectly.

Replace the fuser unit (See page 1-5-16).

Fuser thermal cutout
triggered.

Replace the fuser unit (See page 1-5-16).

Fuser heater lamp
installed incorrectly.

Replace the fuser unit (See page 1-5-16).

Broken fuser heater
lamp wire.

Replace the fuser unit (See page 1-5-16).

6400 Zero cross signal er ror

The zero cross signal does not reach
the control PWB for specified time.

Defective harness
between high voltage
PWB (YC202) and
control PWB (YC311),
or improper connector
insertion.

Reinsert the connector. Also check for conti-

nuity within the connector harness. If none,

remedy or replace the harness (See page 1-

5-25).

Defective harness
between power source
PWB (YC103) and
high voltage PWB
(YC201), or improper
connector insertion.

Reinsert the connector. Also check for conti-

nuity within the connector harness. If none,

remedy or replace the harness (See page 1-

5-25).

Defective power
source PWB.

Replace the power source PWB (See page

1-5-22).
Defective control

PWB.

Replace the control PWB (See page 1-5-

19).

Code Contents

Remarks

Causes Check procedures/corrective measures

Y 112480 - 6 Service Manual

1-4-8

7990 Waste toner full

The waste toner sensor has detected
that the waste toner reservoir (drum
unit) is full.

Waste toner reservoir
(drum unit) is full.

Turn the main power switch off/on to restart

the printer. If the error is not resolved,

replace the drum unit (See page 1-5-12).
Defective waste toner

sensor.

Replace the waste toner sensor.

Defective control
PWB.

Replace the control PWB (See page 1-5-

19).

F010 Control PWB checksum error Defective code ROM

(flash memory).

Turn the power switch off/on to restart the

printer. If the error is not resolved, replace

the control PWB (See page 1-5-19).
Defective control

PWB.

Replace the control PWB (See page 1-5-

19).

F020 Control PWB RAM checksum error Defective main mem-

ory (RAM) on the con­trol PWB.

Turn the power switch off/on to restart the

printer. If the error is not resolved, replace

control PWB (See page 1-5-19).
Defective expanded

memory (DIMM).

Replace the expanded memory (DIMM)

(See page 1-2-4).

F030 Control PWB general failure Defective control

PWB.

Turn the power switch off/on to restart the

printer. If the error is not resolved, replace

control PWB (See page 1-5-19).

F040 Control PWB engine communica-

tion error

Defective control
PWB.

Turn the power switch off/on to restart the

printer. If the error is not resolved, replace

control PWB (See page 1-5-19).

F050 Control PWB engine checksum

error

Some error may have
occurred when down­loading the firmware of
the control PWB.

Download the firmware of the control PWB

again using the memory card (See page 1-

6-2).

Defective control
PWB.

Turn the power switch off/on to restart the

printer. If the error is not resolved, replace

control PWB (See page 1-5-19).

F226 Control PWB video data control

error

Defective control
PWB.

Turn the power switch off/on to restart the

printer. If the error is not resolved, replace

control PWB (See page 1-5-19).

Code Contents

Remarks

Causes Check procedures/corrective measures

Service Manual Y 112480 - 6

1-4-9

1-4-3 Image formation problems

(1)Completely blank
printout.

(2)All-black printout. (3)Dropouts. (4)Black dots. (5)Black horizontal

streaks.

See page 1-4-10 See page 1-4-10 See page 1-4-11 See page 1-4-11 See page 1-4-11

(6)Black vertical
streaks.

(7)Unsharpness. (8)Gray background. (9)Dirt on the top

edge or back of the
paper.

(10)Undulated print­ing at the right edge
(scanning start posi­tion).

See page 1-4-12 See page 1-4-12 See page 1-4-12 See page 1-4-13 See page 1-4-13

ABC
123

ABC
123

ABC
123

ABC
123

ABC
123

ABC
123

This vertical
line should
be straight.

Y 112480 - 6 Service Manual

1-4-10

(1) Completely blank printout.

(2) All-black printout.

Print example Causes Check procedures/corrective measures

Defective drum unit or developin g
unit.

Open the top cover and check that the drum unit and develop­ing unit are correctly seated. Investigate th at the ter m in a l s
between the main charger unit and the drum unit are not in
loose contact (See page 1-5-12 and 1-5-11).

Defective transfer bias output or
developing bias output.

Replace the high voltage PWB (See page 1-5-25).

Poor contact of developing bias term i­nal (spring) and high voltage output
terminal B (J401, J402, J403) on the
high voltage PWB.
Poor contact of transfer bias terminal
(spring) and transfer bias terminal T
(J201, J202, J203) on the high volt­age PWB.

Check the high voltage PWB visually and correct or replace if
necessary (See page 1-5-25).

Defective laser scanner unit. Replace the laser scanner unit (See page 1-5-30).
Defective control PWB. Replace the control PWB (See page 1-5-19).

Print example Causes Check procedures/corrective measures

Defective main charger unit. Open the top cover and check that the drum unit and develop-

ing unit are correctly seated (See page 1-5-12).
Investigate that the terminals between the main charger unit
and the drum unit are not in loose contact.

Poor contact of main charger terminal
(spring) and main charger output ter­minal M on the high voltage PWB.

Check the high voltage PWB visually and correct or replace if
necessary (See page 1-5-25).

Defective main charging output. Replace the high voltage PWB (See page 1-5-25).
Broken main charger wire. Replace the main charger unit (See page 1-5-13).
Defective control PWB. Replace the control PWB (See page 1-5-19).

Service Manual Y 112480 - 6

1-4-11

(3) Dropouts.

(4) Black dots.

(5) Black horizontal streaks.

Print example Causes Check procedures/corrective measures

Defective developing roller (develop­ing unit).

If the defects occur at regular intervals of 62.8 mm/2

1/2" (See

page 2-4-2), the problem may be the damaged developing
roller (in the developing unit). Replace the developing unit
(See page 1-5-11).

Defective drum unit. If the defects occur at regular interval s of 94 mm/3

11/16" (See

page 2-4-2), the problem may be the damaged drum (in the
drum unit). Replace the drum unit (See page 1-5-12).

Defective fuser unit (heat roller or
press roller).

If the defects occur at regular intervals of 73.162 mm/2

7/8", or

78.5 mm/3 1/16" (See page 2-4-2), the problem may be the
damaged heat roller or press roller (in the fuser unit). Replace
fuser unit (See page 1-5-16).

Defective paper specifications. Paper with rugged surface or dump tends to cause dropouts.

Replace paper with the one that satisfies the paper specifica­tions.

Defective transfer roller installation. The transfer roller must be supported by the bushes at the

both ends. Clean the bush to remove oil and debris. Replace
the transfer roller if necessary (See page 1-5-14).

Defective transfer bias output. Replace the high voltage PWB or control PWB (See page 1-5-

25 or 1-5-19).

Print example Causes Check procedures/corrective measures

Defective drum unit or developin g
unit.

If the defects occur at regular intervals of 94 mm/3

11/16" (See

page 2-4-2), the problem may be the damaged drum (in the
drum unit). Replace drum unit (See page 1-5-12).
If the defects occur at random intervals, the toner may be leak­ing from the developing unit or drum unit. Replace the devel­oping unit or drum unit (See page 1-5-11 or 1-5-12).

Print example Causes Check procedures/corrective measures

Defective drum unit's ground. Check that the drum shaft and the grounding tab (printer) are

in good contact. Apply the grounding tab a small amount of
electroconductive grease as required.

Defective drum unit. Replace the drum unit (See page 1-5-12).

ABC
123

ABC
123

ABC
123

Y 112480 - 6 Service Manual

1-4-12

(6) Black vertical streaks.

(7) Unsharpness.

(8) Gray background.

Print example Causes Check procedures/corrective measures

Adhesion of oxide to main charger
wire.

Remove the drum unit (See page 1-5-12). Slide the charger
cleaner (green) left and right 2 or 3 times to clean the charger
wire, then return it to its original position (CLEANER HOME
POSITION). Refer to the operation guide.

Defective drum unit. A streak of toner remaining on drum after printing means that

the cleaning blade (in the drum unit) is not working properly.
Replace the drum unit (See page 1-5-12).

Defective developing roller (develop­ing unit).

Replace the developing unit (See page 1-5-11).

Print example Causes Check procedures/corrective measures

Defective paper specifications. Replace paper with the one that satisfies the paper specifica-

tion.

Defective transfer roller installation. The transfer roller must be supported by the bushes at the

both ends. Clean the bush to remove oil and debris. Replace
the transfer roller if necessary (See page 1-5-14).

Defective transfer bias output. Replace the high voltage PWB or control PWB (See page 1-5-

25).

EcoPrint mode setting. The EcoPrint mode can provides faint, unsharp printing

because it acts to conserve toner for draft printing purpose.
For normal printing, turn the EcoPrint mode off by using the
operator panel. For details, refer to the operation guide.

Print example Causes Check procedures/corrective measures

Print density setting. The print density may be set too high. Try adjusting the print

density. For details, refer to the operation guide.

Defective potential on the drum sur­face.

Replace the drum unit (See page 1-5-12).

Defective main charger grid. Clean the main charger grid (See page 1-5-13).
Defective developing roller (develop-

ing unit).

If a developing unit which is known to work normally is avail­able for check, replace the current developing unit in the
printer with the normal one. If the symptom disappears,
replace the developing unit with a new one (See page 1-5-11).

ABC
123

ABC
123

Service Manual Y 112480 - 6

1-4-13

(9) Dirt on the top edge or back of the paper.

(10) Undulated printing at the right edge (scanning start position).

Print example Causes Check procedures/corrective measures

Toner contamination in various parts. Dirty edges and back of the paper can be caused by toner

accumulated on such parts as the paper chute guide, paper
conveying paths, the bottom of the drum and developing unit,
and the fuser unit inlet. Clean these areas and parts to remove
toner.

Defective transfer roller. If the transfer roller is contaminated with toner, clean the trans-

fer roller using a vacuum cleaner or by continuously printing a
low density page until the symptom has faded away.

Print example Causes Check procedures/corrective measures

Defective polygon motor (laser scan­ner unit).

Replace the laser scanner unit (See page 1-5-30).

Defective control PWB. Replace the control PWB (See page 1-5-19).

ABC
123

This vertical
line should
be straight.

Y 112480 - 6 Service Manual

1-4-14

1-4-4 Electric problems

Problem Causes Check procedures/corrective measures

(1)
The machine does
not operate when the
power switch is
turned on.

No electricity at the power
outlet.

Measure the input voltage.

The power cord is not
plugged in properly.

Check the contact between the power plug and the outlet.

The top cover is not closed
completely.

Check the top cover.

Broken power cord. Check for continuity. If none, replace the cord.
Defective power switch. Check for continuity across the contacts. If none, replace the

power source PWB (See page 1-5-22).

Blown fuse in the power
source PWB.

Check for continuity. If none, remove the cause of blowing and
replace the power source PWB (See page 1-5-22).

Defective interlock switch. Check for continuity across the contacts of interlock switch. If

none, replace the power source PWB (See page 1-5-22).

Defective power source
PWB.

Replace the power source PWB (See page 1-5-22).

Defective control PWB. Replace the control PWB (See page 1-5-19).

(2)
Right cooling fan
motor does not oper­ate.

Broken right cooling fan
motor coil.

Check for continuity across the coil. If none, replace the right cool­ing fan motor.

Defective harness between
right cooling fan motor and
control PWB (YC315), or
improper connector inser­tion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective control PWB. Replace the control PWB (See page 1-5-19).

(3)
Left cooling fan
motor does not oper­ate.

Broken left cooling fan
motor coil.

Check for continuity across the coil. If none, replace the left cool­ing fan motor.

Defective harness between
left cooling fan motor and
control PWB (YC104), or
improper connector inser­tion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective control PWB. Replace the control PWB (See page 1-5-19).

(4)
Registration clutch
does not operate.

Broken registration clutch
coil.

Check for continuity across the coil. If none, replace the registra­tion clutch.

Defective harness between
registration clutch and con­trol PWB (YC308), or
improper connector inser­tion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective control PWB. Replace the control PWB (See page 1-5-19).

(5)
Paper feed clutch
does not operate.

Broken paper feed clutch
coil.

Check for continuity across the coil. If none, replace the paper
feed clutch.

Defective harness between
paper feed clutch and con­trol PWB (YC308), or
improper connector inser­tion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective control PWB. Replace the control PWB (See page 1-5-19).

Service Manual Y 112480 - 6

1-4-15

(6)
Developing clutch
does not operate.

Broken developing clutch
coil.

Check for continuity across the coil. If none, replace the develop­ing clutch.

Defective harness between
developing clutch and con­trol PWB (YC308), or
improper connector inser­tion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective control PWB. Replace the control PWB (See page 1-5-19).

(7)
MP paper feed sole­noid does not oper­ate.

Broken MP paper feed sole­noid coil.

Check for continuity across the coil. If none, replace the MP paper
feed solenoid.

Defective harness between
MP paper feed solenoid
and control PWB (YC309),
or improper connector
insertion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective control PWB. Replace the control PWB (See page 1-5-19).

(8)
Duplex solenoid does
not operate.

Broken duplex solenoid
coil.

Check for continuity across the coil. If none, replace the duplex
solenoid.

Defective harness between
duplex solenoid and control
PWB (YC317), or improper
connector insertion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective control PWB. Replace the control PWB (See page 1-5-19).

(9)
Eraser lamp does not
turn on.

Defective harness between
eraser lamp (YC701) and
control PWB (YC316), or
improper connector inser­tion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

Defective eraser lamp
(PWB).

Replace the eraser lamp (PWB) (See page 1-5-32).

Defective control PWB. Replace the control PWB (See page 1-5-19).

(10)
Paper indicator is
flashing when paper
is present in the cas­sette.

Defective paper sensor. Replace the paper sensor.
Defective harness between

paper sensor and control
PWB (YC306), or improper
connector insertion.

Reinsert the connector. Also check for continuity within the con­nector harness. If none, remedy or replace the harness.

(11)
A paper jam in the
paper feed/convey­ing section or fuser
section is indicated
when the power
switch is turned on.

A piece of paper torn from
paper is caught around reg­istration sensor or exit sen­sor.

Check and remove if any.

Defective registration sen­sor on the high voltage
PWB.

Replace the high voltage PWB (See page 1-5-25).

Defective exit sensor. Replace the exit sensor.

(12)
Attention indicator is
lit when the top cover
is closed.

Defective interlock switch
on the power source PWB.

Check for continuity across the interlock switch. If there is no con­tinuity when the interlock switch is on, replace the power source
PWB (See page 1-5-22).

Problem Causes Check procedures/corrective measures

Y 112480 - 6 Service Manual

1-4-16

1-4-5 Mechanical problems

Problem Causes/check procedures Corrective measures

(1)
No primary paper feed.

Check if the surfaces of the paper feed roller
is dirty with paper powder.

Clean with isopropyl alcohol.

Check if the paper feed roller is deformed. Check visually and replace any deformed

paper feed roller (assembly) (See page 1-5-

6).

Defective paper feed clutch installation. Check visually and remedy if necessary.

(2)
No secondary paper
feed.

Check if the surfaces of the upper and lower
registration rollers are dirty with paper pow­der.

Clean with isopropyl alcohol.

Defective registration clutch installation. Check visually and remedy if necessary.

(3)
Skewed paper feed.

Paper width guide in a cassette installed
incorrectly.

Check the paper width guide visually and

correct or replace if necessary.

(4)
Multiple sheets of paper
are fed at one time.

Check if the separator pad or MPF separation
pad is worn.

Replace the separator pad if it is worn.

Check if the paper is curled. Replace the paper.

(5)
Paper jams.

Check if the paper is excessively curled. Replace the paper.
Check if the contact between the upper and

lower registration rollers is correct.

Check visually and remedy if necessary.

Check if the heat roller or press roller is
extremely dirty or deformed.

Replace the fuser unit (See page 1-5-16).

Check if the contact between the ejection
roller and fuser ejection pulley is correct.

Check visually and remedy if necessary.

(6)
T oner drops on the paper
conveying path.

Check if the drum unit or developing unit is
extremely dirty.

Clean the drum unit or developing unit (See

page 1-5-11 or 1-5-12).

(7)
Abnormal noise is heard.

Check if the pulleys, rollers and gears operate
smoothly .

Grease the bearings and gears.

Check if the following electromagnetic
clutches are installed correctly:
Paper feed clutch, registration clutch and
developing clutch.

Check visually and remedy if necessary.

Service Manual Y 112480 - 6

1-5-1

1-5 Assembly and Disassem bly

1-5-1 Precautions for assembly and disassembly

(1) Precautions

Be sure to turn the power switch off and disconnect the power plug before starting disassembly.
When handling PWBs, do not touch connectors with bare hands or damage the PWB.
Do not touch any PWB containing ICs with bare hands or any object prone to static charge.
When removing the hook of the connector, be sure to release the hook.
Take care not to get the wire caught.
To reassemble the parts, use the original screws. If the types and the sizes of screws are not known, refer to the PARTS
LIST.

(2) Drum

Note the following when handling or storing the drum.
When removing the drum unit, never expose the drum surface to strong direct light.

Keep the drum at an ambient temperature between 0

°C/32 °F and 40 °C/104 °F and at a relative humidity not higher than

90% RH. Avoid abrupt changes in temperature and humidity.
Avoid exposure to any substance which is harmful to or may affect the quality of the drum.
Do not touch the drum surface with any object. Should it be touched by hands or stained with oil, clean it.

(3) Toner container

Store the toner container in a cool, dark place.
Avoid direct light and high humidity.

Y 112480 - 6 Service Manual

1-5-3

1-5-2 Outer covers

(1) Detaching and refitting the top cover

Procedure

1. Open the top cover.

2. Remove two screws.

Figure 1-5-3

3. Extract the boss from the hole.

4. Unhook the A hook.

5. Unhook two B hooks.

6. Remove the connector.

7. Remove the top cover.

Figure 1-5-4

Top cover

Screw

Screw

Top cover

Top cover

Connector

Boss

B hook

B hook

A hook

Hole

Y 112480 - 6 Service Manual

1-5-4

(2) Detaching and refitting the right and left covers

Procedure

1. Remove the top cover (See page 1-5-3).

2. Remove the cassette (See page 1-5-6).

3. Open the front cover.

4. Unhook seven hooks and then remove the
right cover.

Figure 1-5-5

Right cover

Hooks

Service Manual Y 112480 - 6

1-5-5

5. Unhook seven hooks and then remove the
left cover.

Figure 1-5-6

Left cover

Hooks

Y 112480 - 6 Service Manual

1-5-6

1-5-3 Paper feed section

(1) Detaching and refitting the paper feed assembly (paper feed roller and pickup roller)

Procedure

1. Remove the cassette.

Figure 1-5-7

2. Slide the feed shaft.

3. While pressing the lever and then remove
the paper feed roller assembly.

Figure 1-5-8

Cassette

Paper feed roller
assembly

Lever

Feed shaft

Service Manual Y 112480 - 6

1-5-7

4. Check or replace the paper feed assembly
and refit all the removed parts.
When refitting the paper feed roller assem­bly, be sure to align the paper feed roller
pivot with the slotted hole on the feed shaft.

Figure 1-5-9

Paper feed roller
assembly

Paper feed roller
assembly

Feed shaft

Feed shaft

Pivot

Slotted hole

Y 112480 - 6 Service Manual

1-5-8

(2) Detaching and refitting the retard roller assembly

Procedure

1. Remove the cassette (See page 1-5-6).

2. Push the bottom plate down until it locks.

3. Unhook two hooks and then remove the
retard guide.

Figure 1-5-10

4. Remove the retard roller assembly.

Figure 1-5-11

Retard guide

Cassestte

Cassette

Hook

Hook

Hook

Hook

Bottom plate

Retard roller
Assembly

Service Manual Y 112480 - 6

1-5-9

5. Check or replace the retard roller assembly
and refit all the removed parts.
Caution: Before refitting the retard roller
assembly, firmly install the spring onto the
projection of the retard roller assembly.

Figure 1-5-12

Spring

Retard roller
assembly

Projection

Y 112480 - 6 Service Manual

1-5-10

(3) Detaching and refitting the MP paper feed roller

Procedure

1. Open the front cover.

2. Pull the MP feed holder (lever) down (1).

3. Slide the MP feed holder (2).

4. Remove the MP paper feed roller (3).

Figure 1-5-13

5. Check or replace the MP paper feed roller
and refit all the removed parts.
When refitting the MP paper feed roller, be
sure to align the MPF feed shaft pivot with
the slotted hole on the MP paper feed roller.

Figure 1-5-14

MP feed holder

(Lever)

Front cover

MP paper feed roller

MP paper feed roller

MPF feed shaft

Pivot

MP paper feed roller

Slotted hole

Service Manual Y 112480 - 6

1-5-11

1-5-4 Developing section

(1) Detaching and refitting the developing unit

Procedure

1. Open the top cover.

2. Open the front cover.

3. Remove the developing unit (with toner con­tainer).

4. Check or replace the developing unit and
refit all the removed parts.

5. When the developing unit is replaced with a
new one, carry out the following procedure.

6. Perform toner install mode in the service
mode (see page 1-3-12).

Figure 1-5-15

Developing unit

Front cover

Top cover

Y 112480 - 6 Service Manual

1-5-12

1-5-5 Drum section

(1) Detaching and refitting the drum unit

Procedure

1. Remove the developing unit (See page 1-5-

11).

2. Remove the drum unit.

3. Check or replace the drum unit and refit all
the removed parts.

Figure 1-5-16

Drum unit

Service Manual Y 112480 - 6

1-5-13

(2) Detaching and refitting the main charger unit

Procedure

1. Remove the drum unit (See page 1-5-12).

2. Remove the tape.

3. While pushing on the main plate (1), slide
the main charger unit (2).

Figure 1-5-17

4. Remove the main charger unit by lifting it.

5. Check or replace the main charger unit and
refit all the removed parts.

Figure 1-5-18

Main plate

Drum unit

Main charger unit

Main charger unit

Tape

Main charger unit

Y 112480 - 6 Service Manual

1-5-14

1-5-6 Transfer/separation section

(1) Detaching and refitting the transfer roller

Procedure

1. Remove the developing unit (See page 1-5-

11).

2. Remove the drum unit (See page 1-5-12).

3. Slide the paper chute guide and unhook the
hooks.

4. Remove the paper chute guide.

Figure 1-5-19

Hook

Hook

Hook

Hook

Paper chute guide

Paper chute guide

Service Manual Y 112480 - 6

1-5-15

5. Remove the transfer roller’s shaft from the
both transfer bushes.

6. Remove the gear Z16 from the transfer
roller.

Figure 1-5-20

7. Check or replace the transfer roller and refit
all the removed parts.
Caution: When refitting the transfer roller, be
careful about following point.
Push the release lever to raise the lever
end, then insert the front of gear Z16 under
the release lever end.

Figure 1-5-21

Transfer roller

Shaft

Shaft

Transfer roller

Transfer roller

Transfer roller

Gear Z16

Release lever

Gear Z16

Transfer bush

Transfer bush

Transfer roller

Y 112480 - 6 Service Manual

1-5-16

1-5-7 Fuser section

(1) Detaching and refitting the fuser unit

Procedure

1. Remove the outer covers (See page 1-5-3).

2. Remove two connectors.

3. Release the wires form wire clamps.

Figure 1-5-22

4. Remove the connector.

Figure 1-5-23

Connector
(Fuser heater lamp)

Connector
(Fuser thermistor)

Wire clamps

Wires

Connector

Service Manual Y 112480 - 6

1-5-17

5. Remove the rear cover.

Figure 1-5-24

6. Remove two screws and then remove the
fuser unit.

7. Check or replace the fuser unit and refit all
the removed parts.

Figure 1-5-25

Rear cover

Screw

Screw

Fuser unit

Y 112480 - 6 Service Manual

1-5-18

(2) Switching the fuser pressure

The fuser pressure may be decreased to suppress the print quality problems such as paper creases and curls.
It must be cautioned that decreasing the fuser pressure could cause loose toner fusing.

Procedure

1. Remove the cassette (See page 1-5-6).

2. Open the duplex cover.

3. Slide the fuser lever R and L.
Normal: Flush with the front of the machine.
Fuser pressure decreased: Flush with the
rear of the machine.

Figure 1-5-26

Fuser lever R

Duplex cover

Fuser lever L

Fuser lever L (R)

Fuser lever L (R)

Normal

Fuser pressure
decreased

Service Manual Y 112480 - 6

1-5-19

1-5-8 PWBs

(1) Detaching and refitting the control PWB

Procedure

1. Remove the right cover (See page 1-5-4).

2. Remove fourteen connectors form the con­trol PWB.

3. Release the wires from the wire clamps.

Figure 1-5-27

Connectors

(Thirteen)

Connector

Control PWB

Control PWB

Wire clamps

Y 112480 - 6 Service Manual

1-5-20

4. Remove five screws.

5. Remove three connectors form the control
PWB.

6. Unhook the hook and then remove the con­trol PWB assembly .

Figure 1-5-28

Hook

Screws

Control PWB assembly

Control PWB

Screw

Screws

Connectors
(Three)

Service Manual Y 112480 - 6

1-5-21

7. Remove five screws and then remove the
control PWB.

8. Check or replace the control PWB and refit
all the removed parts.
To replace the control PWB, remove the
EEPROM (U300) from the old control PWB
and mount it to the new control PWB.

Figure 1-5-29

Screw

Screw

Screw

Screw

Screw

Control PWB

Control PWB

U300

EEPROM

Y 112480 - 6 Service Manual

1-5-22

(2) Detaching and refitting the power source PWB

Procedure

1. Remove the top cover (See page 1-5-3).

2. Remove the left cover (See page 1-5-4).

3. Remove four connectors.

Figure 1-5-30

4. Remove four P tight screws, two screws and
ground terminal.

5. Remove the power source PWB assembly
from the high voltage PWB’s connector.

Figure 1-5-31

Connector

Connector

Connector

Connector
(YC104)

Power source PWB
assembly

P tight screws

P tight screws

Ground
terminal

Screws

Connecto

r

(YC201)

High voltage PWB

Connector

(YC103)

Service Manual Y 112480 - 6

1-5-23

6. Remove four screws and then remove the
power source plate from the power source
PWB.

7. Check or replace the power source PWB
and refit all the removed parts.
Caution: The power source film must be
installed in the specified position.

Figure 1-5-32

Power source PWB

Screws

Screws

Power source plate

Power source film

Y 112480 - 6 Service Manual

1-5-24

(3) Detaching and refitting the operation panel PWB

Procedure

1. Remove the top cover (See page 1-5-3).

2. Remove two screws and then remove the
panel cover.

3. Remove the operation panel PWB.

4. Remove the connector.

5. Check or replace the operation panel PWB
and refit all the removed parts.
Be sure to fit the GO and Cancel keys in the
appropriate position.

Figure 1-5-33

Connector

Cancel key

(Amber)

Cancel key
(

Amber)

GO key (Green)

GO key (Green)

Screw

Screw

Operation panel PWB

Panel cover

Top cover

Service Manual Y 112480 - 6

1-5-25

(4) Detaching and refitting the high voltage PWB

Procedure

1. Remove the developing unit (See page 1-5-

11).

2. Remove the drum unit (See page 1-5-12).

3. Remove the cassette (See page 1-5-6).

4. Remove the outer covers (See page 1-5-3).

5. Remove the power source PWB (See page
1-5-22).

6. Turn the printer with the bottom side up.

7. Remove the stop ring.

8. Remove the DU holder.

Figure 1-5-34

9. Pull out the DU bush.

10.Remove the DU cover assembly.

Figure 1-5-35

Stop ring

DU holder

DU bush

DU cover assembly

Y 112480 - 6 Service Manual

1-5-26

11.Remove four screws.

12.Unhook three hooks and then remove the
lower base cover.

Figure 1-5-36

Screws

Screws

Hook

Hook

Hook

Lower base cover

Lower base cover

Service Manual Y 112480 - 6

1-5-27

13.Remove the spring.

14.Remove the cassette pin.

Figure 1-5-37

15.Remove two connectors and then remove
the high voltage PWB.

16.Remove the cassette pin holder from the
high voltage PWB.

Figure 1-5-38

Spring

Cassette pin

Cassette pin
holder

High voltage PWB

High voltage
PWB

Connector

Connector

YC202

YC203

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1-5-28

17.Check or replace the high voltage PWB and
refit all the removed parts.
When refitting the high voltage PWB, be
careful about following points.

• Position the ground plate so that it is atop

the high voltage PWB.

• Each interface is firmly in contact with each

spring.

• The bias contact pin must be installed in

the specified position.

• The cassette pin must be inserted in the

cassette pin holder.

Figure 1-5-39

OK NG

High voltage PWB

High voltage PWB

High voltage PWB

Cassette pin

Cassette pin holder

Ground plate

Bias

contact pin

Spring

(Main charger)

Spring
(separation)

Spring
(Developing)

Spring

(Transfer)

Service Manual Y 112480 - 6

1-5-29

1-5-9 Others

(1) Detaching and refitting the main motor

Procedure

1. Remove the right cover (See page 1-5-4).

2. Remove the connector.

Figure 1-5-40

3. Remove the M3 screw and two M4 screws.

4. Remove the main motor.

5. Check or replace the main motor and refit all
the removed parts.

Figure 1-5-41

Connector

Main motor

M3 Screw

M4 screws

Y 112480 - 6 Service Manual

1-5-30

(2) Detaching and refitting the laser scanner unit

Procedure

1. Remove the right cover (See page 1-5-4).

2. Remove the connector from the control
PWB.

3. Release the wire clamp.

4. Draw in the connector inside.

Figure 1-5-42

Clamp

Connector

Connector

Control PWB

Service Manual Y 112480 - 6

1-5-31

5. Remove four screws and then remove the
laser scanner unit.

6. Check or replace the laser scanner unit and
refit all the removed parts.

Figure 1-5-43

Screws

Screws

Laser scanner unit

Y 112480 - 6 Service Manual

1-5-32

(3) Detaching and refitting the eraser lamp

Procedure

1. Remove the laser scanner unit (See page 1­5-30).

2. Remove the connector.

3. Remove the eraser lamp.

4. Check or replace the eraser lamp and refit
all the removed parts.

Figure 1-5-44

Eraser lamp

Connector

Service Manual Y 112480 - 6

1-5-33

(4) Direction of installing the left and right cooling fan mo to rs

When detaching or refitting the left and/or right cooling fan motors, be careful of the airflow direction (intake or exhaust).

Figure 1-5-45

Left cooling
fan motor

Right cooling
fan motor

Exhaust

Intake

Y 112480 - 6 Service Manual

1-5-34

This page is intentionally left blank.

Service Manual Y 112480 - 6

1-6-1

1-6 Firmware

1-6-1 Downloading firmware

Firmware files are named after the following codes:

Figure 1-6-1

Software ID

Compression

S2LZ_1000001021.cmp

Firmware file name example

Product code

2LY: 30/32 ppm model (A4/Letter)
2LZ: 35/37 ppm model (A4/Letter)

Pause (underscore)

Pause (period)

Build number

Update history

Classification (Normally: 0)

Supplement (Normally: 00)

Firmware category
10: Engine controller
30: Main controller

Y 112480 - 6 Service Manual

1-6-2

(1) Downloading the firmware from the memory card

To download data written in a memory card (CompactFlash) to the printer, proceed as explained in this section.

CAUTION

Downloading firmware takes several minutes. Do not turn power off during downloading. If downloading is interrupted by
an accidental power failure, etc., the control PWB may have to be replaced.
Do not download the system firmware and engine firmware at one time. Store the either firmware in a memory card and
download one by one.

Procedure

1. Turn printer power off.

2. Open the rear cover.

Figure 1-6-2

3. Remove two screws and then remove the
optional interface slot cover.

4. Insert the memory card into the memory
card slot.

Figure 1-6-3

Rear cover

Screw

Optional interface
slot cover

Screw

Memory card

Memory card slot

Service Manual Y 112480 - 6

1-6-3

5. Turn printer power on.
The printer starts and finishes downloading
automatically.

Figure 1-6-4

*: 0.8 s

*: 0.8 s

*: 0.8 s

(Repeat)

(Repeat)

Supervisor

mode

Deleting and

writing data

Downloading

complete

Receiving

data

Downloading

start

(Repeat)

(Repeat)

End

End

4.8 s

4.8 s

*****

****

*

*

(Repeat)

*

(Repeat)

*

Pattern

1

Pattern

2

Pattern

3

Downloading failed

Indication example

Sequence of display

Lit (Green)

Lit (Amber)

Lit (Amber)

Off (Amber)

Off (Amber)

Off (Green)

Y 112480 - 6 Service Manual

1-6-4

6. Confirm that downloading was finished nor­mally (See previous page).

7. Turn power off.

8. Remove the memory card.

9. Secure the optional interface slot cover by
using two screws.

10.Close the rear cover.

11.Turn power on again.
Check the printer gets ready and Ready
indicator is lit.

12.Print a status page (See page P.1-3-2).

13.Confirm the status page shows the new
firmware version.

Figure 1-6-5

Screw

Optional interface
slot cover

Screw

Memory card

Memory card slot

Service Manual Y 112480 - 6

2-1-1

2-1 Mechanical Construction

2-1-1 Paper feed/conveying section

Paper feed/conveying section consists of the paper feed unit that feeds paper from the cassette and the MP tray paper
feed unit that feeds paper from the MP tray, and the paper conveying section that conveys the fed paper to the transfer/
separation section.

(1) Cassette paper feed section

Figure 2-1-1 Cassette paper feed section

Figure 2-1-2Cassette paper feed section block diagram

1

9

7

3

4

5

2

6

8

10

11

(1) Pickup roller
(2) Paper feed roller
(3) Feed holder
(4) Retard roller
(5) Retard holder
(6) Retard guide

(7) Bottom plate
(8) Bottom pad
(9) Cassette base
(10) Paper sensor
(11) Actuator (paper sensor)

FEDDRN

MMOTRDYN

YC306-3

Paper sensor

Paper feed
Clutch

Main motor

Control PWB

PAPER

MOTCLK

REMOTEN

YC308-4

YC305-3
YC305-4
YC305-5

Y 112480 - 6 Service Manual

2-1-2

(2) MP tray paper feed section

Figure 2-1-3 MP tray paper feed section

Figure 2-1-4 MP tray paper feed section block diagram

1

2

6

8

5

9

4

7

10

11

12

3

13

(1) MP paper feed roller
(2) MPF separation pad
(3) MPF separator
(4) MPF bottom plate
(5) MPF friction pad
(6) MP paper sensor
(7) Actuator (MP paper sensor)

(8) MPF frame
(9) MPF guide R/L
(10) MPF base
(11) MPF middle tray
(12) MPF upper tray
(13) MPF turn guide

MMOTRDYN

YC304-3

MPFDRN

MP paper sensor

MP paper
feed solenoid

Main motor

Control PWB

HANDSN

YC309-2

MOTCLK

REMOTEN

YC305-3
YC305-4
YC305-5

Service Manual Y 112480 - 6

2-1-3

(3) Paper conveying section

Figure 2-1-5 Paper conveying section

Figure 2-1-6 Paper conveying section block diagram

1

4

3

5

2

(1) Lower registration roller
(2) Upper registration roller
(3) Registration sensor
(4) Actuator (registration sensor)
(5) Feed pulley

MMOTRDYN

REGDRN

Registration
clutch

Main motor

Control PWB

YC311-11

Registration
sensor

High voltage PWB

REGN

YC308-2

MOTCLK

REMOTEN

YC305-3
YC305-4
YC305-5

Y 112480 - 6 Service Manual

2-1-4

2-1-2 Drum section

(1) Drum section

The durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base. The OPC tend to reduce
its own electrical conductance when exposed to light. After a cyclic process of charging, exposure, and development, the
electrostatic image is constituted over the OPC layer.
Since the OPC is materialized by resin, it is susceptible to damage caused by sharp edges such as a screwdriver, etc.,
resulting in a print quality problem. Also, finger prints can cause deterioration of the OPC layer, therefore, the drum (in the
drum unit) must be handled with care. Substances like water, alcohol, organic solvent, etc., should be strictly avoided.
As with all other OPC drums, the exposure to a strong light source for a prolonged period can cause a print quality prob­lem. The limit is approximately 500 lux for less than five minutes. If the drum (drum unit) remains removed form the printer,
it should be stored in a cool, dark place.
.

Figure 2-1-7 Drum section

1

2

3

4

(1) Drum
(2) Drum shaft
(3) Drum cover A
(4) Drum cover B

Service Manual Y 112480 - 6

2-1-5

(2) Main charger unit

As the drum rotates in a “clean (neutral)” state, its photoconductive layer is given a uniform, positive (+) corona charge dis­persed by the main charger wire. Due to high-voltage scorotron charging, the charging wire can get contaminated by oxi­dization after a long run. Therefore, the charger wire must be cleaned at a specific interval. Cleaning the charging wire
prevents print quality problems such as black streaks.

Figure 2-1-8 Main charger unit

Figure 2-1-9 Drum unit and main charger unit block diagram

1

4

2

3

(1) Main charger shield
(2) Main charger wire
(3) Main charger grid
(4) Main charger wire cleaner

Main charger wire

Main charger shield

Main charger grid

Drum

High voltage

PWB

Main charger output

Zener

PWB

M

Y 112480 - 6 Service Manual

2-1-6

2-1-3 Expose section

(1) Laser scanner unit

The charged surface of the drum is then scanned by the laser beam from the laser scanner unit.
The laser beam (780 nm wavelength) beam is dispersed as the polygon motor revolves to reflect the laser beam over the
drum. Various lenses and mirror are housed in the laser scanner unit, adjust the diameter of the laser beam, and focalize
it at the drum surface.

Figure 2-1-10 Laser scanner unit

1

2

3

4

5

7

6

(1) Polygon motor (mirror)
(2) F-θ lens
(3) F-θ lens
(4) LSU mirror
(5) LSU shutter
(6) LSU frame
(7) LSU cover

Service Manual Y 112480 - 6

2-1-7

Figure 2-1-11 Laser scanner unit

1

2

3

8

9

10

4

5

6

7

(1) Polygon motor (mirror)
(2) Laser diode (APC PWB)
(3) Collimator lens
(4) Cylindrical lens
(5) F-θ lens
(6) F-θ lens
(7) PD mirror
(8) SOS lens
(9) Pin photo diode sensor (PD PWB)
(10) LSU mirror

Y 112480 - 6 Service Manual

2-1-8

2-1-4 Developing section

The latent image constituted on the drum is developed into a visible image. The developing roller contains a 3-pole (S-NS)
magnet roller and an aluminum cylinder rotating around the magnet roller. Toner attracts to the magnet sleeve since it is
powdery ink made of black resin bound to iron particles. Developing blade, magnetized by magnet, is positioned approxi­mately 0.3 mm above the magnet sleeve to constitute a smooth layer of toner in accordance with the magnet sleeve revo­lution.

The developing roller is applied with the AC-weighted, positive DC power source. Toner on the magnet sleeve is given a
positive charge. The positively charged toner is then attracted to the areas of the drum which was exposed to the laser
light. (The gap between the drum and the magnet sleeve is approximately 0.32 mm.) The non-exposed areas of the drum
repel the positively charged toner as these areas maintain the positive charge.
The developing roller is also AC-biased to ensure contrast in yielding by compensating the toner’s attraction and repelling
action during development.

Figure 2-1-12 Developing unit and toner container

Figure 2-1-13 Developing sectio n bl oc k diagram

1

3

4

6

7

8

5

2

(1) Magnet sleeve
(2) Magnet roller
(3) Developing blade
(4) Blade magnet

(5) DLP screw A
(6) DLP screw B
(7) DLP case
(8) Toner container

DLPDRN

Developing
clutch

YC308-6

B

Developing
roller

Magnet roller
Magnet sleeve

Developing bias output

High voltage PWB

Control PWB

Service Manual Y 112480 - 6

2-1-9

2-1-5 Transfer/separation section

The transfer/separation section consists of the transfer roller, discharger brush and paper chute guide. A high voltage gen­erated by the high voltage PWB is applied to the transfer roller for transfer charging. Paper after transfer is separated from
the drum.

Figure 2-1-14 Transfer/separation section

Figure 2-1-15 Transfer/separation section block diagram

1

2

3

4

5

(1) Transfer roller
(2) Transfer bushes
(3) Discharger brush
(4) DC brush holder
(5) Paper chute guide

T

Transfer
roller

GND

High voltage
PWB

Transfer bias

Discharger
brush

Y 112480 - 6 Service Manual

2-1-10

2-1-6 Cleaning section

After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development
process. The cleaning blade is constantly pressed against the drum and scrapes the residual toner off to the sweep roller.
The waste toner is collected at the output end of the sweep roller and sent back to the toner container, into the waste toner
reservoir.
After the drum is physically cleaned, it then must be cleaned to the electrically neutral state. This is necessary to erase any
residual positive charge, ready to accept the uniform charge for the next print process. The residual charge is canceled by
exposing the drum to the light emitted from the eraser lamp (PWB). This lowers the electrical conductivity of the drum sur­face making the residual charge on the drum surface escape to the ground.

Figure 2-1-16 Cleaning section

Figure 2-1-17 Cleaning section block diagram

1

3

2

Main frame

Waste toner reservoir

Drum unit

(1) Eraser lamp (PWB)
(2) Sweep roller
(3) Cleaning blade

ERASER

YC316-1

Drum

Eraser
lamp
(PWB)

Control PWB

Service Manual Y 112480 - 6

2-1-11

2-1-7 Fuser section

The toner on the paper is molten and pressed into the paper as it passes between the heat roller and the press roller in the
fuser unit. The heat roller has a heater lamp inside which continuously turns on and off by the fuser thermistor to maintain
the constant temperature onto the heat roller surface. The heat roller is resin coated by florin to prevent toner from accu­mulating on the roller after a long run. Care must be taken while handling the heat roller not to scratch the roller surface as
doing so may result in print problems. Fuser temperature is optimized to the paper type. The heat roller has four separa­tors (claws) which are continuously in contact with its surface. These separators (claws) prevent the paper on which toner
has been fused from being wound around the heat roller causing paper jam. The press roller is made of the heat-resistant
silicon rubber. This roller is used to strongly press the paper towards the heat roller by means of press springs. The tem­perature of the heat roller is constantly monitored by the control PWB using the fuser thermistor. Should the temperature
of the heat roller exceed the predetermined value, the fuser thermal cutout is activated to effectively disconnect the heater
lamp from power.

Figure 2-1-18 Fuser section

1

2

9

10

11

12

3

6

7

4

14

13

8

5

(1) Upper fuser frame
(2) Lower fuser frame
(3) Heat roller
(4) Press roller
(5) Fuser heater lamp
(6) Fuser thermal cutout
(7) Fuser thermistor

(8) Separators
(9) Fuser bushes
(10) Press springs
(11) Press spring holders
(12) Fuser lever L (R)
(13) Exit sensor
(14) Actuator (exit sensor)

Y 112480 - 6 Service Manual

2-1-12

Figure 2-1-19 Fuser section block diagram

N

L

THERM

HEATN

SLEEP

ZCROSS

YC102-1

YC102-3

YC103-6
YC103-7
YC103-8

YC311-5
YC311-6
YC311-3

YC311-16

Fuser unit

Fuser
thermistor

Fuser
heater
lamp

Fuser thermal cutout

Power
source PWB

Control PWB

High

voltage

PWB

Service Manual Y 112480 - 6