Utax LP 3118 Service Manual

Service Manual

Printer

LP 3118

22-02-2005

Service Manual

Printer

LP 4118

22-02-2005

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 printer.

1.Installation Precautions

WARNING

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

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

• Connect the ground wire to a suitable grounding point. Not grounding the printer may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the

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

CAUTION:

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

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

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

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

• Allow sufficient space around the printer 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 printers so equipped. Failure to do this may cause

the printer 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 printer’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 including safety mechanisms

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

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

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

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

• When the service manual or other serious brochure specifies a distance or gap for installation of a

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

• Always check that the printer 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 high potentials and may 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 printer 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 attention should be paid to any forgotten connector,

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 printer, 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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2GL/2FV/2FW

CONTENTS

1-1 Specifications

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

1-1-2 Parts names............................................................................................................................................1-1-7

(1) Printer................................................................................................................................................1-1-7

(2) Operation panel.................................................................................................................................1-1-8

1-1-3 Cross section view ..................................................................................................................................1-1-9

1-2 Handling Precautions

1-2-1 Drum unit and developer unit..................................................................................................................1-2-1

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

1-3 Installation

1-3-1 Unpacking and installation .....................................................................................................................1-3-1

(1) Installation procedure ........................................................................................................................1-3-1

1-3-2 Installing expansion memory (optional for 16/18 ppm printers) ..............................................................1-3-6

1-3-3 Installing a memory card (optional for 16/18 ppm printers).....................................................................1-3-7

1-4 Maintenance Mode

1-4-1 Service mode ..........................................................................................................................................1-4-1

(1) Executing service mode ....................................................................................................................1-4-1

1-5 Troubleshooting

1-5-1 Paper misfeed detection .........................................................................................................................1-5-1

(1) Paper misfeed indication ...................................................................................................................1-5-1

(2) Paper misfeed detection....................................................................................................................1-5-2

1-5-2 Self-diagnosis .........................................................................................................................................1-5-3

(1) Self-diagnostic function .....................................................................................................................1-5-3

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

1-5-3 Electric problems ..................................................................................................................................1-5-14

1-5-4 Image formation problems ....................................................................................................................1-5-17

1-5-5 Mechanical problems ............................................................................................................................1-5-23

1-6 Assembly and Disassembly

1-6-1 Precautions for assembly and disassembly............................................................................................1-6-1

(1) Precautions .......................................................................................................................................1-6-1

1-6-2 Outer covers ...........................................................................................................................................1-6-2

(1) Detaching and refitting the right side cover, right cover, left cover, and top cover............................1-6-2

1-6-3 Paper feeding/conveying section ............................................................................................................1-6-4

(1) Detaching and refitting the paper feed roller .....................................................................................1-6-4

(2) Detaching and refitting the transfer roller ..........................................................................................1-6-5

1-6-4 Process section.......................................................................................................................................1-6-6

(1) Detaching and refitting the developer unit and drum unit..................................................................1-6-6

(2) Drum unit optimization.......................................................................................................................1-6-7

(3) Detaching and refitting the main charger unit....................................................................................1-6-8

1-6-5 Fuser unit ................................................................................................................................................1-6-9

(1) Detaching and refitting the fuser unit.................................................................................................1-6-9

(2) Detaching and refitting the heater lamp, heat roller, fuser thermistor, thermal cutout,

and press roller................................................................................................................................1-6-11

1-6-6 PWBs ....................................................................................................................................................1-6-15

(1) Detaching and refitting the main PWB (16 ppm GDI printer) ..........................................................1-6-15

(2) Detaching and refitting the main PWB (16/18 ppm printers) ...........................................................1-6-16

(3) Detaching and refitting the engine/high voltage PWB and power source PWB ..............................1-6-17

1-6-7 Others ...................................................................................................................................................1-6-20

(1) Detaching and refitting the laser scanner unit .................................................................................1-6-20

(2) Detaching and refitting the eraser lamp (PWB)...............................................................................1-6-22

(3) Detaching and refitting the drive unit...............................................................................................1-6-23

(4) Detaching and refitting the main motor ...........................................................................................1-6-24

2GL/2FV/2FW

1-7 Firmware

1-7-1 Downloading ...........................................................................................................................................1-7-1

(1) Firmware program data format.........................................................................................................1-7-1

(2) Downloading the firmware from the parallel interface (For 16/18 ppm printers) ..............................1-7-2

(3) Downloading the firmware from the memory card (For 16/18 ppm printers).....................................1-7-4

2-1 Mechanical Construction

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

(1) Paper feed section ............................................................................................................................2-1-1

2-1-2 Drum section...........................................................................................................................................2-1-3

(1) Drum unit...........................................................................................................................................2-1-3

(2) Main charger unit...............................................................................................................................2-1-4

2-1-3 Expose section........................................................................................................................................2-1-5

(1) Laser scanner unit.............................................................................................................................2-1-5

2-1-4 Developing section..................................................................................................................................2-1-7

(1) Developer unit ...................................................................................................................................2-1-7

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

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

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

(1) Fuser unit ........................................................................................................................................2-1-11

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

(1) Paper exit section............................................................................................................................2-1-13

2-2 Electrical Parts Layout

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

(1) Electrical parts layout ........................................................................................................................2-2-1

2-3 Operation of the PWBs

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

2-3-2 Engine/high voltage PWB .......................................................................................................................2-3-3

2-3-3 Main PWB ...............................................................................................................................................2-3-6

2-4 Appendixes

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

(1) Timing chart No.1 Cassette paper feeding, Paper size A4 (For 16/16 ppm GDI printers) ................2-4-1

(2) Timing chart No.2 Cassette paper feeding, Paper size A4 (For 18 ppm printer) ..............................2-4-2

(3) Timing chart No.3 Manual feed tray paper feeding, Paper size A4 ...................................................2-4-3

(4) Wiring diagram ..................................................................................................................................2-4-4

(5) Repetitive defects gauge...................................................................................................................2-4-5

2GL/2FV/2FW-1

1-1-1

1-1 Specifications

1-1-1 Specifications

16 ppm GDI printer (FS-720)

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

Printing system ............................... Electrophotographic printing

Paper type ......................................Paper cassette: Plain paper (60 to 105 g/m

2

)

Recycled paper (60 to 105 g/m

2

)

Thick paper (90 to 105 g/m

2

)

Manual feed tray: Plain paper (60 to 163 g/m

2

)

Recycled paper (60 to 163 g/m

2

)

Thick paper (60 to 163 g/m

2

)

Special paper: Transparencies, labels, envelopes, postcards, tracing paper

Paper sizes ..................................... Paper cassette

A4 (210 × 297 mm)
B5 (182 × 257 mm)
A5 (148 × 210 mm)
Folio (210 × 330 mm)
Letter (8

1

/2" × 11" )

Legal (8

1

/2" × 14")

Officio II (8

1

/2" × 13")

Non-standard size (148 × 210 mm to 216 × 356 mm)

Manual feed tray

A4 (210 × 297 mm)
B5 (182 × 257 mm)
A5 (148 × 210 mm)
Folio (210 × 330 mm)
Letter (8

1

/2" × 11" )

Legal (8

1

/2" × 14")

Officio II (8

1

/2" × 13")

Non-standard size (70 × 148 mm to 216 × 356 mm)

Print speeds....................................A4: 16 pages/minutes

Letter: 17 pages/minutes

First print time ................................. 11 seconds or less (ready), 21 seconds or less (sleep)

Warm-up time .................................16 seconds or less (power on), 12 seconds or less (sleep)

Paper feed system.......................... One universal cassette and one manual feed tray

Paper loading capacity ...................Paper cassette: 250 sheets (80 g/m2, 0.11 µm)

Manual feed tray: 1 sheet (80 g/m2, 0.11 µm)

Paper exit system .............................. Face down: 100 sheets (80 g/m2, 0.11 µm)

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

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

Fixing system..................................Heat roller system

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

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

2GL/2FV/2FW

1-1-2

Controller hardware ........................CPU: 32 bit RISC CPU

System ROM: 1 Mbit (on-board)

Main RAM: 8 MB (on-board)

Interface..........................................USB: Full-Speed USB2.0

Controller software..........................Host based

Resolution....................................... 600 dpi mode (600 × 600 dpi)

Dimensions (H × W × D) .................245 × 380 × 390 mm/9.6" × 15.0" × 15.4"

Weight.............................................Main unit: 9.2 kg/20.3 lbs

Power source..................................220 - 240 V AC, 50/60 Hz (European countries), 120 V AC, 60 Hz (U.S.A./Canada)

Power consumption ........................Maximum: 830 W (220 - 240 V model), 823 W (120 V model)

Normal operating: 302 W (220 - 240 V model), 295 W (120 V model)

Ready: 5 W (220 - 240 V model), 5 W (120 V model)

EcoPower: 4.2 W (220 - 240 V model), 3.8 W (120 V model)

Current............................................3.4 A (220 - 240 V model), 6.8 A (120 V model)

Noise............................................... Printing: 49 dB(A), Ready: 28 dB(A)

2GL/2FV/2FW-1

1-1-3

16 ppm printer (FS-820)

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

Printing system ............................... Electrophotographic printing

Paper type ......................................Paper cassette: Plain paper (60 to 105 g/m

2

)

Recycled paper (60 to 105 g/m

2

)

Thick paper (90 to 105 g/m

2

)

Manual feed tray: Plain paper (60 to 163 g/m

2

)

Recycled paper (60 to 163 g/m

2

)

Thick paper (60 to 163 g/m

2

)

Special paper: Transparencies, labels, envelopes, postcards, tracing paper

Paper sizes ..................................... Paper cassette

A4 (210 × 297 mm)
B5 (182 × 257 mm)
A5 (148 × 210 mm)
Folio (210 × 330 mm)
Letter (8

1

/2" × 11" )

Legal (8

1

/2" × 14")

Officio II (8

1

/2" × 13")

Non-standard size (148 × 210 mm to 216 × 356 mm)

Manual feed tray

A4 (210 × 297 mm)
B5 (182 × 257 mm)
A5 (148 × 210 mm)
Folio (210 × 330 mm)
Letter (8

1

/2" × 11" )

Legal (8

1

/2" × 14")

Officio II (8

1

/2" × 13")

Non-standard size (70 × 148 mm to 216 × 356 mm)

Print speeds....................................A4: 16 pages/minutes

Letter: 17 pages/minutes

First print time ................................. 11 seconds or less (ready), 21 seconds or less (sleep)

Warm-up time .................................16 seconds or less (power on), 12 seconds or less (sleep)

Paper feed system.......................... One universal cassette and one manual feed tray

Paper loading capacity ...................Paper cassette: 250 sheets (80 g/m

2

, 0.11 µm)

Manual feed tray: 1 sheet (80 g/m

2

, 0.11 µm)

Paper exit system .............................. Face down: 100 sheets (80 g/m2, 0.11 µm)

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

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

Fixing system..................................Heat roller system

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

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

2GL/2FV/2FW

1-1-4

Controller hardware ........................CPU: PowerPC405 (192 MHz)

System ROM: 4 MB (on-board)

Font ROM: Including System ROM

Main RAM: 16 MB standard (on-board); expanding up to 272 MB (256 MB × 1) at the

maximum by adding optional expansion memory

Optional expansion RAM (DIMM): 1 slot

100-pin DIMM (64, 128 or 256 MB)

Interface..........................................Parallel: Hi-speed (bi-directional), IEEE 1284 Nibble/ECP mode

USB: Full-Speed USB2.0

Controller software..........................a) Emulation

PCL6 (PCL5e/PCL-XL)

b) Fonts:

Bitmap font:

1 font

Outline fonts:

14 fonts

c) Graphic:

(1) Raster graphic:

75, 100, 150, 200*, 300, 600* dpi
(*200 dpi is supported when the resolution is 600 dpi.)

(2) Vector graphic:

Line, Box, Circle, Arc, Fill pattern etc.

(3) Bar code:

One dimensional bar code: 45 types
Two dimensional bar code: 1 type (PDF-417)

(4) Text:

TEXT, RTXT etc.

(5) Others:

Macro, JOB, Device setting etc.

d) Connectivity

Plug &play (Parallel): Windows 9x/Me/2000/XP
Plug & play (Full-Speed USB2.0): Windows 98SE/Me/2000/XP

Resolution....................................... Fast1200 mode (1800 × 600 dpi)

600 dpi mode (600 × 600 dpi)

Dimensions (H × W × D) .................245 × 380 × 390 mm/9.6" × 15.0" × 15.4"

Weight.............................................Main unit: 9.2 kg/20.3 lbs

Power source..................................220 - 240 V AC, 50/60 Hz (European countries), 120 V AC, 60 Hz (U.S.A./Canada)

Power consumption ........................Maximum: 833 W (220 - 240 V model), 828 W (120 V model)

Normal operating: 319 W (220 - 240 V model), 292 W (120 V model)

Ready: 7 W (220 - 240 V model), 6 W (120 V model)

EcoPower: 4.5 W (220 - 240 V model), 4 W (120 V model)

Current............................................3.4 A (220 - 240 V model), 6.8 A (120 V model)

Noise............................................... Printing: 49 dB(A), Ready: 28 dB(A)

Options ...........................................Expansion memory (64/128/256 MB 100-pin DIMM),

memory card (Compact Flash)

2GL/2FV/2FW-1

1-1-5

18 ppm printer (FS-920)

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

Printing system ............................... Electrophotographic printing

Paper type ......................................Paper cassette: Plain paper (60 to 105 g/m

2

)

Recycled paper (60 to 105 g/m

2

)

Thick paper (90 to 105 g/m

2

)

Manual feed tray: Plain paper (60 to 163 g/m

2

)

Recycled paper (60 to 163 g/m

2

)

Thick paper (60 to 163 g/m

2

)

Special paper: Transparencies, labels, envelopes, postcards, tracing paper

Paper sizes ..................................... Paper cassette

A4 (210 × 297 mm)
B5 (182 × 257 mm)
A5 (148 × 210 mm)
Folio (210 × 330 mm)
Letter (8

1

/2" × 11" )

Legal (8

1

/2" × 14")

Officio II (8

1

/2" × 13")

Non-standard size (148 × 210 mm to 216 × 356 mm)

Manual feed tray

A4 (210 × 297 mm)
B5 (182 × 257 mm)
A5 (148 × 210 mm)
Folio (210 × 330 mm)
Letter (8

1

/2" × 11" )

Legal (8

1

/2" × 14")

Officio II (8

1

/2" × 13")

Non-standard size (70 × 148 mm to 216 × 356 mm)

Print speeds....................................A4: 18 pages/minutes

Letter: 19 pages/minutes

First print time ................................. 11 seconds or less (ready), 21 seconds or less (sleep)

Warm-up time .................................16 seconds or less (power on), 12 seconds or less (sleep)

Paper feed system.......................... One universal cassette and one manual feed tray

Paper loading capacity ...................Paper cassette: 250 sheets (80 g/m

2

, 0.11 µm)

Manual feed tray: 1 sheet (80 g/m

2

, 0.11 µm)

Paper exit system .............................. Face down: 100 sheets (80 g/m2, 0.11 µm)

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

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

Fixing system..................................Heat roller system

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

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

2GL/2FV/2FW

1-1-6

Controller hardware ........................CPU: PowerPC405 (266 MHz)

System ROM: 4 MB (on-board)

Font ROM: Including System ROM

Main RAM: 32 MB standard (on-board); expanding up to 288 MB (256 MB × 1) at the

maximum by adding optional expansion memory

Optional expansion RAM (DIMM): 1 slot

100-pin DIMM (64, 128 or 256 MB)

Interface..........................................Parallel: Hi-speed (bi-directional), IEEE 1284 Nibble/ECP mode

USB: Full-Speed USB2.0

Controller software..........................a) Emulation

PCL6 (PCL5e/PCL-XL)
KPDL3
Line Printer
Diablo 630
IBM Proprinter X24E
Epson LQ850

b) Fonts:

Bitmap font:

1 font

Outline fonts:

80 fonts

c) Graphic:

(1) Raster graphic:

75, 100, 150, 200*, 300, 600* dpi
(*200 dpi is supported when the resolution is 600 dpi.)

(2) Vector graphic:

Line, Box, Circle, Arc, Fill pattern etc.

(3) Bar code:

One dimensional bar code: 45 types
Two dimensional bar code: 1 type (PDF-417)

(4) Text:

TEXT, RTXT etc.

(5) Others:

Macro, JOB, Device setting etc.

d) Connectivity

Plug &play (Parallel): Windows 9x/Me/2000/XP
Plug & play (Full-Speed USB2.0): Windows 98SE/Me/2000/XP

Resolution....................................... Fast1200 mode (1800 × 600 dpi)

600 dpi mode (600 × 600 dpi)

Dimensions (H × W × D) .................245 × 380 × 390 mm/9.6" × 15.0" × 15.4"

Weight.............................................Main unit: 9.2 kg/20.3 lbs

Power source..................................220 - 240 V AC, 50/60 Hz (European countries), 120 V AC, 60 Hz (U.S.A./Canada)

Power consumption ........................Maximum: 827 W (220 - 240 V model), 827 W (120 V model)

Normal operating: 315 W (220 - 240 V model), 294 W (120 V model)

Ready: 8 W (220 - 240 V model), 7 W (120 V model)

EcoPower: 4.8 W (220 - 240 V model), 4.4 W (120 V model)

Current............................................3.4 A (220 - 240 V model), 6.8 A (120 V model)

Noise............................................... Printing: 49 dB(A), Ready: 28 dB(A)

Options ...........................................Expansion memory (64/128/256 MB 100-pin DIMM),

memory card (Compact Flash)

2GL/2FV/2FW

1-1-7

1-1-2 Parts names

(1) Printer

Figure 1-1-1































16 ppm GDI printer 16/18 ppm printer

1. Top cover

2. Operation panel

3. Output tray

4. Paper cassette

5. Manual feed tray

6. Paper gauge

7. Paper stopper

8. Right side cover

9. Rear cover

10. AC inlet

11. Power switch

12. Toner container

13. USB interface connector

14. Parallel interface connector

2GL/2FV/2FW

1-1-8

(2) Operation panel

Figure 1-1-2

READY
indicator

GO key

ATTENTION

indicator

CANCEL key

2GL/2FV/2FW

1-1-9

1-1-3 Cross section view

Figure 1-1-3

















Paper path









1. Paper cassette

2. Manual feed tray

3. Paper feeding/conveying section

4. Toner container

5. Developer unit

6. Main charger unit

7. Drum unit

8. Laser scanner unit

9. Transfer section

10. Fuser unit

11. Paper exit section

12. Output tray

2GL/2FV/2FW

1-1-10

This page is intentionally left blank.

2GL/2FV/2FW

1-2-1

1-2 Handling Precautions

1-2-1 Drum unit and developer unit

Note the following when handling or storing the drum (drum unit).

• When removing the drum (drum unit), never expose the drum surface to strong direct light.

• Avoid abrupt changes in temperature and humidity.

• Avoid exposure to any substance which is harmful to or may affect the quality of the drum.

• Do not touch the drum surface with any object. Should it be touched by hands or stained with oil, clean it.
Developer unit and toner container
Store the developer unit and toner container in a cool, dark place.
Avoid direct light and high humidity.

1-2-2 Installation environment

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

2. Humidity: 20 - 80%RH

3. Power supply: 120 V AC (U.S.A./Canada), 220 - 240 V AC (European countries)

4. Power source frequency: 50 Hz

±2%/60 Hz ±2%

5. Installation location

• Avoid direct sunlight or bright lighting. Ensure that the photo-conductor will not be exposed to direct sunlight or other

strong light when removing paper jams.

• Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directed onto

the machine.

• Avoid dust and vibration.

• Choose a surface capable of supporting the weight of the machine.

• Place the machine on a level surface (maximum allowance inclination: 1

°).

• Avoid air-borne substances that may adversely affect the machine or degrade the photo-conductor, such as mercury,

acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.

• Select a room with good ventilation.

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

Machine front: 50 cm/19.7" Machine rear: 20 cm/7.9"
Machine right: 15 cm/5.9" Machine left: 15 cm/5.9"
Machine top: 30 cm/11.8"

Figure 1-2-1 Installation dimensions

a

c

b

a: 245 mm/9.6"
b: 380 mm/15.0"
c: 390 mm/15.4"

2GL/2FV/2FW

1-2-2

This page is intentionally left blank.

2GL/2FV/2FW

1-3-1

1-3 Installation

1-3-1 Unpacking and installation

(1) Installation procedure

Figure 1-3-1

Unpacking.

Installing the toner container.

Loading paper.

Start

Connecting the cable.

Printing a status page for test.

Completion of the machine installation.

2GL/2FV/2FW

1-3-2

Figure 1-3-2 Unpacking

Unpacking.











1. Printer

2. Installation guide

3. Toner container

4. Power cord

5. CD-ROM

2GL/2FV/2FW

1-3-3

1. Rotate the toner container 5 to 6 times and

then shake the container horizontally to dis­tribute the toner evenly.

2. Remove the label from the toner container.

Figure 1-3-3

3. Turn the toner container release lever to the

[UNLOCK] position.

4. Install the toner container in the printer.

Push firmly on the top of the container at the
positions marked [PUSH HERE] until you
hear a click.

5. Turn the toner container release lever to the

[LOCK] position.

6. Close the top cover.

Figure 1-3-4

Installing the toner container.

Toner container

Label

PUSH HERE PUSH HERE

Toner container
release lever

Toner container

Top cover

2GL/2FV/2FW

1-3-4

1. Pull the paper cassette completely out of the

printer.

Figure 1-3-5

2. Push on the base plate until it click into posi-

tion (flat).

3. Adjust the paper length guide and paper

width guides to the paper size required.

4. Load the paper in the paper cassette.

5. Push the paper cassette back into the

printer until it stops.

Figure 1-3-6

Loading paper.

Paper cassette

Paper cassette

Paper width guide

Paper width guide

Paper length guide

Base plate

Paper

2GL/2FV/2FW

1-3-5

1. Connect the printer cable to the USB or par-

allel (16/18 ppm printers only) interface con­nector.

2. Connect the other end of the printer cable to

the PC’s interface connector.

3. Connect the power cord to the printer AC

inlet.

4. Connect the power cord to the wall outlet.

Figure 1-3-7

1. Turn on the printer power switch.

2. Press the GO key for 10 seconds or more.

Test page (16 ppm GDI printer) or service
status page (16/18 ppm printers) will be
printed. See page 1-4-11 or 1-4-3.

3. Check to see if the test page or service sta-

tus page is properly printed.

Connecting the cable.

Parallel interface
connector
(16/18 ppm printers only)

Parallel cable

AC inlet

Power switch

USB interface
connector

USB cable

Power cord

Printing a status page for test.

Completion of the machine installation.

2GL/2FV/2FW

1-3-6

1-3-2 Installing expansion memory (optional for 16/18 ppm printers)

<Procedure>

1. Turn off printer power.

* Caution: Do not insert or remove expansion

memory while printer power is on.
Doing so may cause damage to the printer
and the expansion memory.

2. Open the top cover.

3. Remove the right side cover.

4. Open the stoppers of the memory socket on

the main PWB.

5. Insert the memory so that the two notches of

the memory are engaged with the projec­tions of the memory socket.

6. Close the stoppers of the memory socket.

7. Refit the right side cover.

8. Print a status page to check the memory

expansion. See page 1-4-3.

* If memory expansion has been properly per-

formed, information on the installed memory
is printed with the total memory capacity has
been increased. Standard memory capacity
16 MB (16 ppm printer), 32 MB (18 ppm
printer).

Figure 1-3-8

Right side cover

Top cover

Memory
(DIMM)

Memory socket

Stopper

Stopper

Main
PWB

2GL/2FV/2FW

1-3-7

1-3-3 Installing a memory card (optional for 16/18 ppm printers)

<Procedure>

1. Turn off printer power.

* Caution: Do not insert or remove memory

card while printer power is on. Doing so may
cause damage to the printer and the mem­ory card.

2. Insert the memory card into the memory

card socket on the main PWB.

3. Format the memory card before use. (Refer

to the operation guide.)

Figure 1-3-9

Right side cover

Top cover

Memory
card socket

Memory card

Main PWB

2GL/2FV/2FW

1-3-8

This page is intentionally left blank.

2GL/2FV/2FW

1-4-1

1-4 Maintenance Mode

1-4-1 Service 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 service mode

Printing service status page (For 16 ppm GDI printer) ................ See page 1-4-2.

Printing service status page (For 16/18 ppm printers) ................. See page 1-4-3.

Printing event log (For 16/18 ppm printers) ................................. See page 1-4-6.

Printing test page (For 16 ppm GDI printer) ................................ See page 1-4-11.

Toner install mode........................................................................ See page 1-4-11.

2GL/2FV/2FW

1-4-2

Service items Description

Printing service sta­tus page (For 16 ppm
GDI printer)

Description

Prints a status page for service purpose.
The service status page bears the serial number, engine firmware version, controller firm­ware version and the total print count. Printing a service status page should be executed by
running the dedicated 16 ppm GDI printer software run on a PC.

Purpose

To obtain printer information.

Procedure

1. Load the CD-ROM (Kyocera FS-720 Library) supplied with the printer in the optical drive
and proceed with software installation according to the instructions given.

2. Starting with Windows’s Menu, browse to the Configuration Tool window following the
steps below.

[Start] X [All Programs] X [Kyocera] X [FS-720 Printer] X [Configuration Tool]

Figure 1-4-1 Configuration tool

3. Click [Print Status Page]. A service status page is printed.

Figure 1-4-2 Service status page (For 16 ppm GDI printer)

Serial Number
SPL4700151

Engine Firmware Version
2FV_1000.001.013

Controller Firmware Version
2GL_3000.001.003

Printed Pages
2324

2GL/2FV/2FW

1-4-3

Printing service sta­tus page (For 16/18
ppm printers)

Description

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

Purpose

To acquire the current printing environmental parameters and cumulative information.

Procedure

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

Figure 1-4-3 Service status page (For 16/18 ppm printers)

Service items Description

Released: 15/Jul/2004

Main PWB
firmware version

Release date of the firmware

Firmware version: 2FV_3000.001.024

Firmware version: 132.00

Service Information

Service information
(Refer to next page)

Released: 15/Jul/2004

[0000][22.00FLB][03/03] Total page 9690

/t/P00/U00/F00/N00/

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

/1/1

A:1234567890123456

/03030303/03030303/03030303/03000000/00000000/03030303/03030303/
/03030303/03030303/03030303/03000000/00000000/03030303/03030303/
SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E

/0200000000000000/0000000000000000/0000000000000000/0000000000000000
/0000000000000000/183200005A030500/8080060C12180000/0000000000000000
/0F0000000000FF00/0000000000000000/0000000000000000/0000000000000000
/00000000

SN:SPL9200010

2GL/2FV/2FW

1-4-4

Service items Description

Service information





  

 













 

[0000][22.00FLB][03/03] Total page 9690

/t/P00/U00/F00/N00/

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

/1/1

A:1234567890123456

/03030303/03030303/03030303/03000000/00000000/03030303/03030303/
/03030303/03030303/03030303/03000000/00000000/03030303/03030303/
SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E

/0200000000000000/0000000000000000/0000000000000000/0000000000000000
/0000000000000000/183200005A030500/8080060C12180000/0000000000000000
/0F0000000000FF00/0000000000000000/0000000000000000/0000000000000000
/00000000

SN:SPL9200010

Items Description

 Engine ROM information [Flash ROM version]

 Boot ROM information [Boot ROM version]

 Software jumper switch information

(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 EU, 1: For US
bit 6 = 0: Non MICR mode, 1: MICR mode
bit 7 (Not used)
Second byte: Displayed in OEM mode only

 Tot a l p a g e

 Toner install mode

 Parallel I/O information

 USB information 00: Not connected

01: Full-Speed
02: Hi-Speed

2GL/2FV/2FW

1-4-5

Service items Description

Code conversion

ABCDEF GHI J

0123456789

Items Description

 Operation panel lock status (displayed

only when locked)

01: Partial lock
02: Full lock

 NVRAM error (displayed only when

any error has occurred)

01: ID error
02: Version error
03: Checksum error
04: NVRAM crash error

 Printable area setting /Top offset/Left offset/Page length/Page width

 Left offset for each paper source /Manual feed tray/Paper cassette/

(1/600 inches unit)

 Top offset for paper sources /Manual feed tray/

(1/600 inches unit)

 Operation panel message language PMSG command setting (decimal)

 Number of rebooting for vertical distor-

tion check

-

 fixed asset number (maximum 16 characters)

 Media type attributes Media type (paper weight) setting value from 1 to 28

(unused media types are always 0x00.)

 Media type attributes Media type (density) setting value from 1 to 28

(unused media types are always 0x00.)

 Memory SPD information (slot 1) 2 to 6 byte, 8 to 36 byte, 94 to 95 byte (total 32 byte)

 Engine parameter Hexadecimal, 128 byte (256 digits)

 Machine serial number -

NOTE:

Code conversion

ABCDEF GHI J
0123456789

2GL/2FV/2FW

1-4-6

Printing event log
(For 16/18 ppm print­ers)

Description

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

Purpose

Analyze the failure by determining the cause depending on the history of occurrence.

Procedure

1. Connect the parallel cable between printer and PC.

Figure 1-4-4

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

3. At the DOS prompt, send the following command to the printer:

echo !R! ELOG;EXIT;>prn

Event log will be printed.

Service items Description

Parallel interface
connector

Parallel cable

PC

2GL/2FV/2FW

1-4-7

Figure 1-4-5 Event log (For 16/18 ppm printers)

Service items Description

[EB20MA001/2FV_1000.001.019][C2][40.00SFLB][01]

Total page 12345 DN:SPL0000000 SN:SPL0000000

Firmware version: 2FV_30000.001.024

8 9993 10.48.01.88.01.01

7 9992 10.48.01.88.01.01

6 9991 10.48.01.88.01.01

5 9990 10.48.01.88.01.01

4 9989 10.48.01.88.01.01

3 9979 10.48.01.88.01.01

2 9969 10.48.01.88.01.01

1 1 10.48.01.88.01.01

J00: 0 J43: 0 C:6000: 4 M00: 1
J05: 0 J44: 0 C:6050: 1
J09: 0 J46:
J10: 0 J47:
J11: 0 J50:
J12: 0 J51:
J13: 0 J52:
J14: 0 J53:
J15: 0 J60:
J16: 0 J61:
J23: 0 J86:
J30: 0 J87:
J35: 0 J88:
J40: 0 J89:
J41:
J42:

Released: 15/Jul/2004

# 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 02.00
7 10000 02.00
6 9999 02.00
5 9998 02.00
4 9997 02.00
3 9996 02.00
2 9995 02.00
1 9994 02.00

# Count. item

















  

(i)

10.48.01.88.01.01

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

(h)

(g)

2GL/2FV/2FW

1-4-8

Service items Description

Items Description

 Engine/high voltage PWB mask

version

[Engine mask version/Engine software version]

 Operation panel PWB mask

version

-

 BROM version

 Software jumper switch infor-

mation
(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

 Main PWB mask version

 Main PWB firmware release

date

 Total page counter

 Drum serial number

 Printer serial number

 Paper Jam Log #

Remembers 1 to 8th of
occurrence. If the
occurrence of the
previous paper jam is
less than 8, all of the
paper jams are logged.
When the occurrence
execeeds 8, the oldest
occurrence is removed.

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

Event
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.

2GL/2FV/2FW

1-4-9

Service items Description

Items Description



cont.

(a) Cause of paper jam

10: Paper does not arrive at the registration sensor. [42]
10: Paper does not arrive at the registration sensor. [43]
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]
E0: Paper misfeed occurs due to forced stop when an error occurs
during printing. (such as opening of the top cover)
F0 to FF: Paper misfeed by another cause.

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

(b) Detail of jam location

(c) Detail of paper source (Hexadecimal)

00: Manual feed tray
01: Paper cassette
02 to 07, 09: Not used

(d) Detail of paper size (Hexadecimal)

01: Monarch
02: Business
03: International DL
04: International C5
05: Executive
06: Letter-R
86: Letter-E
07: Legal
08: A4R
88: A4E
09: B5R
89: B5E
0A: A3
0B: B4

0C: Ledger
0D: A5
0E: A6
0F: B6
10: Commercial 9
11: Commercial 6
12: ISO B5
13: Custom
1E: International
C4
1F: JIS hagaki
20: JIS oufuku
21: Officio2
22: Special 1

23: Special 2
24: A3 wide
25: Ledger wide
26: Full bleed
paper (12 × 18)
27: 8K
28: 16K-R
A8: 16K-E
32: Statement-R
B2: Statement-E
33: Folil
34: Youkei 2
35: Youkei 4

[42]

[43]

[48]

[47]

Exit sensor

Registration
sensor

2GL/2FV/2FW

1-4-10

Service items Description

Items Description



cont.

(e) Detail of paper type (Hexadecimal)

01: Plain
02: Transparency
03: Preprint
04: Labels
05: Bond
06: Recycle
07: Vellum
08: Rough
09: Letter head

0A: Color
0B: Prepunched
0C: Envelope
0D: Cardstock
0E: Coated
0F: 2nd side
10: Media 16
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

01: Output tray 02 to 48: Not used

 Service Call Log

(Self diagnostic error)

# Count. Self diagnostic

error code

Remembers 1 to 8 of
occurrence of self
diagnostics error. If the
occurrence of the
previous 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.

See page 1-5-3.

 Maintenance Log # Count. Item

Remembers 1 to 8 of
occurrence 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 cat­egory)

01: Toner con­tainer

 Counter Log

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

(g) Jam (h) Self diagnostic error (i) Toner container

replacing

Indicates the log counter
of paper jams depend­ing on location.

Refer to  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 1-5-3.

Example:
C6000: 4

Self diagnostics error
6000 has happened
four times.

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

T: To n e r c o n ta i ne r
00: Black

Example:
T00: 1

The (black) toner
container has
been replaced
once.

2GL/2FV/2FW

1-4-11

Printing test page
(For 16 ppm GDI
printer)

Description

Prints a test page for service purpose. A page showing a grid image is printed.

Purpose

Performs check on operation and printing image.

Procedure

Press the GO key for 10 seconds or more. Test page will be printed.

Figure 1-4-6 Test page (For 16 ppm GDI printer)

Toner install mode Description

Rotates the drum approximately 15 minutes with toner lightly applied onto the drum using
the high-voltage output control of the engine/high voltage PWB. The cleaning blade in the
drum unit scrapes toner off the drum surface to clean it.

Purpose

To clean the drum surface when an image failure occurs due to contamination. This mode is
useful after the dew condensation on the drum occurs.

Procedure

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

Service items Description

2GL/2FV/2FW

1-4-12

This page is intentionally left blank.

2GL/2FV/2FW

1-5-1

1-5 Troubleshooting

1-5-1 Paper misfeed detection

(1) Paper misfeed indication

When a paper misfeed occurs, the printer immediately stops printing and flash the ATTENTION indicator. To remove paper
misfeed in the printer, pull out the paper cassette or open the rear cover.

Figure 1-5-1 Paper misfeed indication

ATTENTION

indicato

r

2GL/2FV/2FW

1-5-2

(2) Paper misfeed detection

Figure 1-5-2 Paper misfeed detection

Exit sensor

Registration
sensor

2GL/2FV/2FW

1-5-3

1-5-2 Self-diagnosis

(1) Self-diagnostic function

When a self diagnostics error occurs, the printer halts and displays the appropriate error code using a combination of the
READY and ATTENTION indicators.

Figure 1-5-3 Self-diagnostic code indication

Off

Off

Lit

Lit

LED indicator

Indication example

E6

111 1100

1E0

E1

E2

E3

E4

E6

F1

F2

F3

D97980

7990

F040

F010

F020

F030

2000

4000

4200

6050

6000
6010

F050

2 digits4 digits

Self-diagnostic code

DA

11 0 0 000

111 0 0 100

111 0 1 000

111 0 1 100

111 1 0 000

111 1 1 000

111 0 0 110

111 0 1 010

111 0 1 110

110 0 0 111

A06400 1 0 1 0 0 000

110 0 1 011

ATTENTION indicator

Interval

(Hexadecimal)

Repeat

Example: self-diagnostic code: E6 (F050)

Self-diagnostic code conversion table

READY indicator (Green)

READY

ATTENTION indicator (Amber)

ATTENTION

0

7.3 s

2.4 s

16/18 ppm printers only

Remark

The ATTENTION indicator means 1 when it flashes in synchronization with the
READY indicator which flashes at the interval of 1.2 second; and it means 0 when it
turns off: This is repeated 8 times. Two digit self diagnostics codes are indicated in 8
bits (2 digits hexadecimal) using the ATTENTION indicator.

Indicates the
occurrence of a self
diagnostics error.

2GL/2FV/2FW

1-5-4

(2) Self diagnostic codes

Code Contents

Remarks

Causes Check procedures/corrective measures

2000

(E1)

Main motor error

• The main motor ready input is not
given for two seconds during the main
motor is driven.

Defective harness
between engine/
high voltage PWB
and main motor.

Follow the flow chart.

Defective main
motor.

Defective engine/
high voltage PWB.

Defective drive
unit.

No

No

No

No

OK?

Yes

Yes

Print status page.

Start

Reinsert the connector
of harness between
engine/high voltage
PWB and main motor.

Yes

Yes

Connect circuit tester to
pin 1 of CN1 connector
on the main motor.

Connect circuit tester to
pin 5 (REMOTE) of YC5
connector on the
engine/high voltage
PWB.

Replace engine/high
voltage PWB. See page
1-6-17.

Connect oscilloscope to
pin 5 (REMOTE) and pin
3 (MMOTRDY) of CN1
connector on the main
motor.

Print status page.

Replace the main motor. See
page 1-6-24. If not solved,
check or replace drive unit. See
page 1-6-23.

24 V DC

at pin 1 of CN1

connector on the main

motor?

Does pin

5 (REMOTE)

of YC5 connector on

the engine/high voltage

PWB goes high,

then low?

Does pin 3

(MMOTRDY) of

CN1 connector on the

main motor goes high, then low,

within 2 seconds from pin

5 (REMOTE) goes

low?

Replace harness between
engine/high voltage PWB and
main motor.

Turn printer power off,
then on.

Turn printer power off,
then on.

2GL/2FV/2FW

1-5-5

4000

(E2)

Polygon motor (laser scanner unit)
error

• The polygon motor ready input is not
given for eight seconds during the
polygon motor is driven.

Defective harness
between engine/
high voltage PWB
and laser scanner
unit.

Follow the flow chart.

Defective engine/
high voltage PWB.

Defective polygon
motor (laser scan­ner unit).

Code Contents

Remarks

Causes Check procedures/corrective measures

No

No

No

No

No

No

OK?

OK?

OK?

End.

End.

Start

End.

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Connect oscilloscope to
pin 1 (PLGCLK) and pin
3 (PLGON) of YC3
connector on the
engine/high voltage
PWB.

Connect oscilloscope to
pin 2 (PLGDRY) and pin
3 (PLGON) of YC3
connector on the
engine/high voltage
PWB.

Turn power switch off,
then on.

Turn power switch on.

Turn power switch on.

Turn power switch off,
then on.

Turn power switch on.

* 1417 Hz (705

µs)

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace laser scanner
unit. See page 1-6-21.

Replace harness between
engine/high voltage PWB
and laser scanner unit.

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace laser scanner
unit. See page 1-6-xx.

+24 V DC

at pin 5 of YC3

connector on the

engine/high voltage

PWB?

Does pin 3
(PLGON) of YC3
connector on the

engine/high voltage PWB

goes high, then

low?

Does pin

2 (PLGDRY) of

YC3 connector on the

engine/high voltage PWB goes

high, then low, within 8 seconds

after pin 5 (REMOTE)

goes high, then

low?

Does pin

1 (PLGCLK) of

YC3 connector on the

engine/high voltage PWB

output square-wave

*

signal?

Replace harness between
engine/high voltage PWB
and laser scanner unit.

2GL/2FV/2FW

1-5-6

4200

(E3)

PD (Pin photo diode) sensor (laser
scanner unit) error

• The first BD input is not given for 10
seconds after power is turned on and
the laser begins emitting.

• The first BD input is not given for 7
seconds during printing and after the
laser begins emitting.

Defective main
PWB.

Follow the flow chart.

Defective harness
between main
PWB and engine/
high voltage PWB.

Defective engine/
high voltage PWB.

Code Contents

Remarks

Causes Check procedures/corrective measures

No

No

No

No

No

OK?

OK?

End.

End.

Start

(A)

(B)

Yes

Yes

Yes

Yes

Yes

Turn power switch on.

Turn power switch on.

*

1

:16 ppm GDI printer

*

2

:16/18 ppm printers

Connect oscilloscope to
pin 3 (OUTPEN) of
YC4*

1

/YC6*2 connector

on the main PWB.

Connect oscilloscope to
pin 3 (OUTPEN) and pin
7 ( ) of YC4*

1

/YC6*2
connector on the main
PWB.

Turn power switch off,
then on.

Turn power switch off,
then on.

Replace main PWB.
See page 1-6-15 or 16.

Replace main PWB.
See page 1-6-15 or 16.

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace harness between
main PWB and engine/high
voltage PWB.

Continued to
next page.

Continued to
next page.

*3 Pin photo diode sensor detect
horizontal synchronization signal
(Frequency: 1417 Hz, Low level
width: 10

µs)

5 V DC

at pin 5 of

YC4*

1

/YC6*2 connector

on the main PWB?

Does pin

3 (OUTPEN) of

YC4*

1

/YC6*2 connector

on the main PWB goes high,

then before "4200"

error?

Does pin

7

(PDN) of

YC4*

1

/YC6*2 connector

on the main PWB

output pulse

signal

*

3

, within 0.1 second after

pin 3 (OUTPEN) goes

high, then low?

2GL/2FV/2FW

1-5-7

4200

(E3)

cont.

Code Contents

Remarks

Causes Check procedures/corrective measures

No

No

OK?

OK?

No

OK?

No

OK?

End.

End.

No

OK?

No

OK?

End.

End.

Continued from
previous page.

Continued from
previous page.

Yes

Yes

Yes

Yes

Yes

Yes

Turn power switch on.

Turn power switch on.

Turn power switch on.

Turn power switch on.

Turn power switch on.

Replace laser scanner
unit. See page 1-6-21.

Replace main PWB. See
page 1-6-15 or 16.

Replace main PWB. See
page 1-6-15 or 16.

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace harness
between main PWB and
laser scanner unit.

Replace harness
between main PWB
and laser scanner unit.
See page 1-6-15 or 16.

Replace harness between
main PWB and engine/high
voltage PWB.

Replace harness between
main PWB and engine/high
voltage PWB.

(A)

(B)

2GL/2FV/2FW

1-5-8

6000

(E4)

Broken heater lamp error

• The temperature won’t rise by 1
degree Celsius during warming up and
the heater is turned on for 5 seconds.

• The temperature won’t rise by 1
degree Celsius during printing and the
heater is turned on for 5 seconds with
the duty cycle more than 60%.

Defective fuser
thermistor.

Follow the flow chart.

Broken thermal
cutout or heater
lamp.

Defective engine/
high voltage PWB.

Code Contents

Remarks

Causes Check procedures/corrective measures

No

No

Start

Yes

Yes

Replace the engine/high
voltage PWB.
See page 1-6-17.

Replace the fuser
thermistor.
See page 1-6-11.

Replace the thermal
cutout or heater lamp.
See page 1-6-11.

Turn power switch off,
and remove power cord.

Detach YC7 connector
on the engine/high
voltage PWB.

Detach YC1 connector
on the power source
PWB.

Measure resistance
between pins 1 and 2 of
the detached connector.

Measure resistance
between pins 1 and 2 of
the detached connector.

Open

(infinite)?

Open

(infinite)?

2GL/2FV/2FW

1-5-9

6010

(E4)

Fuser low temperature

• After the fuser heater lamp is turned
on, the temperature at the upper fuser

roller lower than 100

°C/212 °F contin-

ues for 30 s.

Defective the fuser
thermistor.

Follow the flow chart.

Defective the
engine/high volt­age PWB.

Code Contents

Remarks

Causes Check procedures/corrective measures

No

Start

Yes

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace the engine/high
voltage PWB.
See page 1-6-17.

Check the installation
condition of the fuser
thermistor. See page 1­6-11.

Remedy or replace the
fuser thermistor.

OK?

No

Yes

End.

Turn power switch off,
then on.

"6010" error

shown?

2GL/2FV/2FW

1-5-10

6050

(E4)

Broken fuser thermistor

• The thermistor AD value is less than 1
for 3 s.

Defective the fuser
thermistor.

Follow the flow chart.

Defective the
engine/high volt­age PWB.

6400

(A0)

Zero cross signal error

• While fuser heater ON/OFF control is
performed, the zero-cross signal is not
input within 3 s.

Defective the
power source
PWB.

Follow the flow chart.

Defective the
engine/high volt­age PWB.

Code Contents

Remarks

Causes Check procedures/corrective measures

No

Start

Yes

Replace engine/high
voltage PWB.
See page 1-6-17.

Replace fuser thermistor.
See page 1-6-11.

Turn power switch off,
and remove power cord.

Detach YC7 connector
on the engine/high
voltage PWB.

Measure resistance
between pins 1 and 2 of
the detached connector.

Open

(infinite)?

No

OK?

End.

Start

Yes

Replace the power
source PWB.
See page 1-6-17.

Replace the engine/high
voltage PWB.
See page 1-6-17.

2GL/2FV/2FW

1-5-11

7980

(D9)

Waste toner full (Total page count less
than 100,000 pages of printing)

• The toner-full sensor has detected that
the waste toner is full before the total
print page of less than 100,000 pages.

Defective drum
unit.

Follow the flow chart.

Defective waste
toner full sensor.

Defective engine/
high voltage PWB.

Code Contents

Remarks

Causes Check procedures/corrective measures

No

No

End.

Yes

Yes

Turn power switch off,
then on.

Turn power switch off,
then on.

Shake the drum unit
horizontally.

Replace the drum unit.
See page 1-6-6.

Replace the waste toner full
sensor or engine/high voltage
PWB. See page 1-6-17.

Start

"7980" error

shown?

"7980" error

shown?

2GL/2FV/2FW

1-5-12

7990
(DA)

Waste toner full (Total page count
more than 100,000 pages of printing)

• The toner-full sensor has detected that
the waste toner is full before the total
print page of more than 100,000
pages.

Defective drum
unit.

Follow the flow chart.

Defective waste
toner full sensor.

Defective engine/
high voltage PWB.

Code Contents

Remarks

Causes Check procedures/corrective measures

No

No

End.

Yes

Yes

Turn power switch off,
then on.

Turn power switch off,
then on.

Shake the drum unit
horizontally.

Replace the drum unit.
See page 1-6-6.

Replace waste toner full
sensor or engine/high voltage
PWB. See page 1-6-17.

Start

"7990" error

shown?

"7990" error

shown?

2GL/2FV/2FW

1-5-13

F010

(F1)

Code ROM checksum error (16/18
ppm printers only)

• Checksum for the code ROM that
holds the system program is wrong.

Defective code
ROM (on-board).

Replace the main PWB. See page 1-6-16.

Defective PWB. Replace the main PWB. See page 1-6-16.

F020

(F2)

Memory check error

• Access to the expansion memory
(DIMM) or RAM on the main PWB
failed.

Defective main
PWB.

Replace the main PWB. See page 1-6-15 or
1-6-16.

Defective expan­sion memory
(DIMM).
(16/18 ppm print­ers only)

Replace the expansion memory (DIMM).
See page 1-3-6.

F030

(F3)

Main PWB system error

• The error pertaining to the system
occurred except the F0 (F010) condi­tion.

Defective main
PWB.

Replace the main PWB. See page 1-6-15 or
1-6-16.

F040

(E0)

Main - Engine communication error

• The communication breakdown
occurred between the main PWB and
the engine/high voltage PWB during
the predetermined period in seconds.

Defective engine/
high voltage PWB.

Replace the engine/high voltage PWB. See
page 1-6-17.

Defective main
PWB.

Replace the main PWB. See page 1-6-15 or
1-6-16.

F050

(E6)

Engine checksum error

• Checksum result failed with the CPU
and engine/high voltage PWB.

Defective engine/
high voltage PWB.

Replace the engine/high voltage PWB. See
page 1-6-17.

Code Contents

Remarks

Causes Check procedures/corrective measures

2GL/2FV/2FW

1-5-14

1-5-3 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 1-6-17.

Blown fuse in the power
source PWB.

Check for continuity. If none, remove the cause of blowing and
replace the fuse.

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

none, replace the engine/high voltage PWB. See page 1-6-17.

Defective power source
PWB or engine/high voltage
PWB.

With AC present, check for 5 V DC at YC4-11, YC7-2, YC10-1,
YC6-1, and 24 V DC at YCYC3-5, YC3-6, YC5-1 YC9-1 on the
engine/high voltage PWB. If none, replace the power source PWB
or engine/high voltage PWB. See page 1-6-17.

(2)
The main motor does
not operate
(Self diagnostic code

2000).

Poor contact in the main
motor connector terminals.

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

Broken main motor gear. Check visually and replace the main motor if necessary.

Defective main motor. Replace the main motor. See page 1-6-24.

Defective engine/high volt­age PWB.

Replace the engine/high voltage PWB. See page 1-6-17.

(3)
The cooling fan
motor does not oper­ate.

Broken cooling fan motor
coil.

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

Poor contact in cooling fan
motor connector terminals.

Reinsert the connector.

(4)
The registration
clutch does not oper­ate.

Broken registration clutch
coil.

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

Poor contact in the registra­tion clutch connector termi­nals.

Reinsert the connector.

Defective harness between
connect PWB and engine/
high voltage PWB.

Check for continuity across the harness. If none, replace the char­ness.

Defective engine/high volt­age PWB.

Replace the engine/high voltage PWB. See page 1-6-17.

Defective connect PWB. Replace the connect PWB.

2GL/2FV/2FW

1-5-15

(5)
The feed clutch does
not operate.

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

clutch.

Poor contact in the feed
clutch connector terminals.

Reinsert the connector.

Defective harness between
connect PWB and engine/
high voltage PWB.

Check for continuity across the harness. If none, replace the char­ness.

Defective engine/high volt­age PWB.

Replace the engine/high voltage PWB. See page 1-6-17.

Defective connect PWB. Replace the connect PWB.

(6)
The eraser lamp
(PWB) does not turn
on.

Poor contact in the eraser
lamp (PWB) connector ter­minals.

Reinsert the connector.

Defective eraser lamp
(PWB).

Check for continuity. If none, replace the eraser lamp (PWB). See
page 1-6-22.

Defective engine/high volt­age PWB.

If the eraser lamp (PWB) turns on when YC8-2 on the engine/high
voltage PWB is held low, replace the engine/high voltage PWB.
See page 1-6-17.

(6)
The heater lamp
does not turn on.

Broken wire in heater lamp. Check for continuity across each heater lamp. If none, replace the

heater lamp. See page 1-6-11.

Thermal cutout triggered. Check for continuity across thermal cutout. If none, remove the

cause and replace the thermal cutout. See page 1-6-11.

(7)
The heater lamp
does not turn off.

Broken fuser thermistor.

Measure the resistance. If it is ∞Ω, replace the fuser thermistor.
See page 1-6-11.

Dirty sensor part of the
fuser thermistor.

Check visually and clean the fuser thermistor sensor parts. See
page 1-6-11.

(8)
No main charging.

Poor insertion main charger
unit.

See page 1-5-18.

Broken main charger wire.

Poor contact of main
charger terminal and high
voltage output terminal on
the engine/high voltage
PWB.

Defective engine/high volt­age PWB.

(9)
No developing bias is
output.

Poor insertion developer
unit.

See page 1-6-6, 1-6-17, 1-5-18.

Poor contact of developing
bias terminal spring and
high voltage output termi­nal (TAB1) on the engine/
high voltage PWB.

Defective engine/high volt­age PWB.

Problem Causes Check procedures/corrective measures

2GL/2FV/2FW

1-5-16

(10)
No transfer bias is
output.

Poor contact of transfer
bias terminal and transfer
bias terminal (J1, J2, J3) on
the engine/high voltage
PWB.

See page 1-5-18, 1-6-17.

Defective engine/high volt­age PWB.

(11)
The message
requesting paper to
be loaded is shown
when paper is
present in the paper
cassette.

Defective paper sensor on
the engine/high voltage
PWB.

Replace the engine/high voltage PWB. See page 1-6-17.

(12)
A paper jam in the
paper feeding/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 engine/high volt­age PWB.

Replace the engine/high voltage PWB. See page 1-6-17.

Defective exit sensor on the
power source PWB.

Replace the power source PWB. See page 1-6-17.

(13)
The indicator
requesting cover to
be closed is dis­played when the top
cover is closed.

Defective interlock switch
on the engine/high voltage
PWB.

Check for continuity across the interlock switch. If there is no con­tinuity when the interlock switch is on, replace the engine/high
voltage PWB. See page 1-6-17.

Problem Causes Check procedures/corrective measures

2GL/2FV/2FW

1-5-17

1-5-4 Image formation problems

(1) Completely

blank printout.

(2) All-black print-

out.

(3) Dropouts. (4) Black dots. (5) Black horizon-

tal streaks.

See page 1-5-18. See page 1-5-18. See page 1-5-19. See page 1-5-19. See page 1-5-20.

(6) Black vertical

streaks.

(7) Unsharpness. (8) Gray back-

ground.

(9) Dirt on the top

edge or back of
the paper.

(10)Undulated print-

ing at the right
edge (scanning
start position).

See page 1-5-20. See page 1-5-21. See page 1-5-21. See page 1-5-22. See page 1-5-22.

ABC
123

ABC
123

ABC
123

ABC
123

ABC
123

ABC
123

This vertical
line should
be straight.

2GL/2FV/2FW

1-5-18

(1) Completely blank printout. Causes

1. Defective drum unit or developer unit.

2. Defective transfer bias potential.

3. Defective laser scanner unit.

4. Defective main PWB.

Causes Check procedures/corrective measures

1. Defective drum unit or developer unit. Open the printer top cover and check that the drum unit and developer
unit is correctly seated. Check for poor contact of the main charger termi­nal between the main charger unit and the drum unit.

2. Defective transfer bias potential.

Check the transfer bias output on the engine/high voltage PWB. This
requires removal of the left cover and the test equipment. Replace the
engine/high voltage PWB if high voltage potential is not available on the
PWB. See page 1-6-17.

3. Defective laser scanner unit. The scanner components within the scanner may be disordered. Replace
the laser scanner unit. See page 1-6-20.

4. Defective main PWB. Defective laser scanner unit control circuit in the main PWB. See page 1­6-15 or 1-6-16.

(2) No image appears

(entirely black).

Causes

1. Defective main charger unit.

2. Defective main charger high voltage output.

3. Defective engine/high voltage PWB.

4. Defective main PWB.

Causes Check procedures/corrective measures

1. Defective main charger unit. Open the printer top cover and check that the drum unit is correctly
seated. Check for poor contact of the main charger terminal between the
main charger unit and the drum unit.

2. Defective main charger high voltage out-

put.

Make sure the main charger high voltage output from the engine/high
voltage PWB correctly arrives at the drum unit (main charger unit).

3. Defective engine/high voltage PWB.

Check the high voltage output on the engine/high voltage PWB. Replace
the engine/high voltage PWB if high voltage potential is not available on
the PWB. See page 1-6-17.

4. Defective main PWB. Replace the main PWB. See page 1-6-15, 1-6-16.

2GL/2FV/2FW

1-5-19

(3) Dropouts. Causes

1. Defective developing roller (in the developer unit).

2. Defective drum unit.

3. Defective fuser unit.

4. Defective paper specifications.

5. Defective transfer roller installation.

6. Defective engine/high voltage PWB (transfer bias potential).

Causes Check procedures/corrective measures

1. Defective developing roller (in the devel-

oper unit).

If the defects occur at regular intervals of 47.2 mm, the problem may be
the damaged developing roller (in the developer unit). Replace the devel­oper unit. See page 1-6-6.

2. Defective drum unit.

If the defects occur at regular intervals of 94 mm, the problem may be the
damaged drum (in the drum unit). Replace the drum unit. See page 1-6-

7.

3. Defective fuser unit.

If the defects occur at regular intervals of 63 mm (heat roller or press
roller), the problem may be the damaged fuser unit. Replace the press
roller or heat roller. See page 1-6-11.

4. Defective paper specifications.

Paper with rugged surface or dump tends to cause dropouts. Replace
paper with the one that satisfies the paper specifications.

5. 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 1-6-11.

6. Defective engine/high voltage PWB

(transfer bias potential).

Check the transfer bias output on the engine/high voltage PWB. This
requires removal of the left cover and the test equipment. Replace the
engine/high voltage PWB if high voltage potential is not available on the
PWB. See page 1-6-17.

(4) Black dots. Causes

1. Defective drum unit.

Causes Check procedures/corrective measures

1. Defective drum unit. If the defects occur at regular intervals of 94 mm, the problem may be the
damaged drum (in the drum unit). Replace drum unit. See page 1-6-7.
If the defects occur at random intervals, the toner may be leaking from the
developer unit and drum unit. Replace developer unit and drum unit. See
page 1-6-6, 1-6-7.

ABC
123

ABC
123

2GL/2FV/2FW

1-5-20

(5) Black horizontal streaks. Causes

1. Defective drum unit’s ground.

2. Defective drum unit

Causes Check procedures/corrective measures

1. Defective drum unit’s ground. The drum axle in the drum unit and its counter part, the grounding tab in
the printer, must be in a good contact. If necessary, apply a small amount
of electro-conductive grease onto the tab.

2. Defective drum unit. Replace the drum unit. See page 1-6-7.

(6) Black vertical streaks. Causes

1. Contaminated main charger wire.

2. Defective drum surface.

3. Defective magnet roller (in the developer unit).

Causes Check procedures/corrective measures

1. Contaminated main charger wire. Clean the main charger wire by sliding the green colored cleaning knob in
and out several times.

2. Defective drum surface. 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 1-6-7.

3. Defective magnet roller (in the developer

unit).

Replace the developer. See page 1-6-6.

ABC
123

ABC
123

2GL/2FV/2FW

1-5-21

(7) Unsharpness. Causes

1. Defective paper specifications.

2. Defective transfer roller installation.

3. Defective transfer bias potential.

4. EcoPrint setting.

Causes Check procedures/corrective measures

1. Defective paper specifications.

Paper with rugged surface or dump tends to cause unsharp printing.
Replace paper with the one that satisfies the paper specifications.

2. 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 1-6-5.

3. Defective transfer bias potential.

Check the transfer bias output on the engine/high voltage PWB. This
requires removal of the left cover and the test equipment. Replace the
engine/high voltage PWB if high voltage potential is not available on the
PWB. See page 1-6-17.

4. EcoPrint 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.

(8) Gray background. Causes

1. Print density setting.

2. Defective drum surface potential.

3. Defective main charger grid.

4. Developing roller (in the developer unit).

Causes Check procedures/corrective measures

1. Print density setting.

The print density may be set too high. Try adjusting the print density. For
details refer to the printer's operation guide.

2. Defective drum surface potential.

The drum surface potential should be approximately 470±15 V. This may
vary depending on production lots. Measurement is possible only by
using the jig and tool specifically designed for this purpose. The drum unit
will have to be replaced if it bears values far out of the allowable range.

3. Defective main charger grid.

Clean the main charger grid.

4. Defective developing roller (in the devel-

oper unit).

If a developer unit which is known to work normally is available for check,
replace the current developer unit in the printer with the normal one. If the
symptom disappears, replace the developer unit with a new one. See
page 1-6-6.

ABC
123

2GL/2FV/2FW

1-5-22

(9) Dirt on the top edge or back of

the paper.

Causes

1. Toner contamination in various parts.

2. Defective transfer roller.

Causes Check procedures/corrective measures

1. 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, paper transportation paths, the bottom
of the drum and developer, and the fuser unit inlet. Clean these areas
and parts to remove toner.

2. Defective transfer roller.

If the transfer roller is contaminated with toner, clean the transfer roller
using a vacuum cleaner or by continuously printing a low-density page
until the symptom has faded away.

(10)Undulated printing at the right

edge (scanning start position).

Causes

1. Defective laser scanner unit.

2. Defective engine controller circuit in the engine/high voltage PWB

Causes Check procedures/corrective measures

1. Defective laser scanner unit.

Defective polygon motor in the laser scanner unit. Replace the laser
scanner unit. See page 1-6-20.

2. Defective engine controller circuit in the

engine/high voltage PWB.

Replace the engine/high voltage PWB. See page 1-6-17.

ABC
123

This vertical
line should
be straight.

2GL/2FV/2FW

1-5-23

1-5-5 Mechanical problems

Problem Causes/check procedures Corrective measures

(1)
No primary paper feed.

Check if the surfaces of the 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. See page 1-6-4.

Defective 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 is worn. Replace the separator pad if it is worn.

Check if the paper is curled. Change the paper.

(5)
Paper jams.

Check if the paper is excessively curled. Change the paper.

Check if the contact between the upper and
lower registration rollers is correct.

Check visually and remedy if necessary.

Check if the upper and lower fuser roller is
extremely dirty or deformed.

Clean or replace the upper and lower fuser
roller.

Check if the contact between the FD roller
and FD pulley is correct.

Check visually and remedy if necessary.

(6)
Toner drops on the paper
conveying path.

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

Clean the drum unit or developer unit.

(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: Feed clutch
and registration clutch.

Check visually and remedy if necessary.

2GL/2FV/2FW

1-5-24

This page is intentionally left blank.

2GL/2FV/2FW

1-6-1

1-6 Assembly and Disassem bly

1-6-1 Precautions for assembly and disassembly

(1) Precautions

Be sure to turn the power switch off and disconnect the power plug before starting disassembly.
When handling PWBs (printed wiring boards), do not touch parts with bare hands. The PWBs are susceptible to static
charge.
Do not touch any PWB containing ICs with bare hands or any object prone to static charge.
Use only the specified parts to replace the fuser thermostat. Never substitute electric wires, as the printer may be seriously
damaged.
Use the following circuit testers when measuring voltages:

• Hioki 3200

• Sanwa MD-180C

• Sanwa YX-360TR

• Beckman TECH300

• Beckman DM45

• Beckman 330 (Capable of measuring RMS values.)

• Beckman 3030 (Capable of measuring RMS values.)

• Beckman DM850 (Capable of measuring RMS values.)

• Fluke 8060A (Capable of measuring RMS values.)

• Arlec DMM1050

• Arlec YF1030C

2GL/2FV/2FW-1

1-6-2

1-6-2 Outer covers

(1) Detaching and refitting the right side cover, right cover, left cover, and top cover

<Procedure>

1. Open the top cover.

2. Remove the right side cover.

Figure 1-6-1 Removing the right side cover

3. Remove the paper cassette.

4. Unlatch the four latches and then remove
the right cover.

Figure 1-6-2 Removing the right cover

Right side cover

Top cover

Right cover

:Four latches
(cover inside)

2GL/2FV/2FW-1

1-6-3

5. Remove the left cover by removing three
hooks and three latches.

* When refitting the left cover, attach in order

( to ) shown in a figure 1-6-3.

Figure 1-6-3 Removing the left cover

6. Remove the one connector.

7. While opening the rear cover and then
remove the two screws.

8. While unhooking the hooks and then
remove the top cover.

Figure 1-6-4 Removing the top cover

: Three latches
(cover inside)

Left cover

Left cover

Hooks

Hook





















Procedure of refitting the left cover

Screw

Screw

Rear cover

Hook

Hook

Connector

Top cover

2GL/2FV/2FW

1-6-4

1-6-3 Paper feeding/conveying section

(1) Detaching and refitting the paper feed roller

<Procedure>

1. Remove the paper cassette.

2. Remove the paper feed roller.

Figure 1-6-5 Removing the paper feed roller

Paper feed roller

2GL/2FV/2FW

1-6-5

(2) Detaching and refitting the transfer roller

<Procedure>

1. Remove the developer unit and drum unit.
See page 1-6-6.

2. Remove the transfer roller from bushes.

Figure 1-6-6 Removing the transfer roller

Transfer roller

Transfer roller

Bush (black)

Spring
(black)

Transfer roller gear

Bush

Spring

Paper passing direction

Paper passing
direction

Bush

LongShort

2GL/2FV/2FW-1

1-6-6

1-6-4 Process section

(1) Detaching and refitting the developer unit and drum unit

When replacing the drum unit which was, for example, damaged due to scratches, the waste toner reservoir is full, per­form the drum unit optimization procedure. See page 1-6-7.

<Procedure>

1. Open the top cover.

2. Remove the developer unit (with toner con­tainer.

Figure 1-6-7 Removing the developer unit

3. Remove the drum unit.

Figure 1-6-8 Removing the drum unit

Developer unit

Top cover

Drum unit

2GL/2FV/2FW-1

1-6-7

(2) Drum unit optimization

When replacing the drum unit which was, for example, damaged due to scratches, the waste toner reservoir is full, per­form the drum unit optimization procedure (drum unit optimization sets the proper main charger current control according
to the surface sensitivity of the drum).

<Procedure>

1. Turn power off.

2. Open the top cover.

3. Remove the developer unit.

Figure 1-6-9 Developer unit

4. Remove the old drum unit.

5. Install the new drum unit.

6. Close the top cover (without installing the
developer unit).

7. Turn power on. The LED indicators dis­played developer unit missing error indica­tion.

READY indicator: Off
ATTENTION indicator: Lit

8. Press the CANCEL key 5 seconds or more.

9. Drum unit optimization is complete when let­ting go off of the CANCEL key.

[Completion]

* Printer starts idling for 10 seconds. (Idling

can be checked by rotation of FD roller)

[Failure]

* Printer does not start idling. Time to press

the CANCEL key was 5 seconds or less.
Redo from step 8.

10. Open the top cover.

11. Install the developer unit.

12. Close the top cover.

Figure 1-6-10 Drum unit and operation panel

Developer unit

Top cover

Drum unit

Top cover

FD roller

READY
indicator

ATTENTION

indicator

CANCEL key

2GL/2FV/2FW

1-6-8

(3) Detaching and refitting the main charger unit

<Procedure>

1. Remove the drum unit. See page 1-6-6.

2 While pushing on the main charger terminal

(), slide the main charger unit ().

3. Remove the main charger unit () by lifting
it.

Figure 1-6-11

Main charger unit

Drum unit

Main charger
terminal

Main charger unit







2GL/2FV/2FW

1-6-9

1-6-5 Fuser unit

(1) Detaching and refitting the fuser unit

<Procedure>

1. Remove the outer covers. See page 1-6-2.

2. Remove the two connectors.

3. Remove the wire from two clamps.

Figure 1-6-12

4. Pull out the rear cover axis (with spring)
from the axis hole () on side.

5. Pull out the rear cover axis from the axis
hole () on side and remove the rear cover
and the spring.

Figure 1-6-13

Connector

Clamp

Clamp

Wire

Connector

Spring

Spring

Rear cover

Axis

Axis hole

Axis

Axis hole





2GL/2FV/2FW

1-6-10

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

Figure 1-6-14

7. Remove the two screws and then separate
the upper fuser frame and lower fuser
frame.

Figure 1-6-15

Fuser unit

Screw

Screw

Screw

Screw

Upper fuser frame

Lower fuser frame

2GL/2FV/2FW

1-6-11

(2) Detaching and refitting the heater lamp, heat roller, fuser thermistor, thermal cutout, and press roller

<Procedure>

1. Remove the fuser unit. See page 1-6-9.

2. Remove the two screws and terminal.

3. Remove the heater lamp.

* Seat the heater lamp aligning its wattage

mark and welding mark faced with the cor­rect direction and side.

Figure 1-6-16

Screw

Heat gear

Welding mark

Screw

Terminal

Heater lamp

Wattage
mark

Heater lamp

2GL/2FV/2FW

1-6-12

4. Pull the heat R bush and heat L bush (with
heat roller) from the upper fuser guide.

5. Remove the heat R bush, heat L bush and
heat gear from the heat roller.

Figure 1-6-17

6. Remove the one screw and then remove the
fuser thermistor.

Figure 1-6-18

Heat roller

Upper fuser guide

Heat roller

Heat roller

Heat L bush

Heat L bush

Heat R bush

Heat R bush

Heat gear

Fuser thermisto

r

Screw

2GL/2FV/2FW

1-6-13

7. Remove the two screws (nuts), plate cord,
and terminal.

8. Remove the thermal cutout.

Figure 1-6-19

Screw

Plate cord

Terminal

Thermal cutout

Screw

Nut

Nut

2GL/2FV/2FW

1-6-14

9. Remove the press roller from the bushes.

Figure 1-6-20 Removing the press roller

Press roller

Lower fuser frame

Bush

Bush

2GL/2FV/2FW

1-6-15

1-6-6 PWBs

(1) Detaching and refitting the main PWB (16 ppm GDI printer)

<Procedure>

1. Remove the right cover. See page 1-6-2.

2. Remove the two connectors from main
PWB.

3. Remove one screw from the USB interface
connector.

4. Remove the three screws and then remove
the main PWB.

Figure 1-6-21

Main PWB

USB interface
connector

Screw

Screw

Screw

Screw

Connectors

2GL/2FV/2FW

1-6-16

(2) Detaching and refitting the main PWB (16/18 ppm printers)

<Procedure>

1. Remove the right cover. See page 1-6-2.

2. Remove the one screw and then remove the
CF guide.

3. Remove the two connectors from main
PWB.

4. Remove three screws from the USB inter­face connector and parallel interface con­nector.

5. Remove the four screws and then remove
the main PWB (with controller box).

Figure 1-6-22

Screws

Screws

Screws

Connectors

Controller box

Main PWB

Parallel
interface
connecto

r

USB
interface
connector

Screw

CF guide

2GL/2FV/2FW

1-6-17

(3) Detaching and refitting the engine/high voltage PWB and power source PWB

<Procedure>

1. Remove the developer unit and drum unit.
See page 1-6-6.

2. Remove the paper cassette.

3. Remove the outer covers. See page 1-6-2.

4. Remove the six connectors.

* When seating the engine/high voltage PWB,

ensure that the developer bias terminal
spring is correctly in contact with the devel­oping bias terminal (TB1) on the engine/high
voltage PWB.

Figure 1-6-23

Connector

Connectors

Developing bias
terminal spring

Engine/high
voltage PWB

Developing
bias terminal (TB1)

2GL/2FV/2FW

1-6-18

5. Remove the two connectors from main
PWB.

6. Remove the drive unit. See page 1-6-23.

Figure 1-6-24

7. Turn the printer bottom side up.

8. Remove the five screws and then remove
the bottom frame plate with PWBs (behind
the plate).

Figure 1-6-25

Connectors

Main PWB (16/18 ppm printers)

Drive unit

Main PWB (16 ppm GDI printer)

Connectors

Bottom frame
plate

(Transfer bias terminal)

Screws

Screws

2GL/2FV/2FW

1-6-19

9. Remove the one screw and terminal from
the bottom frame plate.

* When securing the grounding terminal, hook

the grounding wire to the projection.

10. Remove the three screws from power
source PWB.

11. Remove four screws from the engine/high
voltage PWB.

12. Separate the engine/high voltage PWB and
power source PWB.

13. Check or replace the engine/high voltage
PWB or power source PWB and then refit all
the removed parts.

* To replace the engine/high voltage PWB,

remove the EEPROM (U2) from the old
engine/high voltage PWB and mount it to
the new engine/high voltage PWB.

Figure 1-6-26

Screws

Screw

Screw

Screw

Terminal

Power source PWB

Bottom frame plate

Engine/high
voltage PWB

Connectors

Screws

Screw

EEPROM

Socket

Terminal

Screw

Projection

Power source PWB

Grounding wire

2GL/2FV/2FW

1-6-20

1-6-7 Others

(1) Detaching and refitting the laser scanner unit

<Procedure>

1. Remove the outer covers. See page 1-6-2.

2. Remove the two screws and then remove
the LSU lid.

Figure 1-6-27

Screw

Screw

LSU lid

2GL/2FV/2FW

1-6-21

3. Remove the three screws.

4. Remove the two connectors and then
remove the laser scanner unit.

Figure 1-6-28

Screw

Connectors

Screw

Screw

Laser scanner unit

2GL/2FV/2FW

1-6-22

(2) Detaching and refitting the eraser lamp (PWB)

<Procedure>

1. Remove the laser scanner unit. See page 1­6-20.

2. Remove the one connector.

3. Remove the wire from two clamps.

Figure 1-6-29

4. Remove the wire form clamp.

5. Remove the sheet eraser.

6. Remove the eraser lamp (PWB).

Figure 1-6-30

Connector

Wire

Clamps

Eraser lamp (PWB)

Sheet eraser

Clamp

Wire

2GL/2FV/2FW

1-6-23

(3) Detaching and refitting the drive unit

<Procedure>

1. Remove the right cover. See page 1-6-2.

2. Remove the three connectors.

3. Remove the two screws and then remove
the two grounding plates.

4. Remove the two stoppers and then remove
the two clutches.

Figure 1-6-31

5. Remove the one screw and then remove the
CF guide.

6. Remove the three screws and then remove
the drive unit.

Figure 1-6-32

Screw

Clutch

Clutch
(black)

Stopper

Stopper

Grounding plate

Grounding plate

Screw

Connectors

Screw

Screw

Screw

Drive unit

Screw

CF guide

2GL/2FV/2FW

1-6-24

(4) Detaching and refitting the main motor

<Procedure>

1. Remove the right cover. See page 1-6-2.

2. Remove the one connector from main
motor.

3. Remove the four screws and then remove
the main motor.

Figure 1-6-33

Screws

Screws

Connector

Main motor

2GL/2FV/2FW

1-7-1

1-7 Firmware

1-7-1 Downloading

(1) Firmware program data format

The data to be downloaded are supplied in the following format:

Figure 1-7-1

2: MFP controller
3: Printer (Main) controller
4: Facsimile
5: NIC
6: Operation panel massage language
7: Panel

Firmware description (supplement)

Product code 2FV= 16 ppm printer

2FW= 18 ppm printer

Software ID

Firmware file name example (For 16/18 ppm printers)

Build number

0: Normal
E: Corrective

Pause (under bar)

Pause (period)

Compression

Destination

S2FV_1000001021.cmp

Version up history

Firmware description 1: Engine controller

2GL/2FV/2FW

1-7-2

(2) Downloading the firmware from the parallel interface (For 16/18 ppm printers)

This section explains how to download firmware data from the parallel interface. The printer system can automatically rec­ognize whether the data to be overwritten is for controller firmware.

CAUTION
Downloading the firmware takes several minutes. Do not turn power off during downloading.

1. Turn printer and PC power off.

2. Connect the parallel printer cable between
the PC and the printer.

Figure 1-7-2

Parallel interface
connector

Parallel cable

PC

2GL/2FV/2FW

1-7-3

3. Turn printer power on.

4. Confirm that LED indication status () is
displayed.

5. At the DOS prompt, enter command.

c:\echo!R!UPGR”SYS”;EXIT;>prn

6. Confirm that LED indication status () is
displayed.

7. Confirm that LED indication status () is
displayed. At the DOS prompt, enter com­mand so that the system firmware (example:
S2FV_1000001021.cmp) is copied to the
printer.

c:\copy\2FV_1000001021.cmp prn

8. LED indication status ()() are displayed
during downloading. When LED indication
status () is displayed to indicate down­loading is finished, turn printer power off,
then on.

* If downloading fails, the printer indicates an

error display using the LED indicators. See
table below, LED indication status ().

9. Confirm that LED indication status () is
displayed after warm-up.

10. Print a status page. (See page 1-4-3)

11. Check that the status page shows the
updated firmware version.

Table 1-7-1

Waiting for
parallel data
Receiving data

Deleting and
writing data

Supervisor mode

Ready

Downloading
complete

Downloading
failed













Off

Off

Lit

Lit

LED Indicator explanatory notes

READY indicator

ATTENTION indicator

2GL/2FV/2FW

1-7-4

(3) Downloading the firmware from the memory card (For 16/18 ppm printers)

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 main 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.

1. Turn power switch off.

2. Remove the right side cover.

3. Insert the memory card in the printer’s mem­ory card slot.

Figure 1-7-3

Right side cover

Top c o ver

Memory
card socket

Memory card

Main PWB

2GL/2FV/2FW

1-7-5

4. Turn power switch on.

5. The printers starts and finishes downloading
automatically. LED indication status ()()
are displayed during downloading. When
LED indication status () is displayed to
indicate downloading is finished.

* If downloading fails, the printer indicates an

error display using the LED indicators. See
table below, LED indication status ().

Table 1-7-2

6. Turn power off.

7. Remove the memory card and then refit the
right side cover.

8. Turn power on again. Check the printer gets
ready.

9. Print a status page. (See page 1-4-3)

10. Check that the status page shows the
updated firmware version.

Receiving data

Supervisor mode

Ready

Downloading
complete













Off

Off

Lit

Lit

LED Indicator explanatory notes

READY indicator

ATTENTION indicator

Deleting and
writing data

Downloading
failed

2GL/2FV/2FW

1-7-6

This page is intentionally left blank.

2GL/2FV/2FW

2-1-1

2-1 Mechanical Construction

2-1-1 Paper feeding/conveying section

The paper feeding/conveying system picks up paper from the paper cassette, manual feed tray, feeds it in the printer and
delivers in the output tray. Paper is feed at the precise timing in synchronization with data processing.

(1) Paper feed section

The figure below shows the components in the paper feeding/conveying section and the paths through which the paper
travels. The sensors, clutches, motor etc., are described in the following pages.

Figure 2-1-1 Paper feeding/conveying section

























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

(7) Cassette bottom
(8) Bottom pad
(9) Paper separator
(10) Separator pad
(11) Manual feed tray
(12) Feed guide

2GL/2FV/2FW

2-1-2

Figure 2-1-2 Paper feeding/conveying section block diagram

Registration
clutch

+24V3

REGDR

+24V3

FEDSOLON

+24V3

GND

MMOTRDY

MOTCLK

REMOTE

GND

FEDDOLON

REGSOLON

+24V3

Feed clutch

Main motor

CN1-1
CN1-2
CN1-3
CN1-4
CN1-5

Engine/high voltage PWB

Registration sensor

Paper sensor

YC3-13
YC3-8
YC3-7
YC3-6

YC5-1
YC5-2
YC5-3
YC5-4
YC5-5

Connect PWB

YC401-8

YC402-1

YC403-1
YC403-2

YC402-2

YC401-3
YC401-2
YC401-1

2GL/2FV/2FW

2-1-3

2-1-2 Drum section

(1) Drum unit

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 2-1-3 Drum unit













(1) Drum frame
(2) Drum cover A
(3) Drum cover B
(4) Waste toner cover
(5) Drum (OPC)

2GL/2FV/2FW

2-1-4

(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. Cleaning the charging wire prevents print quality problems such as black streaks.

Figure 2-1-4 Main charger unit

Figure 2-1-5 Drum unit and main charger unit block diagram









Drum

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

Main
charger
wire

Main charger output

Grid

Shield

Drum

Engine/high

voltage PWB

Zener

PWB

470 15 V DC

250 10 µA (default)

Drum surface
potential

2GL/2FV/2FW

2-1-5

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 (27959 rpm) 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 2-1-6 Laser scanner unit













Laser

beam

Drum

(1) Laser scanner unit
(2) MID frame
(3) LSU lid
(4) LSU shutter
(5) LSU mirror
(6) Polygon motor (mirror)