Brother Color Laser Printer SERVICE MANUAL MODEL: HL-4200CN Read this manual thoroughly before maintenance work. Keep this manual in a convenient place for quick and easy reference at all times.
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PREFACE This service manual contains basic information required for after-sales service of the color laser printer (here-in-after referred to as "this machine" or "the printer"). This information is vital to the service technician to maintain the high printing quality and performance of the printer. This service manual covers the HL-4200CN color laser printer. This manual consists of the following chapters: CHAPTER I : SPECIFICATIONS Specifications, etc.
CONTENTS CHAPTER I SPECIFICATIONS.........................................................I-1 1. PRODUCT NAME ......................................................................................... I-1 2. OPTIONAL PRODUCTS ............................................................................... I-1 3. DIMENSIONS / WEIGHT (MAIN UNIT)......................................................... I-1 4. BASIC CONFIGURATION............................................................................. I-1 4.
10.3 Installation Horizontality..................................................................................................... I-16 10.4 Ambient Lighting ................................................................................................................ I-16 11. SAFETY / ENVIRONMENT CONDITIONS................................................ I-16 11.1 Safety Standard ................................................................................................................. I-16 11.
5.4 Front ASSY In .................................................................................................................... III-29 5.5 Chute ASSY Out ................................................................................................................ III-30 5.6 Chute ASSY Exit................................................................................................................ III-32 5.7 Transfer Roll Cartridge ASSY & Fuser ...................................................
3.2 Fail Code List ........................................................................................................................V-3 3.3 Error Code FIP....................................................................................................................V-13 4. HOW TO USE DIAG. (C/E) MODE ............................................................V-38 4.1 Roles of the Control Panel in Diag. (C/E) Mode.................................................................V-38 4.
1.1 How to Use the BSD............................................................................................................VI-1 1.2 Explanations of Symbols .....................................................................................................VI-1 1.3 Signal Name/Other description............................................................................................VI-4 1.4 DC Voltage...................................................................................................
REGULATIONS LASER SAFETY (FOR 120 V MODEL ONLY) This printer is certified as a Class I laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation.
IEC 60825 SPECIFICATION (FOR 220-240 V MODEL ONLY) This printer is a Class 1 laser product as defined in IEC 60825 specifications. The label shown below is attached in countries where required. CLASS 1LASER PRODUCT APPAREIL Å LASER DE CLASSE 1 LASER KLASSE 1 PRODUKT This printer has a Class 3B Laser Diode which emits invisible laser radiation in the Scanner Unit. The Scanner Unit should not be opened under any circumstances.
SAFETY To prevent possible accidents during maintenance operation, you should observe strictly the "Warning" and "Caution" information in this manual. Dangerous operations and operations out of range of this manual should be absolutely avoided. Generally various processes not covered by this manual may be required in actual operation, which should be performed carefully always giving attention to safety.
Power Source Keep the power supply off during maintenance operation to prevent electric shock, burns and other damages. Keep the power plug disconnected during the maintenance operation. If the power supply should be kept connected for measurement of voltage or other similar reasons, sufficient care should be given to prevent electric shock, by following the procedures of this manual. WARNING While the printer is ON, never touch live parts if not required absolutely.
High-temperature Units When servicing high-temperature units (securing unit, etc.), be sure to turn them OFF to prevent burns, injuries and other troubles, remove the power plug and start service processes after they have cooled down enough. WARNING Immediately after completion of operation, they are still hot. Start services after more than 40 minutes. Laser Beams WARNING • • • • If your eyes are exposed to laser beams, you may lose your eyesight.
Warning/Caution Labels Warning labels and caution labels are attached to this laser printer to prevent accidents check those labels for their peeling or stain when servicing the printer. < Caution label for high-temperature units > Unpacking the Printer WARNING The printer must be carried horizontally by two or more persons. CAUTION Extreme care must be taken to avoid personal injuries. Check visually the printer for evidence of any damages. Peel all tapes off the printer.
ACRONYMS In this manual, the manual specific acronyms are used in addition to the generally used ones. The table below contains typical acronyms that are used throughout this manual. ADC AUX. BCR BUR CCW CLN CR CRUM DB FG Hex IDT Automatic Density Control Auxiliary Bias Charge Roll Back Up Roll Counter Clock Wise Cleaning (or Cleaner) Charge Roll CRU Monitor Developing Bias Frame Ground Hexadecimal Intermediate Drum Transfer AG B/W CART. CL.
Service call procedures 1. Notes Before Work 1.1 Safety notes To prevent an accident during maintenance, follow warnings and precautions strictly. Avoid dangerous work. 1. Power supply To prevent an electric shock, burn, or injury, turn off the power and unplug the power cable before maintenance work. If it is inevitable to keep the power on for voltage measurement, take the greatest care not to receive an electric shock. 2.
1.2 Other notes Do maintenance work correctly and efficiently with the following notes in mind: 1. Reference materials Read the related technical information (SB, FTI, FTO and so on) well and do maintenance work systematically. 2. Disassembling Before removing parts for disassembling, check the normal mounting status in advance. 3. Mounting and adjustment Do not start up the machine immediately after finishing part mountings and adjustments.
2. Workflow in the Field < Initial Actions > 1. 2. 3. 4. Question the Customer for details about the system malfunction. Note down the meter count. Inspect the rejected print and determine the machine condition. Check the Machine Log Book. < For UM visit > 1. Perform the Level 1 troubleshooting. 2. Perform the troubleshooting. 3. Print any Internal Test Pattern to check the print quality. (See page V-54) 4. Feed paper from each tray, and clean or replace the feed role as required. 5.
3. Trim Activity Trim activities for HL-4200CN should be made within every SM/UM, mainly for maintaining the machine performance. There is no service call performed only for the trim activity. 3.1 Trim activity procedure 1. Check the overall operation before performing the trim activity. Print any Internal Test Pattern to output three patterns: all colors of 20 % each, halftone and grid. All colors of 20 % each: IBT belt, scratches on the drum surface, and fusing problem are checked.
3.3 Trim checklist C: Check and if necessary clean, replace, or replenish. A: Always check and clean. R: Replace at specified intervals. * See page V-54 for the test pattern output method. No. Work item Each time 100K Rep & Adj No. 1.1 Check before work (Mechanical noise check) C - Start up the machine to see that no abnormal noise occurs 1.
CHAPTER I SPECIFICATIONS
CONTENTS CHAPTER I SPECIFICATIONS.........................................................I-1 1. PRODUCT NAME ............................................................................................ I-1 2. OPTIONAL PRODUCTS .................................................................................. I-1 3. DIMENSIONS / WEIGHT (MAIN UNIT)............................................................ I-1 4. BASIC CONFIGURATION ...........................................................................
8.14 Input Properties ................................................................................................................. I-13 8.14.1 Paper pick-up system ................................................................................................. I-13 8.14.2 Paper pick-up capacity................................................................................................ I-13 8.15 Output Properties.......................................................................................
CHAPTER I SPECIFICATIONS 1. PRODUCT NAME Product Name HL-4200CN 2. OPTIONAL PRODUCTS No. 1 2 3 3. Product Code 54S602 Product Name 1 x 500 – sheet tray 2 x 500 – sheet tray Hard Disk Product Code LT-41CL LT-42CL HD-41CL 4.1 20GB DIMENSIONS / WEIGHT (MAIN UNIT) Width (mm) Depth (mm) Height (mm) 439 590* 445 *: with the manual tray folded 4. Remarks Weight (kg) 34.9kg or less (incl.
4.2 Feeder Unit Option Feeder installed under the printer. This printer basically consists of an option feeder and two universal paper tray (500 sheets each). Fig.
4.3 Tray Feeder Unit Option Feeder installed under the printer. This printer basically consists of an option feeder and a universal paper tray (500 sheets). Fig.1-3 5. FUNCTIONAL CONFIGURATION Functional configuration of this printer is shown below. Fig.
6. 6.1 ELECTRICAL PROPERTIES Power Source Two types of power source as follows are available for this printer, which are selected according to the specifications. * 100V/120V printer: Voltage: 100-127VAC ±10% (90 to 140V), frequency: 50/60Hz ± 3Hz * 220/240V printer: Voltage: 220-240VAC ±10% (198 to 264V), frequency: 50/60Hz ± 3Hz 6.
Width: 439mm ± 1% Depth: 509mm ± 1% (with no cassette installed), 563mm ± 1% (with cassette installed) Height: 172mm ± 1% Mass (No cassette installed + (No CRU): 9.3kg ± 1% (No cassette installed + (CRU): 11.8 kg ± 1% Fig.1-6 Width: 439mm ± 1% Depth: 509mm ± 1% (with no cassette installed), 563mm ± 1% (with cassette installed) Height: 336mm ± 1% Mass (No cassette installed + (No CRU): 14.2 kg ± 1% (No cassette installed + (CRU): 19.2 kg ± 1% Fig.
7.2 Dimensions / Mass of Universal Paper Tray (standard paper supply – 500sheets) Width: 321mm ± 1% Depth: 558mm ± 1% Height: 97mm ± 1% Mass: 2.5kg ± 1% Fig.1-8 7.3 Dimensions / Mass of Consumables 7.3.1 Print head cartridge Width: 339mm ± 3mm Depth: 146mm ± 3mm Height: 179mm ± 3mm Mass: 4.5kg ± 0.1kg Reference: The print head cartridge has CRUM (CRU memory) to record information. Fig.1-9 7.3.2 Transfer roll cartridge Width:309mm ± 3mm Depth:85mm ± 3mm Height:60mm ± 3mm Mass:500g ± 10g Fig.
7.3.3 Toner cartridge Black toner cartridge Yellow toner cartridge Magenta toner cartridge Cyan toner cartridge Width 355mm ± 3mm 355mm ± 3mm 355mm ± 3mm 355mm ± 3mm Depth 51mm ± 3mm 51mm ± 3mm 51mm ± 3mm 51mm ± 3mm Height 55mm ± 3mm 55mm ± 3mm 55mm ± 3mm 55mm ± 3mm Mass 360g ± 10g 315g ± 10g 325g ± 10g 315g ± 10g Fig.1-11 7.4 Installation Space (min. installation space) Minimum space as shown below is required to install the printer when it is used for normal objects.
8. 8.1 FUNCTIONS Recording System OPC drum, 4-tandem cartridges, electro-photographic system using intermediate transfer rolls 8.2 Exposure System Semiconductor laser, simultaneous scanning by 4 beams 8.3 Development System Development with dry type 2-component developer 8.4 Fixing System Heat fusing of the free belt nip system 8.5 Resolution Two types of resolutions can be switched. Printing speed is halved at 1200dpi * Main scanning direction: 600 dots/25.
*3: Fan status is changed depending on the state (temperature, etc.) of the fixing system. 8.7 Process Speed The printer prints by switching two levels, Full speed (printing with the highest process speed of the printer) and Half speed (printing with the half of process speed). The controller cannot instruct to change the process speed. 8.8 Print Mode The printer has four modes, Standard mode, Fine mode, High gloss mode, and Super high gloss mode.
8.9 Paper Mode 8 paper modes are available for this printer. Modes are switched over under the instruction from the controller. (1) Plain paper: Japanese plain paper such as FX-P, L, R, J/JD, and plain paper such as XC-4200 20lb, 24ibs RX-80, 90. (2) Label-L mode: It is mainly selected to run on Japanese labels (V860 etc.). (3) Label-H mode: It is mainly selected to run on labels (3R4469 etc.).
8.10 Warm-up Time When nominal voltage (115/230V) is applied, ready temperature (Fuser Stand-by) is reached within 30 seconds after command is given by the controller. Reference: Measured at 22°C, 55% RH, nominal voltage. 8.11 FPOT (First Print Output Time) FPOT time of the printer is shown in the table below. The time required for the first sheet of paper to be delivered after the START command is given is calculated on the following conditions (rounded to one decimal place).
8.12 Continuous Printing Speed Assuming the time until the trailing end of the 11th sheet is discharged after the trail end of the 1st sheet is discharged as t seconds, number of printed sheets for a minute given by the equation [60/t ×10] is shown in the table below, excluding, however, the time for which the process control is working and during the Fuse Cool Down are not contained.
8.13.3 Guaranteed printing area Area for which the image quality is guaranteed as follows: Area except for 4mm (0.1575 inch) from edges of the paper. Maximum area for which the image quantity is guaranteed as follows: Width: 207.9mm (8.2 inch) × length: 347.6mm (13.7 inch) Fig.1-15 8.14 Input Properties 8.14.1 Paper pick-up system ♦ Paper pick-up with paper tray Feeding method of this printer is ARRF method. ♦ MSI paper pick-up The MSI (Multi Sheet Inserter) is equipped as standard.
8.15 Output Properties 8.15.1 Paper delivery system ♦ FACE DOWN delivery Paper can be delivered by the following method. 8.15.2 Paper delivery capacity ♦ FACE DOWN delivery 250 sheets (Letter/A4 standard paper) 8.15.3 Delivery paper size/mass ♦ FACE DOWN delivery All paper sizes applicable to this printer 8.15.4 Full stack detection ♦ 8.16 Height of paper to be fed Detect when the height reached about 36mm. Paper 8.16.
8.16.3 Paper size Paper size which can be set to each paper pick-up unit is shown in the table below. Cassette Paper size A4 –SEF B5(JIS) –SEF A5 -SEF *1 EXECUTIVE –SEF LETTER –SEF LEGAL(13")-SEF LEGAL(14")-SEF 500 Sheet Paper Universal Tray MSI Tray Minimum size Width 88.9mm(3.5inch)×Length139.7mm(5.5inch) Maximum size Width 215.9mm(8.5inch)×Length 355.6mm(14inch) *1:The end guide which is attached as standard needs to be installed when running on A5 size paper.
9.3 Parts Requiring Periodical Replacement Following parts are replaced when a certain number of sheets are printed (life over) to prevent troubles.
11.3 EMI ♦ 100V system (JPN) VCCI Class B ♦ 120V system (US) FCC Part 15, Subpart B, Class B (ANSI C63.4) 220V / 240V system (EC) EN55022 (CISPR Publication 22), Class B ♦ 11.4 Noise Noise of printing (including simplex, duplex, with option) is as follows.
12.1.2 Guaranteed paper The print image quality specified here is guaranteed with standard paper fed from the paper tray. The evaluation is performed with A4 or letter size of paper. • FX P paper A4 • Xerox 4200 DP Letter • Xerox Premier 80gsm A4 12.1.3 Paper condition The paper used is fresh paper immediately after unpacked, which has been left in the operating environment for 12 hours before unpacking. 12.1.
CHAPTER II INSTALLATION
CONTENTS CHAPTER II INSTALLATION...........................................................II-1 1. TRANSPORTING THE PRINTER ................................................................... II-1 2. INSTALLATION PROCEDURE.......................................................................II-2 2.1 Checking the Packaged Items.............................................................................................. II-3 2.2 Removing the Tapes from the Printer............................................
CHAPTER II 1. INSTALLATION TRANSPORTING THE PRINTER Note the following points when transporting the printer into position. At least two people should carry the printer. Note: Because the printer weighs 34.9kg with the tray and consumables installed, at least two people should carry it. To lift the printer, face the front and back of the printer and grip the recessed areas at the bottom left and right with both hands. Never try to lift the printer by gripping any other areas.
2. INSTALLATION PROCEDURE Install the printer as follows: 2.1 Checking the Packaged Items 2.2 Removing the Tapes from the Printer 2.3 Removing the Paper Tray Protective Materials 2.4 Mounting the Print Head Cartridge 2.5 Preparing the Toner Cartridges 2.6 Loading Paper 2.7 Connecting the Power Code 2.8 Adjusting Color Registrations Note: The printer has various protective materials for protection from vibrations and shocks during move. Remove all the protective materials first.
2.1 Checking the Packaged Items The printer package contains the items shown below. Before starting installation, make sure that no items are missing. Note: Keep the packaging materials if a future long-distance move of the printer is anticipated. < Printer > Fig.2-3 < Print head cartridge > Fig.2-4 < Power code > Fig.2-5 Note: The illustration above shows the 100V power cord.
2.2 Removing the Tapes from the Printer When you first remove the printer from its box, there is packing tape to secure the covers during shipping. Refer to the illustrations below and remove all the packing tape from the printer. < Right side > Fig.2-6 < Left side > Fig.2-7 < Rear side > Fig.
2.3 Removing the Paper Tray Protective Materials Two spacers are installed in the paper tray to protect it from shock and vibrations during shipping. Remove the spacers before using the printer. Follow the procedure below to remove the spacers from the paper tray. Note: Keep the spacers in case you need to transport the printer over long distances in the future. Fig.2-9 1) Gently pull out the paper tray until it stops. Fig.
3) Remove the cardboard spacers from the paper tray. Note: Keep the spacers in case you need to transport the printer over long distances in the future. Fig.2-12 4) Holding the paper tray with both hands, align it with the opening in the printer and gently insert it. Fig.2-13 5) Push the paper tray completely back into the printer. Note: Do use excessive force on the paper tray. Doing so could damage the paper tray or the inside of the printer. Fig.
2.4 Mounting the Print Head Cartridge Follow the procedure below to install the print head cartridge. Fig.2-15 1) Lift the A button ((1)) and open the front cover ((2)). Fig.2-16 2) Open the paper outlet cover. Fig.
3) Open the top of the new print head cartridge box and pull of the top part of the aluminum package. Note: Remove the sheet by working inward from the two notches. Fig.2-18 4) Grip the handle on top of the print head cartridge and gently lift it. Place the cartridge on a flat surface. Note: Lift the print head cartridge by the handle. Do not allow the cartridge to touch anything when removing it from the box. When setting the print head cartridge, do not shake or tilt them. Fig.
6) Take the new print head cartridge out of its package and pull on the longer of the paired seals horizontally toward you. Verify that there is a circle on the leading edge of the tape that you pull out. Do this for another three. Note: If there is no circle on the leading edge of the tape, you cannot use this print head cartridge. Keep the polystyrene packing, aluminum bag and box of the print head cartridge if a future move of the printer is anticipated.
9) With the flat part of the cartridge facing the rear, align the orange rollers on both sides of the print head cartridge with the slots in front of the arrows on the printer, and gently lower the cartridge into the printer. Note: Lowering the cartridge into the printer without correctly aligning the rollers with the slots can damage the cartridge. Do not allow the surface covered with a protective sheet to come into contact with anything. Protective sheet Orange rollers Fig.
12) Close the front cover. Fig.
2.5 Preparing the Toner Cartridges Follow the procedure below to prepare the toner cartridges for use. Note: The toner is harmless but should still be washed off immediately if it comes into contact with hands or clothing. 1) Remove the top cover, and then remove the packing sheet covering the toner cartridges. Fig.2-28 2) Pull the toner seal straight up to remove it. Note: Pull the toner seal straight up. Pulling the toner seal diagonally may tear the seal. Fig.2-29 3) Replace the top cover. Fig.
2.6 Loading Paper Follow the procedure below to load paper into the paper tray. Fig.2-31 1) Pull out the paper tray until it stops. Fig.2-32 2) Hold the tray with both hands, lift up the front slightly and remove it from the printer. Note: Place the tray on a flat surface. Fig.
3) Move the side paper guide out so as to align it with the appropriate paper size mark (A4 in this example). Note: Proper guide position differs between A4 and Letter. Align the side guide to the size mark corresponding to the paper size that you want to load. Fig.2-34 4) Grip the end paper guide with your fingers and gently lift it up. Insert the pins at the bottom of the guide in the holes corresponding to the paper size that you want to load (A4 in this example).
5) Align the four corners of the paper stack and insert the paper (print side up) under the tab. Note: Do not use paper that is folded, creased, or heavily warped. Do not overload the paper tray. Fig.2-36 6) Make sure that the side guides are aligned with the edges of the paper. Note: Pushing the paper guides too hard against the edges of the paper stack can cause a paper jam. However, if the paper guide is too loose, the paper may twist as it feeds through the printer. Fig.
8) Push the paper tray completely back into the printer. Note: Do use excessive force on the paper tray. Doing so could damage the paper tray or the inside of the printer. Fig.2-39 Note: There is an indicator next to the paper tray that tells you how much paper remains in the tray. Use the meter as a guide to refill the paper tray. Fig.
2.7 Connecting the Power Code Connect the power cable as explained below. WARNING Power specifications are listed below. The specifications that apply to your machine depend on your machine configuration. Connect the power plug only to a properly rated power outlet. Otherwise, it can cause fire or electric shocks. If in doubt, contact your Customer Support Center.
2.8 Adjusting Color Registrations Follow the procedure below to adjust the color registration when first installing the printer or after moving it to a new location. 1) Use the control panel to print the color registration adjustment chart. 2) From the lines to the right of the Y (yellow), M (magenta), and C (cyan) pattern, find the values of the straightest lines. Note: You can also use the densest colors of the grid to find the straightest lines.
CHAPTER III STRUCTURE OF SYSTEM COMPONENTS
CONTENTS CHAPTER III STRUCTURE OF SYSTEM COMPONENTS ............III-1 1. PRINTING PROCESS ................................................................................... III-1 1.1 Summary of Printing Process .............................................................................................. III-1 1.2 Schematic Diagram for Printing Processes ......................................................................... III-3 1.3 Description of Printing Process Techniques............................
5.5.1 Major functions............................................................................................................ III-30 5.5.2 Reference diagram ..................................................................................................... III-31 5.6 Chute ASSY Exit................................................................................................................ III-32 5.6.1 Major functions..................................................................................
CHAPTER III STRUCTURE OF SYSTEM COMPONENTS 1. PRINTING PROCESS 1.1 Summary of Printing Process This printer is a "Full-color laser printer" which applies the principal of an electrophotographic recording system. The tandem system comprising a drum and developing unit respectively for each color of yellow, magenta, cyan and black (Y, M, C and K) places toner image of each color on paper producing full-color prints finally through 3 intermediate transfer units (IDT 1: 2, IDT 2: 1).
Drum Y Drum M Charged Drum C Charged Drum K Charged Charged (1) with (1) with (1) with (1) with (2) Exposure (2) Exposure (2) Exposure (2) Exposure (3) Development (3) Development (3) Development (3) Development electricity (4) electricity electricity Primary transfer (Drum IDT1) (4) Primary transfer (Drum IDT1) ® Intermediate transfer unit ( IDT1) (6) electricity ® Intermediate transfer unit ( IDT1) Cleaning ( IDT1) (6) Cleaning ( IDT1) (5) Secondary transfer ( IDT1 IDT2)
1.2 Schematic Diagram for Printing Processes Outline of printing processes is shown in the figures below.
1.3 Description of Printing Process Techniques 1.3.1 Charging with electricity In the charging process, the drum surface rotating at a constant speed is charged uniformly with negative electricity by discharging of RTC (Rubber Tube Charge: Charged film). This process is performed in parallel for yellow, magenta, cyan and black colors. • The RTC is kept in contact with the drum and rotates following the rotations of the drum.
1.3.2 Exposure In the exposure process, the drum surface charged negatively is scanned by laser beams to form invisible electrostatic latent image on the drum surface. This process is performed in parallel for yellow, magenta, cyan and black colors. • Laser beams are emitted from the laser diode in the scanner ASSY. By the rotating polygon mirror, fixed mirror and lens attached to the scanner ASSY of the scanner ASSY, each color of drum surface is scanned from end to end in the axial direction.
Scanner ASSY : Negative electric charge : Positive electric charge Drum surface (Laser beams) Optical conductor Conductor (Laser beams) Electrostatic latent image Fig.3-9 Drum Fig.3-8 < Drum concept > Electric potential on drum (Laser beams) Laser beams Optical conductor -V 0 Conductor Fig.3-10 Fig.
1.3.3 Development In the development process, toner is electrically attached to the invisible statistic latent image on the drum surface to form visible toner image on the drum. This process is performed in parallel for yellow, magenta, cyan and black color respectively. • The toner in the toner cartridge is agitated by the agitator in the toner cartridge and fed into the toner holder.
Toner Cartridge ASSY - : Negative electric charge + : Positive electric charge Agitator : Toner : Carrier Auger Trimmer Rod Magnet Roll Paddle - Auger - Auger - + + Drum + - + - HVPS Fig.3-12 Electric potention on drum Dram surface -V Developing bias Toner image 0 Fig.3-13 Fig.
1.3.4 Primary transfer (drum -> IDT 1) In the primary transfer process, toner image formed on the drum surface is transferred onto the surface of the IDT 1 (Intermediate Drum Transfer 1: intermediate transfer roll 1). Two IDT 1 are provided: yellow and magenta, and cyan and black are respectively transferred to their IDT 1. • IDT 1 is a conductive roll and receives supply of high positive voltage from HVPS.
Drum surface (Yellow toner image) IDT1 surface Yellow toner image Magenta toner image Drum surface (Magenta toner image) Drum surface (Cyan toner image) IDT1 surface Cyan toner image Drum surface Black toner image (Black toner image) Fig.
1.3.5 Secondary transfer (IDT 1 -> IDT 2) In the secondary transfer process, the toner image formed on the IDT 1 surface is transferred onto the surface of the IDT 2 (Intermediate Drum Transfer 1: intermediate transfer roll 2). Two color toner image transferred onto the 2 IDT 1 is transferred to the IDT 2. Thus, 4 color toner image are compiled on the IDT 2 as finished toner image. • 1.3.6 IDT 2 is a conductive roll and receives supply of positive high voltage from HVPS.
IDT1 surface Yellow toner image Magenta toner image IDT2 surface Yellow toner image Magenta toner image Cyan toner image IDT1 surface Black toner image Cyan toner image Black toner image Fig.3-19 1.3.7 Tertiary transfer (IDT 2 - paper) In the tertiary transfer process, finished toner image formed on the IDT 2 surface is transferred onto the paper under the voltage supplied to the transfer roll cartridge. • Transfer roll cartridge is composed in the transfer roll cartridge ASSY.
1.3.8 Cleaning (IDT 2) In the cleaning process, toner remaining on the IDT 2 after the toner image is transferred onto the paper is temporarily held at the IDT 2 cleaner. • 1.3.9 The IDT 2 cleaner is a conductive roll brush and receives positive high voltage from HVPS. The IDT 2 cleaner is placed in contact with the IDT 2 at a position through which it passes after the toner image having been transferred from IDT 1 is transferred onto the paper.
1.3.10 Fixing In the fixing process, toner is fixed on the paper by heat and pressure. • Finished toner image transferred from the belt is easily broken only by touching it with fingers. The toner image is fixed on the paper with the fuser ASSY (fixing unit). The toner melts by heat of the heat roll with the heater lamp as the heat source and is deposited on the paper under pressure given by the belt opposed against the heat roll.
1.3.11 Cleaning (general) In the cleaning (general) process, toner stored in the IDT 1 cleaner and IDT 2 cleaner after the finished toner image is transferred onto the paper and the toner remaining on the transfer roll cartridge are removed. • The toner not completely transferred in the "secondary transfer" and "tertiary transfer" processes is held temporarily in the IDT1 cleaner and IDT2 cleaner. Also, the toner of which polarity is reversed and returned to the drum is held in the refresher.
2) Refresher and RTC High voltage of the polarity (negative) reverse to that at the printing transfer is applied to the IDT1, IDT2, and transfer roll cartridge. At this time, the drum surface is charged negatively by negative voltage of the IDT1. The toner (positive polarity) remaining in the Refresher and RTC are move to the drum electrically by transforming the Refresher and RTC to 0V.
2. FLOW OF PRINT DATA 2.1 Data Flow Print data (electric signal) from the printer controller flows as shown below to turn to the print image finally. Host (electric signal) Printer controller (electric signal) MCU HL-4200 (electric signal) Scanner ASSY (laser beams) Electrostatic latent on drum (invisible image) Toner image on drum Toner image on intermediate transfer unit (IDT1) Toner image on intermediate transfer unit (IDT2) Toner image on paper Print image on paper Fig.
3. DRIVE TRANSMISSION ROUTE 3.1 Drive ASSY main Rotary power of the drive ASSY main is transmitted through the route below. MAIN DRIVE ASSY GEAR IDLER IN Regi.Clutch CLUTCH ASSY TURN GEAR IDLLER ROLL ASSY TURN GEAR IDLLER FEED Regi.Roll CHUTE REGI ASSY GEAR FEED H1 GEAR FEED1 ROLL ASSY FEED PAPER FEEDER CLUTCH TURN GEAR MSI IDT2 ROLL TURN ROLL ASSY FEED IDT1 (2) HOUSING ASSY RETARD CHUTE ASSY OUT Drum (4) PRINT HEAD CARTRIDGE ASSY TRANSFER ROLL CARTRIDGE ASSY Fig.
3.2 Drive ASSY DEVE The rotary power of the Drive ASSY DEVE drives the developers of 4 colors in the print head cartridge ASSY. DEVE DRIVE ASSY Developer (M) Developer (Y) Developer (C) Developer (K) PRINT HEAD CARTRIDGE ASSY Fig.3-26 3.
3.4 Fuser Drive ASSY Rotary power of the fuser drive ASSY drives the fuser ASSY. FUSER DRIVE ASSY Heat Roll Gear Exit Roll Assy Exit FUSER ASSY Fig.3-28 3.5 Motor ASSY DUP Rotary power of the motor ASSY DUP is transmitted through the route below. MOTOR ASSY DUP GEAR 48 GEAR 48 GEAR 40/42 GEAR 40/42 GEAR ROLL GEAR ROLL ROLL EXIT ROLL MID GEAR42 CHUTE ASSY EXIT GEAR 30 ROLL DUP CHUTE ASSY OUT Fig.
3.6 Gear Layout PRINT HEAD CARTRIDGE ASSY CHUTE ASSY OUT TRANSFER ROLL CARTRIDGE ASSY REGI CLUTCH CHUTE REGI ASSY MAIN DRIVE ASSY CLUTCH ASSY TURN GEAR MSI GEAR IDLER FEED HOUSING ASSY RETARD CLUTCH TURN GEAR IDLER IN GEAR FEED1 GEAR IDLER GEAR FEED H1 FRONT PAPER FEEDER (PICK UP ASSY) Fig.3-30 GEAR ROLL GEAR ROLL MOTOR ASSY DUP GEAR 48 GEAR 40/42 GEAR 40/42 GEAR 48 GEAR 42 CHUTE ASSY EXIT GEAR 30 CHUTE ASSY OUT FRONT Fig.
4. PAPER TRANSFER 4.
4.2 Layout of Paper Transfer Route : Laser beam : Paper transfer : Paper sensors ROLL EXIT ROLL PINCH EXIT ROLL MID ROLL PINCH Heat Roll Pinch Roll IDT2 ROLL ASSY EXIT Fuser Belt ROLL DUP ROLL PINCH DUP Transfer Roll Cartridge Metal Roll Regi Roll ROLL ASSY FEED (MSI) ROLL ASSY RETARD ROLL PINCH TURN ROLL TURN CHUTE ASSY TURN ROLL ASSY FEED (PICK UP ASSY) ROLL ASSY TURN (PICK UP ASSY) ROLL ASSY(PICK UP ASSY) ROLL ASSY (Paper Cassette) Fig.
5. FUNCTIONS OF MAJOR FUNCTIONAL COMPONENTS Major functional components comprising the printer are described below referring to their illustrations. Those components are classified into the following blocks based on the configuration of the printer.
5.1 Paper Cassette 5.1.1 Major functions 5.1.2 • Side Guide The side guide can move at right angle to the paper transfer direction to align the paper width. • End Guide The end guide can move in the paper transfer direction to determine the paper size. The ON/OFF of switch ASSY size (see 5.2 Paper Feeder) varies according to the end guide position to detect the paper size. • Roll ASSY (Cassette) The roll ASSY (Cassette) and the roll ASSY (pick up ASSY T1) (see 5.
5.2 Paper Feeder 5.2.1 Major functions • Switch ASSY size Switch ASSY size detects paper size and existence or non existence of the paper tray. • Sensor photo (No paper sensor) Detects existence or non existence of paper in the paper tray based on the position of actuator no paper. (No paper: Sensor beam is intercepted) • Sensor photo (Low paper sensor) The actuator lowers according to how much paper remains in the paper tray.
5.2.2 Reference diagram SENSOR PHOTO(No Paper Sensor) ROLL ASSY FEED(PICK UP ASSY) SENSOR HUM TEMP CLUTCH ASSY TURN SWITCH ASSY SIZE GEAR FEED SPRING FEED GEAR IDLER FEED ROLL ASSY TURN SOLENOID FEED ROLL ASSY(PICK UP ASSY) SENSOR PHOTO(Low Paper Sensor) Fig.
5.3 Housing ASSY Retard 5.3.1 Major functions 5.3.2 • Clutch turn (MSI) Transmits the drive from the drive ASSY main to the roll turn. • Roll turn The roll turn is rotated by the drive from the drive ASSY main through the clutch turn (MSI) to feed the paper from the manual feed tray to the chute REGI (REGI roll) (refer to "5.8 Xerographics"). Reference diagram ROLL TURN CLUTCH TURN ( MSI ) Fig.
5.4 Front ASSY In 5.4.1 Major functions 5.4.2 • Holder ASSY CTD Reads the density of the toner image prepared on the surface of transfer roll cartridge in the transfer roll cartridge unit ASSY (refer to "5.7 Transfer Roll Cartridge ASSY & Fuser") and feeds it back to the process control (refer to "7.4 Process Control"). • Sensor TNR full Detects that the toner collect space in the transfer roll cartridge unit ASSY (refer to "5.
5.5 Chute ASSY Out 5.5.1 Major functions • Sensor photo (Full stack sensor) Detects that the prints discharged onto the top cover have accumulated more than specified number of sheets based on the change of position of the actuator. (Full stack: Sensor beam is received) • Sensor photo (DUP jam sensor) Detects that paper has reached and passed through the roll DUP based on the change of position of the actuator.
5.5.2 Reference diagram SENSOR PHOTO(Full Stack Sensor) SENSOR PHOTO(DUP Jam Sensor) ROLL DUP Gear Idier (DRIVE ASSY MAIN) GEAR MSI ROLL ASSY FEED (MSI) SENSOR PHOTO(MSI No Paper Sensor) SOLENOID FEED MSI Fig.
5.6 Chute ASSY Exit 5.6.1 Major functions 5.6.2 • Motor ASSY DUP Supplies drive to the roll exist, roll MID, and roll DUP. • Roll exit The roll exit rotates under the drive from the motor ASSY DUP, and feeds fixed prints onto the top cover. It reverses in the duplex document mode and feeds the prints after fixed on simplex in the REGI direction. • Roll MID The roll MID rotates under the drive from the motor ASSY DUP, and feeds fixed prints onto the top cover.
5.7 Transfer Roll Cartridge ASSY & Fuser 5.7.1 Major functions • Fuser ASSY The fuser ASSY fixes toner which was transferred onto the paper but not fixed by the heat and pressure and feeds paper before and after being fixed.
5.7.2 Reference diagram FUSER ASSY Exit Sensor FAN FUSER Transfer Roll Cartridge ASSY Fig.
5.8 Xerographics 5.8.1 Major functions • • Scanner ASSY Scanner ASSY (raster output scanner assembly) is an exposure unit to generate laser beams to form electrostatic latent image on the drum surface. In this manual, the scanner ASSY is referred to as scanner ASSY.
5.8.2 Reference diagram Scanner ASSY Print Head Cartridge ASSY OHP SENSOR SENSOR PHOTO(Regi Sensor) CHUTE REGI(Regi Clutch) Fig.
5.9 Toner Cartridge ASSY 5.9.1 Major functions • PWBA CRUM READER The PWB consists of each color toner bottle switch and CRUM. Toner bottle switch: Detects whether toner cartridge (toner bottle) of each color is installed or not. CRUM: Printer specific information is stored. • Sensor no toner (Y) • Sensor no toner (M) • Sensor no toner (C) • Sensor no toner (K) Detects residual toner of each color.
5.9.2 Reference diagram PWBA CRUM READER TONER CARTRIDGE ASSY (Y) TONER CARTRIDGE ASSY (M) S-HVPS TONER CARTRIDGE ASSY (C) TONER CARTRIDGE ASSY (K) PWBA EEPROM HOLDER ASSY TONER HBN(K) (Toner Motor : K) HOLDER ASSY TONER HBN(C) (Toner Motor : C) SENSOR NO TONER(Y) SENSOR NO TONER(M) HOLDER ASSY TONER HBN(M) (Toner Motor : M) SENSOR NO TONER(C) SENSOR NO TONER(K) HOLDER ASSY TONER HBN(Y) (Toner Motor : Y) Fig.
5.10 Frame & Drive 5.10.1 Major functions • Drive ASSY main Supplies the drive to parts as follows. • Paper feeder • Housing ASSY retard • Chute ASSY out (MSI position) • Chute REGI • Print Head Cartridge ASSY (IDT 2, IDT 1, Drum) • Transfer Roll Cartridge unit ASSY • Drive ASSY DEVE Supplies the drive to parts as follows. • Print Head Cartridge ASSY (Developer) 5.10.2 Reference diagram Fig.
5.11 Electrical 5.11.1 Major functions • Fan Rear Discharges heat out of the printer to prevent too high temperature in the printer. • Harness ASSY AC SW Composed of the main switch and inlet and controls supply of AC power from the power source to LVPS. • LVPS The LVPS is provided with two types, 100/120V and 230V. Supplies AC power from the power source to the fuser ASSY heater and generates and supplies stable low voltage DC power used for the logic circuit, etc.
• HDD Optional HDD is used for two uses described below. The space used for each function is divided into partitions by the fixed ratio. The space doesn't have relation each other. The ratio cannot be changed. *Breakdown: (1) Job Log: 2MB (2) PostScript file system: 512MB (It would be the half of the whole HDD if the capacity of HDD is less than 1GB.) (3) Memory sort on HDD: rest of capacity * It can be confirmed on the printer setting list. 1.
6. MODES 6.1 Print Mode The printer has four modes, Standard mode, Fine mode, High gloss mode, and Super high gloss mode. Modes are switched over under the instruction from the controller. 1. Standard mode: 2. Fine mode: 3. High gloss mode: Used for printing with resolution 600dpi Process direction resolution 1200dpi mode Thick paper, special paper, and high glossed plain paper Relation between the resolution, process speed, print mode and paper mode is shown in the table below.
• Error mode Any error was detected in the printer. • Initiglizing mode New parts have been just set to the printer (initializing with a new PHD). • Checking Unit mode Printer is under checking consumable units. 7. CONTROL 7.1 Control of Paper Size "ON/OFF of paper size switch of switch ASSY size " and "Diag tool indication data" are shown in the table below. Note: Paper size switches are indicated as SW1, SW2, and SW3 from the above one.
7.4 Process Control For a stable printing, the parameters related to the image forming must be corrected as necessary. The control of entire printing process including parameter correction control is called "process control". Mainly, the following two controls are made: • Potential control • Toner density control To supplement these two controls, the following controls are provided: • High area coverage mode • Admix mode • Holder ASSY CTD LED light quantity setting 7.4.
7.4.2 Toner density control The toner density must be kept constant to attain stable printing image. To keep the toner density constant, the toner should be dispensed exactly by the quantity consumed for the printing. This system is the PCDC. However, the system with only the PCDC generates a difference from target toner density, thus requiring the system to correct this error. This is the toner density control by the holder ASSY CTD.
7.4.3 High area coverage mode A continuous printing of the image of area coverage exceeding the toner dispense capability causes the toner density in the developer to be lowered. The high area coverage mode extends the next page feed and dispenses the toner during this time, if the toner dispense time reached the specified value during a continuous printing. 7.4.4 Admix mode Even the high area coverage mode may not be able to cope with the reduction of toner density in the developer.
7.5 Color Registration Control The printer uses a tandem system where the drums and developers exclusively for yellow, magenta, cyan, and black are arranged respectively. The images are formed on the drums of respective colors cyan, and black are arranged respectively. The images are formed on the drums of respective colors registration control calculates how much the registration is shifted, and adjusts the scanner write timing.
7.6 Transfer Roll Cartridge Unit ASSY Control 7.6.1 Detecting the installation of transfer roll cartridge unit ASSY Whether the transfer roll cartridge unit ASSY is installed is detected when the power is turned on, or the front cover is opened and closed. The sensor for detecting the installation is not provided, but judgment is made from the output of the holder ASSY CTD.
7.7 Toner Control Whether the toner bottle is installed is detected by the switch toner cartridge ASSY, and the presence of toner in the toner bottle is detected by the sensor no toner . These switches and sensors are provided for respective colors, and detection is made for each color. 7.7.1 Sensor no toner The sensor no toner is provided for each color.
7.8 Fuser Control 7.8.1 Fuser temperature control As for the fuser temperature control, the target temperature is set, then the heat roll surface temperature is controlled so as to be the target temperature by turning on/off the heater lamp. Temperature of individual area of the heat roll is detected by the fuser non-contact sensor (NCS) in the middle of the heat roll and the temp sensor at the edge of it.
CHAPTER IV ASSEMBLY / DISASSEMBLY
CONTENTS CHAPTER IV ASSEMBLY / DISASSEMBLY................................ IV-1 1. REPLACING PROCEDURE OF PERIODICAL REPLACEMENT PARTS ........... IV-1 1.1 1.2 1.3 1.4 Replacing the Fuser ASSY .............................................................................................IV-1 Replacing the Transfer ASSY .........................................................................................IV-4 Replacing the Roll ASSY ..........................................................................
2.3.22 Latch R .................................................................................................................IV-35 2.3.23 Latch L..................................................................................................................IV-36 2.3.24 Fuser drive ASSY .................................................................................................IV-36 2.3.25 Chute ASSY REGI...............................................................................................
2.6.14 2.6.15 2.6.16 2.6.17 2.6.18 2.6.19 2.6.20 2.6.21 2.6.22 2.6.23 2.6.24 2.6.25 Housing ASSY feeder L .......................................................................................IV-76 Sensor HUM temp ................................................................................................IV-77 Housing ASSY feeder R.......................................................................................IV-78 Harness ASSY OPFREC ............................................................
CHAPTER IV ASSEMBLY / DISASSEMBLY 1. REPLACING PROCEDURE OF PERIODICAL REPLACEMENT PARTS Periodical replacement parts are the parts to be replaced periodically to maintain product quality. Refer to APPENDIX5. “PERIODICAL REPLACEMENT PARTS” in detail. 1.1 Replacing the Fuser ASSY WARNING Fuser is high temperature after operation. Be careful when working it not to get burning. 1) Push up latch B and fully open the chute ASSY out. Fig.
4) Lift the levers on both sides of the fuser ASSY. Fig.4-4 5) Hold the levers on both sides as you remove the fuser ASSY from the printer carefully. Fig.4-5 6) Unpack a new fuser ASSY and lift the levers on both sides. Grip the lever and install the fuser ASSY into the printer gently placing pin into the guides. Fig.
7) Push down the levers on both sides of the fuser ASSY. Fig.4-7 8) Push and slide backward the switches on both sides of the fuser ASSY. Fig.4-8 9) Close the Paper outlet cover. 10) Close the chute ASSY. Fig.4-9 Fig.
1.2 Replacing the Transfer ASSY 1) Push up latch A and fully open the chute ASSY. 2) Grip the orange tabs at both ends of the transfer roll and gently lift it out of the printer. 3) Unpack a new transfer roll cartridge unit ASSY and grip the orange tabs. Fig.4-11 Fig.4-12 Fig.
4) Insert the pins at both ends of the transfer roll cartridge unit ASSY into the bearings inside the printer, and gently push the roll into the printer. 5) To lock the transfer roll cartridge into the printer, push down on the tabs until you hear a click. 6) Close the chute ASSY. Fig.4-14 Fig.4-15a Fig.
1.3 Replacing the Roll ASSY 1) 2) 3) Release the cover feed secured to the paper tray at one point and open the cover feed. Release the hook securing the roll ASSY to the shaft retard from the paper tray. Pull out the roll ASSY from the shaft retard. Roll ASSY Cover feed 4) 1.4 Fig.4-16 Push the new roll ASSY into the shaft on the paper tray. Description of Procedures Note: In the procedures, directions are represented as follows. • Front: Front when you are facing the front of this laser printer.
2. DISASSEMBLY PROCEDURE 2.1 Precautions Note: Parts are controlled as spare parts. When servicing for parts for which no procedures are described, observe their assembling condition before starting the service. Note: For optional parts, refer to the manual for them. Note: Though the optional parts are assumed to be removed, they may not be removed if not required for the purpose of service operation.
2.2 Cover of the Printer 2.2.1 Cover ASSY front head 1) Release latch B of the printer and open the front cover. Note: Do not separate the front cover and cover ASSY front head too far in the following process. 2) 3) 4) 5) 6) Release the 4 hooks securing the cover ASSY front head to the front cover. Separate the cover ASSY front head a little from the front cover. Remove the connector from the console panel HIBANA. Remove the connector from the fan assembly.
2.2.2 Console panel HL-4200 1) Release the 3 hooks securing the console panel HL-4200 to the cover ASSY front head. 2) Remove the console panel HL-4200 from the cover ASSY front head. Console panel HL-4200 Cover ASSY front head Bottom view Fig.
2.2.3 Fan fuser 1) Remove 2 screws securing the holder lever out from the rear of the cover ASSY front head. 2) Remove the fan assembly from the cover ASSY front head. 3) Remove the lever out from the holder lever out. 4) Disconnect of the fan fuser. 5) Release the 4 hooks securing the fan fuser the holder lever out. 6) Remove the fan fuser from the holder lever out.
2.2.4 Cover MSI 1) Close the front cover. 2) Open the cover MSI. 3) While pulling the left hand side of the cover MSI, release the boss of the tray ASSY base from the slot in the cover MSI. 4) Repeat for the right hand side. 5) Lower the front of the cover MSI unit the cover MSI releases from the printer. Tray ASSY base Cover MSI Fig.4-22 2.2.5 Tray ASSY base 1) Check that the plate ASSY bottom MSI is shifted down.
2.2.6 STRAP 1) Release hooks that secure the bottom portion of STRAP, and slide the bottom portion of STRAP toward the right to remove from the chute ASSY out. 2) Turning the top of STRAP secured to the upper right of the chute ASSY IN, meet a convex portion with the key hole in the chute ASSY IN and pull out the top of STRAP to remove the STRAP. STRAP Fig.
2.2.7 Cover ASSY front 1) Release latch B and open the chute ASSY out. 2) Remove the top of the link: L from the leaf spring at the back of the cover ASSY front. 3) Remove 2 screws securing the cover ASSY front to the chute ASSY out. 4) Release the 2 hooks securing the cover ASSY front to the chute ASSY out. 5) Remove the cover ASSY front from the chute ASSY out. Link: L Screw, M3x10 Cover ASSY front Fig.4-25 Rear view Cover ASSY front Fig.
2.2.8 Cover ASSY front IN Note: In the following process, do not separate the cover ASSY front IN and link: R too far. 1) 2) 3) 4) Release latch A and open the chute ASSY IN together with the chute ASSY out. Remove 2 screws securing the cover ASSY front IN to the chute ASSY IN. Pull out the cover ASSY front IN slightly from the chute ASSY IN. Remove the top link: R from the leaf spring at the back of the cover ASSY front IN and remove the cover ASSY front IN. Screw, M3x10 Cover ASSY front IN Fig.
2.2.9 Cover top main Note: Before removing the cover top main, remove the toner cartridges. 1) 2) 3) 4) Open the Paper outlet cover. Remove 2 screws securing the cover top main to the printer. Release the 4 hooks securing the cover top main to the printer. Raise the cover top main slightly from the printer and extract the left front edge of the cover top main deflecting it leftward. 5) Remove the cover top main from the printer. Cover top main Screw, M3x10 Fig.
2.2.10 Cover side L 1) Remove 1 screw securing the rear of cover side L to the printer. 2) Release the hook securing the cover side L at the front edge of the printer. 3) Remove the cover side L from the printer. Cover side L Screw, tapping M3x8 Fig.4-30 2.2.11 Paper outlet cover 1) Open the Paper outlet cover. 2) Extract the right and left stud top securing the Paper outlet cover to the printer. 3) Remove the Paper outlet cover from the printer. Paper outlet cover Stud top Stud top Fig.
2.2.12 Cover side R 1) Remove 1 screw securing the rear of cover side R to the printer. 2) Release the hook securing the cover side R at the front of the printer. 3) Remove the cover side R from the printer. Cover side R Screw, tapping M3x8 Fig.4-32 2.2.13 Cover rear 1) Lift the cover rear slightly, put it backwards and remove. Cover rear Fig.
2.2.14 Link: L 1) 2) 3) 4) Remove the top of spring link: L from the projection on the left side of the printer. Slide the link: L rearward and align the shaft of the printer and hole of the link: L. Remove the link: L from the printer together with the spring link: L. Remove the spring link: L from the link: L. Spring link: L Link: L Fig.4-34 2.2.15 Link: R 1) Remove the top of spring link: R from the projection on the right side of the printer.
2.3 Front of the Printer 2.3.1 Chute ASSY out Note: In the following step, lock the chute ASSY out and chute ASSY IN to the printer with latches A and B. 1) Remove the connectors from the connector bracket on the left side surface of the printer. 2) Remove 1 screw which is fixing the earth from the left hand side of printer. 3) Shift the harness of the connector removed above from the bottom portion of the HSG ASSY BIAS on the left side surface of the printer.
8) Remove the ring E on the right and left shaft pivot securing the bottom portion of the chute ASSY out and chute ASSY IN. CAUTION In the following steps, take care not to hurt your hand with burrs of the plate ASSY bottom MSI. 9) Pull out the left shaft pivot from the chute ASSY out inward with radio pliers. 10) Pull out the right shaft pivot from the chute ASSY out inward with radio pliers.
2.3.2 Actuator full 1) While pulling the center of the actuator full shaft upwards, pull the right hand end of the shaft forwards to clear the sensor and release the right end of the shaft. 2) Move the shaft to the right to release the left end of the shaft and remove it. Actuator full 1 3 2 Fig.4-39 2.3.3 Sensor photo: full stack 1) Remove the connector on the sensor photo: full stack. 2) Release the 3 hooks securing the sensor photo: full stack to the chute ASSY out.
2.3.4 Actuator DUP 1) Release the 2 hooks securing the cover actuator to the chute ASSY out. 2) Remove the cover actuator from the chute ASSY out. 3) Pushing the front arm of the actuator DUP down, slide the actuator DUP to the right and extract the left side shaft of the actuator DUP from the left side bush. 4) Extract the actuator DUP from the chute ASSY out together with the spring SNR DUP. 5) Remove the spring SNR DUP from the actuator DUP. Cover actuator Fig.
2.3.5 Sensor photo: DUP 1) Remove the sensor photo: DUP cable. 2) Release the 3 hooks securing the sensor photo: DUP to the chute ASSY out. 3) Remove the sensor photo: DUP from the chute ASSY out. Sensor photo: DUP Fig.4-43 2.3.6 Actuator MSI 1) Pushing down the plate bottom MSI on the chute ASSY out push the actuator MSI inward. 2) Slide the actuator MSI leftward and remove the shaft from the right side of the actuator MSI. 3) Remove the actuator MSI together with the spring sensor MSI.
2.3.7 Sensor photo: MSI 1) Remove the connector on the sensor photo: MSI from the chute ASSY out. 2) Release the 3 hooks securing the sensor photo: MSI to the chute ASSY out. 3) Remove the sensor photo: MSI from the chute ASSY out. Sensor photo: MSI Rear view Fig.4-45 2.3.8 Bracket ASSY eliminator 1) Remove 1 screw securing the bracket ASSY eliminator to the chute ASSY out.
2.3.9 Roll DUP 1) 2) 3) 4) 5) Release the hook remove the gear 30 from the shaft of the roll DUP. Extract the bush earth securing the left end of the shaft to the chute ASSY out. Remove the E-ring securing the right end of the shaft to the chute ASSY out. Extract the bush securing the right end of the shaft to the chute ASSY out. Remove the roll DUP. Roll DUP Chute ASSY out Bush Bush earth Gear 30 Fig.4-47 2.3.10 Latch out 1) Remove the spring latch out from the chute ASSY out.
2.3.11 Roll ASSY feed 1) Release the hook securing the roll core MSI: right to the shaft MSI on the chute ASSY out and push down the plate bottom MSI slightly to release the nip with the roll ASSY feed. 2) Slide the roll ASSY feed to the right on the shaft MSI and lift out the roll ASSY feed forwards. Roll core MSI: right Plate bottom MSI Roll ASSY feed Fig.4-49 2.3.
2.3.13 Shaft ASSY roll feed 1) Release the hook of the spring sol from a convex portion on the stopper sol cam from the chute ASSY out. 2) Release the hook securing the stopper sol cam to the left of shaft MSI, and remove the stopper sol cam from the shaft from the chute ASSY out. 3) Release the hook securing the gear MSI to the right of shaft MSI, and remove the gear MSI from the chute ASSY out. 4) Release the hooks of spring N/F from the left and right ends of shaft ASSY roll feed.
6) Pull off the bush MSI on the shaft MSI toward the inside. 7) Raising the right end of the shaft ASSY roll feed, pull out the shaft ASSY feed from the chute ASSY out. Note: When refitting the cam MSI ensure that it is located connecting on the shaft. When refitting the stopper sol cam, ensure it is in the home position. Shaft ASSY roll feed Bush MSI Bush MSI Fig.4-52 2.3.14 Plate ASSY bottom MSI 1) Remove 2 screws securing the plate out MSI to the chute ASSY out.
2.3.15 Chute ASSY exit 1) Disconnect the connector of the motor ASSY DUP on the chute ASSY out and release the cable from the clips. 2) Remove 2 screws securing the chute ASSY exit to the chute ASSY out. 3) Pull out the chute ASSY exit from the left side surface of the chute ASSY out. Note: When replacing the chute ASSY exit, be careful to avoid the actuator full on the chute ASSY out. Actuator full Chute ASSY exit Screw, M3x10 Left Fig.
2.3.16 Roll exit 1) 2) 3) 4) 5) Release the hook securing the gear roll to the shaft of the roll exit. Remove the gear roll from the shaft of the roll exit. Remove the E-ring from the shaft of the roll exit. Extract the bush earth from the shaft of the roll exit. Raise the right hand end of the shaft from the chute ASSY exit and pull out the roll exit upwards. Roll exit Right Chute ASSY exit Bush earth Gear roll Fig.
2.3.17 Roll MID 1) 2) 3) 4) 5) Release the hook securing the gear roll to the shaft of the roll MID. Remove the gear roll from the shaft. Remove the E-ring from the shaft of the roll MID. Extract the bush earth from the shaft of the roll MID. Remove the shaft of the roll MID from the chute ASSY exit and pull out the roll exit upwards. Right Roll MID Bush earth Chute ASSY exit Gear roll Fig.
2.3.18 Motor ASSY DUP 1) 2) 3) 4) 5) 6) Release the hook securing the gear roll to the shaft of the roll exit. Remove the gear roll from the shaft of the roll exit. Remove the gear 40/42 from the left side of the chute ASSY exit. Remove the gear 48 from the left side of the chute ASSY exit. Remove 3 screws securing the motor ASSY DUP to the chute ASSY exit. Remove the motor ASSY DUP from the chute ASSY exit. Gear roll: exit Motor ASSY DUP Gear 40/42 Gear 48 Screw, M3x6 Sleeve Grommet exit Fig.
2.3.19 Chute ASSY IN Note: In the following step, lock the chute ASSY IN to the printer with latch at A to prevent the chute ASSY IN from drop off. 1) Remove the connectors on the S-HVPS from the left side of the printer. 2) Remove the connectors from the connector bracket on the left side of the printer. 3) Disconnect the connector of harness ASSY FSR3 (FSR32) from the left hand side of a printer.
7) Remove 1 screw securing the wire ASSY FSR earth on the right side of the printer. 8) Release the harness of the fuser drive ASSY from the clamp on the drive ASSY main. 9) Shift the harness of the harness ASSY FSR3 (FSR32,FSR4) from the hook of the housing on the right side of the printer. 10) Release the latch at A from the printer, and pull out the chute ASSY IN frontward and remove. Chute ASSY IN 2.3.20 Fig.
2.3.21 Sensor TNR full 1) Release the 2 hooks securing the sensor TNR full to the chute ASSY IN. 2) Remove the connector on the sensor TNR full. 3) Remove the sensor TNR full from the chute ASSY IN. Sensor TNR full Front Fig.4-61 2.3.22 Latch R 1) Release the hook at the lower part of the spring latch securing it to the hole on the right side of the chute ASSY IN. 2) Release the hook securing the latch R to the chute ASSY IN.
2.3.23 Latch L 1) Release the hook securing the latch L to the left side of the chute ASSY IN. 2) Remove the latch L from the chute ASSY IN. Chute ASSY IN Latch L Fig.4-63 2.3.24 Fuser drive ASSY 1) Remove the screw securing the earth of the harness ASSY FSR to the fuser drive ASSY. 2) Release the harnesses from the harness guides. 3) Remove 3 screws securing the fuser drive ASSY to the chute ASSY IN. 4) Remove the fuser drive ASSY from the chute ASSY IN.
2.3.25 Chute ASSY REGI 1) Release the 2 hooks securing the housing ASSY ELEC to the printer and remove the housing ASSY ELEC upward. Housing ASSY ELEC Fig.4-65 2) 3) 4) Disconnect the 2 connectors of the chute ASSY REGI from the printer. Remove 4 screws securing the chute ASSY REGI to the printer. Lift the left end of the chute ASSY REGI and pull out the chute ASSY REGI leftwards from the printer. Note: Take care not to damage the plastic film when refitting the chute ASSY REGI.
2.3.26 Actuator REGI 1) 2) 3) Holding the shielding portion of the actuator REGI move the actuator REGI left and extract the right hand end of the shaft of the actuator REGI from the bush of the chute ASSY REGI. Pull out the actuator REGI from the chute ASSY REGI together with the spring sensor REGI. Remove the spring sensor REGI from the actuator REGI. Spring sensor REGI Actuator REGI Front Chute ASSY REGI Top Fig.4-67 2.3.
2.3.28 OHP sensor ASSY 1) Remove the E-ring that secures the gear REGI metal to the chute ASSY REGI, and remove the gear REGI metal. 2) Remove the E-ring that secures the gear REGI rubber to the chute ASSY REGI, and remove the gear REGI rubber. 3) Pull out the bush earth that secures the shaft of the roll REGI rubber. Note: In the following steps, take care not to lose the spring REGI: R and spring REGI: L as they will spring.
7) Lift the shaft of roll REGI metal, pull out the roll REGI metal together with the bush metal R (white). Roll REGI metal Chute ASSY REGI Fig.4-71 8) 9) Release the 2 hooks on the bottom of chute ASSY REGI that secure the OHP sensor ASSY. Remove the OHP sensor ASSY from the chute ASSY REGI. Sensor ASSY OHP Rear Fig.
2.3.29 Housing ASSY retard 1) 2) 3) Remove the connector of the clutch turn from on the PWBA HBN MCU. Remove 3 screws securing the housing ASSY retard to the printer. Remove the housing ASSY retard from the printer. Screw, M3x10 Screw, M3x10 Housing ASSY retard Fig.4-73 2.3.30 Clutch turn 1) 2) Remove the E-ring securing the clutch turn to the shaft of the housing ASSY retard. Remove the clutch turn from the shaft of the housing ASSY retard. Housing ASSY retard Clutch turn Fig.
2.3.31 Roll turn 1) 2) 3) 4) Remove the E-ring securing the roll turn to the housing ASSY retard. Pull out the bush earth securing the left side of the roll turn from the housing ASSY retard. Pull out the bush securing the right side of the roll turn from the housing ASSY retard. Slide the roll turn from the housing ASSY retard rightward, and pull out the roll turn left and upward. Roll turn Bush earth Bush Housing ASSY retard Fig.4-75 2.3.
3) 4) Pull out the holder ASSY retard to left upward from the housing ASSY retard. Release the hook securing the shaft RTD to the holder ASSY retard of the printer. Holder ASSY retard Fig.4-77 5) Raise the shaft RTD to right upward, and pull out the roll ASSY retard. Holder ASSY retard Roll ASSY retard Fig.
2.3.33 Stud retard 1) 2) 3) Release the 2 hooks securing the cap retard to the housing ASSY retard. Remove the cap retard from the housing ASSY retard together with the stud retard and spring retard 370. Remove the stud retard from the cap retard. Housing ASSY retard Stud retard Spring retard Cap retard Fig.4-79 2.3.34 PWBA ASSY earth 1) 2) Remove 2 screws securing the PWBA ASSY earth to the printer. Remove the PWBA ASSY earth from the printer. PWBA ASSY earth Fig.
2.4 Top of the Printer 2.4.1 Holder toner cartridge ASSY unit Note: When removing the holder toner cartridge ASSY unit, remove the toner deposit on the holder toner cartridge ASSY with a vacuum cleaner before starting the removal process. Note: When removing the toner deposit on the holder toner cartridge ASSY with a vacuum cleaner, attach an earth cord to the end of the cleaner to avoid the static electricity.
3) 4) 5) 6) 7) 8) 9) Remove the connector (D) on the PWBA EEPROM STD on the left side of the printer. Remove the connector (E) on the S-HVPS on the left side of the printer. From the printer, release the fan harness from the clamps. Remove the connector (F) from the connector block. Release the 2 hooks securing the gear slide to the shaft on the left side of the printer. Remove the gear slide from the printer. Remove the rack V from the printer. S-HVPS “D” PWBA EEPROM Rack V “E” “F” Gear slide Fig.
Note: When replacing the gear slide, meet the leading edge of gear rail on the left side. with the vertex of a triangle mark on the rack V. Rack V Fig.4-84 2.4.2 Holder toner cartridge ASSY 1) 2) 3) 4) 5) 6) 7) On the holder toner cartridge ASSY unit, release the hook securing the toner discharging unit of the holder toner cartridge ASSY (1) on the plate ASSY dispenser L with a mini screwdriver. From the plate ASSY dispenser, pull out the toner discharging unit rightwards.
Holder toner cartridge ASSY (2) Fig.4-86 Holder toner cartridge ASSY (3) Fig.
Holder toner cartridge ASSY (4) Fig.
2.4.3 Actuator toner cartridge ASSY 1) 2) Release the 2 hooks securing the actuator toner cartridge ASSY to the holder toner cartridge ASSY with a mini screwdriver. Remove the actuator toner cartridge ASSY from the holder toner cartridge ASSY. Actuator toner cartridge ASSY Left Holder toner cartridge ASSY Fig.4-89 2.4.4 Bracket sensor 2 and actuator sensor 2 1) Remove the actuator sensor 2 from the actuator toner cartridge ASSY. Bracket sensor 2 Actuator sensor 2 Fig.
2.4.5 Sensor no toner 1) 2) Remove the 4 hooks securing the sensor no toner to the holder toner cartridge ASSY. Remove the sensor no toner from the holder toner cartridge ASSY. Holder toner cartridge ASSY Sensor no toner Fig.4-91 2.4.6 Box ASSY CRUM reader 1) 2) 3) Remove the connector on PWBA CRUM reader. Remove harness ASSY toner 4 from the slit part of HSG base CRUM. Remove two screws which are fixing box ASSY CRUM reader to plate ASSY dispenser HBN.
2.4.7 PWBA EEPROM 1) 2) Remove 1 screw securing the PWBA EEPROM. Remove the PWBA EEPROM from the printer. Screw, M3x6 Left PWBA EEPROM Fig.4-93 2.4.8 S-HVPS 1) 2) Remove 4 screws securing the S-HVPS. Remove the S-HVPS from the printer. S-HVPS Screw, M3x6 Screw, M3x6 Left Screw, M3x6 Fig.
2.4.9 Fan rear 1) 2) 3) 4) Remove the connector on the LVPS from the right side surface of the printer. Shift the harness of the fan rear from 3 hooks of the holder toner cartridge ASSY of the printer. Remove 2 screws securing the fan rear from the printer. Remove the fan rear from the printer. Fan rear Left Right Fig.4-95 2.4.10 Scanner ASSY 1) 2) 3) 4) Remove the connector on the scanner ASSY.
2.5 Right / Left / PCBs of the Printer 2.5.1 Controller Board 1) Loosen the two screws, and then remove the controller board. Note: In replacing the controller board on the printer, connect the connector at the leading end of controller board to the connector of the MCU HL-4200. Screw, M4x7.5 Controller board Screw, M4x7.5 Fig.4-97 2) 3) 4) 5) 6) 7) Remove the two screws from the plate rear ess. Remove the NIC excord ASSY BR. Remove the four screws, and then remove the plate rear ess.
2.5.2 HSG ASSY BIAS 1) 2) 3) Remove 5 screws securing the HSG ASSY BIAS to the left side surface of the printer. Remove the HSG ASSY BIAS from the printer. Remove 8 contact pads from the printer. HSG ASSY BIAS Screw, M3x10 Screw, M3x10 Fig.4-99 2.5.3 Lever drum: L 1) 2) 3) Remove 4 screws securing the plate ASSY lever L from the left side of the printer. Remove the plate ASSY lever L from the printer.
4) 5) Remove the link lever: L from the printer together with the spring lever: 30N and lever drum: L. Remove 4 springs from link lever: L and remove 4 lever drum: L. Note: When replacing the link lever, align the spring IDT L and the bottom of link lever: L with the positions shown in the figure (lever drum: L replacement). Gear IDL. press Gear press L Link lever: L Lever drum: L Fig.4-101 Note: The lever drum: L and link lever: L must be fitted and aligned before refitting spring lever 30N.
2.5.4 Drive ASSY main 1) 2) 3) 4) 5) Remove the connector on the PWBA DRV HBN from the right side of the printer. Remove the connector on the PWBA DRV HBN. Disconnect the connector on the PWBA DRV HBN. Remove 3 screws securing the drive ASSY main to the printer. Remove the drive ASSY main from the printer. Drive ASSY main Fig.
2.5.5 PWBA DRV HBN 1) 2) 3) Remove the all connectors on the PWBA DRV HBN from the right side of the printer. Remove 4 screws securing the PWBA DRV HBN to the printer. Remove the PWBA DRV HBN from the printer. Screw, M3x6 Screw, M3x6 Screw, M3x6 PWBA DRV HBN Fig.
2.5.6 Drive ASSY DEVE 1) 2) Remove 4 screws securing the Drive ASSY DEVE from the right side of the printer. Remove the Drive ASSY DEVE from the printer. Drive ASSY DEVE Screw, DT M4x10 Screw, DT M4x10 Fig.4-105 2.5.7 Actuator I/R 1) 2) 3) 4) From the right side of the printer, release the hook of the spring I/R from the convex portion of the plate ASSY lever R. Release the hook securing the actuator I/R to the shaft on the plate ASSY lever R.
2.5.8 Lever drum: R 1) 2) 3) Remove 4 screws securing the plate ASSY lever R from the right side of the printer. Remove the plate ASSY lever R from the printer. Release the hook of the spring lever 30N hitched over the convex portion of the 4 lever drum: R from the right side of the printer. Spring lever 30N Screw, M3x10 Plate ASSY lever R Screw, M3x10 Spring lever 30N Fig.4-107 4) 5) Remove the link lever: R from the printer together with the spring lever 30N.
Note: When replacing the link lever: R, align the spring IDT R and the bottom of link lever: L with the positions shown in the figure (lever drum: L replacement). Gear IDL. press Link lever: R Gear press R Fig.4-109 2.5.9 LVPS 1) 2) 3) Remove the three connectors from the LVPS. Remove the clamp guide harness. Remove the harness from the guide harness SW. Clamp guide harness Guide harness SW Harness Clamp guide harness Fig.
4) 5) 6) 7) 8) 9) Releasing the hooks at 2 positions, and then remove the guide harness SW. Remove the screw, and then release the ground wire. Disconnect the connector on the guide harness SW. Remove the switch part of the guide harness SW. Releasing the hooks at 2 positions, and then remove the inlet part of the guide harness SW. Remove the guide harness SW. Guide harness SW Inlet part Guide harness SW Ground wire Connector Switch part Fig.
2.5.10 Box ASSY MCU/ESS 1) 2) 3) Remove the connector from the right side of the printer. Remove the connector on the scanner ASSY from the right side of the printer. Remove the connector from the left side of the printer. Box ASSY MCU/ESS Fig.4-113 4) 5) Remove 4 screws securing the box ASSY MCU/ESS to the printer. Pull out the box ASSY MCU/ESS rearward from the printer and remove. Screw, M3x6 Screw, M3x6 Box ASSY MCU/ESS Screw, M3x6 Fig.
2.5.11 Housing ASSY contact 1) 2) Remove the housing ASSY contact from the box ASSY MCU/ESS. Pull out the housing ASSY contact from the box ASSY MCU/ESS and remove it. Housing ASSY contact Fig.
2.5.12 MCU HL-4200 1) 2) 3) Remove 4 screws securing the cover MCU to the box ASSY MCU/ESS. Remove the cover MCU from the box ASSY MCU/ESS. Remove the connectors on the MCU HL-4200 from the box ASSY MCU/ESS. Cover MCU Screw, M3x6 Screw, M3x6 Screw, M3x6 Fig.4-116 4) 5) Remove 6 screws securing the MCU HL-4200 to the box ASSY MCU/ESS. Remove the MCU HL-4200 from the box ASSY MCU/ESS. Screw, M3x6 Screw, M3x6 MCU HL-4200 Fig.
2.6 Paper Feed of the Printer 2.6.1 Chute ASSY turn 1) 2) Release the 2 hooks at the front securing the chute ASSY turn to the printer feeder. The chute ASSY will hang ertically. Chute ASSY turn Fig.4-118 3) 4) Release the hook securing the right and left shaft of the chute ASSY turn to the printer feeder. Pull out the chute ASSY turn from the printer feeder and remove. Chute ASSY turn Fig.
2.6.2 Cover cassette slide 1) Right and left of cover cassette slide are pushed, a claw on either side is removed from the projection of housing feeder L and housing feeder R, and cover cassette slide is removed. Cover cassette slide Fig.
2.6.3 Link actuator 1) 2) Shift the bracket of the link actuator from the shaft of the actuator no paper of the printer. Extract the actuator of the link actuator from the hole on the printer and remove the link actuator. Link actuator Actuator no paper Fig.
2.6.4 Feeder ASSY unit 1) 2) 3) 4) Remove the connector connecting the printer and feeder ASSY unit from the left side of the printer. Remove the 2 connectors connecting the printer and feeder ASSY unit from the right side of the printer. Remove 8 screws securing the feeder ASSY unit to the printer. Remove 4 long screws securing the feeder ASSY unit to the printer. CAUTION The top unit of the printer should be raised up by more than two people.
2.6.5 Pickup ASSY 1) 2) 3) 4) Remove the harness of the pickup ASSY from the right hook of the feeder ASSY unit. Disconnect the harness from the size switch. Remove 2 screws securing the pickup ASSY to the feeder ASSY unit. Lift the pickup ASSY from the feeder ASSY unit. Pickup ASSY Screw, M3x10 Screw, M3x10 Top view Feeder ASSY unit Fig.
2.6.6 Roll ASSY feed 1) 2) Rotate the shaft feed 1 (180°) so that the rubber of the roll ASSY feed L and R faces downward from the printer feeder. Release the hook securing the roll ASSY feed L and R to the shaft feed 1 and remove the roll ASSY feeds. Roll ASSY feed: L Fig.4-124 Roll ASSY feed: R Fig.
2.6.7 Actuator no paper 1) 2) Release the hook securing the actuator no paper to the pickup ASSY and extract the left side shaft of the actuator no paper. Pull out the actuator no paper left and upward from the pickup ASSY. Actuator no paper Top Front Fig.
2.6.8 Sensor photo: No paper 1) 2) 3) Release the hooks at 3 positions securing the sensor photo: no paper to the pickup ASSY. Remove the connector on the sensor photo: no paper. Remove the sensor photo: no paper from the pickup ASSY. Rear Sensor photo: no paper Front Top Fig.4-127 2.6.9 Sensor photo: Low paper 1) 2) 3) Release the hooks at 3 positions securing the sensor photo: low paper to the pickup ASSY. Remove the connector on the sensor photo: low paper.
2.6.10 Solenoid feed 1) 2) 3) Remove 1 screw securing the solenoid feed from the pickup ASSY. Separate the solenoid feed a little from the pickup ASSY and shift the harness of the solenoid feed. Remove the connector of the solenoid feed from the pickup ASSY. Rear Right Solenoid feed Fig.4-129 2.6.11 Clutch ASSY turn 1) 2) 3) 4) Release the hook securing the stopper clutch to the shaft on the right side shaft of the pickup ASSY. Pull out the stopper clutch from the shaft of pickup ASSY.
2.6.12 Roll ASSY turn 1) 2) 3) 4) 5) 6) 7) Release the hook securing the gear feed 2 to the shaft of the pickup ASSY and pull out gear feed 2. Pull out the gear idler from the shaft of pickup ASSY. Pull out the gear idler in from the shaft of the pickup ASSY. Remove the right and left E rings securing the shaft of the roll ASSY turn to the pickup ASSY. Remove the bush/metal securing the right shaft of the roll ASSY turn from the pickup ASSY.
2.6.14 Housing ASSY feeder L 1) Remove 4 screws securing the housing ASSY feeder L to the plate bottom. Housing ASSY feeder L Screw, M3x10 Front Screw, M3x10 Left Fig.4-133 2) 3) Pull down the housing ASSY feeder L inward and extract the 3 hooks out of the hole at the plate bottom. Remove the housing ASSY feeder L upward from the plate bottom. Housing ASSY feeder L Fig.
2.6.15 Sensor HUM temp 1) 2) Remove the screw securing the sensor HUM temp. Remove the harness ASSY TMPA. Harness ASSY TMPA Screw, M3x10 Sensor HUM temp Left Fig.
2.6.16 Housing ASSY feeder R 1) Remove 4 screws securing the support feeder left to the plate bottom. Housing ASSY feeder R Screw, M3x10 Right Screw, M3x10 Screw, M3x10 Front Fig.4-136 2) 3) Pull down the housing ASSY feeder R inward and extract the 3 hooks out of the hole at the plate bottom. Remove the housing ASSY feeder R upward from the plate bottom. Housing ASSY feeder R Fig.
2.6.17 Harness ASSY OPFREC 1) 2) 3) Release the harness ASSY OPFREC from the housing ASSY feeder R of the feeder ASSY unit. Release the 2 hooks securing the harness ASSY OPFREC to the housing ASSY feeder R. Pull out the harness ASSY OPFREC downward from the housing ASSY feeder R. Right Top view Harness ASSY OPFREC Rear Fig.4-138 2.6.18 Switch ASSY size 1) 2) Remove 1 screw securing the switch ASSY size to the housing ASSY feeder R. Remove the switch ASSY size from the housing ASSY feeder R.
2.6.19 Indicator 1) Hold the tip of the indicator with radio pliers and pull the indicator frontward and remove from the housing ASSY feeder R of the feeder ASSY unit. Note: Hold the guide indicator, when replacing the indicator. Guide indicator Indicator Fig.
2.6.20 Guide indicator 1) Release the 2 hooks securing the holder shaft to the housing ASSY feeder R. Holder shaft indicator Lever low paper Fig.4-141 2) 3) Pull out the guide indicator from the housing ASSY feeder R together with the spring indicator and shaft indicator. Pull out the guide indicator from the shaft indicator. Note: Put the leading end of lever low paper on a left convex portion of the guide indicator, when replacing the guide indicator.
2.6.21 Lever low paper 1) 2) Turn the housing ASSY feeder R upside down. Push the support pillow to the left and release the lever low paper shaft. Left view Lever low paper Housing ASSY feeder R Fig.4-143 3) Remove the lever low paper from the housing ASSY feeder R. Lever low paper Fig.
2.6.22 Roll ASSY 5) 6) 7) Release the cover feed secured to the cassette at one point and open the cover feed. Release the hook securing the roll ASSY to the shaft retard from the cassette. Pull out the roll ASSY from the shaft retard. Roll ASSY Cover feed Fig.4-145 2.6.23 Cassette ASSY front 1) 2) 3) Release the bottom and top hook securing the cassette ASSY front from the right side of the cassette using a mini screwdriver or the like.
2.6.24 Holder retard 1) 2) 3) Remove the clutch ASSY friction on the shaft retard from the cassette. Release the hook of the spring retard hitched to the bottom groove of the holder retard from the cassette. Release the hook securing the top portion of the holder retard from the cassette and move the holder retard leftward. Clutch ASSY friction Holder retard Spring retard Fig.4-147 4) Pull out the right end of the holder retard slightly from the cassette and extract the holder retard and remove.
2.6.25 Actuator exit 1) 2) 3) Holding the actuator of the actuator exit from fuser ASSY, pull down the actuator exit rightward an extract the left shaft of the actuator exit. Pull out the actuator exit from the fuser ASSY rightward together with the spring actuator. Remove the spring actuator from the actuator exit. Fuser ASSY Actuator exit Spring actuator Replacement; spring position Fig.
CHAPTER V TROUBLESHOOTING
CONTENTS CHAPTER V TROUBLESHOOTING ............................................... V-1 1. PROGRESSING WITH THE TROUBLESHOOTING ...................................V-1 1.1 Flow of Troubleshooting....................................................................................................V-1 2. LEVEL 1 FIP ................................................................................................V-2 2.1 Level 1 FIP ...................................................................................
10. IMAGE QUALITY SPECIFICATIONS ......................................................V-73 10.1 Parallelism.....................................................................................................................V-73 10.2 Diagonal ........................................................................................................................V-73 10.3 Skew .............................................................................................................................V-73 10.
CHAPTER V TROUBLESHOOTING 1. PROGRESSING WITH THE TROUBLESHOOTING After making sure of actual condition of a trouble, proceed with the troubleshooting process efficiently making use of the Fault Isolation Procedure (FIP), Operation of Diag., Principles of operation, and BSD (Block Schematic Diagram). 1.
2. LEVEL 1 FIP 2.1 Level 1 FIP The level 1 FIP is the first step for trouble diagnosis. The level 1 FIP isolates the presence of various troubles including error codes, and the level 2 FIP provides a guide for proceeding of the troubleshooting. 2.2 Flow of Level 1 FIP Ask the operator about trouble status. Is operator's operating method correct? Y N Instruct how to operate.
3. LEVEL 2 TROUBLESHOOTING 3.1 Level 2 FIP The Level 2 FIP is the trouble diagnostic procedure to sort various troubles in addition to the error codes. In the troubleshooting, executing the steps given in the FIP or checking procedure allows you to find out a cause of trouble in a short time. 3.2 Fail Code List LCD Display 001-360 Turn OFF the Power. < Name of Fail> Contents of Trouble Action Reference BSD Fuser fan or rear fan fail signal detected.
LCD Display 010-350 Turn OFF the Power. < Name of Fail> Contents of Trouble Action Reference BSD Power off/on See fuser failure FIP 2.9.1 2.9.6 Fuser ASSY life expired. Power off/on See fuser life over FIP 2.3.1 2.3.3 Power off/on See environment sensor error FIP 2.8.7 2.8.8 Power off/on 2.3.1 2.3.3 1. Temperature exceeding 235 C detected consecutively 4 times. 2. Temperature below 235 C detected consecutively 4 times. 3.
LCD Display 016-313 Turn OFF the Power. 016-314 Turn OFF the Power. 016-315 Turn OFF the Power. 016-316 Turn OFF the Power. 016-317 Turn OFF the Power. 016-323 Turn OFF the Power. 016-324 Turn OFF the Power. 016-325 Turn OFF the Power. 016-326 Turn OFF the Power. 016-327 Turn OFF the Power. 016-328 Turn OFF the Power. 016-330 Turn OFF the Power. 016-331 Turn OFF the Power. 016-332 Turn OFF the Power. < Name of Fail> Contents of Trouble The controller’s ASIC chip detected this error.
LCD Display < Name of Fail> Contents of Trouble Power off/on 016-334 Turn OFF the Power. Power off/on 016-335 Turn OFF the Power. Power off/on 016-336 Turn OFF the Power. Power off/on 016-350 Turn OFF the Power. Power off/on 016-360 Turn OFF the Power. Detected by IEEE1284 controller.
LCD Display Transp. Error Open A-Cover < Name of Fail> Contents of Trouble Remove the jammed paper. 1. Plain paper detected for a job that is specified transparency. Change paper stock. See media type mismatch FIP 2. Transparency detected for a job that is specified plain paper. Reinsert Xxxxx Toner (X) Action Toner cartridge switch ASSY detected that the toner cartridge is not mounted. Insert toner cartridge.
LCD Display Replace Xxxxx Toner (X) < Name of Fail> Contents of Trouble Toner empty detected. Action Replace toner cartridge. See Yellow toner empty Reference BSD 2.8.5 2.8.8 FIP, Magenta toner empty FIP, Cyan toner empty FIP or Black toner empty FIP Xxxxx indicates Yellow toner (Y), Cyan toner (C), Magenta toner (M) or Black toner (K). Replace Transfer Roll Transfer roll cartridge ASSY life expired.
LCD Display < Name of Fail> Contents of Trouble Action Reference BSD Clean Up CTD Sensor ADC sensor ASSY signal level below the specified value. 2.8.7 2.8.8 Close Front Cover Clean ADC sensor ASSY. See CTD sensor dustiness FIP Font cover is open. Close the front cover. See front cover FIP 2.1.1 2.1.2 Exit tray is full. Remove output paper stack. See full stack FIP 2.9.4 2.9.
LCD Display (When auto select is specified) Push in the Tray (When a tray is specified) Push in All Trays Out of Memory Please Press Set Upper Cassette Detached> < Name of Fail> Contents of Trouble *Any one of trays upper than the feedable tray is open when auto tray select is specified. *Any one of trays upper than the specified tray is open when a tray is specified.
LCD Display Download N/A error Please Press Set < Name of Fail> Contents of Trouble Erase error Please Press Set Write error Please Press Set Verify error Please Press Set Operation Error Please Press Set A violation in the print condition founded. Ready to Print Need Replacement The X toner is low Action Press the Set key.
LCD Display Ready to Print Need Replacement Print Head Cart < Name of Fail> Contents of Trouble Action No action required. Print head cartridge ASSY is near the end of its life. See print head cartridge life Reference BSD 2.3.2 over FIP CRU Warning: Ready to Print Need Maintenance CTD Sensor No action required. ADC sensor ASSY signal level below the specified value.
3.3 Error Code FIP 001-360 Fan Motor Failure FIP Step 1 2 3 4 5 6 7 8 9 10 11 12 Check Initial setting Check the following for evidence of fault. Fuser fan replacing condition Rear fan replacing condition Isolating faulty fan Does the fan rear rotate when printing 1 sheet? Checking fan rear Does fan rear function normally? Using rear fan diagnostic tool, check by digital output test. Checking LVPS for signal Print 1 sheet.
Step 13 14 15 16 17 18 19 20 21 22 23 Check Yes Checking drive PWBA HBN DRV for signal Print 1 sheet. Is P/J42-29PIN<=>P/J42-14PIN +3.3VDC? Checking MCU HL-4200 for signal Print 1 sheet. Is P/J12-2PIN<=>P/J12-17PIN +3.3VDC? Checking fuser fan Does fuser fan function normally? Using fuser fan diagnostic tool, check by digital output test. Checking drive PWBA HBN DRV for signal Print 1 sheet. Is P/J50-7PIN<=>P/J50-9PIN +24VDC? Checking drive PWBA HBN DRV for signal Print 1 sheet.
003-340 Firmware Error FIP Step 1 2 Check Does the error still happen even after powering Off and On was done? Check whether the value of NVM is correct. Is the value of NVM correct? Yes Remedy Go to step [2] Replace MCU HL-4200 No End of work Correct the value of NVM. 003-356 NV-RAM Error FIP Step 1 2 3 4 5 Check Does the error still happen even after powering Off and On was done? Remove following components once, and reinstall them correctly.
010-317 Fuser Detached FIP Step 1 2 3 4 Check Yes Remedy Initial setting Replace the parts Check the following for evidence of fault.
Duplex JAM FIP Step 1 2 3 4 5 6 7 8 9 10 Check Initial setting Check the following for evidence of fault. Chute ASSY exit replacing condition DUP motor replacing condition DUP JAM sensor actuator replacing condition Chute ASSY out replacing condition Checking DUP JAM sensor Does DUP JAM sensor function normally? Using DUP JAM sensor diagnostic tool, check by digital input test.
Step 11 12 13 Check Yes Checking harness ASSY DRV 2-2 for continuity Check the following for continuity. J12-5PIN<=>J42-26PIN Go to step [12] J12-6PIN<=>J42-25PIN J12-7PIN<=>J42-24PIN J12-8PIN<=>J42-23PIN J12-29PIN<=>J42-2PIN Checking DUP motor Replace MCU Check if an error occurs though the HL-4200 motor was replaced with a new one.
Step 9 10 11 12 Check Checking fuser motor Does fuser motor function normally? Using fuser motor diagnostic tool, check by digital output test. Checking PWBA HBN DRV for signal Is P/J52-1PIN<=>P/J60-2PIN +24VDC? Checking harness ASSY DRV 1 for continuity Check the following for continuity. J11-12PIN<=>J41-29PIN J11-13PIN<=>J41-28PIN J11-14PIN<=>J41-27PIN J11-15PIN<=>J41-26PIN J11-16PIN<=>J41-25PIN Checking fuser motor Replace a new fuser motor, and check if the fuser motor rotates when printing 1 sheet.
REGI JAM FIP Step 1 2 3 4 5 6 7 8 9 Check Yes Remedy Initial setting Check the following for evidence of fault. Replace the parts REGI sensor actuator replacing condition concerned chute ASSY REGI replacing condition Checking REGI sensor Does REGI sensor function normally? Go to step [6] Using REGI sensor diagnostic tool, check by Digital Input Test.
Feed JAM FIP Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Check Initial setting Check the following for evidence of fault. Paper cassette replacing condition Paper condition in cassette Wear or damage of rolls and gears in feeder Paper dust or foreign substances in paper path REGI sensor replacing condition Main drive ASSY replacing condition Checking REGI sensor Does REGI sensor function normally? Using diagnostic tool, check by digital input test.
Step 15 16 17 18 19 20 21 22 23 24 25 26 Check Checking harness ASSY DRV1 for continuity Check the following for continuity. J41-30PIN<=>J11-11PIN J41-31PIN<=>J11-10PIN J41-33PIN<=>J11-8PIN Checking clutch ASSY turn for operation Does the turn roll in the feeder run when printing 1 sheet? Checking clutch ASSY turn Does clutch ASSY turn function normally? Using clutch ASSY turn diagnostic tool, check by digital output test. In the test, close the interlock SW.
Step 27 28 29 30 31 32 33 34 35 Check Checking harness ASSY DRV2-2 for continuity Is J12-10PIN<=>J42-21PIN continuous normally? Checking clutch ASSY turn MSI for operation Does the turn roll in the MSI run when printing 1 sheet? Checking clutch ASSY turn MSI Does clutch ASSY turn MSI function normally? Using clutch ASSY turn MSI diagnostic tool, check by digital output test In the test, close the interlock SW. Checking clutch ASSY MSI turn for resistance value Remove the clutch connector J19.
Media Type Mismatch FIP Step 1 2 3 4 5 Check Initial setting Check the following for evidence of fault. OHP sensor replacing condition Chute ASSY REGI replacing condition Checking OHP sensor Does OHP sensor function normally? Using diagnostic tool, check by digital input test. Checking MCU HL-4200 for signal Is P/J32-2PIN<=>P/J32-1PIN 0VDC? Checking MCU HL-4200 for signal Make the paper approach to the sensor. Does P/J32-2PIN<=>P/J32-1PIN change from 0VDC to +3.
Step 8 9 Check Checking MCU HL-4200 for signal Is P/J12-27PIN<=>P/12-17PIN of MCU and HVPS PWBA HBN DRV 0VDC? Checking harness ASSY DRV2-2 for continuity Is J12<=>J42 continuous normally? Yes 1 2 3 4 5 6 7 8 9 Check Initial setting Check the following for evidence of fault.
Cyan Toner Cartridge Detached FIP Step 1 2 3 4 5 6 7 8 9 Check Initial setting Check the following for evidence of fault. Cartridge replacing condition Toner cartridge switch ASSY (C) replacing condition Toner cartridge switch ASSY (C) actuator replacing condition Toner cartridge switch ASSY (C) connector replacing condition Checking toner cartridge switch ASSY Does toner cartridge switch ASSY function normally? Using diagnostic tool, check by digital input test.
Black Toner Cartridge Detached FIP Step 1 2 3 4 5 6 7 8 9 Check Initial setting Check the following for evidence of fault. Cartridge replacing condition Toner cartridge switch ASSY (K) replacing condition Toner cartridge switch ASSY (K) actuator replacing condition Toner cartridge switch ASSY (K) connector replacing condition Checking toner cartridge switch ASSY Does toner cartridge switch ASSY function normally? Using diagnostic tool, check by digital input test.
Transfer Roll Cartridge Detached FIP Step 1 2 3 4 5 6 Check Initial setting Check the following for evidence of fault.
Yellow Toner Empty FIP Step 1 2 3 4 5 6 7 8 9 10 11 Check Yes Remedy Initial setting Check the following for evidence of fault. Replace the parts Low toner sensor replacing condition concerned Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner Go to step [3] cartridge was replaced with a new one. Checking PWBA HBN DRV for signal Is P/J51-16<=>P/J51-15 less than Go to step [6] +0.
Magenta Toner Empty FIP Step 1 2 3 4 5 6 7 8 9 10 11 Check Yes Remedy Initial setting Check the following for evidence of fault. Replace the parts Low toner sensor replacing condition concerned Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner Go to step [3] cartridge was replaced with a new one. Checking PWBA HBN DRV for signal Is P/J51-18<=>P/J51-17 less than Go to step [6] +0.
Cyan Toner Empty FIP Step 1 2 3 4 5 6 7 8 9 10 11 Check Yes Remedy Initial setting Check the following for evidence of fault. Replace the parts Low toner sensor replacing condition concerned Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner Go to step [3] cartridge was replaced with a new one. Checking drive PWBA HBN DRV for signal Go to step [6] Is P/J51-34<=>P/J51-33 less than +0.
Black Toner Empty FIP Step 1 2 3 4 5 6 7 8 9 10 11 Check Initial setting Check the following for evidence of fault. Low toner sensor replacing condition Toner cartridge replacing condition Toner motor replacing condition Checking toner cartridge Check if an error occurs though the toner cartridge was replaced with a new one. Checking PWBA HBN DRV for signal Is P/J51-36<=>P/J51-35 less than +0.
Transfer Roll Cartridge Life Over FIP Step 1 2 3 4 5 6 Check Initial setting Check the following for evidence of fault. Transfer roll cartridge ASSY replacing condition Sensor TNR full replacing condition Checking sensor TNR full Does sensor TNR full function normally? Sensor TNR full using diagnostic tool, check by Digital Input Test.
CRUM ID Error FIP (Print Head Cartridge) Step 1 2 3 4 5 Check Check the following for failure: Installation of toner cartridge Installation of PWB CRUM reader Check connection of PWB CRUM reader. Is the PWB CRUM reader connector properly connected to the harness connector? Check continuity of harness ASSY RFID2 (J341-3411). Is continuity proper between J341<=>J3411? Check continuity of harness ASSY RFID (J34-3411). Is continuity proper between P3411<=>J34? Check Toner Cartridge.
Front Cover FIP Step 1 2 3 Check Initial setting Check the following for evidence of fault. PWBA HBN DRV replacing condition Front cover replacing condition Interlock SW actuator replacing condition Checking interlock SW Does interlock SW function normally? Using interlock SW, check by digital output test. Checking PWBA HBN DRV for signal Close the front cover Is P/J41-35PIN<=>P/J41-22 0VDC? Yes 1 2 3 4 Check Initial setting Check the following for evidence of fault.
Upper Cassette Detached FIP Step 1 2 3 4 Check Initial setting Check the following for evidence of fault. Size switch ASSY replacing condition actuator replacing condition Paper cassette replacing condition Checking size switch ASSY Does size switch ASSY function normally? Size switch ASSY using diagnostic tool, check by digital input test.
Tray2 Paper Near Empty FIP Step 1 2 3 4 5 6 7 Check Initial setting Check the following for evidence of fault. Tray2 low paper sensor replacing condition Sensor actuator replacing condition Does the error occur even if the paper is added? Checking tray2 low paper sensor Does tray2 low paper sensor function normally? Tray2 low paper sensor using diagnostic tool, check by digital input test. Checking PWBA OPTFDR for signal Is P/J82-10 PIN <=>P/J82-9 +3.
4. HOW TO USE DIAG. (C/E) MODE 4.1 Roles of the Control Panel in Diag. (C/E) Mode (Note: Control panel display may differ depending upon the machine configuration.) 5.Menu 1. LCD Menu Ready Alarm 2.Up/Down button 4. Job Cancel/Back button Form Feed Job Cancel Set Back 3.Form Feed/Set button Fig.5-3 1. 2. 3. 4. 5. 6. 4.2 LCD panel: Displaying a diagnostic item and its result. Up/Down buttons: Selecting a diagnostic item. Selecting data at parameter setting.
4.5 Operation Procedure or button and After entering Diag. (C/E) mode, select a diagnostic item with the press the Form Feed/Set button to determine the selection. If there is a lower menu, select a diagnostic item with the or button and press the Form Feed/Set button to determine the selection. Once a diagnostic item has been selected, press the Form Feed/Set button to execute the processing. To exit the diagnosis and return to the upper menu, press the Job Cancel/Back button.
4.6 Diag. Mode Menu Tree S Diag mode Normal Diag ESS Diag CodeROM Test FontROM Test EEPROM Test DRAM Test Centro Test USB Test REMORA Test Cont Panel Test IOT Test HD Test IOT Diag Digital Input Digital Output Power Save Mode Print Info NVM Settings NVM Edit Config Page NVM Save Print Settings NVM Load FailHistoryPage NVM Print Info JamHistoryPage DloadHistoryPage Complete Complete Dip Switch 0 Installation Set Serial No.
Continued from the up page S Test Print CMY 20% [ESS] Gradation [ESS] NIP adjust [ESS] P Regi Adj Chart Parameter PFRegi K to Paper PFRegi 600 K to M PF Regi 600 K to Y PF Regi 600 K to C PF Regi 1200 K to M PF Regi 1200 K to Y PF Regi 1200 K to C Scan Regi K to M Scan Regi K to Y Scan Regi K to C Scan Regi MP Scan Regi Tray 1 Scan Regi Tray 2 Scan Regi Tray 3 Scan Regi Duplex Life Y Toner Read Life M Toner Initialization Life C Toner Life K Toner Life BTR 1 (Life Transfer Roll Cartridge 1) Life Fus
4.7 ESS Diagnosis Function: Executing an ESS related diagnosis. Operation procedure: 1. Enter the Diag. (C/E) mode. 2. 3. Select [CE Maintenance ESS Diag] with the and buttons. Press the Form Feed/Set button to advance to diagnostic menu selection in [CE Maintenance ESS Diag]. 4. Select a diagnostic item with the or button. (For the contents of the diagnostic items, refer to the table below.) Press the Form Feed/Set button to determine the selection.
Details of the control panel test For a control panel check, each button is pressed to see whether the three LED indicator lights go on or off and how the LCD panel display changes. The table below lists the relationships between the buttons and the LED indicator lights and LCD panel display.
4.8.1 Digital input test Function: Displaying a sensor or switch signal level on the LCD panel as "H" or "L" and also the number of changes from "H" to "L" or "L" to "H" Operation procedure: 1. Enter the Diag. (C/E) mode. 2. 3. Select [CE Maintenance IOT Diag] with the and buttons. Press the Form Feed/Set button to advance to diagnostic menu selection in [CE Maintenance IOT Diag]. 4. 5. Select [IOT Diag Digital Input] with the and buttons.
Menu No. DI-11 DI-12 DI-13 DI-14 DI-15 DI-16 DI-17 Part/signal name Test method TRAY1 NO PAPER SENSOR TRAY2 NO PAPER SENSOR TRAY3 NO PAPER SENSOR KIT SENSOR OHP TRAY1 LOW PAPER SENSOR TRAY2 LOW PAPER SENSOR TRAY3 LOW PAPER SENSOR TRAY1 SIZE SWITCH (DISPLAY) DI-18 TRAY1 SIZE SWITCH (SW1) DI-19 TRAY1 SIZE SWITCH (SW2) DI-1a TRAY1 SIZE SWITCH (SW3) DI-1b TRAY2 SIZE SWITCH (DISPLAY) DI-20 TRAY2 SIZE SWITCH (SW1) DI-21 V-45 Block and unblock the sensor with an actuator.
Menu No.
4.8.2 Digital output test Function: Activating a solenoid, clutch, motor, or other parts. Capable of activating two or more parts simultaneously. (Parallel execution) Operation procedure: 1. Enter the Diag. (C/E) mode. 2. 3. Select [CE Maintenance IOT Diag] with the and buttons. Press the Form Feed/Set button to advance to diagnostic menu selection in [CE Maintenance IOT Diag]. 4. 5. Select [IOT Diag Digital Output] with the and buttons.
Menu No.
Menu No. DO-1a DO-1b DO-1c DO-1d DO-1e DO-28 DO-2a DO-2c DO-2e DO-30 DO-32 DO-34 Part/signal name Test method DUP MOTOR ASSY ON (FORWARD LOW SPEED) Check by hearing and visually that the motor rotates in Low-speed mode. Check by hearing and visually that the motor rotates counterclockwise in Low-speed mode. Check by hearing and visually that the motor rotates in Low-speed mode.
Menu No.
4.8.3 NVM Edit Read/Write Refer to Section 7. NVM LIST. Function: Reading or writing NVM Operation procedure: 1. Enter the Diag. (C/E) mode. 2. Select [IOT Diag] with the 3. Select [NVM Settings] with 4. Advance to [NVM Edit] with button. 5. Select a necessary item for the address section (Ad) with the and buttons. The NWM data is read and two to four items are displayed from the input address. Edit NVM Ad0001=00000000* and and and buttons and press the Form Feed/Set button.
4.8.4 NVM Information Print Function: Printing MCU NVM information saved in ESS Operation procedure: 4.8.5 1. Enter the Diag. (C/E) mode. 2. Select [IOT Diag] with the 3. Select [NVM Settings] with 4. Advance to [NVM Print Info] with the Feed/Set button. and and buttons and press the Form Feed/Set button. buttons and press the Form Feed/Set button.
4.9 Installation Setting Function: Setting parameters at printer installation and displaying various counter values Operation procedure: 1. Enter the Diag. (C/E) mode. 2. 3. Select [CE Maintenance Installation Set] with the and buttons. Press the Form Feed/Set button to advance to setting/display item selection in [CE Maintenance Installation Set]. 4. Select a setting/display item with the and buttons. (For the setting/display items, refer to the table below.
*Electronic billing meter (count) function and backup The monochrome and color meters have backup meters. The printer compares the main and backup meters when the power is turned ON. If there is a discrepancy between the main and backup meters, the hardware of both meters is diagnosed by read/write tests. 1. If either or both meters are abnormal, a fatal error (C/E call) is assumed. The C/E replaces ESS-PWBA HBN DRV. 2. If both diagnostic results are correct, the main meter is believed.
4.11 Parameter Setting 4.11.1 Parameter setting/display Function: Setting and displaying parameters held by IOT in NVM Operation procedure: 1. Enter the Diag. (C/E) mode. 2. 3. Select [CE Maintenance Parameter] with the and buttons. Press the Form Feed/Set button to advance to setting/display parameter selection in [CE Maintenance Parameter]. 4. Select a setting/display parameter with the and buttons. (For the setting/display parameters, refer to the table below.
4.11.2 Parameter list print Function: Outputting a list of setting and displaying parameters held by IOT in NVM Operation procedure: 1. Enter the Diag. (C/E) mode. 2. 3. Select [CE Maintenance Parameter] with the and buttons. Press the Form Feed/Set button to advance to setting/display parameter selection in [CE Maintenance Parameter]. 4. 5. 6. Select [Parameter Print] with the and buttons. Press the Form Feed/Set button to determine the selection.
4.12 Information Print Function: Printing printer information Operation procedure: 1. Enter the Diag. (C/E) mode. 2. 3. Select [CE Maintenance Print info] with the and buttons. Press the Form Feed/Set button to advance to print item selection in [CE Maintenance Print info]. 4. 5. 6. Select a print item with the and buttons. Press the Form Feed/Set button to determine the selection. Press the Form Feed/Set button again to print the parameters.
System Fail History HL-4200CN Serial No. 000000 Total Number of Prints = 6938 No. Print Cnt. Chain-Link ---------------------------------------------------------------------------1 6910 016-370 2 6872 016-330 3 6851 016-350 4 6791 016-314 5 6656 016-302 0x00000008 0x00000000 200305120950 6 6647 016-370 7 6624 016-314 8 6228 016-370 Paper Jam History HL-4200CN Serial No. 000000 Total Number of Prints = 6939 No. Print Cnt.
5. DIAGNOSIS FOR STANDALONE PRINTER 5.1 General The test print can be taken place on the standalone printer for operation check. For this purpose, the test print pattern stored in the printer is printed continuously at the continuous printing speed. 5.2 Printing Method 1. Remove the ESS PWB. 2. Load paper, and turn the power ON. WARNING In the following steps, never touch the live parts and driving parts. 3. 4. 5. Short two pins of the test print connector (P31) on the MCU HL-4200.
5.3 Test Print Pattern The test print pattern is lattice patterns composed of black (K), cyan (C), magenta (M), and yellow (Y) patterns in this order every 128 dots in vertical and horizontal directions. Black K Yellow Y Cyan C Magenta M 128dot Approx.2mm 128dot Approx.2mm Fig.
6. TRANSFER ROLL CARTRIDGE ADJUSTING THIRD TRANSFER CURRENT VALUE The transfer current value of the toner image is set so that the image quality can get for each type of paper. This set value is selected by assuming the average characteristic per paper type, therefore, the best image quality may not appear if the paper to be used has the different characteristic from the one which Brother assumes.
4. After 2:Maintenace screen (Init NVM) is displayed, press button three times. 2:Maintenance Init NVM 5. After 2:Maintenace screen (Media CurrentAdi) is displayed, press [Form Feed/Set] button. 2:Maintenance BTR CurrentAdj 6. After BTR CurrentAdi screen (Plain paper) is displayed, press the used paper mode (includes front and back sides). button and select BTR CurrentAdj Plain Paper Note: Refer to 6.2 User mode Menu tree. Example in case of selecting board 1 back side: BTR CurrentAdj ThinkPaper 1 BK 7.
Check the image error was improved by printing the image caused an error after setting. If it is not improved, repeat 1 to 10. Note: Be careful not to cause other image error by changing the current value to the adjusting value too much. The changed adjusting value is maintained for the same paper mode until it is adjust again. 6.2 User Mode Menu Tree 2.
7. NVM LIST CAUTION Never write the data to the NVM numbers not listed below, as they are for the system areas of the printer. CAUTION Never write the data to the items which address field is hatched, as they are read only.
Address Hex Set value Word/ Dec Long 0 0 0 0 0 0 0 0 Description 1221 1222 1223 1224 1225 122E 122F 00 00 00 00 00 00 00 1230 00 0 1231 00 0 1232 00 0 1233 00 0 1234 00 0 1235 00 0 1236 1237 1238 1242 1243 1244 1248 1249 124A 80 38 01 A8 61 00 A0 86 01 128 56 1 168 97 0 160 134 1 146D 146E 146F 1470 1471 05 05 05 05 05 5 5 5 5 5 14ED 05 5 14EE 05 5 14EF 05 5 14F0 05 5 14F1 05 5 Color balance adjustment Color balance adjustment Color balance adjustment Color balan
Address Hex Set value Word/ Dec Long 0 0 0 0 0 0 0 0 Description 1614 1615 1616 1617 1618 1619 161A 161B 00 00 00 00 00 00 00 00 1680 00 0 16B8 16B9 16BA FF FF FF 255 255 255 184F 1850 1851 1852 1853 1854 1855 1856 186C 186D 186E 186F 1870 1871 1872 1873 1874 1875 1876 1877 1878 1879 187A 187B 30 30 20 20 20 1A 1A 1A 1C 1C 18 18 18 14 14 14 14 14 10 10 10 0C 0C 0C 48 48 32 32 32 26 26 26 28 28 24 24 24 20 20 20 20 20 16 16 16 12 12 12 Cleaning interval 0 Full-speed Cleaning interval 1 Full-sp
Address Hex Set value Word/ Dec Long 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1C88 1C89 1C8A 1C8B 1C8C 1C8D 1C8E 1C8F 1C90 1C91 1C92 1C93 1C94 1C95 1C96 1C97 1C98 1C99 1C9A 1C9B 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 1C9C 00 0 1C9D 1C9E 00 00 0 0 1C9F 00 0 1CA0 00 0 1CA1 00 0 1CA2 00 0 1CC0 1CC1 1CC2 1CC3 1CC4 1CC5 1CC6 1CC7 1CC8 1CC9 1CCA 1CCB 1CCC 1CCD 1CCE 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Description Transparency (=OH
Address Hex Set value Word/ Dec Long 0 0 0 0 0 0 0 0 0 0 0 0 0 1CCF 1CD0 1CD1 1CD2 1CD3 1CD4 1CD5 1CD6 1CD7 1CD8 1CD9 1CDA 1CDB 1CDC 00 00 00 00 00 00 00 00 00 00 00 00 00 00 0 1CDD 1CDE 1CDF 00 00 0 0 00 0 00 0 00 0 00 0 2502 00 0 2505 00 0 2508 00 0 250B 00 0 2532 00 0 2535 00 0 2538 00 0 253B 00 0 254D 00 0 2550 00 0 2553 00 0 1CE0 1CE1 1CE2 Description Heavier paper-H Back Face Envelope Back Face Postcard Back Face Plain paper-H Coated Coated Coated Co
Address Hex Set value Word/ Dec Long 2556 00 0 2559 00 0 255C 00 0 255F 00 0 2562 00 0 2565 00 0 2568 00 0 256B 00 0 257D 00 0 2580 00 0 2583 00 0 2586 00 0 2589 00 0 258C 00 0 258F 00 0 Description User temperature correction Halfspeed Heavier-2 (0 deg.C) User temperature correction Halfspeed Transparency (0 deg.C) User temperature correction Halfspeed Envelope (0 deg.C) User temperature correction Halfspeed Postcard (0 deg.
8.
Decimal 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 HEX 0105 0106 0107 0108 0109 010A 010B 010C 010D 010E 010F 0110 0111 0112 0113 0114 0115 0116 0117 0118 0119 011A Decimal 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 HEX 0129 012A 012B 012C 012D 012E 012F 0130 0131 0132 0133 0134 0135 0136 0137 0138 0139 013A 013B 013C 013D 013E Decimal 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352
9. IMAGE QUALITY TROUBLE ENTRY CHART Ask the operator about trouble status. Print internal test pattern. Image quality trouble recurred? Y Check print instructions Are print instructions correct? N Y Is trouble more than performance when compared with standard sample? Acknowledged by operator? Y N Instruct how to submit print job. N Explain to customer. Print from another client/application for host check. Image quality trouble reccurred? Y Troubleshoot according to image quality trouble sample.
10. IMAGE QUALITY SPECIFICATIONS 10.1 Parallelism Fig.5-13 10.2 Diagonal Fig.5-14 10.3 Skew Fig.
10.4 Straightness Fig.5-16 10.5 Magnification Error Fig.5-17 10.6 Registration Fig.
10.7 Guaranteed Printing Area Fig.
11. TEST PRINT 11.1 Test Print Function: Printing an internal test pattern of the printer Operation procedure: 1. 2. While pressing the mode. Enter the password. (Password: Press the and buttons together, turn the power on to enter the Diag. button twice and the Form Feed/Set button.) 3. 4. Go advance to [Test Print] with the and buttons. Press the Form Feed/Set button to advance to diagnostic menu selection in [Test Print]. 5. Select a test pattern with the and buttons.
12. IMAGE QUALITY FIP 12.1 Notes on Image Quality Trouble Check Image quality troubles are checked and processed according to the troubleshooting table by trouble phenomena. In case of a continuous or abnormal image defect, check the installation environment at the customer, the document, and the consumables. 1. Installation environment • Prepare a power supply of 100/120/220±10 VAC.
12.3 Toubleshooting Table by Trouble Phenomena Fig.5-20 Condition: Fogging over print. Toner attaches to margin of print. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc.
Fig.5-21 Fig.5-22 Condition: Black or white streaks in the process direction. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc.
Fig.5-23 Fig.5-24 Condition: Black or white streaks in the shaft direction. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc.
Rolls related with image quality troubles and interval appearing on prints are shown in the table below. Roll Magnet roll Padolle Drum HTC IDT 1 IDT 2 Transfer roll cartridge Heat roll Parts Print head cartridge ASSY Transfer roll cartridge ASSY Fuser ASSY V-81 29 mm 7.
Fig.5-25 Condition: Print is wholly black. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc.
Fig.5-26 Condition: Print is wholly white. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Print head cartridge ASSY, Fuser ASSY, Transfer roll cartridge ASSY, Scanner ASSY, MCU HL-4200, Toner cartridge Item 1 2 3 4 5 6 Check Toner empty Check if the toner cartridge is full with toner.
Fig.5-27 Condition: Print is wholly light. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc.
Fig.5-28 Condition: Black (color) circles remain on the print. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc.
Fig.5-29 Condition: Image is printed in skewed position. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Paper feeder, Chute ASSY REGI, Chute ASSY out, Transfer roll cartridge ASSY, Print head cartridge ASSY, Fuser ASSY, Scanner ASSY Item 1 2 3 4 5 6 Check Faulty paper loading Check if paper is loaded or paper cassette is set correctly.
Condition: Print on creased paper. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc.
Fig.5-30 Condition: Some parts of image are missing and they become flakes. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Transfer roll cartridge ASSY Item 1 2 Check Paper check The recommended size/type of paper is used? The flakes appear on the recommended size/type of paper. Or the flakes appear on the paper other than recommended size/type of paper. V-88 Remedy Change paper.
Fig.5-31 Condition: Toner around image splashes. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Transfer roll cartridge ASSY Item 1 2 Check Paper check The recommended size/type of paper is used? The flakes appear on the recommended size/type of paper. Or the flakes appear on the paper other than recommended size/type of paper. V-89 Remedy Change paper.
Fig.5-32 Condition: Whole image has bluish tinge. Initial check: Parts of different specifications, improper installation, damage, deformation, dirt, foreign substance attached, etc. Major parts to be checked: Transfer roll cartridge ASSY Item 1 2 Check Paper check The recommended size/type of paper is used? The flakes appear on the recommended size/type of paper. Or the flakes appear on the paper other than recommended size/type of paper. V-90 Remedy Change paper.
CHAPTER VI DIAGRAMS
CONTENTS CHAPTER VI DIAGRAMS .............................................................. VI-1 1.PREFACE .......................................................................................................VI-1 1.1 How to Use the BSD............................................................................................................VI-1 1.2 Explanations of Symbols .....................................................................................................VI-1 1.
2.8.5 Low toner sensing ...................................................................................................VI-32 2.8.6 Transfer and cleaning..............................................................................................VI-33 2.8.7 ADC and environment sensing................................................................................VI-34 2.8.8 Monitoring................................................................................................................VI-35 2.
CHAPTER VI DIAGRAMS 1. PREFACE 1.1 How to Use the BSD 1. 2. 3. 4. Enter the chain specified in the chapter of troubleshooting. See the contents to enter the appropriate Chain. Diagnose the failure in the appropriate Chain. If the failure can be isolated, refer to the Parts List No or Adjustment No go to the index of parts or the appropriate adjustment. WARNING Perform installation and removal of parts with the main power switch turned off and the power cord unplugged to avoid electric shock and injury. 1.
A B B A This symbol identifies a signal line is connected in the meet direction. This symbol identifies a signal line is connected in the arrow direction. ZONE E3 This symbol indicates that a signal line is connected within the same Function. It shows that the location to which signal line is connected is marked in Zone (E-3). This symbol indicates that a signal line is connected within the same Function. It shows that the location from which signal line is connected is in Zone (E-4).
This symbol represents a document or paper as well as its direction. This symbol represents a heat, light or air signal as well as its direction. 1 This symbol represents that the part indicated by an arrow is the information on the duplicator with Tag/Mod. 1 This symbol represents that the part indicated by an arrow is the information on the duplicator without Tag/Mod. 1 This symbol represents that the part indicated by an arrow is the information on the duplicator without Tag/Mod.
1.3 Signal Name/Other description Signal Name Signal name configuration REGI SENSOR SENSED Part name Active status (L) Logical value +5VDC Highest level expected The above example indicates that the signal will be (L) when the registration sensor detected a sheet of paper and that it will be (H) when the sensor has not detected a sheet of paper and that the voltage is +5VDC. 1.4 DC Voltage DC voltage is measured between each test point and the frame unless otherwise instructed in Notes.
6 5 4 3 2 1 A B +3.3VDC J27 P14 PL12.1 PL12.1 CONTROL LOGIC MCU HL-4200 PWBA TOP ASSY BRA-PX(US)(EU) ACN (1) WHT ACL (3) BLK 2 WHT J161 1 BLK 1 YEL 2 2 J23 J167 1 YEL (2) (4) HARNESS ASSY AC SW PL12.1 MAIN SWITCH 2 2.9.1 ACN ACL SLEEP MODE 2 SLEEP MODE 2 SLEEP MODE FUSE C RETURN STBY +3.3VDC RETURN +3.3VDC RETURN +5VDC RETURN +24VDC 1 LOW VOLTAGE GENERATION LVPS(100/120V)(230V) PL12.1 2.9.1 ACL 2.1.1 AC POWER ON AND DC DISTRIBUTION 2.9.3 2.9.
6 5 4 3 2 1 2.1.1 1 A INTERLOCK OPEN SIGNAL 1 Virtual Line CONTROL LOGIC MCU HL-4200 PL12.1 2.1.2 MONITORING B C Close Front Door CONSOLE PANEL HIBANA PL1.1 D E VI-6 F G 2.
6 5 4 3 2 1 A CONTROL LOGIC MCU HL-4200 PL12.1 1 - 20 J22 2.2.1 CONTROL PANEL SHILD CABLE B P221 1 - 20 J221 SHILD CABLE C J2211 1 - 20 P220 CONSOLE PANEL HIBANA PL1.1 D VI-7 Ready Alarm E Menu F brother G Set Form Feed Back Job Cancel J 2.
6 5 4 3 2 1 DC COM (2.1.1) +5VDC (2.1.1) DC COM (2.1.1) +3.3DC (2.1.1) 2 2 VIO GRY VIO 4 3 2 J311 1 BRN TEST PRINT J31 1 B DC COM (2.1.1) P30 Flash Write S1 CONTROL +3.3VDC LOGIC MCU HL-4200 PL12.1 2.3.1 MACHINE SELF TEST A D DC COM +5VDC DC COM +3.3DC CONTROL LOGIC Flash Rom (U11) Flash Rom (U10) PWBA TOP ASSY BRA-PX(US)(EU) PL12.1 P14 J27 C USB Pararell F VI-8 P/J 45 Ethernet 100Base TX / 10BaseT J34 P50 NIX EXCOPRO ASSY BR PL12.1 P/J 33 HDD BR PL12.
6 5 4 3 2 1 CONTROL LOGIC CONTROL LOGIC +3.3VDC +3.3VDC DC COM (2.1.1) +3.3VDC (2.1.1) +3.3VDC +3.3VDC +5VDC (2.1.1) DC COM (2.1.1) +3.3VDC (2.1.1) MCU HL-4200 PL12.1 DI-32 B 10 9 8 7 6 5 4 3 YEL YEL YEL YEL YEL YEL YEL YEL EEPROM CLOCK EEPROM DATA CRUM CLOCK 1 2 3 4 6 5 4 3 YEL YEL YEL YEL 2 J71 YEL PWBA EEPROM PL10.1 YEL YEL YEL YEL P71 5 YEL DOUBLE PLUG C YEL YEL YEL 1 2 DC COM +3.
6 5 4 3 2 1 1 1 2.3.1 2.3.2 1 2.3.1 A CRUM DATA ESS ERROR IOT ERROR 1 Virtual Line PL12.1 CONTROL LOGIC MCU HL-4200 2.3.
6 5 4 3 2 1 A CONTROL LOGIC MCU HL-4200 PL12.1 B 11 10 9 8 GRY GRY GRY GRY GRY GRY GRY 31 32 33 D/A MAIN MOTOR 30 GRY MAIN CW/CCW MAIN F/H XMAIN ENA C MOTOR DRIVE DC COM +24VDC SWITCHED PWBA HBN DRV PL12.1 J41 34 7 J11 MAIN CLOCK GRY GRY 2.4.1 MAIN DRIVE CONTROL BLK WHT MAIN_W MAIN_V MAIN_U OFF BLK WHT RED VI-11 MOT 1 DRIVE ASSY MAIN DO-19 (LOW SPEED) PL11.
6 5 4 3 2 1 A B VIO VIO VIO VIO VIO VIO VIO VIO VIO VIO VIO VIO VIO VIO CONTROL LOGIC 6 DC COM 2 VIO VIO SCANNER MOTOR CLOCK VIO VIO VIO SCANNER MOTOR ON(L)+5VDC LD +5VDC VL1_D_K VL1_C_C VL1_B_M VL1_A_Y MO_D_K MO_C_C MO_B_M MO_A_Y XPDATA_D_K XPDATA_C_C XPDATA_B_M 15 19 18 17 14 20 13 12 11 CR1 LASER CONTROL QBLD PWB Scanner ASSY PL9.1 10 9 8 7 6 5 4 3 2 J151 1 VIO +24VDC SWITCHED 3 VIO (2.1.1) DC COM (2.1.
6 5 4 3 2 1 2.5.1 1 A SOS SENSED SIGNAL 1 Virtual Line PL12.1 CONTROL LOGIC MCU HL-4200 2.5.2 MONITORING B C 006-370 CONSOLE PANEL HIBANA PL1.1 D VI-13 E 006-370 IOT Scanner Failure F G J 2.
6 5 4 3 2 1 OPERATOR LOADED PAPER A B TRAY1 SENSOR AND SWITCHES 2.6.1 TRAY1 PAPER STACKING B C DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) PWBA DRV HBN PL12.1 A 9 8 6 5 YEL BLU BLU YEL 3 J47 YEL D 2 YEL 2 J473 3 BLU BLU J472 3 YEL J471 2 YEL SW3 SW2 SW1 PL3.3 1 YEL YEL YEL DI-11 ON(L) +3.3VDC YEL TRAY1 SIZE SWITCH(SW3) DI-1b ON(L) +3.
6 5 4 3 2 1 OPERATOR LOADED PAPER A B C D DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) PL15.5 PWBA OPTFDR 9 8 6 5 YEL YEL YEL YEL 2 2 GRY YEL 2 J823 3 YEL GRY 2 1 P8220 J822 3 GRY GRY DOUBLE PLUG J8220 3 YEL YEL 3 J82 YEL B TRAY2 SENSOR AND SWITCHES PL15.5 SENSOR PHOTO (TRAY2 LOW PAPER SENSOR) PL15.
6 5 4 3 2 1 OPERATOR LOADED PAPER A C DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) PL14.5 PWBA OPTFDR 9 8 6 YEL YEL YEL YEL 2 2 GRY 1 P8220 GRY DOUBLE PLUG J8220 3 5 YEL YEL 3 J82 YEL B TRAY2 SENSOR AND SWITCHES YEL 2 J823 3 YEL GRY 2 J822 3 GRY PL14.5 SENSOR PHOTO (TRAY2 LOW PAPER SENSOR) PL14.
6 5 4 3 2 1 OPERATOR LOADED PAPER A C DC COM (2.1.1) +3.3VDC (2.1) DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) 9 8 6 5 BLU BLU BLU BLU 2 2 GRY 1 P8220 GRY DOUBLE PLUG J8220 3 BLU BLU 3 J83 BLU PWBA OPTFDR PL14.5 B TRAY3 SENSOR AND SWITCHES 2 BLU 2 J833 3 BLU GRY J832 3 GRY A PL14.5 SENSOR PHOTO (TRAY3 LOW PAPER SENSOR) PL14.4 SENSOR PHOTO (TRAY3 NO PAPER SENSOR) 2.6.
6 5 4 3 2 1 1 2.6.3 2.6.3 1 1 1 1 2.6.3 2.6.2A 2.6.2B 1 2.6.3 1 1 2.6.2A 2.6.2B 2.6.1 1 2.6.2A 2.6.2B 1 2.6.1 1 1 2.6.1 2.6.2A 2.6.2B 1 2.6.
6 5 4 3 2 1 2.6.1 2.4.1 TRAY1 PAPER STACK POSITIONED TRAY1 FEED DRIVE A C CONTROL LOGIC PL12.1 MCU HL-4200 9 VIO 10 J12 VIO 2.7.1 TRAY1 PAPER FEEDING B D VIO DO-39 G 13 14 11 BLU BLU YEL YEL TRAY1 TURN CLUTCH ON(L) +24VDC BLU 1 2 1 2 J475 DOUBLE PLUG 2 P475 1 BLU TRAY1 TURN CLUTCH OFF DO-37 TRAY1 TURN CLUTCH ON DO-36 TRAY1 FEED SOLENOID OFF DOUBLE PLUG TRAY1 FEED SOLENOID P474 1 12 J47 ON(L) +24VDC 2 J474 YEL YEL VI-19 +24VDC SWITCHED (2.1.
6 5 4 3 2 1 ROLL ASSY FEED MSI DRIVE OPERATOR LOADED PAPER 2.4.1 A +24VDC SWITCHED (2.1.1) DC COM DC COM (2.1.1) +3.3VDC (2.1.1) CONTROL LOGIC MCU HL-4200 PL12.1 C DO-34 DO-35 MSI FEED SOLENOID ON D 8 7 10 YEL YEL YEL YEL 4 P139 5 YEL 8 YEL 7 J139 YEL DOUBLE PLUG YEL 2 YEL 2 YEL 2 P132 1 YEL VI-20 A A 3 P139 YEL DI-10 G MSI NO PAPER SENSED(H) +3.3VDC SOLENOID FEED MSI PL6.
6 5 4 3 2 1 2.6.2A 2.7.5A TRAY2 PAPER STACK POSITIONED TRAY2 FEED DRIVE A B C D CONTROL LOGIC PL12.1 MCU HL-4200 5 YEL 7 J21 YEL YEL B9 P210 B7 YEL B5 YEL B7 J210 YEL DOUBLE PLUG YEL A10 P810 A8 YEL A5 YEL YEL DC COM 13 14 11 YEL YEL YEL 12 J82 YEL VI-21 +24VDC SWITCHED (2.1.1) 22 +24VDC SWITCHED (2.1.1) DC COM PL15.5 PWBA OPTFDR A7 J810 J81 20 YEL YEL CONNECTOR E F YEL YEL 2 1 1 2 J825 PL15.4 CLUTCH ASSY TURN(TRAY2) PL15.
6 5 4 3 2 1 2.6.2B 2.7.5B TRAY2 PAPER STACK POSITIONED TRAY2 FEED DRIVE A C D CONTROL LOGIC PL12.
6 5 4 3 2 1 2.6.3 2.7.5B TRAY3 PAPER STACK POSITIONED TRAY3 FEED DRIVE A C D CONTROL LOGIC PL12.
6 5 4 3 2 1 A B C CONTROL LOGIC PL12.
6 5 4 3 2 1 B C CONTROL LOGIC PL12.1 MCU HL-4200 13 23 22 21 YEL YEL YEL YEL B13 A9 A8 D/A FEEDER MOTOR B1 YEL A5 A6 YEL YEL YEL YEL A7 J210 YEL A10 YEL YEL YEL P210 A7 YEL A4 CLOCK XB CLOCK XA CLOCK B CLOCK A 20 J21 YEL DOUBLE PLUG 2.7.
6 5 4 3 2 1 ROLL ASSY TURN (TRAY3)DRIVE TRAY3 FED PAPER 2.7.4 TRAY2 FED PAPER ROLL ASSY TURN (TRAY2)DRIVE TRAY1 FED PAPER 2.7.4 2.7.3A 2.7.3B 2.7.3A 2.7.3B 2.7.1 ROLL ASSY TURN (TRAY1)DRIVE 2.7.1 DUPLEX FED PAPER 2.9.4 MSI FED PAPER ROLL TURN DRIVE 2.4.1 2.7.2 REGI ROLL DRIVE 2.4.1 A B A 2.7.6 REGISTRATION B +24VDC SWITCHED (2.1.1) DC COM +24VDC SWITCHED (2.1.1) DC COM DC COM (2.1.1) +5VDC (2.1.1) DC COM (2.1.1) +3.3VDC (2.1.1) CONTROL LOGIC MCU HL-4200 PL12.
6 5 4 3 2 1 1 1 2.7.6 2.7.6 1 2.7.2 A OHP PAPER SENSED SIGNAL REGI PAPER SENSED SIGNAL MSI NO PAPER SENSED SIGNAL 1 Virtual Line PL12.1 CONTROL LOGIC MCU HL-4200 2.7.7 MONITORING B C * = paper size in Manual Tray Transp. Error Open A-Cover Feed Jam Check Tray Regi. Jam Open A-Cover Check Paper in MP Tray Load CONSOLE PANEL HIBANA PL1.1 D VI-27 E F G J 2.
6 5 4 3 2 1 B LASER SCAN IMAGE(M) LASER SCAN IMAGE(C) LASER SCAN IMAGE(K) 2.5.1 2.5.1 LASER SCAN IMAGE(Y) 2.5.1 2.5.1 WARNING: HIGH VOLTAGE HVPS PL12.1 MCU HL-4200 1 J805 1 J804 REFRESHER POWER CHARGI FILM OFF DO-41 CHARGI FILM ON DO-40 2.8.1 CHARGING AND EXPOSURE A PL9.1 REFRESHER(K) RTC(K) REFRESHER(C) RTC(C) REFRESHER(M) RTC(M) REFRESHER(Y) RTC(Y) Print head cartridge ASSY PKG C D EXPOSURE VI-28 CHARGING E F Print head cartridge ASSY G H 2.8.2 2.8.2 2.8.
6 5 4 3 2 1 A 2.8.4 2.8.1 2.8.4 2.8.1 2.8.4 2.8.1 2.8.4 2.8.1 5 4 3 2 GRY GRY GRY GRY 1 J11 GRY DISPENSED TONER(K) LATENT IMAGE(K) DISPENSED TONER(C) LATENT IMAGE(C) DISPENSED TONER(M) LATENT IMAGE(M) DISPENSED TONER(Y) LATENT IMAGE(Y) CONTROL LOGIC MCU HL-4200 PL12.1 GRY GRY 37 38 WARNING: HIGH VOLTAGE HVPS MCU HL-4200 PL12.1 D/A DEVE MOTOR 36 GRY XDEVE ENA DEVE CLOCK MOTOR DRIVE C BLK WHT PL9.
6 5 4 3 2 1 A B CONTROL LOGIC PL12.1 MCU HL-4200 DC COM (2.1.1) PL12.1 1 J3411 J341 2 YEL YEL DOUBLE PLUG 1 J34 ANT_IN P3411 2 GRY GRY 13 J51 GRY PWBA HBN DRV 2.8.3 TONER CARTRIDGE SET J356 J355 J352 PL10.1 PL10.1 PL10.1 HSG ASSY COIL READER (K) PL10.1 HSG ASSY COIL READER (C) PL10.1 HSG ASSY COIL READER (M) HSG ASSY COIL READER (Y) PWBA CRUM READER J351 C J342 5 GRY J350 J353 J354 D J357 CONTROL LOGIC PL10.1 PKG Toner Cartridge K C CONTROL LOGIC PL10.
6 5 4 3 2 1 B CONTROL LOGIC PL12.1 MCU HL-4200 GRY GRY GRY GRY GRY CLOCK XB 9 GRY CLOCK XA 10 GRY CLOCK B 11 GRY CLOCK A 12 GRY CLOCK XB 13 GRY 36 35 34 GRY GRY GRY CLOCK XB 5 GRY CLOCK XA 6 GRY CLOCK B 7 GRY CLOCK A 33 8 GRY GRY 32 31 30 29 28 CLOCK XA 14 GRY 27 GRY CLOCK B 15 GRY GRY 26 21 25 24 23 26 30 29 28 27 31 35 34 33 +24VDC SWITCHED (2.1.1) DC COM DC COM DC COM DC COM 5 MOT HOLDER ASSY TONER HBN(M) PL10.1 5 1 PL10.1 PL10.
6 5 4 3 2 1 A 7 4 1 10 DC COM (2.1.1) +5VDC (2.1.1) 12 DC COM (2.1.1) +5VDC (2.1.1) 3 DC COM (2.1.1) +5VDC (2.1.1) 6 GRY GRY GRY BLU GRY VIO GRY 9 J51 YEL DC COM (2.1.1) +5VDC (2.1.1) PL12.1 PWBA HBN DRV B 3 3 3 GRY 3 J704 1 GRY GRY J703 1 BLU GRY J702 1 VIO GRY J701 1 YEL 2.8.5 LOW TONER SENSING CONTROL LOGIC SENSOR NO TONER(K) PL10.1 CONTROL LOGIC SENSOR NO TONER(C) PL10.1 CONTROL LOGIC SENSOR NO TONER(M) PL10.1 CONTROL LOGIC SENSOR NO TONER(Y) PL10.
6 5 4 3 2 1 A B 25 23 22 24 27 30 26 29 28 YEL DO-59 Transfer roll cartridge PLUS OFF YEL YEL YEL DEVELOPED IMAGE(K) IDT2 DRIVE 2.8.2 2.4.1 3.0V REF REGISTRATED PAPER DEVELOPED IMAGE(C) 2.8.2 DEVELOPED IMAGE(M) 2.8.
6 5 4 3 2 1 A B YEL YEL 11 YEL 13 J140 YEL 14 13 DC COM (2.1.1) +5VDC (2.1.1) DC COM (2.1.1) +5VDC (2.1.1) YEL YEL 3 P141 1 YEL YEL 3 4 GRY 3 2 YEL YEL 5 J1361 YEL 1 YEL 3 J141 YEL DOUBLE PLUG YEL YEL 2 4 J2361 GRY DOUBLE PLUG 3 P2361 1 YEL DOUBLE PLUG LED ONP1361 1 16 J13 YEL YEL 2 4 J24 YEL DC COM DC COM (2.1.1) +5VDC (2.1.1) CONTROL LOGIC PL12.1 MCU HL-4200 2.8.
6 5 4 3 2 1 1 1 2.8.5 2.8.5 2.8.7 2.8.7 2.8.7 1 1 1 1 1 2.8.5 2.8.7 1 1 1 1 1 1 2.8.5 2.8.3 2.8.3 2.8.3 2.8.3 2.8.
6 5 4 3 2 1 FUSER DRIVE 2.9.2 ZN G2 ZN G1 C YEL YEL YEL YEL 4 5 P138 1 YEL DC COM (2.3.2) 2 1 BLU BLU 5 J138 BLU DOUBLE PLUG +3.3VDC (2.3.2) 1 2 GRY 1 J2362 GRY DOUBLE PLUG P2362 3 YEL GRY GRY BLU BLU BLU GRY GRY 3 VIO 28 1 J235 GRY J234 1 HEATER2 ON 1 9 YEL YEL +3.3VDC ACL (2.1.1) ACN (2.1.
6 5 4 3 2 1 A B CONTROL LOGIC PL12.1 MCU HL-4200 16 15 14 13 GRY GRY GRY GRY 12 J11 GRY GRY GRY 26 27 28 J41 29 GRY GRY C MOTOR DRIVE DC COM +24VDC SWITCHED PWBA HBN DRV PL12.1 D/A FUSER MOTOR 25 GRY FUSER CW/CCW FUSER F/H XFUSER ENA FUSER CLOCK 2.9.2 FUSER DRIVE CONTROL BLK WHT FUSER_W FUSER_V FUSER_U MOT 1 FUSER DRIVE ASSY PL5.
6 5 4 3 2 1 CONTROL LOGIC PL12.1 HEAT AIR MCU HL-4200 2.9.1 A REAR FAN LOW 18 13 VIO VIO REAR FAN STOP 19 12 VIO VIO FUSER FAN STOP J42 30 1 J12 VIO VIO FUSER FAN LOW 30 1 VIO VIO COOLING FANS C 4 9 DC COM (2.1.1) YEL DO-16 YEL 6 FAN CONTROL 1 3 MOT PL12.1 J166 2 ZN E1 F LVPS(100/120V) (230V) PL12.1 2 J137 YEL DOUBLE PLUG P137 2 ZN F5 VI-38 MOT FAN REAR REAR FAN ON (HIGH SPEED) (LOW SPEED) REAR FAN OFF 3 REAR FAN DO-14 DO-15 DO-13 YEL E FAN FUSER PL1.
6 5 4 3 2 1 ROLL MID DRIVE ROLL DUP DRIVE ROLL EXIT DRIVE 2.9.5 2.9.5 FUSED PRINT 2.9.5 2.9.1 A B C DC COM (2.1.1) +3.3VDC (2.1.1) DC COM (2.1.1) +3.3VDC (2.1.1) MCU HL-4200 PL12.1 5 4 2 YEL YEL YEL 1 J13 YEL YEL YEL YEL 7 8 10 P139 11 YEL 5 4 2 YEL YEL YEL 1 J139 YEL DOUBLE PLUG 2.9.4 EXIT AND INVERT TRANSPORTATION 2 YEL 2 J134 3 YEL YEL J133 3 YEL D SENSOR PHOTO (FULL STACK SENSOR) PL6.1 1 J134 YEL SENSOR PHOTO (DUP JAM SENSOR) PL6.
6 5 4 3 2 1 B CONTROL LOGIC MCU HL-4200 PL12.1 29 8 7 6 VIO VIO VIO VIO 5 J12 VIO D/A DUP MOTOR CLOCK TDB CLOCK TDA CLOCK B CLOCK A 2.9.
6 5 4 3 2 1 2.9.4 2.9.4 2.9.3 2.9.3 2.9.1 2.9.1 2.9.1 2.9.1 1 1 1 1 1 1 1 1 A PAPER FULL STACK SENSED SIGNAL DUP JAM PAPER SENSED SIGNAL REAR FAN FAIL SIGNAL FUSER FAN FAIL SIGNAL TEMP SENSOR SIGNAL FUSER NCS SIGNAL NO FUSER SIGNAL EXIT PAPER SENSED SIGNEL 1 Virtual Line CONTROL LOGIC MCU HL-4200 PL12.1 2.9.6 MONITORING B C Empty Exit Tray Duplex Jam Open B-Cover 001-360 010-350 010-317 Fuser Jam Open A/B-Cover CONSOLE PANEL HIBANA PL1.
CHAPTER VII PLUG/JACK (P/J) CONNECTOR LOCATIONS
CONTENTS CHAPTER VII PLUG/JACK (P/J) CONNECTOR LOCATIONS.... VII-1 1. LIST OF P/J ...............................................................................................VII-1 2. P/J LAYOUT DIAGRAM .............................................................................
CHAPTER VII 1. PLUG/JACK (P/J) CONNECTOR LOCATIONS LIST OF P/J The following tables list the connector (P/J) coordiates corresponding to 2. P/J Layout Diagram.
P/J Coordiates 132 C-9 133 134 D-8 D-6 135 C-9 136 137 138 C-23 F-8 B-32 139 B-33 140 D-43 141 142 144 145 151 161 162 163 164 165 166 167 168 181 210 220 221 231 B-32 E-24 E-35 E-35 H-22 H-29 H-29 H-27 H-28 H-28 H-27 H-28 H-28 E-38 H-24 E-7 B-33 D-52 232 F-23 311 341 342 351 352 471 472 473 D-42 E-5 E-6 E-36 D-9 I-53 F-53 F-54 Remarks Connects Chute ASSY Out (Solenoid Feed MSI) and Harness ASSY Front 1A Connects Chute ASSY Out (DUP JAM Sensor) and Harness ASSY Front 1A Connects Chute AS
P/J Coordiates Remarks 474 475 511 512 513 514 701 702 703 704 G-54 H-53 I-7 I-6 J-6 J-6 G-6 H-6 H-6 H-6 710 D-6 810 1361 2361 2362 3411 5011 5020 5030 H-54 B-32 E-37 E-36 G-36 F-35 E-35 E-35 Connects Solenoid Feed and PWBA HBN DRV Connects Clutch ASSY Turn and PWBA HBN DRV Connects Holder ASSY MQ-Y (TNR Motor) and PWBA HBN DRV Connects Holder ASSY MQ-M (TNR Motor) and PWBA HBN DRV Connects Holder ASSY MQ-C (TNR Motor) and PWBA HBN DRV Connects Holder ASSY MQ-K (TNR Motor) and PWBA HBN DRV Connects
2.
VII-5
VII-6
VII-7
APPENDIX
CONTENTS APPENDIX 1 ..............................................................................APP-1 1.1 When PCB is replaced ......................................................................................................... 1.1.1 When Controller Board (ESS) is replaced ..................................................................... 1.1.2 When MCU PWBA is replaced ...................................................................................... 1.2 Controller Firmware upgrade...........
APPENDIX 1 1.1 When PCB is replaced The information below is stored in NV-RAM (EEPROM) on ESS. If necessary, transfer the data to a new PCB. - - U8 (Part number) 1. Data set with Control Panel 2. NV-RAM data on MCU that is saved manually 3. Error Log 4. Jam Log 5. Billing Counter U9 (Part number) The information stored is specific to the Controller Board, therefore, the information cannot be used for the new PCB.
1.1.1 When Controller Board (ESS) is replaced Take the EEPROM (U8) out of the Controller Board, then put it in the new U8 on Controller Board. Take out the NIC EXCORD ASSY, then put it on the new Controller Board. 1.1.2 When MCU PWBA is replaced When you replace MCU PWBA, you must temporary save NV-RAM data in EEPROM of Controller Board. 1. Turn the power on while pressing the [↑] and [↓] buttons together. 2. Enter the password. (Password; Press the [ ↓ ] button twice and Form Feed/Set button). 3.
1.2 Controller Firmware upgrade All PCBs are supplied with Firmware written in, however, if there is a problem, you can upgrade PCBs with the following procedures: The following Firmware can be upgraded with the On-demand Downloader - Controller firmware - NIC Boot program (DIP SW (JP2) of NIC card must be ON.) - NIC Firmware The following Firmware must be written in Download mode - Controller Boot program - MCU NVM / Firmware Setting up PC 1. Install the printer driver. 2.
1.2.1 Controller Firmware / NIC Boot program / NIC Firmware upgrade Setting up On-demand Downloader 1. Use the [Menu] button to put the machine off line mode. 2. Select [Menu / 2:Maintenance] by pressing the [↓] button, then press the [Set] button. 3. Select [2:Maintenance / F/W Download] by pressing the [↓] button. 4. Press the [Set] button. [F/W Download / Reject*] is displayed. 5. Press the [↓] button to change it to [F/W Download / Accept], then press the [Set] button. Upgrading Firmware 1.
APPENDIX 2 CONSUMABLES REPLACEMENT Printhead Unit The life is 30,000-page (@ C:5%, M:5%,Y:5% , K:5%). The life will change by “Coverage” and “Job”. 1.Coverage If the print coverage increased, the life decreases as below.
2.Job If each print job increased, the life increases as below.
TR-11CL The life is 25,000-page (by printing BW document and Full color document 50%:50%.). The detail is as follows. The life will be 25,000-page when Printing 5% coverage BW document for 12,500-page Printing 20% coverage (C:5%, M:5%, Y:5%, Mono: 5% bk BK:5%) for 12,500-page Full color: 20% 5% each Above situation is same as the situation below. Printing 12.5% (C:2.5%, M:2.5%, Y:2.5%, BK: Full color: 12.5% 5%) for 25,000-page C:2.5%, M:2.5%, Y:2.
The actual life is over than catalog specification. But as you may know, we are including some margin.
Print Head Cartridge Cleaning Kit User Guide Thank you for choosing this product. If your printer is printing colored dots at regular intervals like in the diagram below, use the cleaning kit to clean the print head cartridge. Printing colored dots at approx. 25 mm intervals. Handling Precautions Attention during cleaning z Do not use this cleaning kit except for cleaning. z No printing during the cleaning. Errors may occur if you print while the cleaning kit is attached.
How to clean the print head cartridge Attach this cleaning kit to the printer so the brush directly brushes the dirty parts of the print head cartridge. Follow the following procedures. Lining up the brush with the dirty part of the print head cartridge 1 Remove the dust and dirt from the brush part of the cleaning kit with the brush cleaner provided. 2 Place the print sample (single sided print samples) on which colored dots were printed face up on a desk.
2 Push up button A (1) and fully open the front door (2). 3 Push the button as shown and open the paper outlet cover. 4 Grip the handle on top of the print head cartridge and gently lift it out of the printer. Place the print head cartridge on a level surface with its back facing you. 5 Holding the cleaning kit with the "↑TOP" facing up, slowly insert it into the print head cartridge. Note that you need to insert the cleaning kit into different slots depending on the color of the dots.
7 Close the paper outlet cover (1), and then close the front door (2). Display will show "Please Wait." The printer will automatically operate to clean the print head cartridge. It'll take about 20 sec. to 2 min. 8 The message changes to "Ready to Print," and the sound of the printer motor stops, go to steps 2 through 4 to remove the print head cartridge. And then carefully remove the cleaning kit. Printing while the cleaning kit is attached may result in poor print quality or may damage the printer.
APPENDIX 4 MEASURE OF TONER CARTRIDGE WEIGHT Toner Cartridge Weight (approximate weight) Yellow Brand new Toner Cartridge 315g ± 1 0g Magenta Cyan Black 325g ± 1 0g 315g ± 1 0g 360g ± 1 0g Weight Toner Weight at Brand new 110g 120g 110g 155g 217g 217g 217g 217g 10g 10g 10g 10g Toner Cartridge Toner Cartridge Weight at Toner Empty Remain Toner Weight at Toner Empty You can print 500 to 600 pages with 10g Toner.
APPENDIX 5 PERIODICAL REPLACEMENT PARTS Periodical replacement parts are the parts to be replaced periodically to maintain product quality. These parts would affect the product quality greatly if they lost their function even if they do not appear to be damaged or there is no change in their appearance.
Note: * A4 or Letter-size single-sided pages at about 5% coverage. The actual number of printed pages may vary depending on the print jobs and paper you use. * Replacement life when converting with utilization ratio CST (Paper Cassette) 85% and MSI (Multi Sheet Inserter) 15%.
