C9000 Series Color LED Page Printer Service Manual ODA 05-18-200 Based on Rev.2 41388601TH Rev.
Document Revision History Corrected items Rev.No. Date No. 1 2000-12-05 2 2000-12-13 3 05-18-2001 41388601TH Rev.
PREFACE This maintenance manual provides procedures and techniques for the troubleshooting, maintenance, and repair of C9000. This manual is written for maintenance personnel, but it should always be accompanied with the C9000 User’s Manual for procedures for handling and operating C9000. For repairing each component of C9000, see the Troubleshooting manual. [Notices] The contents of this manual are subject to change without prior notice.
CONTENTS 1. SPECIFICATIONS ............................................................................................ 7 1.1 1.2 1.3 1.4 Basic System Configuration ............................................................................................. 7 Printer Engine Specifications ........................................................................................... 8 Option Configuration ........................................................................................................
3.3.16 3.3.17 3.3.18 3.3.19 3.3.20 3.3.21 3.3.22 3.3.23 3.3.24 3.3.25 3.3.26 3.3.27 3.3.28 3.3.29 3.3.30 3.3.31 3.3.32 3.3.33 3.3.34 3.3.35 3.3.36 3.3.37 3.3.38 3.3.39 3.3.40 Registration roller Assy (B) ............................................................................... 66 Registration clutch, Registration motor Assy .................................................... 67 Cooling fan .......................................................................................................
Centronics USB Ethernet 41388601TH Rev.2 ROM DIMM × 3 Belt Unit Y-ID Unit M-ID Unit Duplex Unit Figure 1.
1.2 Printer Engine Specifications The inside of the printer is composed of the followings: • • • • • Electrophotographic Processor Paper Paths Controller Block (CU and PU) Operator Panel Power Units (High-Voltage Unit and Low-Voltage Unit) Figure 1-2 shows the printer configuration. Figure 1.2 41388601TH Rev.
1.3 Option Configuration The followings are available as options on C9000. (1) 2nd Tray/ 3rd Tray (2) Duplex Unit (3) Large-Capacity Tray (4) Expansion Memory 64/128/256MB (5) Internal Hard Disk (6) Ethernet Board 41388601TH Rev.
1.4 Specifications (1) Dimensions Height: 18.11 in. Width: 26.22 in. Length: 24.65 in. (2) Weight 158.7 lbs.
(12) Temperatures and Relative Humidities Temperature Temperature (ºF) Operating Temperature (ºC) Remark 17 to 27ºC (Temperatures to assure full color print quality) 50 to 89.6 10 to 32 Non-Operating 32 to 109.4 0 to 43 Storage (Max. One Year) -14 to 109.4 -10 to 43 With drum and toner Transport (Max. One Month) -20 to 122 -29 to 50 With drum and without toner Transport (Max. One Month) -20 to 122 -29 to 50 With drum and toner Power-off Humidity Relative Humidity (%) Remark Max.
*1 Black 41388601TH Rev.
2.0V Regulator PPC 750 L2 Cache Cont D A Delay 5V Internal-CLKSetting Resistance A/D,Cont 80MHz Reset DS1834 2.5V Regulator to C2 and 3.3V ICs 3.
(1) CPU The CPU is 64-bit bus RISC processor PowerPC750, which receives an input of 80MHz (=BUS CLK) and operates at 400MHz, four-times the input. (2) Secondary Cache SRAM SRAM is included as a secondary cache of the CPU on the board. (3) ROM The ROM is inserted into the three 168-pin DIMM slots. The slot A is for a program ROM and the slot B is for the Japanese Kanji font. The slot C is not assigned. (4) RAM The RAM is inserted into the four 168-pin DIMM slots.
2.
2.3 (3) Flash ROM 8 megabits of flash ROM (MBM29F800TA-70) which stores PU programs. (4) EEPROM 4 kilobits of EEPROM (NM93C66N-NW) which is mounted on the board with an IC socket and stores correction values. (5) Pulse Motor Driver The pulse motor driver (A2918, A2919, A3955) drives nine pulse motors to revolve the EP and carry media. (6) SRAM This SRAM (62256LFP-7LL) is used as working memory of the CPU.
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2.4.1 Electrophotographic process (1) Electrophotographic process The following is the outline of electrophotographic process: 1 Charging DC voltage is applied to the charging roller and the surface of the OPC drum is negatively and evenly charged. 2 Exposure The LED head, under image signals, emits light to the negatively charged surface of the OPC drum.
(2) Charging Negative DC voltage is applied to the charging roller contacting the surface of the OPC drum. Power Unit Charging roller OPC drum (3) Exposure The negatively charged surface of the OPC drum is radiated with light from the LED head. The negative charge of the radiated portions of the drum surface attenuates in response to the intensity of the light and a latent electrostatic image responsive to the potentials of the surface is formed on the drum surface.
(4) Developing By the adhesion of toner to the latent electrostatic image on the drum surface, the image is changed to a toner image. The developing is processed at the contact part between the OPC drum and the developing roller. 1 The sponge roller causes toner to adhere to the developing roller. The toner becomes negatively charged.
(6) Fusing When passed between the heat roller and the backup roller, the toner image transferred to the paper is fused into place by the application of heat and pressure to it. The Teflon coated heat roller is heated by the built-in heat roller of 800W/backup roller of 500W (halogen lamp).
2.4.2 Paper running process Figure 2.5 shows how paper moves in the C9000. Fuser Face-down stacker Heat roller Registration roller Assy (B) 4 x LED heads 4 x LED Units Registration roller Assy (B) Eject roller Hopping roller Belt unit Eject roller Low-voltage power supply High-voltage power supply Multipurpose tray Registration roller Assy (A) Cleaning blade Cassette 1 Transfer roller Cassette 2 Feed roller Backup roller Cassette 3 Cassette 4 Cassette 5 Figure 2.
(1) Paper Loading from 1st Tray 1. The paper loading motor runs (CCW), the paper loading clutch is engaged and, until the entrance cassette sensor is turned on, paper is advanced (the on/off operations of the paper loading clutch control the pickup roller). 2. After the paper turns the entrance cassette sensor on, the paper is forwarded a further fixed length and touches the registration roller Assy (A) (this corrects paper skew). 3.
(2) Paper Loading from Option Tray 1. The paper loading motor runs (CW), the paper loading clutch is engaged and, until the carrier sensor on a tray which sits atop a loading tray is turned on, paper is advanced. 2. After the paper turns the carrier sensor on, the paper is forwarded a further fixed length and touches the carrier roller (this corrects paper skew). 3. The carrier clutch is thrown in and the paper is fed into the main body.
(3) Paper Loading from Multipurpose Tray (MT) 1. The release lever usually pushes down the hopping plate to a position to turn the micro SW on (Figure 2.8-a). 2. The running of the motor in the (a) direction drives the MT feed roller, causing the cam to turn. The cam pushes the release lever and the hopping plate picks up paper sent out by the MT feed roller (Figure 2.8-b), where the registration roller Assy (B) does not move as its one-way clutch gear (1) idles. 3.
(4) Carrier Belt 1. The running of the carrier belt motor in the direction of the arrow (a) drives the carrier belt. The belt unit sits with one carrier roller immediately below each color’s drum, and the carrier belt between them. By the application of a fixed voltage, the carrier belt and carrier roller feed paper on the carrier belt into the fuser unit, transferring a toner image from each color’s drum. Drum Carrier belt K Y M C Carrier (transfer) roller Carrier (transfer) belt motor Figure 2.
(5) Driving and Up-and-Down Movements of I/D Unit 1. The I/D unit driving and up-and-down movements are effected by a single-pulse motor. The running of the main motor in the direction of the arrow (a) turns the lever 1 to the left. Then, the lever 2 that was lifted by the lever 1 lowers to move down the I/D unit. After the up-and-down sensor is turned on (Figure 2.10-c), the specified downward pulsing places the I/D unit in its lowest position (or equivalently, printing position).
Plate Pin Spring Board Up-and-down Sensor Figure 2.10-c Figure 2.10-d Figure 2.10-e 41388601TH Rev.
(6) Fuser Unit and Paper Ejection 1. A single-pulse motor drives the fuser unit and the eject rollers. In response to the running of the heat motor in the direction of the arrow (a), the heat roller turns. This roller fuses a toner image to paper by heat and pressure. 2. At the same time, the four eject rollers move to eject the paper. 3. The paper separator solenoid switches the path back and forth between the route to the face-up stacker and the route to face-down stacker.
(7) Duplex Unit 1. When the duplex unit receives an instruction from the printer to print on both sides of a sheet of paper, the solenoid opens the separator after the completion of one side printing of a sheet of paper sent from the tray. The path is switched to that to the duplex unit. At this time, as the roller (1) turns in the direction of the arrow “a,” the paper is retracted on the rear of the cassette. 2.
2.5 Sensor 2.5.
2.5.2 Other sensors 1 Paper Empty sensor This sensor checks whether the paper cassette is empty. 2 Paper Near sensor This sensor checks whether the paper cassette is near empty. 3 MPF Paper Empty sensor This sensor checks whether the front feeder has paper. 4 MPF Hopping switch This microswitch checks whether the front feeder table is in the up position or in the down position. 5 Stacker Full sensor This sensor checks whether the stacker is full.
2.6 Color Misalignment Correction C9000 is equipped with multiple LED heads, which can result in color misalignment. The mechanically induced color misalignment is automatically corrected as follows: 2.
2.8 Paper Jam Detection C9000 detects paper jams after power-on and during printing. When a paper jam occurs, the printer immediately suspends the printing operation. Opening the cover to remove the jammed paper and closing it resumes the printing. Description Error LCD Error Code The entrance cassette sensor does not turn off within fixed time after it turns on. Loading of plural sheets of paper is sensed. Misfeed from Duplex Carrier Assembly Paper could not be loaded from the duplex carrier assembly.
2.9 Cover Opening When the top cover of the printer is open, the cover open microswitch turns opens to cut off the highvoltage power supply, and outputs which are not less than 32V. At the same time, the CPU receives CVOPN signals indicating the status of the microswitch and performs cover open operations.
2.10 Toner Low Detection • Structure This device consists of the stirring gear which revolves at a constant speed, the stirring bar, and the magnet on the stirring bar. The stirring bar turns in synchronization with the protrusion of the stirring gear. Stirring gear Link Stirring bar • Detection A toner low condition is detected by measuring the contact time between the sensor lever magnet and the stirring bar.
Toner Full Condition (At warming-up,A4 transverse:16ppm *1) t1 t1 1.12 TNRSNS T=2.3 Toner Low Condition (At warming-up,A4 transverse:16ppm *1) t1 t1 1.12 TNRSNS T=2.3 • • • • When the toner low condition is detected 20 consecutive times, toner low is detected. (The toner low message is displayed when about 1000 A4 sheets at 5% density have been printed after toner low had been detected.) The detection is not performed until toner low occurs after the detection of toner low.
2.11 Paper Size Detection Via the cam tied to the paper guide of the paper cassette, the four tab pieces are driven according to the set position of the paper guide. Upon installation of the paper cassette, the microswitch detects the condition of the tab pieces and the paper size is recognized. 41388601TH Rev.
2.12 Operation at Power-on 2.12.1 Self-diagnostic test (1) Initial test The following checks are automatically performed at power-on. (a) ROM check (b) RAM check (c) EEPROM check (d) Flash ROM check (2) ROM check The ROM is checked by calculating a HASH value. (3) RAM check (a) Checking is conducted by RAM type. Out-of-specification RAM is judged as an error. (b) The order of mounted RAMs is checked. Out-of-standard RAM is judged as an error.
2.13 Color Misalignment Detection Reflection-type optical sensors (Z71-PCB) are mounted at the right and left ends of the belt, respectively, in front of the toner scraping (cleaning) blade which is at the back of the belt unit. The color misalignment detection pattern is printed on the belt at the right and left ends each and, by reading the patterns by the reflection-type optical sensors, the misalignment amounts are measured with respect to Black to determine correction values.
2.14 Version Read of Periodically Replaced Units The condition (new or used) of the I/D, fuser unit and belt unit are determined by an internal fuse within the units. When the unit is powered on or the upper cover is opened and closed, the printer scans for consumables fuses. If a conducting fuse is found, that unit's counter is reset and the fuse is opened. The life counters of the consumables are checked at each power on and each closing of the upper cover.
3. PARTS REPLACEMENT This section describes the procedure for replacing the parts, assemblies and units in the field. The replacing procedure is given for detachment. To attach, use the reverse procedure. 3.1 Precautions in Replacing Parts (1) Before replacing the parts, be sure to remove the AC cable and the interface cable. (a) To remove the AC cable, always use the following procedure. 1 Flip the power switch of the printer off (to “O”).
[Maintenance Tools] Table 3-1 lists tools necessary to replace the units. Table 3-1 Maintenance Tools No. Service Tools Q' ty Place of use 1 No. 1-100 Philips screwdriver 1 2~2.5 mm screws 2 No. 2-200 Philips screwdriver, Magnetized 1 3~5 mm screws 3 No. 3-100 screwdriver 1 4 No. 5-200 screwdriver 1 5 Digital multimeter 1 6 Pliers 1 7 Handy cleaner 1 8 LED Head cleaner P/N 4PB4083-2248P001 1 9 High voltage probe 1 41388601TH Rev.
3.2 Parts Layout Figure 3.1 41388601TH Rev.
[Top Cover Assy] Figure 3.2 41388601TH Rev.
[Printer Unit-1/2] Figure 3.3 41388601TH Rev.
[Printer Unit-2/2] Figure 3.4 41388601TH Rev.
[Cassette Guide Assy (L), (R)] Figure 3.5 41388601TH Rev.
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[Duplex Unit] D C B A D C E B E A Figure 3.6 41388601TH Rev.
3.3 Replacing Parts This section describes how to replace the parts and assemblies illustrated below. 41531301 41515110 Print Engine Controller PWB (3.3.22) 41502304 × 4 LED Assy (3.3.2) 40737401 Power-Unit AC-DC Switching (115V) (3.3.34) 40737501 Power-Unit AC-DC Switching (230V) (3.3.34) 40737601 HV Power Supply (3.3.35) 41531402, 41531404 Fuser Unit (3.3.37) 41531502 Belt Unit (3.3.38) 41178202 Duplex Unit (3.3.39) 41480901 Printer NIP 41483001 Printer Unit 41481001 Unit-Lower-Frame (3.3.
3.3.1 Top cover (1) (2) Open the top cover Assy. Remove the nine screws 1 to detach the top cover 2. 2 1 1 1 41388601TH Rev.
3.3.2 LED Assy/ LED Assy spring (1) (2) (3) Open the top cove 1. Remove the three cables, and unhook the LED Assy 2 at the two places to demount it (The two springs 3 become detached together with the LED Assy 2). Detach the LED connector 4. When assembling, attach the LED connector 4 to the LED head and insert the flat cable. 1 3 4 3 2 41388601TH Rev.
3.3.3 Top cover unit (1) (2) (3) (4) (5) (6) Remove the top cover (see section 3.3.1). Remove the rear cover (see section 3.3.12). Remove the front cover (see section 3.3.11). Remove the electrical chassis (see section 3.3.21). Unscrew the screws 1 and 2 to remove the limiters (F) 3 and (R) 4. Remove the inner shaft 5, then the top cover unit 8 (The inner springs 6 and 7 become detached). 8 2 7 1 5 4 6 2 1 41388601TH Rev.
3.3.4 Control panel Assy/ Control panel bezel/ LED control PWB/ Toner sensor/ Stack full sensor/ Control panel tape harness/ Eject roller (1) (2) (3) (4) (5) (6) (7) (8) Detach the control panel bezel 1. Remove the screws 2 to demount the control panel 3. Detach the control panel tape harness 4. Remove the screws 6, unhook the connector 7 and demount the LED control PWB 8. Unscrew the screws 9 to remove the plate 0. Disengage the claw to demount the toner sensor A. Demount the stacker full sensor B.
3.3.5 Top cover handle/ Top cover latch/ Top cover latch spring (1) Remove the two screws 1 to detach the top cover handle 2 and disengage the top cover latch 3 (The two top cover latch springs 4 become detached). 1 3 2 4 1 4 41388601TH Rev.
3.3.6 Eject guide Assy (1) Remove the seven screws 1 to detach the eject guide Assy 2. 1 1 2 1 41388601TH Rev.
3.3.7 Cassette Assy/ Blind cover/ Side cover R Assy (1) (2) (3) (4) Detach the cassette Assy 1. Disengage the blind cover 2 at the two places to detach it. Unscrew the two screws to remove the stopper 4. Disengage the claw on the left support of the side cover R to detach the side cover R. 4 5 5 2 1 3 5 5 41388601TH Rev.
3.3.8 Feed rollers (1) (2) Remove the cassette. Unlatch and demount the feed rollers 1. 1 1 1 41388601TH Rev.
3.3.9 Left side cover (1) Remove the four screws 1 to detach the left side cover 2. 2 1 1 41388601TH Rev.
3.3.10 Face-up tray (1) Open the face-up tray in the arrow direction and move the links 2 out of engagement (at two places each of the links) to detach the face-up tray 1. 2 1 2 41388601TH Rev.
3.3.11 Front cover (1) (2) (3) Open the top cover 1. Disengage the claws and remove the blind cover 2. Unscrew the six screws 4 to detach the front cover 3. 1 4 4 4 4 3 4 2 41388601TH Rev.
3.3.12 Rear cover (1) (2) Open the top cover 1, Remove the five screws 3 and 4 to detach the rear cover 2. 4 3 3 1 2 41388601TH Rev.
3.3.13 Multipurpose tray Assy/ Multipurpose tray cover Assy/ Links/ Multipurpose tray top cover/ Multipurpose tray drive gear (1) (2) (3) (4) (5) (6) Remove the rear cover (see section 3.3.12). Remove the front cover (see section 3.3.11). Unscrew the three screws 1 to detach the multipurpose tray top cover 2. Unscrew the two screws 3 and remove the connector to detach the multipurpose tray 4. Disengage 4 and 5 to detach the multipurpose tray cover Assy 5 (the links 7 become detached).
3.3.14 Drum contact Assys (1) Insert a flatblade screwdriver between the printer case and the drum contact Assy 1 to demount the drum contact Assy. 1 41388601TH Rev.
3.3.15 Registration roller Assy (A)/ Registration drive gear (A) (1) (2) (3) (4) (5) Remove the front cover (see section 3.3.11). Remove the rear cover (see section 3.3.12). Remove the multipurpose tray (see section 3.3.13). Unscrew the four screws 1 to demount the registration roller Assy (A) 2. Remove the E ring 3 to detach the registration gear (A) 4. 1 4 3 2 1 41388601TH Rev.
3.3.16 Registration roller Assy (B) (1) (2) (3) (4) (5) (6) (7) Remove the cassette Assy. Remove the front cover (see section 3.3.11). Remove the rear cover (see section 3.3.12). Remove the electrical chassis (see section 3.3.21). Remove the registration clutch (see section 3.3.17). Remove the printer chassis (see section 3.3.23). Unscrew the four screws and pull out the registration Assy (B) 2 in the arrow direction. 1 2 1 1 41388601TH Rev.
3.3.17 Registration clutch, Registration motor Assy (1) (2) (3) (4) Remove the left side cover (see section 3.3.9). Remove the electrical chassis (see section 3.3.21). Remove the connector and the E ring 1, then screws 3 and 4, and then the earth plate 5. Remove the connector and unscrew the two screws 6 to demount the registration motor Assy 7. 6 3 7 5 4 6 2 1 41388601TH Rev.
3.3.18 Cooling fan (1) Unhook the connector 1, and remove the screws 2 and the cooling fan 3. 1 2 3 air direction 41388601TH Rev.
3.3.19 Color registration sensor Assy (1) (2) Remove the two screws 1 and the three connectors to demount the color registration sensor Assy 2. Remove the earth plate B 3. 1 1 2 1 2 3 4 41388601TH Rev.
3.3.20 Duplex guide Assy (1) (2) Unlatch and demount the duplex guide Assy 1. Remove the springs 2. 1 2 2 Main chassis (L side) 41388601TH Rev.
3.3.21 Electrical chassis/ Electrical chassis cooling fan (1) (2) (3) (4) (5) Unscrew the five screws 1 and two screws 2 to remove the plate A 3. Unscrew the thirty-one screws 4 to remove the shield plate B 5. Remove the printer engine controller PWB (see section 3.3.22). Unscrew the eleven screws 6 to detach the electrical chassis 7. Unscrew the two screws 8 to demount the electrical chassis cooling fan 9. 1 1 1 2 3 6 6 7 4 6 9 air direction 8 6 6 5 4 41388601TH Rev.
3.3.22 Printer engine controller PWB (1) (2) (3) Remove the rear cover (see section 3.3.12). Remove the electrical chassis and the electrical cooling fan (see section 3.3.21). Remove the five screws 1 and all the connectors to demount the printer engine controller PWB 2. 2 1 1 41388601TH Rev.
3.3.23 Printer unit chassis (1) (2) Unscrew the screw 1 and remove the AC switch Assy 2. Remove the four black screws 3 and six screws 4 to detach the printer unit chassis 5. 3 4 3 4 4 4 2 3 1 3 4 3 5 41388601TH Rev.
3.3.24 Entrance cassette sensor actuator (1) (2) (3) Remove the printer unit chassis (see section 3.3.23). Turn over the main chassis. Remove the two clamps with tweezers to demount the entrance cassette sensor actuator 1. 1 Main chassis 41388601TH Rev.
3.3.25 Entrance sensor PWB (1) (2) Remove the registration roller Assy (B) (see section 3.3.16). Remove the two screws 1 to demount the entrance sensor PWB 2. 1 2 41388601TH Rev.
3.3.26 Entrance MT sensor actuator and Entrance belt sensor actuator (1) (2) (3) Remove the entrance sensor PWB (R71) (see section 3.3.25). Unlatch and detach the entrance MT sensor actuator 1. Unlatch and detach the entrance belt actuator 2. 2 1 41388601TH Rev.
3.3.27 Main motor fan/ Fuser eject roller (1) (2) (3) (4) (5) (6) Unscrew the two screws 1 to remove the fan Assy 2. Unscrew the fuser eject roller contact 4. Remove the fuser drive gear 5. Unscrew the fuser drive gear Assy 8. Remove the screws and washers 0 to demount the fan A. Unlatch and detach the fuser eject roller bearing (L) B and fuser eject roller C. 0 9 A C 9 0 B 8 5 3 4 2 7 1 1 41388601TH Rev.
3.3.28 Eject sensor Assy (1) (2) Remove the fuser eject roller (see section 3.3.27). Remove the screw 1 and connector 2 to demount the (red/blue) eject sensor Assy 2. 1 2 41388601TH Rev.
3.3.29 Fuser latching handle (L) (1) (2) Remove the latching handle spring 1. Unscrew the fuser latching handle (L) 3. 3 1 2 41388601TH Rev.
3.3.30 Belt motor Assy (1) (2) (3) Remove the fuser latching handle (R) (see section 3.3.32). Unscrew the two screws 1 to detach the two connector 2. Demount the belt motor Assy 3. 1 1 3 2 41388601TH Rev.
3.3.31 Fuser latching handle (R) (1) (2) (3) Remove the printer unit chassis (see section 3.3.23). Remove the E ring 1. Remove the fuser latching handle spring 2 to detach the fuser latching handle (R) 3. 3 1 2 41388601TH Rev.
3.3.32 Main motor Assy (1) (2) (3) Remove the belt motor Assy (see section 3.3.30). Remove all the connectors. Remove the two screws 1 to demount the main motor Assy 2. 1 1 2 41388601TH Rev.
3.3.33 Contact Assy/ Side plate Assy (1) (2) (3) Remove the printer unit chassis (see section 3.3.23). Remove the four screws 1 to detach the side plate Assy 2. Remove the three screws 3 to detach the contact Assy 4. 2 3 1 4 41388601TH Rev.
3.3.34 Low voltage power supply (1) (2) (3) Remove the printer unit chassis (see section 3.3.23). Unhook the connector 1. Remove the eight screws 2 to demount the low voltage power supply 5. 2 1 7 3 8 6 2 5 2 0 0 0 B A 41388601TH Rev.
3.3.35 High voltage power supply (1) (2) (3) Remove the contact Assy (see section 3.3.33). Unhook the connector of the high voltage power supply 2. Remove the two screws 1 to detach the high voltage power supply 2 and the tape harness 3. 1 3 1 2 41388601TH Rev.
3.3.36 Main feed Assy (1) (2) (3) (4) (5) (6) (7) Remove the printer unit chassis (see section 3.3.23). Remove the low voltage power supply and high voltage power supply (see sections 3.3.34 and 3.3.35). Unscrew the five screws 1 to remove the lower plate 2. Unscrew the six screws 3 to demount the main feed Assy 4. Unscrew the screws 5 to detach the cable and then the PCB size board 6. Unscrew the screw 7 to detach the duplex connector 8. Unscrew the screws 9 to detach the second tray connector 0.
3.3.37 Fuser unit (1) (2) Open the top cover 1. Push the right and left fuser levers (blue) 2 in the arrow direction to detach the fuser unit 3. 3 2 41388601TH Rev.
3.3.38 Belt unit (1) (2) (3) Open the top cover 1. Remove the I/D unit. Push the lever (blue) 2 in the arrow direction, raise the handle (blue) and detach the belt unit 3. 3 1 2 41388601TH Rev.
3.3.39 Duplex unit (1) (2) Remove the cassette Assy, the front cover and the front cover inner buffle. Unlatch the rear at the right and left and pull the duplex unit 1 toward the front. 4 5 2 3 1 41388601TH Rev.
3.3.40 CU Assy (1) Pulling out Control Board 1. Loosen the two screws 1. 2. Pull the control board 2 out. 3. Place the control board 2 on a flat table. (2) Detaching Fan 1. Remove the connector 3. 2. Remove the two screws 4. 3. Detach the fan 5. 1 2 1 4 5 3 41388601TH Rev.
(3) Demounting CRM Board 1. Remove the three screws 6 to detach the fan bracket 7. 2. Remove the four screws 8 to detach the plate support 9 and the guide rail 0. 3. Remove the two screws A to detach the guide rail B. 4. Remove the two screws C and three screws D, then demount the CRM board E. 6 7 8 6 9 A E 8 D 9 0 8 D B 8 A 0 C 8 41388601TH Rev.
4. ADJUSTMENT Adjustments are carried out by key operations on the operator panel. The maintenance menu is included in the general menu of this printer. Choose the maintenance menu for adjustment. 4.1 Maintenance Menu and Its Functions The general menu has the category, MAINTENANCE MENU. The items adjustable in this menu are shown below. Maintenance Menu Category DF Functions * Sets the Power Save Mode enabled/disabled.
4.2 Short Plug Settings The CRM board has five short plugs that can be set as follows: Short Plug (WE1,3, 5 and 7) Sets flash ROM DIMM to connect WE signals. (1-2 Short: Disconnects WE signals; 2-3 Short: Connects WE signals.) The factory-shipped short plug is set to the 2-3 short: Re-programmable the Flash ROM DIMM. Short Plug (DIMM2) Sets the banks of ROM DIMM Slot B.
4.4 Adjustment after Part Replacement Adjustment to be implemented after each part replacement is described below. Adjustment and correction of color registration are always required for each part replacement. Adjustment Replaced Part LED Head Color balance adjustment Drum Cartridge (Y, M, C, K) Not required. Fuser Unit Not required. Belt Cassette Assy Not required.
4.5 Color Balance Adjustment Color balance has been adjusted appropriately when a printer is shipped from the plant. However, it may be out of the appropriate balance during use. In such a case, color balance should be modified. Note: Density of each color depends on each other. Therefore, adjustment must be repeated several times to reach the correct color balance. (1) Set letter paper in the tray specified on the operator panel. (2) Press ) several times to display [COLOR MENU].
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4.6 EEPROM Replacement after CRM Board and K73 Board Replacement When replacing the CRM Board or K73 Board, the EEPROM must be removed and re-mounted on the new board (to deliver the user setting and font installation information to the new board). If the EEPROM used by the user is broken and not suitable for further use, the EEPROM on the new board may be used. 41388601TH Rev.
5. REGULAR MAINTENANCE 5.1 Consumables to be Regulary Replaced It is recommended that a user should replace the consumables below according to the replacement standard. (If not replaced, print quality is not assured or it may result in a failure.) Part Name Time for Replacement Replacement Condition Adjustment after Replacement Large-capacity When the message “Toner Low” After 15,000 copies have Replace the Toner cartridge. been printed. Toner Cartridge is displayed.
6. TROUBLESHOOTING PROCEDURES 6.1 Tips for Troubleshooting 6.2 6.3 (1) Check the basic check points covered in the user’s manual. (2) Gather as much information on the problem from the customer as possible. (3) Perform inspections in conditions close to those in which the problem had occurred.
6.4 Preparation for Troubleshooting (1) Operator panel display The failure status of this printer is indicated on the LCD (liquid crystal display) of the Operator panel. Take the proper corrective action according to the message displayed on the LCD. 6.5 Troubleshooting Flow If a problem should develop in this printer, troubleshoot in the following procedure. Problem Problem that results in LCD message indication Image problem (and a problem that does not result in LCD message indication.
6.5.1 LCD Message List The printer indicates a Service Call Error message on the LCD as shown below, detecting an unrecoverable error. Service Call nnn : Error Note: nnn is an error code. When the Service Call message is displayed, the error information corresponding to the error code appears on the lower line of the LCD. The meaning and solutions of each error code are listed in the Table 6-1-1.
Table 6-1-1 Operator Alarms (2/5) Message Cause Service Call CU EEPROM Error 040: Error Error Description Can the printer recover from the error by replacing the EEPROM on the CU board? Solutions Yes Replace the EEPROM. (Settings of the user must be restored on the new.) No Replace the CRM board. (The EEPROM needs replacement.) Service Call U Flash Error. 041: Error On-CU-board Flash ROM Error Does the error message appear again? Yes Replace the CRM board. (The EEPROM needs replacement.
Table 6-1-1 Operator Alarms (3/5) Message Cause Service Call 125: Error Error detected at the MT home position. Error Description Solutions 1) Is the error message displayed? Yes Turn off/on the printer. 2) Does the error repeat? Yes Replace the MT. Temperature rise at the LED head detected. 1) Is the error message displayed? Yes Turn off the printer, leave it for 30 min and then turn it on again. 2) Does the error repeat? Yes Replace the LED head unit.
Table 6-1-1 Operator Alarms (4/5) Message Cause Error Description Install New Drum End of the ID unit life. Is it displayed soon after the ID unit 350: Y Drum Life 26,000 or more replacement? 351: M Drum Life copies printed. 352: C Drum Life 353: K Drum Life Install Duplex Unit The Duplex unit is 360: No Duplex removed from the printer. unit Recovered if the Duplex unit is inserted again? Solutions Yes Confirm the life of the ID unit. No Replace the ID unit.
Table 6-1-1 Operator Alarms (5/5) Message Load *** Papers 490: No paper in the MP Tray (*** = A4, B5 etc.) Cause Error Description Solutions The specified cassette 1) No paper in MT? has no paper or is removed. Or, the 2) Does the Paper out sensor operate cassette be ingused for normally? printing has no more paper. Yes Load papers in MT. No Replace the Paper out sensor.
6.5.2 LCD message troubleshooting (1) LCD Message The message on the LCD (liquid crystal display) tells the problem situation of the printer. Implement the appropriate troubleshooting base on the message. No. Problem Flowchart Number 1 The printer does not work normally after being turned on.
1 The printer does not work normally after turned on. • • Turn off the printer, wait a few seconds, then turn it on again. Is displayed on the LCD (for about 1 second)? • No Is the AC cable connected correctly? No Connect the AC cable correctly. ▼ • Yes Is +5V supplied to the PANEL connector pins on the PU board (K73 PWB)? +5V: Pin 5 0V: Pin 2 Yes Is the operator panel cable connected correctly? No Connect the cable correctly. ▼ Yes Replace the operator panel cable.
2-1 Paper Input Jam (1st Tray) • Does the jam occur soon after the printer is turned on? • Yes Is the paper jammed at the entrance cassette sensor or the entrance MT sensor ? * MT : Multipurpose Tray Yes Remove the jammed paper. A ▼ • No Do the sensor levers (of the entrance cassette sensor and the entrance MT sensor) operate normally? No Replace the defective sensor lever.
2-2 Paper Input Jam (Multipurpose Tray (MT)) • Does the paper jam occur immediately after the printer is powered on? • Yes Is the paper jammed at the entrance cassette sensor or the entrance MT sensor ? Yes Remove the paper jam. ▼ • No A Does the lever of the entrance MT sensor operate normally? No Replace the defective sensor lever.
2-3 Paper Feed Jam • Does the paper jam occur immediately after the printer is powered on? • Yes Is the paper jammed at the entrance belt sensor? Yes Remove the jammed paper. ▼ • No A Does the lever of the write sensor work right? No Replace the lever of the write sensor. ▼ • Yes Does the entrance belt sensor work properly? (Operate the sensor lever and verify the signal on the FSENS connector pin on the engine board (K73 PWB).
2-4 Paper Eject Jam • Does the paper jam occur immediately after the printer is powered on? • Yes Is the paper jammed at the ejection sensor? Yes Remove the jammed paper. ▼ • No Does the lever of the ejection sensor operate normally? No Replace the ejection sensor lever. ▼ • Yes Does the ejection sensor work properly? (Operate the sensor lever and confirm that the sensor works properly or verify the signal on the PARTTEMP connector Pin 8 on the engine board (K73 PWB).
2-5 DUPLEX jam • Does the paper jam occur immediately after the printer is turned on? • Yes Is the paper jammed at the in sensor, rear sensor or front sensor in the DUPLEX unit? Yes Remove the jammed paper. ▼ • No Do the in sensor, rear sensor and front sensor in the DUPLEX unit operate properly? No Replace the defective sensor. ▼ • Yes Check the cable connections at the in sensor, rear sensor and front sensor of the DUPLEX unit, or replace the DUPLEX unit board (V73 PWB).
3 Paper Size Error • Is paper in the specified size used? No Use paper that complies with the specification. Yes Is the paper jammed at the entrance MT sensor or at the paper width sensor? Yes Remove the jammed paper. ▼ • Yes No ▼ • Yes No ▼ • Yes No ▼ • Yes No ▼ • Yes No ▼ • Yes Does the lever of the entrance MT sensor operate normally? Replace the defective sensor lever.
4 Image Drum Unit (IDU) Up/Down Error • Turn off the printer, wait a few seconds, then turn it on again. • Does each drum unit rotate properly while printing? • No Is the resistance of the IDU motor at the rated value (approx. 4.0 Ω)? No Replace the defective IDU motor. ▼ • Yes Is +32V supplied to the POWER connector Pins 7~10 on the engine board? No Replace the low-voltage power unit. ▼ • Yes Check cable connection, or replace the engine board.
5 Fuser Unit Error • Does the fuser error occur immediately after the printer is turned on? A • Yes Does the heat roller thermistor have a open or short circuit? (See Figure 6.1.) (at room temperature 0 °C~ 43 °C, approx. 190 ~ 980 Ω) Yes Replace the fuser unit. ▼ • No Does the back-up roller thermistor have a open or short circuit? (See Figure 6.1.) (at room temperature 0 °C~ 43 °C, approx. 190 ~ 980 Ω) Yes Replace the fuser unit. ▼ ▼ • ▼ • No No • ▼ • Does the fuser error occur about 3 min.
6 Fan Motor Error • Does the fan of the low-voltage power supply unit rotate after the printer is turned on? • Yes Does the error recur after the fan of the low-voltage power supply unit has been replaced? • ▼ • Yes Replace the low-voltage power supply unit.
6.5.3 Image troubleshooting When the printout images are not satisfactory as shown below, follow the troubleshooting procedures given in this section. Printout problem Flowchart No. Light or blurred images, or images in inappropriate color tone (Figure 6.2- A ) 1 Dark background (Figure 6.2- B ) 2 No images on print output (Figure 6.2- C ) 3 Band/stripes in black or color in the longitudinal direction (Figure 6.2- D ) 4 Band/stripes in white or irregular color in the longitudinal direction (Figure 6.
1 Light or blurred images or images in inappropriate color tone on the whole printout area (Figure 6.2- A ) • Is toner low? (Is the message "Toner Low" displayed?) Yes Supply toner. ▼ • No Is the specified paper used? No ▼ • Yes Use the specified paper. Is the lens of the LED head dirty? Yes Clean the LED head lens.
2 Dark background (Figure 6.2- B ) • Was each ID exposed to external light for a long time? Yes Replace the ID unit. ▼ • No Note: Reset the counter after replacement. Are the rollers in the fuser unit contaminated? Yes Replace the fuser unit. ▼ • No Adjust the setting of “MEDIA TYPE”. Light: 60 g/sq.m. Med. light: 64~74 g/sq.m. Medium: 75~90 g/sq.m. Med. heavy: 91~104 g/sq.m. Heavy: 105~122 g/sq.m. Ultra heavy: 123~175 g/sq.m.
3 Blank paper (Figure 6.2- C ) • Is each LED head assembly connected to the junction board (Y71 PWB) and Engine board (K73 PWB)correctly? No ▼ • Yes • Check the cable connection the LED assembly with the junction board (Y71 PWB) and engine board. Is +3.8V supplied to the following POWER connector pins on the junction board (Y71 PWB)? +3.8V: Pin 1, 2, 3, 4, 5, 6, 7, 8 Yes Is +3.
4 Band/stripes in black or color in the longitudinal direction (Figure 6.2- D ) • Is each LED head assembly connected to the junction board (Y71 PWB) correctly? No ▼ • Yes Connect the LED head assembly to the junction board correctly. Check the cable connection, or replace the LED head assembly. Recovered? Yes End ▼ • No Check the cable connection, or replace the junction board (Y71 PWB).
5 Band/stripes in white or irregular color in the longitudinal direction (Figure 6.2- F ) • Is each LED head lens contaminated? Yes Clean the LED head lens. ▼ • No Is each LED head assembly connected to the junction board (Y71 PWB) correctly? No ▼ • Yes Connect the LED head assembly to the junction board (Y71 PWB) correctly. Check the cable connection, or replace the LED head assembly. Recovered? Yes End ▼ • No Check the cable connection, or replace the junction board (Y71 PWB).
6 Poor fusing (Images are blurred or peeled off when touched with a hand.) • Is the specified paper used? No ▼ • Yes No ▼ • Yes Use the proper paper. Is the contact of the fuser unit connected correctly? Connect the contact of the fuser unit properly. Are the rollers in the fuser unit contaminated? Yes Replace the fuser unit. ▼ • No Is the “MEDIA TYPE” (MENU 1) set correctly?. Light: 60 g/sq.m. Med. light: 64~74 g/sq.m. Medium: 75~90 g/sq.m. Med. heavy: 91~104 g/sq.m. Heavy: 105~122 g/sq.m.
7 Cyclical printout defects (Figure 6.2- E ) Cycle 3.71 in. 1.95 in. 2.66in. 1.73 in. 4.45 in. 2.28 in. Defective Part Image Drum Developing Roller Toner Supply Roller Charge Roller Fuser Roller Transfer Roller Solution Replace the ID unit. Replace the ID unit. Replace the ID unit Replace the ID unit. Replace the fuser unit. Replace the belt cassette assembly. Note: After replacement of the ID unit, fuser unit or belt cassette unit, the corresponding counter will be reset. 41388601TH Rev.
8 Missing characters • Is the LED head lens contaminated? Yes Clean the lens of LED head. ▼ • No Is each LED head assembly connected to the junction board (Y71 PWB) correctly? No ▼ • Yes • Check the cable connection, and connect the LED head to the junction board correctly. Is +3.8V supplied to the following HEADPOW connector pins of the junction board (Y71 PWB)? +3.8V: Pin 1, 2, 3, 4, 5, 6, 7, 8 Yes Is +3.
9 Color Misalignment • Are any of the following gears broken? (Gear assy of ID unit, Multipurpose Tray, belt unit and belt motor) Yes Replace the broken gear assembly. ▼ • No Is each LED head unit connected to the junction board (Y71 PWB) correctly? No ▼ • Yes Connect the LED head unit correctly with the junction board. Check the cable connection, or replace the LED head assembly. Recovered? Yes End ▼ • No Check the cable connection, or replace the junction board (Y71 PWB).
0 Printout colors different from the original • Are the LED head lens contaminated? Yes Clean the LED head lens. ▼ • No Is each LED head assembly connected to the junction board (Y73 PWB) correctly? No ▼ • Yes • Check the cable connection (between each LED head and the junction board) and connect the LED assy to the junction board correctly. Is +3.8V supplied to the following HEADPOW connector pins of the junction board (Y71 PWB)? +3.8V: Pin 1, 2, 3, 4, 5, 6, 7, 8 Yes Is +3.
Ground Charge Roller Developing Roller Toner Supply Roller Figure 6.3 41388601TH Rev.
2 3 4 Yellow M Orange Between pins 1 and 2: 7.9Ω Between pins 3 and 4: 7.9Ω Black Black 1 M Main Motor (Y) Between pins 1 and 2: 2.4Ω Between pins 3 and 4: 2.4Ω 2 3 4 1 M 2 Main Motor (M) 3 4 Between pins 1 and 2: 2.4Ω Between pins 3 and 4: 2.4Ω WIRING DIAGRAM Transfer Belt Motor Resistance 7. 1 Illustration Resistance Check Circuit Diagram 7.1 41388601TH Rev.
41388601TH Rev.2 Unit Circuit Diagram Illustration Resistance 1 M Main Motor (C) Between pins 1 and 2: 2.4Ω Between pins 3 and 4: 2.4Ω 2 3 4 1 M 2 Between pins 1 and 2: 2.4Ω Between pins 3 and 4: 2.4Ω Main Motor (B) 3 4 1 M MT Resistration Motor 2 3 4 Between pins 1 and 2: 7.9Ω Between pins 3 and 4: 7.
41388601TH Rev.2 Unit Circuit Diagram 1 Fuser Motor 2 3 4 Illustration Resistance Yellow M Orange Between pins 1 and 2: 7.9Ω Between pins 3 and 4: 7.9Ω Black Black 1 M 2 Feeder Motor 3 Between pins 1 and 2: 7.9Ω or 8.4Ω Between pins 3 and 4: 7.9Ω or 8.
41388601TH Rev.
41388601TH Rev.2 Unit Circuit Diagram 1 +5 V 2 0V 1 +5 V 3 White M Black Red Yellow ID and Fuser M 2 0V Black 1 Upper roller Thermostat a Heater b Fuser Unit Resistance Red 3 FANALM-N CU Board Illustration 2 Lower roller Thermostat a Heater b Thermistor c c Fuse Center d Thermistor e d e Left 133 / f f Thermistor 1 ba Between pins a and b: Between pins c and d: 231.4kΩ Between pins e and f: 231.
7.2 Parts Layout on Boards (1) Print Engine Controller PWB (K73) SHUTTER FRPUCL RCL HOPFF ID BELTHET OPTN REG TR10P CUIF BELTSNS RSNS CPUFL1 JODEN PARTTEMP COVOPN FSENS DUPLEX DUCOV PSIZE HVOLT 41388601TH Rev.
(2) Main Controller PWB: CRM FAN PUIF 84 168 84 168 84 168 84 1 85 1 85 1 85 3 168 1 SDRAM DIMM 85 84 ROM 1 4 85 1 3 85 1 2 85 11 168 84 A 168 84 B 168 C 1 2 A1 B1 C1 1 19 49 50 A36 B36 C36 PCICU 18 36 IDE 1 4 2 3 USB CENT 41388601TH Rev.
LED Control PWB (Y71-2 PWB) TNRSNSY PANEL TNRSNSK KPOW2 YPOW2 TNRSNSM TNRSNSC POWER STUCK MPOW2 CPOW2 (3) OPTN (4) Duplex Control PWB (V73- PWB) MOTOR MAIN1 CL2 CL1 SNS0 SNS1 (5) Control Panel PWB (X71- PWB) 41388601TH Rev.
(6) N71-PWB JODEN (7) Entrance Sensor PWB (R71- PWB) INSNS1 FSNS INSNS2 HUM (8) WRSNS TNR Paper Size Sensing PWB PXC (B73- PWB) SW1 SW2 SW3 SW4 CN11 (9) Sensor PWB (A73-PWB) CN1 LIFT HOP (10) Option I/F PWB (C73-PWB) MAIN1 SAVIF 41388601TH Rev.
8. PARTS LIST 25 22 21 21 24 8 21 23 21 7 21 17 21 19 19 17 30 42 6 21 31 28 17 21 21 21 17 19 5 17 17 21 19 19 41 21 15 17 19 26 14 20 19 13 11 12 19 4 9 19 1 19 2 3 19 Figure 8-1-1/3 41388601TH Rev.
16 19 10 17 C B 19 17 C C 17 A C B 18 A 18 Figure 8-1-2/3 41388601TH Rev.
44 34 39 33 40 38 39 44 32 36 37 35 27 Figure 8-1-3/3 41388601TH Rev.
Table 8-1-1/3 Main Assembly No. Patrs No.
Table 8-1-2/3 No. Patrs No.
Table 8-1-3/3 No. 30 Patrs No.
1 5 4 13 11 12 17 14 6 18 16 8 3 7 15 16 3 3 10 18 3 3 2 3 9 3 2 16 3 2 2 Figure 8-2 41388601TH Rev.
Table 8-2 Top Cover Assembly No. Parts No.
22 12 7 26 27 39 39 39 2 25 24 39 37 1 4 40 39 37 1 20 39 6 23 21 42 18 8 5 17 13 10 11 19 39 9 16 39 39 3 39 Figure 8-3-1/2 41388601TH Rev.
27 29 30 37 37 28 33 37 37 37 35 31 43 37 37 37 36 34 37 32 37 41 37 37 38 37 37 Figure 8-3-2/2 41388601TH Rev.
Table 8-3-1/2 Printer Unit Chassis No. Parts No.
Table 8-3-2/2 No. Parts No.
12 9 11 12 12 12 11 12 11 12 8 11 11 11 11 12 12 1 12 12 7 7 9 10 11 7 7 12 10 10 Figure 8-4-1/2 41388601TH Rev.
12 13 12 6 2 5 2 12 12 2 18 12 12 13 12 4 12 12 17 3 12 15 16 13 Figure 8-4-2/2 41388601TH Rev.
Table 8-4 Paper Tray Guide No. Parts No.
3 3 2 3 3 3 3 3 3 3 3 D C B A 4 4 4 D 4 C 4 E 3 4 B 3 A 1 4 E 3 3 4 3 4 Figure 8-5 41388601TH Rev.
Table 8-5 Duplex Unit No. 1 Parts No. Name Q’ty /Unit Recommended Q’ty/Year per 500 per 1000 per 2000 Remarks 41178201 Duplex Assy 1 - - - ODA 41178203 Duplex Assy 1 - - - OEL 41178207 Duplex Assy 1 - - - APS 2 4PB4043-4718P001 Screw (SP3×10) 2 - - - 3 4PB4083-2500P008 Screw (T3×8) 21 - - - 4 4PB4013-3100P006 Screw (M3×6) 9 - - - 41388601TH Rev.
21 9 20 22 23 24 1 7 25 7 7 9 7 19 Figure 8-6-1/2 41388601TH Rev.
12 12 12 6 2 5 2 12 12 2 6 18 * * * 12 4 12 * 12 * * 17 * 3* 12 12 15 * * 16 13 * These parts are not attached to the lowest tray. Figure 8-6-2/2 41388601TH Rev.
High Capacity Tray Unit, 2nd/3rd Tray Unit No. Parts No.
