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FS-C5015N/C5025N Service Manual

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3. 1 I z L 1 O N 2 i M e A ep c P AAA ee i Optional duplexer AS AA 1 U 42 16 17 ppm printer fp Y i EUR USA model IE 1 optional paper FM cee i feeder W Nee 4 gt A 20 22 ppm printer EF EUR USA model oe optional paper i i TAO OS eA A feeders lt _ Paper path i Main unit 9 4 08e A Paper path d Optional unit Figure 1 1 3Figure 1 1 3 Black drum unit Yellow drum unit Cyan drum unit Magenta drum unit Black developer unit Yellow developer unit Cyan developer unit Magenta developer unit 9 Black toner container 10 Yellow toner container 11 Cyan toner container DADAS 12 13 14 15 16 17 18 19 20 21 Magenta toner container Primary transfer unit Primary transfer cleaning unit MP tray MP tray feed unit Feed unit Fuser unit Controller box Face down tray unit vertical path Paper cassette 2HJ 2HK This page is intentionally left blank 1 2 1 2HJ 2HK Drum unit Note the following when handling or storing the drum drum unit Note the following when handling or storing the drum unit 1 2 3 4 When removing the drum unit never expose the drum surface to strong direct light Avoid abrupt changes in temperature and humidity Avoid exposure to any substance which is harmful to or may affect the quality of the drum D
4. nece cas codes ca enc ec idas 1 4 32 1 5 Assembly and Disassembly 1 5 1 Precautions for assembly and disassembly sse esse eee eee eee eee eee eee 1 5 1 Gli PRECAUTIONS 5 25 eL Pr 1 5 1 2 DIUM ventas E eee edna ey cab ek a ae seein een hes 1 5 1 3 T ner Contacta re ced set paa eaa eera eta ake ca tes Abed aes oe mien hee TEE AE EE ara aA 1 5 1 125 2 Outer COVES eb A A A i d Ec doceo Pee 1 5 2 1 Detaching and refitting the top cover enne nnnm nnne nennen 1 5 2 2 Detaching and refitting the rear cover eene 1 5 3 3 Detaching and refitting the right cover enne 1 5 4 4 Detaching and refitting the left cover emen mener 1 5 5 1 523 Paper TOC Unites O DRM NER PARC MERI REP S tie ed 1 5 6 1 Detaching and refitting the paper feed unit sese eee eee eee eee eee eee 1 5 6 2 Detaching and refitting the paper feed roller 1 5 7 3 Detaching and refitting the retard roller 1 5 8 4 Detaching and refitting the secondary transfer roller 1 5 9 125 4 MP tray teed UN ME e iius eei rere eee fee cute e e ees e e rc tee eo ta ue door xod d 1 5 10 1 Detaching and refitting the MP tray feed unit eme 1 5 10 2 Detaching and refitting the MP tray feed roller ses 1 5 11 1 5 5 Developing SECOND p eee ER EN 1 5 12 1 Detaching and refitting the developer unit emen 1 5 12 125 6 Drum e sla ee ee E e E ete eerie CAE 1 5 13 1 Detaching and refitting the drum unit emn 1 5 13 2
5. 45 Registration clutch sse eee eee eee AG Feed clutch i ettet A7 AG inlet ien rete 48 Expanding memory optional 49 Expanding memory card optional 50 Expanding board optional 1 1647 ppm printer EUR USA model only 2 2 2 Interconnects the engine controller PWB and the electrical parts Consists the top cover paper feed unit switch side cover switch top cover switch 1 paper gauge switch 1 2 registration sensor and wiring relay circuit Indicates the LCD message display and LED indicators Controls key inputs Generates the developing magnet roller bias developing sleeve bias and secondary transfer bias Generates the main charger high voltage and primary transfer rollers bias Detects the waste toner box being full Section of LED light emitting for waste toner detection Detects paper misfeed in the MP tray Detects the ambient humidity Detects the ambient temperature Detects the timing of primary feeding Detects the paper remaining amount level Detects the paper remaining amount level Detects whether the face down tray is full Measures image density for color calibration Installing detection of optional envelope feeder Shuts off 24 V power line when the top cover is opened Detects the top cover open Detects the top cover and left side cover open Shuts off 24 V power line when the left side cover is opened Turn
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7. Dirty heat roller and press roller press belt Clean the heat roller and press roller press belt See page 1 4 18 1 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 5 Image is too light Print example Causes Check procedures corrective measures Defec tive develop ing bias output Defective developer Check the four colors of image by using the test page of ser vice mode If the defect appears on a particular color replace the developer for that color See pages 1 3 14 and 1 5 12 Defective bias high volt age PWB Replace the bias high voltage PWB See page 1 5 46 Defective engine control ler PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective main controller PWB Replace the main controller PWB A0171 See page 1 5 40 Defective drum unit Replace the drum unit See page 1 5 13 Dirty drum Perform the drum surface refreshing See page 1 3 17 Defec tive color calibra tion Dirty sensing surface of the toner ID sensor Clean the sensing surface of the toner ID sensor The printer environment considerably changed since an automatic cali bration was made Perform the color calibration of service mode See page 1 3 14 Dirty SELFOC lens of LED print head Clean the SELFOC lens of LED print head by using lens cleaner 1 4 25 2HJ 2HK 6 Th
8. Defective power supply PWB Replace the power supply PWB See page 1 5 41 Defective installa tion condition of fuser thermistor 1 Check the installation condition of fuser ther mistor 1 if there is trouble remedy or replace See page 1 5 26 1 5 33 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 1 4 13 2HJ 2HK 1 Code Contents Remarks Causes Check procedures corrective measures 6100 Fuser temperature time out error Defective installa Check the installation condition of fuser ther press roller tion condition of mistor 2 if there is trouble remedy or Doing the control which turns on the fuser thermistor 2 replace See page 1 5 26 fuser heater lamp 2 which is built in to the press roller of the fuser unit the te 2 a the fuser thermostat 2 See page 1 fuser temperature which fuser ther oPeraled i mistor 2 detects stipulated temperature Defective engine Replace the engine controller PWB A0004 did not rise within stipulated time controller PWB See page 1 5 41 A0004 Defective power Replace the power supply PWB See page supply PWB 1 5 41 Defective fuser Replace the fuser PWB KP 970 PWB Defective harness Check the harness of the fuser thermistor 1 of the fuser ther check the connection YC693 connector of mistor 2 or poor the fuser PWB KP 970 if there is trouble contact of the con remedy or replace nector termin
9. Printable area setting Top offset Left offset Page length Page width Left offset for each paper source MP tray Cassette 1 Cassette 2 Cassette 3 Cassette 4 Envelope feeder Duplexer Top offset for each paper source MP tray Cassette 1 Cassette 2 Cassette 3 Cassette 4 Duplexer Offset for page rotation Top offset Left offset Optional paper feeder life counter Paper feeder 1 Paper feeder 2 Optional paper feeder life counter Paper feeder 3 6o Optional paper eject unit life counter Duplexer Drum life counter Black Cyan Magenta Yellow Primary transfer unit life counter Developing units counter Black Cyan Magenta Yellow 1 3 5 2HJ 2JK Service items Items Description Description Color print counter Maintenance kit counter Optional unit software version Paper feeder1 Paper feeder 2 Paper feeder 3 Envelope feeder Duplexer Drum ID Black Cyan Magenta Yellow LED print head compensation value Developer refreshing mode counter Black Cyan Magenta Yellow Optional paper feeder bulk stacker installation First 2 bytes Bit 0 MPF Bit 1 to 6 Paper feeder 1 to 6 Bit 7 Duplexer Bit 8 Reserved Bit 9 Envelope feeder Bit 10 to 15 Reserved Second 2 bytes Bit 0 Face up Bit 1 Face down Bit 2 to 15 Reserved Operation panel message lan guage
10. 30 Paper does not arrive at the paper feeder 1 paper sensor 42 Cassette 4 31 Paper does not pass the paper feeder 1 paper sensor 32 32 Paper remains at the paper feeder 1 paper sensor when power is turned on 48 40 Paper does not arrive at the paper feeder 2 paper sensor 33 Cassette 3 40 Paper does not arrive at the paper feeder 2 paper sensor 34 Cassette 4 41 Paper does not pass the paper feeder 2 paper sensor 33 42 Paper remains at the paper feeder 2 paper sensor when power is turned on 33 50 Paper does not arrive at the paper feeder 3 paper sensor 34 Cassette 4 51 Paper does not pass the paper feeder 3 paper sensor 34 52 Paper remains at the paper feeder 3 paper sensor when power is turned on 34 A1 Paper does not arrive at the vertical path sensor 48 duplexer A2 Paper does not arrive at the switchback sensor 49 duplexer A3 Paper does not pass the duplex refeed sensor 49 duplexer A4 Paper does not arrive at the duplexer refeed eject sensor 49 A5 Paper does not pass the duplexer refeed rear edge sensor 49 A6 Paper does not pass the duplexer refeed eject sensor 49 AT Duplexer overflow Third sheet is commanded when second sheet remains 49 A9 Paper remains in the duplexer when power is turned on 49 E0 Paper misfeed occurs due to forced stop when an error occurs during printing FO to FE Paper misfeed by another cause Values within indicate paper
11. PMSG command setting decimal Current temperature Current humidity MAC address Fixed asset number Media type attributes Media type setting value from 1 to 28 paper weight unused media type are always 0x00 Memory SPD information slot 1 Calibration information 1 CTO1 Average background S wave Average background P wave Dark potential S wave Dark potential P wave e es es 6 92 63 E 69 1 3 6 Calibration information 2 CTO2 to CTO9 VO output data information Each 2 bytes in the following order 99 6 95 85 70 55 40 27 15 CT02 S wave background Magenta P wave background Magenta CT03 S wave background Cyan P wave background Cyan CT04 S wave background Yellow P wave background Yellow CT05 S wave background Black P wave background Black CTO6 S wave patch Magenta P wave patch Magenta CTO07 S wave patch Cyan P wave patch Cyan CTO8 S wave patch Yellow P wave patch Yellow CTO9 S wave patch Black P wave patch Black 2HJ 2JK Service items Items Description Description Calibration information 3 CT10 to CT13 Measure bias data infor mation Each 2 bytes in the following order 450V 400V 350V Beta CT10 S wave background Magenta S wave background Cyan S wave background Yellow S wave background Black CT11 P wave background Magenta P wave background Cyan P wave background Yellow P wa
12. 1 2 3 4 5 2009 The primary transfer belt is made of stratum fluorine coat stratum elastic and stratum resin in the order from the surface to the bottom These substances ensure smooth paper travel as well as the durability of the belt itself Moi Primary transfer belt gt Stratum fluorine coated Y Stratum elasticity Stratum resin Figure 2 1 25Primary transfer unit 2 1 19 2HJ 2HK Figure 2 1 26Primary transfer section block diagram 1 Tension roller 7 Primary transfer roller black 2 Backup roller 8 Primary transfer belt 3 Drive base 9 Backup gear 29H 4 Primary transfer roller magenta 10 Image gear 22H 5 Primary transfer roller cyan 11 Image gear 28S 6 Primary transfer roller yellow 12 Toner ID sensor mounted on the main frame O Primary transfer roller 3 Toner ID eruat A sensor n Engine controller PWB NN IDSW YC11 11 IDPW DREF YC11 12 YC11 13 Bias high voltage PWB Output Primary 7 HVADATD e Output transfer bias Pes ome 8 HVACLKD Vid output circuit IC501 9 HVALATD YC6 9 Output 600 V DC variable Figure 2 1 27 Primary transfer section block diagram 2 1 20 2HJ 2HK 2 Primary transfer cleaning unit The primary transfer cleaning unit is composed of the fur brush brush cleaning roller cleaning blade and cleaning screw After
13. 13 Remove the fuser upper cover right pres sure lever and left pressure lever 14 Remove the fuser stay Fuser stay Right pressure lever Pressure Left pressure lever Figure 1 5 44 1 5 28 2HJ 2HK 15 Remove the two screws and then remove the fuser thermostat 1 16 Remove the one screw and then remove the fuser thermistor 1 Fuser thermostat 1 Figure 1 5 45 17 Remove the user lower guide 18 Remove the one tab 19 Remove the two screws and then remove the fuser thermostat 2 20 Remove the one screw and then remove the fuser thermistor 2 Screws Figure 1 5 46 1 5 29 2HJ 2HK 21 Remove the one C ring fuser gear one C ring one bush and one bearing 22 Remove the one C ring one bush and one bearing 23 Remove the heat roller C ring Fuser gear Sy PS Heat roller Bush Bearing Figure 1 5 47 1 5 30 2HJ 2HK 24 Remove the two bushes and two bearings 25 Remove the right stay left stay and press roller 26 Check or replace the fuser thermistor 1 and 2 fuser thermostat 1 and 2 fuser heater lamp 1 and 2 heat roller and press roller then refit all the removed parts Right stay KN Press roller bM Left stay Yr G C ring x Figure 1 5 48 1 5 81 2HJ 2HK 1 1 5 9 Fuser unit 20 22 ppm printer EUR USA model 1 Detaching and refitting the fuser unit Procedure 1 Remove the rear cover See page 1 5 3
14. A e ZA A ZA l A Drum unit Figure 1 5 22 2HJ 2HK 10 Unlock the connector hook on the LED print head and then pull the white FFC out 11 Using the same procedure pull the blue FFC out FFC white ts colored LED print head Nee FFC blue TS Blue colored UNLOCK iN E LED print head Connector hook Connector hook Figure 1 5 23 12 Insert the new blue FFC vertically into the connector Ensure the FFC is in line with the MER New FFC blue connector and not slanted i m Blue colored Figure 1 5 24 1 5 17 2HJ 2HK 13 Turn the connector hook down to lock the new blue FFC 14 Using the same procedure connect the new white FFC to the connector NG Connector hook Figure 1 5 25 15 Attach the LED print head into the new drum unit LED print head 16 Attach the LED print head cover into the new drum unit New drum unit Figure 1 5 27 1 5 18 17 Pass the blue and white FFCs to opening of the LED print head cover 18 Store the FFCs in the crevice between LED print head metal and sponge 19 Close the LED print head cover and hold the three hooks 20 Check that the press springs on both sides of the LED print head are not buckling NOTE If the press springs are buckling pushdown on the central part of the LED print head cover to correct the buckle 2HJ 2HK FFC blue Hook Hook ES ARDE E S FFC white LED print head
15. Causes 2HJ 2HK Check procedures corrective measures 1 Close top cover display is not cancelled to closing the top cover Right edge of the top cover floating it is not closed completely Close the top cover securely Defective top cover switch 2 Replace the top cover switch 2 Defective top cover paper feed unit switch SW701 of the sensor PWB A0001 Replace the sensor PWB A0001 Defective harness 803195 between engine controller PWB A0004 and top cover Switch 2 or poor contact of the connector terminals Check the continuity of the harness S03195 check the connec tion YC11 connector of the engine controller PWB A0004 if there is trouble remedy or replace Malfunctioning interlock rod that interfaces between the top cover and the top cover paper feed unit switch SW701 Check to see if the interlock rod malfunctions If it malfunctions repair it Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective harness 803197 between engine controller PWB A0004 and sensor PWB A0001 or poor con tact of the connector termi nals Check the continuity of the harness S03197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace 2 Close side cover display
16. Terminal 1 5 35 2HJ 2HK 18 While sliding direction of the arrow 1 the exit guide and then detach the axis 19 While detaching the axis and then remove the exit guide 20 Turn the fuser unit bottom side up 21 While unlatching the two latches and then remove the entrance guide Figure 1 5 55 1 5 36 2HJ 2HK 22 Remove the two press plates and two pres suresprings 7 Pressure spring 25 B U Figure 1 5 56 23 Remove the two screws and then remove the fuser B stay 24 Remove the two screws and then remove the fuser C stay Figure 1 5 57 1 5 37 2HJ 2HK 25 Remove the press belt assembly Press belt assembly Figure 1 5 58 26 Remove the two roller holders with pitch plates 27 Remove the belt roller A and belt roller 28 Remove the each two bearings Roller holder Pitch plate Bearing Belt roller A 0506 Belt roller PC Pitch plate de n We E Press belt x SL Roller holder Figure 1 5 59 1 5 38 29 Remove the two screws and then remove the exit UP guide 30 Remove the two C rings 31 Remove the stopper ring and heat Z43S gear 32 Remove the two bearings 33 Remove the heat roller with bushes 34 Remove the two bushes from heat roller Exit UP guide Screw A Heat roller Figure 1 5 60 2HJ 2HK Heat Z43S gear C ring 1 5 39 2HJ 2HK 1 5 10 PWBs 1 Detaching and refitting the main controller PWB Proce
17. 1 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 2HJ 2JK Service items gt gt Print Event Log Description Printing an event log EVENT LOG Description Prints the history of paper misfeeds and self diagnostic errors including up to 16 items from the latest occurrence of such an error If the number of errors exceeds 16 errors will be deleted sequentially from the oldest one Purpose To allow machine malfunction analysis based on the frequency of paper misfeeds and self diagnostic errors Procedure 1 Enter the service mode gt gt Print Event log 2 Press the OK key Message gt gt Print Event Log will be displayed 3 Press the OK key A sheet of event log will be printed a 2F3 1100 001 001 2HK_1000 001 012 2HJ A000 001 002 2HK 3100 001 004 01 Firmware version 2HK 30000 001 018 O 6 Released 28 Apr 2006 Printed Page s 12345 DN SPL6400088 SPL6400148 SPL6400152 SPL6400142 Paper Jam Log Service Call Log Count Service Code 6 8 11234 01 6000 5 7 10000 01 6000 A 6 9999 01 6000 5 9998 01 6000 3 4 9997 01 6000 2 3 9996 01 6000 1110 48 01 88 01 01 E 5953 301 6000 0 a b o d e f 1 9994 01 6000 9 9994 10 48 01 88 01 01 02 Maintenance Log 8 9993 10 48 01 88 01 01 Count item S 9992 10 48 01 88 01 01 8 11234 02 00 6 9991 10 48 01 88 01 01 7 10000 02 00 5 9990 10 48 01 88 01 01 6 22 2 02x00 5 9998 02 00 4 9989 10 48 01 88
18. 2 Remove the right cover and left cover See page 1 5 4 and 1 5 5 3 Remove the two screws and then remove the fuser unit 4 Check or replace the fuser unit and then refit all the removed parts Figure 1 5 49 1 5 32 2HJ 2HK 2 Detaching and refitting the fuser thermistor 1 fuser thermostat 1 fuser heater lamp heat roller and press belt Procedure 1 Remove the fuser unit See previous page 2 Remove the one screw and then the termi nal and nut LL oC Remove the two connectors Remove the wire from wire clamp While unlatching the latch and then remove the fuser L cover of Ww Wire clamp Figure 1 5 51 1 5 33 2HJ 2HK 6 Remove the one tab from the terminal 7 Remove the Lamp hold seal L 8 Remove the wire form the two wire clamps 9 Remove the one screw 10 While unlatching the latch and then detach the fuser R cover 11 Unhook the projection and then remove the fuser R cover 12 Remove the wire from the fuser R cover and Fuser gear sleeve 13 Remove the heater lamp Fuser R cover Heater lamp Fuser gear sleeve Latch Lamp hold seal L Figure 1 5 52 1 5 34 14 Remove the one tab from the terminal 15 While removing the fuser UP cover and then remove the wire 16 Remove the one screw and then remove the fuser thermistor 1 17 Remove the two screws and then remove the fuser thermostat 1 Screws Figure 1 5 53 2HJ 2HK
19. 4 HVCLK3 H 5 HVCLK4 Output CN5 m Output CN9 D A 6 HVBDATD Ei E converter 7 HVBCLKD 1 developer IC501 8 HVBLATD 110 i Ce xi Output CN6 N Output Developing put 1CN10 magnet bias BEER DS output circuit n Magenta 4 7 developer i L 3 Output its N sl EA Output CN7 l 7 Engine relay 42 Output CN11 PWB Bias high voltage PWB TNSEN1 TNSEN2 TNSENS3 TNSEN4 Output Approximately 400 V DC Output 100 V DC and 1 6 kV p p rectangular wave 3 kHz Figure 2 1 12Developing section block diagram YC5 2 YC5 3 YC5 4 YC5 5 YC5 6 YC5 7 YC5 8 YC4 25 YC4 21 YC4 11 YC4 10 2HJ 2HK 2 Touch down developing method Touchdown development system is a development system having the best of both mono component system and dual component system Dual component developer which is a powder of mixture of toner and carrier powder is continuously agitated by mixer screws A and B in the toner hopper in the developer unit The toner and carrier powder are adsorbed to each other by means of electrostatic charge developed by the friction when they are stirred The developing magnet roller is comprised of a magnet and a sleeve which revolves coaxially with the magnet The developer powder forms brushes of toner and carrier on the magnet sleeve along the magnetic field centering the magnet The brushes are truncated to a constant length of height approximately 0 5 to 0 55 millimeters as they pass under the doctor
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21. Avoid direct light and high humidity 1 5 1 2HJ 2HK 1 5 2 Outer covers 1 Detaching and refitting the top cover Procedure 1 Open the rear cover 2 Open the top cover 3 Remove the opening and closing axis from the main unit frame and then remove the top cover 1 5 2 Figure 1 5 1 2HJ 2HK 2 Detaching and refitting the rear cover Procedure 1 Open the rear cover 2 Remove the opening and closing axis from the main unit frame and then remove the rear cover Rear cover Figure 1 5 2 2HJ 2HK 3 Detaching and refitting the right cover Procedure 1 Remove the top cover See page 1 5 2 2 Remove the one screw Right cover 3 Remove the paper feed unit See page 1 5 2 Right cover 4 Using a flat blade screwdriver unlatch the right cover at the nine positions as shown in the diagram Figure 1 5 4 2HJ 2HK 4 Detaching and refitting the left cover Procedure 1 2 3 4 5 Waste toner box Remove the top cover See page 1 5 2 Left cover Lock lever Open the left side cover and then remove the one screw Remove the waste toner box To remove waste toner box press the lock lever in Remove the paper feed unit See page 1 5 6 Using a flat blade screwdriver unlatch the right cover at the nine positions as shown in the diagram I ll B Left cover SS Figure 1 5 6 1 5 5 2HJ 2HK 1 5 3 Paper fee
22. C 71 6 F 60 RH Paper feed System One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m 0 11 um 16 28lb Bond MP tray 100 sheets 80 g m 0 11 um 16lb Bond 1101lb Index Paper eject system Face down 250 sheets 80 g m 0 11 um equipped with a face down paper full sen sor Face up 250 sheets Optional face up tray PT 300 must be installed 100 sheets when the optional duplexer is installed Photoconductor OPC drum diameter 30 mm Charging system Scorotron positive charging Light source eeeeeees LED Developing system Touch down development method Developer Two component Toner replenishing Automatic from the toner container Transfer system Primary transfer Transfer belt negative charged Secondary transfer Transfer roller negative charged Separation system Small radius curvature separation Fixing system sesss Heat roller system Oil less Heat roller diameter 36 mm 500 W halogen heater lamp Pressure roller diameter 36 mm 350 W halogen heater lamp Charge erasing system Exposure by eraser lamp LED Cleaning system Drum Counter blade Primary transfer belt Fur brush 1 1 1 2HJ 2HK 1 Con
23. R O C Phone 02 87511560 KYOCERA MITA Corporation 2 28 1 chome Tamatsukuri Chuo ku Osaka 540 8585 Japan Phone 06 6764 3555 http www kyoceramita com KYOCERA MITA AMERICA INC Headquarters 225 Sand Road Fairfield New Jersey 07004 0008 TEL 973 808 8444 FAX 973 882 6000 New York Branch 1410 Broadway 23rd floor New York NY 10018 TEL 917 286 5400 FAX 917 286 5402 Northeastern Region 225 Sand Road Fairfield New Jersey 07004 0008 TEL 973 808 8444 FAX 973 882 4401 Midwestern Region 201 Hansen Court Suite 119 Wood Dale Illinois 60191 TEL 630 238 9982 FAX 630 238 9487 Western Region 14101 Alton Parkway Irvine California 92618 7006 TEL 949 457 9000 FAX 949 457 9119 KYOCERA MITA CANADA LTD 6120 Kestrel Road Mississauga Ontario L5T 1S8 Canada TEL 905 670 4425 FAX 905 670 8116 KYOCERA MITA MEXICO S A DE C V Av 16 de Septiembre 407 Col Santa In s Azcapotzalco M xico D F 02130 M xico TEL 55 5383 2741 FAX 55 5383 7804 2006 KYOCERA MITA Corporation http www kyoceramita com tl KYOCERG is a trademark of Kyocera Corporation Southeastern Region 1500 Oakbrook Drive Norcross Georgia 30093 TEL 770 729 9786 FAX 770 729 9873 Southwestern Region 2825 West Story Road Irving Texas 75038 5299 TEL 972 550 8987 FAX 972 252 9786 National Operation Center amp National Traini
24. Replacing the LED print head and drum Unse sese eee eee eee eee 1 5 15 1 577 Primary transfer section inerti ede dsediapansusdeedeeseslactanieatasceacaencensuacseatasendssene 1 5 22 1 Detaching and refitting the primary transfer unit sese eee eee eee eee eee eee eee eee ee 1 5 22 2 Detaching and refitting the primary transfer unit sese eee eee eee eee eee eee eee eee eee 1 5 22 3 Replacing the primary transfer Unit sees eee eee eee eee eee eee 1 5 23 4 Detaching and refitting the primary transfer cleaning unit e 1 5 24 1 5 8 Fuser unit 16 17 ppm printer EUR USA modell sese 1 5 25 1 Detaching and refitting the fuser unit mener 1 5 25 2 Detaching and refitting the fuser thermistor 1 and 2 fuser thermostat 1 and 2 fuser heater lamp 1 and 2 heat roller and press roller 1 5 26 1 5 9 Fuser unit 20 22 ppm printer EUR USA model sse 1 5 32 1 Detaching and refitting the fuser unit menn rennen 1 5 32 2 Detaching and refitting the fuser thermistor 1 fuser thermostat 1 fuser heater lamp heat rollerzarid press belt 5 2 mee et rer etre mee eer e ee de eee 1 5 33 1 5 10 PWBS ionem euet adbuc celal es deca Lido 1 5 40 1 Detaching and refitting the main controller PWD sees eee eee eee eee eee 1 5 40 2 Detaching and refitting the engine controller PWB and power supply PWB sess 1 5 41 3 Detaching and refitting the LED print heads
25. check the connec tion YC902 connector of the power supply PWB if there is trouble remedy or replace Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective power supply PWB Replace the power supply PWB See page 1 5 41 1 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 1 4 31 2HJ 2HK 1 1 4 5 Problem Mechanical problems Causes check procedures Corrective measures 1 No primary paper feed Check if the surfaces of the following rollers are dirty with paper powder pickup roller feed roller retard roller and MP feed roller Clean with isopropyl alcohol See page 1 5 7 and 1 5 11 Check if the pickup roller feed roller retard roller and MP feed roller are deformed Check visually and replace any deformed rollers See page 1 5 7 and 1 5 11 Defective installation position of paper feed drive unit or MP tray paper feed unit Check the installation position of paper feed drive unit or MP tray paper feed unit See page 1 5 48 or 1 5 10 2 No secondary paper feed Check if the surfaces of the upper and lower registration rollers are dirty with paper pow der Clean with isopropyl alcohol Defective installation position of paper feed drive unit or MP tray paper feed unit Check the installation position of paper feed drive unit or MP tray paper feed unit See page 1 5 48
26. energization pulse 13 TNM3DR O 0V 24V DC Toner motor 3 yellow On Off 14 ST3AN O 0 24 V DC pulse Drum motor 3 yellow energization pulse 15 424V2 O 24V DC 24 V DC power output 16 ST3B O 0 24 V DC pulse Drum motor 3 yellow energization pulse 17 24V2 O 24V DC 24 V DC power output 18 ST3A O 0 24 V DC pulse Drum motor 3 yellow energization pulse 19 GND Ground 20 GND J Ground 21 TNSEN2 Analog Toner sensor 2 cyan detection voltage input 22 HFANDR O 0 24V DC Main fan motor On Off 23 TNM2DR O 0 24 V DC Toner motor 2 cyan On Off 24 OZFANDR O 0 24V DC Ozone fan motor 1 2 and drum motors cooling fan motor On Off 25 TNSEN1 Analog Toner sensor 1 magenta detection voltage input 26 TNM1DR O 0 24 V DC Toner motor 1 magenta On Off 27 ST2A O 0 24 V DC pulse Drum motor 2 cyan energization pulse 28 ST1BN O 24VDC Drum motor 1 magenta energizatione pulse 29 ST2B O 0 24V DC pulse Drum motor 2 cyan energization pulse 30 ST1AN O 24V DC Drum motor 1 magenta energization pulse 31 ST2AN O 0 24 V DC pulse Drum motor 2 cyan energization pulse 32 ST1B O 0 24V DC pulse Drum motor 1 magenta energization pulse 33 ST2BN O 0 24 V DC pulse Drum motor 2 cyan energization pulse 34 STIA O 0 24 V DC pulse Drum motor 1 magenta energization pulse 2 3 5 2HJ 2HK Connector Pin Signal y o Voltage Description YC5 1 24V2 O 24V DC 24 V DC powe
27. i LIVE Fuser heater Fuser yc901 10 HEAT1DR S lamp 1 thermostat 1 COM Ae vcg01 11 ZCROSS Fuser motor ee eee STFSA STFSAM STFSB STFSBN paper feed unit 2HJ 2HK 1 Engine controller PWB YC12 6 YC12 3 YC12 7 YC12 5 YC12 1 YC12 2 YC12 10 YC12 9 YC11 18 YC11 19 YC11 20 YC11 21 Figure 2 1 40Fuser unit block diagram 20 22 ppm printer EUR USA model 2 1 29 2HJ 2HK This page is intentionally left blank 2 1 30 2HJ 2HK 2 2 1 Electrical parts layout 1 Main frame and controller box CONTROLLER BOX Figure 2 2 1Main frame and controller box 1 Main controller PWD sse eee Controls the software such as the print data processing and provides the interface with computers 2 Engine controller PWB Controls printer hardware such as high voltage bias output control paper conveying system control and fuser temperature control etc 3 Power supply PWB eene Generates 3 3 V DC 5V DC and 24 V DC power source Controls the fuser heater lamp 1 and 2 4 LED print heads relay PWB Consists the LED print head control circuit and wiring relay circuit between engine controller PWB and drum units 2 2 1 2HJ 2HK 1 Engine relay PWB eese Sensor PWB ue ert cec oo 7 Operation panel PWD eee ee
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29. 1 The black toner container has been replaced once 1 3 13 2HJ 2JK Service items gt gt Color Calibration Description Execution of color calibration Description Executing the density of color using Purpose To carry out color calibration manually besides it can be carried out automatically each time the printer is turned on Procedure 1 Enter the service mode gt gt Color Calibration 2 Press the OK key twice The color calibration starts and automatically finishes Completion gt gt Print Test Page 1 3 14 Printing a test page Description Four colors are printed respectively with halftones of three different levels Purpose To check the activation of the developer and drum units of four colors Procedure 1 Enter the service mode gt gt Printing Test Page 2 Press the OK key twice The test page is printed Completion 16 256 Density 24 256 Black 32 256 r Cyan Magenta Green Yellow 1 Since focusing in yellow is hardly readable yellow is mixed with cyan for more readability resulting in green 2 Each portion of colors has three different magnitude of halftones bands If focus is excessively lost dots are not recognizable with the 16 256 band resulting in uneven density It also results in vertical streaks in the 24 256 and or 32 256 bands Figure 1 3 7Test page 2HJ 2JK 1 Service items gt gt Paper feed Special De
30. Causes Check procedures corrective measures 7413 Magenta drum unit non installing Defective harness Check the connection of the magenta drum 1 4 20 error The EEPROM U401 on the drum PWB 1 KP 972 inside the magenta drum unit does not communicate normally The incompatible drum unit is installed to the printer between drum PWB 1 KP 972 and printer main unit or poor contact of the connector termi nals unit and the printer main unit check the con tinuity of the harness S03211 if there is trouble remedy or replace Installing the drum unit which is incompatible with the printer specifi cation Install the compatible drum unit to the printer Defective drum PWB 1 KP 972 Replace the drum PWB 1 KP 972 Defective engine controller PWB Replace the engine controller PWB A0004 See page 1 5 41 A0004 Defective LED print Replace the LED print heads relay PWB heads relay PWB A0176 See page 1 5 44 A0176 Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness S03214 check the connection YC3 con nector of the engine controller PWB A0004 if there is trouble remedy or replace Contents 2HJ 2HK Remarks Causes Check procedures corrective measures Yellow drum unit non installing error The EEPROM
31. Fuser heater lamps control J U13 Abnormal temperature Power detection circuit U1 supply PWB Controller box Fuser thermistor signals fan motor driver 3 3V circuit Q39 5V 24V Sleep mode 24V Main charger control circuit Sleep signal Toner motor Clutch driver Clutches driver circuit circuit Q39 Q14 Q16 Q40 Feed Q15 Q17 Q41 motor Q20 Q22 Feed motor Fuser Q21 Q23 Polar driver IC U21 motor Drum motor driver IC U22 Naci driver IC U14 AA U15 Optional U16 J aa eeder U17 duplexer Transfer charger control Bias high Primary transfer 3 mem motor driver IC U18 ensor signals voltage Fan motor PWB Tr tor D A converter driver circuit U28 Q27 Analog U24 U25 Toner sensors signals Figure 2 3 2Engine controller PWB block diagram Toner ID sensor 2 3 3 2HJ 2HK 1 Connector YC2 Connected to the sen sor PWB Signa 24V1 24V1 24V1 24V1 GND GND 24V2 24V2 24V2 5V2 REGPAPN PAPVOLO PAPVOL1 TCOVOP CASO CAS1 CAS2 Voltage Description 24 V DC 24 V DC power output 24 V DC 24 V DC power output 24 V DC 24 V DC power output 24 V DC 24 V DC power output Ground Ground 24 V DC 24 V DC power output via top cover paper feed unit 24 V DC 24 V DC power output via top cover paper feed unit 24 V DC 24 V DC power output via top cover paper feed unit 5 V DC 5 V DC power output 0
32. Optional interface slot Network interface card Screws Figure 1 2 15 Network interface card Network cable Figure 1 2 16 1 2 8 Installing the hard disk unit optional lt Procedure gt 1 Turn off printer power 2 Remove the two screws and remove the optional interface slot cover 3 Insert the hard disk unit into the optional interface slot 4 Use the two screws to secure the hard disk unit 5 Format the hard disk unit Refer to the operation guide JH li 2HJ 2HK Optional interface slot Hard disk unit Screws Figure 1 2 17 1 2 11 2HJ 2HK This page is intentionally left blank 1 2 12 1 3 1 Maintenance mode 2HJ 2JK 1 The printer is equipped with various service mode that can be accessed with the MENU key operation on the operation panel 1 Executing a maintenance item Message display Ready Press the MENU key Print Menu Map 2 Press the A or Y key several times until Others is displayed Others 3 Press the K key gt MSG Language English Press the A or Y key several times until gt Service gt is displayed gt Service gt Press the gt key Service mode items gt gt Print Status Page gt gt Print Event Log gt gt Color Calibration gt gt Print Test Page To scroll these items press the V or A key repeated
33. PWB A0176 See page 1 5 44 1 4 9 2HJ 2HK Code Contents Diui dii Causes Check procedures corrective measures 5303 Eraser lamp 1 error magenta drum Defective eraser Replace the eraser lamp 1 PWB KP 1 4 10 unit The eraser lamp 1 PWB KP 1090 of the magenta drum unit does not com municate with the engine controller PWB A0004 normally lamp 1 PWB KP 1090 1090 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective drum PWB 1 KP 972 Replace the magenta drum unit See page 1 5 13 Defective harness 803212 between drum PWB 1 KP 972 and eraser lamp 1 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 1 KP 972 if there is trouble remedy or replace Defective harness 803214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the connection YC3 con nector of the engine controller PWB A0004 if there is trouble remedy or replace Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 2HJ 2HK Code Contents Remarks Causes Check procedures corrective measures 5304 Eraser lamp 3 error yellow drum Defective
34. U401 on the drum PWB 3 KP 972 inside the yellow drum unit does not communicate normally The incompatible drum unit is installed to the printer Defective harness between drum PWB 3 KP 972 and printer main unit or poor contact of the connector termi nals Check the connection of the yellow drum unit and the printer main unit check the con tinuity of the harness S03211 if there is trouble remedy or replace Installing the drum unit which is incompatible with the printer specifi cation Install the compatible drum unit to the printer Defective drum PWB 3 KP 972 Replace the drum PWB 3 KP 972 Defective LED print heads relay PWB A0176 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness S03214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness S03214 check the connection YC3 con nector of the engine controller PWB A0004 if there is trouble remedy or replace Toner ID sensor error The detection signal of the toner ID sen sor was abnormal value Defective toner ID sensor Replace the toner ID sensor Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 4
35. blade The developing magnet roller lies along the developing sleeve at the distance of 0 40 millimeters As the developing magnet roller revolves the brushes formed at pole N1 sweep the developing sleeve and the toner is transferred to the developing sleeve as it is attracted by the difference in potential between them The toner on the developing sleeve is approximately 70 micrometer in thickness The developing sleeve is located 0 23 millimeter from the drum The toner is transferred to the drum by means of the DC AC bias applied to the developing sleeve Developer unit 0 50 to 0 55 mm Doctor blade 2 0 40 mm Toner hopper 0 23 mm Main charger LED print head O Developing magnet roller Developing sleeve Developing sleeve Magnetic Developing brush sleeve Figure 2 1 13 2HJ 2HK 3 Developer drive stop mechanism Developer drive stop mechanism detaches the drive transmission of developers other than black developer at the time of monochrome printing and makes stop drives only black developer due to the movable part and the operation of developer drive stop motor with idle plate lever cam lever cam gear and idle arm plate etc which in main drive unit are provided Each drum motor gear K1 Y1 C1 M1 is always geared with each idle gear K2 Y2 C2 M2 so that the drive of idle gear is transmitted to de
36. display is not cancelled to replacing the waste toner box 1 4 30 The waste toner full sensor or the waste toner full sen sor PWB KP 974 the sensor section is dirty Replace the waste toner full sensor or the waste toner full sensor PWB KP 974 Defective harness 803209 between bias high voltage PWB KP 980 and waste toner full sensor PWB KP 974 or poor contact of the connector terminals Check the continuity of the harness S03209 check the connec tion of YC802 connector of the bias high voltage PWB KP 980 check the connection of YC682 connector of the waste toner full sensor PWB KP 974 if there is trouble remedy or replace Defective harness 803208 between waste toner full sensor and waste toner full sensor PWB KP 974 or poor contact of the connec tor terminals Check the continuity of the harness S03208 check the connec tion YC681 connector of the waste toner full sensor PWB KP 974 if there is trouble remedy or replace Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Problem Causes 2HJ 2HK 1 Check procedures corrective measures 6 The paper size is not recognized as the size set with the paper size dial Defective cassette size switch Replace the cassette size switch Defective sensor PWB A0001 Replace the sensor PWB A0001 Defective harness 803207 betwe
37. error The main controller PWB A0171 does not communicate to the engine control ler PWB A0004 normally Defective main con troller PWB A0171 Turn the power off on to restart the printer If the error is not resolved replace the main controller PWB A0171 See page 1 5 40 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 1 4 22 Main PWB video data control error Defective main PWB Turn the power off on to restart the printer If the error is not resolved replace the main controller PWB A0171 See page 1 5 40 1 4 3 Image formation problems 1 No image appears 2 No image appears entirely white entirely black See page 1 4 24 See page 1 4 24 6 The background is 7 White streaks are printed vertically colored See page 1 4 26 See page 1 4 26 11 The leading edge 12 Paper is wrinkled of image begins to print too early or too late E See page 1 4 28 See page 1 4 27 16 Colors are printed offset to each other See page 1 4 28 3 A specific color is 8 Black streaks are 13 Offset occurs 2HJ 2HK 4 The back side gets 5 Image is too light printed solid dirty See page 1 4 25 See page 1 4 24 See page 1 4 25 9 Streaks are printed 10 Spots are printed printed verti
38. five screws 10 Remove the two connectors and then removing the connection with the power supply PWB remove the engine controller PWB 1 5 42 Screws Controller box cover Screws Figure 1 5 64 Connector Figure 1 5 65 2HJ 2HK 11 The EEPROM U12 removing from the EEPROM U12 socket of the old engine EEPROM U12 controller PWB it does again to install in the socket of the new engine controller PWB Engine controller PWB Figure 1 5 66 12 Remove the three screws one terminal one Screw washer and then remove the power supply Power supply PWB PWB 13 Check or replace the engine controller PWB and power supply PWB then refit all the removed parts Figure 1 5 67 1 5 43 2HJ 2HK 3 Detaching and refitting the LED print heads relay PWB Procedure 1 Remove the left cover see page 1 5 5 2 Remove the one screw 3 Remove the two connectors and two tabs 4 Unlatch the four latches and then remove the LED print heads relay PWB 5 Check or replace the LED print heads relay PWB and then refit all the removed parts Latches LED print heads relay PWB Figure 1 5 68 1 5 44 2HJ 2HK 4 Detaching and refitting the main high voltage PWB Procedure 1 Remove the right cover See page 1 5 4 2 Unlatch the four latches and remove the one connector and then remove the main high voltage PWB 3 Check or replace the main high voltage PWB and then refit all the
39. head Step 12 The FFC connection to the printer Step 23 The positioning of the blue and white FFCs ensure they are in the correct order Step 23 Damage of FFC If test print is blurred or out of focus The state of press spring Step 20 1 5 21 2HJ 2HK 1 1 5 7 Primary transfer section 1 Detaching and refitting the primary transfer unit Procedure 1 m Remove the all developer and drum units See page 1 5 12 and 1 5 13 Place a paper on the primary transfer belt Hold the edge of the handle and then raise the handle s Hold the center of two handles by the both hands Remove the primary transfer unit from the printer Check or replace the primary transfer unit and then refit all the removed parts Mr Y Pee PIS P AN NV Handie cT Poo Ch 2 Primary transfer unit Figure 1 5 33 2 Detaching and refitting the primary transfer unit Procedure 1 5 6 Check or replace the primary transfer belt Remove primary transfer unit See above 2 Remove the two handles 3 4 Remove the two screws and then make the Remove the paper chute primary transfer unit two fold Remove the primary transfer belt and then refit all the removed parts 1 5 22 Handle Figure 1 5 34 3 Replacing the primary transfer unit Procedure T 2 2 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Connect the powe
40. on the primary transfer belt If the density of each color is not kept constant the resultant color image will be deteriorated The toner ID sensor mounted on the primary transfer belt to the printer main unit side maintains the constant color fidelity The toner ID sensor includes a LED deflection beam splitters of BS1 and BS2 photo diode PD2 and PD3 that scale toner density and associated components The deflection beam splitter 1 BS1 splits the light from the LED to S wave and P wave S wave oscillates vertically in ref erence to the entrance plane whereas P wave oscillates horizontally in reference to the entrance plane S wave reaches the photo diode PD1 and acts to stabilize the luminosity of the LED by means of the feed back circuit P wave is irradi ated to toner then it produces scattered light wave S and reflection wave P which bounced on the primary transfer belt They reach the deflection beam splitter 2 BS2 where they are distinguished as P wave and S wave respectively then detected by photo diode 2 PD2 and photo diode 3 PD3 Toner 3n K NA LD Primary transfer belt G AX lt 7 Toner ID sensor bo ie n nud i I Bu BS2 BS1 Figure 2 1 31Toner ID sensor 2 1 23 2HJ 2HK 2 1 5 Secondary transfer and separation section The secondary transfer and separation section includes the secondary transfer roller which is installed on the paper feed unit The secondary transfer roller is applied by the
41. p KYOCERA FS C5015N FS C5025N SERVICE MAN Published in October 2006 eds ion 1 CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS It may be illegal to dispose of this battery into the municipal waste stream Check with your local solid waste officials for details in your area for proper disposal ATTENTION IL Y AUN RISQUE D EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE TYPE INCORRECT METTRE AU REBUT LES BATTERIES UTILISEES SELON LES INSTRUC TIONS DONNEES Il peut tre ill gal de jeter les batteries dans des eaux d gout municipales V rifiez avec les fonc tionnaires municipaux de votre r gion pour les d tails concernant des d chets solides et une mise au rebut appropri e Revision history Revision October 26 2006 Replaced pages 1 1 1 1 1 2 1 1 3 1 1 4 1 1 7 1 3 2 1 3 3 1 3 4 1 3 8 1 3 13 1 3 15 1 3 16 1 3 17 1 4 7 1 4 12 1 4 13 1 4 14 1 4 15 1 4 27 1 4 28 1 4 31 1 4 32 1 5 1 1 5 15 1 5 22 1 5 23 1 5 25 1 5 32 1 6 1 1 6 3 2 1 26 2 1 27 2 1 28 2 1 29 2 2 2 2 2 3 2 3 1 2 3 2 2 3 9 2 4 1 2 4 3 2 4 5 Remarks This page is intentionally left blank Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers their machines as well as themselves during maintenance activities Service
42. personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property These symbols are described below AADANGER High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol AAWARNING Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol ACAUTION Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol Symbols The triangle A symbol indicates a warning including danger and caution The specific point of attention is shown inside the symbol NM General warning AN Warning of risk of electric shock A Warning of high temperature G indicates a prohibited action The specific prohibition is shown inside the symbol General prohibited action Disassembly prohibited OO indicates that action is required The specific action required is shown inside the symbol General action required Remove the power plug from the wall outlet Gage Always ground the copier 1 Installation Precautions
43. removed parts Latches Main high voltage PWB Figure 1 5 69 1 5 45 2HJ 2HK 5 Detaching and refitting the bias high voltage PWB Procedure 1 Remove the right cover See page 1 5 4 2 Unlatch the five latches and remove the two connectors and then remove the bias high voltage PWB 3 Check or replace the bias high voltage PWB and then refit all the removed parts Latches Latch Y AS er I E E Bias high voltage PWB Figure 1 5 70 1 5 46 2HJ 2HK 1 5 11 1 Others 1 Detaching and refitting the main drive unit Procedure 1 2 Remove the right cover See page 1 5 4 Remove the nine connectors from the main drive unit 3 Remove the one connector 4 Remove the six screws and four terminals then remove the main drive unit Check or replace the main drive unit and then refit all the removed parts Connectors nine ff Screw and terminal Ld Meg Screw and terminals Screw and terminal Main drive unit Connector Figure 1 5 71 1 5 47 2HJ 2HK 2 Detaching and refitting the paper feed drive unit Procedure 1 Remove the right cover See page 1 5 4 Connectors 2 Remove five connectors 3 Remove the harness from the two wire hooks Wire hooks Ww Du 4 Remove the three screws and then remove the paper feed drive unit 5 Check or replace the pa
44. the main controller PWB Main controller Figure 1 2 12 4 Open the stoppers of the memory socket 5 Insert the memory so that the two notches of the memory are engaged with the projec tions of the memory socket Close the stoppers of the memory socket Reattach the main controller PWB in the printer 8 Print a status page to check the memory expansion If memory expansion has been properly performed information on the installed memory is printed with the total memory capacity has been increased standard memory capacity 128 MB NO Stopper Figure 1 2 13 1 2 8 1 2 6 Installing a memory card optional lt Procedure gt 1 Turn off printer power CAUTION Do not insert or remove memory card while printer power is on Doing so may cause damage to the printer and the mem ory card 2 Insert the memory card into the memory card slot 3 Format the memory card before use Refer to the operation guide Figure 1 2 14 2HJ 2HK 1 2 9 2HJ 2HK 1 2 7 Installing the network interface card optional lt Procedure gt 1 Turn off printer power 2 Remove the two screws and then remove the optional interface slot cover 3 Insert the network interface card into the optional interface slot 4 Use the two screws to secure the network interface card 5 Connect the network cable 6 Configure the network interface card See the IB 2x quick configuration guide 1 2 10
45. the heat roller press roller fuser heater lamp 1 fuser heater lamp 2 and the change guide Paper sent from the secondary transfer and separation section is applied with heat and pressure to permanently fuse toner on paper The change guide switches the destination of paper to the face down tray or optional face up tray It also sends paper to the duplexer Figure 2 1 35Fuser unit 16 17 ppm printer EUR USA model 1 Upper fuser frame 8 Fuser heater lamp 2 2 Lower fuser frame 9 Lower fuser cover 3 Upper exit roller 10 Lower entrance guide 4 Lower exit roller 11 Stay plate 5 Heat roller 12 Change guide 6 Press roller 13 Exit guide 7 Fuser heater lamp 1 14 Fuser frame 2 1 26 2HJ 2HK 1 To face down tray Change guide Upper exit roller d To optional duplexer or face up tray S S Press roller Figure 2 1 36Fuser unit 16 17 ppm printer EUR USA model Engine controller PWB Power supply PWB Fuser PWB FUDR FUSOLDR FDDR FDSOLDR Rear Exit 7 EXITPAPN cover sensor Face up down open T RCOVOPN solenoid sensor TH1 L i TH2 i Fuserheater gt BA l LIVE Y o M YC901 10 HEATTDR vc15 19 Y 1 co YC901 9 in YC12 9 E loe 9S uyg YC901 11 YC12 11 Z x L Fuser i thermostat 2 russ O l Fuser motor Mheaterlamp2 STFSA im A l STFSAN BR Fuser thermi
46. the resolution is 600 dpi 2 Vector graphic Line Box Circle Arc Fill pattern etc 3 Bar code One dimensional bar code 45 types Two dimensional bar code 1 type PDF 417 d Connectivity plug amp play Windows 95 98 ME NT4 0 2000 XP SNMP KM NET viewer 600 api Main unit 345 x 470 x 385 mm 13 5 8 x 18 1 2 x 15 1 4 W x Dx H Main unit Approx 25 kg 55 1 8 lbs including toner containers 220 240 V AC 50 60 Hz 16 ppm printer EUR model 120 V AC 60 Hz 17 ppm printer USA model Maximum 1037 W 220 240 V 16 ppm printer EUR model 1032 W 120 V 17 ppm printer USA model Normal operating 443 W 220 240 V 16 ppm printer EUR model 455 W 120 V 17 ppm printer USA model Ready 117 W 220 240 V 16 ppm printer EUR model 116 W 120 V 17 ppm printer USA model EcoPower 19 W 220 240 V 16 ppm printer EUR model 15 W 120 V 17 ppm printer USA model Gurrea ibam 4 9 A 220 240 V 16 ppm printer EUR model 9 2 A 120 V 17 ppm printer USA model Printing 52 dB A Ready 36 dB A Expansion memory 64 128 256 512 MB 100 pin DIMM memory card CompactFlash hard disk unit HD 5 network interface card IB 21E IB 23 10BASE T 100BASE TX paper feeder PF 60 500 sheets 60 to 105 g m x 3 cassettes A4 A5 B5 legal let ter custom duplexer DU 301 face up output tray PT 301 100 sheets envelope feeder EF 310 1 1 2 Parts names 1 Overall 0
47. to face with the paper feed roller acts to pre vent feeding more than one sheet at a turn of the pick up roller The paper cassette has an opening at the front side This opening is a loophole for the paper that is fed by the optional paper feeder or the duplexer which feeds paper into the printer Figure 2 1 1Paper cassette 1 Guide roller 6 Feed base 11 Bottom plate 2 Paper guide 7 Registration sensor actuator 12 Feed pulley 3 Upper registration roller 8 Pickup roller 13 Retard roller 4 Lower registration roller 9 Feed roller 5 Secondary transfer roller 10 Cassette base To Bottom plate registration roller Feed pulley Bottom springs optional paper feeder or duplexer Figure 2 1 2 2 1 1 2HJ 2HK The paper size dial has predetermined patterns of activating the paper size switches using concaves and convexes according to paper sizes SW1 SW2 and SW3 produce corresponding signals for paper sizes Engine controller PWB Sensor PWB CASO CAS1 CAS2 Cassette size switch Paper size dial CUSTON A5 A4 d Paper cassette Cassette size switch Cassette not installed Other Legal Letter A4 Paper size Paper size dial Concave Function Off 2 1 2 SW2 H H L L H H L SW3 H L H L H L H Convex Function On
48. top 750 mm 29 1 2 a 385 mm 15 1 4 b 345 mm 13 5 8 c 470 mm 18 1 2 Figure 1 2 1Installation dimensions 1 2 1 2HJ 2HK 1 2 4 Unpacking and installation 1 Installation procedure Start U Unpacking Y Installing the toner containers Y Installing the waste toner box Y Loading paper Y Connecting the cables Y Printing a status page for test Y Completion of the machine installation 1 2 2 2HJ 2HK Unpacking 1 Unpack the printer and components When carrying the printer always hold the right and left sides as shown 2 Pull out the paper feed unit and then remove the filter 3 Close the paper feed unit Filter Paper feed unit Figure 1 2 2 Unpacking 4 Check parts and components Printer 2 Document and software Installation guide operation guide CD ROMs 3 Magenta toner container Cyan toner container Yellow toner container Black toner container Waste toner boxes one is a spare Power cord Figure 1 2 3 5 Open the top cover and remove the packing item Topcover Packing item Figure 1 2 4 1 2 3 2HJ 2HK Installing the toner containers 1 Shake the black toner container several times to loosen the toner inside 2 Open the top cover 3 Install t
49. z 8994 02794 99A 999A 99A ol Delyuvan 2 PSLP Z 2 LIL m Pa Sn a laz Q9 lo e9rOA 090A L9WOA Z9rOA 6000v ama 4eja euibu3 o Ov m on ons on on I Em S aho a e Es ers Dese icm E T E OG loz enei ew Leorm em 899A 655A QSPOA ZSPOA BSPOAN PSPDA LGYDA zSvOA ESVOA S mm p n m Zu z6 b252 SERS eB el 2 mane auna ee S Se Ona Din A w Sd O Qi ES Edu She R 56E R SGER 628 BoM w w w we ROMs Ron ROMs worms o ala 101 400 10 20 OSS mo TS aS SK 0 loo amd leued 92 poga munia mace obe B 5EI g sso Line e So game are aula aos ds duda Base 98923 uome1edo oo Bese oo missos BIS DS IN 9S9 aw ewe Ons Ons ZEEE EESBESSSSISSS osos Sp Bese mw S 0 gt O gt 0 x e sc wn ono wn ono olboo S SM MZ DIM YP Qe e 200 A Ly oz o3 Uam E N E La RON AWN Q EL M az ES ka A ono o od o 23 20D a on a wm m J fawn allaalla alla a laen AUN RON RON Ss ojo sues ES aon 3 3 3 88 osia Dasi Pas 3 S 8 a 28 8 pea ejueBey ueko LAOS J010UU 8 3 3 2 3 2 3 2 e1ueBeyw 498g woll9A ueo d Se j 52 gt R yo Qa 10sues p 1osues 10sues z 1osues jejsuen co L J0 OWW y 10 0wW 10 0w z 40 0W lzee0S S 5 118 Jeuo jeuo jeuo jeuo fiewug amp I2 3 E wnq wnq wnq wnq 2 4 3 2HJ 2HK Drum unit 1 Magenta ZLZE0S uaasvu3 Le6 dx L 8Md 4auezG
50. 00 0000 0000 0000 CT06 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT07 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT08 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT09 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT11 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT12 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT13 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 67 CT14 0000 0000 00 00 00 00 00 G CT15 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT16 AAAAAAA AAAAAAA ANAAAAA AAAAAAA AAAAAAA ANAAAAA E00 B00 90 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 000000000000
51. 0000 0000000000000000 DN PL9200007 SPL9200007 SPL9200007 SPL9200007 SN SPL9200010 6 42 Figure 1 3 4Service information 20 22 ppm printer EUR USA model 2HJ 2JK Service items Items Description Description Engine ROM information Engine mask version Engine software version Operation panel ROM infor mation Operation panel mask ROM version Boot ROM information Boot ROM version and flash DIMM type Software jumper switch infor mation hexadecimal First byte second byte dis played in OEM mode only First byte bit 0 2 1 Fixed bit 1 2 0 Overseas 1 Domestic Japan bit 2 3 Not used bit 4 2 0 Kyocera 1 OEM bit 5 2 0 For Europe 1 For US bit 6 0 Non MICR mode 1 MICR mode bit 7 Not used Second byte Displayed in OEM mode only Total page USB information 00 Not connected 01 Full Speed 02 Hi Speed Operation panel lock status displayed only when locked 01 Partial lock 02 Full lock NVRAM error displayed only when any error has occurred 03 Checksum error 04 NVRAM crush error 01 ID error 02 Version error NVRAM download 00 Normal bitO Font data bit1 Host data bit2 Macro data bit3 Program data bit4 Operation panel message data download file name displayed bit5 OEM data bit6 Web template data version displayed bit7 Error occurred
52. 01 01 i 9993 02 00 3 9979 0 48 01 88 01 01 3 9996 02 00 2 9969 10 48 01 88 01 01 2 9995 02 00 1 1 10 48 01 88 01 01 1 9994 02 00 Counter Log J00 0 J43 0 h C 6000 4 i Moo 1 J05 0 J44 0 C 6050 1 J09 0 J46 J10 0 J47 J11 0 J50 J12 0 J51 J13 0 J52 J14 0 J53 J15 0 J60 a J61 323 0 J30 0 J87 J35 0 J88 J40 0 J89 J41 J42 EVENT LOG 9 DN SPL6401106 Figure 1 3 5Event log EVENT LOG 1 3 9 2HJ 2JK Service items Description Detail of event log EVENT LOG Items Description Engine PWB mask ver sion Engine mask version Engine software version Operation panel PWB mask version BROM version Software jumper switch information hexadecimal First byte second byte displayed in OEM mode only First byte bit O 1 Fixed bit 1 2 0 Overseas 1 Domestic Japan bit 2 3 Not used bit 4 2 0 Kyocera 1 OEM bit 5 0 For Europe 1 For US bit 6 0 Non MICR mode 1 MICR mode bit 7 Not used Second byte Displayed in OEM mode only Main PWB firmware ver sion Main PWB firmware release date Total page counter Drum serial number Machine serial number 1 3 10 Paper Jam Log Count The total page count at the time of the paper jam Remembers 1 to 16 of occurrence If the occur rence of the previous paper jam is less than 16 all of t
53. 1 Defective harness 803195 between engine controller PWB A0004 and toner ID sensor or poor contact of the connector termi nals Check the continuity of the harness 803195 check the connection YC11 con nector of the engine controller PWB A0004 if there is trouble remedy or replace Backup data error The serial number of the machine writ ten on the EEPROM of the engine con troller PWB A0004 differs with that is written on both the flash memory of the engine controller PWB A0004 and the EEPROM of the drum PWB as a backup Replacing both the engine controller PWB A0004 and the drum unit at the same time Check that the machine operates properly by reverting the engine controller and the drum unit to the old ones To replace the engine controller PWB A0004 and the drum unit at the same time turn on the printer after replacing either one Check that the printer operates properly and then turn off the printer Replace the other and turn on the printer to check that the printer operates properly Be sure to replace one by one 1 4 21 2HJ 2HK Contents Remarks Causes Check procedures corrective measures Engine firmware error Serious status inconsistency that is fatal to keep controlling in the engine firm ware is detected Malfunction of the engine firmware or defective engine firmware Turn the power off on to restart the printer If the error is not re
54. 1 Paperimisi6ed detection aie te ette Rha get ta enlaces 1 4 1 1 Paper misfeed indication cr ette P pie nieder eie RE 1 4 1 2 Paper imisteed Te Tels l iiir endete ree creer rete cte re Ene dae b reete daa d dr shoes 1 4 1 E Self diagnosis oe ecd dete D aid ieee Pee 1 4 2 Et Selfdiagriostic TUI ctio ect etm rn tie certe rette eee nice Der bonc qd ete gre 1 4 2 2 Self diagnostic COdes 2 cere ete Cond Dr ud er re ee e v ge ee e duro 1 4 3 174 3 Image formation problems sc s uoc tetti t tee ce cft P dae cte 1 4 23 1 No image appears entirely white mener 1 4 24 2 No image appears entirely black emere nere 1 4 24 3 A specific color is printed solid ooooooocionccccnnoconanacananononnoncno narco raro nn nano no naar menn 1 4 24 4 The back side gets lll TTT 1 4 25 5 Image Is too light aide lis 1 4 25 6 The background is colored TT 1 4 26 7 White streaks are printed vertically sees eee eee eee eee 1 4 26 8 Black streaks are printed vertical sese eee eee eee 1 4 27 9 Streaks are printed horizontal sse esse eree 1 4 27 10 Spots AE Pride a eeepc ree ve e IRA ee dece es 1 4 27 11 The leading edge of image begins to print too early or too late ooo eee eee eee eee eee eee 1 4 27 12 Papert IS wrinkled te ee tere Fo eoe P e ede t EN eee 1 4 28 SS HT 1 4 28 14 Partof image is missing 2 irem HERD nci rie Eb EE v ae DO ees er RE NER Rt eed eee oe 1 4 28 1
55. 200007 SPL9200007 SPL9200007 SPL9200007 SN SPL9200010 Figure 1 3 3Service information 16 17 ppm printer EUR USA model 1 3 3 2HJ 2JK 1 1 3 4 Service items Description Service information 20 22 ppm printer EUR USA model Service information 2F3 1100 001 000 2HK 1000 001 012 2HJ A000 001 002 2HK 3100 001 004 01 00 Printed page s 9690 O 4 U00 F00 N00 D10 DM0301 DAN 0002001001210052 0 9 9 0020 0020 1061 0811 0 0 0 0 o of of of 0 0 0 0 0 of 02 3 12 AAAAAAA AAAAAAA 09 AAAAAAA BAAAAAA AAAAAAA AAAAAAA AAAAAAA ANAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA 07 08 O AAAAAAA Q1 AAAAAAA 0000 0000 0000 0000 0000 23 0000 0000 0000 0000 24 00000000 00000000 00000000 00000000 99 AAAAAAA AAAAAAA AAAAAAA AAAAAAA 0003 0003 0 30 88 2 279929 BO 00 00 00 00 00 00 GD A 1234567890123456 62 03030303 03030303 03030303 03000000 00000000 03030303 03030303 63 SPD1 0203040508090A0B0C0DOF101112131415161718191A1B1C1D181F2021222358 64 CTO1 0000 0000 0000 0000 69 cro2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT03 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT04 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 CT05 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 00
56. 3 Replace the yellow developer unit See page 1 5 12 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective engine relay PWB A0009 Replace the engine relay PWB A0009 1 4 18 Black drum unit non installing error The EEPROM U401 on the drum PWB 4 KP 972 inside the black drum unit does not communicate normally The incompatible drum unit is installed to the printer Defective harness between drum PWB 4 KP 972 and printer main unit or poor contact of the connector termi nals Check the connection of the black drum unit and the printer main unit check the continu ity of the harness S03211 if there is trou ble remedy or replace Installing the drum unit which is incompatible with the printer specifi cation Install the compatible drum unit to the printer Defective drum PWB 4 KP 972 Replace the drum PWB 4 KP 972 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness 803214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the connection YC3 con nector of the engine controll
57. 5 FUSING IS ee in Pe ee nC aie ee EHE re RUMP EIE 1 4 28 16 Colors are printed offset to each oher seene eee 1 4 28 14 4 Electrics problems nni a pue d PAPAE BI a Ee dept 1 4 29 1 Close top cover display is not cancelled to closing the top cover seeee 1 4 29 2 Close side cover display is not cancelled to closing the top cover see eee eee eee eee 1 4 29 3 Close paper transfer unit display is not cancelled to closing the paper feed unit 1 4 30 4 Cassette 1 not loaded display is not cancelled to closing the paper cassette 1 4 30 5 Check waste toner box display is not cancelled to replacing the waste toner box 1 4 30 6 The paper size is not recognized as the size set with the paper size dial 1 4 31 7 Paper misfeed display is not cancelled sss sees eee eee 1 4 31 1 4 5 Mechanical problerris e danish etch a hailed ne 1 4 32 1 No primary paper feed ertet dn ttr rre RERUM E NEARE 1 4 32 2 No secondary paper feed eee entrent nnne tnt nnne nennen nennen nennen 1 4 32 S Skewed paper feed co eub eme eddie ecol ed rateitzhias 1 4 32 4 Multiple sheets of paper are fed at one time sse eee eee 1 4 32 5 Paper AIMS iia 8 eo A TT 1 4 32 6 Toner drops on the paper CONVEYING path sese eee eee eee 1 4 32 7 Abnormal noise is heard
58. 5 V DC Registration sensor On Off 0 5 V DC Paper gauge sensor 1 On Off 0 5 V DC Paper gauge sensor 2 On Off 0 5 V DC Top cover switch 1 Top cover Close Open 0 5 V DC Cassette size switch lower button On Off 0 5 V DC Cassette size switch middle button On Off 0 5 V DC Cassette size switch upper button On Off 24V3 24 V DC 24 V DC power output via side cover switch GND Ground EECLK O 0 5V DC pulse Clock for EEPROM data reading ana writing ERS1DR 0 24 V DC Eraser lamp 1 black On Off EEDATA 0 5 V DC pulse EEPROM data signal ERS2DR 0 24 V DC Eraser lamp 2 yellow On Off ERS3DR 0 24 V DC Eraser lamp 3 cyan On Off 5V1 5V1D 5V DC 5 V DC power output ERS4DR 0 24 V DC Eraser lamp 4 magenta On Off 5V1 5V1D 5V DC 5 V DC power output RD 0 5 V DC Control signal LVDSPO Analog LED print head control video data signal LVDS LVDSNO Analog LED print head control video data signal LVDS LVDSP1 Analog LED print head control video data signal LVDS LVDSN1 Analog LED print head control video data signal LVDS LVDSP2 Analog LED print head control video data signal LVDS LVDSN2 Analog LED print head control video data signal LVDS LVDSP3 Analog LED print head control video data signal LVDS LVDSN3 Analog LED print head control video data signal LVDS LVDSP4 Analog LED print head control video data signal LVDS LVDSN4 Analog LED print head control video data signal LVDS LVDSP5 Analog LED print
59. 7 SIN 0 3 3 V DC pulse Serial communication data input 58 SCLKIN 0 3 3 V DC pulse Serial communication synchronizing clock signal 59 SOUT O 0 3 3 V DC pulse Serial communication data output 60 SDIR O 0 3 3 V DC Control signal 2 3 7 2HJ 2HK Connector Pin Signal y o Voltage Description YC10 1 5V1 O 5VDC 5 V DC power output Connected 2 PDATA l O 0 3 3 V DC pulse Operation panel PWB control data signal to the opera 3 FPDIR 0 3 3 V DC Operation panel PWB communication direction control signal tion panel 4 FPCLK 0 3 3 V DC pulse Operation panel PWB control data synchronizing clock signal PWB 5 GND Ground 6 FPRSTN 0 5 V DC Operation panel PWB reset signal YC11 1 TCOVOP2 10 5 V DC Top cover switch Top cover Close Open Connected 2 GND J Ground to the regis 3 24V2 O 24VDC 24 V DC power via top cover paper feed unit switch tration 4 REGCLDR O 0 24V DC Registration clutch On Off clutch feed 5 24V2 O 24V DC 24 V DC power output via top cover paper feed unit switch clutch MP 6 FEDCLDR O 0 24 V DC Feed clutch On Off Leda 7 24V2 O 24V DC 24 V DC power output via top cover paper feed unit switch toner ID 8 MPSOLDR O 0 24V DC MP tray feed solenoid On Off sensor feed 9 5V1 O 5VDC 5 V DC power motor fuser 10 f WI Ground motor and 11 IDSW Analog Toner ID sensor detection voltage S wave input developer 12 IDSW Analog Toner ID sensor detection
60. AAWARNING Do not use a power supply with a voltage other than that specified Avoid multiple connections to one outlet they may cause fire or electric shock When using an extension cable always check that it is adequate for the rated current o oo eee eee eee eee eee eee Connect the ground wire to a suitable grounding point Not grounding the copier may cause fire or electric shock Connecting the earth wire to an object not approved for the purpose may cause explosion or electric shock Never connect the ground cable to any of the following gas pipes lightning rods ground cables for telephone lines and water pipes or faucets not approved by the proper authorities dsrin orire ee rentre dad vgn See des ACAUTION Do not place the copier on an infirm or angled surface the copier may tip over causing injury O Do not install the copier in a humid or dusty place This may cause fire or electric shock S Do not install the copier near a radiator heater other heat source or near flammable material This may cause fiig T S Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool as possible Insufficient ventilation may cause heat buildup and poor copying performance S Always handle the machine by the correct locations when MOVING it sse sees eee eee eee Q Always use anti toppling and locking devices on copiers so equipped Failure to do this may caus
61. C6 20 YC6 22 ERS2DR YC2 4 a YC3 5 YC401 4 ycaot 5 YC14 4 YC401 2 YC14 2 et ee eee y DATA10 to 19 DATA 20 to 29 YC7 9 to 18 YC9 9 to 18 YC9 20 YC9 22 E Gag EBSSDR vega YC401 7 YC401 4 yc4o1 5 YC401 2 YC15 2 YC401 1 YC15 1 ADATA10 to 19 ADATA 20 to 29 SDA SCLK YC8 9 to 18 YC10 9 to 18 YC10 20 YC10 22 yo2 6 ERS4DR ogg ERS4DR vCc16 7 YC401 4 S v C401 5 YC401 2 Figure 2 1 17Drum section block diagram 2 1 13 2HJ 2HK 2 Waste toner ejecting mechanism The waste toner which is ejected from the drum units drops on the waste toner conveyer through a duct The waste toner is conveyed towards the primary transfer cleaning unit finally stored in the waste toner box Primary transfer SS cleaning unit SY Z Likes LS From From From magenta Z cyan yellow black grum V drum unit drum unit drum unit E From Waste toner duct La Waste toner box Waste toner A ls a Figure 2 1 18Waste toner ejecting mechanism 2 1 14 2HJ 2HK 3 LED print head The LED print head is comprised of SELFOC lens array and an LPH PWB The LPH PWB arrays 5184 of LED chips in line It also includes the driver circuit for the LED chips The light which is switched on and off depending on video data irradiate the drum through the SELFOC lens to form an image The LED print head is of 600 dpi therefore the exposure of the light is as dense as 600 dots per
62. ER STATUS PAGE Firmware version 2HJ_3000 001 017 Released 25 Apr 2006 Service Information 2F3_1100 001 001 2HJ_1000 001 003 2HJ_A000 001 002 2HJ 3100 001 004 03 03 Printed page s U00 F00 N00 D10 DM0301 DAN 0002001001210052 0020 0020 1061 0811 0 0 0 0 0 of 0 0 0 ABAABAA ARABAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA ARAAAAA ARAAAAA AAAAAAA AAAAAAA AAAAAAA 0000 0000 0000 0000 0000 0000 00000000 00000000 00000000 00000000 AAARAAA AAAAAAA AAAAAAA AAAAAAA 0003 0003 0 30 88 00 00 00 00 00 00 A 1234567890123456 03030303 03000000 00000000 03030303 0303935 SPD1 0203040508090A080C0Dwr OTETE202122235E 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 DN SPL9200007 SPL9200007 SPL9200007 SPL9200007 SN SPL9200010 Toner Coverage 1 3 2 3 4 Toner Coverage Average K 13266 4 1 1 Toner Coverage Average C 9277 4 1 8 Toner Coverage Average M 9277 4 1 6 Toner Coverage Average Y 9277 4 0 1 0 0 0 0 0 0 Toner Coverage Last Page K C M Y Toner coverage Example 16 17 ppm printer EUR USA model Refer to next page Figure 1 3 1Service status page 2HJ 2JK 1 Service items Description Toner cover
63. Figure 2 1 3 2HJ 2HK Paper gauge sensing circuit The actuator which has a light reflector at one end keeps tracking of the height of the paper stack in the paper cassette The angle of the reflector varies according to the actuator angle which means the amount of paper remaining As the reflector moves across the detecting surface of paper gauge sensor photo interrupter 1 and 2 the on and off states of these sensors vary in combination as shown in the table below allowing to determine the amount of remaining paper in the cassette LIS Paper feed unit Sensor PWB Paper gauge p sensor 1 PH702 H Paper gauge Actuator Reflecting mirror sensor 2 PH703 Sensing input Actuator position PH702 PH703 1 to 1 3 1 3 to 2 3 2 3 to full Figure 2 1 4 2HJ 2HK Secondary transfer roller Upper registration roller Lower registration roller Guide rollers To fuser unit paper cassette Feed roller Pickup roller Figure 2 1 5Paper feed unit Engine controller PWB Feed clutch FEDCLDR YC11 6 Registration clutch REGCLDR YC11 4 Feed motor STFDA YC11 14 STFDAN YC11 15 STFDB YC11 16 STFDBN YC11 17 Figure 2 1 6Paper cassette paper feed section block diagram 2 1 4 2HJ 2HK Paper feeding from MP tray The MP tray bottom which is driven by the MP feed solenoid press the paper against the MP feed roller The sheet is rewound to the MP feed roller th
64. H PWB or with com pensating data the printer displays service call 0951 0952 0953 or 0954 within approximately 30 seconds LED print heads relay PWB Engine Main ASEE Ten controller controller AHSYNC ASTBN Bus EE ADATA 10 to 19 ADATA 20 to 29 EG LVDSNO to 11 VIDEO LVDS 00000000C data output S o EEDATA t SOUT o SIN Serial S gt communication S Serial ESO communication LA Ol Lo H Flash memory Drum unit E YVY LVDS Low Voltage Differential Signaling LED print head Figure 2 1 20LED print head block diagram 2 1 16 2HJ 2HK 4 Main charger unit Main charger unit is comprised of the main charger wire main charger grid main charger shield and the main charger cleaner which are modularized and fitted to the drum unit Figure 2 1 21 Main charger wire Main charger grid Main charger shield Main charger cleaner PONS Main charger grid Main charger cleaning pad Main charger shield Main charger cleaning knob Figure 2 1 22 Main charger unit 2 1 17 2HJ 2HK Main high voltage PWB Output Wire o Grid i be E Es Zener a PWB1 n rum MCH1DR MCH2DR Me ia i MCHSDR Magenta drum unit MCH4DR Main charger unit Output Shield a h
65. HK 1 1 1 1 Specifications 16 17 ppm printer EUR USA model Mc Desktop Printing system sese eee eee eee ee Electrophotographic four color CMYK printing using Advanced Beam Array Paper type cocoooconccconccconcnonaninncnnancnns Cassette Plain preprinted bond recycled rough letterhead color prepunched high quality and custom MP tray Plain transparency preprinted labels bond recycled vellum rough letterhead color prepunched envelope cardstock coated thick high quality and custom Paper sizes eese Cassette A4 B5 A5 Folio 8 1 2 x 14 Legal 8 1 2 x 11 Letter Oficio Il Executive ISO B5 Envelope C5 16K and Custom MP tray A4 B5 A5 Folio 8 1 2 x 14 Legal 8 1 2 x 11 Letter Oficio Il Statement Executive A6 B6 ISO B5 Env Monarch Envelope 10 Envelope 9 Envelope 6 Envelope DL Envelope C5 16K Hagaki Oufuku Hagaki Youkei 2 Youkei 4 and Custom Print SpeedS suus Cassette A4 16 pages minute B5 17 pages minute A5 17 pages minute Letter 17 pages minute Legal 14 pages minute MP tray A4 15 pages minute B5 16 pages minute A5 16 pages minute Letter 16 pages minute Legal 13 pages minute First print me s sese eee eee Standby mode 16 seconds or less A4 Sleep mode 96 seconds or less A4 Warm up time sese e e Sleep mode 80 seconds or less room temperature 22 C 71 6 F 60 RH Power on 80 seconds or less room temperature 22
66. Il Statement Executive A6 B6 ISO B5 Env Monarch Envelope 10 Envelope 9 Envelope 6 Envelope DL Envelope C5 16K Hagaki Oufuku Hagaki Youkei 2 Youkei 4 and Custom Print speeds seer Cassette A4 20 pages minute B5 22 pages minute A5 22 pages minute Letter 22 pages minute Legal 18 pages minute MP tray A4 19 pages minute B5 20 pages minute A5 20 pages minute Letter 20 pages minute Legal 16 pages minute First print me s sese eee eee Standby mode 13 seconds or less A4 Sleep mode 81 seconds or less A4 Warm up time sese e e Sleep mode 68 seconds or less room temperature 22 C 71 6 F 60 RH Power on 68 seconds or less room temperature 22 C 71 6 F 60 RH Paper feed system One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m 0 11 um 16 28lb Bond MP tray 100 sheets 80 g m 0 11 um 16lb Bond 1101lb Index Paper eject system Face down 250 sheets 80 g m 0 11 um equipped with a face down paper full sen sor Face up 100 sheets optional face up tray PT 301 must be installed Photoconductor OPC drum diameter 30 mm Charging system Scorotron positive charging Light SOUICE sse s sees sere eser ereer eee LED Developing system Touch down development method Develo
67. KP 1090 Expanding memory DIMM slot E 2 a a ms za ox Zener PWB 4 KP 931 4 PWB KP 1090 a E E o o S g uw 3 KP 931 Zener PWB Eraser lamp 3 PWB KP 1090 Zener PWB 2 KP 931 2 PWB KP 1090 a E S o g w LEZE0S TP Lu Ev os x ENS iva Aes 235 co Oto STR zz 358 Bm De us aso eje E vv E ioli alr 3 ane 8 8 Ss sls 9 amp amp amp F NR e S Nr 9 9 Haisual 14 4 8 amp l RR Re S es EE 88 Is SE amp 8 1 vvLEOS S A EE H vt wo foo o e H HR E E B E 2 gl E zadal y E 3 S i Z Z Sos 8 8 6 6 Oev1vav i OL LST vz rt we we EVLYAY e erp QNODr1033 it e et ezvivav D
68. LA o 2 5 LP LL bb EL ZNOXLN ZAOXLA Zl 8 Ov OL 09 01 NATIOXLN AMTOXLA gt z E 6e 6 6 6 SNGXLA BdOXLA S 52 G 88 8 88 8 6NAXLA 6dAXLA 5 8s 28 4 L L OLNGXLA OLdOXLA E s2 96 9 96 9 LINOXLA LLdOXLA o 0 o xo s2 7 x SEI S S N E OND S 9 Tog 2 very vE V AC E NEE 2 ot zt STO Bo E AS ASt E og s a25 SSS zee ee o AG AS ame o D go a a e 5E ze OEY 85 LE L Le L AS AS L a S M A A S m 2 4 2 2HJ 2HK 1 2 Wiring diagram 20 22 ppm printer EUR USA model
69. LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the insertion of YC3 of the engine controller PWB A0004 if there is trouble remedy or replace Defective FFCs 803011 between LED print head 1 and LED print heads relay PWB A0176 or poor contact of the FFC terminals Check the connection of the FFCs with the magenta drum unit and the printer main unit check the continuity of the FFCs S803011 check the connection of the LED print head 1 if there is trouble remedy or replace See page 1 5 15 2HJ 2HK 1 Code Contents Remarks Causes Check procedures corrective measures 0954 LED print head 3 EEPROM commu Defective LED print Replace the LED print head 3 See page 1 nication error yellow drum unit head 3 5 15 The LED print head 3 EEPROM of the yellow drum unit does not communicate E ae sss AZ LED print head to the with the engine controller PWB A0004 prin sag ew 16 S SR CUI incompatible with normally e the printer specifi cation Defective engine Replace the engine controller PWB A0004 controller PWB See page 1 5 41 A0004 Defective LED print Replace the LED print heads relay PWB heads relay PWB A0176 See page 1 5 44 A0176 Defective harness Check the continuity of the harness S03214 between S03214 check the insertion of YC3 of the
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71. Q O Qm E GM GO TH1 TH2 FDSOLDR 5V2 RCOVOPN FUSOLDR EXITPAPN 24V2 HEAT2DR HEAT1DR ZCROSS 24V1 24V1 24V1 24V1 GND GND GND GND GND GND GND GND 3 3V1 3 3V1 3 3V1 3 3V1 5V1 5V1 Oo 00 00 OO 0000 000000 Analog Analog 0 24 V DC 5V DC 0 5 V DC 0 24 V DC 0 5 V DC 24 V DC 0 24 V DC 0 24 V DC 0 5 V DC pulse 24 V DC 24 V DC 24 V DC 24 V DC 3 3 V DC 3 3 V DC 3 3 V DC 3 3 V DC 5V DC 5V DC Fuser thermistor 1 detection voltage output Fuser thermistor 2 detection voltage output Face up down solenoid control signal 5 V DC power output Rear cover open close sensor Rear cover Open Close Face up down solenoid control signal Exit sensor On Off 24 V DC power output Fuser heater lamp 2 On Off Fuser heater lamp 1 On Off Zero cross signal output N C 24 V DC power output 24 V DC power output 24 V DC power output 24 V DC power output Ground Ground Ground Ground Ground Ground Ground Ground 3 3 V DC power output 3 3 V DC power output 3 3 V DC power output 3 3 V DC power output 5 V DC power output 5 V DC power output Connected to the fuser PWB GND 24V2 FDDR EXITPAPN FUSOLDR 5V1 RCOVOPN TH1 TH2 24 V DC 0 24 V DC 0 5 V DC 0 24 V DC 5V DC 0 5 V DC Analog Analog Ground 24 V DC power output Face up down solenoid control signal Exit sensor On Off Face up down solenoid control signal 5 V DC power output Rea
72. SA model Normal operating 452 W 220 240 V 16 ppm printer EUR model 450 W 120 V 17 ppm printer USA model Ready 173 W 220 240 V 16 ppm printer EUR model 170 W 120 V 17 ppm printer USA model EcoPower 16 W 220 240 V 16 ppm printer EUR model 16 W 120 V 17 ppm printer USA model 4 7 A 220 240 V 16 ppm printer EUR model 9 2 A 120 V 17 ppm printer USA model Printing 52 dB A Ready 36 dB A Expansion memory 64 128 256 512 MB 100 pin DIMM memory card CompactFlash hard disk unit HD 5 network interface card IB 21E IB 23 10BASE T 100BASE TX paper feeder PF 60 500 sheets 60 to 105 g m x 1 cassette A4 A5 B5 legal letter custom duplexer DU 301 face up output tray PT 300 250 sheets 2HJ 2HK 1 20 22 ppm printer EUR USA model A eie Desktop Printing system sese eee eee eee ee Electrophotographic four color CMYK printing using Advanced Beam Array Paper type sese Cassette Plain preprinted bond recycled rough letterhead color prepunched high quality and custom MP tray Plain transparency preprinted labels bond recycled vellum rough letterhead color prepunched envelope cardstock coated thick high quality and custom Paper siz6s iube Cassette A4 B5 A5 Folio 8 1 2 x 14 Legal 8 1 2 x 11 Letter Oficio Il Executive ISO B5 Envelope C5 16K and Custom MP tray A4 B5 A5 Folio 8 1 2 x 14 Legal 8 1 2 x 11 Letter Oficio
73. SELFOC lens of LED print head Clean the SELFOC lens of LED print head by using lens cleaner Focus is lost with the LED print head Check the four colors of image by using the test page of ser vice mode If the defect appears on a particular color replace the LED print head for that color See pages 1 3 14 1 5 15 Defective LED print head Check the four colors of image by using the test page of ser vice mode If the defect appears on a particular color replace the LED print head for that color See pages 1 3 14 1 5 15 Defec tive main charg ing out put Adhesion of oxide to main charger wire Clean the main charger wire by using main charger wire cleaner Dirty main charger grid Clean the main charger grid by using main charger grid cleaner Dirty main charger shield Replace the main charger unit Foreign object in one of the develop ers Check the image by using the test print of service mode If the white line appears on a particular page replace the developer for that color See pages 1 3 14 and 1 5 12 Adhesion of soiling to primary transfer belt Replace the primary transfer unit See page 1 5 22 8 Black streaks are printed vertically Print example Causes 2HJ 2HK 1 Check procedures corrective measures Dirty main charger wire Clean the main charger wire by using main charger wire cleaner Poor insertion of th
74. Top cover Magenta toner container Cyan toner container Yellow toner container Black toner container Paper feed unit MP tray Paper cassette Paper size window Paper size dial Figure 1 1 1Figure 1 1 1 Paper gauge Left side cover Waste toner box Power switch Magenta main charger unit Cyan main charger unit Yellow main charger unit Black main charger unit Main charger wire cleaner Lens cleaner 2HJ 2HK Rear cover Fuser cover Paper feed unit release lever Memory card slot AC inlet Optional interface slot USB interface connector Network interface connector 2HJ 2HK 2 Operation panel 000 lu O READY D um E DATA PASARAN e INTERFACE SIZE TYPE D ATTENTION Figure 1 1 2Figure 1 1 2 Message display Interface indicator INTERFACE Paper size indicator SIZE Paper type indicator TYPE Ready indicator READY Data indicator DATA Attention indicator ATTENTION lt key Left K key Right A key Up Y key Down MENU key OK key CANCEL key GO key z m z E tE 1 1 3 Cross section view 20 22 ppm printer EUR USA model bs O oe 2HJ 2HK 1 amp
75. WB Replace the bias high voltage PWB See page 1 5 46 Malfunction of the developer installa tion 2 No image appears entirely black Print example Causes Reinstall the developer See page 1 5 12 Check procedures corrective measures No main charging Poor contact of output ter minal of main high volt age PWB Check the installation of the main high voltage PWB If it instal lation incorrectly reinstall it See page 1 5 45 Defective main high volt age PWB Replace the main high voltage PWB See page 1 5 45 Defective engine control ler PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB 3 A specific color is printed solid Print example Causes Replace the LED print heads relay PWB A0176 See page 1 5 44 Check procedures corrective measures 1 4 24 Defective main charger unit which corresponds to the color causing the problem Check if the main charger unit is properly seated If necessary reseat it properly Disconnected main charger wire Replace main charger unit 4 The back side gets dirty Print example Causes 2HJ 2HK 1 Check procedures corrective measures Dirty secondary transfer roller Clean the secondary transfer roller Dirty paper conveying path of the paper feed unit Clean the paper conveying path of the paper feed unit
76. a inch The EEPROM on the LPH PWB stores data for compensation of fluctuation of luminosity over all LED chips in the array LED chips LPH PWB EEPROM 5184 pieces SELFOC lens CCS HHR LLL array o 600 dot inch Drum Figure 2 1 19LED print head 2 1 15 2HJ 2HK Data to print is processed by the main controller PWB and transferred to the LED print head relay PWB in synchronization with VIDEO signal through the engine controller PWB VIDEO signal is sent from ASIC U22 on the mail controller PWB to ASIC U1 on the LED print head relay PWB using LVDS method LVDS stands for Low Voltage Differential Signaling which uses 16 pairs of signal lines 32 in all The main controller PWB converts VIDEO signal into a unique format using LVDS depending on compensating data stored in a flash memory The LED print head has an EEPROM on the LPH PWB The EEPROM includes data for compensating the fluctuation of luminosity of every LED chip At power up the compensating data in EEPROM are cached in the flash memory on the main controller PWB In a subsequent power up the main controller PWB refers the flash memory to obtain the compen sating data and the EEPROM is checked with its checksum only If the LED print head or the main controller PWB is replaced checksum becomes error The compensating data is trans ferred to the main controller PWB again from the EEPROM In case of failure with EEPROM on the LP
77. aced at 200 000 images of printing The interval counter must be manually reset using this service item Maintenance kit includes the following units Maintenance kit Item For EUR model For USA model Maintenance kit MK 540 MK 542 Drum units x 4 Black developer unit DV 510K DV 512K Yellow developer unit DV 510Y DV 512Y Magenta developer unit DV 510M DV 512M Cyan developer unit DV 510C DV 512C Primary transfer set Primary transfer unit and pri mary transfer cleaning unit Paper feed unit FE 510 Fuser unit FK 521 Ozone filters x 2 Part No 2D902530 Feed rollers set Retard roller Part No 5AAVROLL 052 MP tray feed roller Part No 5AAVROLL 051 20 22 ppm printer EUR USA model only 1 3 15 2HJ 2JK 1 Service items Description Purpose To reset the life counter for the developer units and drum units included in maintenance kit Procedure for replacing the maintenance kit 1 Remove the four old drum units See page 1 5 13 2 Remove the LED print head from each old drum unit and then refit to the new drum unit See page 1 5 15 3 Install the four new drum units 4 Replace the four developer units See page 1 5 12 5 Replace the fuser unit See page 1 5 32 6 Replace the paper feed unit See page 1 5 6 7 Replace the primary transfer unit See page 1 5 23 8 Replace the primary transfer cleaning unit See page 1 5 24 9 Replace the t
78. age K Black C Cyan M Magenta Number of pages printed coverted Toner coverage yY Yellow in reference to A4 or Letter size ESTE m Coverage Coverage Coverage Coverage 0 0 0 0 Toner coverage of the page printed most previously Black Cyan Magenta Yellow Figure 1 3 2Toner coverage Service information 16 17 ppm printer EUR USA model Service information 2F3 1100 001 001 2HJ 1000 001 003 2HJ A000 001 002 2HJ 3100 001 004 03 03 Printed page s 9690 U00 F00 N00 D10 DM0301 DAN 0002001001210052 6 0 8 9 0020 0020 1061 0811 0 0 0 0 oo o 0 0 0 D 2 B 2 AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA D 20 AAAAAAA 1 AAAAAAA 22 0000 0000 23 0000 0000 0000 0000 4 00000000 00000000 00000000 00000000 Q9 AAAAAAA AAAAAAA AAAAAAA AAAAAAA 0003 0003 0 30 88 e eee 60 00 00 00 00 00 00 67 A 1234567890123456 62 03030303 03030303 03030303 03000000 00000000 03030303 03030303 63 SPD1 0203040508090A0B0C0D0F101112131415161718191A1B1C1D1F1F202122235E 40 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 DN SPL9
79. al LVDS 9 VTXDP8 Analog LED print head control video data signal LVDS 2 3 6 2HJ 2HK Connector Pin Signal y o Voltage Description YC8 10 VTXCLKP 0 3 3 V DC pulse LED print head control clock signal Connected 11 VTXDP7 Analog LED print head control video data signal LVDS to the main 12 VTXDP6 Analog LED print head control video data signal LVDS controller 13 VRXDPO Analog LED print head control video data signal LVDS PWB 14 VRXDP1 Analog LED print head control video data signal LVDS 15 VRXCLKP 0 3 3 V DC pulse LED print head control clock signal 16 VTXDP5 Analog LED print head control video data signal LVDS 17 VTXDP4 Analog LED print head control video data signal LVDS 18 VTXDP3 Analog LED print head control video data signal LVDS 19 VTXDP2 Analog LED print head control video data signal LVDS 20 VTXDP1 Analog LED print head control video data signal LVDS 21 VTXDPO Analog LED print head control video data signal LVDS 22 GND Ground 23 FPDIR O 0 3 3 V DC Operation panel PWB communication direction signal 24 FPCLK O 0 3 3 V DC pulse Serial communication synchronizing clock signal 25 FPRSTN 0 3 3 V DC Operation panel PWB reset signal 26 GND Serial communication data output 27 SYSRESN 0 5 V DC System reset signal 28 GND J Ground 29 SBSYN O 0 5 VDC Control signal 30 GND J Ground 31 5V1 O 5VDC 5 V DC power out
80. al y o Voltage Description YC3 39 LVDSP14 O Analog LED print head control video data signal LVDS Connected 40 LVDSN14 O Analog LED print head control video data signal LVDS to the LED 41 LVDSP15 O Analog LED print head control video data signal LVDS print heads 42 LVDSN15 O Analog LED print head control video data signal LVDS relay PWB 43 45V1 5V1P O 5VDC 5 V DC power output 44 FDPFUL 0 5 VDC Paper full sensor On Off 45 5V1 O 5VDC 5 V DC power output 46 5V1 5V1P O 5VDC 5 V DC power output 47 GND Ground 48 GND J Ground 49 GND J Ground 50 GND Ground YC4 1 ST4A O 0 24 V DC pulse Drum motor 4 black energization pulse Connected 2 STMIDBN O 10 24 V DC pulse Primary transfer motor energization pulse to the 3 ST4B O 0 24 V DC pulse Drum motor 4 black energization pulse engine relay 4 STMIDAN O 0 24 V DC pulse Primary transfer motor energization pulse PWB 5 ST4AN O 0 24 V DC pulse Drum motor 4 black energization pulse 6 STMIDBN O 0 24 V DC pulse Primary transfer motor energization pulse 7 ST4BN O 0 24V DC pulse Drum motor 4 black energization pulse 8 STMIDA O 10 24 V DC pulse Primary transfer motor energization pulse 9 TNM4DR O 0 24 V DC Toner motor 4 black On Off 10 TNSEN4 Analog Toner sensor 4 black detection voltage input 11 TNSENS Analog Toner sensor 3 yellow detection voltage input 12 ST3BN O 0 24 V DC pulse Drum motor 3 yellow
81. als Defective fuser Replace the fuser heater lamp 2 See page heater lamp 2 1 5 26 Defective harness Check the continuity of the harness S803204 220 240 803204 220 240 V AC model 803205 V AC model 120 V AC model check the connection S03205 120 VAC YC693 connector of the fuser PWB KP model between 970 if there is trouble remedy or replace fuser unit connec tor and fuser heater lamp 2 Defective harness Check the continuity of the harness S03203 between 803203 check the connection CN2 con fuser unit connec nector of the power supply PWB if there is tor and power sup trouble remedy or replace ply PWB 6120 Fuser abnormal high temperature Defective engine Replace the engine controller PWB A0004 error press roller Abnormal high fuser temperature of the press roller was detected 16 17 ppm printer EUR USA model only 1 4 14 controller PWB A0004 See page 1 5 41 Defective fuser PWB Replace the fuser PWB KP 970 Defective power supply PWB Replace the power supply PWB See page 1 5 41 Defective installa tion condition of fuser thermistor 2 Check the installation condition of fuser ther mistor 2 if there is trouble remedy or replace See page 1 5 26 Contents 2HJ 2HK 1 Remarks Causes Check procedures corrective measures Fuser thermistor 2 broken error press roller It was judged it has been broken from the fac
82. and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the insertion of YC3 of the engine controller PWB A0004 if there is trouble remedy or replace Defective FFCs S03011 between LED print head 2 and LED print heads relay PWB A0176 or poor contact of the FFC terminals Check the connection of the FFCs with the cyan drum unit and the printer main unit check the continuity of the FFCs S03011 check the connection of the LED print head 2 if there is trouble remedy or replace See page 1 5 15 1 4 5 2HJ 2HK Code Contents Diui diu Causes Check procedures corrective measures 0953 LED print head 1 EEPROM commu Defective LED print Replace the LED print head 1 See page 1 1 4 6 nication error magenta drum The LED print head 1 EEPROM the magenta drum unit does communicate with the engine controller PWB A0004 normally head 1 5 15 Installing the LED print head which is incompatible with the printer specifi cation Install the compatible LED print head to the black drum unit Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness 803214 between engine controller PWB A0004 and
83. and gears operate smoothly Grease the bearings and gears Check if the following drive unit are installed correctly Main drive unit Paper feed drive unit Correct See page 1 5 47 or 1 5 48 1 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 1 4 32 2HJ 2HK 1 1 5 1 Precautions for assembly and disassembly 1 Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly When handling PWBs do not touch connectors with bare hands or damage the PWB Do not touch any PWB containing ICs with bare hands or any object prone to static charge Use only the specified parts to replace the fuser unit thermostat Never substitute electric wires as the printer may be seri ously damaged When removing the hook of the connector be sure to release the hook 2 Drum Note the following when handling or storing the drum When removing the drum unit never expose the drum surface to strong direct light Keep the drum at an ambient temperature between 0 C 32 F and 40 C 104 F and at a relative humidity not higher than 9096 RH Avoid abrupt changes in temperature and humidity Avoid exposure to any substance which is harmful to or may affect the quality of the drum Do not touch the drum surface with any object Should it be touched by hands or stained with oil clean it 3 Toner container Store the toner container s in a cool dark place
84. bias high voltage PWB of DC bias The image constituted by toner on the primary transfer belt is transferred on paper by means of the difference in potential The paper is separated from the transfer belt as the curvature radius of the secondary transfer roller is considerably small Paper chute Feed base Paper feed unit Secondary transfer roller Figure 2 1 32 Transfer roller gear To Secondary transfer roller v SS fuser unit LB S CUN Feed base Paper feed unit Figure 2 1 33Secondary transfer unit 2 1 24 2HJ 2HK The primary transfer roller bias is triggered by a serial data which is generated by the engine controller PWB and derived from the bias high voltage PWB The engine controller PWB converts current and voltage into serial data and applies it to the bias high voltage PWB The bias high voltage PWB then uses D A converter IC501 and revert it into analog voltage The analog voltage is applied to the high voltage output circuit which in turn applies the secondary transfer roller with the bias accordingly Engine controller PWB Bias high voltage PWB Secondary transfer TT roller bias High 6 HVBDATD output OR Eus IC501 BEE DD Secondary transfer roller Figure 2 1 34Secondary transfer unit block diagram 2 1 25 2HJ 2HK 1 2 1 6 Fuser section 1 Fuser unit 16 17 ppm printer EUR USA model The fuser unit is composed of
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86. cally horizontally See page 1 4 27 See page 1 4 27 See page 1 4 27 14 Part of image is missing 15 Fusing is loose See page 1 4 28 See page 1 4 28 See page 1 4 28 1 4 23 2HJ 2HK 1 No image appears entirely white Print example Causes Check procedures corrective measures The LED print head has not done function ing Defective FFC connection to the LED print heads relay PWB Check the FFC connection to the LED print heads relay PWB Do not attempt to disconnect connect the FFC while power is on See page 1 5 15 Defective FFC connection to the LED print head Check the FFC connection to the LED print head See page 1 5 15 Defective main controller PWB Replace the main controller PWB A0171 See page 1 5 40 Defective LED print heads relay PWB Replace the LED print heads relay PWB A0176 See page 1 5 44 Defec tive develop ing sleeve bias or develop ing mag net bias output Defective engine control ler PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective main high volt age PWB Replace the main high voltage PWB See page 1 5 45 Defec tive sec ondary transfer bias out put Defective engine control ler PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective bias high volt age P
87. ce Defective toner sensor 4 Replace the black developer unit See page 1 5 12 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective engine relay PWB A0009 Replace the engine relay PWB A0009 Contents 2HJ 2HK Remarks Causes Check procedures corrective measures Cyan developer unit non installing error The toner sensor 2 inside the cyan developer unit did not output the density detection signal judged the engine con troller PWB A0004 the cyan developer unit is not installed Defective harness of the toner sensor 2 defective con nection of the con nector between cyan developer unit and the printer main unit or poor contact of the connector ter minals Check the damage of harness of the toner sensor 2 check the connection of the con nector with the cyan developer unit and the printer main unit if there is trouble remedy or replace Defective toner sensor 2 Replace the cyan developer unit See page 1 5 12 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective engine relay PWB A0009 Replace the engine relay PWB A0009 Magenta developer unit non install ing error The toner sensor 1 inside the magenta developer unit did not output the density detection signal judged the engine con troller PWB A0004 the
88. ck the paper storage conditions replace the paper Replace the paper Perform the drum surface refreshing See page 1 3 17 Replace the drum unit See page 1 5 13 Paper damp Paper creased Drum condensation Flawed drum Flawed primary transfer belt 15 Fusing is loose Print example Causes Replace the primary transfer unit See page 1 5 22 Check procedures corrective measures Check if the paper meets specifications replace paper Check the fuser pressure springs See page 1 5 26 1 5 33 Wrong types of paper Defective pressure for the heat roller and press roller press belt X Flawed heat roller or press roller press belt 1 Replace the heat roller and press roller press belt See page 1 5 26 1 5 33 1 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 16 Colors are printed offset to each other Print example Causes Check procedures corrective measures The drum unit is not properly seated in its position Perform the color registration to correct Refer to operation guide The primary transfer belt is not in its proper position or the primary transfer unit is defective 1 4 28 Confirm the position of the primary transfer belt Check the pri mary transfer unit Replace the primary transfer unit See page 1 5 22 1 4 4 Electric problems Problem
89. cover l Opening FFC blue LED print head metal Sponge Drum unit rim Figure 1 5 28 Press spring Figure 1 5 29 1 5 19 2HJ 2HK 21 Refit the drum unit into the printer and lock the release levers 22 Connect one connector 23 Insert the blue and white FFCs horizontally to the FFC connectors LED print heads relay PWB NOTE Ensure the FFCs are not inserted at a slant to the connectors 1 5 20 Figure 1 5 30 FFC connectors LED print heads relay PWB FFC connector Figure 1 5 31 2HJ 2HK 24 Refit the connector cover 25 Refit the developer units and toner contain ers to the printer 26 Close the top cover Figure 1 5 32 27 Turn the power on Print a test page selected from the service mode MENU of the operation panel 28 Check that there is no fault in a print out NOTE After the LED print head has been replaced the printer requires approximately 30 seconds until it gets ready This is required because the printer needs to download the data stored in the EEPROM mounted on the LED print head for optimizing the LED print head performance CAUTION If there is a fault with the test page or a fault is displayed on the self diagnostic display check the following If the test print image is partly missing or a fault is displayed The FFC connection to the LED print
90. d unit 1 Detaching and refitting the paper feed unit Procedure 1 Pull out the paper feed unit until stop 2 While pressing the left and right lock release buttons and then remove the paper feed unit 1 5 6 Lock release button Lock release button Paper feed unit Figure 1 5 7 2 Detaching and refitting the paper feed roller Procedure 1 2 3 5 6 Remove the paper feed unit See previous page Turn over the paper feed unit While pushing the lock release buttons and then detach the joint Unlatch the latches and then remove paper feed roller unit Unlatch the three latches and then remove the feed bracket cover Remove the feed roller and pickup roller The one way clutch is built in to the pickup gear Z32S When the pickup gear Z32S is installed again the surface of one way clutch side is directed to feed bracket cover side Check or replace the feed roller and then refit all the removed parts 2HJ 2HK Latches Figure 1 5 8 Paper feed roller unit PE One way clutch Pickup gear Z32S Latch Pickup roller Feed roller Figure 1 5 9 Latches Feed bracket cover 1 5 7 2HJ 2HK 3 Detaching and refitting the retard roller Procedure 1 Remove the paper cassette 2 Unlatch the two latches and then remove the retard roller holder 3 Remove the retard roller from retard roller Retard roller holder 4 Check or replace the retard r
91. drum units which are isomorphic to each other in cyan magenta yellow and black colors In the drum unit the main charger disperses charging potential over the drum to evenly charge the drum When the light emitted by LED hits the charged drum the electrostatic latent image is developed on the drum The electro static latent image is developed by toner applied by the developer unit and transferred onto the primary transfer belt in four colors The toner remaining on the drum is scraped off by the cleaning blade and driven outside by the spiral screw The residual potential on the drum is discharged by the exposure to the eraser lamp Thus the drum becomes ready for the next main charging Figure 2 1 15Drum unit Waste toner exit screw Eraser lamp PWB Drum frame Lens cleaner Main charger unit LED print head Drum Cleaning blade PONS ood 2 1 11 2HJ 2HK Figure 2 1 16Drum unit 2 1 12 2HJ 2HK LED print heads relay PWB Q LED print head LPH PWB 1 2 3 4 2 Eraser lamp PWB 1 2 3 4 3 Drum PWB 1 2 3 4 LVDSPO to 11 LVDSNO to 11 Main YC2 1 to 32 controller PWB ADATA10 to 19 ADATA 20 to 29 YC5 9 to 18 SDA YC5 20 SCLK vC5 25 YC3 9 to 18 YC2 1 E YC3 2 YC402 1 M ERAS1 YC401 7 YC2 2 4 YC3 3 YC401 4 ycaor s YC401 2 YC11 2 YC11 1 AS Engine controller E L YO4 9 to 18 PWB YC6 9 to 18 Y
92. dure 1 Turn off the power switch and then remove the power cord 2 When the optional memory card has been installed in the memory card slot already remove that 3 Remove the two screws and then remove the main controller PWB A Memory card slot Figure 1 5 61 1 5 40 2HJ 2HK 2 Detaching and refitting the engine controller PWB and power supply PWB To replace the engine controller PWB and the drum unit at the same time turn on the printer after replacing either one Check that the printer operates properly and then turn off the printer Replace the other and turn on the printer to check that the printer operates properly Be sure to replace one by one Refer to self diagnostic code 9530 See page 1 4 21 Procedure 1 Remove the main controller PWB See pre vious page 2 Remove the right cover left cover and rear cover See page 1 5 4 1 5 5 and 1 5 3 3 Remove the one screw and then remove the wire clamp and terminal 4 Remove the all machine left five machine right four connectors Connectors Connectors Ll crew 9 T SS Wire clamp Remove three screws Loose the one screw A Remove the main unit frontal projections and remove the controller box NON L Main frame Screw A Screw Screw LR 3 Controller box Figure 1 5 63 1 5 41 2HJ 2HK 8 Remove the six screws and then remove the controller box cover 9 Remove the
93. e the copier to move unexpectedly or topple leading to injury sese sees eee eee ee eee eee Q Avoid inhaling toner or developer excessively Protect the eyes If toner or developer is acciden tally ingested drink a lot of water to dilute it in the stomach and obtain medical attention immedi ately If it gets into the eyes rinse immediately with copious amounts of water and obtain medical IUe E EA AE AE E A A S E E Advice customers that they must always follow the safety warnings and precautions in the copier s instruction handbook A Q 2 Precautions for Maintenance AAWARNING Always remove the power plug from the wall outlet before starting machine disassembly Always follow the procedures for maintenance described in the service manual and other related A este ected TTE O Under no circumstances attempt to bypass or disable safety features including safety mechanisms ANC protective circuit rore it ee o ete tia iidae S Always use parts having the correct specifications eee eee eee eee eee Q Always use the thermostat or thermal fuse specified in the service manual or other related bro chure when replacing them Using a piece of wire for example could lead to fire or other serious Q accident 2 45 EE E E T A E A E AET When the service manual or other serious brochure specifies a distance or gap for installation of a part always use the correct scale and measure carefully eee eee ee ng Alwa
94. e background is colored Print example Causes Check procedures corrective measures Defec tive develop ing sleeve bias out put Defective developer Check the four colors of image by using the test page of ser vice mode If the defect appears on a particular color replace the developer for that color See pages 1 3 14 and 1 5 12 Defective bias high volt age PWB Replace the bias high voltage PWB See page 1 5 46 Defective engine control ler PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective main controller PWB Replace the main controller PWB A0171 See page 1 5 40 Defective drum unit Replace the drum unit See page 1 5 13 Defective primary transfer cleaning unit Replace the primary transfer cleaning unit See page 1 5 24 Defec tive color calibra tion Dirty sensing surface of the toner ID sensor Clean the sensing surface of the toner ID sensor The printer environment considerably changed since an automatic cali bration was made 7 White streaks are printed vertically Print example Causes Perform the color calibration of service mode See page 1 3 14 Check procedures corrective measures 1 4 26 Defec tive LED print head output Poor insertion of LED cleaner Check if the LED cleaner unit is properly seated If necessary reseat it properly Dirty
95. e ee 8 Bias high voltage PWB 9 Main high voltage PWB 10 Waste toner full sensor PWB 11 Waste toner full sensor 12 MP tray paper Sengar eee eee eee eee eee 13 Humidity sensor eee eee 14 Temperature Sensor see eee eee eee eee eee 15 Registration Sensor 16 Paper gauge sensor 1 sees eee eee 17 Paper gauge sensor 2 eee eee eee eee 18 Paper full SENSO see eee eee eee 19 Toner ID Sens r sese essere 20 Envelope feeder install sensor 21 Top cover feed unit switch 22 Top cover switch 1 sese 23 Top cover switch 2 sese eee eee 24 Side cover switch eee 25 POWer SWIICh ott eei eie 26 Cassette size switch eee 21 Feed MO aee 28 Fuser Motori piene ea ia 29 Primary transfer motor 30 Drum motor 1 r rr earar aae 31 Drm motor 2 emi 32 Drum Motor Ieir areren egante 33 Drum motor Accord 34 Toner motor T a 35 Toner motor Divan 36 Toner motor 2 eee 37 Toner motor d 38 Ozone fan motor T 39 Ozone fan motor 2 sese 40 Main fan motor eee eee 41 Drum motor cooling fan motor 42 Controller box fan motor 43 Developer drive stop motor 44 MP tray feed solenoid
96. e engine controller PWB A0004 See page 1 5 41 Defective harness 803197 between engine controller PWB A0004 and sensor PWB A0001 or poor con tact of the connector termi nals Check the continuity of the harness S03197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace 4 Cassette 1 not loaded display is not cancelled to closing the paper cassette Defective cassette size switch Replace the cassette size switch Defective sensor PWB A0001 Replace the sensor PWB A0001 Defective harness 803207 between cassette size switch and sensor PWB A0001 or poor contact of the connector terminals Check the continuity of the harness S03207 check the connec tion YC703 connector of sensor PWB A0001 if there is trouble remedy or replace Defective harness 803197 between engine controller PWB A0004 and sensor PWB A0001 or poor con tact of the connector termi nals Check the continuity of the harness S03197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 5 Check waste toner box
97. e main charger wire cleaner Check if the main charger wire cleaner is properly seated If necessary reseat it properly Dirty or Dirty drum Perform the drum surface refreshing See page 1 3 17 flawed Flawed drum drum Replace the drum unit See page 1 5 13 Deformed or worn cleaning blade in the drum unit Replace the drum unit See page 1 5 13 Defect fur brush of the primary trans fer cleaning unit Replace the primary transfer cleaning unit See page 1 5 24 Worn primary transfer belt 9 Streaks are printed horizontally Print example Causes Replace the primary transfer unit See page 1 5 22 Check procedures corrective measures Poor contact of output terminal of main charger unit Insert the main charger unit properly Poor contact of grounding terminal of drum unit Replace the drum unit See page 1 5 13 Poor contact of developing bias termi nal of developer 10 Spots are printed Print example Causes Replace the developer See page 1 5 12 Check procedures corrective measures Dirty or flawed drum Perform the drum surface refreshing See page 1 3 17 Deformed or worn cleaning blade in the drum unit Replace the drum unit See page 1 5 13 Defect fur brush of the primary trans fer cleaning unit Replace the primary transfer cleaning unit See page 1 5 24 Flawed developin
98. e overcurrent of toner motor 1 Defective toner motor 1 Replace the toner motor 1 See page 1 5 50 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Lump of toner inside magenta toner container or defectiveness of toner replenish ment drive system Replace the magenta toner container Toner motor 3 overcurrent detection error yellow toner The engine controller PWB A0004 detected the overcurrent of toner motor 3 Defective toner motor 3 Replace the toner motor 3 See page 1 5 50 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Lump of toner inside yellow toner container or defec tiveness of toner replenishment drive system Replace the yellow toner container 1 4 16 Black developer unit non installing error The toner sensor 4 inside the black developer unit did not output the density detection signal judged the engine con troller PWB A0004 the black developer unit is not installed Defective harness of the toner sensor 4 defective con nection of the con nector between black developer unit and the printer main unit or poor contact of the connector ter minals Check the damage of harness of the toner sensor 4 check the connection of the con nector with the black developer unit and the printer main unit if there is trouble remedy or repla
99. e printer s operation panel and carry out the memory card for matting procedure 1 5 When formatting is complete turn printer Y power off Memory Card gt Ready Operation panel keys Press the MENU key Press the A or Y key Press the gt key Press the A or V key gt Format 1 Press the OK key U gt Format 7 Press the OK key Processing I Format information is automatically printed Ready Figure 1 6 3 6 Remove the formatted memory card from the memory card slot 7 Insert the memory card to the PC s slot or to the adaptor 8 Copy the firmware file to download to the root directory of the memory card 9 Remove the memory card from the PC s slot or the adaptor Memory card Adapter Memory card reader writer Figure 1 6 4 1 6 2 10 Confirm that the printer s power switch is set to off 11 Insert the memory card into the printer s memory card slot 12 Turn printer power on 13 When message display 1 is displayed to detect firmware in the memory card 14 Message display 2 is displayed during downloading 15 When message display 3 is displayed to indicate downloading is finished 16 Turn printer power off 17 Remove the memory card from memory card slot 18 Turn printer power on 19 Confirm that message display 4 is dis played after warm up 20 Print the status page Print the status page to ch
100. e sees sees eee essere yeee enen ennenen O Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks O Remove toner completely from electronic components sss A Run wire harnesses carefully so that wires will not be trapped or damaged sees O After maintenance always check that all the parts screws connectors and wires that were removed have been refitted correctly Special attention should be paid to any forgotten connector trapped wire and missing SCTeWS sse ee sese ee eee ee essere neee teeta acca ennenen Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling Replace with new ones if necessary eee eee eee eee Q Handle greases and solvents with care by following the instructions below sss eee eee eee ee e Q Use only a small amount of solvent at a time being careful not to spill Wipe spills off completely Ventilate the room well while using grease or solvents Allow applied solvents to evaporate completely before refitting the covers or turning the power switch on Always wash hands afterwards Never dispose of toner or toner bottles in fire Toner may cause sparks when exposed directly to UI Ilaec TI EU IP O Should smoke be seen coming from the copier remove the power plug from the wall outlet imme NN 3 Miscellaneous WARNING Never attempt to heat the drum or expose i
101. eck that the firmware version has been updated Memory card slot Figure 1 6 5 Power switch On ELCHE 3 06 04 26 E1F9 B Y Power switch Off 2HJ 2HK 1 Message display Product code 2HJ 16 17 ppm printer EUR USA model 2HK 20 22 ppm printer EUR USA model 2 Firmware category 10 Engine controller 30 Main controller Supplement Classification 5 Update history 6 build number Release date Year Month Day Checksum emory card slot Memory card Power switch On Figure 1 6 6 1 6 3 2HJ 2HK This page is intentionally left blank 1 6 4 2HJ 2HK 2 1 1 Paper feed section There is paper feed from the paper cassette which can load paper 500 and paper feed from the MP tray which can load paper 100 in paper feed method of this printer The paper feed section is composed of paper cassette paper feed unit paper feed drive unit MP tray and MP tray feed unit 1 Paper feeding from paper cassette The paper cassette is fit underneath the paper feed unit The paper stored in the paper cassette is lifted up so that it is pressed against the pickup roller as the bottom plate in the paper cassette is raised by the lifter mechanism The sheet at top is rewound to the pick up roller and sent to the paper feed roller which forward the paper in the printer In order to pre vent paper misfeed during feeding the retard roller which is positioned face
102. en cassette size switch and sensor PWB A0001 or poor contact of the connector terminals Check the continuity of the harness S03207 check the connec tion YC703 connector of sensor PWB A0001 if there is trouble remedy or replace Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 7 Paper misfeed display is not cancelled Defective registration sen sor Replace the sensor PWB A0001 Defective sensor PWB A0001 Replace the sensor PWB A0001 Defective harness S803197 between engine controller PWB A0004 and sensor PWB A0001 or poor con tact of the connector termi nals Check the continuity of the harness S03197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace Defective exit sensor Replace the fuser PWB KP 970 A0003 Defective harness 803197 between fuser PWB KP 970 A0003 and fuser connector or poor contact of the connector terminals Check the continuity of the harness S03197 check the connec tion YC691 connector of the fuser PWB KP 970 A0003 if there is trouble remedy or replace Defective harness 803203 between power supply PWB and fuser connector or poor contact of the con nector terminals Check the continuity of the harness S03203
103. en forward to the registration roller by means of the MP middle roller Figure 2 1 7MP tray paper feed section 1 MP frame 5 MP middle tray 2 MP feed roller 6 MP base 3 MP middle roller 7 Separator 4 8 Multi bottom MP tray cover MP feed roller MP tray feed unit To fuser unit ud 7L MP tray ees Paper feed unit Figure 2 1 8 2HJ 2HK MP feed solenoid in Feed motor OND Engine controller PWB MPSOLDR vc 5 STFDA STFDAN STFDB STFDBN YC11 14 YC11 15 YC11 16 YC11 17 Figure 2 1 9MP tray paper feed section block diagram 2HJ 2HK 1 2 1 2 Developing section 1 Developer unit Developing section is composed of mixer screw developing blade developing magnet roller and developing sleeve Figure 2 1 10Developer unit 1 Developing sleeve 5 Mixer screw A 2 Developing magnet roller 6 Developer case 3 Doctor blade 7 Developer lid 4 Mixer screw B Developer case A Doctor blade Developing sleeve L Developing magnet roller AS Figure 2 1 11Developer unit 2 1 7 2HJ 2HK Engine controller PWB Black L4 D Developing magnet roller i developer 2 Developing sleeve a t 8 Toner sensor US Output S Output 42 lt Output CN8 Developing 3 magnet bias 2 HVCLK1 output circuit 3 HVCLK2
104. engine controller engine controller PWB A0004 if there is PWB A0004 and trouble remedy or replace LED print heads relay PWB A0176 or poor contact of the connector termi nals Defective FFCs Check the connection of the FFCs with the S03011 between magenta drum unit and the printer main unit LED print head 3 check the continuity of the FFCs 803011 and LED print check the connection of the LED print head heads relay PWB 3 if there is trouble remedy or replace See A0176 or poor page 1 5 15 contact of the FFC terminals 1200 Side registration motor error Defective duplexer Refer to the duplexer s service manual The duplexer PWB of the optional z duplexer cannot detect the home posi Se WE o Controller PE A0004 tion of the adjust guide A0004 2610 Paper feed motor error top Defective paper Refer to the paper feeder s service manual The notification that was received the feeder motor clock sensor cannot detect the 7 revolution of the paper feed motor of the Devecive engine Replace the engine controller PWB A0004 optional paper feeder top A0004 2620 Paper feed motor error middle Defective paper Refer to the paper feeder s service manual The notification that was received the feeder motor clock sensor cannot detect the 7 revolution ofthe paper feed motor ofthe CES engine Replace the engine controller PWB A0004 optional paper feeder middle A0004 2630 Paper feed mo
105. er PWB A0004 if there is trouble remedy or replace 2HJ 2HK Code Contents Remarks Causes Check procedures corrective measures 7412 Cyan drum unit non installing error Defective harness Check the connection of the cyan drum unit The EEPROM U401 on the drum PWB 2 KP 972 inside the cyan drum unit does not communicate normally The incompatible drum unit is installed to the printer between drum PWB 2 KP 972 and printer main unit or poor contact of the connector termi nals and the printer main unit check the continu ity of the harness S803211 if there is trou ble remedy or replace Installing the drum unit which is incompatible with the printer specifi cation Install the compatible drum unit to the printer Defective drum PWB 2 KP 972 Replace the drum PWB 2 KP 972 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness 803214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness S03214 check the connection YC3 con nector of the engine controller PWB A0004 if there is trouble remedy or replace 1 4 19 2HJ 2HK Code Contents Puis
106. er Press roller 16 17 ppm printer EUR USA model 114 61 mm Heat roller 20 22 ppm printer EUR USA model 2 4 5 2HJ 2HK This page is intentionally left blank 2 4 6 KYOCERA MITA EUROPE B V Hoeksteen 40 2132 MS Hoofddorp The Netherlands Phone 31 20 654 0000 Home page http www kyoceramita europe com Email info kyoceramita europe com KYOCERA MITA NEDERLAND B V Beechavenue 25 1119RA Schiphol Rijk The Netherlands Phone 31 20 58 77 200 KYOCERA MITA UK LTD 8 Beacontree Plaza Gillette Way Reading Berks RG2 OBS U K Phone 44 1189 311 500 KYOCERA MITA ITALIA S p A Via G Verdi 89 91 20063 Cernusco s N Milano Italy Phone 39 02 92179 1 S A KYOCERA MITA BELGIUM N V Hermesstraat 8A 1930 Zaventem Belgium Phone 32 2 720 9270 KYOCERA MITA FRANCE S A Parc Les Algorithmes Saint Aubin 91194 GIF SUR YVETTE France Phone 33 1 6985 2600 KYOCERA MITA ESPANA S A Edificio Kyocera Avda de Manacor No 2 28290 Las Matas Madrid Spain Phone 34 91 631 8392 KYOCERA MITA FINLAND OY Kirvesmiehenkatu 4 00880 Helsinki Finland Phone 358 9 4780 5200 KYOCERA MITA SCHWEIZ Hohlstrasse 614 8048 Z rich Switzerland Phone 41 1 908 4949 KYOCERA MITA DEUTSCHLAND GMBH Mollsfeld 12 40670 Meerbusch Germany Phone 49 2159 918 0 KYOCERA MITA GMBH AUSTRIA Eduard Kittenberger Gasse 95 1230 Wien Austria Phone 43 1 86338 210 KYOCERA MITA SVENSKA AB Vretenv gen 2 6
107. eraser Replace the eraser lamp 3 PWB KP unit The eraser lamp 3 PWB KP 1090 of the yellow drum unit does not communi cate with the engine controller PWB A0004 normally lamp 3 PWB KP 1090 1090 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective drum PWB 3 KP 972 Replace the yellow drum unit See page 1 5 13 Defective harness S803212 between drum PWB 3 KP 972 and eraser lamp 3 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 3 KP 972 if there is trouble remedy or replace Defective harness S803214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the connection YC3 con nector of the engine controller PWB A0004 if there is trouble remedy or replace Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 1 4 11 2HJ 2HK 1 Contents Remarks Causes Check procedures corrective measures Fuser temperature time out error heat roller Doing the control which turns on the fuser heater lamp 1 which is built in to the heat roller of the fuser unit the fuser temperature which fuser thermistor 1 detects stipula
108. g and refitting the waste toner duct Procedure 1 Remove the primary transfer unit See page 1 5 22 2 Remove the primary transfer cleaning unit See page 1 5 24 3 Unlatch the three latches and then remove the waste toner duct 4 Check or replace the waste toner duct and then refit all the removed parts 1 5 52 Waste toner duct Figure 1 5 77 2HJ 2HK 1 1 6 1 Downloading firmware The system firmware can be update by downloading new firmware Downloading can be made by using a memory card that contains the new firmware Firmware file name example Software ID Compression L S2HK 1000001021 cmp QQ LLLI LI Ll La Product code Pause period 2HJ 16 17 ppm printer EUR USA model 2HK 20 22 ppm printer Build number EUR USA model Pause under bar Version up history 0 Normal E Corrective Firmware description supplement Firmware description 10 Engine 30 System Figure 1 6 1 1 6 1 2HJ 2HK 1 Downloading the firmware from the memory card The procedure below provides how to download firmware from a memory card Note that you can download both the sys tem and engine firmware at a time Procedure 1 Turn printer power off 2 Insert the memory card into the printer s memory card slot ZG Memory card slot MEL emory card Memory card slot Figure 1 6 2 3 Turn printer power on Message display 4 Press MENU key on th
109. g sleeve roller Replace the developer See page 1 5 12 Dirty heat roller and press roller press belt Clean the heat roller and press roller press belt See page 1 5 26 1 5 33 1 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 11 The leading edge of image begins to print too early or too late Print example Causes Check procedures corrective measures Registration clutch operating incor rectly Check the installation of the registration clutch If it operates incorrectly replace it Defective engine controller PWB Replace the engine controller PWB A0004 See page 1 5 41 Defective main controller PWB Replace the main controller PWB A0171 See page 1 5 40 1 4 27 2HJ 2HK 1 12 Paper is wrinkled Print example Causes Check procedures corrective measures Paper curled Check the paper storage conditions replace the paper Paper damp 13 Offset occurs Print example Causes Check the paper storage conditions replace the paper Check procedures corrective measures Deformed or worn cleaning blade in Replace the drum unit See page 1 5 13 the drum unit Wrong types of paper 14 Part of image is missing Print example Causes Check if the paper meets specifications Replace paper Check procedures corrective measures Che
110. he black toner container into the printer The black toner container must be installed in the front most developer 1 2 4 Black toner container Figure 1 2 5 i Top cover Black toner container 3 Figure 1 2 6 2HJ 2HK 4 Push in the black toner container firmly until it locks in the developer Black toner container Figure 1 2 7 5 Turn the lock lever backward to the lock position Lock lever 6 Install other toner containers in the same procedure E 7 Close the top cover P zy Magenta Yellow Cyan Black I A Ti al en fex L L E Seo Figure 1 2 8 1 2 5 2HJ 2HK Install the waste toner box 1 Open the side cover 2 Install the waste toner box 3 Close the side cover Loading paper tion window 1 2 6 Remove the paper cassette from the printer 2 Adjust the paper guides and the paper stop per according to the paper size to be used 3 Turn the dial so that the size of the loaded paper is indicated in the paper size indica Side cover Fig
111. he paper jams are logged When the occur rence exceeds 16 the oldest occurrence is removed Event Log code 2 digit hexadecimal 6 cate gories a Cause of a paper jam b Position of paper jam c Paper source d Paper size e Paper type f Paper exit Refer to the next page for the details of each log code a Cause of paper jam 10 Paper does not arrive at the registration sensor 42 MP tray 10 Paper does not arrive at the registration sensor 31 Cassette 1 10 Paper does not arrive at the registration sensor 31 Cassette 2 10 Paper does not arrive at the registration sensor 31 Cassette 4 10 Paper does not arrive at the registration sensor 31 Duplexer 10 Paper does not arrive at the registration sensor 41 Envelope feeder 10 Paper does not arrive at the registration sensor 31 Cassette 3 2HJ 2JK Service items Description Description a Cause of paper jam 11 Paper does not pass the registration sensor 48 12 Paper remains at the registration sensor when power is turned on 48 20 Paper does not arrive at the exit sensor 48 21 Paper does not pass the exit sensor 48 22 Paper remains at the exit sensor when power is turned on 48 30 Paper does not arrive at the paper feeder 1 paper sensor 42 Cassette 2 30 Paper does not arrive at the paper feeder 1 paper sensor 42 Cassette 3
112. head control video data signal LVDS LVDSN5 Analog LED print head control video data signal LVDS LVDSP6 Analog LED print head control video data signal LVDS LVDSN6 Analog LED print head control video data signal LVDS LVDSP7 Analog LED print head control video data signal LVDS 0000 00005 Connected to the LED print heads relay PWB ONDARON 000000000000000000000000000000000050 m MMM MM MA a a ma a ud a HHO G Qn E GM O OG YO Q E GM O LVDSN7 Analog LED print head control video data signal LVD Analog LED print head control video data signal LVD Analog LED print head control video data signal LVD Analog LED print head control video data signal LVD Analog LED print head control video data signal LVDS Analog LED print head control video data signal Analog LED print head control video data signal LVDS Analog LED print head control video data signal LVDS Analog LED print head control video data signal Analog LED print head control video data signal Analog LED print head control video data signal LVDS Analog LED print head control video data signal LVDS N Y LVDSP8 LVDSN8 LVDSP9 LVDSN9 LVDSP10 LVDSN10 LVDSP11 LVDSN11 LVDSP12 LVDSN12 LVDSP13 LVDSN13 G G GQ G G G G GQ M IO N O Qn E GM O O OO Co 00 Analog LED print head control video data signal LVDS 2 3 4 2HJ 2HK Connector Pin Sign
113. igh l l voltage A1 Wire output circuit L N Y xcu i i ON S Grid E f E ND R Zener i L Dum PWB 2 Lu ne l D A YC1 7 HVADATD See converter YC1 8 HVACLKD Cyan drum unit IC501 YC1 9 HVALATD Main charger unit Output Shield og L Wire CN em ON y Grid MEME NS Zener L mum j PWB3 Lc ud AA Yellow drum unit Main charger unit Output Shield Wire 5 0 Grid E Y o Drum Black drum unit 2 1 18 Output 320 uA 7 kV variable Figure 2 1 23Main charger output block diagram Engine controller PWB YC6 2 YC6 3 YC6 4 YC6 5 YC6 7 YC6 8 YC6 9 2HJ 2HK 2 1 4 Primary transfer section Primary transfer section is composed of the primary transfer unit and primary transfer cleaning unit 1 Primary transfer unit The primary transfer unit is comprised of the primary transfer belt tension rollers and four primary transfer rollers of col ors Color image is transferred on the transfer belt as the four layers different colors The toner ID sensor mounted on the main frame monitors the density of the toner on the primary transfer belt Primary transfer 8 cleaning unit A Figure 2 1 24Primary transfer unit Tension roller Backup roller Drive roller Primary transfer roller magenta Primary transfer roller cyan Primary transfer roller yellow Primary transfer roller black Primary transfer belt Drive base 0 Tension base
114. ignal input N C 24V DC 24 V DC power input 24V DC 24 V DC power input 24V1 24 V DC 24 V DC power input 24V1 24 V DC 24 V DC power input GND Ground GND Ground GND Ground GND Ground GND Ground GND Ground GND Ground GND Ground 3 3V1 3 3 VDC 3 3 V DC power input 3 3V1 3 3 V DC 3 3 V DC power input 3 3V1 3 3 VDC 3 3 V DC power input 3 3V1 3 3 VDC 3 3 V DC power input 5V1 5V DC 5 V DC power input 5V1 5V DC 5 V DC power input BFANDR 0 5 V DC Controller box fan motor On Off Connected GND Ground to the con troller box fan motor 1 16 17 ppm printer EUR USA model only ce JO Qn E G N o m M M hM M MM MMM amp 2 o HHA eas 00 JO Qm E GM 000 Jl O Q E GM O 00 00 0 2 3 9 2HJ 2HK 2 3 3 Main controller PWB ASIC CPUDI31 0 CPUDH 31 0 MA 12 0 MCSN 4 1 MCKE 4 0 MRASN MCASN MWEN MBA 1 0 MDQS 3 0 DM 3 0 MCKP 6 4 3 1 0 MCKN 6 4 3 1 0 MREFOUTP MREFOUTN MREFINP MREFINN ROMA 4 2 ROMK ROMCSN 1 0 Se e qus ROMB RoMRB Teman ROMA 1 ont ROMCSN 2 Fon ROMOEN 1 ROM KUIOCSN 0 KUIOIORN 0 KUIOIOWN 0 KKUIORDY 0 0 KUIDREQ 0 KUIOACKN 0 KUIO KUIODACKN o KUIORSTN 0 KUIOIRN 0 Memory card CFOCSN 1 0 CFOEN 0 FCWEN 0 CFOCDET 2 1 CFWAITN 0 CFRST 0 CFIORN 0 FCIOWN o CFIOACKN 0 CFIREQN 0 31 0 MDQ 31 0 Transce
115. is not cancelled to closing the top cover Defective side cover switch SW702 of the sensor PWB A0001 Replace the sensor PWB A0001 The actuator of the side cover switch SW702 of the sensor PWB A0001 is bent Check the bending of the actuator of the side cover switch if there is trouble remedy or replace Defective sensor PWB A0001 Replace the sensor PWB A0001 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective harness S803197 between engine controller PWB A0004 and sensor PWB A0001 or poor con tact of the connector termi nals Check the continuity of the harness S803197 check the connec tion YC2 connector of the engine controller PWB A0004 check the connection YC701 and YC702 connectors of the sensor PWB A0001 if there is trouble remedy or replace 1 4 29 2HJ 2HK Problem Causes Check procedures corrective measures 3 Close paper transfer unit display is not cancelled to closing the paper feed unit Defective top cover paper feed unit switch SW701 of the sensor PWB A0001 Replace the sensor PWB A0001 Malfunctioning interlock rod that interfaces between the top cover and the top cover paper feed unit switch SW701 Check to see if the interlock rod malfunctions If it malfunctions repair it Defective engine controller PWB A0004 Replace th
116. it was not reset AAAAAA perform the steps 20 to 22 again Perform the Execution of color calibration See page 1 3 14 Perform the Printing a test page and then make sure printing image See page 1 3 14 2HJ 2HK 1 Primary trans unit belt Handle En Primary transfer unit Figure 1 5 35 Service status page extracts from the service information Service Information 2F3 1100 001 001 2HJ 1000 001 003 2HJ A000 001 002 2HJ 3100 200 F00 N00 D10 DM0301 DAN 0002001001210052 0020 0020 1061 0811 0 0 0 0 0 0 of of C AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAA AAAAAAA AAAAAAA Primary transfer unit life counter C gt R KCFG LFRE ITTR 0 EXIT Parallel x printer cable H Parallel interface connector Figure 1 5 36 1 5 23 2HJ 2HK 4 Detaching and refitting the primary transfer cleaning unit Procedure 1 Remove the primary transfer unit See page1 5 6 2 Pull out the primary transfer cleaning unit from the main unit frame a little with under neath the right 1 3 Pull out the waste toner outlet 2 which is on the left side of the primary transfer clean ing unit from the main unit frame Remove the primary transfer cleaning unit Check or replace the primary transfer clean Primary transfer ing unit and then refit all the removed parts cleaning unit eu
117. iver Latch LD 16 0 LD 31 0 LA 23 2 LD 15 0 LA 21 2 PPC750CXr 23 2 EXTBOEN FPCLK FPDIR FPDAT Engine e FPRSTN SCLKN SO I SBSY SDIR UDP UDM UREXT URKELVIN USBINTTH USBVBUSH USB2 0 LD 15 0 LA 16 2 USBCLK URESET URVALID UTXREADY URXACTIVE URXERR UOPMODE 1 0 ULSTATE 1 0 USUSPPEND UTERMSELUTXVALID USBDATA 15 0 UXCVRSEL PHY e Transceiver VTXCLKP VTXCLKN VTXDP 11 0 VTXDN 11 0 VRXCLKP VRXCLKN Video e LA 11 2 VRXDP 1 0 VRXDN 1 0 DBCLK DBTXD DBRXD DBG Trans former Ether C e ECRS ECOL ETXEN ETXCLK ETXD 3 0 ERXER ERXDV ERXCLK ERXDV 3 0 PHY EMDIO EMDC PHYIR MACLED Figure 2 3 3Main controller PWB block diagram 2 3 10 2HJ 2HK 1 Appendixes 2 4 1 diagram 16 17 ppm printer EUR USA model 1 Wiring n sozeos
118. ly gt gt Paper feed Special gt gt Maintenance gt gt Drum To print a status page for service purpose See page 1 3 2 To print an event log EVENT LOG Displayed when FRPO 11 is set to 1 See page 1 3 9 To execute color calibration See page 1 3 14 To print a test page See page 1 3 14 To set paper feed operation as printer driver priority mode See page 1 3 15 To reset the counter after replacing the maintenance kit See page 1 3 15 To perform developer refreshing See page 1 3 16 To perform drum surface refreshing See page 1 3 17 1 3 1 2HJ 2JK 1 Service items gt gt Print Status Page Description Printing a status page for service purpose Description Prints a status page for service purpose The status page includes various printing settings and service cumulatives Purpose To acquire the current printing environmental parameters and cumulative information Procedure 1 Enter the service mode gt gt Print Status Page 2 Press the OK key Message Print Status Page will be displayed 3 Press the OK key Two pages will be printed The second page includes service information Service information Main controller PWB Refer to next page firmware version Release date of the firmware PAGE PRINTER STATUS PAGE Firmware version 2HJ 3000 001 017 Released 25 Apr 2006 E PAGE PRINT
119. m Figure 1 5 37 1 5 24 1 5 8 Fuser unit 16 17 ppm printer EUR USA model 1 Detaching and refitting the fuser unit Procedure 1 Remove the rear cover See page 1 5 3 2 Remove the right cover and left cover See page 1 5 4 and1 5 5 3 Remove the two screws and then remove the fuser unit 4 Check or replace the fuser unit and then refit all the removed parts Figure 1 5 38 2HJ 2HK 1 Fuser unit 1 5 25 2HJ 2HK 2 Detaching and refitting the fuser thermistor 1 and 2 fuser thermostat 1 and 2 fuser heater lamp 1 and 2 heat roller and press roller Procedure 1 Remove the fuser unit See previous page 2 While two latches unlatching remove the fuser bottom cover by making slide 3 Remove the one tab 4 Remove the two screws form the terminals 1 5 26 Terminals Screws Figure 1 5 40 2HJ 2HK al Remove the three connectors from the fuser PWB Remove the one tab While unlatching the latches and then remove the fuse unit connector Remove the terminal NO 9 Remove the one screw and then remove the fuser left cover IS hn E Fuser left cover Figure 1 5 42 1 5 27 2HJ 2HK 10 Remove the one screw and then remove the fuser right cover 11 Remove the fuser heater lamp 1 and 2 Fuser heater lamp 2 Press roller 350 W Fuser right cover Screw Figure 1 5 43 12 Remove the two pressure springs
120. m serial number Black Cyan Magenta Yellow Machine serial number NOTE Code conversion 1 3 7 2HJ 2JK 1 Service items Plain Description Media type attribute Paper feed source Paper Enve cas lope sette feeder Paper destination Face Face down up tray tray Type adjust default Normal2 MP tray Duplexer Transparency Extra Thick Preprinted Normal2 Labels Thick1 Bond Normal2 Recycled Normal2 Vellum Thin Rough Normal2 Letter Head Normal2 Color Normal2 Prepunched Normal2 Envelope Thick1 Cardstock Thick2 Coated Normal2 2 nd Side Thick Thick1 Fine Normal2 Reserved Reserved Reserved Custom1 Normal2 Custom2 Normal2 Custom3 Normal2 Custom4 Normal2 Custom5 Normal2 Custom6 Normal2 Custom7 Normal2 1 3 8 Custom8 Normal2 Type adjust setting peed in gloss mode 3 4 1 2 N NormaH Normal2 Normal3 Thick Thick2 Thick3 Extra Thick Note that a half speed is 55 1 50 2 of the normal speed Since the speed of printing in gross mode gets slower than normal printing in media types including Thick2 Thick3 and Extra Thick is not possible in gloss mode
121. magenta devel oper unit is not installed Defective harness of the toner sensor 1 defective con nection of the con nector between magenta developer unit and the printer main unit or poor contact of the con nector terminals Check the damage of harness of the toner sensor 1 check the connection of the con nector with the magenta developer unit and the printer main unit if there is trouble rem edy or replace Defective toner sensor 1 Replace the magenta developer unit See page 1 5 12 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective engine relay PWB A0009 Replace the engine relay PWB A0009 1 4 17 2HJ 2HK Contents Remarks Causes Check procedures corrective measures Yellow developer unit non installing error The toner sensor 3 inside the yellow developer unit did not output the density detection signal judged the engine con troller PWB A0004 the yellow devel oper unit is not installed Defective harness of the toner sensor 3 defective con nection of the con nector between yellow developer unit and the printer main unit or poor contact of the con nector terminals Check the damage of harness of the toner sensor 3 check the connection of the con nector with the yellow developer unit and the printer main unit if there is trouble remedy or replace Defective toner sensor
122. misfeed locations hexadecimal b Position of paper jam Printer Envelope feeder Rear cover Duplexer j y E A VERTI ANS UB Inside th printen 48 E AZ NUT t N NIS feeder 1 feeder 2 Figure 1 3 6 1 3 11 2HJ 2JK Service items Description Description c Detail of paper source Hexadecimal 00 MP tray 01 Paper cassette 1 02 Paper cassette 2 03 Paper cassette 3 Duplexer 04 Paper cassette 4 Not used 05 to 06 Not used Envelope feeder d Detail of paper size Hexadecimal 00 indefinite 01 Monarch 02 Business 03 International DL International C5 Executive Letter R Letter E Legal A4R A4E BBH BBE B4 Ledger A5 A6 B6 Commercial 9 Commercial 6 ISO B5 Custom size Cd Postcard Reply paid postcard Oficio II Special 2 A3 wide Ledger wide Full bleed paper 12 x 8 8K 16K R 16K E Statement R Statement E Folio Youkei 2 Youkei 4 0A A3 Special 1 e Detail of paper type Hexadecimal Custom 1 Custom 2 Custom 3 Custom 4 Custom 5 Custom 6 1B Custom 7 1C Custom 8 Plain Color Transparency Prepunched Preprinted Envelope Labels Cardstock Bond Coated Recycle 2nd side Vellum Media 16 Rough 11 High quality Letter head f Detail of paper exit locati
123. n the type of the error Error codes 0100 to 9530 service 0123456 Error code Error codes Call service D020 F000 F010 and F020 F990 4 Error code Error codes Error power off F000 F030 F040 and F226 5536 Error code Figure 1 4 3Error message display 1 4 2 2 Self diagnostic codes Contents 2HJ 2HK Remarks Causes Check procedures corrective measures EEPROM U12 write error When it cannot make normal to access to the EEPROM U12 which is installed in the socket of the engine controller PWB A0004 The total counter serial number and engine parameter etc are stored in the EEPROM U12 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 EEPROM U12 installing malfunc tion Check the bending of the lead pin and float ing of the IC there is trouble if there is trou ble remedy or replace Paper feeder communication error When turning on power the ASIC of the engine controller PWB A0004 recog nized the optional paper feeder but when it becomes not be able to commu nicate from the middle After the error occurring when power source is turned on off there are times when the paper feeder is not recog nized Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective paper feeder After removing or replacing the pa
124. ncy sheet 3M CG3700 or thick paper with the of more than weight above 135 g m to MP tray Press MENU key and print a status page The toner soiling which comes in contact with the heat roller and the press roller belt will be transferred onto paper Until the toner soiling is cleared repeat Usually when 4 5 it prints the soiling goes out the above procedure 1 3 18 2HJ 2HK Paper misfeed detection 1 4 1 1 Paper misfeed indication When a paper misfeed occurs the printer immediately stops printing and displays the paper misfeed message on the operation panel To remove paper misfed in the printer pull out the paper cassette pull out the paper feed unit or open the rear cover 0 D Q o o oO E ge oO o E E eo o wo a Paper Jam MP tray Paper misfeed location Figure 1 4 1 2 Paper misfeed detection Paper full sensor 1 4 1 sensor Paper path as ee ee ee LC j s ADT mr Figure 1 4 2Paper misfeed detection 2HJ 2HK 1 4 2 Self diagnosis 1 Self diagnostic function This printer is equipped with self diagnostic function When a problem is detected the printer stops printing and display an error message on the operation panel An error message consists of a message prompting a contact to service personnel total print count and a four digit error code indicating the type of the error The display varies depending o
125. nection YC3 con nector of the engine controller PWB A0004 if there is trouble remedy or replace Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 2HJ 2HK Code Contents Remarks Causes Check procedures corrective measures 5302 Eraser lamp 2 error cyan drum unit Defective eraser Replace the eraser lamp 2 PWB KP The eraser lamp 2 PWB KP 1090 of the cyan drum unit does not communi cate with the engine controller PWB A0004 normally lamp 2 PWB KP 1090 1090 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective drum PWB 2 KP 972 Replace the cyan drum unit See page 1 5 13 Defective harness S803212 between drum PWB 2 KP 972 and eraser lamp 2 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 2 KP 972 if there is trouble remedy or replace Defective harness 803214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the connection YC3 con nector of the engine controller PWB A0004 if there is trouble remedy or replace Defective LED print heads relay PWB A0176 Replace the LED print heads relay
126. ng Center 2825 West Story Road Irving Texas 75038 5299 TEL 972 659 0055 FAX 972 570 5816 Latin America Division 8240 N W 52nd Terrace Dawson Building Suite 108 Miami Florida 33166 TEL 305 421 6640 FAX 305 421 6666 Printed in U S A
127. ntrol signal Yellow On Off PWB 5 MCH4DR O 0 24V DC Main charger output control signal Black On Off 6 5V1 O 5VDC 5 V DC power output 7 HVADATD O 0 5V DC pulse Output control D A converter serial signal 8 HVACLKD O 0 5 V DC pulse Output control D A converter clock signal 9 HVALATD O 0 5V DC pulse Output control D A converter data latch signal 10 GND Ground YC7 1 GND Ground Connected 2 OPRDYN 10 5 V DC Optional unit ready signal Ready Not ready to the 3 OPSEL2 O 0 5 VDC Optional unit select signal bit2 optional 4 OPSDO O 0 5 V DC pulse Optional unit serial communication data output paper 5 OPSEL1 O 0 5V DC Optional unit select signal bit1 feeder 6 OPSDI 0 5 V DC pulse Optional unit serial communication data input duplexer 7 OPSELO O 0 5 V DC Optional unit select signal bitO 8 OPSCLK O 0 5 VDC pulse Optional unit serial communication clock signal 9 NC J Not connected 10 OP5V O 5VDC 5 V DC power output via fuse 11 GND Ground 12 OP24V O 24V DC 5 V DC power output via fuse YC8 1 5V1 O 5VDC 5 V DC power output Connected 2 5V1 O 5VDC 5 V DC power output to the main 3 5V1 O 5VDC 5 V DC power output controller 4 3 3V1 O 3 3V DC 3 3 V DC power output PWB 5 GND J Ground 6 VTXDP11 Analog LED print head control video data signal LVDS 7 VTXDP10 Analog LED print head control video data signal LVDS 8 VTXDP9 Analog LED print head control video data sign
128. o not touch the drum surface with any object Should it be touched by hands or stained with oil clean it 1 2 2 Developer unit and toner container Store the toner container in a cool dark place Avoid direct light and high humidity 1 2 3 1 ev B Installation environment Temperature 10 to 32 5 C 50 to 90 5 F Humidity 15 80 RH Power supply 120 V AC 9 0 A 220 240 V AC 5 0 A Average Power source frequency 50 Hz 0 2 60 Hz 0 2 Installation location Avoid direct sunlight or bright lighting Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams Avoid extremes of temperature and humidity abrupt ambient temperature changes and hot or cold air directed onto the machine Avoid dust and vibration Choose a surface capable of supporting the weight of the machine Place the machine on a level surface maximum allowance inclination 1 Avoid air borne substances that may adversely affect the machine or degrade the photoconductor such as mer cury acidic of alkaline vapors inorganic gasses NOx SOx gases and chlorine based organic solvents Select a room with good ventilation Allow sufficient access for proper operation and maintenance of the machine Machine front 600 mm 23 5 8 Machine rear 200 mm 7 7 8 400 mm 15 3 4 when the optional face up output tray is installed Machine right 250 mm 10 Machine left 300 mm 13 13 16 Machine
129. of replace ment are logged Count The total page count at the time of the replace ment of the toner con tainer This is virtually logged as the occurrence of the Toner Empty condition since the replacement of the toner container is not precisely detectable Item Code of maintenance replac ing item 1 byte 2 category 01 Toner container First byte Replacing item 01 Toner container Second byte Type of replac ing item 00 Black 01 Cyan 02 Magenta 03 Yellow First byte Replacing item 02 Maintenance kit Second byte Type of replac ing item 00 Fixed Counter Log Comprised of three log counters including paper jams self diagnos tics errors and replacement of the toner container g Jam Indicates the log counter of paper jams depending on location Refer to 00 Paper Jam Log All instances including those are not occurred are displayed h Self diagnostic error Indicates the log counter of self diagnostics errors depending on cause See page 1 4 2 Example C6000 4 Self diagnostics error 6000 has happened four times i Maintenance item replac ing Indicates the log counter depending on the mainte nance item for maintenance T Toner container 00 Black 01 Cyan 02 Magenta 03 Yellow M Maintenance kit 20 22 ppm printer EUR USA model only 00 MK 540 EUR model MK 542 USA model Example TOO
130. oller and then refit all the removed parts 1 5 8 P DN Retard roller Retard roller holder Paper cassette Figure 1 5 10 4 Detaching and refitting the secondary transfer roller Procedure 1 e RO Remove the paper feed unit See page 1 5 6 Removing the hook by sliding and then remove the paper chute Remove the secondary transfer roller Remove the transfer roller gear Check or replace the secondary transfer roller and then refit all the removed parts 2HJ 2HK Secondary transfer roller Figure 1 5 11 Transfer roller gear Paper feed unit 1 5 9 2HJ 2HK 1 5 4 MP tray feed unit 1 Detaching and refitting the MP tray feed unit Procedure 1 Remove the paper feed unit See page 1 5 6 2 Remove the paper right cover See page 1 5 4 3 Remove the main high voltage PWB See page 1 5 45 4 Remove the paper feed drive unit See page 1 5 48 5 While pushing the two latches from inside the main unit frame and then remove the MP tray feed unit 6 Check or replace the MP tray feed unit and then refit all the removed parts MP tray feed unit e Figure 1 5 12 1 5 10 2 Detaching and refitting the MP tray feed roller Procedure 1 Remove the paper feed unit See page 1 5 6 2 Pull up the MP tray holder and then sliding do 3 Remove the MP tray feed roller 4 Check or replace the MP tray feed roller and then refit all the removed parts MP t
131. on Hexadecimal 01 Face down output tray FD 15 Multi tray bin 2 Mailbox bin 2 02 Face up output tray Finisher face 16 Multi tray bin 2 Mailbox bin 2 up FU 1F Multi tray bin 3 Mailbox bin 3 03 Finisher face down FD 20 Multi tray bin 3 Mailbox bin 3 04 Finisher sub tray FU 29 Multi tray bin 4 Mailbox bin 4 05 Job separator FD 2A Multi tray bin 4 Mailbox bin 4 OB Multi tray bin 1 Mailbox bin 1 FD 33 Multi tray bin 5 Mailbox bin 5 OC Multi tray bin 1 Mailbox bin 1 FU 34 Multi tray bin 5 Mailbox bin 5 0D Mailbox general FD 3D Mailbox bin 6 FD OE Mailbox general FU 3E Mailbox bin 6 47 Mailbox bin 7 48 Mailbox bin 7 F F F F F F F F D U D U D U D U 1 3 12 2HJ 2JK 1 Service items Items Description Description Service Call Self diagnostic error Log Remembers 1 to 8 of occurrence of self diag nostics error If the occur rence of the previous diagnostics error is less than 8 all of the diagnos tics errors are logged Count The total page count at the time of the self diag nostics error Service Code Example 01 6000 01 means a self diagnostic error 6000 means a self diagnostic error code See page 1 5 3 Maintenance Log Remembers 1 to 8 of occurrence of replace ment If the occurrence of the previous replace ment of toner container is less than 8 all of the occurrences
132. or 1 5 10 3 Skewed paper feed Check if the paper is curled Change the paper 4 Multiple sheets of paper are fed at one time Check if the paper is excessively curled Change the paper Check if the surfaces of the following rollers are dirty with paper powder pickup roller feed roller retard roller and MP feed roller Clean with isopropyl alcohol See page 1 5 7 and 1 5 11 Check if the pickup roller feed roller retard roller and MP feed roller are deformed Check visually and replace any deformed rollers See page 1 5 7 and 1 5 11 Deformed guides along the paper conveying path Check visually and replace any deformed guides 5 Paper jams Check if the contact between the upper and lower registration rollers is correct Check visually and remedy if necessary Replace the pressure spring if it is deformed Check if the press roller press belt is extremely dirty or deformed Clean or replace the press roller press belt See page 1 5 26 1 5 33 or 1 3 18 Check if the contact between the heat roller and its separation claws is correct Repair if any springs are off the separation claws See page 1 5 26 1 5 33 6 Toner drops on the paper conveying path Check if the developer unit or drum unit is extremely dirty Clean the developer unit or drum unit See page 1 5 12 or 1 5 13 7 Abnormal noise is heard Check if the pulleys rollers
133. oz SSA 09 0 09 0 410S aN9 IZ vas 68 62 68 62 NIOIS AS8S zz ONS 88 82 89 82 NI TOS INO T ez 29 22 29 22 KFAOOS S3HSAS 3 ve _ 99 92 99 92 GND GND S Gz 5 sose ss sz l93 Suda E 92 O paryz valvz V1W0dd3 M10d3 dz esez eg ez GND HIdd4 E sz eS ez 29 22 GND GND 62 LS 12 19 12 ONOXLA OdOXLA 0 0 08 03 05 02 INOXLA LdaXLA E QNS po E 5 6 6 6b 61 ZNOAXLA ZdAXLA o re wmm ol x 8b 81 8 81 ENOXLA CdOXLA E Ev LEOS m KIL L L PNOXLA PdOXLA 8 9v 91 9 91 SNOXLA SdQXLA E a St SL Sb St NE IOXHA dXIOXHA e 5 vvith v v LNOXHA LdQXHA gt 2 eb el b l ONAXHYA 0dAXHA G ao 2 Zb z1 2v et NOXLA SdQXLA 2 LLL LIL L JNNOXLA ZdOXLA as 8 Ov OL 0b 01 NATOXLA AMTOXLA gt E c 66 6 66 6 8NAXLA 8dAXLA E E 88 8 86 8 SNOXLA 6dQX LA US 1 L LZE Z OLNOXLA OLdOIXLA sz 96 9 96 9 LLNOXLA LLdOXLA aa er 52 gt Se 8 SE S AS S AN 9 59 e 94 ve y ve y NEE AE mt s Sto Eo ee e eee ASt AS og oe 1975 oS Ze z ze z AG AG AA 3E zt OE z895 L L Le 1 AS AS RO Eo o H imi k p d Le 2 4 4 2HJ 2HK 1 3 Repetitive defects gauge First occurrence of defect y 31 16 mm Upper registration roller LII H A AAA LL 33 28 mm Developing sleeve 51 21 mm Lower registration roller y 59 33 mm Secondary transfer roller y 94 4 mm Drum y 113 04 mm Heat roll
134. ozeos 20894 8 o umop dn Fargas e Z gt 3 vozeos eozeos Md lddns semog Jeo 8 BELE e0e4 LLL 26954 3 1012euu02 Josues p1eog S aNd pun 1asny pesu 9Beyon ysy serg vos Josues 19p99 MG E z Josues OJIMS UOIIMS e1nje1eduie edojoAu3 p1eog eBeyo 0204 poo 26ne6 iedeg pedis NU BS a or 4 uBiu uen L U91IMS u DS 8 m Josuss 40sues 0892 x n 5 107144 04Hd 10sues Ena o9PIS 1809 dol 9901 o lo nega 0694 jaded 3 E pq Le abneb sade go oL o Pas gMd g 8 99 Fare ae L089A fel dN sosod 1049A n josuas 204Hd eoZms T zoLMS S 10sues 8 B8 45252022 299955 5 gt E E a I Pars Uu x cOuonokoON oO09uoosomw Boo orem uonensibeug 0 0A apo amp oo oo 2woroo o 0 2A i FORT CROSS SMK G S toloo dmmmt t le oao i ad j960f550 2222222909297 ES NPPSS mS PTT punog E D E GO G E OS o ES E SHI 22266 i ZVN NNNNA I lt L lt RY MMM 2 I O RARA oe Qoo e je Lj ZZZ ZM MQ g 3 ror pu NARODOONDODO o Pi 0000000 eo 90A ZOA SLOA 104 Gin YOA LOA 989589539929 3S355 ATEN KM KOM E Ae SRTR NENTS ETTEREN Z 10 0w S L 40 OW lo lee eeeaa3oasEBel wv wv IOa Ta TOKO KIO KOD JOJOUI x 434141381332 IRE 40302 9 Z 22 99 9 59 9 UM euer Z AMO E a IR ERRES o ue uen Z e gazzooz m Im 15 NZ Ie Or o 0 e 010A LLOA 5 SIS Ee S BEST p m m g 83 panos REN Bee 3332 E SLR RRR DnR WN YNN LATYA Noah uma ON DN AU N N N DIRONZDLCONOARON Bp5piuoonorov zoO99wWdooesom N nnn z
135. per Two component Toner replenishing Automatic from the toner container Transfer system Primary transfer Transfer belt negative charged Secondary transfer Transfer roller negative charged Separation system Small radius curvature separation Fixing Syster eritin Heat roller diameter 36 5 mm 850 W halogen heater lamp Oil less Press belt Charge erasing system Exposure by eraser lamp LED Cleaning system Drum Counter blade Primary transfer belt Fur brush 2HJ 2HK 1 Controller hardware Interface o edid tete Controller software Resolution sss Dimensions cene CPU Power PC750CXr 500 MHz System ROM 8 MB 32 Mbit x 2 Font ROM 2 MB 16 Mbit x 1 Main RAM 128 MB standard DIMM expanding up to 640 MB 512 MB x 1 at the maximum by adding optional expansion memory Optional expansion RAM DIMM 1 slot 100 pin DIMM 64 128 256 or 512 MB USB Hi Speed USB Optional interface KUIO LV x 1 Network interface card IB 21E IB 23 10 Base TX 100 Base TX a Emulation PCL6 PCL5c PJL PCL XL protocol class 2 1 KPDL3 PostScript 3 compatible b Fonts Bitmap font 1 Line Printer bitmap font Outline fonts 80 PCL fonts c Graphic 1 Raster graphic 75 100 150 200 300 600 dpi 200 dpi is supported when
136. per feeder do the operation check If operation is normal replace the paper feeder Defective duplexer If the duplexer is installed after removing or replacing the duplexer do the operation check If operation is normal replace the duplexer Defective harness S03202 between engine controller PWB A0004 and interface connec tor or poor contact of the connector ter minals Check the continuity of the harness 803202 Check the insertion of YC7 of the engine controller PWB A0004 if there is trouble remedy or replace Duplexer communication error When turning on power the ASIC of the engine controller PWB A0004 recog nized the optional duplexer but when it becomes not be able to communicate from the middle After the error occurring when power source is turned on off there are times when the duplexer is not recognized Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective duplexer After removing or replacing the duplexer do the operation check If operation is normal replace the duplexer Defective paper feeder If the optional paper feeder is installed after removing or replacing the paper feeder do the operation check If operation is normal replace the paper feeder Defective harness S03202 between engine controller PWB A0004 and interface connec tor or poor contact of the connector ter minal
137. per feed drive unit and then refit all the removed parts Paper feed drive unit Screws Figure 1 5 73 1 5 48 3 Detaching and refitting the fuser drive unit Procedure 1 2 Remove the right cover See page 1 5 4 Remove the main drive unit See page 1 5 47 3 Remove the one connector 4 Remove the two screws and the remove the fuser drive unit Check or replace the fuser drive unit and then refit all the removed parts Figure 1 5 74 Screw 2HJ 2HK Fuser drive unit Screw Connector 1 5 49 2HJ 2HK 4 Detaching and refitting the toner motor 1 2 3 and 4 Procedure 1 Remove the right cover See page 1 5 4 2 Remove the one connector l Toner motor 3 Remove the hole which is inserted into the Black projection of main unit frame side slide toner motor 4 to up in order to remove the hook Remove the toner motor 4 Check or replace the toner motor 4 and then refit all the removed parts Also four toner motors with the same procedure there is no order eus Yellow Cyan Magenta autos Figure 1 5 75 1 5 50 2HJ 2HK 5 Detaching and refitting the ozone filters Procedure 1 Open the top cover 2 Remove the ozone filters from the ozone fan motor 1 and 2 3 Check or replace the ozone filters and then refit all the removed parts Ozone filters Ozone fan motor 1 Figure 1 5 76 1 5 51 2HJ 2HK 6 Detachin
138. pply PWB 1 6 41 A0004 Defective installa Check the installation condition of fuser ther tion condition of mistor 1 if there is trouble remedy or fuser thermistor 1 replace See page 1 5 26 1 5 33 6030 Fuser thermistor 1 broken error heat Defective engine Replace the engine controller PWB A0004 roller It was judged it has been broken from the fact that it is not the input signal from of the fuser thermistor 1 which detects the fuser temperature of the heat roller controller PWB A0004 See page 1 5 41 Defective harness of the fuser PWB between fuser ther mistor 1 or poor contact of the con nector terminals Check harness of the fuser PWB KP 970 A0003 check the connection YC694 con nector of the fuser PWB KP 970 A0003 if there is trouble remedy or replace Defective harness 803203 between fuser PWB and fuser connector or poor contact of the connector termi nals Check the continuity of the harness 803203 check the connection YC691 con nector of the fuser PWB KP 970 A0003 if there is trouble remedy of replace Defective harness 803203 power supply PWB and fuser connector or poor contact of the connector termi nals Check the continuity of the harness 803203 check the connection YC902 con nector of the power supply PWB if there is trouble remedy or replace Defective fuser PWB Replace the fuser PWB KP 970 A0003
139. put 32 5V1 O 5VDC 5 V DC power output 33 5V1 O 5VDC 5 V DC power output 34 3 3V O 12 3 V DC 3 3 V DC power output 35 43 3V O 12 3 V DC 3 3 V DC power output 36 VTXDN11 Analog LED print head control video data signal LVDS 37 VTXDN10 Analog LED print head control video data signal LVDS 38 VTXDN9 Analog LED print head control video data signal LVDS 39 VTXDN8 Analog LED print head control video data signal LVDS 40 VTXCLKN 0 3 3 V DC pulse LED print head control clock signal 41 VTXDN7 Analog LED print head control video data signal LVDS 42 VTXDN6 Analog LED print head control video data signal LVDS 43 VRXDNO Analog LED print head control video data signal LVDS 44 VRXDN1 Analog LED print head control video data signal LVDS 45 VRXCLKN 0 3 3 V DC pulse LED print head control clock signal 46 VTXDN5 Analog LED print head control video data signal LVDS 47 VTXDN4 Analog LED print head control video data signal LVDS 48 VTXDN3 Analog LED print head control video data signal LVDS 49 VTXDN2 Analog LED print head control video data signal LVDS 50 VTXDN1 Analog LED print head control video data signal LVDS 51 VTXDNO Analog LED print head control video data signal LVDS 52 GND J Ground 53 GND Ground 54 FPDATA l O 0 3 3 V DC pulse Operation panel PWB control data signal 55 EGIR O 0 3 3 V DC Control signal 56 GND Ground 5
140. r PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the insertion of YC3 of the engine controller PWB A0004 if there is trouble remedy or replace Defective FFCs 803011 between LED print head 4 and LED print heads relay PWB A0176 or poor contact of the FFC terminals Check the connection of the FFCs with the black drum unit and the printer main unit check the continuity of the FFCs S803011 check the connection of the LED print head 4 if there is trouble remedy or replace See page 1 5 15 2HJ 2HK Code Contents Remarks Causes Check procedures corrective measures 0952 LED print head 2 EEPROM commu Defective LED print Replace the LED print head 2 See page 1 nication error cyan drum unit The LED print head 2 EEPROM of the cyan drum unit does not communicate with the engine controller PWB A0004 normally head 2 5 15 Installing the LED print head which is incompatible with the printer specifi cation Install the compatible LED print head to the black drum unit Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness 803214 between engine controller PWB A0004
141. r cord and then turn on the power switch Print the status pages See page 1 3 2 Turn off the power switch and then remove the power cord Remove the all drum and developer units See page 1 5 13 and 1 5 12 Place a paper on the primary transfer belt Hold the edge of the handle and then raise the handle s Hold the center of two handles by the both hands Remove the primary transfer unit from the printer Place a paper on the new primary transfer unit belt Hold the edge of the handle and then raise the handle s Hold the center of two handles by the both hands Install the new primary transfer unit into the printer Remove the paper on the new primary transfer unit belt Put the two handles down on the home posi tion Refit all removal parts Connect the power cord and then turn on the power switch Print a status page See page 1 3 2 Make sure reset of the primary transfer unit life counter AAAAAA on the service infor mation See right figure and then follow the following procedure When It was reset Go to the step 24 When It was not reset Go to the step 19 Connect the parallel printer cable between printer and PC Send the following command from PC IR KCFG LRFE ITTR 0 EXIT Turn off and on the power switch Print the status pages See page 1 3 2 Make sure reset of the primary transfer unit life counter AAAAAA on the service infor mation See right figure NOTE When if
142. r cover open close sensor rear cover Open Close Fuser thermistor 1 detection voltage output Fuser thermistor 2 detection voltage output Connected to the fuser heater lamp 1 and 2 1 fuser ther mostat 1 and 2 gt OANDOAARWD HEATER LIVE NC HEATER COM NC HEATER LIVE oj O0 O00 1 16 17 ppm printer EUR USA model only 2 3 2 220 240 V AC 120 VAC 220 240 V AC 120 VAC 220 240 V AC 120 VAC AC power output for fuser heater lamp pd Not Connected Fuser heater lamps output common Not Connected AC power output for fuser heater lamp 1 2 3 2 Engine controller PWB Operation panel PWB Main controller PWB Engine controller PWB Sensors switches signals 2HJ 2HK 1 Sensor Reset IC RESET U10 Data Address multiplex bus Address bus Address bus LED print heads control EEPROM EEPROMs control U12 Controller box fan motor Main high voltage PWB Paper full sensor signal PWB Face up down solenoid control al Eraser driver Exit sensor signal circuit Q13 Zero cross signal aL ASIC
143. r output via top cover paper feed unit switch Connected 2 HVCLK1 O 3KHz rectangular wave Developing sleeve magenta output to the bias 3 HVCLK2 O 3KHz rectangular wave Developing sleeve cyan output high voltage 4 HVCLK3 O 3KHz rectangular wave Developing sleeve yellow output PWB 5 HVCLK4 O 3KHz rectangular wave Developing sleeve black output 6 HVBDATD O 0 5 V DC pulse Output control D A converter serial signal 7 HVBCLKD O 0 5 V DC pulse Output control D A converter clock signal 8 HVBLATD O 0 5 V DC pulse Output control D A converter data latch signal 9 GND Ground 10 5V1 O 5VDC 5 V DC power output 11 MPFSENS1 0 5V DC MP tray paper sensor On Off 12 MPFSENS2 0 5V DC Envelope feeder install sensor Installed Not installed 13 WTLEDDR O 0 5 VDC pulse Waste toner full sensor emitter drive output 14 WTSENS 0 5V DC pulse Waste toner full sensor receiver input Full at voltage above the 2 V DC 15 AIRTEMPH Analog Temperature sensor detection voltage input 16 WETCK1 O 0 5 V DC pulse Humidity sensor control signal 1 KHz 17 WETCK2 Analog Temperature sensor detection signal 18 GND Ground YC6 1 24V3 24V DC 24 V DC power input via side cover switch Connected 2 MCH1DR O 0 24 V DC Main charger output control signal Magenta On Off to the main 3 MCH2DR O 10 24 V DC Main charger output control signal Cyan On Off high voltage 4 MCH3DR O 0 24 V DC Main charger output co
144. ray feed roller MP tray feed unit Figure 1 5 13 2HJ 2HK 1 5 11 2HJ 2HK 1 5 5 Developing section 1 Detaching and refitting the developer unit Procedure 1 Open the top cover 2 Remove the one connector Release RN Connector 3 While releasing two release levers and then remove the developer unit Use the same procedure for other developers Figure 1 5 14 1 5 12 1 5 6 Drum section 1 Detaching and refitting the drum unit To replace the drum unit and the engine controller PWB at the same time turn on the printer after replacing either one Check that the printer operates properly and then turn off the printer Replace the other and turn on the printer to check that the printer operates properly Be sure to replace one by one Refer to self diagnostic code 9530 See page 1 4 21 Procedure 1 2 3 Remove the developer unit See previous page Remove the each connector cover Remove the FFC a and FFC b from the FFC connectors Remove the one connector 2HJ 2HK Connector cover Magenta Connector cover Black Connector cover Yellow FFC connector FFC connector Connector blue color marking FFC Flexible Flat Cable Figure 1 5 15 1 5 13 2HJ 2HK 5 While releasing two release levers and then remove the drum unit also 4 colors with the Release lever Drum unit same procedure there is no order Yellow 6 Check or replace
145. relay PWD eee eee eee eee eee 1 5 44 4 Detaching and refitting the main high voltage PWD sees eee eee eee eee eee eee eee 1 5 45 b Detaching and refitting the bias high voltage PWD eee eee eee eee eee eee eee 1 5 46 4 521 T Others c e A LAG eate eA ie ae 1 5 47 1 Detaching and refitting the main drive unit sss sees eee eee eee eee eee eee eee 1 5 47 2 Detaching and refitting the paper feed drive Unit sss sese eee ee eee eee eee 1 5 48 3 Detaching and refitting the fuser drive Unit sees eee eee eee eee eee eee eee ee 1 5 49 4 Detaching and refitting the toner motor 1 2 3 and 4 00 eee sees eee eee eee 1 5 50 5 Detaching and refitting the ozone tera sese eee eee eee eee eee eee 1 5 51 6 Detaching and refitting the waste toner duct eene 1 5 52 1 6 Firmware 1 6 1 Downloading firmware e epe da 1 6 1 1 Downloading the firmware from the memory Gard sss sese eee eee eee eee eee eee eee 1 6 2 2 1 Mechanical construction 2 1 1 Paper feed section 4 nece voe pel et Sn a ee eves 2 1 1 1 Paper feeding from paper casset ssseesse esse esser eeseessee esse serene ennenen nenne enter nnne nnns nnne nns 2 1 1 2 1 2 Developing Section xni etae m E ee eee tens 2 1 7 1 Developer nto e ba as 2 1 7 2 Touch down developing method sss sees 2 1 9 3 Developer drive stop MechanisM oococonnncnonnccnnnocconnccnnnnccnnnne nora 2 1 10 2 1 9 DUNN SECTION cir A al na 2 1 11 leher E E A S 2 1 11 2 Wa
146. rgency 1 16 17 ppm printer EUR USA model only 2 2 3 2HJ 2HK This page is intentionally left blank 2 2 4 2HJ 2HK 1 2 3 1 Operation of the PWBs 1 Power supply PWB Power supply PWB Engine AC Power Current ole input switch fuse p foo 4 oo Rectifier Transformer PWB Noise circuit T o 424V1 filter lt gt T 24 V DC circuit rectifier e smoothing TI circuit GND gt HH 5V1 5V DC rectifier smoothing Zero cross Switching control circuit GND signal circuit IC1 _ 3 3V1 generation DC DC circuit converter circuit ZCROSS Photo coupler HEAT1DR PC1 HEAT2DR TH1 gt thermostat 2 ila EXITPAPN FUDR Fuser FDDR thermistor 1 a mu Xx YN Fuser Exit sensor Face up down thermistor 2 Fuser PWB EE Bee gt 16 17 ppm printer EUR USA model only Figure 2 3 1Power supply PWB block diagram 2 3 1 2HJ 2HK 1 Connector Signal Voltage Description CNT Connected to the AC inlet AC LIVE AC NEUTRAL 220 240 V AC 120 VAC 220 240 V AC 120 VAC AC power input Frame ground AC power input YC901 Connected to the engine con troller PWB 0 JO Qn E G N M M MMM MM MA LAL L L L eg Yd OD Qn E GM O QO G
147. s Check the continuity of the harness S03202 Check the insertion of YC7 of the engine controller PWB if there is trouble remedy or replace Duplexer firmware error When turning on power the ASIC of the engine controller PWB A0004 recog nized the optional duplexer but the firm ware checksum error is reported from the duplexer The duplexer is not recognized because of the defective firmware Defective duplexer After removing or replacing the duplexer do the operation check If operation is normal replace the duplexer 1 4 8 2HJ 2HK Code Contents Diui diu Causes Check procedures corrective measures 0951 LED print head 4 EEPROM commu Defective LED print Replace the LED print head 4 See page 1 1 4 4 nication error black drum unit The LED print head 4 EEPROM of the black drum unit does not communicate with the engine controller PWB A0004 normally The incompatible LED print head is installed to the printer head 4 5 15 Installing the LED print head which is incompatible with the printer specifi cation Install the compatible LED print head to the black drum unit Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective LED print heads relay PWB A0176 Replace the LED print heads relay PWB A0176 See page 1 5 44 Defective harness 803214 between engine controlle
148. s ON OFF the AC power source Detects the paper size dial setting of the paper setting dial Drives the paper feed section Drives the primary transfer cleaning unit fuser unit and exit section Drives the primary transfer unit Drives the magenta drum unit Drives the cyan drum unit Drives the yellow drum unit Drives the black drum unit Replenishes the magenta developer with toner Replenishes the cyan developer with toner Replenishes the yellow developer with toner Replenishes the black developer with toner The exhaust gas of ozone The exhaust gas of ozone Dissipates heat from the fuser unit Dissipates heat from the drum motors Dissipates heat from the controller box Detaches and makes stop the drive transmission of developers other than black developer at the time of monochrome printing Controls the primary paper feed from the MP tray Controls the second paper feed Controls the paper cassette paper feed Connects the AC power source For expanding main RAM Expands the print job function Expands the interface network interface card or hard disk unit 2HJ 2HK 1 2 Drum unit developer unit and fuser unit S 9 97 901 RN O 12 13 14 15 FUSER UNIT 16 17 ppm printer EUR USA model DRUM UNIT FUSER UNIT 20 22 ppm printer EUR USA model Figure 2 2 2Drum unit developer unit and fuser unit Drum PWB 1 2 3 4 sense Drum PWB 1 magenta drum PWB 2 c
149. sa go LL BOISH3IVIVOS3 gal sa 1 YEVIVOV e t us ue AES Haesna Ht us 2 8 yun xejdng _ g S2vIvav 6 01 6 01 41 0HAS LAS HQvSH3 gioj eroi Jape Jaded S 92v1vav GQEAS du i IIE i r H euondo oL 9 Li 1i Het LUZ L 8H GEVIVOY E i Li OdSQA VONSQAT LUI gU LISE AS d sal gig 4S0 VINSOAT stoi sto dSGAVZNSGAT i a E E 49 LB 21 81 21 81 3033353825508 5 0 zz x 6 01 6 01 5dSQA VENSGA T LO 61 02 61 02 8o ez S LUzi 11 21 2 289 dA VENSOAT H rezz izzz o Ufa bala m ES gup erp LLL SASGA VSNSONT ez pal ez pz 400 Pereo s Sc ih 9dSQAT9NSQAT1 E 9 7 S s UE lz a E Li 9 _ lee gt __letoz e102 8dSGAVE8NSGAT ezioe ezioe gt 6 S 8 ree izzz HISIA VeNSONT ze zel ze ze S los 9 gt cave espe LL OFISGAVOINSGAT cere cerve E 2 dejos cejas PLASOAT LENSOAT ggjo9 ce 99 TASA th 72 92 1Z 8Z bdSGAVZINSGAT zegel cac aO EN S lt ozo ez oe S dSQAVEINSOAT 6g op aent A c o E srel zeze L PLASOAVPINSOM 10 spl Lep 9 v H H a M g a eerve ceive H NU H etivv evivv sl 9 Q g 99 se 99 15 Ma L adad i grar larar a E L 4 e ee ze ge i e EAST PdVAST VAS ti ry ray 20 87 5 o 8 6 0v 6c oy LL GNS ONS iL 6p 08 erne 6 LOIVLVOY amp QNO QNO pizeos 7 Ol HVIVOV e a ejeid wing sese J zi zivivav E S 1NOO C ei eLvLvav i 5 ERN Slim 3 5 E a 9 V1vav a S tele QNO 5 EH Ziwivav 1 1M3d03 o T amp gi 8 VIVOV SLZEOS Q 2s 6hvivav
150. scription Setting the paper feed operation printer driver priority mode Description With printer driver priority mode when selecting the specific paper feed location a cassette or MP tray with the printer driver it is not automatic selection paper is fed from the selected location Message Add Paper is displayed when there is no paper in that location When selecting the MP tray as the paper feed location paper is fed with the timing of maxi mum size A4 As for the setting media type setting the paper type setting of the printer driver is notified to the engine controller PWB Duplex printing operation is still the ordinary operation and paper jam occurs if paper size is different from the setting of the printer Purpose To set the printer driver priority mode which priority is given to the setup of a printer driver when the ordinary paper feed operation mode is not suitable for the usage condition of the user Method 1 Enter the service mode gt gt Paper feed 2 Press the OK key Message Paper feed will be displayed 3 Select the mode Special or Normal pressing the W key or A key Special Ordinary paper feed operation mode Default Normal Printer driver priority mode 4 Press the OK key Completion gt gt Maintenance Counter reset for the maintenance kit 20 22 ppm printer EUR USA model only Description The Install MK message means that maintenance kit should be repl
151. secondary transferring is done the toner which remains in the primary transfer belt is collected back in the waste toner box The brush cleaning roller and the fur brush are applied with the DC bias of approximately 500 V DC through the conductive cleaning frame from the main high voltage PWB The voltage at the fur brush is approximately 300 V DC The toner remaining on the primary transfer belt is transferred onto the fur brush that is biased and continuously revolving It is then scraped off of the fur brush by the metal brush cleaning roller in the cleaning frame The brush cleaning roller has the cleaning blade which scrapes off the waste toner The waste toner scraped off of the brush cleaning roller falls onto the cleaning screw then driven outward from the cleaning frame Figure 2 1 28Primary transfer cleaning unit block diagram 2 1 21 2HJ 2HK Fur brush Brush cleaning roller Cleaning frame Engine controller PWB Main high voltage PWB Fur brush D A YC1 7 HVADATD Vog g 500 V DC Output bias output converter ___YC1 8 HVACLKD 26 7 circuit C501 YC1 9 HVALATD YC6 8 Figure 2 1 29Primary transfer cleaning unit block diagram From waste toner duct EE E CREER EE waste toner box Figure 2 1 30Primary transfer cleaning unit Fur brush Brush cleaning roller Cleaning blade Cleaning screw Tom 2 1 22 2HJ 2HK A full color image is developed by recoating four colors
152. solved check the update information on the engine firmware Update the engine firmware as needed Operation panel PWB communica tion error The operation panel PWB A0007 does not communicate to the main controller PWB A0171 normally 30 seconds Defective main con troller PWB A0171 Turn the power off on to restart the printer If the error is not resolved replace the main controller PWB A0171 See page 1 5 40 Defective operation panel PWB A0007 Replace the operation panel PWB A0007 Main controller PWB memory check error It could not access to the standard memory or the optional expanding memory which are mounted on the main PWB A0171 normally Defective main con troller PWB A0171 Turn the power off on to restart the printer If the error is not resolved replace the main controller PWB A0171 See page 1 5 40 Defective expand ing memory If the expanding memory is installed after removing or replacing the expanding mem ory do the operation check If operation is normal replace the expanding memory See page 1 3 8 Main controller PWB system error The error which is related to the system other than the error code F000 F010 and F020 occurred Defective main con troller PWB A0171 Turn the power off on to restart the printer If the error is not resolved replace the main controller PWB A0171 See page 1 5 40 Engine controller PWB communica tion
153. ste toner ejecting mechanism sees esec esereeeee esser esse esec esec e serere resserrer ennenen ennenen ene 2 1 14 3 EED printihead A Seq ached A EO CREDE DAMM UTERE 2 1 15 4 Malr charger Uitte O 2 1 17 2 1 4 Primary transtorno 2 1 19 1 Primary transSter Ts TE 2 1 19 2 Primary transfer cleaning unit nennen mener 2 1 21 2 1 5 Secondary transfer and separation section sees eee eee eee 2 1 24 2 1 6 Fuser Section x n eet te AAA etc A ze 2 1 26 1 Fuser unit 16 17 ppm printer EUR USA model seen 2 1 26 2 Fuser unit 20 22 ppm printer EUR USA model eene 2 1 28 2 2 Electrical Parts Layout 2 221 Electrical parts layout ate it 2 2 1 1 Main frame and controller box nennen nennen nennen nnne nnne nnns 2 2 1 2 Drum unit developer unit and fuser unit sss sees eee eee eee eee eee eee 2 2 3 2 3 1 Operation ofthe PWBs 35 encierra eoe ape me ds 2 3 1 1 Power Supply PW TTT 2 3 1 2 3 2 Engine controllenP WB T 2 3 3 2 3 3 Main controller PWB Jae e Ree ie et A A FU e e PR Te EL 2 3 10 2 4 Appendixes 2 4 1 eTel 2 4 1 1 Wiring diagram 16 17 ppm printer EUR USA model sese sees eee 2 4 1 2 Wiring diagram 20 22 ppm printer EUR USA model sss ee eee 2 4 3 3 Repetitive defects QaUge cccesececceeseeeseneeeseneeeeeeeeeesnseseseeeeeseneneneaseseaneeesueeeensensseseenetenenmeeneneneees 2 4 5 This page is intentionally left blank 2HJ 2
154. stor 1 D SIS Figure 2 1 37Fuser unit block diagram 16 17 ppm printer EUR USA model 2 Fuser unit 20 22 ppm printer EUR USA model 2HJ 2HK 1 The fuser unit is composed of the heat roller press belt fuser heater lamp 1 and the change guide Paper sent from the secondary transfer and separation section is applied with heat and pressure to permanently fuse toner on paper The change guide switches the destination of paper to the face down tray or optional face up tray It also sends paper to the duplexer Figure 2 1 38Fuser unit 20 22 ppm printer EUR USA model 5 09 NO n EO 10 cs Fuser UP cover Entrance guide Exit guide Exit UP guide Fuser A stay Fuser B stay Fuser C stay Separator plate Change guide 10 11 12 13 14 15 16 17 18 Press plate Exit roller Exit pulley Press belt rollers Heat roller Press belt Heater lamp Exit sensor actuator Fuser thermostat 1 2 1 28 TO To face down tray To optional duplexer or E Ne face up tray G Exit pulley Exit roller OR Press bel Press belt roller face down tray Change guide From Figure 2 1 39Fuser unit 20 22 ppm printer EUR USA model Ae ion P ly PWB Fuser PWB i G SUPPIY FUDR FUSOLDR FDDR FDSOLDR Rear EX 7 EXITPAPN sensor cover Face up down open E RCOVOPN solenoid sensor C TH1 LT Fuser thermistor 1 1
155. t that it is not the input signal from of the fuser thermistor 2 which detects the fuser temperature of the press roller Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective harness of the fuser PWB between fuser ther mistor 2 or poor contact of the con nector terminals Check harness of the fuser PWB KP 970 check the connection YC693 connector of the fuser PWB KP 970 if there is trouble remedy or replace Defective harness 803203 between fuser PWB and fuser connector or poor contact of the connector termi nals Check the continuity of the harness 803203 check the connection YC691 con nector of the fuser PWB KP 970 if there is trouble remedy or replace Defective harness 803203 power supply PWB and fuser connector or poor contact of the connector termi nals Check the continuity of the harness 803203 check the connection YC902 con nector of the power supply PWB if there is trouble remedy or replace Defective fuser PWB KP 970 Replace the fuser PWB KP 970 Defective power supply PWB Replace the power supply PWB See page 1 5 41 Defective installa tion condition of fuser thermistor 2 Check the installation condition of fuser ther mistor 2 if there is trouble remedy or replace See page 1 5 26 Zero cross signal error The zero cross signal which from the power supply PWB is o
156. ted temperature did not rise within stipulated time 16 17 ppm printer EUR USA model 1 4 12 Defective installa tion condition of fuser thermistor 1 Check the installation condition of fuser ther mistor 1 if there is trouble remedy or replace See page 1 5 26 1 5 33 Fuser thermostat 1 operated Replace the Fuser thermostat 1 See page 1 5 26 1 5 33 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective power supply PWB Replace the power supply PWB See page 1 5 41 Defective fuser PWB Replace the fuser PWB KP 970 A0003 Defective harness of the fuser ther mistor 1 or poor contact of the con nector terminals Check the harness of the fuser thermistor 1 check the connection YC694 connector of the fuser PWB KP 970 1 A0003 if there is trouble remedy or replace Defective fuser heater lamp 1 Replace the fuser heater lamp 1 See page 1 5 26 1 5 33 16 17 ppm printer EUR USA model Defective harness S03204 220 240 V AC model S03205 120 V AC model between fuser unit connec tor and fuser heater lamp 1 Check the continuity of the harness 803204 220 240 V AC model 803205 120 V AC model check the connection YC694 connector of the fuser PWB KP 970 A0003 if there is trouble remedy or replace YC694 connector of the fuser PWB KP 970 1 A0003 if there is tro
157. tes the drum approximately 3 2 minutes with toner lightly applied onto the drum using the high voltage output control of the engine controller PWB The cleaning blade in the drum unit scrapes toner off the drum surface to clean it Purpose To clean the drum surface when image failure occurs due to contamination This mode is useful when dew condensation on the drum occurs Procedure 1 Enter the service mode gt gt Drum 2 Press the OK key Message gt gt Drum will be displayed 3 Press the OK key Drum surface refreshing will start and finish after approximately 3 1 2 2 minutes 1 16 17 ppm printer EUR USA model 20 22 ppm printer EUR USA model 1 3 17 2HJ 2JK 1 3 2 Maintenance 1 Method of removing the toner soiling which comes in contact with heat roller and press roller press belt When misfeeding has occurred in the fuser unit misfeed paper can coil around the heat roller or the press roller press belt Removing the misfed paper will cause there are times when the toner soiling remains in the heat roller or the press roller press belt Follow the procedure below in this case and remove the toner soiling from the heat roller or the press roller press belt 1 2 3 Remove the misfed paper Cancel misfeed by opening and closing a cover wait until the message display shows Ready Press MENU key and set paper type to Transparency and paper source to MP tray Set the a sheet transpare
158. the drum unit and then S refit all the removed parts gt Drum unit Magenta Drum unit Black NOTE When refitting the drum unit insert the FFC straightly to the FFC connector when connecting the FFC Figure 1 5 16 1 5 14 2 Replacing the LED print head and drum unit Replacement kit packing contents 2HJ 2HK 1 Drum unit kit 16 17 ppm printer EUR USA model 20 22 ppm printer DK 511 EUR USA model DK 521 Drum unit Procedure LK 510 LED print head kit 16 17 ppm printer EUR USA model 20 22 ppm printer LK 520 T UR USA model 1 2 3 4 Switch off the printer Open the top cover Remove the toner containers and developer units Remove the drum unit connector cover for the color to be replaced 5 Remove two Flexible Flat Cables FFCs and one connector Figure 1 5 19 1 5 15 2HJ 2HK 6 Turn the release lever and remove the drum unit 7 Remove the three hooks and then remove the LED print head cover from the drum unit 8 Remove the FFCs form the LED print head cover 9 Remove the LED print head from the drum unit CAUTION When handling the LED heads discharge the body of static electricity by using an anti static wrist strap band or anti static globes NOTE Do not touch the pins painted red 1 5 16 Release lever Drum unit 58 Release m c 2
159. tor error bottom Defective paper Refer to the paper feeder s service manual The notification that was received the motor clock sensor cannot detect the revolution of the paper feed motor of the optional paper feeder third 20 22 ppm printer EUR USA model only feeder Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 1 4 7 2HJ 2HK Code Contents Diui dii Causes Check procedures corrective measures 5301 Eraser lamp 4 error black drum unit Defective eraser Replace the eraser lamp 4 PWB KP 1 4 8 The eraser lamp 4 PWB KP 1090 of the black drum unit does not communi cate with the engine controller PWB A0004 normally lamp 4 PWB KP 1090 1090 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Defective drum PWB 4 KP 972 Replace the black drum unit See page 1 5 13 Defective harness 803212 between drum PWB 4 KP 972 and eraser lamp 4 PWB KP 1090 or poor con tact of the connec tor terminals Check the connection of the YC402 connec tor of the drum PWB 4 KP 972 if there is trouble remedy or replace Defective harness 803214 between engine controller PWB A0004 and LED print heads relay PWB A0176 or poor contact of the connector termi nals Check the continuity of the harness 803214 check the con
160. tr 17 154 Solna Sweden Phone 46 8 546 55000 2006 KYOCERA MITA Corporation ol KYOCERd is a trademark of Kyocera Corporation KYOCERA MITA NORGE Postboks 150 Oppsal NO 0619 Oslo Olaf Helsetsvei 6 NO 0694 Oslo Norway Phone 47 22 62 73 00 KYOCERA MITA DANMARK A S Ejby Industrivej 1 DK 2600 Glostrup Denmark Phone 45 5687 1100 KYOCERA MITA PORTUGAL LDA Rua do Centro Cultural 41 Alvalade 1700 106 Lisbon Portugal Phone 351 21 842 9100 KYOCERA MITA SOUTH AFRICA PTY LTD 527 Kyalami Boulevard Kyalami Business Park Midrand South Africa Phone 27 0 11 540 2600 KYOCERA MITA AMERICA INC Headquarters 225 Sand Road Fairfield New Jersey 07004 0008 U S A Phone 973 808 8444 KYOCERA MITA AUSTRALIA PTY LTD Level 3 6 10 Talavera Road North Ryde N S W 2113 Australia Phone 02 9888 9999 KYOCERA MITA NEW ZEALAND LTD 1 3 Parkhead Place Albany P O Box 302 125 NHPC Auckland New Zealand Phone 09 415 4517 KYOCERA MITA THAILAND CORP LTD 9 209 Ratchada Prachachem Road Bang Sue Bangkok 10800 Thailand Phone 02 586 0320 KYOCERA MITA SINGAPORE PTE LTD 121 Genting Lane 3rd Level Singapore 349572 Phone 67418733 KYOCERA MITA HONG KONG LIMITED 11 F Mita Centre 552 566 Castle Peak Road Tsuen Wan New Territories Hong Kong Phone 24297422 KYOCERA MITA TAIWAN Corporation 7F 1 2 No 41 Lane 221 Gangchi Rd Neihu District Taipei Taiwan 114
161. troller hardware Interface Controller software Resolution sss Dimensions zen Dat Current CPU Power PC750CXr 400 MHz System ROM 8 MB 32 Mbit x 2 Font ROM 2 MB 16 Mbit x 1 Main RAM 128 MB standard DIMM expanding up to 640 MB 512 MB x 1 at the maximum by adding optional expansion memory Optional expansion RAM DIMM 1 slot 100 pin DIMM 64 128 256 or 512 MB USB Hi Speed USB Optional interface KUIO LV x 1 Network interface card IB 21E IB 23 10 Base TX 100 Base TX must be installed a Emulation PCL6 PCL5c PJL PCL XL protocol class 2 1 KPDL3 PostScript 3 compatible b Fonts Bitmap font 1 Line Printer bitmap font Outline fonts 80 PCL fonts c Graphic 1 Raster graphic 75 100 150 200 300 600 dpi 200 dpi is supported when the resolution is 600 dpi 2 Vector graphic Line Box Circle Arc Fill pattern etc 3 Bar code One dimensional bar code 45 types Two dimensional bar code 1 type PDF 417 d Connectivity plug amp play Windows 95 98 ME NT4 0 2000 XP SNMP KM NET viewer 600 dpi Main unit 345 x 470 x 385 mm 13 5 8 x 18 1 2 x 15 1 4 W x Dx H Main unit Approx 24 kg 52 15 16 lbs including toner containers 220 240 V AC 50 60 Hz 16 ppm printer EUR model 120 V AC 60 Hz 17 ppm printer USA model Maximum 1001 W 220 240 V 16 ppm printer EUR model 1003 W 120 V 17 ppm printer U
162. tto any organic solvents such as alcohol other than the specified refiner it may generate toxic gas sese eee eee O This page is intentionally left blank CONTENTS 1 1 Specifications E Specifications e 1 1 1 11527 Parts MAMOS sss TO 1 1 5 1 Overall EE 1 1 5 2 Operation pane TTT 1 1 6 11 3 Cross section VIeW rte Re eU e ee O data 1 1 7 1 2 Installation 1 251 Drum unit ied Ri ERES 1 2 1 1 2 2 Developer unit and toner container nnne nnne nennen nennen 1 2 1 122 3 Installation enivironiment ro rete prt tute gZ Zc ec RAE ERAN CER ende 1 2 1 1 2 4 npacking and installatiQr 25 1 o idad ia 1 2 2 1 Installation procedure detiene tee Den ee e Er ete Ero A A 1 2 2 1 2 5 Installing expansion memory optional sese eee eee eee ee eee eee 1 2 8 1 2 6 Installing a memory card OPtiona l sese eee eee eee eee 1 2 9 1 2 7 Installing the network interface card optional sees eee eee eee eee eee 1 2 10 1 2 8 Installing the hard disk unit optional sss eee ee eee eee eee 1 2 11 1 3 Maintenance Mode 1 321 MAINTENANCE ule TTT 1 3 1 1 Executing a maintenance item sse essere eeceeeseceeseceeseeeceeeeceeseneeeesaeneneneneesesneeseseaeeesensseseaeneneneneeneneneees 1 3 1 ES A dE Re ERO REESE US ORE ECRIRE IDE AS 1 3 18 1 Method of removing the toner soiling which comes in contact with heat roller and press roller OTEA eT reU m EH Pe EG ERE HD ui De RIA E AES oie eei 1 3 18 1 4 Troubleshooting 1 4
163. uble remedy or replace 20 22 ppm printer EUR USA model Defective harness S03204 220 240 V AC model S03205 120 V AC model between fuser unit connec tor and fuser heater lamp 1 Check the continuity of the harness 803204 220 240 V AC model 803205 120 V AC model check the connection YC694 connector of the fuser PWB KP 970 A0003 if there is trouble remedy or replace 16 17 ppm printer EUR USA model Defective harness 803203 between fuser unit connec tor and power sup ply PWB Check the continuity of the harness 803203 check the connection CN2 con nector of the power supply PWB if there is trouble remedy or replace 20 22 ppm printer EUR USA model Defective harness 803206 between fuser unit connec tor and power sup ply PWB Check the continuity of the harness 803206 check the connection CN2 con nector of the power supply PWB if there is trouble remedy or replace 20 22 ppm printer EUR USA model 2HJ 2HK 1 Code Contents Pila Causes Check procedures corrective measures 6020 Fuser abnormal high temperature Defective engine Replace the engine controller PWB A0004 error heat roller controller PWB See page 1 5 41 Abnormal high fuser temperature of the A0004 heat roller was detected S Defective fuser Replace the fuser PWB KP 970 PWB A0003 2 Defective power Replace the power supply PWB See page su
164. ure 1 2 9 Im SB LS lae ZA SQ Paper size window Paper cassette Figure 1 2 10 Qr Waste toner box Connecting the cables the printer and the computer 2 Connect the power cord to the printer AC inlet 3 Connect the power cord to the wall outlet Printing a status page for test 1 Turn on the printer power switch The mes sage will change from Self test to Ready when initialization is complete Use the following key operation to print a status page for test Press the MENU key when Ready is dis played Press the Y or A key to display Print Sta tus Page Press the OK key to display Print Status Page Press the OK key Processing will be dis played and the status page will be printed When printing is complete Ready will appear again 2 Checkto see if the status page is properly printed Completion of the machine installation Connect the USB or ethernet cable between Figure 1 2 11 Power cord 2HJ 2HK 1 2 7 2HJ 2HK 1 2 5 Installing expansion memory optional lt Procedure gt 1 Turn off printer power CAUTION Do not insert or remove expan sion memory while printer power is on Doing so may cause damage to the printer and the expansion memory 2 If a memory card is currently installed in the memory card slot See the figure remove the memory card first 3 Remove two screws and then remove
165. utputted to the engine controller PWB A0004 was not detected Defective power supply PWB Replace the power supply PWB See page 1 5 41 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Toner motor 4 overcurrent detection error black toner The engine controller PWB A0004 detected the overcurrent of toner motor 4 16 17 ppm printer EUR USA model only Defective toner motor 4 Replace the toner motor 4 See page See page 1 5 50 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Lump of toner inside black toner container or defec tiveness of toner replenishment drive system Replace the black toner container 1 4 15 2HJ 2HK Contents Remarks Causes Check procedures corrective measures Toner motor 2 overcurrent detection error cyan toner The engine controller PWB A0004 detected the overcurrent of toner motor 2 Defective toner motor 2 Replace the toner motor 2 See page 1 5 50 Defective engine controller PWB A0004 Replace the engine controller PWB A0004 See page 1 5 41 Lump of toner inside cyan toner container or defec tiveness of toner replenishment drive system Replace the cyan toner container Toner motor 1 overcurrent detection error magenta toner The engine controller PWB A0004 detected th
166. ve background Black CT12 S wave patch Magenta S wave patch Cyan S wave patch Yellow S wave patch Black CT13 P wave patch Magenta P wave patch Cyan P wave patch Yellow P wave patch Black Calibration information 4 CT14 Background P wave max 2 bytes Background P wave min 2 bytes Developing bias data Magenta 1 byte Developing bias data Cyan 1 byte Developing bias data Yellow 1 byte Developing bias data Black 1 byte LED control voltage 1 byte Calibration information 5 CT15 Relative compensation for toner 2 bytes Each 2 bytes in the following order Magenta 450 400 350 Beta Cyan 450 400 350 Beta Yellow 450 400 350 Beta Black 450 400 350 Beta Calibration information 6 CT16 Total number of times Number of cancellation Number of retries E10 error E11 error E12 error Calibration result 1O Calibration result bias x1 E00 Completed normally E10 Sensor value does not proportionally increase E1X Calibration sensor Toner ID sensor error E11 Sensor value increases too few E12 Sensor value increases too few and does not increase proportionally E20 Calibration cancelled from engine request 2 B00 Completed normally All biases C M Y K are within range of Ox8B OxE1 B10 Bias sensor value error One of the biases C M Y K is less than 0x8A or more than OxE2 Engine parameter setting Hexadecimal 256 bytes 512 digits Dru
167. veloper gear K3 Y3 C3 M3 and developers are driven Since the shaft of idle gear K2 which transmits a drive to a black developer is being fixed to main drive unit although a drive is transmitted to developer gear K3 and a black development unit always drives But idle gear which transmits drive to developer of the other colors Y2 C2 M2 because in idle arm plate which mobility it does it is installed the idle gear Y2 C2 M2 with developer gear Y3 C3 M3 connection leaves due to the mobility of idle arm plate the mechanism where drive is separated According to this mechanism although all developers are driven at the time of color printing only a black developer is driven at the time of monochrome printing Color printing Cam lever Developer drive stop motor Idle plate lever Cam gear Es Idle arm plate Idle arm plate Idle arm plate Main drive unit Drum motor gear Idle gear Developer gear K1 for black K2 for black K3 for black Y1 for yellow Y2 for yellow Y3 for yellow C1 for cyan C2 for cyan C3 for cyan M1 for magenta M2 for magenta M3 for magenta Figure 2 1 14 2 1 10 2HJ 2HK 2 1 3 Drum section The drum unit includes a photoconductive drum eraser lamp LED print head cleaning blade and a main charger unit The drum unit is removable with the main charger unit 1 Drum unit The tandem development system uses four
168. voltage P wave input drive stop 13 IDREF O Analog Toner ID sensor LED light emitting control signal motor 14 STFDA O 0 24 V DC pulse Feed motor energization pulse 15 STFDAN O 0 24 V DC pulse Feed motor energization pulse 16 STFDB O 0 24 V DC pulse Feed motor energization pulse 17 STFDBN O 0 24 V DC pulse Feed motor energization pulse 18 STFSA O 0 24 V DC pulse Fuser motor energization pulse 19 STFSAN O 0 24 V DC pulse Fuser motor energization pulse 20 STFSB O 0 24 V DC pulse Fuser motor energization pulse 21 STFSBN O 0 24 V DC pulse Fuser motor energization pulse 22 DVEMOTA O 0 24V DC Developer drive stop motor Fwd Rev 23 DVEMOTB O 24 0V DC Developer drive stop motor Rev Fwd 24 GND J Ground 2 3 8 2HJ 2HK 1 Y 5 o Connector YC12 Connected to the power supply PWB Signal THI TH2 FDSOLDR 45V2 RCOVOPN FUSOLDR EXITPAPN 24V2 HEAT2DR HEAT1DR ZCROSS 24V1 24V1 Voltage Description Analog Fuser thermistor 1 detection voltage input Analog Fuser thermistor 2 detection voltage input 0 24 V DC pulse Face up down solenoid control signal BV DC 5 V DC power input 0 5 V DC Rear cover open close sensor rear cover open close 0 24 V DC Face up down solenoid control signal 0 5 V DC Exit sensor On Off 24V DC 24 V DC power input 0 24 V DC Fuser heater lamp 2 On Off 0 24 V DC Fuser heater lamp 1 On Off 0 5 V DC pulse Zero cross s
169. wo ozone filters See page 1 5 51 10 Replace the retard roller See page 1 5 8 11 Replace the MP tray feed roller See page 1 5 11 Procedure Enter the service mode Maintenance 1 Press the OK key Message gt gt Maintenance is displayed 2 Press the OK key twice The counter for each component is reset immediately Completion NOTE Occurrences of resetting the maintenance kits are recorded on the service status page and event log in number of pages or images at which the maintenance kit was replaced See page 1 3 2 and 1 3 9 This may be used to determine the possibility that the counter was erroneously or unintentionally reset gt gt DEV CLN 1 3 16 Developer refreshing Description The laser output of the image data for developer refreshing is carried out and operation to exposure developing and primary transfer is performed by 10 pages Paper is not fed Purpose To perform when occurring the decrease of image density or the developing problem Procedure 1 Enter the service mode gt gt DEV CLN 2 Press the OK key Message gt gt DEV CLN will be displayed 3 Press the OK key Developer refreshing will be started Completion A4 paper size 33 mm Toner image on the primary transfer belt 200 mm lt Figure 1 3 8Developer refreshing Image data 2HJ 2JK 1 Service items gt gt Drum Description Drum surface refreshing Description Rota
170. yan drum PWB 3 yellow drum PWB 4 black wiring relay circuit inside each color drum unit Drum individual information in EEPROM storage Zener PWB 1 2 3 4 sues Adjusts the main charger grid electrostatic potential Fuser PWB ccccsceeceeeceseeeeeeeseeenseneeeeseees Relays wirings from electrical components on the fuser unit Eraser lamp 1 2 3 4 Eliminates the residual electrostatic charge on the drum Toner sensor 1 2 3 4 Measures the toner concentration in the toner hopper Fuser thermistor 1 sssuues Detects the temperature of the heat roller Fuser thermistor 2 Detects the temperature of the press roller EXIT SONS OM sii sdacteccenzaecdcesencsaseecteaceeetscletsesess Detects paper misfeed in the fuser unit Rear cover open close sensor Detects the rear cover open Face up down solenoid Switches the output stack between face up and face down LED print head 1 2 3 4 sss LED print head 1 magenta LED print head 2 cyan LED print head 3 yellow LED print head 4 black lighting of dot light to drum of each color drum unit Fuser heater lamp T eee eee eee eee Heats the heat roller Fuser heater lamp 27T Heats the press roller Fuser thermostat 1 sese eee eee eee eee Disable power for the fuser heater lamp 1 in emergency Fuser thermostat 2 Disable power for the fuser heater lamp 2 1 in eme
171. ys check that the copier is correctly connected to an outlet with a ground connection e e Check that the power cable covering is free of damage Check that the power plug is dust free If it is dirty clean it to remove the risk of fire or electric shock eee eee Q Never attempt to disassemble the optical unit in machines using lasers Leaking laser light may damage eyes sorra teg ee R A E A AAN G Handle the charger sections with care They are charged to high potentials and may cause electric shock if handled Bi se J AACAUTION Wear safe clothing If wearing loose clothing or accessories such as ties make sure they are safely secured so they will not be caught in rotating sections see eee eee eee eee eee NM Use utmost caution when working on a powered machine Keep away from chains and belts A Handle the fixing section with care to avoid burns as it can be extremely hot sees eee eee A e Check that the fixing unit thermistor heat and press rollers are clean Dirt on them can cause abnormally high temperatures H Q Do not remove the ozone filter if any from the copier except for routine replacement Q Do not pull on the AC power cord or connector wires on high voltage components when removing them always hold the plug itself sees eee S Do not route the power cable where it may be stood on or trapped If necessary protect it with a cable cover or other appropriate item sese

FS-C5015N/C5025N Service Manual

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