DP-2800 (MCA) S/M

SERVICEMANUAL

Published in June ’985A270760

R

DP-2800

DP

-280

0

SERVICEMANUAL

DP-2800

Safety precautions

This booklet provides safety warnings and precautions for our servicepersonnel to ensure the safety of their customers, their machines as wellas themselves during maintenance activities. Service personnel areadvised to read this booklet carefully to familiarize themselves with thewarnings and precautions described here before engaging inmaintenance activities.

Safety warnings and precautions

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

DANGER: High risk of serious bodily injury or death may result frominsufficient attention to or incorrect compliance with warningmessages using this symbol.

WARNING: Serious bodily injury or death may result from insufficientattention to or incorrect compliance with warning messagesusing this symbol.

CAUTION: Bodily injury or damage to property may result frominsufficient attention to or incorrect compliance with warningmessages using this symbol.

SymbolsThe triangle ( ) symbol indicates a warning includingdanger and caution. The specific point of attention is showninside the symbol.

General warning.

Warning of risk of electric shock.

Warning of high temperature.

indicates a prohibited action. The specific prohibition isshown inside the symbol.

General prohibited action.

Disassembly prohibited.

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

General action required.

Remove the power plug from the wall outlet.

Always ground the copier.

1. Installation Precautions

WARNING

•Do not use a power supply with a voltage other than that specified.Avoid multiple connections to one outlet: they may cause fire or electricshock. When using an extension cable, always check that it isadequate for the rated current. ..............................................................

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

CAUTION

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

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

•Do not install the copier near a radiator, heater, other heat source ornear flammable material. This may cause fire. ......................................

•Allow sufficient space around the copier to allow the ventilation grills tokeep the machine as cool as possible. Insufficient ventilation maycause heat buildup and poor copying performance...............................

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

•Always use anti-toppling and locking devices on copiers so equipped.Failure to do this may cause the copier to move unexpectedly ortopple, leading to injury. .........................................................................

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

•Advice customers that they must always follow the safety warningsand precautions in the copier’s instruction handbook............................

2. Precautions for Maintenance

WARNING

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

•Always follow the procedures for maintenance described in the servicemanual and other related brochures. .....................................................

•Under no circumstances attempt to bypass or disable safety featuresincluding safety mechanisms and protective circuits. ............................

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

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

•When the service manual or other serious brochure specifies adistance or gap for installation of a part, always use the correct scaleand measure carefully............................................................................

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

•Check that the power cable covering is free of damage. Check that thepower plug is dust-free. If it is dirty, clean it to remove the risk of fire orelectric shock. ........................................................................................

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

•Handle the charger sections with care. They are charged to highpotentials and may cause electric shock if handled improperly. ............

CAUTION

•Wear safe clothing. If wearing loose clothing or accessories such asties, make sure they are safely secured so they will not be caught inrotating sections. ...................................................................................

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

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

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

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

•Do not pull on the AC power cord or connector wires on high-voltagecomponents when removing them; always hold the plug itself. .............

•Do not route the power cable where it may be stood on or trapped. Ifnecessary, protect it with a cable cover or other appropriate item. .......

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

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

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

•After maintenance, always check that all the parts, screws, connectorsand wires that were removed, have been refitted correctly. Specialattention should be paid to any forgotten connector, trapped wire andmissing screws. .....................................................................................

•Check that all the caution labels that should be present on the machineaccording to the instruction handbook are clean and not peeling.Replace with new ones if necessary. .....................................................

•Handle greases and solvents with care by following the instructionsbelow: ....................................................................................................· 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 thecovers or turning the main switch on.

· Always wash hands afterwards.

•Never dispose of toner or toner bottles in fire. Toner may causesparks when exposed directly to fire in a furnace, etc. ..........................

•Should smoke be seen coming from the copier, remove the powerplug from the wall outlet immediately. ....................................................

3. Miscellaneous

WARNING

•Never attempt to heat the drum or expose it to any organic solventssuch as alcohol, other than the specified refiner; it may generate toxicgas. ........................................................................................................

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CONTENTS

Chapter 1 PRODUCT INFORMATION

Printer identification labeling ........................................................................ 1-1Printer Specifications ................................................................................... 1-2Front and rear views .................................................................................... 1-5Options ......................................................................................................... 1-7Environmental requirements ........................................................................ 1-8About the toner .......................................................................................... 1-11

Chapter 2 INSTALLATION/OPERATION

Unpacking ................................................................................................... 2-1Installing the printer ..................................................................................... 2-3Expanding memory ..................................................................................... 2-8Installing KPDL .......................................................................................... 2-13Using the Control Panel ............................................................................ 2-14

Chapter 3 MAINTENANCE/ADJUSTMENTS

Life expectancy of modules ......................................................................... 3-1Toner container ............................................................................................ 3-2Cleaning the printer ...................................................................................... 3-4Replacing the developer unit ........................................................................ 3-9Updating the firmware ................................................................................ 3-12Adjusting the transfer bias .......................................................................... 3-16

Chapter 4 OPERATION OVERVIEW

Electrophotographics system ...................................................................... 4-1Paper feeding system ............................................................................... 4-18Print timing charts ..................................................................................... 4-29Basic engine functions .............................................................................. 4-32Engine controller system ........................................................................... 4-33Logic controller system ............................................................................. 4-43

Chapter 5 DISASSEMBLY

General Instructions ..................................................................................... 5-1Before starting disassembly ......................................................................... 5-2Disassembly ................................................................................................. 5-3

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Chapter 6 TROUBLESHOOTING

Board layouts .............................................................................................. 6-1Diagnostic ................................................................................................... 6-2General error handling ................................................................................ 6-7Error messages ........................................................................................... 6-8Call-Service person errors ........................................................................ 6-13Print quality problems ................................................................................ 6-33Correcting a paper jam .............................................................................. 6-41Correcting paper jams ............................................................................... 6-43

Appendix A PRINTER INTERFACE

Parallel interface .........................................................................................A-1Serial interface ............................................................................................ A-3

Appendix B STATUS PAGE

Status page ..................................................................................................B-1

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CONTENTS

Chapter 1 PRODUCT INFORMATION

Printer identification labeling ................................................................................... 1-1US/Canada version ...................................................................................................... 1-1

Printer Specifications ................................................................................................ 1-2Recommended flash cards .......................................................................................... 1-4

Front and rear views .................................................................................................. 1-5Front view .................................................................................................................... 1-5Internal assemblies ...................................................................................................... 1-6Rear view ..................................................................................................................... 1-6

Options ....................................................................................................................... 1-7

Environmental requirements .................................................................................... 1-8Environmental conditions ............................................................................................. 1-8Clearance ..................................................................................................................... 1-9Places to avoid ........................................................................................................... 1-10Note on power ............................................................................................................ 1-10

About the toner ........................................................................................................ 1-11Toner container handling ........................................................................................... 1-11Toner storage ............................................................................................................. 1-12

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Printer identification labelling

The printer has a label bearing its model and serial number at its back. This label alsocontains other safety precautions.

US/Canada version

DP-2800

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

This Class B digital apparatus complies with Canadian ICES-003.Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

THIS LASER PRODUCT CONFIRMS TO THE APPLICABLEREQUIREMENTS OF FEDERAL REGULATIONS 21 CFR CHAPTER 1, SUBCHAPTER J.

MITA INDUSTRIAL CO.,LTD.2-28 1-CHOME TAMATSUKURI CHUO-KU OSAKA JAPAN MADE IN JAPAN

MANUFACTURED

60Hz 120V 10A

PRECAUCIONRETIRE EL CORDON ELECTRICO ANTESDE REALIZAR SERVICIO O REEMPLAZAREL FUSIBLE.

ATTENTIONPOUR PRÉVENIR LES CHOCSÉLECTRIQUES, COUPER L

,ALIMENTATION

AVANT DE REMPLACER LE FUSIBLE.

CAUTIONREMOVE POWER CORDBEFORE SERVICE AND FUSE REPLACEMENT.

FOR HOME OR OFFICE USE

Tested To ComplyWith FCC Standards

8J68UL1950

PRINTER

YM

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Printer Specifications

EngineSpecificationPrint method ……………………… Electrophotography laser scanPrint speed (when printingmultiple copies of thesame page) ……………………… A4/11" × 81/2": 28 pages/min., B4 (257 × 364 mm):

18 pages/min., A3/11" × 17": 16 pages/min.Resolution (dpi) ………………… 600 horizontal/600 verticalSmoothing ………………………… KIR 2 (2400 horizontal/600 vertical)First print (A4/11" × 81/2" or letter,23°C), depends on input data …… 10 seconds or less (75 seconds or less with sleep

mode on)Warm-up time at 23° …………… 65 seconds or lessMaximum duty cycle (A4) ……… 100,000 pages/monthLaser diode ……………………… Visible laserMain charger ……………………… Scorotron wireTransferring ……………………… Biased rollerSeparation ………………………… DCDrum cleaning …………………… BladeDrum discharging ………………… LED arrayFuser ……………………………… Heat and pressurePaper ……………………………… Plain paper (as specified separately)Capacity of paper feed tray(80 g/m2 [0.11 mm thickness]) … Cassette: 500 sheets, MP tray: 100 sheetsCapacity of output trays(80 g/m2 [0.11 mm thickness]) … 500 sheets

ControllerSpecificationCPU ……………………………… PowerPC603e/100 MHzSystem ROM size ……………… 4 MB, flash DIMM or masked DIMMResident font ROM size ………… 4 MBOption fonts ROM ……………… 2 MB (PK-4)Main RAM ………………………… 4 MBAdditional RAM (SIMM) ………… 64 MB maximum (72-pin SIMM × 2)Memory card ……………………… SRAM or flush, JEIDA 4.2/PCMCIA 2.1

See Recommended flash cards in this chapter.Host interface …………………… Parallel: High-speed, bi-directional (IEEE1284),

Serial: RS-232C/RS-422A, Option, KCIO (HDD).Page description language ……… Prescribe IIStandard emulation modes …… HP LaserJet 5Si, IBM Proprinter X24E, Diablo 630,

Epson LQ-850

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Weight and dimensionsSpecificationMain unit ………………………… Width: 56 cm (22")

Height: 34.5 cm (13.6")Depth: 56.6 cm (22.3")Weight: 41.5 kg (18.7 lb.)

Paper feeder ……………………… Width: 56 cm (22")Height: 24.7 cm (9.7")Depth: 56.6 cm (22.3")Weight: 19.5 kg (8.8 lb.)

Power requirementsSpecificationVoltage requirements …………… US/Canada: 120 V AC ±10%, 60 Hz ±2%.Watts ……………………………… Maximum: 1200 W

Normal operation: 677 WStandby: 215 WSleeping: 34 W

Environmental requirementsSpecificationOperating temperature andhumidity …………………………… 10 to 32.5°C (50 to 90.5°F), 20 to 80% RHMaximum altitude ………………… 2,000 m (6,500 feet)Noise emission (Excludingpeaks, measured at 1m fromprinter, as per ISO7779) ………… 50 dB (A) maximum/38 dB (A) at standby/

unmeasurably low at sleeping)

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Recommended flash cards

The printer provide support for a JEIDA/PCMCIA category of memory card in both SRAMand flush types of up to 32 MB. Following is a list of makes and models of flush cardsrecommended for use with the printers.

Note that the flush card to be used should be operable on 5 V DC.

Model Capacity

AMD AmC001CFLKA 1 MB

AmC002CFLKA 2 MB

AmC004CFLKA 4 MB

AmC010CFLKA 10 MB

AmC004DFLKA 4 MB

AmC008DFLKA 8 MB

AmC020DFLKA 20 MB

Fujitsu MB98A81063 1 MB

MB98A81183 2 MB

MB98A81273 4 MB

MB98A81373 8 MB

MB98A81473 16 MB

Panasonic BN-02MHF4C (CC) 2 MB

BN-04MHF4C (CC) 4 MB

Centennial FL01M-20-11114-03 1 MB

FL02M-20-11114-03 2 MB

FL04M-20-11114-03 4 MB

FL08M-20-11114-03 8 MB

Maxell EF-2M-TB (DC) 2 MB

EF-4M-TB (DC) 4 MB

EF-8M-TB (DC) 8 MB

EF-16M-TB (DC) 16 MB

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Front and rear views

Front view

Front control panel

Paper-full sensor

Front cover

MP (multi-purpose) tray

Paper feeder

Option feederconnector

Vent

Paper feeder side cover

Upper paper cassette

Lower paper cassette

Power switch

Face-up paper tray

Left side cover

Face-down trayLeft side view

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Internal assemblies

Toner container

Feed unit handle

Fuser releaselever

Fuser unit

Toner container release lever(Green colored)

Feed unit

Drum unit

Drum release lever(Green colored)

Developer release lever

Developer

Memory card slot

Harddiskdrive slot

Parallel interfaceconnector

Serial interfaceconnector

Paper cassetteaccess door

Option interfaceslot cover

Rear panel

Power receptacle

Rear view

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Options

The example option units are shown below. The instruction handbook come with the printerhas more information regarding the accessories available for this model.

Paper feeder supplied as standard

First optional paper feeder

Second optional paper feeder

Bulk paper stacker

Inboard duplexer

Wheels (Caster kit)

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Environmental requirements

Environmental conditions

The Environmental requirements section on page Chapter 1-2 should be observed toensure the optimum operation of the printer. The use of the printer in a location which doesnot satisfy the requirements may result in troubles and risk shortening its service life.

The printer will work best if it is installed in a location that is:• Level and well supported (Place the printer on a sturdy table or desk.)• Not exposed to sunlight or other bright light (not next to an uncurtained window). Do not

place the printer on an unstable cart, stand, or table.• Near an AC wall outlet, preferably one that can be used for the printer alone. The outlet

should have a ground slot, or an adapter should be used. If you use an extension cord,the total length of the power cord plus extension cord should be 17 feet or 5 meters or less.

• Well ventilated, not too hot or cold, and not too damp or dry (See section Environmentalrequirements on page Chapter 1-2). If you install the printer where the temperature orhumidity is outside the requirements in section Environmental requirements in chapter 1,the best print quality may not be expected and there will be an increased chance of paperjams.

• Provide a sufficient clearances around the printer to ensure ventilation and ease ofaccess.

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Clearance

Allow the necessary minimum clearance on all sides of the printer (below). A total space of92 by 138 cm (36 by 54") is needed.

Clearance Dimensions

Left 1 45 cm (17.7"), or 30 cm (12") if the face-up tray is not used.

Front 2 60 cm (24")

Right 3 45 cm (17.7")

Back 4 20 cm (8")

Above 5 30 cm (12")

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1

3

4

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Places to avoid

Avoid installing the printer in locations exposed to:• Direct drafts of hot or cold air.• Direct drafts of outside air. (Avoid locations next to outside doors.)• Sudden temperature or humidity changes.• Any source of high heat, such as a radiator or stove.• Excessive dust. Dust and smoke may cause contamination on the laser scanner window,

causing print quality problem.• Vibration.• Ammonia fumes or other harmful fumes. (In case of humigating the room or saturate it with

insecticide, remove the printer first.)• Avoid greenhouse-like rooms. (Because of sunlight and humidity.)• Avoid enclosed spaces that block ventilation.• Avoid sites more than 6500 feet or 2000 meters above sea level.

Note on power

Use only the power source voltage conforming to the printer’s rated power voltage. Do notuse other power sources.• Disconnect the printer from the power source before attempting removal or re-placement

of an electrical component or a printed-circuit board.• The printer should not be connected to a power source until the instruction is given to do

so when performing tests described in this handbook.• In connecting the printer power, exercise an extreme care in handling the power supply

or any other electric parts which may give an electric shock.• Before performing maintenance or repair, power from both the power source and the

associated peripheral devices (computer, sorter, etc.) should be disconnected, unlessotherwise specified.

• To avoid possible electrical shock, extreme caution must be exercised in handling thepower cord and any other electrical part.

• An easily accessible socket outlet must be provided near the equipment.

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About the toner

The printer should use the proprietary toner kit. To ensure the high print quality and longservice life, the following handling precautions should apply.

Caution: As the printers are designed to ensure the optimum print quality when used withthe proprietary toner, we do not recommend to use any refilled toner containersthat may be available commercially. This is because we have no means forcontrol over how such refilled toner could affect the print quality and the reliabilityof the printer.

Toner container handling

To loosen and mix the toner inside before use, with the label side down, thoroughly shakethe toner container (in the direction of the arrow) 5 times or more.

Caution: Do not attempt to disassemble or refill the toner container.

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Toner storage

The toner contained in the container is susceptible to temperature and humidity. To ensurethe high print quality, store the toner container in a place that satisfy the followingenvironmental conditions:

Temperature: –20 to 40°C (–4 to 104°F)Humidity: 15 to 90% RH

Note: If the toner container is removed from the printer’s developer unit, put it in aprotective bag and keep it in a dark place.

Caution: If the printer is shipped for return, etc., do not ship it with the toner containerinstalled. Otherwise, toner may leak and contamination may result in the printer.

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CONTENTS

Chapter 2 INSTALLATION/OPERATION

Unpacking .................................................................................................................. 2-1Unpacking the paper feeder ........................................................................................ 2-1Unpacking the printer .................................................................................................. 2-2

Installing the printer .................................................................................................. 2-3Connecting the printer and the paper feeder .............................................................. 2-3Installing toner ............................................................................................................. 2-4Developer initialization ................................................................................................ 2-7

Expanding memory ................................................................................................... 2-8Minimum memory requirements .................................................................................. 2-8SIMM specifications .................................................................................................... 2-8Notes on handling SIMM ............................................................................................. 2-9Getting access to the memory sockets ..................................................................... 2-10Installing SIMM .......................................................................................................... 2-12Testing the expansion memory ................................................................................. 2-12

Installing KPDL ........................................................................................................ 2-13Installing the KPDL ROM .......................................................................................... 2-13Getting access to the KPDL ROM socket ................................................................. 2-14

Using the Control Panel ......................................................................................... 2-14Front control panel .................................................................................................... 2-14Control panel view ..................................................................................................... 2-14Basic key operation ................................................................................................... 2-14Indicators ................................................................................................................... 2-15Mode selection menu ................................................................................................ 2-15Service mode ............................................................................................................ 2-15

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Unpacking

The printer is delivered in two cartons—the printer carton and the paper feeder carton. Sincethe paper feeder is installed under the printer, begin unpacking and installing with the paperfeeder.

Unpacking the paper feeder

To unpack the paper feeder, proceed as diagrammed below.

Warning: The paper feeder weighs approximately 20 kg (9 lb.).

Place the paper feeder on a stable, level surface (table, floor, etc.). Note that wheels areavailable for the printer as the Caster kit.

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Unpacking the printer

To unpack the printer, proceed as shown in the diagrams below. Check that the listed partsare all present.

Warning: The printer weighs approximately 41 kg (18 lb.). Lift it using two or more people.

Do not cut tapes as they are reusable for future packing.

Take out the accessories: 1 Power cable, 2 Drum unit

cover, 3 Toner kit 4 Documents

incl. CD-ROM.

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4

2

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Installing the printer

Installing the printer requires several steps. Proceed as follows in sequence.If the printer is used with casters, fit them now before proceeding.

Connecting the printer and the paper feeder

The printer should be mounted over the paper feeder as shown below. Align the pins 1 andthe connector 2 on the paper feeder with the matching holes and the connector located atthe bottom of the printer, then slowly lower the printer onto the paper feeder.

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Installing toner

First open the top cover 1 atop the printer. Slide the toner container release levers 2 tothe right side position. (This is the “open” position in which the toner container becomesremovable.)

1

2

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Peel off the seal 1 on the bottom of the toner container by carefully pulling off.

Label side

1

Take the toner container from the toner kit supplied with the printer. With its label side facingdown, give it a good shake (5 to 6 times).

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Insert the toner container in the printer as below. Align the two locating keys at the sides ofthe container with the mating slots in the printer.

Caution: To avoid trouble, the toner container must be correctly seated and locked in theprinter. To do this, press the far side of the container 1 at the PUSH HEREmarks.

Making sure that the toner container is seated correctly on the developer, press the twoPUSH HERE markings on the toner container using both hands.

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When the toner container is inserted in the printer properly, slide the toner container releaselevers to the left side position until it stops. After installing the toner container, close the topcover down firmly.

Developer initialization

The printer is shipped from the factory with no toner supplied in its developer unit. When theprinter is first switched on after the toner container is installed in the manner above, therewill be a delay of several minutes before the printer gets ready to print a job.This delay is necessary for the printer to fill the developer reservoir with a sufficient amountof toner to continuously support a print job. The period of time for this delay varies dependingon model: approximately 5 minutes.Since the automatic implementation of the developer initialization is done only once at firstswitching power on, if a new developer is installed in the printer, the developer must beinitialized manually using the service mode on the front panel. Refer to the section Feedingtoner into the new developer in chapter 3.

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Expanding memory

Expanded printer memory is required particularly when a memory error occurred. It enablesthe printer to print more complex pages, download more fonts, and define more macros.Since expanding memory requires removal of the main circuit board from the printer andhandling of SIMM (single in-line memory module), the following procedures should befollowed only by a qualified service technician.

Minimum memory requirements

By default, the printer is equipped with 4 MB of memory at the shipment which is expandableup to a maximum of 68 MB (two 32 MB SIMMs). The minimum memory requirements forthe printer with various options installed are listed in the table below. Refer to this table forobtaining a rough approximation on how much memory is required for a particular need.

Resolution

Printing environment 300 dpi 600 dpi

HP emulation 2 MB 2 MB

HP+duplex (using duplexer) 2 MB 3 MB

HP+KPDL 2 MB 3 MB

HP+KPDL+duplex 3 MB 5 MB

HP+KPDL+resource protection n/a 10 MB

HP+KPDL+resource protection+duplex n/a 14 MB

SIMM specifications

Memory size in MB ……………… 1, 2, 4, 8, 16, 32Number of pins …………………… 72Access speed …………………… 80 ns or fasterParity ……………………………… With/withoutBus width ………………………… 32 bits

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Notes on handling SIMM

Before proceeding to install SIMM, read the following notes for handling the main circuitboard and SIMMs.• Protect the electronics by taking these precautions:• Before touching the main circuit board, touch a water pipe or other large metal object to

discharge yourself of static electricity. While doing the work, it is recommended that youwear an antistatic wrist strap.

• Touch the main circuit board and SIMM only by the edges, not in the middle. See below.

• Follow the instructions the SIMM manufacturer should provide.

Yes

No

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Getting access to the memory sockets

The main circuit board of the printer is equipped with two sockets for memory expansion.Expansion memory is available in the form of a SIMM. To gain access to the main board,the printer’s rear panel should be removed.

Warning: Turn the printer’s power off. Unplug the printer’s power cable and disconnect theprinter from the computer or the network.

Turn the power switch off. Remove the main board access panel 1 by removing 6 (plated)screws. The main controller board 2 is exposed for inserting SIMMs.

1

2

Caution: When the main board is open, use care to avoid foreign objets from entering themain board area. Otherwise, a serious damage to the printer could result.

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Locate the sockets for the SIMMs on the main controller board by referring to the diagramon the next page. Locate the sockets for memory expansion on the main board. Thesesockets have 72 pins and are symbolized as YS1 and YS2.

Expansion SIMM sockets

KPDL ROM socket

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Installing SIMM

Insert the SIMM 1 into the socket 2 as shown. Carefully push the board upright until itsnaps into place. Make sure that the catches at the ends of the socket fit into the holes 3at the ends of the SIMM board.

1

2

3

Testing the expansion memory

After installing SIMMs in the printer, test the printer to see if the installation has beensuccessful. To test the expansion memory, turn printer power on and print a status page.If the installation has been successful, the Total memory (Memory Allocation) of the statuspage will show the expanded memory size corresponding to the amount of memory added.

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Installing KPDL

KPDL is an upgrade for adding implementation of the PostScript page description language.Upgrade is done by inserting a KPDL FONT ROM into an empty socket on the printer’s maincircuit board.For details on KPDL, refer to the KPDL Upgrade Kit instruction handbook supplied withKPDL FONT ROM.

Installing the KPDL ROM

Before installing the KPDL ROM delivered, carefully straighten the pins as follows.

Make sure that none of the pins are bent.

To insert the ROM into its socket, position the ROM in the socket as shown. Make sure thatthe U-shaped indentation at the end of the ROM is oriented in the same direction as theU-shaped indentation at the end of the socket. Align all pins of the ROM properly with theirsocket holes.

ROM

Socket “U” indentations

Getting access to the KPDL ROM socket

Refer to the previous section Expanding memory, page Chapter 2-8, and remove theprinter’s rear panel.Locate the socket for inserting the KPDL ROM. Refer to the diagram on page Chapter 2-11.This socket is marked as U13, adjacent to another (shorter) empty socket (U13).

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Using the control panel

This section provides explanation on how to use the printer’s control panel. This is more fullydetailed in the instruction handbook.

Front control panel

The printer’s control panel has the LED indicators and a quartz message display to providea quick access to the printer’s conditions. It also features the control keys for adjusting thevarious conditions on the fly. Note that the adjustments made using these keys may beoverridden by the settings made from within an application software.

Control panel view

Basic key operation

The control keys are used to configure the printer as follows. For more detailed explanationson these keys, refer to the printer’s instruction handbook.

Key Function

ON LINE Switches the printer online and offline.

CANCEL Abandons a printing job, resets numeric values or cancels asetting procedure.

STACK Selects whether printed pages are delivered to the face-down orface-up tray.

FEED Selects the cassette feed or manual (MP tray) feed.

—CONTINUE Resumes printing when the message display indicates a memoryerror. Also, enters in a submenu item during mode selection.

Cycles forward through the item selections or enters numericvalues.

—FORM FEED Prints and feeds out one page. Also, exits a submenu item duringmode selection.

MODE/EXIT Enters/exits the mode selection for changing the printer’sconfiguration.

ON LINE ATTENTIONDATA

CANCEL STACK FEED

FORM FEED

ENTER

STATUS

EXIT

MODE

o

RESOLUTION COPIESINTERFACE SIZE

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– Cycles reverse through the item selections or enters numericvalues.

ENTER/STATUS Prints a page of status information. During mode selection, thiskey finalizes numeric values and other selections for changingthe printer’s configuration.

Indicators

Indicator Status Function

1–ONLINE/Green Steady The printer is on-line and ready to prints receiveddata.

Off The printer is off-line. The printer stores but not printsreceived data.

2–DATA/Green Flashing The printer is receiving data from the host computer.

Steady The printer is processing the data for printing or forwriting on a memory card.

3–ATTENTION/Red Flashing (1) The printer is warming up. (2) The printer wasstopped because of an error such as the insufficientmemory, memory card errors, etc. (See chapter 6.)

Steady (1) The printer needs attention for a problem that canbe cleared by the user such as an open cover,missing toner kit, paper-full stack, etc. (2) The printerwas stopped because of a problem that needsservicing provided by a service technician.

Mode selection menu

The MODE key on the control panel allows to set or change the printer environment suchas the number of copies to make, emulation, etc., and to print a font list, manipulating amemory card, etc.During operating in the mode selection, several front panel keys serve exclusively for itssecondary function as labeled beside them (EXIT, +, –, ENTER, , ). The diagram onthe next page gives a full load map to the full options and the sequence of mode selectionas well as usage of these secondary keys.

Service mode

Within Others option, the Service mode can be accessed by authorized service personnel.This mode provides the following three treatments for service purpose:• printing a service information (a service status page)• cleaning on the drum surface• accelerating initial toner replenishment for a new developer

The service mode is available only when the printer is ready. To activate these features, seechapter 3. While in service mode, the printer accepts print data but does not print it.

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CONTENTS

Chapter 3 MAINTENANCE/ADJUSTMENTS

Life expectancy of modules ..................................................................................... 3-1

Toner container .......................................................................................................... 3-2When to replace the toner container ........................................................................... 3-2Toner container replacement ....................................................................................... 3-3Toner saver mode (EcoPrint) ....................................................................................... 3-3

Cleaning the printer ................................................................................................... 3-4Main charger unit ......................................................................................................... 3-4Cleaning the paper feed unit ........................................................................................ 3-7

Replacing the developer unit .................................................................................... 3-9Replacement ................................................................................................................ 3-9Installing a new developer ......................................................................................... 3-10Feeding toner into the new developer ........................................................................ 3-11

Updating the firmware ............................................................................................. 3-12Firmware data format ................................................................................................. 3-12Downloading engine firmware data ............................................................................ 3-13Downloading controller firmware data ........................................................................ 3-13Downloading data from a memory card ..................................................................... 3-14Errors during downloading ......................................................................................... 3-15

Adjusting the transfer bias ..................................................................................... 3-16

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Life expectancy of modules

The table below shows the nominal life expectancy for modules. Detailed part informationfor each module (except toner containers) can be found in Parts List.For refurbishment purpose, the modules are available as a kit after 350,000 pages havebeen printed. The contents of this kit is also shown in this table.

Nominal lifeModule (pages) Remarks

Toner 25,000 User-replaceable (20,000 for the initially suppliedcontainer container)

Drum unit 350,000

Developer unit 350,000

Fuser unit 350,000

Transfer roller 350,000

Refurbishment 350,000 Includes a drum unit, a developer unit, a fuser(“Maintenance”) kit*1 unit, a transfer roller, and a waste toner conveyer.

*1 To install the kit, refer to the instruction handbook included in the kit.

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Toner container

The toner container is the only consumable that the printer requests (until it has printed350,000 pages) to replace periodically during normal operation (user-replaceable). Thefollowing toner container is available for use with model.

Model Life in pages*2

Toner kit 25,000 (1,100 g)

*2 Based on letter or A4 size paper; average print density of 5%.

When to replace the toner container

The printer gives two steps of user attention for toner replacement as explained below:

Step 1—The toner is almost run out. The message display indicates:

Replace Toner … Clean printer

The printer will print approximately 2,500 pages (A4 or letter/5% coverage) until step 2. Thisis the earliest chance to replace the toner container and clean various parts inside the printer(See Cleaning the printer on page Chapter 3-4).

Step 2—The toner is run out. The printer halts printing and the message display indicates:

Replace Toner … Clean printer

This instructs the user to install a new toner kit to bring the printer back in normal operation.Cleaning various parts inside must be also done in this occasion (See Cleaning the printeron page Chapter 3-4).

Observe the following cautions when replacing the toner container:• Do not attempt to disassemble the toner container and reuse the waste toner inside.• Keep magnetic media such as floppy disks away from the toner container.• Be sure to clean the parts as instructed in this section at the same timing of replacing toner

container.• Use of the toner kit is highly recommended for the optimum operation of the printer.

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Toner container replacement

To replace the toner container, open the top cover 1. Pull the toner container release levers2 to the right position as shown. Lift and pull out the toner container 3.

1

3

2

Then, refer to section Installing toner in chapter 2 to install the new toner container. Afterinstalling the new toner container, several parts in the printer must be cleaned as instructedin section Cleaning the printer on page Chapter 3-4.

If the toner container has been replaced when the message

Replace Toner … Clean printer

was displayed, then, the message

Clean printer … press CONTINUE

will be displayed after replacement. After cleaning the inside of the printer following theprocedure shown below, press the CONTINUE key; the message will disappear and theprinter will be ready for printing.

Toner saver mode ( EcoPrint )

The EcoPrint enables to reduce the amount of toner consumed on the page so as to saveprinting costs by drastically extending the toner container life. EcoPrint mode is factory-setto off and turned on by the printer’s front control panel (also accessible through theapplication software with the assistance of the printer driver). See details in the printer’sinstruction handbook.

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Cleaning the printer

To avoid print quality problems, the following printer parts must be cleaned with every tonercontainer replacement.

Main charger unit

The main charger unit should be cleaned in its two parts—the charger wire and grid (Seethe picture below.)—whenever the toner container is changed. Cleaning of the main chargercan be done without needing any tools thanks to its self-cleaning system.

Grid

Charger wire

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To clean the charger wire, first open the front cover 1. Pull the cleaning knob (green) 2slowly in and out a few times. This pulls a cleaning pad inside the drum unit along the wire.

2

1Then, clean the grid using the grid cleaner supplied with the toner kit.

Take the grid cleaner 3 from protective bag in the new toner kit, and remove the cap 4.

Pad (impregnated with water)

4

3

The grid cleaner pad is impregnated with water. Perform the following cleaning procedurebefore the pad dries.

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Attach the grid cleaner 3 to the drum unit as shown in the diagram below. Insert the fixturepin on the cleaner into the hole on the drum unit with the pad facing up.

Hold and pull up the main charger, then draw it out until it stops. Then, push it all the wayin. Repeat this procedure for 5 times or more.

3

Then, pull it horizontally out.

To release the main charger unit for pulling,first pull it up…

After cleaning is done, pull the main charger unit in place using the reverse manner of theabove. Close the front cover.

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Cleaning the paper feed unit

The paper feed unit must be cleaned of paper dust whenever the toner container isreplaced. To gain access to the paper feed unit, first, open the front cover. Draw out thepaper feed unit by the handle (green) 5 on its front side.Cleaning the paper feed unit should be done on several parts—the separation charger,registration rollers, paper ramp, etc. as follows.

Caution: Do not touch the transfer roller (black sponge roller) 6 during the cleaningprocedure.

Take out the cleaning brush 7 recessed in the front of the paper feed unit. Cleaning theseparation charger (saw-toothed) 8 by sweeping with the brush.

8

7

65

The printer can get ready for printing approximately 15 seconds after replacing the tonercontainer.

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Obtain the cleaning cloth (Locate in a new toner kit). Wipe the registration rollers 9 andpaper ramp 0 as shown below.

When cleaning is done, set the paper feed unit back in place by pushing on the handle. Makesure that the paper feed unit has been correctly seated, close the front cover.

9

0

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Replacing the developer unit

In case that the developer unit is to be removed from the printer for shipment or replacingto a new one, it should be handled following the instructions below.Also, a new developer unit, after installing, needs a special treatment that replenishes thedeveloper with toner for printing. This can be done by using the front control panel (Seesection Feeding toner into the new developer on page Chapter 3-11).

Replacement

To replace the developer unit currently installed in the printer, first turn the printer power off.Open the toner container access door. Refer to section Toner container replacement onpage Chapter 3-3 and remove the toner container. Open the front cover. Locate thedeveloper unit release lever 1 and turn it clockwise to the upper position. Grasp thedeveloper’s front end as shown below and slowly draw the developer 2 out from the printer.

Caution: If you ship the developer unit removed from the printer for repair, etc., pack thedeveloper in the container package designed for this purpose.

2

1

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Installing a new developer

To install a new developer, use the reverse manner as above. Note that the new developeris shipped from the factory with a protective cover 1 installed. Leave the protective coverinstalled with the developer until the developer has been installed in the printer.

When the developer has been installed in the printer, grasp and pull the protective cover allthe way out, as shown below. Latch in the developer release lever.

1

Caution: Push in the developer unit slow and gently. If the developer contains toner,pushing in the developer unit rudely can cause the distribution of toner to becomeuneven in the far side of the developer. Also, it may risk damaging the connectorat the far end of the developer (and the mating connector in the printer).

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Feeding toner into the new developer

The new developer unit is shipped from the factory with no toner contained. The developercan be automatically replenished with toner when a toner container is installed onto it andthe printer is turned on. However, because the toner reservoir in the developer has a largecapacity, it requires a lengthy period of time until a substantial amount of toner has been fedto get the printer ready.A great many seconds of time for this is greatly deducted by using the service menu in theprinter’s mode select routine as accessed by its front control panel. Follow these steps touse this feature, top to bottom. (For details on using the front control panel keys, refer to theprinter’s instruction handbook.)

Key to press: Relevant display:

MODE

(repeatedly) Others>

(repeatedly) >Service>

>>Developer

ENTER >>Developer?

ENTER Turn printer power off, then on.

When printer power is turned on again, the printer continually engages in this mode forseveral minutes after which the printer reverts to the ready state.

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Updating the firmware

The printer accepts update of the engine and system firmware as well as the front panelmessage data through the parallel interface. A PC that is connected to the printer’s parallelinterface and capable of running in DOS mode is required for this purpose.Updating using these data is implemented by directly downloading the new firmware datafor rewriting the flush memory chips in the printer. The printer must enter to the supervisormode (See page Chapter 3-12) to update the engine firmware using Prescribe commandsas explained in this section.

The engine firmware and controller (system) firmware must be updated separately. Wesupply three types of data for updating the printer’s firmware as follows:• Engine firmware data• Controller (system) firmware data• Front panel message data

These data may be stored in a memory card for field use. To store (write) data in a memorycard, and reread them into the printer through the slot, refer to the printer’s instructionhandbook.Each single data must be written on a memory card. Do not write more than one data ona memory card.

Firmware data format

The firmware data to be downloaded is identified using the following file specification:

de0330.dat1 2 3 4

Identifies…

1 de: Engine firmware datads: Controller (system) firmware datadm: Front panel message data

2 03: This machine

3 Version of data (2 to 4 digits)

4 dat: Engine/controller firmware datadan: Panel message data for Danishswe: Panel message data for Swedishita: Panel message data for Italianspa: Panel message data for Spanish

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Downloading engine firmware data

To download engine firmware or panel message data, use Prescribe BOOT command.

Perform in sequence: Relevant display

Turn printer power on. Make sure the printer is Ready.

At the DOS prompt, send the following command to theprinter.

!R! BOOT "SPR";

Note: Do not add an EXIT; command in the above.

The display indicates Supervisor mode when theabove command is sent to the printer.

DOS COPY (/b) the data to download from the hostcomputer. The display shows Downloading whiledownloading data.

When downloading finishes, the display reverts toSupervisor mode. In this state, turn power off.

Turn power on again. Check the display shows Ready.

Caution: Do not turn off printer power while data are being downloaded (approximatelyone minute).

Confirm the status page shows the new engine version. If the message display indicatesCall service person Dn (n=0, 1, …), refer to section Errors during downloading on pageChapter 3-14.

Downloading controller firmware data

To download controller firmware data, use Prescribe UPGR command as follows.

Perform in sequence: Relevant display

Turn printer power on. Make sure the printer is Ready.

At the DOS prompt, send the following command to theprinter:

!R! UPGR "SYS";

Note: Do not add an EXIT; command in the above.

The display should indicate Supervisor Mode when theabove command is sent to the printer.

DOS COPY (/b) the data to download from the hostcomputer. The display shows Downloading whiledownloading data.

Ready

Supervisor mode

Downloading

Supervisor mode

Ready

Ready

Supervisor mode

Downloading

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When downloading finishes, the display reverts toSupervisor mode. In this state, turn power off.

Turn power on again. Check the display shows Ready.If not, refer to section Errors during downloading on pageChapter 3-14.

Caution: Downloading controller firmware takes several minutes (depending on theprocessing speed of the computer used). Do not turn power off during downloading.

Confirm the status page shows the new firmware version (See Appendix B, page B-4). If themessage display indicates Call service person Dn (n=0, 1, …), refer to section Errors duringdownloading on page Chapter 3-14.

Downloading data from a memory card

To download data written in a memory card to the printer, proceed as follows. Data in amemory card can be selectively downloaded when the Prescribe RWER command is used.Refer to the Prescribe Command Reference Handbook in the CD-ROM purchased with theprinter for details about the RWER command.

Perform in sequence: Relevant display

Insert the memory card in the printer’s memory card slotof the printer.

Turn printer power on. The printer automatically readsdata in the memory card, indicating Downloading onthe message panel during downloading.

When the data is successfully read, the message displayindicates Supervisor mode .

Turn printer power off.

Remove the memory card from the printer.

Turn printer power on again. Check the display showsReady.

Confirm the status page shows the new firmware version (See Appendix B, page B-2). If themessage display indicates Call service person Dn (n=0, 1, …), refer to section Errors duringdownloading below.

Ready

Supervisor mode

Downloading

Supervisor mode

Ready

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Errors during downloading

The following messages may be indicated on the message display when an error occurredduring downloading firmware data. Take the appropriate corrective action. If the correctiveaction does not terminate the error, contact the manufacturer.

Error message Meaning Corrective action

Call service personD0 - Checksum error

Call service personD1 - Machine compatibilityerror

Call service personD2 - Version compatibilityerror

Call service personD3 - Data error

Checksum error occurredduring downloading. Theengine ROM is empty.

The data to be downloaded isnot compatible with theprinter.

The version of the data doesnot match the current engineversion.

The data to be downloaded iscorrupted.

Turn printer power offonce, then on again.Try downloading again.

Obtain correct data forthe printer model.

Obtain the correctversion of data.

Obtain the correct data.

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Adjusting the transfer bias

Printing on paper with extra thickness of 91 to 200 g/m2, such as postcards, OHP,envelopes, etc., tend to result in faint printing because of insufficient penetration of transferbias developer at the transfer roller. Whereas, for thin paper types, the regular transfer biasmay be so strong that the paper cannot effectively leave the drum surface after transferring,causing paper jam.

For the satisfactory transferring process on different paper thickness, the transfer bias isuser-switchable in three degrees between –1.7 and –3.4 kV.

To select the transfer bias for different paper thickness, perform the following steps.

Steps Display

Press MODE key.

Press key repeatedly until Paper type/Normal is displayed.

Press ENTER key. The question mark beginsflashing besides Normal .

Press key. Press ENTER key to select the thickpaper type.

Or, to select the thin paper type to press key.Press ENTER to select the thin paper type.

Paper type

Normal

Paper type

Normal ?

Paper type

Thick ?

Paper type

Thin ?

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CONTENTS

Chapter 4 OPERATION OVERVIEW

Electrophotographics system .................................................................................. 4-1Electrophotographic cycle ........................................................................................... 4-1Amorphous-silicon drum ............................................................................................. 4-2Charging the drum ...................................................................................................... 4-3Toner ........................................................................................................................... 4-4Exposure ..................................................................................................................... 4-5Scanner unit ................................................................................................................ 4-6Laser scanning ............................................................................................................ 4-9Development ............................................................................................................. 4-10Developing roller bias ................................................................................................ 4-11Image transfer ........................................................................................................... 4-13Fusing ....................................................................................................................... 4-14Drum cleaning and erasing static charge .................................................................. 4-16Typical photo process timing chart ............................................................................ 4-17

Paper feeding system ............................................................................................. 4-18Paper control signals ................................................................................................. 4-19Paper feeding components ....................................................................................... 4-20Control devices ......................................................................................................... 4-21Paper feeder control devices .................................................................................... 4-22Printing from paper feeder cassettes ........................................................................ 4-23Printing from the MP tray .......................................................................................... 4-24Printing from the optional envelope feeder ............................................................... 4-25Paper jam detection .................................................................................................. 4-26Message display at a paper jam ............................................................................... 4-28

Print timing charts .................................................................................................. 4-29

Basic engine functions ........................................................................................... 4-32

Engine controller system ....................................................................................... 4-33Configuration memory ............................................................................................... 4-33High-voltage generator .............................................................................................. 4-33Laser scanner control ................................................................................................ 4-33Polygon motor control ............................................................................................... 4-33Safety interlock .......................................................................................................... 4-34The engine gate arrays ............................................................................................. 4-35Pin assignment .......................................................................................................... 4-36GATE ARRAY B ........................................................................................................ 4-37Power supply ............................................................................................................. 4-40Power distribution ...................................................................................................... 4-42

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Logic controller system .......................................................................................... 4-43Main logic controller overview ................................................................................... 4-43Controller block diagram ........................................................................................... 4-44Printing data processing ............................................................................................ 4-45Main logic component ............................................................................................... 4-46API ROM socket (U09) .............................................................................................. 4-46API ROM socket pin assignment .............................................................................. 4-47System DiMM (YS3) .................................................................................................. 4-48RAM (U11 and U12) .................................................................................................. 4-48Memory card slot interface (YC4) ............................................................................. 4-48Option interface (YC5) .............................................................................................. 4-49Option interface pin assignment - Continued ............................................................ 4-49KUIO interface (YC6) ................................................................................................ 4-50Parallel interface ....................................................................................................... 4-51Serial interface .......................................................................................................... 4-51Engine interface ........................................................................................................ 4-52Engine interface connector assignment .................................................................... 4-52Signals used for the engine interface ........................................................................ 4-53

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Electrophotographics system

Electrophotography is the technology used in laser printing which transfers data representingtexts or graphics objects into a visible image which is developed on the photosensitive drum,finally fusing on paper, using light beam generated by a laser diode.

The key features for the electrophotography system of the printer are:• Real 600 dpi resolution (equivalent to 2400 dpi resolution thanks to KIR smoothing

technique)• Ultra long life amorphous silicon drum (non-heating)• Paper support for up to A3 (Ledger) size• Microfine mono component toner

Electrophotographic cycleThe electrophotography system of the printer performs a cyclic action made of seven stepsas follows. Each step is technically explained in the following sections.

2 Exposure

4 Transfer

3 Developing7 Erasing

1 Main Charging

6 Cleaning

5 Fusing

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Amorphous-silicon drum

The printer uses the long lasting amorphous silicon (a-Si) drum. The photoconductive layeris coated over the aluminum cylinder base as shown below. The aluminum base iselectrically grounded to the ground.

The photoconductive layer is charged evenly over its surface by positive high voltagecharging (corona charging) given by the main charger unit (the wire and grid). The area onthe charged drum surface which is exposed to the laser beam, as the print image isstatistically drawn over the drum, loses the charge as it is escaped through the ground. Theresultant electrostatic latent (negative) image is then developed by toner and transfer to themedium like paper.

Aluminum base cylinder

Photoconductive layer

The amorphous silicon photo conductor is extremely hard, non-toxic, and highly resistiveagainst chemical substances. These characteristics of the amorphous material make itselfup to a most durable, stable photoconductor for the electrophotography printer.

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Charging the drum

Figure below is a simplified diagram of the electrophotographics components. Charging thedrum is done by the main charger unit marked A in the diagram.

As the drum B rotates in a “clean (neutral)” state, its photoconductive layer is given auniform, positive (+) corona charge dispersed by the main charger wire A.Due to high-voltage scorotron charging, the charging wire can get contaminated byoxidization and therefore must be cleaned periodically from time to time using the methodexplained in chapter 3. Cleaning the charging wire prevents print quality problems such asblack streaks caused by the oxide ac-cumulated around the charging wire.

AB

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Toner

The toner is fed from toner kit. The toner is of dry mono component type and comprised ofthe following substances as depicted below.

Single component toner

A ResinB FerriteC SilicaD Polisher

AB

C

D

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Exposure

The charged surface of the drum B is then scanned by the laser beam from the scannerunit A.

A

B

+ + + + +

LASER BEAM

a-Si LAYER

250 V

20 V

0 V

+ + + +

+ + + +

– – – –

LASER BEAM

ALUMINUM

The laser beam is switched on for a black dot and off for a white (blank) dot according tothe print data. Whenever it is illuminated by the laser beam, the electrical resistance of thephotoconductor is reduced, the potential on the photoconductor is also lowered fromapproximately 250 V to 20 V, effectively driving the charge through the a-Si layer down tothe aluminum base.

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Scanner unit

The 600 dpi scanner unit includes the laser diode that produces the 670 nm wavelengthlaser beam. This wavelength is specifically designed to match the photoconductiveresponse of amorphous silicon.The diagrams below show the components inside the scanner unit in two views—horizontaland vertical. The function of each component is described in the following pages. Note thatthe directive arrows indicate the laser beam paths.

TOP VIEW

0

1

74

5

3

6

2

9

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SIDE VIEW

1 Laser diode ...................................... emits diffused, visible laser.2 Collimeter lens ................................. aligns the laser beam to the cylindrical lens.3 Cylindrical lens ................................. compensates the slant angle at which the laser

beam hits a polygon mirror segment.4 Polygon mirror (motor) ..................... has ten mirror segments around its octagonal

circumference; each mirror corresponding to onescanned line width on the drum when laser beamscans on it.

5 Primary f-theta lens .......................... See below.6 Secondary f-theta lens ..................... The primary (above) and secondary f-theta lenses

equalize focusing distortion on the drum edges.The effective length of line (“A,” “B” below) thelaser beam draws on the drum becomes longer asthe laser beam hits closer to the drum edges. Inthe figure below, distances represented by “A”and “B” are not the same (A > B) until the f-thetalenses are provided between the polygon mirrorand the drum (A’ = B).

Drum

8

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7 Diversion mirror ................................ diverts the laser beam vertically onto the drum.Note the diffused laser beam finally pin-points onthe drum.

8 Protective glass ................................ prevents dust, debris, etc., from entering thescanner assembly.

9 Sensor mirror ................................... bends the very first shot of a laser scan towardsthe beam detection sensor (See next.).

0 Beam detector sensor ...................... when shone by the sensor mirror above, thisphotosensor generates a trigger signal for theengine controller to start activating the paperfeeding system.

A A

B

Secondary f-theta lens

Primary f-theta lensPolygon mirror

Laser diode

θθ

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Laser scanning

The laser beam hits one of ten polygonal mirrors. As the mirror revolves (at the nominalrevolution of 17,700 rpm), the laser beam reflects off of it and reaches the charged drumsurface in a lengthwise manner.A pair of (plastic) lenses provides focusing the horizontally sweeping laser beam onto thedrum. As the drum rotates, the laser beam sweeps the entire length of the drum so that thedrum’s entire circumference is exposed to the laser beam. The revolution of the polygonmirror motor and the drum itself is timing-controlled so that each successive sweeping ofthe laser beam produces a 1/600 inch offset. The printer’s controller system continuouslyturns the laser beam on and off to put a dot at every 1/600 inch distance horizontally.Synchronizing the output data with one scanning line is achieved by the photo sensorprovided next to the first mirror. At the beginning of each laser sweeping, the beam hits thephoto sensor which in turn sends a command to the logic controller for synchronization.

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Development

The latent image constituted on the drum is developed into a visible image. The developingroller contains a magnet core and an aluminum cylinder rotating around the magnet coreat a speed twice faster than that of the drum. Toner attracts to the developing roller sinceit is magnetic. A magnetized blade above the developing roller constitutes a smooth layerof toner in accordance with the roller revolution.

Magnetism

0.3 – 0.4 mm0.1 mm

Developing roller

Blade

Drum Magnet

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Developing roller bias

The developing bias is adjusted so that the toner, charged positive while each particle isrubbing each other in the developer, is selectively developed onto the area of low potentialby adhering. The bias is AC weighted, positive DC power source.Since the gap between the developing roller and the drum is wider than the averagediameter of the toner, the toner should fly over to the drum surface to accomplishdevelopment. This method is known as the non-contact development method.

Drum

Toner

Develop. rollerDrum

Toner

AC + DC

Toner sensor

Blade

Develop. roller

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A toner replenishment sensor is provided within the developer. As the toner supply from thetoner container dwindles and the toner level lowers in the reservoir, the sensor translatesit through its sensing plate, urging the toner motor to feed more toner.

20 V

Surfacepotential =

250 V

Developing roller bias

Developing

160 V DC + 1.8 kV AC

Area exposed by laser

Area not exposed by laser

Toner+ + + + + + +

Toner

Toner sensor

Developer unit

Sensing plate

Sensable level

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Image transfer

The image developed by toner on the drum (A below) is transferred onto the paper usingthe electric charge attraction given by the toner itself and the transfer roller (B below). Thetransfer roller is negatively biased so that the positively charged toner is attracted onto thepaper while it is pinched by the drum and the transfer roller.

The nominal transfer bias is set to approximately –1.7 kV (limit) with the 55 µA current. Sincethe ideal potential of the transfer bias varies depending on the thickness of paper, the biasis raised to approximately –2.2 kV/55 µA for thicker paper (91 to 200 g/m2). Double-sidedprinting using a duplexer automatically increases the transfer bias to the above value. Onthe other hand, the bias current is reduced to 40 µA (–1.7 kV) for thin paper. The bias isswitched automatically as the printer detects the thickness of the paper, and also switchablemanually on the printer’s control panel. For details on switching the transfer bias, refer tothe printer’s instruction handbook.

Paper separationAfter the image transfer process, the paper is forcibly peeled off the drum by means of theseparation electrode. The separation electrode is located next to the transfer roller, givingthe positive charge to attract paper downwards.

+

–

A

B

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Fusing

The toner on the paper is permanently fused onto the paper as it passes between the florin-finished heat roller (A below) and the pressure roller (B below) in the fuser unit. The toneris molten and pressed into the paper.

The heat roller has two halogen lamps, turning alternatively on depending on the size of thepaper passing through to maintain the preheat temperature at approximately 185°C/365°F.This ensures the even temperature dispersal over the long heat roller. See the picture andtable below.

A

B

Thermo-cutThermistor

EngineController

Heat distribution

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Heater(s) activated

Paper size Middle heater Edge heater

Idle Off On

A3, A4 landscape On On

B4 On+ On

Letter landscape On+ On

Letter, A4, A5 On OffLedger On On

The heat roller temperature is constantly monitored by the engine control circuit using thea thermistor. In the above table, each eater is turned “On” as commanded by the thermistor.The “On+” status for paper sizes of B4 and letter (landscape) mean that the heater is turnedon a couple of seconds longer than that commanded by the thermistor.

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Drum cleaning and erasing static charge

The drum needs to be physically cleaned of toner which is remaining on its surface in thedevelopment process. The cleaning blade (A below) is constantly pressed against thedrum and scrapes the residual toner on the drum off to the refresher roller (B below). Therefresher roller drives the toner to the spiral (fins) roller (C below). The waste toner iscollected at the output end of the spiral roller and sent back to the toner container, into thewaste toner reservoir.

D

A

C B

After the drum is physically cleaned, it then must be cleaned to an electrically neutral state.This is necessary to erase any residual positive charges, ready to accept the next uniformcharge. The residual charge is canceled by exposing the drum to the light emitted from theeraser LED (D above). This lowers the electrical conductivity of the drum surface makingthe residual charge on the drum surface escape to the ground.

5A2

4-17

Typical photo process timing chart

The following chart shows the signals used for photo processing. These signals activate thecorresponding device in the following timing sequences. A simple description for thesesignals follow.

MHVDR (Main High Voltage Drive) — turns on the main charger bias for charging the toner. This signal is kept on during the job is being processed.

ERASER — turns on the eraser (LED array) as soon as the motor begins to rotate revolving.

BIAS — turns on the developer bias on the magnet roller. The duration of this signal isdependent on the current paper size. The bias is reduced to approx. 100 V between paperA. This avoids gray background effect by attracting excessive toner on the magnet rolleronto the drum (which will subsequently be collected back in the drum unit by means of thecleaning blade).

THVDR (Transfer High Voltage Drive) — turns on the transfer bias. Note that the transferbias is weakened (from –1—2 kV to –600 V) while paper is not present between the transferroller and the drum unit. This avoids contamination on the back side of paper B.

SHVDR (Separation-charger High Voltage Drive) — turns on the separator to scrape thepaper off of the drum unit.

MOTOR

PAPER

MHVDR

ERASER

BIAS

THVDR

Page 1 Page 2

SHVDR

B

A

5A2

4-18

Paper feeding system

The paper feeder providing two paper cassettes is fitted to the printer externally at thebottom of the printer. The printer can be installed with up to 6 cassettes by adding up to twomore paper feeder options (basically the same paper feeder fitted as the standard paperfeeder).The paper feeding system picks up paper from the cassette or the MP tray. At a precisetiming, it feeds it to the electrophotography system. It finally delivers the printed page toeither the face-down or face-up tray, or to the optional stacker/finisher.The figure below shows the components in the paper path within the printer. The sensors,solenoids, etc., are also described in the following pages.

PAPER FEEDING DIAGRAM

6 4

5 3

7

2

21

1 Paper cassette2 Paper feed rollers3 Registration rollers+clutch4 Drum5 Transfer roller6 Fuser rollers7 Manual feed roller

5A2

4-19

Paper control signals

The following diagram shows the control signals that control the sensors and the rollers forguiding paper. The engine controller provides these signals in conjunction with theelectrophotography process that is driven by the main controller system.

Manualfeed

clutch

Regist. clutch

Engine Controller

Clutches

Sensors

Rollers

MP tray

FD

WS

D*/

FU

PS

D*

JAM

FD

*

PA

PF

L*

MM

OT

*

RH

VD

R*

Face-downpaper-fullsensor

Face-downjam sensor

TH

VD

R*

RE

GC

L*

JAM

R*

SU

BC

L*

EN

VP

AS

S*

MF

EE

D*

MP

FP

AP

*

EM

OT

*

Heat Roller

Drum

Paper Cassette

Paper feeder

Paper Cassette

Transfer rollerRegist roller

Regist.jam

sensor

Papersensor

Papersensor

Envel.pass

sensor MPfeed

sensor

Stacksolenoid

Face-upjam sensor

Pressure RollerSeparation

charger

M

M

Sub-clutch

5A2

4-20

Paper feeding components

The figure below shows the locations of the sensors, clutches, microswitches, and fans.Each number corresponds to the description in the table on the next page. The board Idsaccompany those parts mounted on the board.

0

54

3 6 2 ! 7 9 1 @ * ^ &

#$‹%(⁄

¤

‡

Œ›‰Á

—ˇˆ ب”„ ´ fl ‚

8

)

fi

·

5A2

4-21

Control devices

Symbol Title Location Board

1 Controller box fan (FAN3) Controller box

2 Printer side cover switch Face-down unit KP-552

3 Face-down paper-full sensor Face-down unit

4 Face-down jam sensor Face-down unit

5 Face-up jam sensor Face-down unit

6 Face-up/down solenoid Face-down unit

7 Scanner fan (FAN4) Top cover

8 Interlock switch—front Front frame KP-556

9 Drum/fuser fan Rear frame

10 Tower sensor Rear frame KP-574

11 Power supply fan (FAN2) Shield box

12 Main motor Drive unit

13 Registration clutch Drive unit

14 Intermediate clutch Drive unit

15 Registration jam sensor Rear frame

16 Interlock switch–top MP feed unit

17 Top cover switch MP feed unit

18 Toner container sensor MP feed unit KP-603

19 MPF paper sensor MP feed unit

20 MPF paper size sensors 1 and 2 MP feed unit KP-576

21 MPF solenoid MP feed unit

22 Envelope feeder sensor MP feed unit

23 Toner container switch Rear frame

5A2

4-22

Paper feeder control devices

Symbol Title Location Board

24 Upper cassette paper sensor/bottom limit Upper cassette KP-583sensor

25 Upper cassette paper size sensors 1/2/3 Upper cassette KP-581

26 Upper cassette LED Upper cassette KP-585

27 Upper cassette paper level switch Upper cassette

28 Lower cassette paper sensor/bottom limit Lower cassette KP-583sensor

29 Lower cassette paper size sensors 1/2/3 Lower cassette KP-581

30 Lower cassette LED Lower cassette KP-585

31 Lower cassette paper level switch Lower cassette

32 Upper cassette switch Drive plate

33 Lower cassette switch Drive plate

34 Upper jam sensor

35 Lower jam sensor

36 Right side cover switch

37 Upper cassette base elevation motor Drive plate

38 Lower cassette base elevation motor MP feed unit

39 Intermediate stepping motor Drive plate

40 Feed stepping motor Drive plate

5A2

4-23

Printing from paper feeder cassettes

At the moment the logic controller finishes data processing, the logic controller passesPRINTN signal to the engine controller. The engine controller then activates the clutch forthe feed roller of the currently selected cassette (in the paper feeder) and the sub clutch inthe printer to start feeding paper. As the paper kicks the registration jam sensor, itmomentarily stops there before the print data starts laser scanning on the drum.

When the laser scanner and the fuser are ready, the engine controller sends VSREQNsignal to the logic controller to verify the readiness of data. When the logic controller finishesdata processing, it sends VSYNCN and VDATA to the engine controller. Now the paper isreleased from the registration rollers and through under the drum unit, starting the imagedevelopment, transferring, and fusing. The paper having passed through the fuser unit kicksthe face-down or face-up paper jam sensor (and the paper-full sensor at the face-downoutlet, if the paper was destined to the face-down stack). When the paper is not detectedby these sensors in the expected time of period, depending on the current paper size, theengine controller halts printing and report the occurrence of a paper jam.The size of the paper currently in the selected cassette is acknowledged to the enginecontroller by means of the on-off status of the photosensors PT1, PT2, and PT3 in the paperfeeder, at the end of the paper cassette. The table below summarizes the on-off status ofthese photosensors in accordance with the supported paper sizes.

Sensor 1

Sensor 2

Solenoid

Paper

Bottom plate

Pick-up roller

Feed rollerOne-way clutch

Arm

Torque limiter

Retard roller

Fee

d m

echa

nism

5A2

4-24

PAPER SIZE SENSING

Paper size PT1 PT2 PT3

Ledger (portrait) Off On On

A3 (portrait) On On On

B4 (portrait) Off Off Off

Legal (portrait) Off Off On

B5 (portrait) Off On Off

Letter (landscape) On On Off

A4 (landscape) On Off On

A5 (landscape) On Off Off

Off=high/On=low

Printing from the MP tray

The presence of paper in the MP tray is detected by the MP feed sensor (See page Chapter4-19). When the controller is ready to print, the engine controller activates the clutch for themanual feed roller. The manual feed roller pulls the paper on the MP tray and sends itforward to the registration roller after the envelope pass sensor is cleared. The rest of theprinting process is the same as that of the paper feeder explained on page Chapter 4-23.The size of the paper currently on the MP tray is detected by two sensors (See page Chapter4-20). Photosensors PT1 and PT2 are activated in accordance with the setting of the paperguides (adjusted manually). The table below summarizes the on-off status of thesephotosensors.

5A2

4-25

MP TRAY SIZE SENSING

Paper size PT1 PT2

A3 On On

Ledger On On

A4 (landscape) On On

Letter (landscape) On On

B4 Off On

8" width Off On

Letter (portrait) Off Off

Legal Off Off

A4 (portrait) Off Off

8" width (portrait) Off Off

B5 (portrait) Off Off

A5 (portrait) Off Off

Hagaki Off Off

5" width Off Off

Printing from the optional envelope feeder

The envelope feeder (or universal feeder) is electrically connected to the printer via aconnector at the right side panel. This connector provides connection of the paper presenceand the envelope feeder motor to the printer’s engine system.The envelope feeder motor sends the paper towards the registration roller after theenvelope pass sensor is cleared. The rest of the printing process is the same as that of thepaper feeder explained on page Chapter 4-23.

5A2

4-26

Paper jam detection

The sensors illustrated in the following diagram are used to track the paper while it is movingthrough the printer. More detailed sensor information can be found from the diagrams insection Paper feeding components on page Chapter 4-20.

A

B

C

D

E

1

HI

2

3

4

5

6

G

F

5A2

4-27

Each sensor coded above represents the following locations. When a paper jam occurs, thecode(s) is actually indicated on the message display in order for the user to easily knowwhere to remove the jammed paper.

Code Suggested jam location

A Envelope feeder (optional)

B MP tray

C Top paper feeder jam door

D Middle paper feeder jam door

E Bottom paper feeder jam door

F Optional stacker

G Face-up stack outlet/Printer side cover

H Paper feed unit/Fuser unit

I Duplexer (optional)

1 First paper cassette

2 Second paper cassette

3 Third paper cassette (optional)

4 Fourth paper cassette (optional)

5 Fifth paper cassette (optional)

6 Sixth paper cassette (optional)

5A2

4-28

Message display at a paper jam

When paper jammed within the printer system, the sensor(s) triggers the signal to theengine controller, which indicates the jam position. At the same time, the engine controllercauses the message display to show Open front cover. This urges the user to refer to theinstructions that is affixed at the back side of the front cover of the printer.A sample of the display transition when a jam occurred follows. Read through from top tobottom.

When a paper jam occurs, the display shows:

After opening the front cover, the actual jampositions are indicated:

As the paper is removed in order of the display,the specific position code will go out.

When all jam locations are cleared of jam, thedisplay shows:

Close the front cover. The printer startswarming up.

When the printer reverts to normalcy, theprinting job resumes.

Paper jamOpen front cover

Paper jamC, F, G, H, I, 6

Paper jamF, G, H, I, 6

Front coverOpen

Please wait

ProcessingPAR 600 A4 001

5A2

4-29

Print timing charts

Line speed=125 mm/s; feed speed=263 mm/s [paper feeder], 125 mm/s [MP tray]

A4 landscape feed [210 mm]/28 ppm/Cass 6

0

MM

OT

SC

AN

ER

SC

RD

Y

LAS

ER

RE

GC

L

JAM

R

JAM

FD

PA

PF

UL

SU

BC

L

FD

WS

D

SU

BM

_1

SU

BM

_2

SU

BM

_3

ST

ML_

3

PS

EN

1_1

PS

EN

2_1

PS

EN

1_2

PS

EN

2_2

PS

EN

1_3

PS

EN

2_3

MH

VD

R

ER

AS

E

BIA

S

16(S

)15

1413

1211

109

87

65

43

21

1251

510

0

8983

3800

2990

2990

845

880

515

2658

1740

3518

8983

8983

4500

6643

6340

8483

1251

5

3883

2988

2870

2505

1875

1510

3653

4513

2735

4878

4648

5843

3730

5013

5448

3720 38

65

3875

5488

8571

6628

8771

5788

7931

7963

1006

8

9513

7548

5820

6443

6443

8983

8488

1041

6 1061

1

4300

430

0V

SR

EQ

4300

6172

6060

644

3V

SR

EQ

8315

6198

9092

9070

8273

7370

9691

1123

511

213

1000

312

211

1214

6

6343

6428

6353

6353

6353

5133

4293

2150

1155

55 105

2248

6208

4018

3365

3023

2370

1375

100

1000 (m

s)

5A2

4-30

A3 [420 mm]/16 ppm/Cass 6

0

MM

OT

SC

AN

ER

SC

RD

Y

LAS

ER

RE

GC

L

JAM

R

JAM

FD

PA

PF

UL

SU

BC

L

FD

WS

D

SU

BM

_1

SU

BM

_2

SU

BM

_3

ST

ML_

3

PS

EN

1_1

PS

EN

2_1

PS

EN

1_2

PS

EN

2_2

PS

EN

1_3

PS

EN

2_3

MH

VD

R

ER

AS

E

BIA

S

16(S

)15

1413

1211

109

87

65

43

21

1587

510

0

3800

2990

2990

3928

845

880

515

4703

2538

5996

4500

8323

1184

3

1587

5

4668

2870

2505

1875

1510

533356

9835

3376

91

4528

8686

6693

3720 38

65

3875

6813

6813

5973

6628

1045

1

7468

1077

210

750

1174

411

883

1557

115

506

1459

514

573

7548

7500

7878

7852

7740

1187

5

8468

1137

1

1229

1

812

3V

SR

EQ

1234

3

1234

380

208321

7326

6361

4338

4163

6328

8033

3168

2173

100

100

105

55

1155

2150

6428

7148

7148

8033

8033

8023

7128

4300

7370

827381

23

8123

430

0V

SR

EQ

1025

1

1129

111

323

1119

3

1209

6

1234

3

1234

3

4300

0 (m

s)

5A2

4-31

A4 [210 mm]/26 ppm/MP tray [Cassette mode]0

MM

OT

SC

AN

ER

SC

RD

Y

LAS

ER

RE

GC

L

JAM

R

JAM

FD

PA

PF

UL

SU

BC

L

FD

WS

D

MP

FB

CL

MP

SIZ

E

MH

VD

R

ER

AS

E

BIA

S

16(S

)15

1413

1211

109

87

65

43

21

1274

9

5788

7548

6677

1497

500

525

6577 66

28

5580

5605

7589

8717

6877

4500

1274

9

8805 90

05

8468

1006

810

650

1274

9

1000

3

9747

5820

6677

3800

430

0V

SR

EQ

6677

100

175

175

0 100

6340

9217

4300

6428

5080

1084

512

445

1144

711

469

9925

9070

9092

8197

8165

7370

6270

4300

4300

6172

667

7V

SR

EQ

8549

9217

9217

0(m

s)

100

5212

9217

1190

6060

8273

1238

0

1-1-15

5A2

CONTENTS

Chapter 5 DISASSEMBLY

General Instructions .................................................................................................. 5-1

Before starting disassembly ..................................................................................... 5-2

Disassembly ............................................................................................................... 5-3Developer unit .............................................................................................................. 5-3Removing the paper feed unit ...................................................................................... 5-6Removing the transfer roller unit .................................................................................. 5-7Removing the drum unit ............................................................................................... 5-9Main charger unit ....................................................................................................... 5-10Removing the controller cover ................................................................................... 5-11Removing the controller box ...................................................................................... 5-13Right side cover/Feeder unit ...................................................................................... 5-15Removing the face-down unit .................................................................................... 5-17Removing the manual feed roller/Separator .............................................................. 5-19Drive gears assembly ................................................................................................ 5-20Removing the fuser unit ............................................................................................. 5-22Removing the laser scanner ...................................................................................... 5-26

5A2

5-1

General Instructions

This chapter provides procedures for removal and replacement of field replacementcomponents. For other components not shown in this chapter, the diagrams in the Parts Listattached with this handbook will help locate the component.For replacement of a component, use the reverse of the removal procedures explained inthis chapter.Before proceeding, make sure printer power is switched off and the power cord is unpluggedfrom the printer. See Warning below.

Warning: To avoid injury to human bodies, make sure that AC power is removed and thepower cord is unplugged from both the power line and the printer.

Caution: To secure a self-tapping screws, align it with the thread carefully. First turn itcounterclockwise, then slowly clockwise. Do not over-tighten. In case theselftapped thread is damaged, the affected part must be replaced with a newpart.

5A2

5-2

Before starting disassembly

Warning: Before proceeding, unplug the power cord from the printer and the powersupply.

Warning: Never attempt to operate the printer with a component removed.

Caution: The printer uses electrostatic-sensitive parts inside (on boards, laser scanner,etc.). Provide an antistatic (discharging) device, such as a wrist strap, that caneffectively discharge your body before touching boards, laser scanner, etc.

5A2

5-3

Disassembly

Developer unitFirst, the toner container must be removed.Open the top cover. The toner container 1 must be removed first: Pull the toner containerrelease lever 2 as below. Pull the toner container 3 slowly up, keeping it as level aspossible.

12

3

5A2

5-4

Open the front cover. Locate the developer unit release lever 1 and turn it clockwise to theupper position. Grasp the developer’s front end as shown below and slowly draw thedeveloper 2 out from the printer.

2

1

Notes:• After removing the developer, seal it in the protective bag and place it on a flat surface.

Do not place the developer in a dusty area.• Do not place floppy disks near the developer.

5A2

5-5

REPLACING THE DEVELOPER UNIT

To replace the developer unit into the printer, be sure to align the guides and rails on thedrum unit with each other. Do not force to slide the drum unit in unless they are properlyaligned with each other.

When the developer unit has been fully seated, remove the protective cover.

Caution: Do not rush the developer unit into the printer. It may cause damaging thedeveloper unit connector and an uneven toner distribution inside the developerunit which may result in a printing problem.

5A2

5-6

Removing the paper feed unit

The paper feed unit can be removed from the printer without using a tool.

Note: If duplexer is installed in the printer, uninstall it before proceeding.

While holding and pushing the locking tab 1 at the left side of the paper feed unit, draw thepaper feed unit all the way out.

1

5A2

5-7

Removing the transfer roller unit

Before removing the transfer roller unit, remove the paper feed unit out of the printer. Then,the transfer roller comes out without needing a tool.

Caution: Do not touch the transfer roller (sponge) surface. Oil and dust (particles of paper,etc.) on the transfer roller can significantly deteriorate the print quality (whitespots, etc.).

The transfer roller unit 1 is held in place by two joints at both ends. To remove the transferroller unit: Hold the tab at both left and left sides of the transfer roller unit first. Whenremoving, tilt the transfer roller unit upward so that the joints are aligned to free the transferroller unit.

1

5A2

5-8

INSTALLING THE TRANSFER ROLLER UNIT

To install the (new) transfer roller unit, align the mounting holes 1 of the transfer roller unitwith the joints 2 of the paper feed unit.

CLEANING THE TRANSFER ROLLER UNIT

To clean the transfer roller, remove the transfer roller unit out from the feed unit as shownon page 5-7. Use a vacuum cleaner, moving nozzle along the roller, but do not let the nozzledirectly touch on the roller, while rotating the transfer roller by the gear. Thoroughly cleanthe entire surface of the roller.

1

2

5A2

5-9

Removing the drum unit

Caution: Removing or reinstalling the drum unit requires the drum protective coversupplied with the new drum kit package. Do not forcibly attempt to remove thedrum without following the procedures provided below, using the drum protectivecover.

Caution: Store the drum unit in a clear, clean place, not exposed to a strong light source.Seal it in a protective bag. Avoid bump the drum surface onto hard objects.

To remove the drum unit 1, first insert the drum unit protective cover 2 as shown below.This unlatches the drum unit for removal. Be sure to install the protective cover firmly in.

2

1

3

While pressing the drum release lever 3 at the left side of the printer, as shown below, pullthe drum unit all the way out. It should come off with the protective cover. When the drumunit is halfway out, hold the handle at the top of the drum unit.

5A2

5-10

Main charger unit

Pull the main charger 1 until it stops. While pushing the (white) locking button 2 the printer,pull the main charger unit all the way out.

The main charger unit is technically explained in chapter 4, Operation.

2

1

5A2

5-11

Removing the controller cover

Remove the controller cover by removing the screws 1 below.

Disconnect the two connectors 2 on CONN1 board at the back.

11

2 2

5A2

5-12

Open the front cover and remove the screws 3 below.

3

Remove the screws 4 and 5. All these are self-tapping screws of the same type. Then,remove the top cover.

45

5A2

5-13

Removing the controller box

Remove the middle bracket by removing four screws 1.

Remove the connectors 2.

11

1 1

2

5A2

5-14

Remove two screws 3 to remove the controller box.

3

3

5A2

5-15

Right side cover/Feeder unit

Remove four screws, 1 and 2, and remove the right side cover.

21

Remove three screws 3.

3

3

3

5A2

5-16

Remove the screw 4 at the front side.

Remove the controller box (Refer to Removing the controller box, the previous section.),then remove the screw 5 below to remove the ground wire (black) 6 of the feederassembly.

After removing the above screw, set the drum unit release lever to the left (down) position.Then, carefully remove the feeder assembly.

4

5

6

5A2

5-17

Removing the face-down unit

Remove the face-up tray by pulling the left and right arms of the tray while pushing in thelocking tab 1 for each arm.

Remove six screws 2 and remove the left cover.

11

2

22

22

2

5A2

5-18

Remove the screw 3 on the front side (below). Then, remove the one on the rear side.

3

5A2

5-19

Removing the manual feed roller/Separator

While pressing the locking tab 1 in, remove the manual feed roller.

To remove the separator 2, use a small flat blade screwdriver in the manner shown below.

1

2

5A2

5-20

Drive gears assembly

Begin removing the driver gear assembly by first removing the sub gears assembly C. Thisassembly mounts gears for driving the toner container and the waste toner conveyer. Toremove this assembly, remove two screws 1.

Then, remove the waste toner conveyer housing. To remove this part, remove three screws2. The right side cover must be removed first. Remove five screws. Detach two connectors.Then remove the drive assembly from the printer.

1

Sub gears assembly C

2

2

Waste toner conveyer housing

5A2

5-21

3

Main motor assembly

To remove the main motor assembly, remove all screws indicated as 3 below.

To remove the drive gears assembly, remove three screws 4 as shown below.

4

5A2

5-22

Removing the fuser unit

The fuser unit can be detached from the feed unit without needing a tool. To remove thefuser unit, first, open the feed unit. To open the feed unit, raise and hold the (green) handleand pull the feed unit frontwards gently.

Warning: The fuser is hot after the printer was running. Wait until it cools down.

Feed unit

Fuser unit

5A2

5-23

To remove the fuser unit, unlatch the fuser unit from the feed unit. This is done by releasingthe latch at both sides of the fuser unit in the manner shown below.

Then, hold the fuser unit using both hands and lift gently. Remove as shown below.

Latches: Move to the arrowed direction to release the fuser unit.

Fuser unit

5A2

5-24

Removing heater lamps

The fuser unit includes two heater lamps which are different in function and shape (length).To gain access to the heater lamps in the fuser, first, remove the cover (on the connectorside) as shown below, by removing two screws 1.

Remove the screw 2 shown below and remove the terminal.

11

Fuser unit

2

5A2

5-25

3

Remove the appropriate screw 3 to remove the lamp.

Warning: The heater is extremely hot immediately after the printer was running. Allowsubstantial period of time until it cools down. Also, the heater is fragile: Handleit with great care.

Cautions:• The heater lamps are fragile. Use extreme care when handling not to drop or break.• Do not directly touch on the heater lamp. Finger prints on the heater’s outer surface can

prevent proper fusing of toner on paper.

5A2

5-26

Removing the laser scanner

To remove the laser scanner, the top cover and the face-down unit must be removed first.For details, see page 5-12.

Warning: The laser scanner contains electrostatic-sensitive parts inside (laser diode, etc.).Before touching the laser scanner, provide an antistatic (discharging) device,such as a wrist strap, that can effectively discharge your body.

To remove the laser scanner, remove screws 1 and 2. Detach connectors as needed.After removing the scanner, handle it carefully.

1

2

1-1-17

5A2

CONTENTS

Chapter 6 TROUBLESHOOTING

Board layouts ............................................................................................................ 6-1Overall boards layout (Rear view) ............................................................................... 6-1

Diagnostic .................................................................................................................. 6-2Engine diagnostics flow ............................................................................................... 6-3Logic controller diagnostics flow ................................................................................. 6-6

General error handling ............................................................................................. 6-7Panel indicator ............................................................................................................ 6-7

Error messages ......................................................................................................... 6-8Memory card errors ................................................................................................... 6-11

Call-Service person errors ..................................................................................... 6-13A1: Uninstalled waste toner conveyer ....................................................................... 6-13A2: Fuser overheating ............................................................................................... 6-15A3: Fuser heater disconnection ................................................................................ 6-16A4: Developer unit life-fuse error .............................................................................. 6-17B1 – B6: Feed cassette bottom plate motor error ..................................................... 6-18C1: Duplex communication error ............................................................................... 6-19C2: Duplex printing registration error ........................................................................ 6-19C3: Void .................................................................................................................... 6-19C4: Document finisher IPC communication error ...................................................... 6-19C5: Document finisher backup RAM error ................................................................ 6-20C6: Document finisher sensor error .......................................................................... 6-20C7: Void .................................................................................................................... 6-20C8: Document finisher staple unit movement motor error ......................................... 6-20C9: Document finisher staple motor error ................................................................. 6-20CA: Document finisher alignment motor error ........................................................... 6-20CB: Document finisher tray motor error .................................................................... 6-21CC: Document finisher paper feed motor error ......................................................... 6-21CD: Document finisher paper exit motor error/Sorter error ....................................... 6-21D0 – D4: Firmware program errors ........................................................................... 6-21E0: Communication failure ........................................................................................ 6-22E1: Main motor error ................................................................................................. 6-23E2: Laser scanner motor error .................................................................................. 6-25E3: Laser beam detection error ................................................................................. 6-25E4: Fuser heater error ............................................................................................... 6-27E5: Eraser error ......................................................................................................... 6-28E8: Fuser unit life fuse error ...................................................................................... 6-29E9: Toner motor error ................................................................................................ 6-29F0: Controller system lock error ................................................................................ 6-30F1: Main controller ROM checksum error ................................................................. 6-30F2: RAM read/write error ........................................................................................... 6-30

1-1-18

5A2

F3: Controller system error ....................................................................................... 6-30Other errors relating to the controller board .............................................................. 6-31Option harddisk errors ............................................................................................... 6-32

Print quality problems ............................................................................................ 6-33Completely blank printout .......................................................................................... 6-33All-black printout ........................................................................................................ 6-33Dropouts .................................................................................................................... 6-34Black dots .................................................................................................................. 6-35Horizontal streaks ..................................................................................................... 6-35Black vertical streaks ................................................................................................ 6-35Unsharp printing ........................................................................................................ 6-36Gray background ....................................................................................................... 6-37Dirt on the top edge or back of the paper .................................................................. 6-38Repetitive defects gauge ........................................................................................... 6-39Drum cleaning ........................................................................................................... 6-40

Correcting a paper jam ........................................................................................... 6-41Locating and correcting paper jams .......................................................................... 6-42

Correcting paper jams ............................................................................................ 6-43Paper jam removal diagrams .................................................................................... 6-46

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6-1

Board layouts

Overall boards layout (Rear view)

Symbol(above) Board No. Description

1 KP-536 Main logic board

2 KP-537 System ROM (Flash DIMM)

3 KP-544 Engine board

4 KP-564 Wiring liaison board (CON1)

5 — Power supply

1

2

3

4

5

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6-2

Diagnostic

The printer automatically executes its self-diagnostic test when it is powered up. Thesequence and the items to be diagnosed are explained below.When the printer locates the error with a specific item, it calls for operator’s attention byshowing the appropriate Call service person message on the operator panel display. TheCall service person message is followed by one of the following codes:• A, Development component• B, Paper cassettes• C, Duplexer, stacker, finisher• D, Firmware downloading• E, Engine controller• F, Main controller

Flowcharts on the following pages show the order and the items diagnosed in each system.

Note: Diagnostic test is canceled if one of the user-accessible covers is opened during thetest.

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6-3

Engine diagnostics flow

Yes

No

Yes

No

Yes

No

Yes

Yes

No

A

Poweron

Engine ROM checksum OK? D0: Firmware program error

Fuser heater temp. normal? A2: Fuser overheating

Fuser heater normal?

A3: Fuser heater disconnection

Is fuser new?

Fuser life fuse blown?

E8: Fuser unit life fuse error

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6-4

Yes

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Is developer new?

Developer life fuse blown?

A4: Developer unit life-fuse error

Fuser thermistor normal?

E4: Fuser heater error

Polygon motor normal?

E2: Laser scanner motor error

Laser pin-photo detects laser?

E3: Laser beam detection error

Main motor normal? E1: Main motor error

A

B

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6-5

Yes

No

Yes

No

Yes

No

Yes

Engine ready

Toner being fed?

E9: Toner motor errorToner motor normal?

A1: Uninstalled waste toner conveyer

Waste toner conveyer normal?

E4: Fuser heater errorFuser temp. rises

in normal time?

B

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6-6

Logic controller diagnostics flow

Yes

Yes

Yes

No

No

No

System ROM checksum OK?

Power on

F1: System ROM error

Communication established between

engine and main CPUs?

E0: Communication error

System memory OK? F2: System memory error

Controller is ready.

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6-7

General error handling

This section provides how to handle general errors as indicated on the message display.Refer to the section starting on page for errors calling for service person assistance.

Panel indicatorThe symbol mark on the front panel provides following user-handling errors. Proceed withCorrective actions indicated below.

Indicator Indication Corrective action

Flashing The printer has run low on toner. The tonershould be replaced as soon as possible.Clean the printer after replacement.

Lit Toner is low or has run out. Replace with anew toner container.

Fast flashing Paper is jammed in the location flashing.

Slow flashing The paper has run out in the paper cassetteor multi-purpose tray. Add paper to thepaper feed source.

Lit This indicates either the current paper feederor the paper output point.

Flashing A paper jam has occurred in the optionalduplexer. Remove the paper jam in theduplexer.

Lit An optional duplexer has been attached,and the printer is printing in duplex printingmode.

Flashing The printer is warming up (Please wait) orthe printer has insufficient memory available.Confirm the message indicated on themessage display.

Lit A message will be displayed in the messagedisplay. Take corrective action according tothe message displayed. The table on thefollowing pages lists the corrective action totake in response to each message.

Low toner

Paper feeding

Duplexer

ATTENTION

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6-8

Error messages

The printer indicates on its front control panel various messages ranging from user-recoverable errors to call-service person errors. The instructions below indicate how torespond to all those problems indicated by the error messages. For call-service personerrors, further reference to the descriptions including flowcharts may be required asinstructed in Corrective action below.

Message Corrective action

Top cover The top cover is open. Close it tightly.Open

Front cover The front cover is open. Close it tightly.Open

Side cover The printer’s side cover is open. Close it tightly.Open

Paper feeder 1 The paper feeder’s side cover is open. Close it tightly. If anside cover Open optional paper feeder is installed, the paper feeder having the

problem will be indicated number in the message. If themaximum of three feeders are installed, the upper feeder is 1,the middle feeder is 2, and the bottom feeder is 3.

Face-down tray The face-down tray has become full. You must remove allpaper full printed pages from the face-down tray. The face-down tray

can hold approximately 500 sheets.

Add paper The paper source is out of paper. Add paper to the papercassette or multi-purpose tray.

Set paper Add a sheet of paper to the multi-purpose, and press thePress CONTINUE CONTINUE key. Printing will start. This message appears

when the multi-purpose tray is in manual mode.

Load paper The paper size does not match. The size of the paper in the(paper size) cassette is different to the size specified by the application

software or by PRESCRIBE II command. Put paper of thespecified size into the cassette.

If the CONTINUE key is pressed, printing will be resumed.However, if more than one sheet is to be printed, the samemessage will again be displayed from the second sheetonward.

You can abandon printing by pressing the CANCEL key.

Cassette The cassette is not closed securely, Close it tightly.not loaded

Paper jam Paper has become jammed. Open the front cover. The loca-Open front cover tion of the paper jam is displayed in the message display.

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6-9

Message Corrective action

Paper jam This message appears when the front cover is open during a############## paper jam.

Letters A through I and numbers 1 through 6 will appear inplace of the #’s. For details on the meaning of the textdisplayed, see page Chapter 6-34. A label displaying thesenumber indications is also attached to the back of the frontpanel. The indicator on the front panel also flashes thelocation of the paper jam.

Warning The printer’s internal memory is running low. Remove anyLow memory unnecessary download fonts and/or macros. You can check

the amount of user memory currently available by printing astatus page.

Replace Toner There is not enough toner inside the toner container. Be sureClean printer to promptly replace with a new toner as the printer will stop

printing before long. Clean the printer after replacement.

Replace Toner There is no more toner in the toner container. The printer hasClean printer stopped because there is no more toner. Replace with a new

toner kit. After replacing, be sure to clean the printer.

Clean printer Please clean the inside of the printer. After cleaning the insidePress CONTINUE of the printer, press the CONTINUE key and the printer will be

ready for printing. This message will be displayed whenreplacing the toner container after the message ReplaceToner Clean printer has been displayed.

Missing No toner container is installed. Install the toner container. TheToner kit printer does not operate when this message is displayed.

Install MK The maintenance kit needs to be replaced. Replace themaintenance kit since the total number of printed pages hasreached 350,000. Contact the licensed dealer from which youpurchased the printer or service outlet. The maintenance kitincludes a drum unit, developer unit and so on.

Call service A failure requiring the attention of service personnel hasperson##:####### occurred. A failure requiring the attention of service personnel

has occurred and the printer has stopped. The correspondingerror code and total printed pages are displayed in themessage display (part indicated by #’s).

Memory overflow Current print processing cannot continue due to insufficientPress CONTINUE memory. Check available user memory by printing a status

page, and either remove unnecessary download fonts and/ormacros or expand the printer’s memory.

Press the CONTINUE key to print data as far as it was stored.You can abandon printing by the CANCEL key.

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6-10

Message Corrective action

Print overrun Current print processing cannot continue due to insufficientPress CONTINUE memory. The data transferred to the printer was too complex

to print on a page.Check available user memory by printing a status page, andeither remove unnecessary download fonts and/or macros orexpand the printer’s memory.

Note: After this message has been displayed, Page protectmode will be on. To maintain optimum use of memoryduring printing, display >Page protect from the modeselect menu, and re-select Auto.

Press the CONTINUE key to print data as far as it was stored.You can abandon printing by the CANCEL key.

MEMORY CARD err The memory card is missing. This message appears whenInsert again the memory card has been removed from the memory card

slot during memory card operations. Re-insert the samememory card in the same slot. the printer will continue withmemory card processing.

Insert the same Insert the same memory card. This message appears whenMEMORY CARD the memory card has been removed from the memory card slot

during memory card operations and replaced with a differentmemory card. Re-insert the same memory card in the sameslot. the printer will continue with memory card processing.

Warning battery The memory card’s battery is low. This message appearsMEMORY CARD when the printer is in the ready state and the battery of the

memory card installed in the printer is low. You can still enterthe memory card mode, but the battery should be changed assoon as possible.

Battery error Insert a new battery in the memory card. This messageMEMORY CARD appears when the printer is in the ready state and the battery

in the memory card is missing or completely dead. Memorycard operations are not possible. Insert a new battery in thememory card.

Format error The memory card requires formatting. This message appearsMEMORY CARD when the printer is in the ready state and the memory card is

not formatted. Be sure to format the memory card. (See theinstruction handbook.)

MEMORYCARD err ## This message appears when an error occurs during accessPress CONTINUE to the memory card using the PRESCRIBE ICCD command

or from the printer’s control panel. Look at the error codegiven in place of ## and refer to the corresponding descriptiongiven below. Note that only error codes 09 and 11 aredisplayed due to memory card operations made from thecontrol panel.

For details, see Memory card errors which follows on pageChapter 6-11.

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6-11

Message Corrective action

I/F occupied The interface selected is currently being used. This messageonly appears if an optional interface is installed.

The interface is secured while the interface name displayedin the message display is flashing even if the printer is in theready state. How long this takes depends on the interfacerelease timeout (FRPO J2) setting.

This message appears, and then the ATTENTION indicatorlights, when an attempt is made to select a secured interfacefrom the control panel or when an attempt is made to performmemory card operations while the interface indicator is flashing.

Repeat operations after releasing the interface.

Processing Compressed data is printed due to insufficient memory.PAR FIT A4 Compressed data is printed due to insufficient memory when

FIT flashes in the resolution indicator. The quality of printeddata is reduced when this occurs. FIT will continue flashingeven after printing is finished. The resolution indicator willautomatically return to reading 600 dpi when any key ispressed, when a timeout occurs, or when subsequent data isreceived. Expand printer memory to avoid this error.

Processing 600 dpi processing cannot be performed due to insufficientPAR 600 A4 memory. When 300 flashes in the resolution indicator even

though the printer was set to 600 dpi, the printer automaticallyset resolution to 300 dpi due to insufficient memory andcontinued printing. The resolution indicator will automaticallyreturn to reading 600 dpi when any key is pressed, when atimeout occurs, or when subsequent data is received.

Processing Expand printer memory to avoid this error.PAR 300 A4

Memory card errors

Error Applicablecode card type Meaning

01 SRAM Card size error (An attempt was made to write data of greaterthan 32 MB in size.). Reduce the size of the data to be written fromthe host computer to 16 MB or less; or, a file name could not befound in the memory card.

02 SRAM No memory card inserted. Insert a proper memory card.

03 SRAM/flush Non PCMCIA card. Replace the card with a PCMCIA card.

04 SRAM Not RAM card. Use a SRAM-type card if you want to write datato an memory card.

05 SRAM Memory card battery error. Replace the memory card’s internalbattery with a new one.

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6-12

Error Applicablecode card type Meaning

06 SRAM Memory card protect error. Release the write protection on thememory card when you write data to the memory card.

07 SRAM Non format. Reformat the memory card using MODE SELECT(See the printer’s instruction handbook).

08 SRAM Partition name error. Follow instructions given attempt in Chapter2 to properly name the destination.

09 SRAM Memory card data full error (An attempt was made to write dataexceeding the capacity of the memory card). Abandon the writingoperation on the host computer first. Press CONTINUE key;when the message turns to Waiting, press FORM FEED key(Ready).

10 — Reserved

11 SRAM Data name full (An attempt was made to write more than 127destination data names). Press CONTINUE key (Ready).

12 — Reserved

13 Flush Erase logic error with flash memory card. Try replacing thememory card.

14 — Reserved

15 Flash Non PCMCIA flush card. Replace the card with a PCMCIA flushcard.

16 — Reserved

17 Flush Unable to write to the flash memory card due to insufficient printermemory. Either delete unnecessary macros or fonts stored in theprinter, or extend the printer’s available memory.

18 Flush Writing error. Try replacing the memory card.

19 — Reserved

For details on memory card availability, see section Printer specifications in chapter 1.

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6-13

Call-Service person errors

The printer does not operate when a message beginning with Call service person (A, B, C,D, E, F) is displayed. The message is categorized by an alphanumeric code. Proceed withthis section for taking a corrective action depending on the code.The Corrective action may be useful for on-site service. Follow the flowchart if one isprovided in that item for further analysis of the problem.

A1: Uninstalled waste toner conveyer

Meaning Suggested causes Corrective action

• Waste toner converyer is notinstalled.

• The belt is not rotating in theconveyer unit.

• Connection failure between theCON1 board and the conveyerboard

• Engine gate arrays (U2/U6) failure

• Defective LED driving circuit on theengine board. Defective LED onthe conveyer board. Connectionfailure between the waste tonerconveyer board and the phototransistor. Defective phototransistor.

• Contaminated waste tonerconveyer housing or photoreceptor.

• The waste toner driving system inthe toner container is not workingproperly.

The waste toner con-veyer is not installed,or the conveyer isclogged inside withwaste toner.

Install a waste tonerconveyer or replace theconveyer and belt.Replace KP-544 orKP-546. Check cableS02070 for possibledisconnection. [If notcorrected, replace thecable.]

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6-14

Yes

Yes

No

No

No

No

Yes

Yes

No

Yes

A1

Waste toner conveyer installed?

Can sweep roller in toner container

be manual rotated?

Install conveyer.

Turn power off, then on.

Remove conveyer.

Replace conveyer and tower-guide assembly.

Replace with a new toner container.

A1 shown? End

Is waste toner emitted through the waste

toner outlet?

Open waste toner outlet of drum and manipulate to turn.

Replace with a new drum unit.

Turn power off, then on.

Still A1? End

Replace KP-544. If not recovered, replace KP-564. If not recovered, replace cable S02070 between KP-564 and KP-574.

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6-15

A2: Fuser overheating

Meaning Suggested causes Corrective action

• Defective photo-coupler (lowvoltage) for heaters

• Defective engine gate array U2

• Defective heater control circuit(engine board) or heater tempera-ture detector

The fuser unit isoverheating.

Replace KP-544./Re-place the switchingregulator./Check orreplace S02069 cableKP-544 and the switchingregulator./Replace fuser.

Yes

No

No

Yes

A2

Temp adj pot. meter on fuser board at

fully clockwise position?

Thermistor fit tightly?

Replace fuser unit.

Replace fuser unit.

Replace KP-544. Replace the switching regulator. Check or replace S02069 cable KP-544 and the switching regulator. Replace fuser.

Remove fuse unit.

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6-16

A3: Fuser heater disconnection

Meaning Suggested causes Corrective action

• Blown-out heater lamp(s)

• Defective connection between theengine board and the low voltagesupply.

• Malfunctioning engine CPU

• Defective heater disconnectionsensor circuit in the low voltagesupply

• Defective thermo-cut (Replace thefuser unit.)

Either or both heaterlamp(s) is blown out.

Replace KP-544. Re-place KP-564. Check/replace S02054 cable.Replace fuser unit.

No

Yes

A3

Less than 10Ω? Replace fuser unit.

Replace KP-544. If not recovered, replace KP-564, power supply, S02069 cable between KP-544 and power supply, or S02054 cable between KP-544 and power supply, in the order of the above.

Remove fuser unit.

Measure the resistance across primary terminals (See right fig.) of fuser connector.

1

2

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6-17

A4: Developer unit life-fuse error

Meaning Suggested causes Corrective action

• Defective engine gate array

• Defective fuse cut circuit on theengine board

Try turning the printer offand on several times.Replace developer unit.Replace KP-544.

The life fuse won’t cutin the developer unit.

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6-18

B1 – B6: Feed cassette bottom plate motor error

Meaning Suggested causes Corrective action

• Excessive torque on the motor(activating the current protectioncircuit)

• Stuck motor

• Defective feed board PU (U1)

• Defective motor driver circuit(transistors) or over-currentdetector circuit

No

Yes

No

Yes

B1 – B6

Error still happens? Replace the cassette.

Change cassette to other cassette. Turn printer power off, then on.

Connect ckt tester to pin 5 of KP-546/U1. Measure voltage.

High level (>3.5 V)?

Replace motor. If not recovered, S02088 between KP-546 and cassette. If not recovered, replace cassette or KP-546.

Replace KP-546.

Replace the motor.Check/replace S02088/S02089 cables. Tryreplacing with othercassette to see if thatcassette is faulty.Replace KP-546.

The feed cassettebottom plate motorwon’t revolve.

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6-19

C1: Duplex communication error

Meaning Suggested causes Corrective action

• Defective engine gate array (U6)

• Defective engine CPU (U1)

• Duplexer CPU (U1) malfunction

• Defective U2, U5, U6 on duplexerboard

• Defective connection betweenKP-544 (YC4) and KP-568 (YC1),KP-568 (YC3) and liaisonconnector, liaison connector andKP-587 (YC1), or defective liaisonconnector

C2: Duplex printing registration error

Meaning Suggested causes Corrective action

• Defective registration motor

• Defective home position sensor

• Malfunctioning motor driving circuit(U2/U6/U7) on duplexer board

• Defective duplxer CPU (U1)

• Connection error between theregistration motor and KP-587(YC5), or home position sensorand KP-587 (YC7)

C3: Void

C4: Document finisher IPC communication error

Meaning Suggested causes Corrective action

• Defective IPC (intelligent protocolcontroller) LSI (communicationchip)

• Defective interface connector/cable

Communication errorbetween the duplexerand the printer.

Try reinstalling duplexer.Check/replace cablebetween printer andduplexer. Replace KP-587. Replace KP-544.Replace duplexer.Replace KP-568.

The duplexer’s regis-tration boards are notin the home position.

Check foreign objects orfractions of paper induplexer. Try manipu-lating adjusters to checkfor smooth move. Checkphoto sensor for normalconnection. Check/replace S02100 cable.Replace home positionsensor. Replace KP-587.Replace duplexer.

Communication errorwith the documentfinisher

Check interface cablebetween document fin-isher and printer.Replace KP-544 (engine)or KP-568 (CON3) in theprinter. Replace S02053cable.

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6-20

C5: Document finisher backup RAM error

Meaning Suggested causes Corrective action

• Defective backup RAM

C6: Document finisher sensor error

This error means any of the following sensors in the document finisher is defective:• Input sensor• Exit path sensor• Inversion sensor• Printer connection sensor• Stack height limit sensor• Stack home position sensor• Offset sensor• Cover sensor• Stacker full sensor

C7: Void

C8: Document finisher staple unit movement motor error

Meaning Suggested causes Corrective action

• The driver circuit for the motor isdefective.

• The staple unit is defective.

• The motor is defective.

C9: Document finisher staple motor error

Perform the same procedure as C8 for the document finisher’s staple motor.

CA: Document finisher alignment motor error

Perform the same procedure as C8 for the document finisher’s alignment motor exceptmaking check on connector J11.

Backup RAM error inthe document finisher

Replace documentfinisher.

The staple unit move-ment motor does notrotate.

Check connector J8 forthe driver board. If notcorrected, replace docu-ment finisher.

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6-21

CB: Document finisher tray motor error

Perform the same procedure as C8 for the document finisher’s tray motor except makingcheck on connector J7.

CC: Document finisher paper feed motor error

Perform the same procedure as C8 for the document finisher’s feed motor except makingcheck on connector J11.

CD: Document finisher paper exit motor error/Sorter error

Perform the same procedure as C8 for the document finisher’s exit motor except makingcheck on connector J10.The CD error also suggests that the bulk paper stacker is defective.

D0 – D4: Firmware program errors

These errors are explained in chapter 3, Downloading firmware programs.

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6-22

E0: Communication failure

Meaning Suggested causes Corrective action

• Error with CPU and gate arrays ofeither the engine or main controller

• Connection error between theengine board and the main con-troller board

• Program overrun in the engine ormain controller

The engine controllerdoes not respond tothe main controller.

Check/replace S02051cable. Replace KP-544.Replace KP-536.

No

Yes

E0

Cable S02051 between KP-544 and

KP-536 wired properly?

Reconnect properly.

Replace KP-544. If not cured, replace KP-536.

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6-23

E1: Main motor error

Meaning Suggested causes Corrective action

• Error with CPU and gate arrays ofeither the engine or main controller

• The motor brake circuit is activatedbecause of an abnormal torque ofthe motor.

• Overheating protection circuit isactivated because of the over-heating main motor IC

• Defective engine gate array (U2)

• Defective main motor driving circuit(transistor arrays, etc.) on theengine board

• Defective buffer IC for FG signaldetection on the engine board

The main motor won’trevolve, or will revolvetoo slow.

Replace KP-544. Re-place main motor. Check/replace S02056 cable.Replace drive unit.

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6-24

Yes

Yes

Yes

Yes

No

No

No

Yes

No

No

E1

Does motor rotate 5 seconds or more?

Can main motor be manipulated

to turn?

Turn power on and off.

Replace DRIVE ASSY.

Turn printer power off, then on.

Turn printer power off, then on.

Can drive gears for fuser,

drum, and developer be manipulated

to turn?

E1 shown again?

E1 shown again? End

End

Replace motor. If not recovered, replace S02056 cable between motor and KP-544. If not recovered KP-544.

Locate the unit preventing the motor to rotate.

Replace the unit.

Replace main motor. If not cured, replace cable S02056 between main motor and KP-544.

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6-25

E2: Laser scanner motor error

Meaning Suggested causes Corrective action

• Defective scanner motor (e.g., atits axle holder)

• Connection error between polygonmotor and liaison connector, orliaison connector and KP-570 (YC3)

• Defective engine gate array (U2/U6)

• Defective scanner motor drivertransistor

E3: Laser beam detection error

Meaning Suggested causes Corrective action

• Laser diode does not emit.

• Connectionerror between KP-578(YC2) and KP-579 (YC101 [withinscanner]), KP-578 (YC1) andKP-570 (YC2), KP-578 (YC1) andKP-564 (YC3), KP-570 (YC1) andKP-564 (YC3), or KP-572 (YC1)and KP-564 (YC3)

• Defective or contaminated pin-photo IC

• Malfunctioning interlock detectioncircuit on the ending board

• Defective engine gate array U2

The revolution of thepolygon motor doesnot reach the prede-termined revolution.

Check/replace cables.Replace KP-544. ReplaceKP-564. Replace KP-570.Replace scanner unit.

Beam detection isfailed. The photo de-tector failed to detectlaser beam.

Check/replace cables.Replace KP-544. ReplaceKP-564. Replace KP-570.Replace scanner unit.

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6-26

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

Yes

E3

Turn power off, then on.

Turn power off, then on.

Replace scanner unit.

Turn power off, then on.

Turn power off, then on.

Replace S2108 cable.

Is pin low forapprox. 900 µs?

Replace KP-544.

Is pin 10 low?

Is pin 10 low?

Is pin 3 low?

Is pin 3 low?

E3?

E3?

End

Replace KP-544.

End

Replace KP-570.Replace KP-564.

Replace KP-564.

Connect ckt tester to pin 3 of KP-564/YC3.

Connect ckt tester to pin 45 of KP-544/U2.

Connect ckt tester to pin 10 of KP-564/YC3.

Connect ckt tester to pin 45 of KP-544/YC2.

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6-27

E4: Fuser heater error

Meaning Suggested causes Corrective action

• Connection error between theengine board and the fuser unit

• Defective engine gate array U2

• Defective comparators on theengine board

• Defective thermistor (cut)

• Connection error between the fuserboard and the thermistor

• Connection error between theengine board and the low-voltagepower supply

• Defective engine gate array U2

• Defective transistors, logic gate ICs,comparators, etc. on the engineboard

• Defective thermistor (showing highresistance even at heating)

The fuser heater doesnot turn on. [E4 is indi-cated immediatelyafter power is on.]

The fuser heater doesnot turn on. [E4 is indi-cated several minutesafter power is on.]

Replace KP-544. Re-place fuser (temp.adjustment is required.)Check/replace S02054cable.

No

No

Yes

Yes

E4

Less than 1M Ω?

E4 shown within 30 seconds since

power is on?

Replace KP-544. If not recovered, replace fuser unit.

Replace fuser unit (req. Temperature adjustment).

Measure resistance between pins 4 and 5 of KP-550/YC1.

Replace KP-544. If not recovered, replace cable between KP-544 and fuser unit.

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6-28

E5: Eraser error

Meaning Suggested causes Corrective action

• Connector error between CON1board and the drum liaison board

• Defective connector between thedrum liaison board and the drumboard

• Defective transistors and logic gateICs in the eraser controller circuiton the engine board

• Connection error between drumunit board and eraser lamp

• Broken eraser lamp

Yes

Yes

No

No

E5

R=∞?

R=∞?

Install drum unit.

Remove drum unit.

Replace drum unit.

Measure resistance between pins 1 and 7 of KP-562.

Measure resistance between pins 2 and 6 of KP-564/YC7.

Replace KP-544. If not recovered, replace KP-564.

Replace KP-558. If not recovered replace S02070 cable between KP-564 and KP-568.

The eraser does notturn on.

Replace KP-544. ReplaceKP-564. Replace drumunit. Check/replaceS02070 cable.

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6-29

E8: Fuser unit life fuse error

Meaning Suggested causes Corrective action

• Defective gate array U6

• Defective fuse cut circuit on theengine board

E9: Toner motor error

Meaning Suggested causes Corrective action

• Overcurrent in the toner motorcircuitry due to an excessive torque

• Toner motor locked

• Defective gate array U2

• Defective toner motor drivertransistor or overcurrent detector

*Also, try rotating the toner kit gear (feed gear). Compare the torque with a new toner kit.Replace the toner kit if the torque is abnormal. Replace developer unit if the toner kit isnormal.

Turn printer power off andoff several times. Re-place fuser unit. ReplaceKP-544.

The fuser unit life fusewon’t blow out.

The toner motor doesnot revolve, or thecurrent protectioncircuit is activated.

Replace toner container.*

Replace developer unit.Replace KP-544. Re-place KP-599. Check/replace S02052 andS02076.

Yes

Yes

No

E9

Damaged toner container

gears?

E9 shown?

Replace developer.

Turn printer off, then on.

Turn printer off, then on.

Replace toner container.

Replace KP-544. If not recovered, replace KP-599, KP-560, S02076 cable between KP-599 and KP-560 or S02052 cable between KP-544 and KP-599, in the order of priority.

NoEnd

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6-30

F0: Controller system lock error

Meaning Suggested causes Corrective action

Connection error between maincontroller board and engine con-troller board, engine board andCON1 board, or CON1 board andfront panel board.

F1: Main controller ROM checksum error

Meaning Suggested causes Corrective action

Checksum is failed — Replace KP-537with the system ROM (cont. ROM).

F2: RAM read/write error

Meaning Suggested causes Corrective action

Checksum is failed — Replace option SIMM’s.with the RAM on the Replace KP-536.main controller board.

F3: Controller system error

Meaning Suggested causes Corrective action

Error other than F0, — Turn printer power off,F1, and F2. [privilege then on again. If notviolation, bus error, solved, replace the mainetc.] controller board.

Main controller can notcommunicate withcontrol panel [shownapprox. 30 secondssince OS fails tocontinue operating.]

Replace KP-536 (maincont.). Check/replaceS02051. Replace KP-544(engine). Replace KP-564(CON1).

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6-31

Other errors relating to the controller board

Symptom Suggested causes Corrective action

A situation in which OS is notable to run is occurred.

Wrong printer driver is used.Wrong emulation is used.Parameters are incorrect on theparallel interface. The surgeprotection devices on the maincontroller is defective.

—

Defective wiring around the frontpanel. Defective front panelboard.

Display freezes whileindicating Processing.

Printed charactersgarbled.

Harddisk error oc-curred.

No display on themessage display.

Turn power on and off. Or,replace the main controllerboard.

If the parallel interface is beingused, investigate for theadequate length of theparallel cable. Also, checkthat the cable is properlyshielded. Or, replace the maincontroller board.

See Option harddisk errorson page Chapter 6-32.

Check wiring between themain board and engine board;between the engine boardand CON1 board; and CON1board and front panel board.Replace the front panel boardand/or main board.

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6-32

Option harddisk errors

The printer indicates Harddisk error messages on the message display when it detectserrors with the option harddisk (if installed). This message is followed by a two-digit codewhich provides the following meaning and corrective action to the specific error.To clear the error message and continue operating the printer, press the CONTINUE key.

Harddiskerror code Meaning Corrective action

01 Turn printer power off then on again. Ifnot recovered, consider reformatting theharddisk.*

[Warning—Formatting erases all dataexisting in the harddisk. ]

02 Ensure that the harddisk is installedproperly in the printer. For instructions,refer to the handbook accompanyingthe harddisk unit.

03 Unlock the write-protection state byKPDL or PJL. Consult the system admin-istrator if required.

04 Free harddisk space by removingunnecessary file in the harddisk.

05 Ensure whether a file with the specifiedname exists on the harddisk. If the fileexists, ensure that correctly matchingfile name is called, i.e. case. Print out apartition list from the printer to obtain alist of the included partition names in theharddisk. (See the printer’s handbook.)

06 Install more memory in the printer. (Seethe printer’s handbook.)

* For instruction on how to format the harddisk, refer to the instruction handbook for theprinter or the harddisk.

Format error or the harddisk isdamaged.

No harddisk installed.

Harddisk is write-protected.

Insufficient capacaity on harddisk,or the number of files stored hasexceeded 10,000.

The specified file does not exist.

The memory available for use bythe file system is insufficient.

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6-33

Print quality problems

Print quality problems range from uneven tone to completely blank output. The troubleshootingprocedure for each type of problem is given below.

Completely blank printoutCheck the developer unit. • Check that the developer unit is inserted correctly

• Check that the developer’s connector is connectedproperly.

• Check that toner is adhered around the developingroller. If no toner appears to be on the roller, try feedingtoner into the developer using the manner described inchapter 3 (See page 3-9).

Check main charging potential. • Check the main charging output on the HV board. Thisrequires removal of the left side cover and the testequipment. Replace the HV board if high voltagepotential is not available on the board.

Check the laser scanner. • The scanner components within the scanner may bedisordered. Note that the laser scanner is concealed toprotect the components which are susceptible to dust.It should not be disassembled except within a dust-freechamber. Replace the scanner unit if necessary.

All-black printoutCheck the main charger unit • Open the printer side cover and check that the maininstallation. charger unit is correctly seated. To do this, take out the

main charger unit from the printer; then reinstall itcarefully.

Check the grid plate (the • The grid plate must be flat and fit horizontally in place.mesh metal bottom part of the Replace the main charger unit if necessary.charger unit).

Check the drum bias. • Make sure the bias from the HV board is correctlyarrived at the drum unit.

Check high voltage potential • Check the high-voltage output on the HV board. Thisat the HV board. requires removal of the left side cover and the test

equipment. Replace the HV board if high voltagepotential is not available on the board.

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6-34

Dropouts

Note the spacing of the • If the defects occur at regular intervals of 63 mm, thedefects. Use the Repetitive problem may be a dirty transfer roller. Clean or replacedefect gauge on page 6-39. the transfer roller.

• If the defects occur at regular intervals of 94 mm, theproblem may be a damaged drum unit or fuser roller.Replace the drum unit or fuser unit accordingly.

Try changing the transfer • Use the MODE SELECT key on the printer’s controlbias potential (Normal or panel. For details, refer to the instruction handbookThick). accompanying the printer.

Check paper for property. • Paper with rugged surface or dump tends to cause thistype of failure.

Check the paper chute • The paper chute (the metallic fixture provided betweeninstallation. the transfer roller and the fuser unit for antistatic

purpose) must not be fit loose. Press the paper chutedown firmly if necessary.

Check the transfer roller • The transfer roller must be supported by the axle holderinstallation. at the both ends. Clean the axle holder to remove oil

and debris. Replace the transfer roller if necessary.

Check the transfer bias • Check the transfer bias output on the HV board. Thispotential. requires removal of the left side cover and the test

equipment. Replace the HV board if high voltagepotential is not available on the board.

ABC123

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6-35

Black dotsNote the spacing of the • If the defects occur at regular intervals of 94 mm, thedefects. Use the Repetitive problem may be a damaged drum unit or fuser roller.defects gauge on page 6-39. Replace the drum unit or fuser unit accordingly.

• If the defects occur at random intervals, the toner maybe leaking from the drum unit. Replace the drum unit.

• If the defects occur at regular intervals of 38 mm, theproblem may be a toner lump on the developing roller.Remove the lump using a soft brush. Note that thedeveloping roller surface is fragile: Contact themanufacturer for type of the brush to use.

Horizontal streaksCheck drum ground. • The drum axle and its counter part—drum grounding

tab in the printer must be in a good contact. If necessary,apply a small amount of electro-conductive greaseonto the tab. See the manufacturer for which type ofgrease to use.

Check main charger contacts. • Take out the main charger unit; check the electricterminals to see if they are clean.

The drum unit may be • Replace the drum unit.defective.

Black vertical streaks

Contaminated main charger • Clean the main charger wire by pulling the greenwire. colored cleaning knob in and out several times.

Check the drum surface for • A streak of toner remaining on drum after printinga streak of toner laying means that the cleaning blade in the drum unit is notlengthwise. working properly. Replace the cleaning blade; or replace

the drum unit.

Defective developer unit. • Replace the developer unit.

ABC123

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6-36

Unsharp printing

Check contamination on • Clean the main charger wire by pulling the green colorthe main charger wire and main charger wire cleaner know in and out severalthe grid. times.

Check paper for property. • Paper with rugged surface or dump tends to cause thistype of failure.

Check the paper chute • The paper chute (the metallic fixture provided betweeninstallation. the transfer roller and the fuser unit for antistatic

purpose) must not be fit loose. Press the paper chutedown firmly if necessary.

Try changing the transfer bias • Use the MODE SELECT key on the printer’s controlpotential (Normal or Thick). panel. For details, refer to the instruction handbook

accompanying the printer.

Check the transfer roller • The transfer roller must be supported by the axle holderinstallation. at the both ends. Clean the axle holder to remove oil

and debris. Replace the transfer roller if necessary.

Check the transfer bias • Check contamination on the main charger wire and thepotential. grid.

Check EcoPrint setting. • The EcoPrint mode can provides faint, unsharp printingbecause it acts to conserve toner for draft printingpurpose. For normal printing, turn the EcoPrint modeoff by using the MODE SELECT key on the printer’scontrol panel.

Refresh drum. • Try cleaning the drum surface using the printer’s built-in cleaning system specifically provided for this purpose.For details, refer to page 6-40.

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6-37

Gray background

Check contamination on the • Clean the main charger wire by pulling the green colormain charger wire and the grid. main charger wire cleaner know in and out several

times.

Check the grid plate (the • The grid plate must be flat and fit horizontally in place.mesh metal bottom part of Replace the main charger unit if necessary.the charger unit).

Check the print density setting. • The print density may be set too high. Try adjusting theprint density using the MODE SELECT key. For detailsrefer to the printer’s instruction handbook.

Check the surface potential of • The drum potential values may vary depending onthe drum. production lots and the measurement is possible only

by using the jig and tool specifically designed for thispurpose. The drum unit will have to be replaced if it willbear the values far out of the allowable range.

The developer unit may be • If a developer unit which is known to work normally isdefective. available for check, replace the developer currently

used in the printer with it. If the symptom disappears,replace the developer unit with a new one.

ABC123

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6-38

Dirt on the top edge or back of the paper

Check toner contamination in • Dirty edges and back of the paper can be caused byvarious parts. toner accumulated on such parts as the paper chute,

paper transportation paths, the bottom of the developerunit, and the fuser inlet. Clean these areas and parts toremove toner.

Check the transfer roller. • If the transfer roller is contaminated with toner, cleanthe transfer roller using a vacuum cleaner; or bycontinuously printing a low-density page until thesymptom has faded away.

ABC123

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6-39

Repetitive defects gauge

Use the following measurements for checking repetitive occurrences on the printed page.See the above section for details.

FIRST OCCURRENCE OF DEFECT

32 mm: DEVELOPING ROLLER

37.5 mm: UPPER REGISTRATIONROLLER

50 mm: LOWER REGISTRATIONROLLER

66 mm: TRANSFER ROLLER/DEVELOPING PULLEY

94.3 mm: FUSER PRESSUREROLLER

116.3 mm: FUSER HEAT ROLLER

128.3 mm: DRUM UNIT

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6-40

Drum cleaning

This mode is meant to provide a manual means of drum cleaning in addition to the regularcleaning procedure made automatically in a photographic cycle. In this mode, the drumturns for the period of approximately three minutes with no main charging dispersed overthe drum. Since the cleaning blade in the drum continuously attempt to scrape soils andpaper dust on its surface, the drum can be brought in a clean state.

To clean the drum using this feature, perform the following, top to bottom:press MODE then,

press repeatedly until: Others>

press then,

press repeatedly until: >Service>

press , the display should show: >>Developer

press , the display should show: >>Drum

press ENTER, the display should show: ?

press ENTER

The drum then starts turning and stops after approx. 3 minutes. The printer reverts to Ready.

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6-41

Correcting a paper jam

This section describes how to remove paper when it jams in the printer. The printer will stopwhenever paper jams in the printer or paper is not fed from a cassette. The printer will gooffline and the message Paper jam Open front cover will appear in the messagedisplay.

Paper jamOpen front cover

Opening the printer’s front cover will cause the message display to change. It will nowindicate the coded location (A through I and 1 through 6) of the paper jam.

Example:

Paper jamC, H, 1

In this example, paper is jammed in the paper feeder (C), paper feed unit (H), and in theupper cassette (1). The corrective action to take in cases like this is explained using actualexamples beginning from page 6-45.The meanings of symbols appearing on the message display and the correspondinglocations of paper jams are given in the table on the next page. Be sure to correct paperjams according to the procedure given on the following pages.

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6-42

Locating and correcting paper jams

MESSAGE DISPLAY INDICATOR AND PAPER JAM LOCATION

Ind. Meaning of Indicator Corresponding Printer Location

A Optional paper feeder(Envelope feeder or Universalfeeder)

B Multi-purpose tray

C Paper feeder included withprinter

D Optional paper feeder

E Optional paper feeder

F Optional paper stacker(Document finisher or Bulkpaper stacker)

G Face-up output tray

H Paper feed unit

I Optional duplex printing unit(Duplexer)

1 Cassette 1

2 Cassette 2

3 Cassette 3

4 Cassette 4

5 Cassette 5

6 Cassette 6

F

G

A

H

I

1

2

3

4

5

6

B

C

D

E

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6-43

Correcting paper jams

Warning: Pull out the paper feed unit (See below.) and wait a while to allow the fuser unitto cool. Do not touch the fuser unit as this may result in a burn injury.

Warning: Take care not to leave any small pieces of paper in the printer when removingpaper jams as this may result in fire.

Note: Data remaining in the printer will be lost if power is turned off while correcting a paperjam.

After checking the location of the paper jam using the table on the previous page, takecorrective action according to the table on the next page. After removing all jammed paper,the printer will automatically resume printing.

Fuser unit

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6-44

Ind. Meaning of indicator Corresponding printer location

A When a paper jam occurs in the optionalfeeder, pull it out carefully. (For details,read the instruction handbook for eachseparate option.)

B When a paper jam occurs in the multi-purpose tray, first completely remove alljammed paper and then open and closethe front cover.

C, D, E Open the side cover of the paper feederindicated and remove the jammed paper.See page Chapter 6-47.

F Remove the paper jammed in the paperstacker. (For details, read the paperstacker instruction handbook.)

G If printing stops before a page iscompletely output, carefully remove thatsheet of paper. See Chapter 6-48.

H If printing stops before a page iscompletely output, carefully remove thatsheet of paper.

Open the front cover and carefully pullout the paper feed unit as far as it will go.If paper is jammed in the registrationrollers, remove it by the easiest meanspossible. See page Chapter 6-49. Pulljammed paper out of the fuser unit in thesame manner. See page Chapter 6-49.After all paper has been completelyremoved, return the paper feed unit.

Open the front cover and carefully pullout the paper feed unit as far as it will go.Open the fuser unit cover (grasp the tab[green]) and check inside the fuser unit.Jammed paper may sometimes be leftinside the fuser unit. See page Chapter6-51.

I Open the front cover, pull out the duplexprinting unit and remove the jammedpaper. (For details, read the duplexprinting unit instruction handbook.)

1 – 6 Pull out the cassette indicated andremove the jammed paper. After all paperhas been completely removed, open andclose the front cover.

Check the optional paper feeder(Envelope feeder or Universalfeeder).

Check the multi-purpose tray.

Check the optional paper feeder. (Dand E are only displayed when anoptional paper feeder is installed.)

Check the optional paper stackerDocument finisher or Bulk paperstacker.

Check the face-up output tray.

Check the face-down output tray.

Check the paper feed unit.

Check the fuser unit.

Check the optional duplex printingunit (Duplexer).(Only when installed)

Check the cassette indicated.

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6-45

Example: Understanding the paper jam indication

In the example below, paper is jammed in the paper feeder (C), the upper cassette (1), andthe paper feed unit (H).

Paper jamC, H, 1

1. When paper jams in multiple locations such as in this example, begin taking correctiveaction from the location displayed at left. After the paper jam in the paper feeder (C) iscorrected, the display will change as follows.

Paper jamH, 1

2. Next, pull out the paper feed unit and remove the jammed paper. After removing thepaper the display will change as follows.

Front coverOpen

3. Close the front cover. This completes removal of this paper jam.

The page on which the paper jam occurred may not be re-printed depending on the locationof the paper jam.Frequent occurrence of paper jams may indicate you are using a paper specification whichdoes not suit the printer. If this appears to be the case, try switching to a different type ofpaper.

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6-46

Paper jam removal diagrams

These diagrams are for assistance in following instructions on page Chapter 6-41.

DIAGRAM 1: PAPER FEEDER

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6-47

DIAGRAM 2: FACE-UP STACK

Step 1

Step 2

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6-48

Step 3

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6-49

DIAGRAM 3: TRANSFER UNIT

Step 1

Step 2

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6-50

DIAGRAM 4: FUSER UNIT

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1-1-21

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CONTENTS

Appendix A PRINTER INTERFACE

Parallel interface .......................................................................................................A-1Port pin assignment ....................................................................................................A-1Parallel interface connection .......................................................................................A-2

Serial interface .......................................................................................................... A-3Serial interface specifications ...................................................................................... A-3Data error information (Snn) .......................................................................................A-4Changing the serial interface configuraion .................................................................. A-4Serial port pin assignment ........................................................................................... A-6Serial interface connection .......................................................................................... A-7RS-232C interface voltage levels ................................................................................A-7Connector configurations ............................................................................................ A-8RS-232C protocol ........................................................................................................ A-9

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A-1

Parallel interface

The printer uses a bi-directional parallel interface for high-speed data transmission for thehost computer. This interface includes the buffers which are compatible with the IEEE 1284standards. The parallel interface provides support for the ECP and nibble modes in thisstandards.

Port pin assignment

The pins of the parallel interface connector carry the signals listed below.

No. Terminal Signal No. Terminal Signal

1 nStrobe (STBIN1/2*) 19 Ground GND

2 Data1 (PAD0) 20 Ground GND

3 Data2 (PAD1) 21 Ground GND

4 Data3 (PAD2) 22 Ground GND

5 Data4 (PAD3) 23 Ground GND

6 Data5 (PAD4) 24 Ground GND

7 Data6 (PAD5) 25 Ground GND

8 Data7 (PAD6) 26 Ground GND

9 Data8 (PAD7) 27 Ground GND

10 nAck (ACKOUT) 28 Ground GND

11 Busy (BUSYOUT) 29 Ground GND

12 PError (PERROR) 30 Ground GND

13 Select (SELECT) 31 nInit (INIT*)

14 nAutoFd (AUTOFD*) 32 nFault (FAULT*)

15 Not defined NC 33 Not defined Pull-up (1kW)

16 Logic ground GND 34 Not defined NC

17 Chassis ground (GND) 35 Not defined Pull-up (1kW)

18 Peri-logic power (VCC) 36 nSelect In (SELECTI*)

*: Negative logic**: Maximum rated current for pin 18 is 0.25A (fused).***: Pin 17 is grounded through a chip bead or a chip resistor.

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A-2

Parallel interface connection

Detailed descriptions of the parallel interface signals follow.

Signal Meaning

A negative-going Strobe* pulse causes the printer toread and latch the data on the Data 0 [1] to Data 7 [8]signal lines.

These eight signals form the data byte sent from the hostcomputer to the printer. Data 7 [8] is the most significantbit.

This negative-going pulse acknowledges the previouscharacter received by the printer. Acknowledge* pulsesare sent only when Busy is low.

This signal is high when the printer is busy and low whenit is able to accept more data. Every high-to-low transitionis followed by an Acknowledge* pulse.

This signal goes high when the printer runs out of paper.

This signal is high when the printer is on-line and lowwhen the printer is off-line. It goes low when the upperunit is raised, or when the ON LINE key is pressed to setthe printer off-line.

Note: The Paper Empty and On-Line signals are notused unless enabled by the FRPO command (O2parameter).

This signal is used in the Epson version of the Centronicsinterface to receive a carriage return. In high-speedmode, it is used as an interrupt.

This line is connected to the printer’s +5 V DC line(+5 V ±0.5 V, 250 mA maximum [serial and paralleltotal], fused).

This signal is used in the standard Centronics interfaceto enable the computer to reset the printer. It is ignoredby the printer.

When the high-speed parallel line control is on (FRPOO2 = 2), this line returns error status.

This signal line is not used.

This signal is high when the printer’s power is on.

This signal is used in some versions of the Centronicsinterface to enable the computer to force the printer on-line. In high-speed mode, it is used as an interrupt.

Strobe* [nStrobe] (Pin 1)

Data 0 [1] to Data 7 [8](Pins 2 to 9)

Acknowledge* [nAck](Pin 10)

Busy [Busy] (Pin 11)

Paper Empty [PError](Pin 12)

On-Line [Select] (Pin 13)

Auto-Feed [nAutoFd](Pin 14)

+5 V DC (pin 18)

Prime [nInit] (Pin 31)

Error* [nFault] (Pin 32)

Auxiliary output 1 (Pin 33)

Power Ready (Pin 35)

Select In [NSelectIn](Pin 36)

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A-3

Serial interface

The printer is equipped with a serial port whose circuitry duplicates the option interface card.The device responsible for controlling the serial interface is integrated in the gate array in thecontroller system. The serial interface supports both protocols of RS-232C and RS-422A.In the RS-232C protocol, CTS and DSR signals are included to support SNMP (SimpleNetwork Management Protocol) protocol (used typically for Windows 95’s plug-and-playfunction). Toggling the protocol between RS-232C and RS-422A is made by a shortingjumper socket that is accessible on the controller board. (The jumper wire arrangement, thatused to be provided for the succeeding models to switch the DTR polarity is not used withthese models.) To change the serial interface protocol, refer to Changing the serial interfaceconfiguration section which follows.A 25-pin D-sub connector is used for the serial interface. The extra signals used forRS-422A are assigned to these pins that are not used for RS-232C according to the IBMpin assignment scheme.

Serial interface specificationsThe table below summarizes the specifications for the serial interface used in the printer.The parameter options can be selected using either the printer’s front panel or PrescribeFRPO command.

Item Option parameters Selection Default

Interface mode*1 RS-232C or RS-422C By changing hardware RS-232Cjumper (See the next (factorysection) setting)

Baud rate 300, 600, 1200, 2400, Front panel or FRPO 9600 (96)4800, 9600, 19200, H1 command38400, 57600, 115200

Data bit length 7, 8 Front panel or FRPO 8H2 command

Parity bit length None (0), odd (1), even (2), Front panel or FRPO None (0)ignore (3) H4 command

Protocol*2 DTR [pos] & Xflow [buf] (0), Front panel [(1) through DTR [pos]DTR [pos] (1), DTR [neg] (4) only] or FRPO H5 & Xflow(2), Xflow [buf] (3), ETX command [buf] (0)[nobuf] (4), Xflow [nobuf](5), ETX [buf] (6), Xflow[buf] & ETX [nobuf] (7)

Error robust Robust On (0), Robust FRPO D0 command Robust Oncontrol*3 Off (1), Error Control & (0)

Robust Off (10), ErrorControl & Robust On (11)

Status send ^C, ^T, Esc.B, Esc.

*1 The serial interface mode currently engaged is indicated at the bottom of the servicestatus page as: RS2 = RS-232C mode, RS4 = RS-422C mode.

*2 In the protocols that do not use DTR, DTR is fixed to be positive.*3 Robust: Xon is sent every 3 to 5 seconds during ready or waiting. Error Control: Sets

the printer off line when an error occurs or at off line state.

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A-4

Data error information (S nn )

A data error occurred on the serial interface is indicated on the service status page. The Snncode in the same row as Service information on the status page shows various errorconditions as follows:

S code Meaning

S00 No error

S01 Framing error

S02 Overrun error

S03 Overrun error and framing error

S04 Parity error

S05 Parity error and framing error

S06 Parity error and overrun error

S07 Parity error, overrun error, and framing error

Changing the serial interface configuration

To change the serial interface protocol from RS-232C to RS-422A, or vice versa, the maincontroller board must be taken out of the printer. Protect the electronics by taking theseprecautions:

Before touching the main circuit board, touch a water pipe or other large metal object todischarge yourself of static electricity. While doing the work, it is recommended that youwear an antistatic wrist strap.Touch the main circuit board only by the edge.

Refer to the diagram below and remove the rear panel cover.

Rear panel cover

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A-5

To change the serial protocol from RS-232C to RS-422A, for example, carefully remove thejumper connector from the main circuit board, and reconnect to the pin position shown inthe diagram.

RS-232C position RS-422A position

After finishing the above procedure, replace the rear panel cover back by referring thediagram above into the printer. Secure the panel cover by the six screws.

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A-6

Serial port pin assignment

The pins of the parallel interface connector carry the signals listed below. The RS-422Aspecific signals are noted in the Definition.

No. Signal Flow Definition

1 FG — Frame ground

2 TxD Printer → host Transmit data: RS-232C

3 RxD/RDA Host → Printer Receive data/receive data (Reversed)

4 RTS Printer → host Transmit request

5 CTS Host → printer Transmit permitted

6 DSR Host → printer Data-set-ready

7 SG Signal ground

9 SDA Printer → host Transmit data (Reversed): RS-422A

10 SDB Printer → host Transmit data: RS-422A

11 +5 V DC — Peri-logic power

18 RDB Host → printer Receive data: RS-422A

20 DTR Printer → host Data-terminal-ready

Others Not connected — Undefined

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A-7

Serial interface connection

Detailed descriptions of the serial interface signals follow.

Signal Meaning

FG (Pin 1) This pin is connected directly to the printer frame.

TxD (Pin 2) RS-232C only: This output carries asynchronous datasent by the printer to the computer. It is used mainly inhandshaking protocols.

RxD/RDA (Pin 3) This input carries serial asynchronous data sent by thecomputer to the printer. In RS-422A, this carries theinversed differential data (RDA).

RTS (Pin 4) This output is always held high (above 3 V).

CTS (Pin 5)/DSR (Pin 6) Unused.

SG (Pin 7) All signals can transmit between the printer and the hostcomputer to send each signals with a signal ground.

SDA (Pin 89) This output transmits asynchronous inversed form ofdifferential data from the printer to the computer.

SDB (Pin 810) This output carries asynchronous non-inversed form ofdifferential data from the computercmputer to the printer.

+5 V DC (Pin 11) This line is connected to the printer’s +5 V DC line (+5 V±0.5 V, 250 mA maximum [serial and parallel total],fused).

DTR – Data Terminal This output is used as a buffer nearly-full handshake line.Ready (Pin 20) It is held high (above 3 V) when the buffer can accept

more data.

RS-232C interface voltage levels

The voltage levels of the RS-232C signals conform to EIA RS-232C specifications. FALSEis from 3 volts to 15 volts. TRUE is from -3 volts to -15 volts. Voltages between -3 volts and3 volts are undefined. The voltage levels of the RS-422A signals are equivalent to those ofthe RS-232C signals except the signals used for transmission and reception.

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A-8

Connector configurations

The printer uses a DB-25 connector for the serial interface. Depending on the computerconfiguration for serial interface, use either of the appropriate configurations. A specialcable must be prepared or obtained for the RS-422A configuration by referring to thediagram (last) below.

RS-232C – FOR COMPUTERS WITH A DB-9 CONNECTOR:

RS-232C – FOR COMPUTERS WITH A DB-25 CONNECTOR:

Computer serial port

(DB-9)

Printer serial port (DB-25)

RXD-2TXD-3DTR-4

GND-5DSR-6RTS-7CTS-8

2-TXD3-RXD4-RTS5-CTS6-DSR

7-SG20-DTR

Computer serial port (DB-25)

Printer serial port (DB-25)

GND-1TXD-2RXD-3RTS-4CTS-5DSR-6GND-7

DTR-20

1-FG2-TXD3-RXD4-RTS

5-CTS6-DSR7-SG20-DTR

5A2

A-9

RS-422A

Computer serial

interface

Printer serial port

(DB-25)

1-FG3-RD-7-SF9-SD-10-SD+18-RD+

Frame gr.

Signal gr.

Rx term.Tx term.

On the computer serial port, investigate pin assignments depending on the computermanufacturer’s instruction. Since the RS-422A configuration does not employ control linesexcept for data transmission/reception, select a mode in which signals such as DTR are notused.

RS-232C protocol

The serial interface supports the full baud rates of: 300, 600, 1,200, 2,400, 4,800, 9,600, and19,200, 38,400, 57,600, and 115.2k (bps). For adjusting serial interface parametersincluding baud rate, parity, etc., refer to chapter 7 in the printer’s instruction handbook.

5A2

B-1

Status page

The printer can print different types of the status page—the user status page and the servicestatus page. This section exclusively describes the service status page. For information onthe user status page, refer to the printer’s instruction handbook.Information obtainable on the service page include various settings for the printer, servicestatistics, etc. To print a service status page, proceed as follows:

1 Ensure that the message display is indicatingReady.

2 Press the MODE SELECT key.

3 Press until the message display indicatesOthers>.

4 Press .

5 Press repeatedly until the message displayindicates >Service>.

6 Press . Press until the message displayindicates >>Print status page.

7 Press ENTER. The question mark (?)appears at the end.

8 Press ENTER again. The service statuspage is printed.

Service information on the status page

An example of the service status page is shown below. (Note the details born by a statuspage may differ from a firmware version to another.) Most of the service information islocated under Service information.

Others>

>Service>

>>Print status page>

>>Print status page?

5A2

B-2

Example of the service status page

Most of these service information on the status page are alphannumerically-coded. Eachitem is explained below.

Software version: Released: dd/month/yyyy

PAGE PRINTER STATUS PAGE

Service information [A2/48-03][07] /P00/S00/F01/E01/N02/D10:DM0301.DAN Total page 3464 /0078/0033/1061/0811/AAAAAEI/AAAAAAA/AAAEJDJ/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ DN:SPL7400084/AAEJIJ/AAEFBE/AAEFBE/AA/DF/RS2 SN:SPL6500004

“/” is the separator.

5A2

B-3

Service information on the service status page

Example Meaning Description

Top of the pageSoftware version: Controller firmware version*

Released: Rreeased date of the dd/month/yyyyfirmware (above)

Bottom of the page, Upper line[A2/48-03] Engine ROM version/flush ROM version-product ID

[07] Front panel ROM mask version

/P00 Parallel interface mode 00=Unidirectional, 04=Nibble(Normal), 05=Nibble (Hispeed),07=ECP

/S00 Serial interface error 00=Normal, bit 0=Framing error,bit 1=Overrun, bit 2=Parity error

/F01 Front control panel 01=Locked, 02=Fully locked

/E01 Option interface error 01=Diagnostics error, 02=Boarderror, 03=Board power-up,04=Board disconnection

/N02 NVRAM error (Shown only 01=ID error, 02=Version error,if error occurred) 03=Checksum error,

04=NVRAM error

/D10:DM301.DAN NVRAM download 00=None downloaded, bit 4=Frontinformation panel message data name,

bit 7=Error

Total page 3464 Total page count —(Also see below.)

Bottom of page, middle line/0078 Top margin Inches+1/100 inches (FRPO L1/L2)

/0033 Left margin Inches+1/100 inches (FRPO L3/L4)

/1061 Page length Inches+1/100 inches (FRPO L5/L6)

/0811 Page width Inches+1/100 inches (FRPO L7/L8)

/0(9) Left margin offset for paper in 1/600 inchsources (Manual feed tray,printer’s cassette, paperfeeder’s cassette (ifinstalled), from left to right)

* The firmware information also appear on the normal status page.

5A2

B-4

Example Meaning Description

Bottom of page, lower line/DN:SPL6X40262 Serial number for the drum unit

/AA Internal use

/DF Internal use

/RS2 Serial interface mode RS2=RS-232C, RS4=RS-422A

SN:SPL6500004 Serial number for the printer —

A B C D E F G H I J

A B C D E F G H I J

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

5A2

S02098 S02097

S02076

S02082

S02074

S02068

S02052

S02056

S02078S02077

S02083 S02084

S02081

S02053

S02055

S02080

S02085

S02059

S02060

S02061

S02062

S02058

S02057

S02051

S02054

S02070

S02095

S02063

S02072

S02069

S02102

S02

064

S02

109

S02066

S02067

S02071

S02075

S02073

YC

781

YC

782

Deve Unit

Mag. Roller

Toner Sensor

Toner Motor

3

3

3

3

3

33

4

5

28

14

15

4

8

32

3

2 2

7

2

2

Deve PWB(KP-548)

Dvrly PWB (KP-560)

CON2 PWB (KP-599)

ENVPWB(KP-502)

50

B

YC2

YC1

YC8

YC5

YC3 YC6

YC

6

YC

4

YC4

YC2YC1YC1YC1

YC1

YC1YC1

YC1

YC1

YC1YC1

YC2

YC2YC3

YC1

YC2 YC5

YC1

YC3

YC4

YC

7Y

C10

YC

5

YC

5

YC2

YC2

YC7 YC8YC12

YC10 YC11

YC

2

YC

1

YC2 YC3YC8

YC

1

YC

1

YC1

YC

1

YC

1

YC

1

YC7

YC6

YC1

YC1 YC1

YC2

YC3

YC4

YC1

YC1

YC1

YC1 YC9

Toner Bottle PWB (KP-552)

MPF Solenoid

Envelope feederorUniversal feeder

ENVPASPhoto Sensor

MPFPAPPWB (KP-576)

MPFPAPPhoto Sensor

TCOV SW

ETON PWB(KP-603)

F1 125V/2A

+24V

CN1 Main MotorPWB

Regist Cluch

Sub Cluch

RegjamPhoto Sensor

A

Inter LockSwitch

Drive UnitP

aper

fe

eder

(Opt

ion)

Pap

er

feed

er(O

ptio

n)

Pap

er

feed

er

F1125V2A+5V

F2125V3.15A+24V

CON3 PWB(KP-568)

Fuser PWB (KP-550)

Fuser Unit

Duplexer(Option)

Bulk paper stackerorDocument stacker(Option)

Thermistor

Heater Thermo Cut Out

Drum Unit

Eraser

Drum PWB(KP-562)

Engine PWB(KP-544)

60

Zener PWB(KP-605)

CON1 PWB(KP-564)

HTON PWB(KP-574)

DRRLY PWB(KP-558)

Fan3

Fan1

Fan2

Fan4

CONTOROLLER BOX

Main PWB(KP-536)

F100E125V/0.5A+5V

Dimm PWB(KP-537)

34SimmSerial

Interface

ParallelInterfaceMemoryCard

OptionInterface KUIO

Interface

8

R

T

FG

FG FG

MB

B

A

A03 BLOCK DIAGRAM

CN6

CN

5C

N2

CN

1

CN

4C

N3

SWITCHING PS BOX

Switching PS PWB

4

4

4

4

3

3

3

3

5

5

8

7

7

3

3

33

3 3

2

2

3 3

6

HV PWB

AC Inlet

Power SW

Inter LockPWB(KP-556)

FUP/FDWSolenoidFUP

PhotoSensor

FDWPhotoSensor

FDFULPhotoSensor

LeftCoverPWB(KP-552)

Laser DiAPC-B PWB(KP-579)

PoligonMotor

APC-A PWB(KP-578)

K/B PWB(KP-539)

PD PWB(KP-572)

Apcrelay PWB(KP-570)

M

14

Tra

nsfe

r R

olle

r

Rel

ease

Bru

sh

SEL1

SEL0GND

GNDSID

+24V

2

FAN3

DR*

TBoTLE*GND

+24V2

MPFSD*

123456789

1011121314151617181920

+24V2+24V2+24V2DVUNIT*ENVPASI*VCCMPPSIZE1VCCGNDGNDGND

GNDENVPAPI*ENVUNTI*HANDSI*PF7UNTI*REGCLD*EMoTD*SUBCLD*

GND

212223242526272829303132

MPFBSD*MPPSIZE2DEVHITD*MPFPAPREToNLED*JAMRG*TCoPTBoTLE*ETNEMP*TNMoTD*TNMoTR*TNENDI*

12345678

GNDTNENDI*VCCDVUNIT*DEVHITD*TNMoTR*TNMoTR*TNMoTD

2122232425262728

FINTXGNDFINTXGNDFINRXGNDGNDGND

123456789

1011121314151617181920

+24V2

VCCVCCSEL2GND

GND

VCC

+24V2+24V2+24V2

SoUTGNDSCK*GND

VCC

2122232425262728293031323334

N.CRDYo*VSREQo*VSYNCI*PdoN.CPRINTI*oUTPEo*N.CGNDVIDEo*

GNDGND

GND

123456789

1011121314151617181920

GNDGNDSCLKIGNDSCDVCCVCCVCCVCCVCCCBSYI*

CINHo*EGIRo*RESET*CPRDYIPToUToFPDATAFPDIRFPCLK

SBSYo*

123456789

10111213

TNMoTDTNMoTR*TNMoTR*DEVHITD*DVUNIT*VCCTNENDI*GNDGNDGNDGND

GNDGND

A1A2A3A4A5A6A7A8A9

A10B1B2B3B4B5B6B7B8B9

B10

PF7UNTI*HANDSI*GNDENVPAPI*ENVUNTI*EMoTD*oP24VGNDENVPASI*VCCGND

MPFSIZE1VCCN.CGNDMPFPAPRVCCGNDTCoP

MPFSIZE2

123456789

1011121314

TVSENSITISENSITHPIDRD*THVRDRD*THVDRD*HVoLTTISETRISETRHVDRD*HVCLKMHVDRD*

+24V2BSEL

GND

12345

SCANCKSCRDYI*SCAN*GND+24V2

1234

5VSAFELoNBo*LASERoGND

1234

VCCPDLDGND

1234567

VCCFPDTVCCFPDIRo

FPCLKoGND

GND

1234567

+24V2+24V2+24V2N.C

+24V+24V

+24V

1234567

+24V2+24V2+24V2+24V2

MMoTDR*FG

GND

1 2 3 4 5 6 7 8 9 10 11 12 13 14

LCoP

GND

VCC

PAFL

*G

NDVC

CJA

MFD

W*

GND

VCC

JAM

FUP*

GND

+24V

2FD

WSD

D*

FUPS

DD*

1 2 3 4 5 6 7 8 9 10 11 12 13

VCC

DRUN

IT*

GND

EESC

oEE

SCLK

EEDA

TAER

ASED

*G

NDG

NDG

NDG

ND

GND

GND

123456789

1011121314

GNDSCK*GNDGNDSoUTSID+24V2+24V2VCCVCCGND

SEL1SEL2

SEL0

123456789

1011121314

GNDSCK*GNDSoUTGNDSIDSEL0SEL1SEL2FINTXGND

GNDFINLIFE

14 N.C

FINRX12345678

SEL0SEL1SEL2SoUTSCK*SIDoP5VoP5V

1234

oP24VoP24VGNDGND

1 2 3 4 5 6 7 8 9 10 11 12

GND

ERAS

ED*

EEDA

TAEE

SCLK

EECS

oG

NDDR

UNIT

*VC

CG

NDTo

WER

HTLD

*VC

C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

+24V

2Lo

NBo*

LASE

Ro*

GND

SCAN

CKSC

RDYI

*SC

AN*

GND

GND

PDI*

VCC

VDo+

VDo-

GND

N.C

N.C

123456789

1011121314151617181920

GNDGNDGNDGNDGNDGNDVCCVCCVCCVCCVCC

+24V2+24V2+24V2+24V2+24V2+24V2+24V2+24V2

VCC

2122232425262728293031323334353637383940

TOWER*HTLD*N.C.N.C.

N.C.

DRUNIT*JAMFUP*HT2 (S)TCoUNTD*

HT1 (C)FAN1DR*

LCoP*JAMFDW*PAFLFCoP*FUPSDD*FDWSDD*EESCSoEEDATA

FAN2D*

4142434445464748495051525354555657585960

ERASED*EESCLKFPDIRoFPCLKoPDI*FPDTSCAN*SCANCKN.C.SCRDYI*N.C.

LoNBo*LASERoGNDGNDGNDVDATAGNDGND

N.C.

12345

FUUNIT*GNDFSFHITTHERMIVCCFS

12345

GNDGNDGNDGNDVCC

6

1234

HT1 (C)HT2,(S)FAN2D*+24V2

VCC

123

LAMPMoNPHSTRIGGND

123

GNDJAMRG*VCC

123

VCCEToNLED*EToNPTR

FAN2

4

FAN2

4

FAN1

D*

FAN4

D*

FCoP

FCoP

+24V2

+24V2

REGCLD*

SUBCLD*

General wiring diagram

©1997 MITA INDUSTRIAL CO., LTD.MITA and are registered trademarks of MITA INDUSTRIAL CO., LTD.

MITA COPYSTAR AMERICA, INC.Headquarters:225 Sand Road, P.O. Box 40008Fairfield, New Jersey 07004-0008TEL : (973) 808-8444FAX : (973) 882-6000

New York Show Room:149 West 51st street,New York, NY 10019TEL : (212) 554-2679FAX : (212) 554-2625

Northeastern Region:225 Sand Road, P.O. Box 40008Fairfield, New Jersey 07004-0008TEL : (973) 808-8444FAX : (973) 882-4401

Midwestern Region:225 Spring Lake Drive,Itasca, Illinois 60143TEL : (630) 250-7447FAX : (630) 250-8787

Western Region:14101 Alton Parkway,P.O.Box 57006, Irvine,California 92618-7006TEL : (714) 457-9000FAX : (714) 457-9119

Southeastern Region:1500 Oakbrook Drive,Norcross, Georgia 30093TEL : (770) 729-9786FAX : (770) 729-9873

Southwestern Region:2825 West Story Road,Irving, Texas 75038-5299TEL : (972) 550-8987FAX : (972) 570-4704

Dallas Parts Distribution Center& National Training Center:2825 West Story Road,Irving, Texas 75038-5299TEL : (972) 659-0055FAX : (972) 570-5816

MITA COPYSTAR CANADA, LTD.6120 Kestrel Road,Mississauga, Ontario L5T 1S8TEL : (905) 670-4425FAX : (905) 670-8116

MITA COPYSTAR MEXICO, S.A. DE C.V.Av. 16 de Septiembre #407Col. Santa Inés,Delegación AzcapotzalcoMéxico, D.F. C.P. 02130TEL : 3-83-27-41FAX : 3-83-78-04

Printed in U.S.A.

1-1-22

5A2

1-1-23

5A2

CONTENTS

Appendix B STATUS PAGE

Status page ................................................................................................................B-1Service information on the status page ........................................................................ B-1Example of the service status page ............................................................................. B-2Service information on the service status page ........................................................... B-3

5A2

1-1

Printer identification labelling

The printer has a label bearing its model and serial number at its back. This label alsocontains other safety precautions.

US/Canada version

DP-2800

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

This Class B digital apparatus complies with Canadian ICES-003.Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

THIS LASER PRODUCT CONFIRMS TO THE APPLICABLEREQUIREMENTS OF FEDERAL REGULATIONS 21 CFR CHAPTER 1, SUBCHAPTER J.

MITA INDUSTRIAL CO.,LTD.2-28 1-CHOME TAMATSUKURI CHUO-KU OSAKA JAPAN MADE IN JAPAN

MANUFACTURED

60Hz 120V 10A

PRECAUCIONRETIRE EL CORDON ELECTRICO ANTESDE REALIZAR SERVICIO O REEMPLAZAREL FUSIBLE.

ATTENTIONPOUR PRÉVENIR LES CHOCSÉLECTRIQUES, COUPER L

,ALIMENTATION

AVANT DE REMPLACER LE FUSIBLE.

CAUTIONREMOVE POWER CORDBEFORE SERVICE AND FUSE REPLACEMENT.

FOR HOME OR OFFICE USE

Tested To ComplyWith FCC Standards

8J68UL1950

PRINTER

YM

5A2

1-2

Printer Specifications

EngineSpecificationPrint method ……………………… Electrophotography laser scanPrint speed (when printingmultiple copies of thesame page) ……………………… A4/11" × 81/2": 28 pages/min., B4 (257 × 364 mm):

18 pages/min., A3/11" × 17": 16 pages/min.Resolution (dpi) ………………… 600 horizontal/600 verticalSmoothing ………………………… KIR 2 (2400 horizontal/600 vertical)First print (A4/11" × 81/2" or letter,23°C), depends on input data …… 10 seconds or less (75 seconds or less with sleep

mode on)Warm-up time at 23° …………… 65 seconds or lessMaximum duty cycle (A4) ……… 100,000 pages/monthLaser diode ……………………… Visible laserMain charger ……………………… Scorotron wireTransferring ……………………… Biased rollerSeparation ………………………… DCDrum cleaning …………………… BladeDrum discharging ………………… LED arrayFuser ……………………………… Heat and pressurePaper ……………………………… Plain paper (as specified separately)Capacity of paper feed tray(80 g/m2 [0.11 mm thickness]) … Cassette: 500 sheets, MP tray: 100 sheetsCapacity of output trays(80 g/m2 [0.11 mm thickness]) … 500 sheets

ControllerSpecificationCPU ……………………………… PowerPC603e/100 MHzSystem ROM size ……………… 4 MB, flash DIMM or masked DIMMResident font ROM size ………… 4 MBOption fonts ROM ……………… 2 MB (PK-4)Main RAM ………………………… 4 MBAdditional RAM (SIMM) ………… 64 MB maximum (72-pin SIMM × 2)Memory card ……………………… SRAM or flush, JEIDA 4.2/PCMCIA 2.1

See Recommended flash cards in this chapter.Host interface …………………… Parallel: High-speed, bi-directional (IEEE1284),

Serial: RS-232C/RS-422A, Option, KCIO (HDD).Page description language ……… Prescribe IIStandard emulation modes …… HP LaserJet 5Si, IBM Proprinter X24E, Diablo 630,

Epson LQ-850

5A2

1-3

Weight and dimensionsSpecificationMain unit ………………………… Width: 56 cm (22")

Height: 34.5 cm (13.6")Depth: 56.6 cm (22.3")Weight: 41.5 kg (18.7 lb.)

Paper feeder ……………………… Width: 56 cm (22")Height: 24.7 cm (9.7")Depth: 56.6 cm (22.3")Weight: 19.5 kg (8.8 lb.)

Power requirementsSpecificationVoltage requirements …………… US/Canada: 120 V AC ±10%, 60 Hz ±2%.Watts ……………………………… Maximum: 1200 W

Normal operation: 677 WStandby: 215 WSleeping: 34 W

Environmental requirementsSpecificationOperating temperature andhumidity …………………………… 10 to 32.5°C (50 to 90.5°F), 20 to 80% RHMaximum altitude ………………… 2,000 m (6,500 feet)Noise emission (Excludingpeaks, measured at 1m fromprinter, as per ISO7779) ………… 50 dB (A) maximum/38 dB (A) at standby/

unmeasurably low at sleeping)

5A2

1-4

Recommended flash cards

The printer provide support for a JEIDA/PCMCIA category of memory card in both SRAMand flush types of up to 32 MB. Following is a list of makes and models of flush cardsrecommended for use with the printers.

Note that the flush card to be used should be operable on 5 V DC.

Model Capacity

AMD AmC001CFLKA 1 MB

AmC002CFLKA 2 MB

AmC004CFLKA 4 MB

AmC010CFLKA 10 MB

AmC004DFLKA 4 MB

AmC008DFLKA 8 MB

AmC020DFLKA 20 MB

Fujitsu MB98A81063 1 MB

MB98A81183 2 MB

MB98A81273 4 MB

MB98A81373 8 MB

MB98A81473 16 MB

Panasonic BN-02MHF4C (CC) 2 MB

BN-04MHF4C (CC) 4 MB

Centennial FL01M-20-11114-03 1 MB

FL02M-20-11114-03 2 MB

FL04M-20-11114-03 4 MB

FL08M-20-11114-03 8 MB

Maxell EF-2M-TB (DC) 2 MB

EF-4M-TB (DC) 4 MB

EF-8M-TB (DC) 8 MB

EF-16M-TB (DC) 16 MB

5A2

1-5

Front and rear views

Front view

Front control panel

Paper-full sensor

Front cover

MP (multi-purpose) tray

Paper feeder

Option feederconnector

Vent

Paper feeder side cover

Upper paper cassette

Lower paper cassette

Power switch

Face-up paper tray

Left side cover

Face-down trayLeft side view

5A2

1-6

Internal assemblies

Toner container

Feed unit handle

Fuser releaselever

Fuser unit

Toner container release lever(Green colored)

Feed unit

Drum unit

Drum release lever(Green colored)

Developer release lever

Developer

Memory card slot

Harddiskdrive slot

Parallel interfaceconnector

Serial interfaceconnector

Paper cassetteaccess door

Option interfaceslot cover

Rear panel

Power receptacle

Rear view

5A2

1-7

Options

The example option units are shown below. The instruction handbook come with the printerhas more information regarding the accessories available for this model.

Paper feeder supplied as standard

First optional paper feeder

Second optional paper feeder

Bulk paper stacker

Inboard duplexer

Wheels (Caster kit)

5A2

1-8

Environmental requirements

Environmental conditions

The Environmental requirements section on page Chapter 1-2 should be observed toensure the optimum operation of the printer. The use of the printer in a location which doesnot satisfy the requirements may result in troubles and risk shortening its service life.

The printer will work best if it is installed in a location that is:• Level and well supported (Place the printer on a sturdy table or desk.)• Not exposed to sunlight or other bright light (not next to an uncurtained window). Do not

place the printer on an unstable cart, stand, or table.• Near an AC wall outlet, preferably one that can be used for the printer alone. The outlet

should have a ground slot, or an adapter should be used. If you use an extension cord,the total length of the power cord plus extension cord should be 17 feet or 5 meters or less.

• Well ventilated, not too hot or cold, and not too damp or dry (See section Environmentalrequirements on page Chapter 1-2). If you install the printer where the temperature orhumidity is outside the requirements in section Environmental requirements in chapter 1,the best print quality may not be expected and there will be an increased chance of paperjams.

• Provide a sufficient clearances around the printer to ensure ventilation and ease ofaccess.

5A2

1-9

Clearance

Allow the necessary minimum clearance on all sides of the printer (below). A total space of92 by 138 cm (36 by 54") is needed.

Clearance Dimensions

Left 1 45 cm (17.7"), or 30 cm (12") if the face-up tray is not used.

Front 2 60 cm (24")

Right 3 45 cm (17.7")

Back 4 20 cm (8")

Above 5 30 cm (12")

2

1

3

4

5

5A2

1-10

Places to avoid

Avoid installing the printer in locations exposed to:• Direct drafts of hot or cold air.• Direct drafts of outside air. (Avoid locations next to outside doors.)• Sudden temperature or humidity changes.• Any source of high heat, such as a radiator or stove.• Excessive dust. Dust and smoke may cause contamination on the laser scanner window,

causing print quality problem.• Vibration.• Ammonia fumes or other harmful fumes. (In case of humigating the room or saturate it with

insecticide, remove the printer first.)• Avoid greenhouse-like rooms. (Because of sunlight and humidity.)• Avoid enclosed spaces that block ventilation.• Avoid sites more than 6500 feet or 2000 meters above sea level.

Note on power

Use only the power source voltage conforming to the printer’s rated power voltage. Do notuse other power sources.• Disconnect the printer from the power source before attempting removal or re-placement

of an electrical component or a printed-circuit board.• The printer should not be connected to a power source until the instruction is given to do

so when performing tests described in this handbook.• In connecting the printer power, exercise an extreme care in handling the power supply

or any other electric parts which may give an electric shock.• Before performing maintenance or repair, power from both the power source and the

associated peripheral devices (computer, sorter, etc.) should be disconnected, unlessotherwise specified.

• To avoid possible electrical shock, extreme caution must be exercised in handling thepower cord and any other electrical part.

• An easily accessible socket outlet must be provided near the equipment.

5A2

1-11

About the toner

The printer should use the proprietary toner kit. To ensure the high print quality and longservice life, the following handling precautions should apply.

Caution: As the printers are designed to ensure the optimum print quality when used withthe proprietary toner, we do not recommend to use any refilled toner containersthat may be available commercially. This is because we have no means forcontrol over how such refilled toner could affect the print quality and the reliabilityof the printer.

Toner container handling

To loosen and mix the toner inside before use, with the label side down, thoroughly shakethe toner container (in the direction of the arrow) 5 times or more.

Caution: Do not attempt to disassemble or refill the toner container.

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Toner storage

The toner contained in the container is susceptible to temperature and humidity. To ensurethe high print quality, store the toner container in a place that satisfy the followingenvironmental conditions:

Temperature: –20 to 40°C (–4 to 104°F)Humidity: 15 to 90% RH

Note: If the toner container is removed from the printer’s developer unit, put it in aprotective bag and keep it in a dark place.

Caution: If the printer is shipped for return, etc., do not ship it with the toner containerinstalled. Otherwise, toner may leak and contamination may result in the printer.