Service Manual MFP - Copy CD 1018 Date: 17-03-2005
Service Manual MFP - Copy DC 2018 Date: 17-03-2005
CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. CAUTION Double-pole/neutral fusing.
Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol. WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.
1. Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current. ............................................................................................ • Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or electric shock.
2. Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly............... • Always follow the procedures for maintenance described in the service manual and other related brochures. ......................................................................................................................................... • Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
• Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself. ...................................................................................................... • Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item. ..............................................................................................
2GM CONTENTS 1-1 Specifications 1-1-1 Specifications ....................................................................................................................................... 1-1-2 Names of parts ..................................................................................................................................... (1) Main body .......................................................................................................................................
2GM (15) Fixing is poor. ............................................................................................................................... (16) Image center does not align with the original center. ................................................................... 1-5-4 Electrical problems ............................................................................................................................. (1) The machine does not operate when the power switch is turned on. ...........
2GM 1-6-13 1-6-14 1-6-15 1-6-16 1-6-17 Removing the exposure lamp ............................................................................................................ Removing the scanner mirror A ......................................................................................................... Removing the scanner motor ............................................................................................................. Removing the main charger unit ................................
2GM 2-3-6 CCD PWB .......................................................................................................................................... 2-3-22 2-3-7 Operation PWB .................................................................................................................................. 2-3-24 2-3-8 Scanner PWB .....................................................................................................................................
2GM 1-1-1 Specifications Type ............................................... Desktop Copying system .............................. Indirect electrostatic system Originals ......................................... Sheets of paper (Maximum original size: folio/81/2" × 14" [legal]) Platen: Sheets of paper, books, 3-dimensional objects (Maximum original size: folio/ 81/2" × 14" [legal]) Original feed system ...................... Contact glass: fixed Document processor (optional): sheet-through Copy paper ...
2GM Power source ................................. 120 V AC, 60 Hz, 7.8 A 220 - 240 V AC, 50/60 Hz, 4.0 A Power consumption ........................ 854 W Options ........................................... Paper feeder, document processor (DP), additional memory and fax system • Printing functions Printing speed ................................ A4/81/2" × 11": 18 prints/min. A5: 10 prints/min. 81/2" × 14": 15 prints/min. First print speed ............................. Apporox.
2GM 1-1-2 Names of parts (1) Main body ‹ fi fl › ⁄ ‡ ) ¤ 1 ( ( 3 & * 2 4 5 6 ^ 7 ! % $ # # @ 9 8 0 Figure 1-1-1 Names of parts 1 Original cover 2 Contact glass 3 Original size indicator plate 4 Operation panel 5 Front top cover 6 Front cover 7 Process unit 8 Toner container 9 Lock lever 0 Toner container release lever ! Main charger cleaner @ Cassette # Paper guide $ Paper stopper % Stopper extension lock ^ Face-down output tray & MP tray * Extension tray ( Paper width guides ) Power switch
2GM (2) Operation panel 1 2 4 5 6 3 * ( 8 9 7 ) ⁄ ¤ 0 ‹ ! @ › $ # fl fi ‡ — · ‚ Figure 1-1-2 1 Status/Job cancel key and indicator 2 Copy key and indicator 3 Send key and indicator 4 One-touch keys (1 to 8) 5 Scan color select key and indicator 6 Program key and indicator 7 Scan resolution key and indicator 8 Function key and indicator 9 Print indicator 0 Send/Receive indicator ! Memory indicator @ Error indicator # System menu/Counter key and indicator $ Log out key and indicator %
2GM 1-2-1 Drum Note the following when handling or storing the drum. • When removing the process unit, never expose the drum surface to strong direct light. • Keep the drum at an ambient temperature between 10 °C/50 °F and 32.5 °C/90.5 °F and at a relative humidity not higher than 80% RH. Avoid abrupt changes in temperature and humidity. • Avoid exposure to any substance which is harmful to or may affect the quality of the drum. • Do not touch the drum surface with any object.
2GM 1-3-1 Unpacking and installation (1) Installation procedure Start Unpack. Remove the tapes, pads and sheets. Remove the pin holding scanner unit. Install a toner container. Connect the power cord. Inisializing the machine. Load paper. Using the one-touch key sheet. Make test copies. End of installation.
2GM Unpack.
2GM CAUTIONS • Be sure to hold both the front and rear sides of the machine when carrying it, as shown in the illustration. • Be sure not to pull the cassette out when holding the front of the machine. • Be sure that the original cover is closed whenever transporting the machine. • Do not attempt to carry the machine by holding only the top portion. Doing so may result in you dropping the machine and thereby damaging the machine and/or its covers.
2GM Remove the tapes, pads and sheets. 1. Remove the sheet and the two tapes. Tapes Sheet Figure 1-3-3 2. Open the original cover.
2GM 3. Remove the eight tapes, the two pads and the sheet. Pad Pad Tapes Sheet Tapes Tape Tape Figure 1-3-5 4. Pull the cassette out of the machine. Cassette Figure 1-3-6 Cassette spacer 5. Remove the cassette spacer from inside the cassette.
2GM Remove the pin holding scanner unit. 1. Remove the yellow pin for scanner unit and the paper tag from the left side of the machine. Pin Paper tag Figure 1-3-8 Install a toner container. 1. Open the front top cover and front cover. Front top cover Front cover Figure 1-3-9 2. Store the pin for scanner unit on the inside of the front cover as shown in the illustration. * Be sure to save this pin as it is essential that it be used whenever the machine is moved.
2GM 3. Remove the process unit from the machine. CAUTIONS • Place the process unit on a clean, level surface. • Never expose the process unit to any sort of impact or shock. • The drum in the process unit is sensitive to light. Never expose the drum even to normal office lighting (500 lux) for more than five minutes. Process unit Figure 1-3-11 4. Remove the protective cardboard. Protective cardboard Figure 1-3-12 5. Move the lock lever until it is in its unlocked position (marked UNLOCK).
2GM 6. Shake the toner container horizontally back and forth five or six times so that the toner inside of it becomes evenly distributed. Toner container Figure 1-3-14 7. Remove the orange protective seal. Seal Figure 1-3-15 8. Align the knob on the left side of the container with the groove in the process unit and set the toner container into the process unit.
2GM 9. Hold the process unit stable and push on the areas marked PUSH HERE on the toner container until the container clicks into place. Toner container Figure 1-3-17 10. Push the lock lever back into its locked position. Lock lever Figure 1-3-18 11. Set the process unit into the machine by aligning the pins on both sides of the process unit with the guides inside the machine, and then slide the process unit all the way back into the machine until it stops.
2GM 12. Close the front cover. Front cover Figure 1-3-20 13. Close the front top cover.
2GM Connect the power cord. 1. Connect the power cord. Power cord Figure 1-3-22 Initializing the machine. 1. Turn the power switch to the machine ON ( | ). Power switch Figure 1-3-23 The machine will begin replenishing the toner. Wait until it has completed that operation. (15 minutes) Once the toner has been replenished and the machine is once again in a ready-to-use state, Ready to copy will appear on the message display and the Start indicator will light green.
2GM Load paper. 1. Pull the cassette out of the machine. Cassette Figure 1-3-25 2. Adjust the paper stopper in the rear portion of the cassette to fit the size of the paper being loaded there by pressing in on the release buttons and sliding the paper stopper to the corresponding paper size. NOTES • The paper sizes are marked on the bottom of the cassette. • The default factory setting is for A4/Letter size paper.
2GM 4) Press down on the stopper extension lock and slide the paper stopper towards the rear of the cassette to set the lock into place. The paper stopper is in position for Folio and Oficio II size paper. Paper stopper Stopper extension lock Figure 1-3-28 3. Adjust the paper width guides by pressing in on the release buttons and sliding the guides to fit the width of the paper being loaded in the cassette. NOTES • The paper sizes are marked on the bottom of the cassette.
2GM NOTES • Always adjust the paper stopper and paper width guides before loading paper into the cassette. Failure to do so may result in skewed paper feed and/or a paper jam. • Make sure that the paper is set securely against the paper stopper and the paper width guides. If there is any gap between the paper and the stopper or guides, readjust the paper stopper and/or the paper width guides, as appropriate.
2GM Using the one-touch key sheet. 1. Remove the one-touch key sheet from bottom side of the operation panel. One-touch key sheet Figure 1-3-33 2. Enter the information for the registered destinations onto the one-touch key sheet. (There are 4 spare one-touch key sheets included with this machine.) 3. Insert the sheet back between the one-touch keys from the bottom side of the operation panel.
2GM 1-3-2 Connecting the cables (1) Connecting the network cable To connect the machine to a network, use an network cable (10Base-T or 100Base-TX). Procedure 1. Turn the power switch located on the rear side of the machine off (O), and remove the power cord from the outlet. Power switch Figure 1-3-35 2. Connect the network cable to the network connector at the rear side of the machine. 3. Connect the other end of the network cable to network device (hub). 4. Make network settings.
2GM (2) Connecting the printer cable To connect the machine directly to your computer, use either a parallel cable or USB cable. Procedure 1. Turn the power switch located on the rear side of the machine off (O), remove the power cord from the outlet and turn the power off to computer. Power switch Figure 1-3-37 2. Connect the printer cable to the parallel interface connector or USB interface connector located at the rear side of the machine. 3.
2GM 1-3-3 Installing the document processor (option) Procedure 1. Remove all of the components to the document processor from the box. CAUTION Be sure to hold both sides of the document processor when carrying it, as shown in the illustration. Be particularly careful NOT to touch the guide film or the thin white surface indicated by the A in the illustration. A Document processor Figure 1-3-39 2. Turn the power switch located on the rear side of the machine off (O). Disconnect the power cord.
2GM 4. Attach the document processor to the machine. CAUTION Be sure that the connection cable does not get caught between the document processor and the machine when attaching the document processor to the machine. Connection cable Figure 1-3-42 5. Gently close the document processor. Document processor Figure 1-3-43 6. Attached the open end of the connection cable to the connector on the machine.
2GM CAUTION Be sure to tighten the pins securely when connecting the cable. Pins Figure 1-3-45 7.Connect the power cord and turn the power switch on ( | ). Warm up will begin. 1 will appear on the operation panel and the start indicator will light when the machine is in a ready state.
2GM 1-3-4 Installing the expanding memory (option) The main PWB of the machine is equipped with one socket for memory expansion. Expansion memory is available in the form of DIMM (Dual In-line Memory Module). CAUTION Take precautions that no foreign substances such as metal chips or liquid get inside the machine during the installation process. Operation of the machine during the presence of a foreign substance may lead to fire or electric shock. WARNING Turn the power switch off.
2GM 1-3-5 Installing the fax system (option) Turn the machine's power switch to OFF and unplug the machine from the power supply before installing the fax system. Precautions for handling the FAX assembly The FAX assembly is delivered in an antistatic airpadded bag. To prevent any damage, briefly touch a large metal object to ensure discharge of static electricity before removing the FAX assembly from the bag. Hold the FAX assembly by the metal plate on front as shown.
2GM 3. Connect the modular cord to the line jack. 120 V specifications: Connect the modular cord with the attached ferrite core to the machine. Line jack Figure 1-3-51 220-240 V specifications only 4. Attach the core to the power cord of the machine so that the stopper section is located near the power plug as shown in the illustration. Core Stopper section Figure 1-3-52 5. Plug the power cord into the machine. Turn the machine on.
2GM Initialization procedure after installation of fax system 1. Insert the machine power plug to the wall outlet and turn the power switch on. 2. Run maintenance item U601. 3. Enter a destination code using the numeric keys (refer to the destination code list) and then press the enter key. * Enter a destination code with three digits.
2GM 1-4-1 Maintenance mode The machine is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item Start Press the system menu/counter key. Select Service setting using the up/down cursor keys. While pressing the start key and the # key, press the enter key. Maintenance mode is entered. Select Maintenance mode using the up/down cursor keys. Press the enter key. Enter the maintenance item number using the up/down keys.
2GM (2) Maintenance modes General Item Maintenance No.
2GM (3) Contents of maintenance mode items Maintenance item No. U000 Outputting an own-status report Description Description Outputs lists of the current settings of the maintenance items, and paper jam and service call occurrences and event log report. Purpose To check the current setting of the maintenance items, or paper jam or service call occurrences.
2GM Maintenance item No. Description Item 1 Paper Jam Log Description #: Log number 1 to 16 jams are recorded. (If the number of jams exceeds 16, the oldest log is deleted.) Count.: Number of pages Total page counter at the time of jam Event: Log code Six types of two-digit hexadecimal numbers are displayed.
2GM Maintenance item No.
2GM Maintenance item No. U020 Initializing all data Description Description Initializes all the backup RAM on the engine PWB to return to the original settings. Purpose Used when replacing backup RAM on the engine PWB. After initialization, run U157 “Changing the developing drive time” and U411 “Adjusting the scanner automatically.” Method 1. Press the enter key. A selection item appears. 2. Select Execute using the up/down cursor keys. 3. Press the enter key. All data in the backup RAM is initialized.
2GM Maintenance item No. U063 Adjusting the shading position Description Description Changes the shading position. Purpose Used when white lines continue to appear longitudinally on the image after the shading plate is cleaned. This is due to flaws or stains inside the shading plate. To prevent this problem, the shading position should be changed so that shading is possible without being affected by the flaws or stains. Method Press the enter key. Setting 1.
2GM Maintenance item No. U074 Adjusting the DP input light luminosity Description Description Adjusts the luminosity of the exposure lamp for scanning originals from the DP. Purpose Used if the exposure amount differs significantly between when scanning an original on the contact glass and when scanning an original from the DP. Method Press the enter key. Setting 1. Change the setting using the left/right cursor keys.
2GM Maintenance item No. U089 Outputting a MIP-PG pattern Description Description Selects and outputs a MIP-PG pattern created in the machine. Purpose When performing respective image printing adjustments, used to check the machine status apart from that of the scanner with a non-scanned output MIP-PG pattern. Method 1. Press the enter key. A selection item appears. 2. Select the item to be output using the up/down cursor keys.
2GM Maintenance Description item No. U089 Method: 1dot PG output 1. Change the setting using the left/right cursor keys. 2. 3. 4. 5. Description Setting range Initial setting Number of 1dot pattern 1 to 16 1 Press the enter key. The value is set. Press the system menu/counter key. The machine enters the PG pattern output mode. Press the start key. A MIP-PG pattern is output. To return to the indication for setting, press the system menu/counter key.
2GM Maintenance item No. U144 Setting toner loading operation Description Description Sets toner loading operation. Purpose To run when drum filming (background blur in paper edge section) occurs. Method Press the enter key. Setting 1. Change the setting using the left/right cursor keys. Setting value Description 0 1 Toner not loaded Toner loaded Initial setting: 1 2. Press the enter key. The setting is set. Completion Press the back key. The indication for selecting a maintenance item No. appears.
2GM Maintenance item No. U161 Setting the fusing control temperature Description Description Changes the fusing control temperature. Purpose Normally no change is necessary. However, can be used to prevent curling or creasing of paper, or solve a fusing problem on thick paper. Method Press the enter key. A selection item appears. Setting 1. Select the item to be set using the up/down cursor keys. 2. Change the setting using the left/right cursor keys.
2GM Maintenance item No. U203 Operating DP separately Description Description Simulates the original conveying operation separately in the DP. Purpose To check the DP. Method 1. Press the enter key. A selection item appears. 2. Select the item to using the up/down cursor keys. Display Operation DP DP (Non P) With paper Without paper (continuous operation) 3. Press the start key. The operation starts. * When operation with paper is selected, if no original is set in the DP, this mode cannot be run.
2GM Maintenance Description item No. U403 Adjusting margins for scanning an original on the contact glass Adjustment See page 1-6-48. U404 Adjusting margins for scanning an original from the DP Adjustment See page 1-6-53.
2GM Maintenance item No. U425 Setting the target Description Description When running U411 “Adjusting the scanner automatically,” input the color data value of the specified patch written in the LAB value table on the back side of the original for adjustment (P/N: 2A668011). Note that incorrect value input results in improper automatic adjustment. Purpose To run before running U411 “Adjusting the scanner automatically.” Method Press the enter key. A selection item appears. Setting 1.
2GM Maintenance Description item No. U901 Checking/clearing print counts by paper feed locations Description Displays or clears print counts by paper feed locations. Purpose To check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts. Method 1. Press the enter key. The print count will be displayed for each paper feed location. Display Paper source Bypass Cassette 1 Cassette 2 All Clear MP tray Cassette Optional cassette Clearing all counts 2.
2GM Maintenance item No. U927 Clearing accounting counter Description Description Clears the total count, scanner count and machine life count. The counts, however, can be cleared only one time. If either of the total count, canner count or machine life count exceeds 1,000, this mode cannot be run. Purpose To start the counters with value 0 when installing the machine. Method 1. Press the enter key. A selection item appears. 2. Select Execute using the up/down cursor keys.
2GM 1-4-2 System settings In addition to a maintenance function, the machine is equipped with a system settings which can be operated by users (mainly by the machine administrator). In this machine system settings, default settings can be changed. (1) Executing a system setting item • Executing a system setting item Start Press the System Menu/ Counter key. Select an setting item using the up/down cursor keys. Press the enter key.
2GM (2) System settings Adjusting the contrast of the message display 1. Select Adjust and press the enter key. 2. Select LCD Contrast and press the enter key. 3. Select the desired contrast and press the enter key. Selecting the message language 1. Select Common Setting and press the enter key. 2. Select Language and press the enter key. 3. Select the language to be used in the message display and press the enter key. Setting the default operation mode 1. Select Common Setting and press the enter key. 2.
2GM Setting of the reset time 1. Select Date/Timer Set. and press the enter key. 2. Select Reset Timer and press the enter key. 3. Register the current reset timer and press the enter key. Setting defalt original size 1. Select Common Setting and press the enter key. 2. Select Orig./Paper Set. and press the enter key. 3. Select Def. Org. Size and press the enter key. 4. Select the desired size and press the enter key. Setting the low power time 1. Select Date/Timer Set. and press the enter key. 2.
2GM 1-4-3 Service settings The machine is equipped with a service settings which can be operated by service person. (1) Executing a service setting item ¥ Executing a system setting item Start Press the System Menu/ Counter key. Select Service Setting using the up/down cursor keys. Press the enter key. Select an setting item using the up/down cursor keys. Press the enter key. Execute the system setting item Select the Exit using the right select key.
2GM (2) Contents of service setting items Service items Ser. Status Page Description Printing a status page for service purpose Description Prints a status page for service purpose. The status page includes various printing settings and service cumulatives. Procedure 1.Select [Ser. Status Page] using up/down cursor keys and press the enter key. 2.Select [Yes] using the left select key. Service status pages (2 pages) are output.
2GM Service items Description Items 1 Destination information 2 Area information 3 4 Printable area Offset for each paper source 5 6 Margin Operation panel key lock status 7 USB information 8 Engine information (Hexadecimal) 9 Maintenance information (Hexadecimal) Description 1: For Europe/Australia/New Zealand 2: For America/Canada/South America 3: For Europe/Middle East/Asia 17/18/19/21: OEM 1: Europe 2: North America 3: Asia (except Chine) 4: Japan 5: Australia 6: China Legth/Width MP tra
2GM Service items Description Items 9 1-4-24 Description Maintenance information (Hexadecimal) No.
2GM Service items Description Items 9 Description Maintenance information (Hexadecimal) No.
2GM Service items NW Status Page Description Printing a status page for network Description Prints a status page that lists information on the network settings. Procedure 1. Select [NW Status Page] using up/down cursor keys and press the enter key. 2. Select [Yes] using the left select key. Network status pages (3 pages) are output.
2GM Service items New Developer Description Toner installation mode Description Executes toner install operation when replacing the toner. Procedure 1. Select [New Developer] using up/down cursor keys and press the enter key. 2. Select [Yes] using the left select key. 3. [Completed] is displayed and set the toner install mode. 4. Turning the power switch off and back on. [Adding Toner] is displayed at the time of the next power switch on, and toner installation operation is executed..
2GM Service items FAX Country Code Description Setting the FAX destination code Note: This setting is only available when the optional fax system is installed in the machine. Description To set the fax destination code. Basically, the setting need not be changed. Procedure 1. Select [FAX Country Code] using up/down cursor keys and press the enter key. 2. Enter the country code using the numeric keys. Remote Diag.
2GM 1-5-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the machine immediately stops copying or printing and displays the jam location on the operation panel. To remove paper jammed in the machine, open the face-up output tray, front top cover, front cover or pull the cassette out. To remove original jammed in the optional DP, open the DP original cover.
2GM (2) Paper misfeed detection conditions ; ; Registration sensor Exit sensor Figure 1-5-2 1-5-2
2GM Section Jam code Description Conditions 03 No paper feed When the power switch is turned on or front top cover is closed, the machine detects activation of the registration sensor or the exit sensor. 04 Cover open JAM A cover open state is detected during copying or printing. 05 Secondary paper feed timeout When the machine waits for secondary paper feed, 15 s or more have elapsed.
2GM (3) Paper misfeeds • Main body Problem Causes/check procedures (1) A paper jam in the conveying, fusing or exit section is indicated as soon as the power switch is turned on. Jam code 03 A piece of paper torn from paper is caught around registration sensor or exit sensor. Check visually and remove it, if any. Defective registration sensor. Check if YC8-7 on the engine PWB remains low when the registration sensor is turned on and off. If it does, replace the registration sensor.
2GM Problem (5) A paper jam in the paper feed section is indicated during copying or printing (multiple sheets in the MP tray). Jam code 20 (6) A paper jam in the paper feed section is indicated during copying or printing (multiple sheets in the cassette). Jam code 21 (7) A paper jam in the paper feed section is indicated during copying or printing (multiple sheets in the optional cassette).
2GM Problem Causes/check procedures (9) A paper jam in the exit section is indicated during copying or printing (jam in the exit section). Jam code 50 Defective registration sensor. Check if YC8-7 on the engine PWB remains low when the registration sensor is turned on and off. If it does, replace the registration sensor. Defective exit sensor. Check if YC7-7 on the engine PWB remains low when the exit sensor is turned on and off. If it does, replace the exit sensor.
2GM • DP Problem Causes/check procedures Corrective measures (1) An original jams when the power switch is turned on. A piece of paper torn from an original is caught around the DP timing switch. Remove any found. Defective DP timing switch. Check if YC10-6 on the engine PWB remains low when the DP timing switch is turned on and off. If it does, replace the DP timing switch. (2) An original jams in the DP is indicated during copying (no original feed). Jam code 70 Defective DP timing switch.
2GM 1-5-2 Self-diagnosis (1) Self-diagnostic function This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled. C and a number between 0030 and 7990 altenates, indicating the nature of the problem. After removing the problem, the self-diagnostic function can be reset by turning interlock switch off and back on.
2GM Code Contents Remarks Causes Check procedures/corrective measures Poor contact in the connector terminals. Check the connection of connectors YC13 on the main PWB and YC3 on the operation PWB, and the continuity across the connector terminals. Repair or replace if necessary. Defective main PWB or operation PWB. Replace the main PWB or operation PWB and check for correct operation.
2GM Code Contents C2000 Main motor problem • LOCK ALM signal remains high for 1 s, 1 s after the main motor has turned on. C3100 C3200 1-5-10 Scanner carriage problem • The home position is not correct when the power is turned on or copying the document placed on the contact glass. Exposure lamp problem • In indicator check before starting copying, the average value in scanning of the shading plate with the CCD is 128 or more.
2GM Code C4000 C4010 C6000 C6020 Contents Polygon motor synchronization problem • The polygon motor does not reach the stable speed within 15 s of the START signal turning on. Polygon motor steady-state problem • The polygon motor rotation is not stable for 5 s after the polygon motor rotation has been stabilized. Broken fusing heater wire • In fusing warm-up, the time to reach 50 °C/122 °F exceeds 13.
2GM Code C6050 C6400 C7800 C7810 1-5-12 Contents Abnormally low fusing unit thermistor temperature • The fusing temperature remains below 90°C/194°F for 1 s. Zero-crossing signal problem • The engine PWB does not detect the zero-crossing signal for the time specified below. At power-on: 3 s Others: 5 s Broken external temperature thermistor • The input voltage is 0.5 V or less. Short-circuited external temperature thermistor • The input voltage is 4.5 V or more.
2GM Code Contents Remarks Causes Check procedures/corrective measures C7980 Waste toner reservoir overflow problem (when the total number of copies is less than 100 thousand sheets) • After E31 is displayed, 1,000 sheets are copied. Or waste toner exceeds 5 g. Defective waste toner sensor or engine PWB. Shake the process unit from side to side and turn the power switch off and then on. If the problem cannot be solved, replace the process unit.
2GM Remarks Code Contents CF5-- Controller system error Defective main PWB. If this error occurs again even after the power switch is turned off and then on again, contact the Service Administrative Division. CF6-- Controller system error Defective main PWB. If this error occurs again even after the power switch is turned off and then on again, contact the Service Administrative Division. CF7-- Controller system error Defective main PWB.
2GM 1-5-3 Image formation problems (1) No image appears (entirely white). (2) No image appears (entirely black). (3) Image is too light. (4) Background is visible. See page 1-5-16 See page 1-5-16 See page 1-5-17 See page 1-5-17 (5) A white line appears longitudinally. (6) A black line appears longitudinally. (7) A black line appears laterally. (8) One side of the print image is darker than the other.
2GM (1) No image appears (entirely white). Causes 1. No transfer charging. Causes Check procedures/corrective measures 1. No transfer charging. A. The connector terminals of the high voltage PWB make poor contact. Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable. B. Defective engine PWB. Replace the engine PWB and check for correct operation. C. Defective high voltage PWB. Replace the high voltage PWB and check for correct operation.
2GM (3) Image is too light. Causes 1. Insufficient toner. 2. Deteriorated developer. 3. Dirty or deteriorated drum. Causes Check procedures/corrective measures 1. Insufficient toner. If the add toner indicator lights, replace the toner container. 2. Deteriorated developer. Replace the process unit. 3. Dirty or deteriorated drum. Replace the process unit. (4) Background is visible. Causes 1. Deteriorated developer. Causes Check procedures/corrective measures 1. Deteriorated developer.
2GM (6) A black line appears longitudinally. Causes 1. Dirty contact glass. 2. Dirty or flawed drum. 3. Deformed or worn cleaning blade. 4. Dirty scanner mirror. Causes Check procedures/corrective measures 1. Dirty contact glass. Clean the contact glass. 2. Dirty or flawed drum. Replace the process unit. 3. Deformed or worn cleaning blade. Replace the process unit. 4. Dirty scanner mirror. Clean the scanner mirror. (7) A black line appears laterally. Causes 1. Flawed drum. 2.
2GM (9) Black dots appear on the image. Causes 1. Dirty or flawed drum. 2. Dirty contact glass. 3. Deformed or worn cleaning blade. Causes Check procedures/corrective measures 1. Dirty or flawed drum. Replace the process unit. 2. Dirty contact glass. Clean the contact glass. 3. Deformed or worn cleaning blade. Replace the process unit. (10) Image is blurred. Causes 1. Deformed press roller. 2. Paper conveying section drive problem. Causes Check procedures/corrective measures 1.
2GM (12) Paper creases. Causes 1. Paper curled. 2. Paper damp. Causes Check procedures/corrective measures 1. Paper curled. Check the paper storage conditions. 2. Paper damp. Check the paper storage conditions. Causes 1. Defective cleaning blade. (13) Offset occurs. Causes Check procedures/corrective measures 1. Defective cleaning blade. (14) Image is partly missing. Causes Replace the process unit. Causes 1. Paper damp. 2. Paper creased. 3. Flawed drum.
2GM (15) Fusing is poor. Causes 1. Wrong paper. 2. Flawed press roller. Causes Check procedures/corrective measures 1. Wrong paper. Check if the paper meets specifications. 2. Flawed press roller. Replace the press roller (see page 1-6-26). (16) Image center does not Causes align with the original 1. Misadjusted center line of image printing. center. 2. Misadjusted scanner center line. 3. Original placed incorrectly. Causes Check procedures/corrective measures 1.
2GM 1-5-4 Electrical problems Problem Causes Check procedures/corrective measures No electricity at the power outlet. Measure the input voltage. The power cord is not plugged in properly. Check the contact between the power plug and the outlet. The front cover is not closed completely. Check the front cover. Broken power cord. Check for continuity. If none, replace the cord. Defective power switch. Check for continuity across the contacts. If none, replace the power switch.
2GM Problem Causes Check procedures/corrective measures Broken MP feed clutch coil. Check for continuity across the coil. If none, replace the MP feed clutch. Poor contact in the MP feed clutch connector terminals. Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable. Defective engine PWB. Check if YC5-2 on the engine PWB goes low when the MP feed clutch is turned on. If not, replace the engine PWB. Broken registration clutch coil.
2GM Problem Causes (13) Main charging is not performed. Broken main charger wire. Check procedures/corrective measures See page 1-5-16. Leaking main charger housing. Poor contact in the high voltage PWB connector terminals. Defective engine PWB. Defective high voltage PWB. (14) Transfer charging is not performed. Poor contact in the high voltage PWB connector terminals. See page 1-5-16. Defective engine PWB. Defective high voltage PWB.
2GM 1-5-5 Mechanical problems Problem (1) No primary paper feed. Causes/check procedures Corrective measures Check if the surfaces of the feed roller and MP feed roller are dirty with paper powder. Clean with isopropyl alcohol. Check if the feed roller and MP feed roller are deformed. Check visually and replace any deformed rollers (see pages 1-6-5, 6). Electrical problem with the feed clutch and MP feed clutch. See pages 1-5-22, 23.
2GM 1-6-1 Precautions for assembly and disassembly (1) Precautions • Be sure to turn the power switch off and disconnect the power plug before starting disassembly. • When handling PWBs, do not touch connectors with bare hands or damage the board. • Do not touch any PWB containing ICs with bare hands or any object prone to static charge. • Use only the specified parts to replace the fuser unit thermostat. Never substitute electric wires, as the machine may be seriously damaged.
2GM 1-6-2 Removing the process unit 1. Open the front top cover. 2. Open the front cover. 3. Lift the process unit together with the toner container out of the machine. Front top cover Front cover Process unit Figure 1-6-1 Removing the process unit CAUTIONS • After removing the process unit, seal it in the protective bag and place it on flat surface. Do not place the process unit in a dusty area. • Do not give impact to the process unit. • Do not place floppy disks near the process unit.
2GM 1-6-3 Removing the principal outer covers (1) Removing the front top cover/face-down output tray 1. Remove the screw and then remove the memory cover. 2. Remove the screw and then remove the rear cover. Screw Rear cover Memory cover Screw Figure 1-6-2 Removing the memory cover and rear cover 3. While unlatching the two latches and then remove the front top cover/face-down output tray.
2GM (2) Removing the right cover 1. Remove the front top cover/face-down output tray (see page1-6-3). 2. Remove the memory cover (see page 1-6-3). 3. Unlatch the snaps and hook, remove the right cover. Right cover :Snap/Hook (inside cover) Right cover Figure 1-6-4 Removing the right cover (3) Removing the left cover 1. Remove the front top cover/face-down output tray (see page1-6-3). 2. Unlatch the snaps and hooks, remove the left cover.
2GM 1-6-4 Removing the feed roller CAUTION When refit the feed roller, fit the D-cut shaft into the D-shape hole of the feed roller. 1. Remove the cassette and the process unit (see page 1-6-2). 2. Stand the machine the front side up. 3. Move the feed roller in the direction A, and remove the feed roller.
2GM 1-6-5 Removing the MP feed roller 1. 2. 3. 4. 5. Remove the engine PWB (see page 1-6-9). Remove the screw. Remove the grounding plate. Remove the stop ring . Remove the MP feed clutch.
2GM 6. 7. 8. 9. Remove the screw. Remove the toner sensor and spring. Remove two screws. While pressing the latch by using the driver and then remove the MP feed unit. Toner sensor Screw Screw Spring Screw Latch MP feed unit Figure 1-6-8 Removing the MP feed unit 10. Remove the stop ring and then remove the MP feed roller.
2GM 1-6-6 Removing the transfer roller 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 (white spots, etc.). When refitting the bushes and springs, make sure to refit the black colored bush and spring on the left side. Also, observe the correct direction to which the bush is fit in reference to the paper passing direction. 1. Remove the process unit (see page 1-6-2). 2.
2GM 1-6-7 Removing the primary circuit PWBs (1) Removing the engine PWB 1. Remove the right cover (see page 1-6-4). 2. Remove all (twelve) connectors from the engine PWB. 3. Remove three screws. 4. Remove the engine PWB. * When replacing the PWB with a new PWB, remove the EEPROM from the old PWB and mount it to the new PWB.
2GM (2) Removing the main PWB 1. Remove the right cover (see page 1-6-4). 2. Remove the connector. 3. Remove the screw and then remove the speaker. Connector Speaker Screw Figure 1-6-12 Removing the speaker 4. Remove three connectors. 5. Remove the flexible flat cable. 6. Remove seven screws and then remove the main controller shield (with main PWB).
2GM 7. Remove two screws at the back of the main PWB. * When replacing the PWB with a new PWB, remove the EEPROM from the old PWB and mount it to the new PWB.
2GM (3) Removing the power supply PWB and high voltage PWB 1. Remove the process unit (see page 1-6-2). 2. Remove the left cover (see page 1-6-4). 3. Remove three connectors from the power supply PWB. 4. Remove eight screws. 5. Remove the power supply PWB and high voltage PWB. (Note: The high voltage PWB is directly connected to the bias PWB.) 6. Separate the high voltage PWB from the power supply PWB.
2GM (4) Removing the bias PWB 1. Remove the cassette and process unit (see page 1-6-2). 2. Remove the left cover (see page 1-6-4). 3. Remove the power supply PWB and high voltage PWB (see page 1-6-12). 4. Stand the machine with the front side up. 5. Remove the connector from the bias PWB. 6. Remove five screws. 7. Remove the bottom cover. 8. Remove two connectors from the bias PWB. 9. Remove the bias PWB.
2GM 1-6-8 Removing the main motor and drive unit 1. 2. 3. 4. 5. Remove the cassette and process unit (see page 1-6-2). Remove the right cover (see page 1-6-4). Remove three connectors from the main motor. Remove four screws. Remove main motor.
2GM 6. 7. 8. 9. Remove the engine PWB (see page 1-6-9). Remove wires from wire saddles on the cord cover. Remove the screw. Remove the cord cover.
2GM 10. Remove the main PWB (see page 1-6-10). 11. Remove the screw and then remove the grounding plate. 12. Remove the screw and then remove the feed clutch. 13. Remove three stop rings. 14. Remove MP feed clutch (gear), feed clutch (gear), and registration clutch (gear).
2GM 15. Remove four screws. 16. Remove the drive unit.
2GM 1-6-9 Removing and splitting the fuser unit WARNING • The fuser unit is hot after the machine was running. Wait until it cools down. CAUTION • When refitting the fuser unit, make sure the fuser unit gear and the machine’s drive gear are properly meshed with each other. For this, rotate the main motor several turns before fusing screws. 1. 2. 3. 4. 5. Remove the rear cover (see page 1-6-3). Remove the right and left cover (see page 1-6-4). Remove two connectors. Remove two screws.
2GM 6. Remove two screws. 7. Open and split the fuser unit.
2GM (1) Removing the separation claws WARNING The separation claws are extremely hot immediately after the copier was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (see page 1-6-18). 2. Loosen the stopper screws. 3. Hold the separation claw upright, and remove the separation claw and separation claw springs.
2GM (2) Removing the heater lamp WARNING • The heater lamp is extremely hot immediately after the machine was running. • Allow substantial period of time until it cools down. Also, the heater lamp is fragile: Handle it with great care. CAUTION • 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 lamp’s outer surface can prevent proper fusing of toner on paper.
2GM (3) Removing the heat roller WARNING • The heat roller is extremely hot immediately after the machine was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (see page 1-6-18). 2. Remove the heater lamp (see page 1-6-22). 3. Press the lamp A holder away from the heat roller. Pull up both heat R bush and heat L bush at the same time.
2GM 4. Remove the heat gear Z33, heat R bush, and heat L bush from the heat roller.
2GM (4) Removing the thermistor 1. Remove and split the fuser unit (see page 1-6-18). 2. Remove the heater lamp (see page 1-6-21). 3. Remove the heat roller (see page 1-6-22). 4. Remove the screw. 5. Remove the thermistor.
2GM (5) Removing the thermal cutout CAUTION • Do not bend the terminals of the thermal cutout. 1. 2. 3. 4. 5. Remove and split the fuser unit (see page 1-6-18). Remove the heater lamp (see page 1-6-21). Remove the heat roller (see page 1-6-22). Remove two screws. Remove the thermal cutout.
2GM (6) Removing the press roller WARNING • The press roller is extremely hot immediately after the machine was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (see page 1-6-18). 2. Remove the press roller from the fuser unit.
2GM 1-6-10 Removing the scanner unit 1. Remove the right and left cover (see page 16-4). 2. Remove the speaker (see page 1-6-10). 3. Remove five connectors and two flexible flat cables from the scanner PWB. 4. Remove five screws and then remove the scanner PWB.
2GM 4. Remove two screws. 5. Slide the scanner unit and then remove the scanner unit.
2GM 1-6-11 Removing the laser scanner unit and the eraser lamp 1. Remove the scanner unit (see page 1-6-27). 2. Remove two screws and then remove grounding plate. 3. Remove each two screws and then remove the right and left scanner stays. Screws Screws Left scanner stay Grounding plates Right scanner stay Screws Figure 1-6-32 Removing the right and left stays Screws 4. Remove four connectors. 5. Remove six screws and then remove the LSU shield.
2GM 6. Remove three screws. 7. Remove two connectors from the laser scanner unit. 8. Remove the laser scanner unit. * When refitting the laser scanner unit, tighten a screw in order of 3 from 1.
2GM 9. Remove the eraser lamp.
2GM 1-6-12 Removing the ISU unit 1. Unhook two hooks by using screw driver through the holes and then remove the operation unit. Hole Operation unit Hook Hook Hole Figure 1-6-36 Removing the operation unit 2. Remove two screws and then remove the original holder cover.
2GM 3. Remove two screws and then remove two grounding plates. 4. Remove the stopper ring and then detach the scanner shaft. * Detach the shaft taking care to tilt it as little as possible. Stopper ring Screw Grounding plates Scanner shaft Screw Figure 1-6-38 Detaching the scanner shaft 5. Remove the flexible flat cable from the ISU PWB’s connector. 6. Remove the scanner belt from the belt hook of scanner unit. 7. Remove the ISU unit from the scanner shaft.
2GM 1-6-13 Removing the exposure lamp 1. Remove the ISU unit (see page 1-6-32). 2. Remove two connectors from the inverter PWB. 3. Remove the screw and then remove the inverter PWB. ISU unit Inverter PWB Connectors Screw Figure 1-6-40 Removing the inverter PWB 4. While unhooking the hook and then slide the exposure lamp mount.
2GM 5. Remove the exposure lamp and cables from the exposure lamp mount. • Do not touch the glass surfaces of the exposure lamp with bare hands.
2GM 1-6-14 Removing the scanner mirror A 1. Remove the ISU unit (see page 1-6-32). 2. Remove the exposure lamp (see page 1-634). 3. Unhook two mirror A holders and then remove the scanner mirror A.
2GM 1-6-15 Removing the scanner motor 1. Remove the original holder cover (see page 1-6-32). 2. Remove the right cover (see page 1-6-4). 3. Remove the speaker (see page 1-6-10). 4. Remove the connector from the scanner PWB. Scanner PWB Connector Figure 1-6-44 Removing the scanner motor (1) Screw 5. Remove two screws and then remove two grounding plates. Screw Grounding plates Figure 1-6-45 Removing the scanner motor (2) 6. Loosen two screws and then release the tension of a scanner belt. 7.
2GM 8. Remove three screws and then remove the grounding plate. Screws Grounding plate Screw Figure 1-6-47 Removing the scanner motor (4) 9. Remove the stopper ring and then detach the scanner shaft. * Detach the shaft taking care to tilt it as little as possible.
2GM 10.Remove the cable from the cable clamps. 11. Remove four screws and then remove the scanner motor mount with scanner motor. Screws Screw Scanner motor mount Cable Cable clamps Figure 1-6-49 Removing the scanner motor (6) 12. Remove the screw and then remove the scanner motor.
2GM 1-6-16 Removing the main charger unit 1. Remove the process unit from the machine (see page 1-6-2). 2. Unlatch three snaps, and remove the main charger cap. 3. Draw the main charger unit in the direction of arrow A, then pull it out in the direction of arrow B. Main charger unit B A Snap C Terminal Snaps Main charger cap Main charger unit Figure 1-6-51 Removing the main charger unit CAUTION • When refitting the main charger unit, hold terminal down C, then push frontwards.
2GM 1-6-17 Adjustment the maintenance mode (1) Adjusting the leading edge registration of image printing Make the following adjustment if there is a regular error between the leading edges of the copy image and original. U034 U066 (P. 1-6-46) U071 (P. 1-6-50) Caution: Check the copy image after the adjustment. If the image is still incorrect, perform the above adjustments in maintenance mode. Procedure Leading edge registration (10 mm) Start Enter maintenance mode.
2GM (2) Adjusting the center line of image printing Make the following adjustment if there is a regular error between the center lines of the copy image and original when paper is fed from the cassette. U034 U067 (P. 1-6-47) U072 (P. 1-6-52) Caution: Check the copy image after the adjustment. If the image is still incorrect, perform the above adjustments in maintenance mode. Procedure Center line of printing Start Enter maintenance mode. Correct image Enter 034 using up/down cursor keys.
2GM (3) Adjusting the amount of slack in the paper Make the following adjustment if the leading edge of the copy image is missing or varies randomly, or if the copy paper is Z-folded. Procedure Start Enter maintenance mode. Enter 051 using up/down cursor keys. Correct image Press the enter key. Copy example 1 Copy example 2 Figure 1-6-54 Select the item to be adjusted using up/down cursor keys. Regist. Cas.1: Drawer Regist. MPT: MP tray Regist. Cas.2: Optional drawer Press the enter key.
2GM (4) Adjusting magnification of the scanner in the main scanning direction Perform the following adjustment if the magnification in the main scanning direction is not correct. U065 (main scanning direction) U065 (auxiliary scanning direction) (P. 1-6-45) U067 (P. 1-6-47) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.
2GM (5) Adjusting magnification of the scanner in the auxiliary scanning direction Perform the following adjustment if the magnification in the auxiliary scanning direction is not correct. U065 (main scanning direction) (P. 1-6-44) U065 (auxiliary scanning direction) U070 (P. 1-6-49) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Start Enter maintenance mode. Enter 065 using up/down cursor keys.
2GM (6) Adjusting the scanner leading edge registration Perform the following adjustment if there is regular error between the leading edges of the copy image and original. U034 (P. 1-6-41) U071 (P. 1-6-50) U066 Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Leading edge registration Start Enter maintenance mode. Enter 066 using up/down cursor keys. Original Copy example 1 Figure 1-6-57 Press the enter key.
2GM (7) Adjusting the scanner center line Perform the following adjustment if there is a regular error between the center lines of the copy image and original. U034 (P. 1-6-42) U072 (P. 1-6-52) U067 Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner center line Start Enter maintenance mode. Original Enter 067 using up/down cursor keys. Copy example 1 Copy example 2 Figure 1-6-58 Press the enter key.
2GM (8) Adjusting the margins for scanning an original on the contact glass Perform the following adjustment if the margins are not correct. U404 (P. 1-6-53) U403 Caution: Check the copy image after the adjustment. If the image is still incorrect, perform the above adjustments in maintenance mode. Procedure Scanner leading edge margin (3 ± 2.5 mm) Start Ejection direction (reference) Scanner left margin (3 ± 2.5 mm) Enter maintenance mode. Scanner right margin (3 ± 2.
2GM (9) Adjusting the DP magnification Adjust magnification in the auxiliary scanning direction if magnification is incorrect when the DP is used. U065 (P. 1-6-44) U070 Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Start Enter maintenance mode. Enter 070 using up/down cursor keys. Original Copy example 1 Copy example 2 Figure 1-6-60 Press the enter key. Press the system menu/counter key. Press the enter key.
2GM (10) Adjusting the DP leading edge registration Perform the following adjustment if there is a regular error between the leading edge of the original and the copy image. U034 (P. 1-6-41) U066 (P. 1-6-46) U071 Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Leading edge registration Start Enter maintenance mode. Enter 071 using up/down cursor keys. Copy example 1 Original Press the enter key.
2GM (11) Adjusting the DP trailing edge registration Perform the following adjustment if the original scanning end position is not correct when the DP is used. Caution: If the copy image looks like copy example 2, clean the DP original scanning section. Procedure Start Enter maintenance mode. Enter 071 using up/down cursor keys. Original Copy example 1 Press the enter key. Copy example 2 Figure 1-6-62 Select Trail Edge Adj. (DP trailing edge registration) using up/down cursor keys.
2GM (12) Adjusting the DP center line Perform the following adjustment if there is a regular error between the centers of the original and the copy image. U034 (P. 1-6-42) U067 (P. 1-6-47) U072 Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Reference Start Enter maintenance mode. Original Copy example 1 Enter 072 using up/down cursor keys. Figure 1-6-63 Press the enter key. Press the enter key.
2GM (13) Adjusting the margins for scanning the original from the DP Perform the following adjustment if margins are not correct. U403 (P. 1-6-48) U404 Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure DP leading edge margin (3 ± 2.5 mm) Start Ejection direction (reference) Enter maintenance mode. DP left margin (3 ± 2.5 mm) DP right margin (3 ± 2.5 mm) Enter 404 using up/down cursor keys. Press the enter key.
2GM 1-7-1 Upgrading the firmware on the main PWB • When using Compact Flash Firmware upgrading requires the following tools: Compact Flash (Products manufactured by SANDISK are recommended.) NOTE • When writing data from a computer to a new Compact Flash, be sure to format it from the computer in advance. • Since the data is supplied with a compressed file, extract the data and then write it to the Compact Flash. • Do not write data other than the files below to the Compact Flash.
2GM • When replacing DIMM Firmware upgrading requires the following tools: DIMM (P/N 2GM01210/302GM01210) Procedure 1. Turn the power switch off and disconnect the power plug. 2. Remove the pin and then remove the memory cover. 3. Remove the DIMM from the DIMM slot on the main PWB. 4. Insert the new DIMM into the DIMM slot on the main PWB. * Insert the DIMM securely all the way into the slot. If the power switch is turned on when the DIMM is not properly inserted, the main PWB may be damaged. 5.
2GM 2-1-1 Paper feeding system The paper feeding system picks up paper from the cassette, MP tray, or if installed, the optional cassette, feeds it in the machine, and delivers in the output tray. Paper is fed at the precise timing in synchronization with data processing. The paper feeding system finally delivers the printed page to either the face-down or face-up tray as manipulated by the user.
2GM (1) Paper feed control The following diagram shows interconnectivity of the feeding system components including the sensors and rollers. The engine PWB provides the signals in conjunction with the electrophotography process that is driven by the main PWB.
2GM (2) Paper feeding mechanism Driving power train A For process unit; drum (From main unit) B For process unit; toner container, developing roller etc.
2GM 2-1-2 Original scanning system The scanner unit consists of the image scanning unit (ISU) for main-direction scanning, and drive part for traveling the ISU unit to sub-direction.
2GM Scanner unit Original ISU unit Scanner PWB Exposure lamp CCD image sensor Inverter PWB CCD PWB LAMP YC2-2 Scanner home position sensor SW SWN CCDCLKN CCDCLK RSN CPN SH CCDG(O) CCDB(E) CCDR YC1-4 YC1-5 YC1-14 YC1-12 YC1-10 YC1-8 YC1-6 YC1-18 YC1-20 YC1-22 YC1-29, 30 Main PWB Engine PWB YC7-2, 1 YC3-5 YC3-4 YC3-3 YC6-2 YC6-3 YC6-4 YC6-6 YC6-8 YC6-10 YC6-12 YC6-16 YC6-18 YC6-20 LAMP YC11-9 LAMPHI YC11-10 LAMPLOW YC11-11 Scanner motor CN11-1— CN11-4 HPSWN CN10-4 Figure 2-1-5 Scanner co
2GM (1) ISU unit The ISU unit consists of an exposure lamp, three mirrors, an ISU lens, a CCD PWB, and so on. Also an inverter PWB for driving the exposure lamp and a scanner home position sensor for detecting the home position of the ISU unit are incorporated. The original on the contact glass is exposed to the light of the exposure lamp that is reflected by the reflector. The image is input through reflection by the three mirrors and through the ISU lens to the CCD image sensor on the CCD PWB.
2GM 2-1-3 Electrophotographic system Electrophotography is the technology used in laser printing which transfer data representing texts 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. This section provides technical details on the machine’s electrophotography system. (1) Electrophotographic cycle The electrophotography system of the machine performs a cyclic action made of six steps as follows.
2GM (1-1) Process unit mechanism 3 2 Driving power train ) ( ⁄ A For drum (From main unit) B For toner container, developing roller, etc.
2GM (2) Main charging (2-1) Photo conductive drum The durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base. The OPC tend to reduce its own electrical conductance when exposed to light. After a cyclic process of charging, exposure, and development, the electrostatic image is constituted over the OPC layer. Since the OPC is materialized by resin, it is susceptible to damage caused by sharp edges such as a screwdriver, etc., resulting in a print quality problem.
2GM (2-2) Charging the drum The following shows a simplified diagram of the electrophotographic components in relation to the engine system. Charging the drum is done by the main charger unit.
2GM (3) Exposure The charged surface of the drum is then scanned by the laser beam from the laser scanner unit. Laser scanner unit Drum Figure 2-1-11 Exposure The laser beam (780 nm wavelength) beam is dispersed as the polygon motor (polygon mirrors) revolves to reflect the laser beam over the drum. Various lenses and mirror are housed in the scanner unit, adjust the diameter of the laser beam, and focalize it at the drum surface.
2GM (3-1) Laser scanner unit 3 2 4 5 1 6 Diversion mirror Figure 2-1-12 Laser scanner unit 1 Laser diode ................................................... Emits diffused, visible laser. 2 Cylindrical lens .............................................. Compensates the vertical angle at which the laser beam hits a polygon mirror segment. 3 Polygon mirror (motor) ..................................
2GM (3-2) Drum surface potential The laser beam is continually switched on and off depending on the print data. It is on for a black (exposed) dot and off for a white (blank) dot. Since the drum surface is evenly charged, whenever it is illuminated by the laser beam, the electrical resistance of the photoconductor is reduced and the potential on the photoconductor is also lowered. Resulted on the drum surface is an electrostatic image which represents the data to print.
2GM (4) Development The latent image constituted on the drum is developed into a visible image. The developing roller contains a 3-pole (S-NS) magnet core and an aluminum cylinder rotating around the magnet core. Toner attracts to the developing roller since it is powdery ink made of black resin bound to iron particles. Doctor blade, magnetized by magnet, is positioned approximately 0.3 mm above the developing roller to constitute a smooth layer of toner in accordance with the roller revolution.
2GM (5) Transfer The image developed by toner on the drum is transferred onto the paper because of the electrical attraction between the toner itself and the transfer roller. The transfer roller is negatively biased so that the positively charged toner is attracted onto the paper while it is pinched by the drum and the transfer roller.
2GM (6) Fusing The toner on the paper is molten and pressed into the paper as it passes between the heat roller and the press roller in the fuser unit. Heat roller Press roller Figure 2-1-16 Fusing The heat roller has a halogen lamp inside which continuously turns on and off by the thermistor to maintain the constant temperature onto the heat roller surface. The heat roller is resin coated by florin to prevent toner from accumulating on the roller after a long run.
2GM (6-1) Fuser unit mechanism 0 ! @ 1 2 9 8 3 7 4 6 5 Figure 2-1-17 Fuser unit mechanism 1 Heat roller 2 Idle gear Z34 3 Exit gear Z23 4 Idle gear Z18 5 Heat gear Z33 6 Press roller 7 Heater lamp 8 Thermal cutout 9 Separator(s) 0 Thermistor ! Exit pulley(s) @ Lower exit roller 2-1-17
2GM (7) Cleaning After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development process. The cleaning blade is constantly pressed against the drum and scrapes the residual toner off to the sweep roller. The waste toner is collected at the output end of the sweep roller and sent back to the toner container, into the waste toner reservoir.
2GM 2-2-1 Electrical parts layout (1) Main unit @ D 4 %$# 08 7 5E F !G 3 B A C 2 9 ( 6 ^ * 1 & Figure 2-2-1 Main unit 1 Main PWB 2 Engine PWB 3 Power supply PWB A Power switch B Exit sensor C AC Inlet 4 High voltage PWB D Interlock switch 5 Bias PWB E Cassette switch F Registration sensor G Paper sensor 6 Main motor 7 Cooling fan 8 Registration clutch 9 Feed clutch 0 MP feed clutch ! MP paper sensor @ Toner sensor [PWB] # Waste toner sensor [PWB] $ Eraser lamp [PWB] % Laser scanner unit ^ Heater
2GM (2) Scanner unit 6 7 3 4 2 1 5 Figure 2-2-2 Scanner unit 1 Operation PWB 2 CCD PWB 3 Scanner PWB 4 Inverter PWB 5 Scanner home position sensor 6 Scanner motor 7 Exposure lamp 2-2-2
2GM 2-3-1 Main PWB CPUA [31:0] SDA [12:0] SDRAM (U14,15) Parallel I/F (YC3) USB (YC4) Ethernet (YC5) Front panel (YC13) Engine I/F (YC7) Debugger I/F (YC10) Transceiver (U4,6,8,10) CCDRD,CCDBED,CCDGOD, CCDSH,CCDCLP,CCDRS, CCDCLK,CCDSW[1:0] VDFONSPL,OUTPEN.
2GM 1 50 20 YC2 U26 8 A30 B30 YC8 1 1 YC6 U42 U24 YC3 YS4 U41 1 U13 1 U39 U15 U20 YC7 A1 B1 U14 1 U34 U12 YS1 38 YC13 20 9 YC1 U23 YS2 X10 X8 U29 U4 U9 U6 U7 U8 U10 U5 U21 YC4 U1 YC10 U28 U30 X1 X6 YC5 1 X3 5 YS5 X4 U11 U35 U2 U40 13 YC9 U27 U22 1 Figure 2-3-2 Main PWB silk-screen diagram 2-3-2 X7
2GM Connector Pin No. YC1 A1 A2 Connected A3 to the FAX A4 control A5 PWB A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 Signal NC NC AUDIO +3.3 V GND A13 A11 A9 GND A6 A4 A2 GND OP2IFn OP2IRn RDY GND IORn RESETn D15 GND D12 D10 D8 GND D5 D3 D1 GND NC NC TXDREQ +3.3 V A15 A14 A12 A10 A8 A7 A5 A3 A1 +3.
2GM Connector Pin No.
2GM Connector Pin No.
2GM Connector Pin No. Signal YC6 19 GND 20 CCDR Connected to the scanner PWB YC7 Connected to the engine PWB YC8 Connected to the laser scanner unit YC10 Connected to the debugger I/F YC13 Connected to the scanner PWB 2-3-6 I/O I Description Ground Image data R (red) signal (analog) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 SGND SGND +3.3 V +3.3 V +5 V OUTPEN SGND PLGCLK EGSO SCKN EGSI PDMASKN SBSY SDIR EGRN SGND RSTN SGND OVSYNC SGND I I I I O I O O I I I I I I - Ground Ground 3.
2GM 2-3-2 Engine PWB Scanner motor Engine PWB ISUMOTA, ISUMOTNA ISUMOTB, ISUMMOTONB Scanner PWB Optional DP LAMP, LAMPHI, LAMPLOW Main PWB RSTIN HPSWN PLGCLK Reset IC U3 RSTN CPU U1 PLGDRN CCD PWB Scanner home position sensor Inverter PWB Exposure lamp PFMDRN PFSEN, PFPFPER, PFCLK PLGRDYN Optional paper feeder +24V3 MOTORN Laser scanner unit MRDYN Cassette switch Registration sensor SWIN RESIT PAPERN Main motor EEDIO EESCK EEPROM U5 Paper sensor FAN1 FAN2 Feed clutch FEDDRN RESDRN
2GM 1 13 YC15 1 10 3 1 YC11 YC10 1 3 YC13 5 1 YC14 1 YC12 U6 U5 U3 YC16 U1 1 1 YC5 2 1 2 10 YC9 1 3 1 YC8 YC6 2 1 1 20 YC4 1 5 YC1 YC2 1 YC3 7 3 X1 15 U7 YC7 1 Figure 2-3-4 Engine PWB silk-screen diagram 2-3-8 16
2GM (1) Eraser lamp control circuit The CPU (U1) turns pin #86 (ERASER) of U1 to H level, transistors (Q18) turns on consequently, and the 24 V DC given at pin #1 of connector YC14 applies to the eraser lamps. The eraser lamps thus illuminate as the current flows through the eraser lamp, the pin #2 of connector YC14, resistors (R109, R110, and R111), transistor Q18 and the ground.
2GM (2) Heater lamp control circuit Activation of the heater lamp is dominated by the HEAT signal which is derived by the engine CPU (U1) at its pin #74. When its level is high, transistor Q8 turns on, photo-triac PC2 and triac TRC1 turn on simultaneously, and the heater lamp is applied with the primary AC voltage in turn. Switching of triac TRC1, as affected by the HEAT signal is made in synchronization with the zero-cross signal ZCROSS which is generated by the power supply unit.
2GM The AC power for the heater is applied in one of the five variations of the zero cross switchings as shown in Figure 2-3-7. Each variation is constituted with the unit of ten positive and negative envelops in five cycles, as obtained by varying the duration during which TRC1 turns on. The heater lamp is energized while TRC1 is kept on; the heater lamp is turned off while TRC1 is kept off.
2GM Heater lamp turn-on pattern in 1 cycle (10 half waves) 1 2 3 4 5 6 7 8 9 10 On On On On On On On On AC wave + Variation No.1 (Duty 100 %) 0V − Conductivity staus of Triac (TRC1) Zero cross point On On + Variation No.2 (Duty 80 %) 0V − On On On On On On On On Off Off On On Off On On Off On On Off Off On Off Off On Off Off On On Off Off Off Off Off Off Off Off Off Off Off Off + Variation No.3 (Duty 60 %) 0V − + Variation No.
2GM (3) Polygon motor control circuit The main controller PWB supplies the 2598.4 Hz clock pulse (PLGCLK) via the engine PWB to the PLL control IC (IC1) for the polygon motor. To begin printing, the engine CPU U1 turns PLGDR to H level, the PLL control IC (IC1) starts to revolve the polygon motor so that the revolution is 25,984 rpm which depends on the PLGCLK clock pulse.
2GM Connector Pin No. YC3 1 2 Connected 3 to the main 4 PWB 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 YC4 Connected to the main motor YC5 Connected to the MP feed clutch YC6 Connected to the registration clutch YC7 Connected to the bias PWB 2-3-14 Signal SGND OVSYNK SGND RSTN SGND EGRN SDIR SBSY PDMASKN EGSI SCKN EGSO PLGCLK SGND OUTPEN +5 V +3.3 V +3.
2GM Connector Pin No.
2GM Connector Pin No.
2GM 2-3-3 Power supply PWB The power supply PWB provides the AC power input and DC power and outputs. The high voltage bias generator circuit is mounted on a separate PWB. A simplified schematic diagram is shown below.
2GM • 100 V YC3 YC4 YC1 YC2 Q121 L2 F2 PC2 PC4 C103 PC1 Q122 Q522 C104 PC3 PC5 TRA1 NTC1 T1 D1 Q20 Q1 C5 N Q502 D101 C102 D102 C101 L L1 • 200 V YC4 YC3 YC1 YC2 Q121 L2 F2 PC2 PC4 C103 PC1 Q122 Q522 C104 PC3 PC5 TRA1 NTC1 T1 D1 Q20 Q1 C5 N Q502 D101 C102 D102 C101 L L1 Figure 2-3-10 Power supply PWB silk-screen diagram 2-3-18
2GM 2-3-4 Bias PWB The bias PWB contains the developing bias output circuit, registration sensor, paper empty sensor, and the cassette switch. It also provides a liaison connection to the high voltage PWB, power supply, and the toner sensor.
2GM 2-3-5 High voltage PWB The high voltage PWB contains the high voltage output circuit, interlock switch circuit as well as providing a liaison connection with the power supply PWB, bias PWB, and the engine PWB.
2GM (1) Interlock switch The interlock switch is located on the high voltage PWB and opened and closed in conjunction with the front cover or the front top cover via the interlock lever. This switch connects and disconnects the +24 V DC power supply line.
2GM 2-3-6 CCD PWB The CCD PWB consists mainly of a CCD sensor (U4) that scans an original. The CCD sensor (U4) is driven to scan an original by the CCD sensor control signals (CCDCLKN, SH_BW, SH_RGB, SW, SWN, CPN, and RSN) based on the clock for driving the CCD sensor (CCDCLK) supplied from the main PWB through the scanner PWB. The image signals obtained from scanning of an original are divided into three analog signals (CCDR2, CCDG2, and CCDB2) for output.
2GM 1 30 U6 U9 YC1 U7 U8 U4 U3 YC3 2 1 1 3 YC2 Figure 2-3-17 CCD PWB silk-screen diagram Connector Pin No.
2GM 2-3-7 Operation PWB The operation PWB consists of key switches and LEDs. The lighting of LEDs is determined by scan signals (SCAN0 to SCAN7) and LED lighting selection signals (LED0 to LED3) from the main PWB. The key switches operated are identified by the scan signals (SCAN0 to SCAN7) and the return signals (KEYIN0 to KEYIN7). As an example, to light LEDG9, the LED lighting selection signal (LED3) should be driven low in synchronization with a low level on the scan signal (SCAN0).
2GM K9 K1 K5 X1 U2 K2 K13 YC1 K17 K10 K14 K18 K11 K15 K19 YC2 K6 K3 K7 U1 U3 K4 K8 K12 K16 K20 YC3 X2 YC5 K28 K23 K26 U4 K24 K21 K22 K25 K39 YC7 K35 K32 U6 K36 U7 K29 K27 YC6 K31 K45 K40 K43 K33 K37 K41 K34 K38 K42 K44 K30 Figure 2-3-19 Operator PWB silk-screen diagram Connector Pin No.
2GM 2-3-8 Scanner PWB The scanner PWB consists of scanner driver circuit Q1 to Q5 and exposure lamp driver circuit U1, relays signals from engine PWB, main PWB, operation PWB, CCD PWB and optional document processor.
YC7-6 YC7-2 PSEL1 HVISEL YC7-7 EXITN YC8-13 YC8-7 RESIT THVDR YC6-2 REGDRN YC8-15 YC4-1 FEDDRN RTHVDR YC7-10 HVCLK YC14-2 YC7-8 MHVDR2 ERASERN YC8-10 MHVDR1 YC4-9 YC11-1,2,3,4 YC10-4 HPSWN MOTA, MOTNA, MOTB, MOTNB MOTORN YC3-2 OVSYNC 100 ms 130 ms 97 ms 81 ms 367 ms 5397 ms 100 ms 167 ms 263 ms 100 ms 90 ms 263 ms 100 ms 167 ms 81 ms 100 ms 99 ms 390 ms 248 ms 90 ms 100 ms 390 ms 1375 ms 1375 ms Timing chart No.
2-4-2 YC7-6 YC7-2 PSEL1 HVISEL YC7-7 EXITN YC8-13 YC8-7 RESIT THVDR YC6-2 REGDRN YC8-15 YC4-1 FEDDRN RTHVDR YC7-10 HVCLK YC14-2 YC7-8 MHVDR2 ERASERN YC8-10 YC4-9 YC11-1,2,3,4 YC10-4 YC3-2 MHVDR1 MOTA, MOTNA, MOTB, MOTNB MOTORN HPSWN OVSYNC 100 ms 115 ms 81 ms 130 ms 358 ms 3815 ms 100 ms 167 ms 263 ms 232 ms 90 ms 100 ms 390 ms 116 ms 100 ms 167 ms 86 ms 263 ms 90 ms 100 ms 347 ms 1375 ms 1375 ms ×81/2" original onto two sheets of A5R/51/2"× ×81/2" copy
YC7-6 YC7-2 HVISEL YC7-7 EXITN PSEL1 YC8-7 RESIT YC8-13 YC6-2 REGDRN THVDR YC4-1 FEDDRN YC8-15 YC7-10 HVCLK RTHVDR YC7-8 MHVDR2 YC14-2 YC8-10 MHVDR1 ERASERN YC4-9 YC11-1,2,3,4 YC10-4 YC3-2 MOTORN MOTA, MOTNA, MOTB, MOTNB HPSWN OVSYNC 100 ms 130 ms 116 ms 81 ms 325 ms 100 ms 167 ms 263 ms 4668 ms 90 ms 263 ms 100 ms 100 ms 167 ms 82 ms 390 ms 275 ms 90 ms 100 ms 390 ms 116 ms 1375 ms 1375 ms Timing chart No.
2GM Wiring diagram C D E F G H 1 +24V3 SGND DPCOVSWN DPORGSWN DPMOT0 MOTA MOTB +5V PGND OPSWN DPTIMSWN DPDETN MOTNA MOTNB DPMOT1 YC5 THERM 1 1 +5V 2 2 1 1 3 3 L N 7 YC4 FAN 1 1 2 2 +24V1 Cooling fan Thermal cutout Power switch Power supply PWB L L N N 8 AC inlet A B C MCN1 YC1 YC3 LINE1/LINE2 A1/B1 A1/B1 LINE1/LINE2 A2/B2 A2/B2 N.C./N.C. A3/B3 A3/B3 N.C./N.C. A4/B4 A4/B4 N.C./N.C.
