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4060 Service and Parts Manual
1750040-001A
General Information
SERVICE MANUAL
CHAPTER 1 GENERAL INFORMATION
Chapter 1 contents include: Section 1-1 1-2 Introduction...................................................................................................... Printer Specifications ....................................................................................... 1-2.1 Printer General Specifications ...................................................... 1-2.2 Printer Print Speed Specifications ................................................ 1-2.3 Printer Physical Specifications ..................................................... 1-2.4 Printer Electrical Specifications.................................................... 1-2.5 Environmental Specifications For All Equipment ........................ Summary of Printer Optional Features and Feature Specifications................. Large-Capacity Hopper (LCH) ........................................................................ 1-4.1 LCH Overview.............................................................................. 1-4.2 LCH Paper Handling Specifications ............................................. 1-4.3 LCH Physical Specifications ........................................................ 1-4.4 LCH Electrical Specifications....................................................... 1-4.5 LCH Environmental Specifications .............................................. Large-Capacity Stacker (LCS)......................................................................... 1-5.1 LCS Overview .............................................................................. 1-5.2 LCS Paper Handling Specifications.............................................. 1-5.3 LCS Physical Specifications ......................................................... 1-5.4 LCS Electrical Specifications ....................................................... 1-5.5 LCS Environmental Specifications............................................... Printer Custom Paper Tray............................................................................... Printer Consumable Specifications .................................................................. Best Printing Area Specifications .................................................................... System Configuration Component Locations and Descriptions...................... 1-9.1 Front and Right Side of the Printer ............................................... 1-9.2 Behind the Front Door .................................................................. 1-9.3 Behind the Upper Right Cover ..................................................... 1-9.4 Behind the Lower Right Cover ..................................................... 1-9.5 Rear and Left Side of the Printer .................................................. 1-9.6 Rear-Inside of the Printer.............................................................. 1-9.7 Large-Capacity Hopper (LCH) Accessory ................................... 1-9.8 Large-Capacity Stacker (LCS) Accessory .................................... Printer Component Block Diagram ................................................................. Safety and Regulatory Information.................................................................. Servicing Approach ......................................................................................... 1-3 1-4 1-4 1-5 1-6 1-6 1-8 1-9 1-9 1-9 1-10 1-11 1-12 1-12 1-12 1-12 1-13 1-14 1-14 1-14 1-15 1-15 1-17 1-20 1-20 1-22 1-24 1-25 1-26 1-28 1-30 1-31 1-32 1-36 1-36
1-3 1-4
1-5
1-6 1-7 1-8 1-9
1-10 1-11 1-12
1-1
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1-1.
Introduction
This chapter provides specifications, safety compliance, options, available supplies, printing paper and design, system configuration, related manuals, and servicing approach for the 4060 cut sheet printer and supporting optional Large-Capacity Hopper (LCH) and Large-Capacity Stacker (LCS) paper handlers. The 4060 non-impact printer combines semiconductor laser optical technology and twocomponent dry development process technology to print on cut-sheet plain paper. Figure 1-1 illustrates an installed printer and the external large capacity paper handling options.
LTR
LTR
LTR
LCS
M3894SA
LCH
Figure 1-1.
4060 Printer With Optional LCH and LCS Paper Handlers
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1-2.
Printer Specifications
This section provides general, print speed, physical, electrical, environmental specifications as well as safety standards applicable to all equipment and an illustration of the printer laser equipment warning label. 1-2.1. Printer General Specifications
Table 1-1 lists general specifications for the 4060 printer.
Table 1-1.
Item Printing technology Printing speed Paper Resolution Paper capacity Size Type Laser diode, Electro-photography 40 ppm (Letter and A4 landscape) Letter, Legal, Ledger. Executive, A3, A4, A5, B4 (JIS), B5 (JIS) Plain Paper, Label paper, Recycle paper, Transparency paper, Bond paper, Pre-punched paper 600 × 600 dpi
4060 Printer General Specifications
Specifications
· 3 trays × 500 sheets (64 g/m2) standard · 1 tray × 500 sheets (64 g/m2) optional custom tray · 3,000 sheets (A4, Letter size only) optional Large-Capacity Hopper (LCH)
Stacker capacity
· 500 sheets (64 g/m2) face down tray · 2,000 sheets optional Large-Capacity Stacker (LCS)
1-2.2.
Printer Print Speed Specifications
Table 1-2 lists the specifications for the 4060 printer print speeds.
Table 1-2. 4060 Printer Print Speed Specifications
Simplex *2 40 25 21 40 21 40 40 24 30 21 Duplex *2 40 25 15 40 15 40 40 24 30 15
Paper Size (direction) Letter (landscape) Legal (portrait) Ledger (portrait) Executive (portrait) A3 (portrait) A4 (landscape) A5 (portrait) B4 (JIS) (portrait) B5 (JIS) (portrait) B4 (ISO) (portrait) *1
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B5 (ISO) (portrait) *1 Custom (paper width = 120mm to 297mm, paper length = 182mm to 215.9mm) *1 Custom (paper width = 120mm to 297mm, paper length = 215.9mm to 431.8mm) *1 Notes: *1: Can be fed from optional custom paper tray only.
40 24 34
40 24 34
*2: Unit of measure: Images Per Minute (IPM). All the speeds have ±5% tolerance.
1-2.3.
Printer Physical Specifications
Table 1-3 lists the printer physical specifications. Figure 1-2 illustrates the physical specifications and Figure 1-3 illustrates the required printer service area dimensions.
Table 1-3.
Item Dimensions Weight Service area Front 650 mm (25.6 in) Width 585 mm (23.0 in)
4060 Printer Physical Specifications
Specification Depth 640 mm (25.2 in) Approximately 135 kg Back 850 mm (33.5 in) Left 850 mm (33.5 in) Right 850 mm (33.5 in) Height 1,030 mm (40.6 in)
1-2.4.
Printer Electrical Specifications
Table 1-4 lists the printer electrical specifications.
Table 1-4.
Item Input power Voltage Phase Frequency Power consumption Heat capacity
4060 Printer Electrical Specifications
Specifications 120 to 127 VAC ± 10%, 12A 200 to 240 VAC ± 10% 7A Single-phase 50/60Hz ±5% 1,300 VA or less than during operating 894 kcal per hour
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40.5 in. (1030 mm)
LTR
LTR
LTR
23.0 in. (585 mm)
1.38 in (35 mm)
25.2 in. (640 mm)
Figure 1-2.
4060 Printer Physical Dimensions
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33.5 in. (850 mm) 84.3 in. (2140 mm) Printer 25.2 in. (640 mm)
Operating Side
25.6 in. (650 mm)
33.5 in. (850 mm)
23.0 in. (585 mm) 90.0 in. (2285 mm)
33.5 in. (850 mm)
Figure 1-3.
4060 Printer Required Service Area Dimensions
1-2.5.
Environmental Specifications For All Equipment
Table 1-5 lists environmental specifications applicable to the printer, LCH, and LCS units.
Table 1-5. 4060 Printer, LCH Option, and LCS Option Environmental Specifications
Item Ambient Condition Device condition Temperature Humidity Temperature and humidity gradients Acoustic noise Dust Ozone emission Operating 10 to 35 °C 20 to 80% RH (no condensation) Specification Non-operating 0 to 35 °C 20 to 80% RH (no condensation)
15 °C per hour or less and 30% RH per day or less (no condensation) 55 dBA or less (printer only) 0.15 mg./m3 (stearic acid) 0.1 PPM or less
1-3.
Summary of Printer Optional Features and Feature Specifications
Table 1-6 lists the options available with the 4060 printer along with their associated specifications.
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Table 1-6.
Item Large-Capacity Hopper (LCH) Large-Capacity Stacker (LCS) Custom paper tray
4060 Printer Available Options and Specifications Summary
Specification 3,000 sheets (75 g/m2) 2,000 sheets (75 g/m2) 500 sheets (75 g/m2) Model Number 4060 (Letter) 4060 (A4) 4060 (120 VAC) 4060 (240 VAC)
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1-4.
1-4.1.
Large-Capacity Hopper (LCH)
LCH Overview
Models 4060 and 4060 are the user-installable optional Large-Capacity Hoppers (LCH) units for the 4060 printer, connecting to the right side of the printer. The 4060 can feed Letter size paper only, and the 4060 can feed A4 size paper. Both LCHs can be installed up to 3000 sheets of paper (75g/m2). Figure 1-4 illustrates the Large-Capacity Hopper unit.
11.3 in (287 . mm)
17.6 in (446 . mm)
PRINTER
22.2 in (562 . mm)
Figure 1-4.
Large-Capacity Hopper Physical Dimensions
1-4.2.
LCH Paper Handling Specifications
Table 1-7 lists the LCH paper related specifications.
Table 1-7.
Item
LCH Paper Handling Specifications
Specifications
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Processing speed Paper Paper capacity Size Type
40 ppm (4060: Letter landscape and 4060: A4 landscape) 4060: Letter and 4060: A4 Plain paper, Label paper, Transparency, Bond paper, Pre-punched paper 64 to 90g/m2 3,000 sheets (75g/ m2)
1-4.3.
LCH Physical Specifications
Table 1-8 lists the LCH physical dimensions, unit weight, and required service area dimensions and Figure 1-4 illustrates these dimensions. Figure 1-5 illustrates the LCH service area requirements.
Table 1-8.
Item Dimensions Weight Service area Width 287 mm (11.3 in) About 17 kg (38 lbs) Front 650 mm (25.6 in) Back 850 mm (33.5 in) Right 850 mm (33.5 in)
LCH Physical Specifications
Specification
Depth 446 mm (17.6 in)
Height 562 mm (22.2 in)
33.5 in. (850 mm) 84.3 in. (2140 mm) LCS Printer LCH 25.2 in. (640 mm)
Operating Side
25.6 in. (650 mm)
33.5 in. (850 mm) 21.25 in. (540 mm)
23.0 in. (585 mm) 11.38 in. (289 mm) 122.6 in. (3114 mm)
33.5 in. (850 mm)
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Figure 1-5.
LCH, Printer, and LCS Required Service Area Dimensions
1-4.4.
LCH Electrical Specifications
Table 1-9 lists the LCH electrical specifications.
Table 1-9.
Item Input power Power consumption
LCH Electrical Specifications
Specification 24VDC, supplied from 4060 printer 30VA or less during operation
1-4.5.
LCH Environmental Specifications
Refer to Table 1-5 for LCH environmental specifications.
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1-5.
1-5.1.
Large-Capacity Stacker (LCS)
LCS Overview
Figure 1-6 shows the user-installable optional Large-Capacity Stacker (LCS) paper handler that connects to the left side of the printer. Model 4060 is for 120V, and model 4060 is for 240V. The LCS can stack up to 2000 sheets of paper (75g/m2).
21 in. ) 33 mm (5
. 17.4 in ) 42 mm (4
in. 36.0 ) mm (913
PRINTER
Figure 1-6.
Large-Capacity Stacker Physical Dimensions
1-5.2.
LCS Paper Handling Specifications
Table 1-10 lists the LCS paper handling specifications.
Table 1-10.
Item Processing speed Paper Size Type 40 ppm Letter, Legal, Ledger, Executive, A3, A4, A5, B4(JIS) (ISO), and B5 (JIS) (ISO) Plain paper, Label paper, Transparency, Bond paper, Pre-punched paper 64 to 90g/m2
LCS Paper Handling Specifications
Specifications
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Paper capacity
2,000 sheets (75g/ m2)
1-5.3.
LCS Physical Specifications
Table 1-11 lists the LCS physical dimensions, unit weight, and also provides the required service access area dimensions. Figure 1-6 illustrates these specifications.
Table 1-11.
Item Dimensions Weight Service area Width 533 mm (21 in) About 32 kg (70 lbs) Front 650 mm (25.6 in) Back 850 mm (33.5 in) Left 850 mm (33.5 in)
LCS Physical Specifications
Specification Depth 442 mm (17.4 in) Height 913 mm (36.0 in)
1-5.4.
LCS Electrical Specifications
Table 1-12 lists the LCS electrical specifications.
Table 1-12. LCS Electrical Specifications
Specification 4060 Voltage Phase Frequency Power consumption Heat capacity 100 to 120 VAC ±10% Single-phase 50/60 Hz 5% 120 VA or less during operation 83 kcal per hour 4060 200 to 240 VAC ±10%
Item Input Power
1-5.5.
LCS Environmental Specifications
Table 1-5 lists the LCS environmental specifications.
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1-6.
Printer Custom Paper Tray
Model 4060 printer custom paper tray is user-installable, optional custom paper tray for the 4060 printer that is compatible and switchable with the standard printer paper tray. The custom paper tray can hold up to 500 sheets (75g/m2) of free sized paper as listed in Table 1-13 specifications.
Table 1-13. Custom Paper Tray Physical Specifications
Paper Size Minimum Maximum Inches 4.7 x 7.2 11.7 x 17 Millimeters 120 x 182 297 x 431.8
Paper size information for the custom tray is selectable. The custom tray also supports the following standard media sizes: Letter, Legal, Ledger, Executive, A3, A4, A5, B4 and B5. The printing speed from the custom tray is listed in Table 1-2 (measured on and after the second page in continuous printing mode).
1-7.
Printer Consumable Specifications
This section explains how the replacement rate is established for the printer consumables. The 4060 User Manual provides details about consumables kit contents, ordering, and replacement procedures. Table 1-14 lists the consumables and their respective replacement cycle specifications. Ensure that consumables are replaced at the recommended intervals by monitoring the usage of the printer.
Table 1-14.
Consumable Item Toner Developer Drum Transfer Charger Fuser Cleaning Roller Ozone Filter Collector Bottle Printer Pick Roller Kit LCH Pick Roller Kit
Consumables and Replacement Cycle
Replacement cycle
20,000 images for continuous printing, with 4% coverage for each bottle (average 18,000 images) 1,600 drum count for each bottle (160,000 images for continuous printing, average 114,000 images) 2,500 drum count (250,000 images for continuous printing, average 178,500 images) 2,500 drum count (250,000 images for continuous printing, average 178,500 images) 3,000 page length count (approx. 300,000 images) 40,000 images for continuous printing with 4% coverage (average 36,000 images) 3,200 drum count (320,000 images for continuous printing, average 228,000 images) 20,000 images for continuous printing with 4% coverage (average 18,000 images) 5,000 page length count each (approx. 500,000 images) 5,000 page length count each (approx. 500,000 images)
Notes supporting Table 1-14: (1) All the values for replacement cycle shown above are based upon printing on A4 size paper.
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(2) All the listed values are theoretical. The damage due to improper handling, maintenance, papers, environments, and other uncontrollable occasions are not considered in these values. (3) All the values for replacement cycle/life shown above depends on printing usage's and conditions:
·
Drum Counts: The drum counter will increment every 150 seconds (equals 100 images of A4 paper at continuous printing). This counter increments during Warming-up, Intermittent printing and Auto-patrol sequence. Calculation of the average printed images is based on 1/1.4 of continuous printing; the combination of intermitted printing mode and continuous printing mode.
·
Page Length count: The page length counter will increase after 100 simplex A4 images are stacked. On duplex printing the page length counter is incremented by two. For the Printer Pick Roller Kit and the LCH Pick Roller Kit, this counter always increments as simplex printing. When another size paper is used, the counter increments according to the Table 1-15 listed values.
Table 1-15. Page Length Count
Increment by 100 sheets at simplex printing 1 2 2 1 1 1 2 2 1.5 Increment by 100 sheets at duplex printing 2 4 4 2 2 2 4 4 3
Paper size Letter Legal Ledger Executive A5 A4 A3 B4 (JIS) B5 (JIS)
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1-8.
Best Printing Area Specifications
The printed images must be in an area within a 0.5 inch (12 mm) border. Printing outside of this boundary may be of lower quality. Figure 1-7 shows the best printing area.
Margin
Best area
Figure 1-7.
Best Printing Area
If data is printed outside the best printing area, you may obtain poor print quality Figure 1-8 shows the print area of the 4060 printer.
Feed direction E D
Paper
| D-E | | F-G |
1.5 mm 1.5 mm
F G
Figure 1-8.
Print Area Specifications
If data is printed outside the printing-assured area as listed in Table 1-16 it will cause poor print quality such as:
· ·
Paper feed skew (up to ±2mm) that may cause missing characters. Bad paper transport that may cause a paper jam.
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Table 1-16.
A (mm) A5 A4 A3 LETTER LEGAL 139.6 288.6 288.6 271.0 207.5
Print Area Specifications
A (mm) LEDGER EXECUTIVE B5(JIS) B4 (JIS 271.0 175.75 248.6 173.6 B (mm) 423.4 258.3 355.6 248.6
B (mm) 201.6 201.6 411.6 207.5 347.2
Figure 1-9 shows the printing position precision.
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Ideal print area MAGNIFICATION
Print area
Paper
I H | H-I | | J-K | 2.5 mm 1.5 mm
J K
Feed direction A SKEW Print section Paper
| A-B |
2mm/432mm
B
Feed direction E D OFFSET Paper
| D-E | | F-G |
1.5 mm 1.5 mm
F G
Figure 1-9.
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Print Positions
General Information
SERVICE MANUAL
1-9.
1-9.1.
System Configuration Component Locations and Descriptions
Front and Right Side of the Printer
Ejection unit Standby switch Display contrast Control panel Front cover Front door Upper right cover Tray1 Tray2 Tray3 Lower right cover Paper size indicators Paper level indicators Main power switch LCH cover
. ..... . .. .......
Paper stacker shelf
Figure 1-10.
Front and Right Side of the Printer
The front of the printer contains the Control Panel and the controls most often used. In Figure 110, starting at the Control Panel at the top left and reading clockwise, refer to the following points of interest:
· · · · · ·
The Control Panel consists of function buttons and a liquid crystal display (also referred to as the LCD display) that presents messages about printer activity. The Display contrast allows you to adjust the brightness of the LCD display. The Ejection unit deposits paper on the paper stacker shelf. The Standby switch readies the printer for printing. The Paper stacker shelf holds printed pages. The Upper right cover provides access to the toner and developer areas.
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· · · · · · · ·
The LCH cover should be exchanged to the paper input guide when LCH is installed. The Lower right cover covers the paper path from the paper trays. The Paper size indicators show what size of paper is in each tray. The Main power switch applies power to the printer. The Paper level indicators tell you the amount of paper in the paper trays. The Trays 1, 2, and 3 hold the printer's standard paper supply. You can also obtain and install optional adjustable custom trays that hold custom sizes of paper. The Front door provides access to the printer's interior. The Front cover provides access to the printer's floppy disk drive bay. Behind the Front Door
1-9.2.
Fuser locking knob
.... ..... .... ..
Cleaning roller Fuser unit Drum unit locking knob Precharger cleaner Drum unit Knob 2 Lever b1
Knob 1
Lever 5 Decurler roller knob Decurler lever Lever 4 Duplex unit Duplex roller knob Handle 3 Lever 6 Transfer unit
LTR
Figure 1-11.
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Behind the Front Door
General Information
SERVICE MANUAL
When you open the front door of the printer, you see the printer internal components shown in Figure 1-11:
· · · · · · · · · · · · · · · ·
The Fuser unit applies heat and pressure to the paper using upper and lower rollers which fuse the toner to the paper. The Drum unit contains the precharger, photoconductor drum, precharger cleaner, and toner cleaning unit. The Transfer unit moves the print image from the drum to the paper and then separates the paper from the drum. The Duplex unit reverses and transports the paper to the printing unit for double sided printing. The Cleaning roller lubricates and collects excess toner on the fuser roller. The Drum unit locking knob secures the drum. The Decurler roller knob is used to clear paper jams in the immediate area. The Duplex roller knob is used to clear paper jams in the duplex paper path (during doublesided printing). Knob 1 is used to clear paper jams as the paper exits the paper trays and enters the drum area. Knob 2 is used to clear paper jams as the paper exits the paper trays and enters the drum area. Handle 3 lowers the transfer assembly guide to clear paper jams in the drum area. Decurler lever provides access to paper in the decurler area to clear paper jams. Lever b1 sets and release the developer unit when the drum or developer unit is removed. Lever 4 releases tension on paper in the fuser area to clear paper jams. Lever 5 provides access to paper in the reverser area to clear paper jams. Lever 6 provides access to paper in the duplexer area to clear paper jams.
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1-9.3.
Behind the Upper Right Cover
. ..... .... ......
Toner collector bottle Developer collector bottle
Toner hopper Developer unit Upper right cover
Figure 1-12.
Behind the Upper Right Cover
By opening the upper right cover, you gain access to the printer's consumables, as shown in Figure 1-12:
· ·
The Toner hopper contains a supply of toner. The Control Panel notifies you through the controller when the toner supply is running low, and when the printer is out of toner. The Developer unit contains a supply of developer that, when mixed with toner, forms the visual image on the photoconductor drum. The Control Panel notifies you through controller when the developer life is over. The Developer collector bottle collects used developer for disposal. This bottle is the empty bottle after suppling the new developer. The Toner collector bottle collects used toner for disposal.
· · ·
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1-9.4.
Behind the Lower Right Cover
Upper paper feed unit
Middle paper feed unit
Lower paper feed unit
Figure 1-13.
Printer Lower-right Side View
By opening the lower right cover, you gain access to the paper feed units as shown in Figure 1-13:
·
The Upper, Middle, and Lower paper feed units feed paper picked from the three paper trays.
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1-9.5.
Rear and Left Side of the Printer
Main controller (Under top cover) Optical unit (Under main controller) Ejection unit
Upper left cover LCS cover
Ozone filter LCS attachment points (under covers)
LCH connector AC input power connector LCS connector Lower connector not used
Figure 1-14.
Rear and Left Side of the Printer
The rear of the printer has the features shown in Figure 1-14:
· · ·
The Ozone filter inhibits ozone exhaust. The Ejection unit ejects the paper to paper stacker and this cover of unit can be opened to clear paper jams in this area. The LCS cover provides access to the LCS paper path (if installed).
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· · · · · · ·
The LCS cover should be exchanged to the paper exit guide when LCS is installed. The LCS attachment covers conceal LCS securing hardware. The LCS connector provides an LCS cable interface (if installed). The Lower connector is for future upgrades. The AC input power connector can accept either 120-127 or 200-240 VAC input power (fuser unit must be matched to the input voltage). The LCH connector provides an LCH cable interface. The Optical unit (located underneath the main controller) consists of two semi-conductor laser diodes and a rotating mirror spindle motor and lens. The laser generator outputs dualbeams from the laser diodes.
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1-9.6.
Rear-Inside of the Printer
Drive unit E
Drive unit D
High voltage power supply
Drive unit M
RN101 CNFAN2 ACN4J CNFAN1 DCNJ6 DCNJ5 DCNJ3
DCNJ9 DCNJ10 DCNJ1 DC NJ2
Low voltage power supply (Behind Mechanism Controller Board)
PC Board
PC Board
Mechanism Controller Board
CN14
CN9
CN10
CN11
CN12
Figure 1-15.
Printer Rear Inside View
The rear of the printer has the features shown in Figure 1-15:
· ·
The Drive unit D controls toner feed drive screw for toner flow control. The Drive unit E controls the ejection unit feed belt.
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CN13
CN7
CN5 CN6
CN8
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· ·
The Drive unit M controls the printer print unit. The High voltage power supply develops and regulates high voltages to the drum unit components (precharger, photoconductor drum, and cleaning unit), the transfer assembly components (transfer charger and AC charger) and the developer unit. The Low voltage power supply develops and regulates low voltages used by the motors and the control circuits and so on. The Mechanism controller contains the control circuits which control the mechanical movement of paper through the printer.
· ·
1-9.7.
Large-Capacity Hopper (LCH)
LCH release handle Paper shelf lowering button LCH door Door handle
PRINTER
Paper shelf
Figure 1-16.
Large-Capacity Hopper
The cut sheet printer can also load paper from the optional Large-Capacity Hopper (LCH) accessory (shown in Figure 1-16). The LCH sits on rails attached to the printer and is electrically connected to the printer by a cable, and obtains its power from the printer. The LCH highlights are:
· ·
The LCH release handle, when squeezed, detaches the LCH from the printer. The Paper shelf lowering button, when pressed, lowers the shelf for paper replenishment.
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· · ·
The see-through LCH door allows visual inspection of the paper supply. The Door handle provides easy access to the paper supply. The elevator-type movable Paper shelf supports the paper supply.
1-9.8.
Large-Capacity Stacker (LCS)
ON OF F
Main Power Switch Input power cord connector
LCS Interface control cable
Figure 1-17.
Large-Capacity Stacker
The cut sheet printer can stack paper onto the optional Large-Capacity Stacker (LCS) accessory stacker (shown in Figure 1-17). The LCS uses a standard power cord that may be plugged into any wall outlet. The LCS is mechanically connected to the printer and is electrically connected to the printer by a cable. Power is controlled by the ON/OFF switch.
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1-10. Printer Component Block Diagram
ACIN
(005) AC1J ACIN
FG
(006) DCNJ10 CN10
RL1
RL2
LV POWER SUPPLY
OPTICAL UNIT CN4
CNFAN2 CNFAN2J
CNFAN1 CNFAN1J
CN6 DCNJ6
CN7 DCNJ7 (006)
CN5 DCNJ5
CN3 DCNJ3 +12V r12 +5V r11
SPJ4 (006)
(005) FAN5P
(005) FAN4P (006) OPPJ HDDJ (024) CNT12 CN14 OPERATOR PANEL HDD (024) MCNJ1 CN1
(006) DNDC CNDC HV POWER SUPPLY VB ACH +HV -HV CNJ11 CN11
(006) CNJ10 CN10
FAN 5
FAN 4
MAIN CONTROLLER
MECHANISM CONTROLLER
+12V
004 -1A
PRE-CHARGER FG TRANSFER CHARGER
FG
AC CHARGER VB DEVELOPING UNIT FG TRANSFER CHARGER UNIT
Figure 1-18.
Printer Component Block Diagram (Sh 1 of 4)
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005 -1C
LH24J
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(023) FDD FDD
(023) CN3
(022) HD0
(024)
(024)
(022) OPTICAL UNIT
HDD MAIN CONTROLLER CN2 (014, 015, 016) INF0 (022)
OPERATOR PANEL
CN1 (022)
CN2 (015, 016)
(014) HV1J CN1 HV POWER SUPPLY (014) CNJ16 CN16 CNJ14 CN14
(014, 015, 016) CNJ15 CN15
(015, 016)
(008) (008) CN1J CN1 TNSP TNSJ
(008) TEMPP TEMPJ (008) SWE26 (008) SWE25 mSW DEVELOPER WASTE BOTTLE (008) SWE27 mSW TONER WASTE BOTTLE
MECHANISM CONTROLLER CN4 CNJ4 (011) CN3 CNJ3 (010) CN2 CNJ2 (009)
TONER DENSITY SENSOR
TONER EMPTY SENSOR
mSW DEVELOPER DISCHARGE SHUTTER
(009) CN2 CNJ2 PM1 PM PICK MOTOR1
(009) PSJ1 PS1 PS1
(009) PLSJ1 PLS1 PAPER LEVEL SENSOR
(009) PEMPJ1 PEMP1 PAPER EMPTY SENSOR
(008) MGSHJ MGSPH DSM PM DEVELOPER DISCHARGE SHUTTER MOTOR (010) PEMPJ2 PEMP2 PAPER EMPTY SENSOR
(008) TNMJ TNMP TNM PM TONER MOTOR
(011) PMP3 PMJ3 PM3 PM PICK MOTOR3
(011) PSJ3 PS3 PS1
(011) PLSJ3 PLS3 PAPER LEVEL SENSOR
(011) PEMPJ3 PEMP3 PAPER EMPTY SENSOR
(010) PMP2 PMJ2 PM2 PM PICK MOTOR2
(010) PSJ2 PS2 PS2
(010) PLSJ2 PLS2 PAPER LEVEL SENSOR
Figure 1-18.
Printer Component Block Diagram (Sh 2 of 4)
-30
General Information
SERVICE MANUAL
FUSER UNIT FUSER INTERLOCK SWITCH SW (005) ACN4J CN4 TINTSW THERMISTOR TH PS6P PS7P STFL TEMPERATURE SWITCH LAMP SW PS6 PS7 STACKER FULL
LV POWER SUPPLY
CNTP CNTJ DUPLEX MOTOR MAIN MOTOR M MMJ mSW REGIST ROLLER CLUTCH S RCLP SCRSJ TONER DISCHARGING SCREW SENSOR PM PS5 PS5 PSSP DMJ DMP DPM (018) SBMJ SBMP STCHJ STCHP STSLJ STSLP STSL (017) SWITCH BACK MOTOR PM STACKER SELECT SOLENOID S PURGE SOLENOID S
DRUM INTERLOCK SWITCH
MM (019) DUSET (019)
RCL (019) PSCRS (019)
SBM (017) STCH (017)
CNJ21 CN21
(019)
CNJ20 CN20
(018)
CNJ18 CN18
(017)
MECHANISM CONTROLLER
CN5 CNJ5 (012)
CN6 CNJ6 (013)
CN8 CN8J (008)
CN9 CN9J (006)
(012) TPSJ TPSP PAPER SIZE SENSOR BOARD mSW TSETSW1
(012) mSW TSETSW2
(012) mSW TSETSW3
(013) FMP FMJ FM PM FEED MOTOR
(013) CLM1P CLM1J CLM1 M
(013) CLM2P CLM2J CLM2 M
(013) CLM3P CLM3J CLM3
(008) DCNJ1 CN1
(006) DCNJ2 CN2
(006) mSW CSW1
(006) mSW CSW2 RIGHT DOOR OPEN
(006) mSW CSW3 RIGHT DOOR OPEN
(006) mSW CSW5
TRAY TRAY TRAY DETECTION DETECTION DETECTION SWITCH1 SWITCH2 SWITCH3
LV POWER SUPPLY M
LEFT DOOR OPEN
EJECTION UNIT COVER OPEN
LIFT LIFT LIFT MOTOR1 MOTOR2 MOTOR3
Figure 1-18.
Printer Component Block Diagram (Sh 3 of 4)
1-31
General Information
SERVICE MANUAL
DISCHARGE LED FAN 1 FAN 2 FAN 6 FAN 7 LED CLED FAN1J FAN1P +12V (002) (007) FAN2J FAN2P (007) FAN6J FAN6P (007) FAN7J FAN7P (007) CLEDJ CLEDP (020) PS2J (020) PS3J (020) PS4J (020) PS2 PS3 PS4
CNJ22 CN22
(007)
CNJ23 CN23
(020)
MECHANISM CONTROLLER
CN7 CNJ7 LM24J (021)
CN12 CNJ12 (021)
CN13
(002)
LARGE-CAPACITY HOPPER (LCH) OPTION
LARGE-CAPACITY STACKER (LCS) OPTION
Figure 1-18.
Printer Component Block Diagram (Sh 4 of 4)
-32
General Information
SERVICE MANUAL
1-11. Safety and Regulatory Information
The safety and regulatory information for the 4060 printer is located in the 4060 User Manual.
1-12. Servicing Approach
The printer is serviced by: (1) Understanding the layout and specifications of the printer and the associated options as described in this chapter. (2) Understanding the printer theory of operation described in chapter 2. (3) Using the information about loading and using the main program with the operator panel read-outs as described in chapter 3. (4) Performing general troubleshooting techniques provided in chapter 4. (5) Performing detailed troubleshooting using specific alarm or condition specific flow charts provided in chapter 5. (6) Performing failed field replaceable unit (FRU) removal and replacement procedures provided in chapter 6. For FRUs whose repair procedures are obvious because they are simple are not documented here but repair instructions may be provided in the replacement FRU package, depending on complexity of repair. (7) Referencing the printer, LCH, and LCS illustrated parts breakdown illustrations and associated part listings in chapter 7 and using printer wiring diagrams in appendix A.
1-33
General Information
SERVICE MANUAL
1-13.
Interior Label
This product is a Class I laser product. The warning labels shown are located outside on the optical unit.
Caution
Use of controls or adjustment of performance for procedures not specified herein way result in hazardous radiation exposure.
-34
Theory of Operation
SERVICE MANUAL
CHAPTER 2 THEORY OF OPERATION
Chapter 2 contents include: Section 2-1 2-2 Introduction...................................................................................................... Overview of Printing Process .......................................................................... 2-2.1 Mechanical Operation ................................................................... 2-2.2 Video Data Control ....................................................................... 2-2.3 Developer Replacement ................................................................ Paper Feed Operation....................................................................................... 2-3.1 Operational Timing Charts ........................................................... Printer Power ................................................................................................... 2-4.1 Low Voltage Power Supply Block Diagram ................................. 2-4.2 High Voltage Power Supply Block Diagram ................................ 2-4.3 Power-on Sequence Timing Chart ................................................ 2-3 2-3 2-3 2-6 2-11 2-16 2-16 2-25 2-25 2-27 2-30
2-3 2-4
2-1
Theory of Operation
SERVICE MANUAL
2-1.
Introduction
This chapter describes the 4060 printer printing process with overviews of the mechanical components, functions, and timing sequences.
2-2.
Overview of Printing Process
This section describes the printing process through an overview of the mechanical and functional operations. Chapter 1 provides locational views of these components. The printing process section consists of the following mechanical components:
· · · · · · · ·
Photoconductor drum Precharger Optical unit Developer unit Transfer unit LED erase unit (also called a discharging lamp) Cleaning unit Fuser unit NOTE The photoconductor drum, precharger, and cleaning unit (except for discharging lamp) are assembled into the drum.
2-2.1.
Mechanical Operation
The paper is fed from the paper tray and is processed in each component of the printer as follows: 1. Precharger The precharger charges all the surface of the photoconductor drum evenly with approximately -600V by the grid control. 2. Optical unit The optical unit emits two modulated laser beams to the surface of the photoconductor drum to reduce the electric potential to approximately -100V (or less). The electric potential on the part to which the beam was not emitted remains unchanged. Figures 2-1, 2-2, and 2-3 illustrate the optical unit operations.
2-2
Theory of Operation
SERVICE MANUAL
Main Controller PCB
OPTICAL UNIT
Photoconductor Drum Laser Diode Reflector 2
Photo Diode Optical Unit Controller PCB
Power Supply Unit
+24V DC Reflector 1 On/Off Control Circuit
Laser Driver A
Video Interface Circuit Laser Driver B Laser Diode Rotating Mirror Laser Beam Beam Detector Spindle Motor Spindle Motor Driver Spindle Motor Alarm Circuit
Eject cover interlock switch
Mechanism Controller PCB
Relay
Front cover interlock switch
Relay
Upper right cover interlock switch Beam Detect Alarm Circuit
Relay
Lower right cover interlock switch
Fan 1
Fan Alarm Circuit
Figure 2-1.
Dual-beam Optical Unit Functional Diagram
Relay
2-3
Theory of Operation
SERVICE MANUAL
Laser Source unit (including laser diodes, collimator lens, etc.) Laser Diode A [5mW, 1=780nm] Laser Diode B [5mW, 1=780nm] LaserBeam
Rotating mirror
Scanning lens 1
Beam Detector (BD) Refractor 1 Scanning lens 2 Refractor 2 Cover glass Scanning line B A Scanning directions
Figure 2-2. Optical Unit Laser Scanning System
B
A
Dot pitch
Photoconductor Drum
Paper feed
Figure 2-3.
Laser Scanning of Photoconductor Drum
3.
Developer unit
2-4
Theory of Operation
SERVICE MANUAL
The developer unit stirs two-component developer (toner and carriers) to generate frictional electricity. The charged toner sticks to the laser-applied area (-100 V) on the photoconductor drum. 4. Transfer assembly The transfer assembly transfers a toner image from the photoconductor drum to a paper. This transfer is caused by the corona charge from the back side of the paper by the positive charge. The paper sticks to the photoconductor drum electrostatically. The AC discharger separates the paper from the photoconductor drum by electrical neutralization and by the natural stiffness of paper. 5. LED erase unit (lamp discharger) The LED erase unit removes the electrostatic charge remaining on the photoconductor drum. 6. Cleaning unit The remaining toner is removed with a cleaning blade. The next cycle of the printing operation begins. 7. Fuser unit The fuser pressure roller heats and presses the paper. The roller is heated by a halogen lamp in the roller. The toner on the paper is fused and the toner image is fixed. 2-2.2. Video Data Control
Function: (1) VIDEO VIDEO is serial video data. (2) BD BD is a pulse signal that indicates the laser-beam scan start position. The controller uses the BD signal as the video synchronization signal in the laser-beam main scan direction. The VIDEO signal output in each scan period is determined at the falling edge of the BD signal. (3) VR VR is the VS request signal that is to be sent from the printer to the controller. (4) VS
2-5
Theory of Operation
SERVICE MANUAL
VS is the video synchronization signal in the paper feeding (secondary scanning) direction.
r (3 e (4 *VR
*VS
(2 w
*BD Tbd
q (1
*VIDEO
Tvs(*1)
Tvp: Printing-assured area Tv: Printing area
Figure 2-4.
Printing Control in Paper Transport Direction (VIDEO Control)
Note: The Tvs time is equivalent to the distance of 5 millimeters.
2-6
Theory of Operation
SERVICE MANUAL
Tbd: BC period *BD
min. 1 µs
*VIDEO
Ths
Twp: Printing-assured area (82) Tw: Printing area (*1)
Ths
*BD Thd (*3) *VIDEO Tvd: 1 dot Ths
Figure 2-5.
Printing Control In Beam Main Scan Direction (VIDEO Control)
Notes: 1. 2. The Tw time is equivalent to the printing paper width. The printing-not-assured area in the paper width direction begins at a position 5 millimeters from the left edge of the paper. This area ends at a position 5 millimeters from the right edge of the paper. The variation of the Thd width in each line scan should not exceed 1/8 of the video-signal ldot time width Tvd.
Table 2-1. VIDEO Signal Control Parameters (Not Depending On Paper Size)
Tvs (ms) 13.89 Tbd (µs) 235.195 Tvd (ns) 135.821 to 222.222 Ths (µs) 2.005 to 3.281
3.
Printing resolution 600 dpi
2-7
Theory of Operation
SERVICE MANUAL
Table 2-2.
Paper size W × V (mm) A3 portrait 297 × 420 A4 landscape 297 × 210 A5 portrait 148 × 210 Letter landscape 279.4 × 215.9 Legal portrait 215.9 × 355.6 Ledger portrait 279.4 × 431.8 Executive portrait 266.7 x 184.15 B4 (JIS) portrait 257 x 364 B5 (JIS) portrait 182 x 257 Custom tray 1 120 to 297 x 182 to 215.9 Custom tray 2 120 to 297 x 216 to 431.8
VIDEO Signal Control Parameters (600 dpi, Depending On Paper Size)
Printing in 600 dpi Tv (ms) 2333.37 (9,921 lines) 1166.80 (4,961 lines) 1166.80 (4,961 lines) 1199.49 (5,100 lines) 1975.64 (8,400 lines) 2398.99 (10,200 lines) 1027.8 (4,370 lines) 2022.21 (8,598 lines) 1427.87 (6,071 lines) 1011.10 to 1194.49 (4299 to 5100 lines) 1194.49 to 2398.99 2348.48 (9964 lines) Tvp (ms) 2277.86 (9,685 lines) 1111.06 (4,724 lines) 1111.06 (4,724 lines) 1143.99 (4,864 lines) 1920.13 (8,164 lines) 2343.48 (9,964 lines) 972.26 (4,133 lines) 1966.70 (8,362 lines) 1372.36 (5,835 lines) 1143.99 (4864 lines) Thd (µs) 2.801 to 3.667 (165 dots) 2.801 to 3.667 (165 dots) 32.682 to 42.778 (1,925 dots) 6.333 to 8.289 (373 dots) 19.066 to 24.956 (1,123 dots) 6.333 to 8.289 (373 dots) 8.676 to 14.194 (511 dots) 10.832 to 14.178 (638 dots) 25.874 to 33.867 (1,524 dots) 42.104 to 2.801 68.889 to 4.583 (2480 to 165 dots) 42.104 to 2.801 68.889 to 4.583 Tw (µs) 119.115 to 155.911 (7,016 dots) 119.115 to 155.911 (7,016 dots) 59.354 to 77.689 (3,496 dots) 112.053 to 146.667 (6,600 dots) 86.586 to 113.333 (5,100 dots) 112.053 to 146.667 (6,600 dots) 106.959 to 175.000 (6,300 dots) 103.072 to 134.911 (6,071 dots) 72.987 to 95.533 (4,299 dots) 40.101 to 119.115 65.611 to 194.889 (2362 to 7016 dots) 40.101 to 119.115 65.611 to 194.889 (2362 to 7016 dots) Twp (µs) 115.108 to 150.667 (6,780 dots) 115.108 to 150.667 (6,780 dots) 55.347 to 72.444 (3,260 dots) 108.045 to 141.422 (6,364 dots) 82.579 to 108.089 (4,864 dots) 108.045 to 141.422 (6,364 dots) 102.935 to 168.417 (6,063 dots) 99.064 to 129.666 (5,835 dots) 68.980 to 90.289 (4,063 dots) 36.077 to 115.108 59.028 to 188.333 (2125 to 6780 dots) 36.077 to 115.108 59.028 to 188.333 (2125 to 6780 dots)
(5100 to 10,200 lines)
(2480 to 165 dots)
2-8
Theory of Operation
SERVICE MANUAL
1 scanning cycle Beam detection signal from the Optical Unit Start signal to the main controller via video interface Video data from the main controller via video interface V.D.2 V.D.3 V.D.4 V.D.5 V.D.6 V.D.7 A B A B
***
A
B
***
VIDEO Interface Circuit
ED ON LD A (BD; beam detection = horizontal synchronous signal from optical unit) LD B Video 1 ED ON Video 2 Video 4 Video 3
ED ON Video 5 ED ON
Figure 2-6.
Sequence Control of VIDEO Data Timing Diagram
2-9
Theory of Operation
SERVICE MANUAL
2-2.3.
Developer Replacement
The operator must replace the developer by using the developer replacement command DVEXC. The developer replacement request (MESG) and developer end life (OPC) are reset by completing the developer replacement. Replace the developer in the following procedure: Developer replacement start direction -> Developer ejection and supply -> Developer replacement end direction The printer status during developer replacement is indicated with PRSQl code ($99 to $9F). In the following explanations, PRSQl = $99 to $9F indicates developer replacement state, and other PRSQl values indicate normal states. (1) Developer replacement execution command = $98 If any error shown in Figure 2-7 "Developer Replacement Operation Suppression Errors" exists, the command is rejected by CMDER and CME.
Any cover open (EMSR2: bit 5, bit 6, bit 7) Developer unit interlock (EMSR3: bit 0) Drum interlock (EMSR3: bit 1) Toner motor alarm (SVC = $50) Screw rotation alarm (SVC = $51) Developer ejection alarm (SVC = $52) Main motor alarm (SVC = $69) Communication alarm (SVC = $B3) High-voltage power supply alarm (SVC = $6F)
Internal fan alarm 1 (SVC = $A0) Internal fan alarm 2 (SVC = $Al) Internal fan alarm 6 (SVC = $A5) Internal fan alarm 7 (SVC = $A6) EEPROM alarm (SVC = $B4)
Figure 2-7.
Developer Replacement Operation Suppression Errors
(1) Developer replacement procedure start: PARA1 = $01 [Function]
·
The developer replacement execution command directs the printer to start developer replacement.
[Printer operation]
· · ·
All the operations of the printer mechanism stop. Any errors other than the developer replacement operation suppression error are reset. PRSQ1 is set to $99.
2-10
Theory of Operation
SERVICE MANUAL
[Restrictions]
·
This command is valid when the PRSQ1 value is one of the following: - $00 (out of operation) - $30 - $31 (initialization)
· · ·
If PRSQ1 is a value of $99 to $9F, the command is invalid, but is not rejected. If PRSQ1 is other than the above values, the command is rejected. If the developer bottle is not set, EMS (EMSR3, bit 5) is set and the command is rejected.
(2) Developer ejection start: PARAl = $02 [Function]
·
The developer ejection start command directs the printer to start the developer ejection operation.
[Printer operation]
·
During the developer ejection operation, PRSQl is set to $9B.
[Restrictions]
·
The developer ejection start command is valid when the PRSQl value is one of the following: - $99 (developer replacement start) - $9A (developer ejection operation stop)
· ·
If PRSQl is $9B (developer ejection operation), the developer ejection start command is invalid, but is not rejected. If PRSQl is other than the above values, the command is rejected.
(3) Developer pouring end: PARAl = $04 [Function]
·
The developer pouring end command directs the printer to end the new developer pouring operation.
[Printer operation]
·
The printer transfers to PRSQ1=$97 when the developer replacement procedure end command.
2-11
Theory of Operation
SERVICE MANUAL
[Restrictions]
· ·
The developer pouring end command is not valid when PRSQl is other than $9E. If PRSQl is a value other than those above, the command is rejected.
(4) Developer replacement procedure end: PARAl = $06 [Function]
·
The developer replacement procedure end command directs the printer to end the developer replacement operation.
[Printer operation]
·
When PRSQ1 is $9F (developer replacement completion), the developer replacement request (MESG) and developer life end state (OPC) are reset. Moreover, the specified developer life value is placed in the developer life management counter. When PRSQ1 is $9F, the printer starts automatic toner density adjustment.
·
[Restrictions]
· ·
The developer replacement procedure end command is valid when PRSQl is $99, $9C, $9F or $00. If PRSQl is a value other than those above, the command is rejected.
(2) Developer replacement status The developer replacement operation status is indicated with PRSQl code $99 to $9F. During developer replacement operation, detection of errors other than the developer replacement operation suppression error is masked. (1) Developer replacement start: PRSQl = $99
· ·
$99 indicates that the printer received a developer replacement start command and is waiting for another command. In this state, the following developer replacement commands can be accepted and executed: - Developer ejection start command - Developer replacement procedure end command
·
When the printer power is turned off then on in this state, the printer is set to the normal state.
(2) Developer ejection stop: PRSQl = $9A
·
$9A indicates that the developer ejection operation stopped. This stop occurs when a
2-12
Theory of Operation
SERVICE MANUAL
developer replacement operation suppression error was detected or the printer power was turned off during developer ejection operation.
· ·
The only developer replacement command that can be accepted and executed in this status is the developer ejection start command. When the printer power is turned off then on in this state, the printer is set to the developer ejection stop state.
(3) Developer ejection operation: PRSQl = $9B
· ·
$9B indicates that the printer received a developer ejection start command and is ejecting developer. The developer ejection operation terminates after about 30 seconds unless a stop cause occurs (developer replacement operation suppression error). Then, the printer goes to the developer ejection operation completion state. During the developer ejection operation, any developer replacement commands cannot be accepted. When the printer power is turned off then on in this state, the printer is set to the developer ejection stop state.
· ·
(4) Developer ejection completion: PRSQl = $9C
· · ·
$9C indicates that the printer completed the developer ejection operation and is waiting for pouring the new developer. The upper right door is opened in this state, then PRSQ1 is set to $9E, waiting for supplying the new developer. When the printer power is turned off then on in this state, the printer is set to the developer ejection completion state.
(5) Developer ejection-supply operation: PRSQ1=$9E
·
$9E indicates that the printer is executing the developer ejection-supply operation.
(6) Developer bottle replacing: PRSQ1 = $97
· ·
$97 indicates that the developer bottle is on replacing. When the printer power is turned off in this status and is turned on again, the printer keeps this status.
(7) Developer ejection-supply completion: PRSQl = $9F
· ·
$9F indicates that the printer completed the developer ejection-supply operation and is waiting for another command. The only developer replacement commands that can be accepted and executed in this
2-13
Theory of Operation
SERVICE MANUAL
status is the developer replacement end command.
·
When the printer power is turned off then on in this status, the printer resets the developer replacement request (MESG) and developer life end state (OPC). The printer also places the specified developer life value into the developer life management counter. Then, it starts automatic toner density adjustment.
(3) Toner density control slice level setup When a developer replacement end command is completed, the printer initializes the mechanism unit. At the same time, the printer sets the toner density control slice level for the newly supplied developer. During the slice level processing, the mechanism unit initialization continues for about 90 seconds. Sequence 1 through 8 lists the developer replacement status transition conditions: (1) A developer replacement procedure start command was received (2) A developer ejection start command was received (3) The 30-second ejection operation completed normally (4) An error that stopped the developer ejection was detected (5) A developer ejection-supply start command was received (6) The developer supply operation is completed (7) A developer replacement procedure end command was received (8) No developer is detected before the automatic toner density adjustment
2-3.
2-3.1.
Paper Feed Operation
Operational Timing Charts
The paper feed operation can be determined by using the following table and figure references:
· · · · ·
Table 2-1 "VIDEO Signal Control Parameters (Not Depending On Paper Size)," Page 2-8 Table 2-2 "VIDEO Signal Control Parameters (600 dpi, Depending On Paper Size)," Page 2-9 Figure 2-6 "Sequence Control of VIDEO Data Timing Diagram," Page 2-10 Figure 2-8 "Paper Feed Operation Timing Chart," Page 2-17 Figure 2-9 "Printing Sequence Timing Chart," Page 2-18
2-14
Theory of Operation
SERVICE MANUAL
· · · · ·
Figure 2-10 "Double-sided Printing Sequence Timing Chart," Page 2-19 Table 2-3 "Printing Sequence Specifications," Page 2-20 Figure 2-11 "Prepick Sequence Timing Diagram and Charts," Page 2-21 Table 2-4 "Jam Codes, Names, Conditions and Messages," Page 2-22 Figure 2-12 "Position of Jam Detection Sensors," Page 2-24
2-15
Theory of Operation
SERVICE MANUAL
Refer to Figure 2-8 "Paper Feed Operation Timing Chart": When the power is turned on and when the cover is opened, then shut, or when the error reset command is received:
Power ON Spindle motor Temperature = 185°C Fuser
Process operation
PRSQ1 (*1) Max 3 s 31 30 About 120 s Max. 200 s *1 Not defined 31 00
Figure 2-8.
Paper Feed Operation Timing Chart
2-16
Theory of Operation
SERVICE MANUAL
Refer to Figure 2-9 "Printing Sequence Timing Chart":
t2 MPU (Controller) PSTRT MCP (Printer) Process operation Off CME t3 CME VR PEND VS DREQ VR PEND VS DREQ
PSTRT Prepared Exposed Not Exposed Exposed
PRSQ1 Pick operation
0
1
2
4
1
2
4
t1
t1 t2 t3
Max. 35 sec 0 to 10 sec (= 0: Maximum processing speed) If t2 exceeds 10 seconds, the VS alarm occurs. 0 to 10 ms 0 ms is normal. (PEND and DREQ are issued simultaneously.)
Figure 2-9.
Printing Sequence Timing Chart
2-17
Theory of Operation
SERVICE MANUAL
Refer to Figure 2-10 "Double-sided Printing Sequence Timing Chart": An example of duplex printing sequence is shown below. Two pages can be contained in the double-sided printing path. Only one page can be contained for the A3 and Ledger portrait size paper. If one sheet of paper is left in the double-sided printing path, single-sided printing can be performed except A3 and Ledger size paper.
Reserve w
w Sheet 2 Reserve r r
Surface q
q
Surface e
e
Sheet 3 Reserve y
y
Surface t
t
Sheet 4 Reserve i
MPU (Controller) MPC (Printer) DPUST path full bit DPUST count
w r w y e i t PSTRT PSTRT PSTRT PSTRT PSTRT PSTRT PSTRT w r t w y e i
00
01
02
01
02
01
02
01
Figure 2-10.
Double-sided Printing Sequence Timing Chart
CME, VR, VS, DREQ, and PEND for the PSTRT command are omitted. The printer issues the double-sided PSTRT command from DREQ or PEND within the time shown below, and assures the maximum printing speed. a. Printing sequence ! - " - # - $ Time from ! to " for sending one sheet: (To be determined) b. Printing sequence ! - # - " - $ Time from # to " for sending two sheets: See Table 2-3 "Printing Sequence Specifications" c. Printing sequence ! - # - " - % - $ Time from % to $:(See Table 2-3 "Printing Sequence Specifications" 1 # to ":(See Table 2-3 "Printing Sequence Specifications" 2
2-18
Theory of Operation
SERVICE MANUAL
Table 2-3.
Paper size A5 (V) Letter (H) A4 (H) Legal (V)
Printing Sequence Specifications
Table 1þþms 825 785 825 130 Table 2þþms 255 265 255 375
NOTE For A3 (V) and legal (V) paper, the printing sequence supports single-sheet sending.
2-19
Theory of Operation
SERVICE MANUAL
Refer to Table 2-11 "Prepick Sequence Timing Diagram and Charts":
One page PREPK command MPL (Controller) MPL (Printer) BSTR3, PKPQ One page VR VS t1 One page VR VS DREQ PEND Two pages VR VS
Two pages PREPK command t2
Two pages PSTRT
PRSQ2, PKON PRPST. Path full bit PRPST. Number of sheets PRSQ1
t1 t2
00 00
01 01
00 02
01
00 01 02
Within 20 seconds If t, exceeds 20 seconds, the PREPK alarm occurs. If the PREPK command is received within the time shown in the table below, printing speed is at the maximum.
t2 (ms) Paper size Upper paper tray A5 (V) Letter (H) A4 (H) Legal (V) Ledger (V) A3 (V) 510 550 510 1320 1745 1675 Middle paper tray 310 350 310 1120 1545 1475 Lower paper tray 110 150 110 920 1345 1275
Figure 2-11.
Prepick Sequence Timing Diagram and Charts
2-20
Theory of Operation
SERVICE MANUAL
Refer to Table 2-4 "Jam Codes, Names, Conditions and Messages" and Figure 2-12 "Position of Jam Detection Sensors":
Table 2-4.
Jam Code 01 02 03 11 Jam Name Jam 0-1 Jam 0-2 Jam 0-3 Jam1-1
Jam Codes, Names, Conditions and Messages
Definition Message Paper tray 1 pick error
Paper did not reach sensor PS1-1 from the upper tray before specified time passed after the pick roller started.
Paper did not reach sensor PS1-2 from the middle tray before specified Paper tray 2 pick error time passed after the pick roller started. Paper did not reach sensor PS1-3 from the lower tray before specified time passed after the pick roller started. When the printer is reset, there is paper at PS1-1, or Paper did not reach PS2 before specified time passed after the paper reached PS1-1. When the printer is reset, there is paper at PS1-2, or Paper did not reach PS2 before specified time passed after the paper reached PS1-2. When the printer is reset, there is paper at PS1-3, or Paper did not reach PS3 before specified time passed after the paper reached PS1-3. When the printer is reset, there is paper at PS2, or Paper did not reach PS3 before specified time passed after the paper reached PS2. When the printer is reset, there is paper at PS3. When the regist roller clutch is turned on, there is not paper at PS2. Paper did not reach PS4 before specified time passed after the regist roller clutch is turned on. Paper did not leave PS2 before specified time passed after the regist roller clutch is turned on. When the printer is reset, there is paper at PS4. The time when paper passed PS4 differs from the standard time specified by paper size printing. Paper did not reach PS7 before specified time passed after the paper reached PS4. Paper tray 3 pick error Feed path 1 jam
12
Jam 1-2
Feed path 2 jam
13
Jam 1-3
Feed path 3 jam
18
Jam 1-8
Feed path 4 jam
25
Jam 3-1
Fusing unit jam 1
26
Jam 3-2
Fusing unit jam 2
29 2B 31 32
Jam 4-1 Jam 4-2 DPU Jam 1 DPU Jam 2
Ejection unit jam 1
When the printer is reset, there is paper at PS6 and PS7. The time when Ejection unit jam 2 paper passed PS7 differs from the standard time specified by paper size. Paper did not reach PS5 before specified time passed after the switch back motor on the duplex unit was rotated. When the printer is reset, there is paper at PS5. Paper did not reach PS3 before specified time passed after the duplex motor turn on. Paper did not reach PS3 before specified time passed after the paper reached PS5. Duplex path jam 1 Duplex path jam 2
2-21
Theory of Operation
SERVICE MANUAL
Table 2-4.
Jam Code 41 Jam Name STK Jam 1
Jam Codes, Names, Conditions and Messages (Cont)
Definition Message
When the printer is reset, there is paper blocking one of the LCS paper LCS jam 1 sensors. Paper did not reach one of two LCS sensor before specified time passed after the paper reached PS4. Paper did not reach KSEN before specified time passed after the pick roller of the LCH started. The time when paper passed KSEN differs from the standard time specified by paper size. When the printer is reset, there is paper at KSEN. LCH jam 1 LCH jam 2 LCH jam 3
51 52 53
Jam 1 Jam 2 Jam 3
2-22
Theory of Operation
SERVICE MANUAL
Ejection tray full (ESF)
Ejection tray
PS7 (ES7)
PS6 (ES6)
PS4
Photoconductor drum
PS3 PS2
Fuser Register roller Paper feed unit PS5 (DS5) PS1-2 (FS12) PS1-1 (FS11)
Upper tray
PS1-3 (FS13) Middle tray
Lower tray
Figure 2-12.
Position of Jam Detection Sensors
2-23
Theory of Operation
SERVICE MANUAL
2-4.
Printer Power
Chapter 1 provides the overall printer interconnection block diagram and appendix A provides the detailed printer interconnection wiring diagram. This section provides the functional block diagrams of the low and high power supplies and also the timing chart of the power-on sequence. 2-4.1. Low Voltage Power Supply Block Diagram
Figure 2-13 illustrates the low voltage power supply major functions.
2-24
Theory of Operation
SERVICE MANUAL
CB1 ACIN CB2
NOISE FILTER
AC INPUT JUDGEMENT CIRCUIT (VOLTAGE) RC1 PC4, Q9, D20, ETC
AC INPUT JUDGEMENT CIRCUIT (INPUT OR NOT) PC2, Q10, ETC
NOISE FILTER
CR1 CR2
TRIAC DRIVER FOR THE HEATER PC4, PC1, Q102, PC3, Q103, ETC 100V
1 PFC CIRCUIT
TH1 HEATER OUTPUT 3
200V
AUXILIARY POWER CIRCUIT Q7, Q8, T1, D101, Z101, ETC
L7, Q1, Q2 RC2, Z1, ETC
1
2
MAIN CONVERTER
SEQUENCE CIRCUIT *ENPOFF/ON *HTON *PWROY 5V CHOPPER 2 Q132, RC115, L115, ETC 1 POW ST2 POW ST1 *FANALM1 *FANALM2
Q51, Q52, D57, Q57, ETC
+5V
CONTROLLER RECTIFIER PC51, PC52, PC53, Z51, ETC RC111 CAPACITOR REACTOR L111
24V OUTPUT ON/OFF CIRCUIT Q126, Q127, PC111, Q124, ETC +24V
2 RC113RC114
+ FAN2 OUTPUT ON/OFF CIRCUIT Q104, ETC FAN2 FAN1 +12V +
GND
VOLTAGE DETECTOR PC51, Q131, ETC
Figure 2-13.
LVPS Block Diagram
2-25
Theory of Operation
SERVICE MANUAL
2-4.2.
High Voltage Power Supply Block Diagram
Figure 2-14 through Figure 2-18 illustrate the high voltage power supply major functions.
+DC24V +DC6V
REGULATOR (+DC5V)
D0
. . .
D1
. . .
INVERTER (LS14) D/A CONVERTER +HV ANALOG CONTROLLER ANALOG CONTROLLER ANALOG CONTROLLER ANALOG CONTROLLER
-VB
PHOTO COUPLER
ACH (AC)
C0
INVERTER (LS14)
ACH (DC)
C1
WA
FG
Figure 2-14.
HVPS D/A Converter Block Diagram
2-26
Theory of Operation
SERVICE MANUAL
TRANSFORMER (T1) +DC24V +DC5V -HVON OSCILLATION CONTROLLER RECTIFIER CIRCUIT -HV
FG
HVALM SG
ALARM DETECTOR
Figure 2-15.
HVPS -HV Block Diagram Block Diagram
TRANSFORMER (T2) +DC24V +DC5V +HVON D/A CONVERTER ANALOG CONTROLLER OSCILLATION CONTROLLER RECTIFIER CIRCUIT +HV
FG
HVALM SG
ALARM DETECTOR
Figure 2-16.
HVPS +HV Block Diagram Block Diagram
2-27
Theory of Operation
SERVICE MANUAL
TRANSFORMER (T3) +DC24V +DC5V VBON D/A CONVERTER ANALOG CONTROLLER OSCILLATION CONTROLLER RECTIFIER CIRCUIT VB
FG
HVALM SG
ALARM DETECTOR
Figure 2-17.
HVPS VB Block Diagram
+DC24V +DC5V ACHON
CONTROL OSCILLATOR
TRANSFORMER (T4) RESONANT CONVERTER CIRCUIT ACH (Vpp)
D/A CONVERTER
ANALOG CONTROLLER
CIRCUIT
FG TRANSFORMER (T5) ACH (Voff) RECTIFIER CIRCUIT
OSCILLATION CONTROLLER D/A CONVERTER ANALOG CONTROLLER
HVALM SG
ALARM DETECTOR
Figure 2-18.
HVPS ACH Block Diagram
2-28
Theory of Operation
SERVICE MANUAL
2-4.3.
Power-on Sequence Timing Chart
"*" means the active-low signal. Main Switch
Figure 2-19 illustrates the printer power-on timing sequence.
ON *Standby Switch
+5V, +12V MAIN CONTROLLER STARTS (Power start 2; always low unless any interlock activated)
*POWST2 *PWRRDY (Power Ready)
Relay RL1.2 ON MECHANISM CONTROLLER AND OPTICAL UNIT START *POWST1 (Power start 1; always low unless any interlock activated)
+24V PICK MOTOR 1 PICK MOTOR 2 PICK MOTOR 3 LIFT MOTOR FEED MOTOR SWITCH BACK MOTOR DUPLEX MOTOR MAIN MOTOR SPINDLE MOTOR LDENB (Laser diode enable) BDCE (Begin detection enable) DISCHARGE LED
[HV POWER SULLY] HVON (Precharger) VBON (Developing biqs) Power on initilize sequence ends.
Figure 2-19.
Power-on Sequence Timing Chart
2-29
Theory of Operation
SERVICE MANUAL
2-30
Printer Maintenance Program
SERVICE MANUAL
CHAPTER 3 PRINTER MAINTENANCE PROGRAM
This chapter must be developed for the 4060 printer maintenance program, if installed, driven by the main controller and the software installed.
31-1
Printer Maintenance Program
SERVICE MANUAL
31-2
General Troubleshooting
SERVICE MANUAL
CHAPTER 4 GENERAL TROUBLESHOOTING
Chapter 4 sections include: Section 4-1 4-2 4-3 4-4 4-5 Introduction...................................................................................................... Troubleshooting Overview .............................................................................. Error Message and Problem Summaries.......................................................... Standard Tools and Test Equipment ................................................................ Hints and Tips .................................................................................................. 4-3 4-3 4-3 4-7 4-8
4-1
General Troubleshooting
SERVICE MANUAL
4-1.
Introduction
This chapter provides a troubleshooting overview, adjustment procedures, a listing of standard tools and test equipment required for printer maintenance, and helpful hints and tips.
4-2.
Troubleshooting Overview
Troubleshooting the 4060 printer and the optional Large-Capacity Hopper (LCH) begins by recognizing a fault condition whether reported by the machines or by observation. This chapter provides one location for summaries of information found elsewhere in this manual and also provides reference diagrams and procedures that may be referenced by many troubleshooting flow charts.
4-3.
Error Message and Problem Summaries
Error messages are displayed on the operator panel. The messages are explained in detail in chapter 5. The message codes are the starting points for troubleshooting flow charts. The failure codes and messages are:
· ·
Printer component sensors Paper jam sensors
Table 4-1 "Sensor Codes and Messages" Table 4-2 "Jam Codes and Messages"
4-2
General Troubleshooting
SERVICE MANUAL
Table 4-1.
Displayed Code SVC08 SVC09 SVC0A SVC0B SVC0D SVC0E SVC0F SVC27 SVC28 SVC29 SVC50 SVC51 SVC52 SVC54 SVC56 SVC57 SVC58 SVC59 SVC5A SVC5B SVC69 SVC6F SVC79 SVC7A SVC7B SVC7C SVC7D SVC7E
Sensor Codes and Messages
Code Meaning or Problem Description
Upper Pick Motor Alarm Middle Pick Motor Alarm Lower Pick Motor Alarm Reversing Motor Alarm Feed Motor Alarm Stacker Select Solenoid Alarm Duplex Motor Alarm Fuser Alarm (Time-out) Fuser High-temperature Alarm Fuser Low-temperature Alarm Toner Motor Alarm Toner Discharge Screw Alarm Developer Discharge Alarm Developer Discharge Shutter Alarm Automatic Adjustment Alarm Toner High-density Alarm Toner Low Density Alarm Reference Voltage Alarm (Too High) Reference Voltage Alarm (Too Low) Toner Hopper Alarm Main Motor Alarm High Voltage Power Alarm Spindle Motor Alarm BD1 (Beam Detection) Alarm BD2 (Beam Detection) Alarm Beam Detection High-speed Alarm Beam Detection Low-speed Alarm Laser Diode (LD) Alarm
4-3
General Troubleshooting
SERVICE MANUAL
Table 4-1.
Displayed Code SVCA0 SVCA1 SVCA5 SVCA6 SVCB0 SVCB1 SVCB3 SVCB4 SVCB5 SVCB6 SVCB7 SVCC4 SVCC5 SVCD8
Sensor Codes and Messages (Cont)
Code Meaning or Problem Description Fan Alarm 1 Fan Alarm 2 Fan Alarm 6 Fan Alarm 7 Watchdog Timer Alarm - Master) Watchdog Timer Alarm - Slave) Communication Alarm (For Mechanism Controller) EEPROM Alarm Video Synchronous (VS) Alarm Pre-pick Alarm Video Request (VR) Alarm LCH Elevator Descent Alarm LCH Elevator Ascent Alarm LCS Stacker Alarm
Table 4-2.
Jam Code 01 02 03 11 12 13 Jam Name Jam 0-1 Jam 0-2 Jam 0-3 Jam1-1 Jam 1-2 Jam 1-3
Jam Codes and Messages
Definition Message Paper tray 1 pick error Paper tray 2 pick error Paper tray 3 pick error
Paper did not reach sensor PS1-1 from the upper tray before specified time passed after the pick roller started. Paper did not reach sensor PS1-2 from the middle tray before specified time passed after the pick roller started. Paper did not reach sensor PS1-3 from the lower tray before specified time passed after the pick roller started.
When the printer is reset, there is paper at PS1-1, or Feed path 1 jam Paper did not reach PS2 before specified time passed after the paper reached PS1-1. When the printer is reset, there is paper at PS1-2, or Feed path 2 jam Paper did not reach PS2 before specified time passed after the paper reached PS1-2. When the printer is reset, there is paper at PS1-3, or Feed path 3 jam Paper did not reach PS2 before specified time passed after the paper reached PS1-3.
4-4
General Troubleshooting
SERVICE MANUAL
Table 4-2.
Jam Code 18 25 Jam Name Ja