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magicolor® 3100 Series

Service Manual

1750051-001B
The essentials of imaging
www.minolta-qms.com

ii

Introduction

Introduction

1. Trademarks
The following are trademarks or registered trademarks of their respective owners. Other product names mentioned in this manual may also be trademarks or registered trademarks of their respective owners. Registered trademarks are registered in the United States Patent and Trademark Office; some trademarks may also be registered in other countries. QMS, magicolor, and the MINOLTA-QMS logo are registered trademarks of MINOLTA-QMS, Inc. Minolta is a trade-mark of Minolta Co., Ltd.

2. Copyright Notice
This manual is Copyrighted © 2001 by MINOLTA-QMS, Inc., One Magnum Pass, Mobile, AL 36618. All Rights Reserved. This manual may not be copied in whole or in part, nor transferred to any other media or language, without the express written permission of MINOLTA-QMS, Inc.

v

Cautions for operation
1. Marks giving caution
Maintenance operations requiring special cautions or additional information to descriptions of this manual are presented as "Warning", "Caution", or "Note", according to their nature. If instructions are not observed, death or serious injury may be caused.

If instructions are not observed, injuries of workers or physical damages to assets (including this laser printer) may result.

Particularly important essentials for procedures, steps, rules, and others.

Reference Incidental information to descriptions.

2. Related documents
M Instruction manuals (standard user manuals) Describe operation and handling of this laser printer. M Performance specifications Describe in detail various specifications of this laser printer. (In the event of discrepancy between this manual and the performance specifications, the performance specifications shall take preference.) M Spare parts list Information on maintenance parts (spare parts) for this laser printer

3. Safety
To prevent possible accidents during maintenance operation, you should observe strictly the "Warning" and "Caution" information in this manual. Dangerous operations and operations out of range of this manual should be absolutely avoided. Generally various processes not covered by this manual may be required in actual operation, which should be performed carefully always giving attention to safety.

3.1 Power source
Keep the power supply off during maintenance operation to prevent electric shock, burns and other damages. Keep the power plug disconnected during the maintenance operation. If the power supply should be kept connected for measurement of voltage or other similar reasons, sufficient care should be given to prevent electric shock, by following the procedures of this manual. vi

Introduction While the printer is ON, never touch live parts if not required absolutely.

Power is supplied to the power switch / inlet (LVPS ASSY) even while the printer is off. Never touch its live components.

Do not touch live parts unless otherwise specified.

vii

3.2 Driving units
When servicing gears or other driving units, be sure to turn them OFF and plug off. Drive them manually when required. Never touch the gears or other driving units while the printer is running.

3.3 High-temperature units
When servicing high-temperature units (securing unit, etc.), be sure to turn them OFF to prevent burns, injuries and other troubles, remove the power plug and start service processes after they have cooled down enough. Immediately after completion of operation, they are still hot. Start services after more than 40 minutes.

3.4 Laser beams
·If your eyes are exposed to laser beams, you may lose your eyesight. ·Never open the cover if warning label for laser beams is attached there. ·Before disassembling and reassembling this laser printer, be sure to turn it OFF. ·When servicing this laser printer while it is running, be sure to follow the procedures specified in this manual. ·You should understand the features of the laser beams which are capable of having an injurious action on the human body, not to extend the danger over the workers as well as other people around the printer. Laser beams have features as follows: ·Frequencies are smaller in width than other beams (sun and electric bulbs) and phases are uniform so that high monochromatic and convergence performance can be obtained and thin beams of light can reach places at a long distance. ·Due to the high convergence, beams are concentrated in high density and high temperature, which is dangerous to human body. Reference: Laser beams of this laser printer is invisible rays which you cannot see.

viii

Introduction

3.5 Warning/caution labels
Warning labels and caution labels are attached to this laser printer to prevent accidents Check those labels for their peeling or stain when servicing the printer. 3.5.1 Caution label for high-temperature units

ix

4. List of Abbreviations
ADC AG AUX B/W BCR BTR BUR C CART CCW CL CLN CLK CR CRU CRUM CW DB DTS EP FDR FG FRU Hex I/F IDT ID K L/H L/P LD LEF M Automatic Density Control Analog Ground Auxiliary Blank and White Bias Charge Roller Bias Transfer Roller (Image Transfer Roller) Back Up Roller Cyan Cartridge Counterclockwise Clutch Cleaning (or Cleaner) Clock Charge Roller Customer Replaceable Unit CRU Monitor Clockwise Developing Bias Detack Saw Electrophotography Feeder Frame Ground Field Replaceable Unit Hexadecimal Interface Intermediate Drum Transfer Image Density (or Identification) Black Left Hand Low Paper Laser Diode Long Edge Feed Magenta MPT MSI N/F NP NVM OPC P/H PCDC PHD Pixel PPM PV PWB R/H REGI ROS RTN SEF SG SNR SOL SOS SPI SYNC T/A TC TEMP TR TRANS WDD XERO Y Multipurpose Tray Multi Sheet Inserter Normal Force No Paper Non Volatile Memory Organic Photo Conductor Paper Handling Pixel Count Dispense Control Printer Head (Imaging Cartridge) Picture Cell (Picture Element) Prints per Minute Print Volume Printed Wiring Board Right Hand Registration Raster Output Scanner Return Short Edge Feed Signal Ground Sensor Solenoid Start of Scan Scans per Inch Synchronous Take Away Toner Concentration Temperature Transfer Transport Wide Range Dynamic Damper Xerographic Yellow

x

Introduction

Unpacking the Printer
The printer must be carried horizontally with two or more persons.

Extreme care must be taken to avoid personal injuries

Check visually the printer for evidence of any damages. Peel all tapes off the printer. Remove protection parts (2 pieces) from the paper tray.

xi

xii

Contents

CONTENTS

Introduction ..................................................................................................... iii
1. Trademarks ...................................................................................................................... v 2. Copyright Notice ............................................................................................................... v 1. Marks giving caution........................................................................................................ vi 2. Related documents.......................................................................................................... vi 3. Safety .............................................................................................................................. vi
3.1 Power source .........................................................................................................................................vi 3.2 Driving units ......................................................................................................................................... viii 3.3 High-temperature units ........................................................................................................................ viii 3.4 Laser beams ........................................................................................................................................ viii 3.5 Warning/caution labels...........................................................................................................................ix

4. List of Abbreviations ......................................................................................................... x

Contents........................................................................................................ 13

Chapter 1 Troubleshooting ........................................................................ 1-23
1. Progressing with the Troubleshooting .........................................................................1-25
1.1 Flow of Troubleshooting.................................................................................................................... 1-25 1.2 Preparatory Requirements................................................................................................................ 1-26 1.3 Cautions for Service Operations ....................................................................................................... 1-27 1.4 Cautions for FIP Use......................................................................................................................... 1-28

2. Level 1 FIP ..................................................................................................................1-30
2.1 Level 1 FIP........................................................................................................................................ 1-30 2.2 Flow of Level 1 FIP ........................................................................................................................... 1-30

3. Level 2 FIP ..................................................................................................................1-31
3.1 Level 2 FIP........................................................................................................................................ 1-31 3.2 Error / Status Code List..................................................................................................................... 1-31 3.3 Operating / Clearing the Error........................................................................................................... 1-34 3.4 Error Code FIP.................................................................................................................................. 1-37 3.5 Image Trouble FIP ............................................................................................................................ 1-81 3.6 Roller Circumferences ...................................................................................................................... 1-81 3.7 Other FIPs......................................................................................................................................... 1-92

4. Preventive Maintenance ..............................................................................................1-94

Chapter 2 Operation of Diagnostics........................................................... 2-95
1. Diagnostics for a Standalone Printer ...........................................................................2-97
1.1 General ............................................................................................................................................. 2-97 1.2 Printing Method................................................................................................................................. 2-97

1.3 Test Print Pattern .............................................................................................................................. 2-98

2. Diagnostics Using the MINOLTA- QMS magicolor 3100 Diagnostics (Hanabi Service Commander) .........................................................................................2-99
2.1 General ............................................................................................................................................. 2-99 2.2 Preparation ..................................................................................................................................... 2-100 2.3 Operation of magicolor 3100 Diagnostics ....................................................................................... 2-101 2.4 Test Print......................................................................................................................................... 2-103 2.5 Input Test ........................................................................................................................................ 2-104 2.6 Output Test ..................................................................................................................................... 2-107 2.7 Operation of EEPROM.................................................................................................................... 2-110

Chapter 3 Removal and Replacement Procedures ................................. 3-119
1. Removal and Replacement Procedures.................................................................... 3-121
1.1 Before starting service work............................................................................................................ 3-121 1.2 Description of procedures ............................................................................................................... 3-122

RRP1. COVERS............................................................................................................ 3-123
RRP1.1 CONSOLE PANEL HANABI (PL1.1.1).................................................................................... 3-123 RRP1.2 COVER ASSY FRONT HEAD (PL1.1.2) ................................................................................. 3-124 RRP1.3 FAN FUSER (PL1.1.7) ............................................................................................................ 3-126 RRP1.4 COVER TOP MAIN (PL1.1.9) ................................................................................................. 3-128 RRP1.5 COVER ASSY TOP PHD (PL1.1.10) ...................................................................................... 3-129 RRP1.6 COVER REAR (PL1.1.20)....................................................................................................... 3-130 RRP1.7 LINK:L (PL1.1.23).................................................................................................................... 3-131 RRP1.8 LINK:R (PL1.1.23) ................................................................................................................... 3-132 RRP1.9 COVER SIDE R (PL1.1.24) ..................................................................................................... 3-133 RRP1.10 COVER ASSY FRONT IN (PL1.1.25) ................................................................................... 3-134 RRP1.11 COVER MSI (PL1.1.26) ........................................................................................................ 3-136 RRP1.12 TRAY ASSY MSI (PL1.1.28) ................................................................................................. 3-137 RRP1.13 COVER ASSY FRONT (PL1.1.29)........................................................................................ 3-138 RRP1.14 COVER SIDE L (PL1.1.30) ................................................................................................... 3-140

RRP2. PAPER CASSETTE........................................................................................... 3-141
RRP2.1 ROLL ASSY (PL2.1.1)............................................................................................................. 3-141 RRP2.2 HOLDER RETARD (PL2.1.3).................................................................................................. 3-142 RRP2.3 CASSETTE ASSY FRONT (REFERENCE ONLY) ................................................................. 3-144

RRP3. PAPER FEEDER ............................................................................................... 3-146
RRP3.1 CHUTE ASSY TURN (PL3.1.2)............................................................................................... 3-146 RRP3.2 COVER CASSETTE REAR (PL3.1.3)..................................................................................... 3-148 RRP3.3 FEEDER ASSY UNIT (REFERENCE ONLY) ......................................................................... 3-150 RRP3.4 HOUSING ASSY FEEDER L (REFERENCE ONLY) .............................................................. 3-152 RRP3.5 HOUSING ASSY FEEDER R (REFERENCE ONLY) ............................................................. 3-154 RRP3.6 SENSOR HUM TEMP (PL3.2.2) ............................................................................................. 3-156 RRP3.7 HARNESS ASSY OPFREC (PL3.2.3)..................................................................................... 3-157 16

Table of Contents RRP3.8 SWITCH ASSY SIZE (PL3.2.4) ............................................................................................... 3-158 RRP3.9 LEVER LOW PAPER (PL3.2.7) .............................................................................................. 3-160 RRP3.10 INDICATOR (PL3.2.8)........................................................................................................... 3-162 RRP3.11 GUIDE INDICATOR (PL3.2.10) ............................................................................................ 3-164 RRP3.12 PICKUP ASSY (PL3.3.1)....................................................................................................... 3-166 RRP3.13 ROLL ASSY FEED (PL3.3.2) ................................................................................................ 3-168 RRP3.14 SENSOR PHOTO:NO PAPER (PL3.3.3) .............................................................................. 3-170 RRP3.15 SENSOR PHOTO:LOW PAPER (PL3.3.3) ........................................................................... 3-171 RRP3.16 ACTUATOR NO PAPER (PL3.3.4) ....................................................................................... 3-172 RRP3.17 LINK ACTUATOR (PL3.3.5).................................................................................................. 3-173 RRP3.18 SOLENOID FEED (PL3.3.16) ............................................................................................... 3-174 RRP3.19 CLUTCH ASSY TURN (PL3.3.17) ........................................................................................ 3-175 RRP3.20 ROLL ASSY TURN (PL3.3.19).............................................................................................. 3-176 RRP3.21 ROLL ASSY (PL3.3.22)......................................................................................................... 3-177

RRP4. HOUSING ASSY RETARD................................................................................ 3-178
RRP4.1 HOUSING ASSY RETARD (PL4.1.1) ..................................................................................... 3-178 RRP4.2 ROLL TURN (PL4.1.2) ............................................................................................................ 3-179 RRP4.3 ROLL ASSY RETARD (PL4.1.5)............................................................................................. 3-180 RRP4.4 CLUTCH TURN (PL4.1.9) ....................................................................................................... 3-182 RRP4.5 STUD RTD (PL4.1.10) ............................................................................................................ 3-183

RRP5. FRONT ASSY IN ............................................................................................... 3-184
RRP5.1 FRONT ASSY IN (PL5.1.1) ..................................................................................................... 3-184 RRP5.2 SENSOR ADC ASSY (PL5.1.11) ............................................................................................ 3-187 RRP5.3 SENSOR TNR FULL (PL5.1.13) ............................................................................................. 3-188 RRP5.4 FUSER DRIVE ASSY (PL5.1.18)............................................................................................ 3-190 RRP5.5 LATCH R (PL5.1.21) ............................................................................................................... 3-192 RRP5.6 LATCH L (PL5.1.30)................................................................................................................ 3-193

RRP6. CHUTE ASSY OUT ........................................................................................... 3-194
RRP6.1 CHUTE ASSY OUT (PL6.1.1) ................................................................................................. 3-194 RRP6.2 SENSOR PHOTO:FULL STACK (PL6.1.4)............................................................................. 3-197 RRP6.3 ACTUATOR FULL (PL6.1.5) ................................................................................................... 3-198 RRP6.4 SENSOR PHOTO:DUP (PL6.1.4) ........................................................................................... 3-199 RRP6.5 SENSOR PHOTO:MSI (PL6.1.4) ............................................................................................ 3-200 RRP6.6 ELIMINATOR ASSY (PL6.1.9) ................................................................................................ 3-201 RRP6.7 ROLL DUP (PL6.1.12)............................................................................................................. 3-202 RRP6.8 ACTUATOR DUP (PL6.1.13) .................................................................................................. 3-204 RRP6.9 LATCH OUT (PL6.1.18) .......................................................................................................... 3-206 RRP6.10 ROLL ASSY FEED (PL6.1.27) .............................................................................................. 3-207 RRP6.11 ACTUATOR MSI (PL6.1.37) ................................................................................................. 3-208 RRP6.12 SOLENOID FEED MSI (PL6.1.40) ........................................................................................ 3-209 RRP6.13 SHAFT ASSY ROLL FEED (REFERENCE ONLY)............................................................... 3-210 RRP6.14 PLATE ASSY BOTTOM MSI (PL6.1.42)............................................................................... 3-212

RRP7. CHUTE ASSY EXIT ........................................................................................... 3-213
RRP7.1 CHUTE ASSY EXIT (PL7.1.1)................................................................................................. 3-213 17

RRP7.2 ROLL EXIT (PL7.1.4) ............................................................................................................. 3-214 RRP7.3 ROLL MID (PL7.1.5)................................................................................................................ 3-215 RRP7.4 MOTOR ASSY DUP (PL7.1.8) ................................................................................................ 3-216

RRP8. BTR ASSY & FUSER......................................................................................... 3-217
RRP8.1 FUSER ASSY (PL8.1.1).......................................................................................................... 3-217 RRP8.2 ROLL ASSY EXIT (PL8.1.3).................................................................................................... 3-218 RRP8.3 ACTUATOR EXIT (PL8.1.7) .................................................................................................... 3-220 RRP8.4 BTR UNIT ASSY (PL8.1.12) ................................................................................................... 3-221 RRP8.5 STRAP (PL8.1.13)................................................................................................................... 3-222

RRP9. XEROGRAPHICS .............................................................................................. 3-224
RRP9.1 ROS ASSY (PL9.1.1) .............................................................................................................. 3-224 RRP9.2 HSG ASSY BIAS (PL9.1.4) ..................................................................................................... 3-226 RRP9.3 CHUTE ASSY REGI (PL9.1.6) ................................................................................................ 3-228 RRP9.4 SENSOR PHOTO:REGI (PL9.1.8).......................................................................................... 3-230 RRP9.5 ACTUATOR REGI (PL9.1.9) ................................................................................................... 3-231 RRP9.6 OHP SENSOR ASSY (PL9.1.12) ............................................................................................ 3-232

RRP10. TCRU ASSY .................................................................................................... 3-236
RRP10.1 HOLDER TCRU ASSY UNIT (REFERENCE ONLY) ............................................................ 3-236 RRP10.2 HOLDER TCRU ASSY (1) (PL10.1.1)................................................................................... 3-239 RRP10.3 HOLDER TCRU ASSY (2) (PL10.1.2)................................................................................... 3-240 RRP10.4 HOLDER TCRU ASSY (3) (PL10.1.3)................................................................................... 3-241 RRP10.5 HOLDER TCRU ASSY (4) (PL10.1.4)................................................................................... 3-242 RRP10.6 SWITCH TCRU ASSY (PL10.1.18)....................................................................................... 3-243 RRP10.7 SENSOR TONER LOW (PL10.1.8)....................................................................................... 3-244 RRP10.8 PWBA EEPROM STD (PL10.1.16) ....................................................................................... 3-245 RRP10.9 S-HVPS (PL10.1.17) ............................................................................................................. 3-246

RRP11. FRAME & DRIVE ............................................................................................. 3-247
RRP11.1 LEVER DRUM:L (PL11.1.4) .................................................................................................. 3-247 RRP11.2 LEVER DRUM:R (PL11.1.4) ................................................................................................. 3-250 RRP11.3 ACTUATOR I/R (PL11.1.8) ................................................................................................... 3-253 RRP11.4 DEVE DRIVE ASSY (PL11.1.13) .......................................................................................... 3-254 RRP11.5 MAIN DRIVE ASSY (PL11.1.14) ........................................................................................... 3-255 RRP11.6 PWBA ASSY EARTH (PL11.1.16) ........................................................................................ 3-256

RRP12. ELECTRICAL...................................................................................................3-258
RRP12.1 PWBA HNB MCU (PL12.1.1) ................................................................................................ 3-258 RRP12.2 FAN REAR (PL12.1.2) .......................................................................................................... 3-260 RRP12.3 CONTROLLER BOARD (PL12.1.4)(TBD)............................................................................. 3-261 RRP12.4 LVPS (PL12.1.10) ................................................................................................................. 3-262 RRP12.5 HARNESS ASSY AC SW (PL12.1.11).................................................................................. 3-264 RRP12.6 PWBA HNB DRV (PL12.1.12) ............................................................................................... 3-265 RRP12.7 BOX ASSY MCU/ESS (REFERENCE ONLY) ...................................................................... 3-266 RRP12.8 HOUSING ASSY CONTACT (PL12.1.14)............................................................................. 3-268

18

Table of Contents

Chapter 4 Plug/Jack (P/J) Connector Locations ...................................... 4-271
1. Connector [P (plug) / J (jack)].................................................................................... 4-273
1.1 List of P/J ........................................................................................................................................ 4-273 1.2 P/J layout diagram .......................................................................................................................... 4-275

Chapter 5 Parts List ................................................................................. 5-279
1. Parts List.................................................................................................................... 5-281
1.1 Caution for use of parts list ............................................................................................................. 5-281

Chapter 6 Principles of Operation............................................................ 6-313
1. Printing Process ........................................................................................................6-315
1.1 Summary of Printing Process ......................................................................................................... 6-315 1.2 Schematic Diagram for Printing Processes .................................................................................... 6-316 1.3 Description of Printing Process Techniques ................................................................................... 6-317

2. Flow of Print Data ...................................................................................................... 6-330
2.1 Data Flow........................................................................................................................................ 6-330

3. Drive Transmission Route ......................................................................................... 6-331
3.1 MAIN DRIVE ASSY ........................................................................................................................ 6-331 3.2 DEVE DRIVE ASSY........................................................................................................................ 6-332 3.3 HOLDER TCRU ASSY (Y, M, C, K)................................................................................................ 6-332 3.4 FUSER DRIVE ASSY ..................................................................................................................... 6-333 3.5 MOTOR ASSY DUP ....................................................................................................................... 6-333 3.6 Gear · Layout .................................................................................................................................. 6-334

4. Paper Transport......................................................................................................... 6-335
4.1 Paper Transport Route (without option).......................................................................................... 6-335 4.2 Layout of Paper Transport Route.................................................................................................... 6-336

5. Functions of Major Functional Components ..............................................................6-337
5.1 Paper Cassette ............................................................................................................................... 6-338 5.2 Paper Feeder .................................................................................................................................. 6-340 5.3 Housing Assy Retard ...................................................................................................................... 6-342 5.4 Front Assy In................................................................................................................................... 6-344 5.5 Chute Assy Out............................................................................................................................... 6-346 5.6 Chute Assy Exit............................................................................................................................... 6-348 5.7 BTR Assy & Fuser .......................................................................................................................... 6-350 5.8 Xerographics................................................................................................................................... 6-352 5.9 TCRU Assy ..................................................................................................................................... 6-354 5.10 Frame & Drive............................................................................................................................... 6-356 5.11 Electrical ....................................................................................................................................... 6-358

6. MODES ..................................................................................................................... 6-360
6.1 Print Mode....................................................................................................................................... 6-360 19

6.2 Operation Modes ............................................................................................................................ 6-360

7. Control ....................................................................................................................... 6-361
7.1 Control of Paper Size...................................................................................................................... 6-361 7.2 Selective Control on Paper Pick-up Unit......................................................................................... 6-361 7.3 ROS Light Quantity Control ............................................................................................................ 6-361 7.4 Process Control .............................................................................................................................. 6-362 7.5 Color Registration Control............................................................................................................... 6-365 7.6 BTR UNIT ASSY Control ................................................................................................................ 6-366 7.7 Toner Control .................................................................................................................................. 6-367 7.8 Fuser Control .................................................................................................................................. 6-368

Chapter 7 Wiring Diagrams and Signal Information................................. 7-369
1. General Wiring Diagram ............................................................................................ 7-371 1. Wiring Diagram between Parts................................................................................. 7-373
1.1 Configuration................................................................................................................................... 7-373 1.2 Notes on Using the Wiring Diagram between Parts........................................................................ 7-375

Chapter 8 Printer Specifications .............................................................. 8-401
1. Configuration of Printer.............................................................................................. 8-403
1.1 Basic Configuration......................................................................................................................... 8-403 1.2 Functional Configuration ................................................................................................................. 8-403

2. Electrical Properties...................................................................................................8-404
2.1 Power Source ................................................................................................................................. 8-404 2.2 Power Consumption........................................................................................................................ 8-404

3. Mechanical Properties ............................................................................................... 8-404
3.1 Dimensions/Mass of Printer ............................................................................................................ 8-404 3.2 Dimensions/Mass of Universal Paper Tray (standard paper supply - 500 sheets) ......................... 8-405 3.3 Dimensions/Mass of Consumables (CRU) ..................................................................................... 8-405 3.4 Installation Space (min. installation space)..................................................................................... 8-406

4. Functions ...................................................................................................................8-407
4.1 Recording System........................................................................................................................... 8-407 4.2 Exposure System............................................................................................................................ 8-407 4.3 Development System...................................................................................................................... 8-407 4.4 Fixing System ................................................................................................................................. 8-407 4.5 Resolution ....................................................................................................................................... 8-407 4.6 Operation Mode .............................................................................................................................. 8-407 4.7 Speed Mode.................................................................................................................................... 8-408 4.8 Print Mode....................................................................................................................................... 8-408 4.9 Paper Mode .................................................................................................................................... 8-408 4.10 Warm-up Time .............................................................................................................................. 8-409 4.11 FPOT (First Print Output Time) ..................................................................................................... 8-409 20

Table of Contents 4.12 Continuous Printing Speed ........................................................................................................... 8-409 4.13 Printing Area ................................................................................................................................. 8-410 4.14 Input Properties............................................................................................................................. 8-411 4.15 Output Properties.......................................................................................................................... 8-412 4.16 Paper ............................................................................................................................................ 8-412

5. Consumables............................................................................................................. 8-413
5.1 Items of Consumables .................................................................................................................... 8-413 5.2 Consumable Life ............................................................................................................................. 8-413 5.3 Parts Requiring Periodical Replacement ........................................................................................ 8-414

6. Operating Environment.............................................................................................. 8-414
6.1 Installation Temperature / Humidity ................................................................................................ 8-414 6.2 Installation Altitude.......................................................................................................................... 8-414 6.3 Installation Horizontality .................................................................................................................. 8-414 6.4 Ambient Lighting ............................................................................................................................. 8-414

7. Safety / Environment Conditions ............................................................................... 8-414
7.1 Safety Standard .............................................................................................................................. 8-414 7.2 Laser Safety Standard .................................................................................................................... 8-414 7.3 EMI.................................................................................................................................................. 8-414 7.4 Noise............................................................................................................................................... 8-415

8. Print image Quality .................................................................................................... 8-415
8.1 Image Quality Guarantee Conditions.............................................................................................. 8-415

9. Option ........................................................................................................................ 8-415
9.1 Options to be Installed by Users ..................................................................................................... 8-416

Index ......................................................................................................... I-417

21

22

Chapter 1 Troubleshooting

Chapter 1 Troubleshooting Troubleshooting in this manual assumes use of Diag. tools (maintenance tools). However, the troubleshooting allows for the case where the Diag tools are not used. You can correct troubles according to these troubleshooting procedures after understanding them well.

1. Progressing with the Troubleshooting
After making sure of actual condition of a trouble, proceed with the troubleshooting process making use of the Fault Isolation Procedure (FIP), "Operation of Diagostics" (Chapter 2), "Plug/Jack (P/J) Connector Locations" (Chapter 7), and "Principles of Operation" (Chapter 6).

1.1 Flow of Troubleshooting
Flow of the troubleshooting is as follows:

Prior check

Condition check

Diagnostic operation Operational principle Wiring connection diagram

Start

Level 1 FIP

Level 2 FIP

Trouble recovery check

Preventive maintenance

End

1-25

1.2 Preparatory Requirements
Be sure to check the following items before starting any troubleshooting procedures: 1) 2) Voltage of the power supply is within the specifications (measure the voltage at the electric outlet). Power cord is free from breakage, short-circuit, disconnected wire, or incorrect connection in the power cord. 3) 4) The laser printer is properly grounded. The laser printer is not installed at a place subjected to too high temperature, too high humidity, too low temperature, too low humidity or rapid change of temperature. 5) The laser printer is not installed close to water service, humidifier, heat generating unit, or fire, in very dusty place, or a place exposed to air flow from the air conditioning system. 6) 7) 8) 9) The laser printer is not installed in a place where volatile gas or inflammable gas is generated. The laser printer is not installed under direct sunbeams. The laser printer is installed in a well-ventilated place. The laser printer is installed on a stout and stable plane.

10) Paper used meets specifications (standard paper is recommendable). 11) The laser printer is handled properly. 12) Parts which should be periodically replaced are replaced each time when specified number of sheets have been printed.

1-26

Chapter 1 Troubleshooting

1.3 Cautions for Service Operations
1) Be sure to remove the power cord except when it is specifically required. If the printer is kept ON, never touch the conductive parts while it is not specifically required. The power switch/inlet of LVPS is live even while the power supply is cut off. Never touch the live parts. 2) When checking some parts with covers removed and with the interlock and safety and power switches ON, remove the connector (P/J151) on the ROS ASSY except when it is specifically required. When checking some parts with covers removed and with the interlock and safety and power switches ON, laser beams may be irradiated from the ROS ASSY. Since it is dangerous, be sure to remove the connector (P/J151) while it is not required. 3) When checking some parts with the left cover removed and power ON, be sure to remove the connector (P/J5011) on the HVPS while it is not required. When checking some parts with the left cover removed and power ON, high voltage may be applied by the HVPS. Be sure to remove the connector (P/J5011) on the HVPS. When connecting the connector (P/J5011) on the HVPS according to the instructions of the FIP, never touch the HVPS and parts of high voltage. 4) When using Diag. tools or other tools of high voltage, be sure to keep them covered except when otherwise specified. When using Diag.Tool or other tools of high voltage, never touch parts of high voltage. When using Diag.Tool or other tools of high voltage, be sure to follow the procedure of this manual. 5)When operating the driving units using the Diag or other tools, be sure to keep them covered unless otherwise specified. When operating the driving units using the Diag or other tools, never touch the driving units. When operating the driving units using Diag or other tools, be sure to observe the procedures in this manual. 6) 7) When touching hot parts, be careful not to get burnt. Workers should wear a wrist band or the like to remove static electricity from their body, grounding their body while working.

1-27

1.4 Cautions for FIP Use
1) It is assumed in the FIP that the printer controller (CONTROLLER PWB) is normally functioning. If the trouble cannot be corrected by troubleshooting, replace the printer controller with a normal one and check for proper operation again. If the trouble is still not corrected, replace the major parts and then related parts in succession and confirm according to the procedure of the "Initial check" and "Major check parts". 2) When troubleshooting according to the FIP, normal HNB MCU PWB, Imaging Unit (PHD) or other parts may be necessary for isolation of failed parts. Prepare them in advance. 3) 4) In the initial check according to the FIP, check only items which can be simply checked. In the initial check according to the FIP, check the constitutive parts of the major check parts and related parts, as well as major check parts. 5) When working with the printer, Be sure to remove the power cord except when required specifically. Never touch live parts if not required, while the power cord is connected. 6) Connector condition is denoted as follows: [P/J12] ¡ Connector (P/J12) is connected. [P12] [J12] 7) ¡ Plug side with the connector (P/J12) removed (except when attached directly to the board). ¡ Jack side with the connector (P/J12) removed (except when attached directly to the board).

[P/J1-2PIN <=> P/J3-4PIN] in the FIP means measurement with the plus side of the measuring instrument connected to [P/J1] and the minus side to [4PIN] of [P/J3].

8)

[P/J<=>P/12] in the FIP means measurement for all terminals corresponding between [P/J1] and [P/J2] referring to "Wire connecting diagram".

9)

In [P/J1-2PIN <=> P/J3-4PIN] in the FIP where voltage is measured, [P/J3-4PIN] on the rear minus side is always at the AG (analog ground), SG (signal ground), or RTN (return). Therefore, after checking of proper continuity between AGs, SGs, or RTNs respectively, the rear minus side can be connected to the PIN of AG, SG or RTN instead of [P/J3-4PIN]. However, care should be taken not to mistake since [AG], [SG], and [RTN] are not on the same level.

10) Measure the voltage of small connectors with the special tool. Handle the tool with care, as the leading edge of the tool is pointed. 11) When measuring the voltage, set the PDH ASSY, FUSER ASSY, BRT ASSY and paper tray, close the FRONT COVER ASSY and power ON if not required specifically. 12) Numerical values in the FIP are only for standard. If numerical values are approximate, they should be considered permissible.

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Chapter 1 Troubleshooting 13) Parts which are always removed to check as indicated in the FIP and procedures for that purpose are not specifically referred to here. They should be handled carefully. 14) "Replacement" in the FIP indicates replacement of parts which are considered to be the source of trouble to be checked after replacing those parts, assemblies containing them, or parts (HIGH ASSY). 15) In the FIP, the paper pick-up unit by means of the paper tray at the lower part of the printer is referred to as "try 1", the first level of the paper pick-up unit feeder unit as "try 2", and the second level as the "tray3". 16) In the FIP, existence and non-existence of Diag tools (maintenance tools,) are distinguished in some cases. Correct troubles according to the instructions in the FIP. 17) In the FIP, procedures are differentiated depending on specifications. Correct troubles according to the instructions in the FIP. 18) For optional parts, some troubleshooting procedure may follow the manual for those options, of which you should take note. Keep those manuals for the optional parts when required.

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2. Level 1 FIP
2.1 Level 1 FIP
The level 1 FIP is the first step for trouble diagnosis. The level 1 FIP isolates the presence of various troubles including error codes, and the level 2 FIP provides a guide for proceeding of the troubleshooting.

2.2 Flow of Level 1 FIP

Ask the operator about trouble status Is operator's operating method correct? Y N

Is error code displayed? Y N

Instruct how to operate

Is trouble related to image quality? Y N

Image quality FIP

Print in the mode where the trouble occurred to check if error or jam occurs Y N

Level 2 FIP

Level 2 FIP

Other FIP

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Chapter 1 Troubleshooting

3. Level 2 FIP
3.1 Level 2 FIP
The Level 2 FIP is the trouble diagnostic procedure to sort various troubles in addition to the error codes. In the troubleshooting, executing the steps given in the FIP or checking procedure allows you to find out a cause of trouble in a short time.

3.2 Error / Status Code List
This error / status cord list is based on the interface specifications. Since the error / status codes are represented by the printer controller on the printer, display on the printer is shown in parentheses below.

Reference FIP 1

Name of error Contents of error Yellow Toner Cartridge Detached (Yellow Toner Cartridge Missing) Cartridge sensor detected no-toner cartridge. Magenta Toner Cartridge Detached (Magenta Toner Cartridge Missing) Cartridge sensor detected no-toner cartridge. Cyan Toner Cartridge Detached (Cyan Toner Cartridge Missing) Cartridge sensor detected no-toner cartridge. Black Toner Cartridge Detached (Black Toner Cartridge Missing) Cartridge sensor detected no-toner cartridge. PHD Detached (Imaging Unit Missing) Machine detected no-Imaging Unit (PHD). BTR Detached (Transfer Unit Missing) Machine detected no-Transfer Unit (BTR). Fuser Detached (Fuser Unit Missing) Machine detected no-FUSER ASSY. CRUM ID Error (Call for Service CRUM ID Error) ID of Imaging Unit (PHD) is different from the recorded ID. CRUM ID Error (Invalid Imaging Unit) ID of Imaging Unit (PHD) is different from the recorded ID. Media Type Mismatch (Media Type Mismatch) 1. Plain paper was detected in the printing by selecting OHP. 2. OHP was detected in the printing by selecting plain paper. Feed Jam (Media Feed Jam) Regi sensor cannot detect paper within specified time. Regi Jam (Media Jam Registration) Regi sensor cannot detect passage of paper within specified time. Fuser Jam (Media Jam Fuser) Exit sensor cannot detect passage of paper within specified time.

Reference FIP page # 37

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

38 39 40 41 42 43 44 45 46 47 50 51 1-31

Reference FIP

Name of error Contents of error Duplex Jam (Media Jam Duplex) Duplex jam sensor cannot detect passage of paper within specified time. ROS Failure (Call for Service ROS Motor) 1. Laser power down. 2. SOS signal not detected. Fuser Failure (Call for Service Fuser Failure) 1. Temperature exceeding 235°C detected consecutively 4 times. 2. Temperature below 120°C detected consecutively 4 times. 3. Resistance value of STS sensor over 2437KW detected consecutively 4 times. 4. Target temperature is not reached more than 60 seconds after the fuser lamp lighted up. 5. After the target temperature is reached, the fuser lamp was kept ON for more than specified time. 6. Value of the STS sensor does not change after the lamp lights up. 7. Temperature exceeding 230°C detected during printing process consecutively twice. NV-RAM Error (Call for Service NV-RAM Error) Error of NV-RAM ADC Sensor Error (ADC Sensor Dustiness Warning) Power down of ADC sensor Fan Motor Failure (Call for Service Fan Motor Error) Failure of Fan Motor Low Density Error (Call for Service Low Density) Toner density is low. Firmware Error (Call for Service Firmware Error) Error of software Environment Sensor Error (Call for Service ENV Sensor Error) 1. The temperature over +100°C or below -20°C was detected. 2. The humidity over 100% was detected. Yellow Toner Empty (Yellow Toner Low) Yellow toner emptied. Magenta Toner Empty (Magenta Toner Low) Magenta toner emptied. Cyan Toner Empty (Cyan Toner Low) Cyan toner emptied. Black Toner Empty (Black Toner Low) Black toner emptied. PHD Life Over (Replace Imaging Unit) Imaging Unit (PHD) life expired. BTR Life Over (Replace Transfer Unit) Transfer Unit (BTR) life expired. Fuser Life Over (Replace Fuser Unit) FUSER ASSY life expired.

Reference FIP page # 52

14

15

54

16

55

17 18 19 20 21 22 23 24 25 26 27 28 29 1-32

56 57 58 60 61 62 63 64 65 66 67 68 69

Chapter 1 Troubleshooting Reference FIP 30 31 32 33 34 35 36 37 38 39 40 Name of error Contents of error ADC Sensor Dustiness (ADC Sensor Dustiness Error) ADC sensor signal level below specified value. Front Cover (Front Cover Open) Front cover open. BTR Life Warning (Transfer Unit Life Low) Transfer Unit (BTR) life running out. Fuser Life Warning (Fuser Life Low) Fuser life running out. Paper Empty (Put %s in %s Bin) Paper in the paper cassette exhausted. Upper Cassette Detached (Adjust Input Bin) Paper cassette dislocated. Full Stack (Output Bin Full) Delivery tray full of paper Yellow Toner Empty 2 (Yellow Toner Empty) Yellow toner emptied. Magenta Toner Empty 2 (Magenta Toner Empty) Magenta toner emptied. Cyan Toner Empty 2 (Cyan Toner Empty) Cyan toner emptied. Black Toner Empty 2 (Black Toner Empty) Black toner emptied. Reference FIP page # 70 71 72 73 74 75 76 77 78 79 80

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3.3 Operating / Clearing the Error
In the table below, "shutdown" means that control over motors, ROS ASSY, FUSER ASSY and so on is stopped after a certain time. In the table below, "print" means that printing is continued even if error message is generated.

Diag Error Message (Display Error Message) Yellow Toner Cartridge Detached (Yellow Toner Cartridge Missing) Magenta Toner Cartridge Detached (Magenta Toner Cartridge Missing) Cyan Toner Cartridge Detached (Cyan Toner Cartridge Missing) Black Toner Cartridge Detached (Black Toner Cartridge Missing) PHD Detached (Imaging Unit Missing) BTR Detached (Transfer Unit Missing) Fuser Detached (Fuser Unit Missing) CRUM ID Error (Call for Service CRUM ID Error) or (Invalid Imaging Unit) Media Type Mismatch (Media Type Mismatch) Feed Jam (Media Feed Jam) Regi Jam (Media Jam Registration) Fuser Jam (Media Jam Fuser) Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown

Operation Method of clearing

Imaging Unit (PHD) replacement Shutdown Transfer Unit (BTR) replacement Shutdown Power OFF/ON after replacing the FUSER ASSY Shutdown Imaging Unit (PHD) replacement Shutdown Power OFF/ON after removing the jam paper Next paper is not picked up after a sheet of paper is delivered during operation Open and close the front cover after removing the jammed paper Shutdown Open and close the front cover after removing the jammed paper Shutdown Open and close the front cover after removing the jammed paper

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Chapter 1 Troubleshooting Diag Error Message (Display Error Message) Duplex Jam (Media Jam Duplex) ROS Failure (Call for Service ROS Motor) Shutdown Open and close the front cover after removing the jammed paper Shutdown Power ON/OFF Operation Method of clearing

Fuser Failure (Call for Shutdown Service Fuser Failure) Power ON/OFF NV-RAM Error (Call for Service NV-RAM Error) ADC Sensor Error (ADC Sensor Dustiness Warning) Fan Motor Failure (Call for Service Fan Motor Error) Low Density Error (Call for Service Low Density) Firmware Error (Call for Service) Environment Sensor Error (Call for Service Sensor Error) Yellow Toner Empty (Yellow Toner Low) Magenta Toner Empty (Magenta Toner Low) Cyan Toner Empty (Cyan Toner Low) Black Toner Empty (Black Toner Low) PHD Life Over (Replace Imaging Unit) BTR Life Over (Replace Transfer Unit) Fuser Life Over (Replace Fuser Unit) ADC Sensor Dustiness (ADC Warning) Front Cover (Front Cover Open) Shutdown Power ON/OFF Shutdown Power ON/OFF Shutdown Power ON/OFF Shutdown Power ON/OFF Shutdown Power ON/OFF Shutdown Power ON/OFF Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown Imaging Unit (PHD) replacement Shutdown Transfer Unit (BTR) replacement Shutdown Clearing the counter after replacing the FUSER ASSY Print Open and close the front cover after cleaning the sensor Shutdown Close the front cover

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Diag Error Message (Display Error Message) Yellow Toner Near Empty (Yellow Toner Low) Magenta Toner Near Empty (Magenta Toner Low) Cyan Toner Near Empty (Cyan Toner Low) Black Toner Near Empty (Black Toner Low) PHD Life Warning (Imaging Unit Life Low) BTR Life Warning (Transfer Unit Life Low) Fuser Life Warning (Fuser Life Low) ADC Sensor Dustiness (ADC Sensor Dustiness Error) Paper Empty (Put Paper in Input Bin) Upper Cassette Detached (Adjust Input Bin) Full Stack (Output Bin Full) Yellow Toner Empty 2 (Yellow Toner Empty) Magenta Toner Empty 2 (Magenta Toner Empty) Cyan Toner Empty 2 (Cyan Toner Empty) Black Toner Empty 2 (Black Toner Empty) Print Toner cartridge replacement Print Toner cartridge replacement Print Toner cartridge replacement Print Toner cartridge replacement Print

Operation Method of clearing

Imaging Unit (PHD) replacement Print Transfer Unit (BTR) replacement Print Replace the FUSER ASSY and clear the counter Print Clean the sensor and open and close the front cover Print (Paper cannot be delivered from the cassette) Replenish the paper Print (Paper cannot be delivered from the cassette) Paper cassette replacement Print Take out paper from the delivery tray Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement Shutdown Toner cartridge replacement

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Chapter 1 Troubleshooting

3.4 Error Code FIP FIP-1 Yellow Toner Cartridge Detached (Yellow Toner Cartridge Missing)
Step Check Initial check. Check the following for damage: Cartridge condition SW TCRU ASSY (Y) condition SW TCRU ASSY (Y) actuator condition SW TCRU ASSY SW TCRU ASSY (Y) connector condition Check SW TCRU ASSY Using the diagnostic tool, check by Diagnostic Input Test. Does SW TCRU ASSY (Yellow Cartridge Toner Bottle Sensor) function normally? Check PWBA HNB DRV for signal Is P/J51-11PIN <=> P/J51-12PIN 0VDC? Check SW TCRU ASSY (Y) for signal Is P/J431-2PIN<=>P/J431-1PIN 0VDC? Check SW TCRU ASSY (Y) for continuity Is P431-2PIN <=> P431-1PIN of SW TCRU ASSY (Y) check continuous? Check HARNESS ASSY TNR for continuity J51 <=> J431 check continuous? Check PWBA HNB DRV for signal Is P/J42-4PIN<=>P/J42-14PIN 0VDC? Check PWBA HNB MCU for signal Is P/J12-27PIN <=> P/J12-17PIN of PWBA HNB MCU PWB 0VDC? Check HARNESS ASSY DRV2 for continuity J12 <=> J42 check continuous?

Yes

No With tool Go to step [2] Without tool Go to step [3]

1

Replace the parts concerned

2

Replace PWBA HNB MCU Go to step [7] Go to step [6] Go to step [6]

Go to step [3]

3 4 5

Go to step [4] Go to step [5] Replace SW TCRU ASSY (Y) Replace HARNESS ASSY TNR Replace PWB HNB DRV Go to step [9] Replace HARNESS ASSY DRV2

6 7 8

Go to step [7] Go to step [8] Replace PWBA HNB MCU Replace PWBA HNB MCU

9

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FIP-2 Magenta Toner Cartridge Detached (Magenta Toner Cartridge Missing)
Step Check Initial check Check the following for damage. Cartridge condition SW TCRU ASSY (M) condition SW TCRU ASSY (M) actuator condition SW TCRU ASSY SW TCRU ASSY (M) connector condition Check SW TCRU ASSY Using the diagnostic tool, check by Diagnostic Input Test. Does SW TCRU ASSY (Magenta Cartridge Toner Bottle Sensor) function normally? Check PWBA HNB DRV for signal Is P/J51-13PIN <=> P/J51-14PIN 0VDC? Check SW TCRU ASSY(M) for signal Is P/J432-2PIN <=> P/J432-1PIN 0VDC? Check SW TCRU ASSY (M) for continuity P432-2PIN <=> P432-1PIN of SW TCRU ASSY (M) check continuous? Check HARNESS ASSY TNR for continuity J51 <=> J432 check continuous? Check PWBA HNB DRV for signal Is P/J42-5PIN <=> P/J42-14PIN 0VDC? Check PWBA HNB MCU for signal Is P/J11-26PIN <=> P/J11-17PIN of HNB MCU WITHMCU PWB 0VDC? Check HARNESS ASSY DRV2 for continuity J12 <=> J42 check continuous?

Yes

No With tool Go to step [2] Without tool Go to step [3]

1

Replace the parts concerned

2

Replace PWBA HNB MCU Go to step [7] Go to step [6] Go to step [6]

Go to step [3]

3 4 5

Go to step [4] Go to step [5] Replace SW TCRU ASSY (M) Replace HARNESS ASSY TNR Replace PWB HNB DRV Go to step [9] Replace HARNESS ASSY DRV2

6 7 8

Go to step [7] Go to step [8] Replace PWBA HNB MCU Replace PWBA HNB MCU

9

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Chapter 1 Troubleshooting

FIP-3 Cyan Toner Cartridge Detached (Cyan Toner Cartridge Missing)
Step Check Initial check Check the following for damage. Cartridge condition SW TCRU ASSY (C) condition SW TCRU ASSY (C) actuator condition SW TCRU ASSY SW TCRU ASSY (C) connector condition Check SW TCRU ASSY Using the diagnostic tool, check by Diagnostic Input Test. Does SW TCRU ASSY (Cyan Cartridge Toner Bottle Sensor) function normally? Check PWBA HNB DRV for signal Is P/J51-29PIN <=> P/J51-30PIN 0VDC? Check SW TCRU ASSY (C) for signal Is P/J433-2PIN <=> P/J433-1PIN 0VDC? Check SW TCRU ASSY (C) for continuity P433-2PIN <=> P433-1PIN of SW TCRU ASSY (C) check continuous? Check HARNESS ASSY TNR for continuity J51 <=> J433 check continuous? Check PWBA HNB DRV for signal Is P/J42-6PIN <=> P/J42-14PIN 0VDC? Check PWBA HNB MCU for signal Is P/J12-25PIN <=> P/J12-17PIN of PWBA HNB MCU PWB 0VDC? Check HARNESS ASSY DRV2 for continuity J12 <=> J42 check continuous?

Yes

No With tool Go to step [2] Without tool Go to step [3]

1

Replace the parts concerned

2

Replace PWBA HNB MCU Go to step [7] Go to step [6] Go to step [6]

Go to step [3]

3 4 5

Go to step [4] Go to step [5] Replace SW TCRU ASSY (C) Replace HARNESS ASSY TNR Replace PWB HNB DRV Go to step [9] Replace HARNESS ASSY DRV2

6 7 8

Go to step [7] Go to step [8] Replace PWBA HNB MCU Replace PWBA HNB MCU

9

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FIP-4 Black Toner Cartridge Detached (Black Toner Cartridge Missing)
Step Check Initial check Check the following for damage. Cartridge condition SW TCRU ASSY (K) condition SW TCRU ASSY (K) actuator condition SW TCRU ASSY SW TCRU ASSY (K) connector condition Check SW TCRU ASSY Using the diagnostic tool, check by Diagnostic Input Test. Does SW TCRU ASSY (Black Cartridge Toner Bottle Sensor) function normally? Check PWBA HNB DRV for signal Is P/J51-31PIN<=>P/J51-32PIN 0VDC? Check SW TCRU ASSY (K) for signal Is P/J434-2PIN<=>P/J434-1PIN 0VDC? Check SW TCRU ASSY (K) for continuity P434-2PIN <=> P434-1PIN of SW TCRU ASSY (K) check continuous? Check HARNESS ASSY TNR for continuity J51 <=> J434 check continuous? Check PWBA HNB DRV for signal Is P/J42-3PIN <=> P/J42-14PIN 0VDC? Check PWBA HNB MCU for signal Is P/J12-28PIN <=> P/J12-17PIN of PWBA HNB MCU PWB 0VDC?