FS-1016MFP

SERVICE MANUAL
Published in February 2006 842G4110 2G4SM060 First Edition

Revision history
Revision Date Replaced pages Remarks

Safety precautions

This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.

The specific action required is shown inside the symbol. Warning of high temperature. CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol. indicates a prohibited action. The specific point of attention is shown inside the symbol. Warning of risk of electric shock. General action required. Remove the power plug from the wall outlet. Disassembly prohibited. indicates that action is required. Symbols The triangle ( ) symbol indicates a warning including danger and caution. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol. General prohibited action. . General warning.Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol. Always ground the copier. The specific prohibition is shown inside the symbol.

............. Never connect the ground cable to any of the following: gas pipes... other heat source or near flammable material... ................................. ...... .. Not grounding the copier may cause fire or electric shock....... • Avoid inhaling toner or developer excessively................................................................................ Insufficient ventilation may cause heat buildup and poor copying performance...... ............................... This may cause fire......... rinse immediately with copious amounts of water and obtain medical attention.. Connecting the earth wire to an object not approved for the purpose may cause explosion or electric shock.. Failure to do this may cause the copier to move unexpectedly or topple........ heater................................ . ...Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified........................... ground cables for telephone lines and water pipes or faucets not approved by the proper authorities............. drink a lot of water to dilute it in the stomach and obtain medical attention immediately........................................ When using an extension cable............ • Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool as possible........................ CAUTION: • Do not place the copier on an infirm or angled surface: the copier may tip over................... lightning rods.. This may cause fire or electric shock...... • Connect the ground wire to a suitable grounding point... Protect the eyes...... • Advice customers that they must always follow the safety warnings and precautions in the copier’s instruction handbook............................................................... .... .... always check that it is adequate for the rated current..................... .......................... ..................... leading to injury..... If toner or developer is accidentally ingested... .......................................................................... Avoid multiple connections to one outlet: they may cause fire or electric shock............................... causing injury...... • Do not install the copier near a radiator....................... If it gets into the eyes............1................................... • Always handle the machine by the correct locations when moving it... • Always use anti-toppling and locking devices on copiers so equipped............................. • Do not install the copier in a humid or dusty place.........

............................................. • Handle the charger sections with care........... • Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits........ ................. ................................................. .... CAUTION • Wear safe clothing................ make sure they are safely secured so they will not be caught in rotating sections.. . • Check that the power cable covering is free of damage..............................2.................................. • Always follow the procedures for maintenance described in the service manual and other related brochures.. always use the correct scale and measure carefully............................ They are charged to high potentials and may cause electric shock if handled improperly.... • Always use the thermostat or thermal fuse specified in the service manual or other related brochure when replacing them................ • Handle the fixing section with care to avoid burns as it can be extremely hot........ Check that the power plug is dust-free...............Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly............................................................ .............. Leaking laser light may damage eyesight.................................................................................................................................................................................................... • When the service manual or other serious brochure specifies a distance or gap for installation of a part.. for example..... Keep away from chains and belts... If wearing loose clothing or accessories such as ties......................... ................. Dirt on them can cause abnormally high temperatures............... • Always use parts having the correct specifications... ... ...................................... • Never attempt to disassemble the optical unit in machines using lasers....................................... clean it to remove the risk of fire or electric shock....................... ............................................... Using a piece of wire.................................. If it is dirty.................... ................................................ could lead to fire or other serious accident........................................................... heat and press rollers are clean.............. .. ................ • Use utmost caution when working on a powered machine........................................... • Check that the fixing unit thermistor...... ......... • Always check that the copier is correctly connected to an outlet with a ground connection...................... .................. ............

................. • Do not pull on the AC power cord or connector wires on high-voltage components when removing them................ remove the power plug from the wall outlet immediately............. always check that all the parts................... ........... always hold the plug itself............................... ........ Ventilate the room well while using grease or solvents............. ........ • Remove toner completely from electronic components......... ..... being careful not to spill.................................................... connectors and wires that were removed...... trapped wire and missing screws.......... Use only a small amount of solvent at a time................................ it may generate toxic gas.. • Handle greases and solvents with care by following the instructions below: ..... • Do not route the power cable where it may be stood on or trapped.................................. Toner may cause sparks when exposed directly to fire in a furnace..... Always wash hands afterwards........... Allow applied solvents to evaporate completely before refitting the covers or turning the power switch on....... ...................................... • After maintenance.............. ................ ............ from the copier except for routine replacement....................................... protect it with a cable cover or other appropriate item.................. Replace with new ones if necessary.................. • Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling. other than the specified refiner............. Wipe spills off completely......................................................................... screws................... .............. have been refitted correctly. etc... ........... • Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........................ ................ ................................ • Never dispose of toner or toner bottles in fire..... if any........ • Should smoke be seen coming from the copier................................ 3........................................................... .............................. Special attention should be paid to any forgotten connector...............................Miscellaneous WARNING • Never attempt to heat the drum or expose it to any organic solvents such as alcohol..• Do not remove the ozone filter.......... • Run wire harnesses carefully so that wires will not be trapped or damaged.................. If necessary........

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...............................1-4-22 1-5 Assembly and Disassembly 1-5-1 Precautions for assembly and disassembly.................................................................................................................................................................................1-5-6 (1) Detaching and refitting the developer unit and drum unit.............................1-5-5 1-5-4 Process section...........1-5-19 (6) Detaching and refitting the drive unit.....................................................................................1-5-17 (5) Detaching and refitting the eraser lamp (PWB)...........................1-5-38 (3) Detaching and refitting the original feed roller.......................................................................................................................................................................................................1-4-15 (2) No image appears (entirely black)..................................1-3-1 1-4 Troubleshooting 1-4-1 Paper misfeed detection ..........................................................CONTENTS 1-1 Specifications 1-1-1 Specifications.................................................................................................................................................................1-5-1 (1) Precautions .........................................................1-5-22 (2) Detaching and refitting the optical module unit .............................................................................................1-4-15 (3) Dropouts..........................................................................1-5-20 (7) Detaching and refitting the main motor .....................................................1-4-18 (10) Undulated printing at the right edge (scanning start position) .................. ............................................................................................................................ fuser thermistor.......................1-5-39 .......................................................................1-5-10 (3) Detaching and refitting the engine/high voltage PWB and power source PWB ....................................................................................................................1-5-14 (4) Detaching and refitting the laser scanner unit ..............................................................1-4-1 (1) Paper misfeed indication ..................................................................................................................1-3-1 (1) Printing the system configuration page ......................1-5-4 (2) Detaching and refitting the transfer roller ......................................................1-5-2 (1) Detaching and refitting the right cover..........................................................................................................1-4-17 (8) Gray background ............................................................................................................1-5-37 (1) Detaching and refitting the document processor (DP) ................................1-1-1 1-1-2 Parts names........................................................................................................................ and press roller....................................1-1-3 (1) Operation panel.............................1-5-29 (4) Detaching and refitting the exposure lamp..........................1-4-1 1-4-2 Self-diagnosis ...................................................................................................................................................................................................1-5-21 1-5-6 Scanner unit............................................1-5-24 (3) Detaching and refitting the main PWB ........................................................................................................1-5-6 (2) Detaching and refitting the main charger unit....................................1-1-5 1-2 Installation 1-2-1 Installation environment ........................................................................................................................................................................................................1-4-16 (4) Black dots .........................1-5-8 (1) Detaching and refitting the fuser unit..................................................................................................................................................1-5-1 1-5-2 Outer covers and scanner unit...............................................................................................................................1-4-18 1-4-4 Electric problems ........................................................................................................1-5-31 (5) Detaching and refitting the inverter PWB ..........................................................................................................................................................................................................................1-5-2 1-5-3 Paper feeding/conveying section ............................................................1-5-4 (1) Detaching and refitting the paper feed roller ...............................................................................................................................................................................1-4-17 (7) Unsharpness ...........1-5-33 (6) Detaching and refitting the scanner home position sensor ................................... thermal cutout.........................1-4-18 (9) Dirt on the top edge or back of the paper...............................................................................................................................................................................................................................................1-2-1 1-2-2 Unpacking and installation ........................................................1-4-2 (2) Service error message ...............................................................................................................................................................................................................................................1-4-2 (1) Self-diagnostic function .........................1-4-14 (1) Completely blank printout..........................................................................1-2-2 (1) Installation procedure ..........................................1-5-37 (2) Detaching and refitting the pad assembly ........................................................................................................................................................................1-4-16 (6) Black vertical streaks .......1-5-36 1-5-7 Document processor (DP) ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-4-3 1-4-3 Image formation problems .....................................................................................................1-5-35 (7) Detaching and refitting the scanner motor .........................................................1-4-19 1-4-5 Mechanical problems ..............................................................................................1-5-7 1-5-5 Fuser unit ....................................................................................1-2-2 1-3 Service Mode 1-3-1 Service mode ................................................................1-5-22 (1) Detaching and refitting the scanner unit............................................................................................. left cover and top cover ........................................1-1-4 1-1-3 Machine cross section .....1-5-8 (2) Detaching and refitting the heater lamp.......................................................................................................................................................................................1-4-16 (5) Black horizontal streaks ......................................................................................................................................... heat roller................................................................

............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2-2-1 2-3 Operation of the PWBs 2-3-1 Power source PWB.................................................................................................................................................................................................................................................................2-3-7 2-4 Appendixes (1) Wiring diagram ...........................................2-1-5 2-1-4 Developing section..............................2-2-1 (1) Electrical parts layout .................................................2-1-4 2-1-3 Expose section.............................................................................................................................................................................................................2-1-13 2-1-9 Scanner section ...................................2-1-1 2-1-2 Drum section........................................................................................................................................................................2-1-13 (1) Paper exit section..........................................................................2-1-3 (1) Drum unit............................................................2-1-17 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout.........................................................................................................................................................2-1-7 2-1-5 Transfer section .............................................................................................................................2-1-15 (1) Scanner unit ...................................2-4-1 (2) Repetitive defects gauge.............................................................2-1-16 2-1-10 Document processor (DP) section ................2-1-3 (2) Main charger unit...2-1-5 (1) Laser scanner unit.....................2-3-3 2-3-3 Main PWB ............................................................................2-4-2 ..........................................................................................................................................................................................................................................................................................................................................................................................................2-1-10 2-1-7 Fuser section ....2-1-7 (1) Developer unit ..................................................................................................................................................................2-1-1 (1) Paper feed section ..................................................................................................................................................................................2-3-1 2-3-2 Engine/high voltage PWB .........................................................................................................................................................................................................................................................................................................................................................................................2-1-17 (1) Document processor (DP)...............................2-1-15 (2) Optical module unit...........1-6-1 2-1 Mechanical construction 2-1-1 Paper feeding/conveying section ................2-1-11 (1) Fuser unit .....................................2-1-9 2-1-6 Cleaning section ...............................................................1-6 Firmware 1-6-1 Updating the firmware on the main PWB.2-1-11 2-1-8 Paper exit section ................................................................................................................................................................................................................................................................................

. Legal: 15 copies/min............. A5/A6: 10 copies/min.... 32 MB Ambient conditions ... recycled paper.......................2 A 220 to 240 V AC.............. folio................. First copy (1:1... 25 seconds or less (power on)........... envelope #10.... envelope #6......... 120 V AC....... A5.... Paper cassette: A4.............2G4 1-1 Specifications 1-1-1 Specifications Main body Printing system .. Heat roller system Charge erasing system................ Transfer roller (negative-charged) Separation system ........ 1 to 99 sheets Zoom ratios............................................................................. books and 3-dimensional objects Copy sizes .. OPC drum (diameter 30 mm/1 3/16") Charging system........................ A5: 10 copies/min..... 3... Exposure by eraser lamp (LED) Cleaning system .. 16K Paper types.. oficio II Manual feed tray: A4........... Document processor (1:1) A4: 16 copies/min..................... Any 1 % increment between 25 and 400 % 1-1-1 ........... 60 Hz.... Mono component dry developing method Toner replenishing: Automatic from the toner container Transfer system .......... Legal: 15 copies/min...9 A Dimensions (W) × (D) × (H) ......................... Paper cassette: 250 sheets Manual feed tray: 1 sheet Output tray capacity .............. letter. Approx................ 8............... 15 kg/33 lbs Required space (W) × (D) ... executive. Platen (1:1) A4: 16 copies/min...................500 lux or less Power source.......... envelope monarch.... legal.... Scanning and printing: 600 × 600 dpi Continuous copying .. A5.................... 20 s or less (sleep) Memory.....562 ft Illumination: 1........ 100 sheets (face-down) Photoconductor............... adhesive backed labels.................. envelope #9......... B5 (ISO)................. Electro-photographic Originals.......................... 476 × 392 × 489 mm/18 3/4" × 15 7/16" × 19 1/4" Weight............... statement....... Letter: 17 copies/min... B5: 14 copies/min... envelope DL. B5: 14 copies/min................... Platen 12 seconds or less Document processor 14 seconds or less Resolution............ 50 Hz...... B5 (JIS).. B6...... Drum: Counter blade Warm-up time .......... recycled paper........................... 479 × 437 mm/18 7/8" × 17 3/16" Copying functions Copying speed.......... Temperature: 10 to 32. envelopes and post cards supported Paper feed source capacity . letter.......... Sheets of paper........5 °C/50 to 95 °F Humidity: 20 to 80 %RH Altitude: Maximum 2...... oficio II... envelope C5......... B5 (JIS). Letter/A4) ....... Letter: 17 copies/min..................... thick paper 60 to 163 g/m2 Transparency.... Scorotron (positive charging) Developing system .000 m/6................... Small diameter separation Fixing system. folio.............. Paper cassette: Plain paper. A6................. legal.. thick paper 60 to 105 g/m2 Manual feed tray: Plain paper........

.. 300 dpi Resolution.......... 24-Bit color mode).................. USB (TWAIN): 1 port (Hi-speed USB) Document processor (DP) Original feed system . 60 to 105 g/m2 Maximum number of originals........ BMP Host Interface ............ Automatic feeding Originals.................................. 600 × 600 dpi Host Interface ...................... USB: 1 port (Hi-speed USB) Scanning functions Scanning Speed..........................8 scan/min..............2G4 Printing functions Printing speed.... Monochrome: 16 scan/min..... PDF.................. Maximum: Legal Minimum: Statement and A5R Original paper weight ........ Letter/A4.................. A4: 16 pages per minute/Letter: 17 pages per minute First print........................ 1:1................... Full color or grayscale: 4....................................... Not available Paper feed ............................... TIFF........................................... JPEG (8-Bit gray mode........ Sheets of paper Original size ........................... Recycled paper made from 100% recycled pulp may be used with this product.................... 50 sheets (50 to 80 g/m2) Environmental specifications Duplex copying ...................... Full color: 24 bit/dot (each color) Grayscale: 8 bit/dot Monochrome: 1 bit/dot File format. 600 × 300 dpi Color mode ......................... 11 seconds or less Resolution................................................. 1-1-2 ............................

17. 13. 25. 24. 6.2G4 1-1-2 Parts names Figure 1-1-1 1. Scanner unit Front cover Paper cassette Manual feed tray Toner container Developer unit Drum unit Shipping lock Original size indicator plate Operation panel Original cover Platen Output tray 14. 12. Paper stopper USB Interface connector 5 V DC output (for print server) Rear cover Power switch AC inlet Original table Original insert guides Left cover Ejection extension Original eject table Document processor (DP) 1-1-3 . 5. 15. 9. 22. 3. 8. 21. 7. 16. 19. 11. 10. 20. 18. 2. 4. 23.

Copy mode key and indicator Collate key and indicator Combine key and indicator SCAN key COPY key and indicator key key Numeric keys EcoPrint key and indicator Stop/Clear key 11. 8. Exposure adjustment key/Exposure display Zoom key Memory overflow indicator Toner indicator Scan To PC key Message display Menu key Cancel key OK key Start key 1-1-4 . 20. 6. 18. 15. 3. 19. 2. 5. 17. 12. 14. 10. 13. 7. 4. 16. 9.2G4 (1) Operation panel / Figure 1-1-2 1.

Paper cassette Manual feed tray Paper feeding/conveying section Toner container Developer unit Main charger unit Drum unit Laser scanner unit 9. 3. 4. Transfer section Fuser unit Paper exit section Output tray Operation unit Scanner unit Optical module unit Document processor (DP) 1-1-5 . 2. 13. 12. 14. 8. 7.2G4 1-1-3 Machine cross section Paper path Figure 1-1-3 Machine cross section 1. 5. 15. 11. 10. 16. 6.

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5°F Humidity: 15 . abrupt ambient temperature changes.3% Installation location Avoid direct sunlight or bright lighting.3%/60 Hz ±0. 9. Allow sufficient access for proper operation and maintenance of the machine. and hot or cold air directed onto the machine. 3. SOx gases and chlorine-based organic solvents.80%RH Power supply: 120 V AC.2G4 1-2 Installation 1-2-1 1. Avoid dust and vibration. 5.0 A (Average) Power source frequency: 50 Hz ±0. 4. 2. NOx. Avoid extremes of temperature and humidity. Rear: 25 cm 9 13/16" Right: 30 cm 11 13/16" Left: 30 cm 11 13/16" Front: 100 cm 39 3/8" Figure 1-2-1 1-2-1 . Select a room with good ventilation. Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams.240 V AC. 5.5°C/50 to 90. Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor. Machine front: 100 cm/39 3/8" Machine rear: 25 cm/9 13/16" Machine right: 30 cm/11 13/16" Machine left: 30 cm/11 13/16" 6. Choose a surface capable of supporting the weight of the machine. Installation environment Temperature: 10 to 32. such as mercury. inorganic gasses.0 A 220 . Place the machine on a level surface (maximum allowance inclination: 1°). acidic of alkaline vapors.

Installing the toner container. Figure 1-2-2 1-2-2 . Attaching the language sheet label sheets. Initializing the printer and printing a report page for test. Connecting the cables. Unlocking the shipping lock. Loading the paper. Installing the printer software. Installing the original table and ejection extension. Completion of the machine installation. Installing the scanner software.2G4 1-2-2 Unpacking and installation (1) Installation procedure Start Unpacking. Print a document.

Machine (main body) Power cord Toner container Original table Ejection extension Operation guide and Installation guide CD-ROMs Language label sheets 1-2-3 . 2. 5. 6. 7. Figure 1-2-3 Unpacking 1.2G4 Unpacking. 4. 8. 3.

Unlock the shipping lock.2G4 Unlocking the shipping lock. Open the front cover. Open the document processor (DP). 2. Open the scanner unit. Scanner unit Front cover Figure 1-2-5 1-2-4 . 1. Close the document processor (DP). 3. 1. Document processor (DP) Shipping lock Figure 1-2-4 Installing the toner container. 2.

Seal Figure 1-2-7 1-2-5 .2G4 3. Remove the seal from the toner container. Remove the seal from the toner container. Toner container Figure 1-2-6 5. Shake the container horizontally to distribute the toner evenly. 4.

Install the toner container in the printer. Turn the toner container release lever to the [LOCK] position. 9. Close the scanner unit.2G4 6. Turn the toner container release lever to the [UNLOCK] position. Scanner unit Front cover Toner container Toner container Figure 1-2-9 1-2-6 . Close the front cover. 7. Push firmly on the top of the container at the positions marked [PUSH HERE] until you hear a click. 10. Toner container Toner container release lever Figure 1-2-8 8. 11.

2G4 Loading the paper. 5. Press the release button on the left guide and slide the guides to the paper size required. Pull the paper cassette completely out of the machine. Adjust the position of the width guides located on the left and right sides of the paper cassette. 3. Install the original table. Length guide Paper Width guide Width guide Paper cassette Figure 1-2-10 Installing the original table and ejection extension. 1. Push the paper cassette back into the machine until it stops. 4. Load the paper in the paper cassette. Press the release button and adjust the paper length guide to the paper size required. Ejection extension Original table Figure 1-2-11 1-2-7 . 1. 2. 2. Install the ejection extension.

2. 1. Language label sheet Language label sheet Operation panel Figure 1-2-12 1-2-8 . Attach the language label sheet on the operation panel.2G4 Attaching the language label sheets. Remove the language label sheet.

USB interface connector AC inlet Power cord USB cable PC Figure 1-2-13 1-2-9 . 4. 1. 3. 2. Connect the power cord to the wall outlet. Connect the printer cable to the USB interface connector.2G4 Connecting the cables. Connect the other end of the printer cable to the PC’s USB interface connector. Connect the power cord to the printer AC inlet.

] 4. Press the or key to select [3. Configuration]. NOTE: If the Welcome to the Found New Hardware Wizard dialog box displays. Figure 1-2-15 5. NOTE: If the installation program fails to launch. 3. Click Select Language. The machine will begin to warm up after which the basic screen is displayed. Usage report]. 3. select Cancel. Press the or key to select [31. Switch on the PC and activate Windows. the License Agreement Notice is displayed. Menu Map] or [33. Turn the power switch on. Report. 6. Press the Menu key. Insert the CD-ROM (Product Library FS1016MFP) into the CD-ROM drive. Figure 1-2-16 1-2-10 . Once the installation program launches. [32. Printing of the report will begin. Report] screen. Required operating systems (OS) for using the Software: Microsoft Windows 98SE/Me/ 2000/XP 1. 2.exe. Press the OK key.2G4 Initializing the printer and printing a report page for test. 2. The display returns to the [3. 4. Press the OK key. 1. Figure 1-2-14 Installing the printer software. use Windows Explorer to access the CD-ROM and double-click Setup. 5. Click Accept to proceed. Click View License Agreement to display and read it. Ensure the machine is plugged in and connected to the PC’s USB port before installing software from the CD-ROM.

7. 11. if a software installation warning for an unsigned device driver is displayed. select Universal Serial Bus (USB) to select the connection method. Figure 1-2-17 9.2G4 6. 8. Click Install Printer Software. When the installation is complete. Click Finish to leave the install program and return to the disc main menu. Figure 1-2-19 10. 1-2-11 . When installing software for Windows XP. Click Next. For the simple. click Continue Anyway to bypass the warning and install the driver. The Installation Wizard starts. the Installation Completed Successfully window is displayed. Figure 1-2-18 NOTE: If you selected Custom Mode. The installation program installs the software. and follow the onscreen instructions. default installation. select Express Mode and click Next. All device drivers have been fully tested. Click OK. Click the language to be used.

Click View License Agreement to display and read it. Click Scanner Driver. The Kyocera MFP Setup starts. NOTE: If the installation program fails to launch. Switch on the PC and activate Windows. Once the installation program launches. 9. 6. the License Agreement Notice is displayed. Figure 1-2-23 1-2-12 . 10. Click Next. Click Printer Utilities. Click Select Language. Insert the CD-ROM (Product Library FS1016MFP) into the CD-ROM drive.2G4 Installing the scanner software. select Cancel. The installation program installs the software. 3. Select the language and click OK. 4. Click Accept to proceed. 1. 2. NOTE: If the Welcome to the Found New Hardware Wizard dialog box displays. Click the language to be used. Figure 1-2-21 7. Figure 1-2-22 8. use Windows Explorer to access the CD-ROM and double-click Setup.exe. Figure 1-2-20 5.

NOTE: When installing software for Windows XP. Select the drop down list of printer names. 1.2G4 11. Completion of the machine installation. if a software installation warning for an unsigned device driver is displayed. 2. click Continue Anyway to bypass the warning and install the driver. All device drivers have been fully tested. Figure 1-2-24 Print a document. select Collate. the Install Shield Wizards Complete window is displayed. 3. From the application File menu. Click Finish to leave the install program and return to the Printer Utilities menu. 12. All the printers installed are listed. When the installation is complete. Select the FS-1016MFP. Select OK to start printing. The Print dialog box displays. enter the number of copies required and if printing more than one set. 1-2-13 . select Print. Select the options required.

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42 Memory Information Total Memory: 32 MBytes Available Memory: 14 MBytes and 458 KBytes Default Settings Language Paper Size Power Saving Time(min) Copy Mode Zoom Density Paper Saver Toner Saver Text Mode Background Remove MIxed Mode Background Remove = = = = = = = = = = English A4 15 Text 100% 3 Off On Off Off Figure 1-3-1 System configuration page 1-3-1 . Printing of the system configuration page will begin. Configuration].10 Menu Version:0. Purpose To acquire the current printing environmental parameters and cumulative information.2G4 1-3 Service Mode 1-3-1 Service mode (1) Printing the system configuration page Description Lists information on the settings and environments of use for this machine. Press the or key to select [31. 2. Press the OK key. Press the Menu key. System Configuration Page SYSTEM CONFIG Product Information Product Name: Engine Serial Number: Scanner Serial Number: Product Born Date 3/5/2005 Power ON time :2 hours 20 min System F/W Version:0. Report. Report] screen.57 Profile Version:1. 5. Procedure 1.] 3. Press the or key to select [3.1 Scanner F/W Version:2. The display returns to the [3. Press the OK key.47 Printer F/W Version:050119. 4.

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2G4 1-4 Troubleshooting 1-4-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs. To remove paper misfed in the printer. the printer immediately stops printing and displays the paper misfeed message on the operation panel. Document feed sensor Document conveying sensor Registration sensor Exit sensor Figure 1-4-1Paper misfeed detection 1-4-1 . open the original cover.To remove original jammed in the DP. open the front cover or the rear cover or pull out the paper cassette.

When a problem is detected. [PRINTER ERROR] Service Call-#### Error code [SCANNER ERROR] Lamp error Error causes Figure 1-4-2Error message display 1-4-2 . the machine stops printing and an error message is displayed on the operation panel.2G4 1-4-2 Self-diagnosis (1) Self-diagnostic function This machine is equipped with a self-diagnostic function.

Reinsert the connector (See page P. remedy or replace the FFC (See page P.1-5-28). If this message still remains.1-4-2. Shipping lock is locked. Defective exposure lamp. Reinsert the FFC. P. P. and check again.1-5-29). Defective inverter PWB. terminals. Poor contact in expo. Turn the power switch off and then back on again. [SCANNER ERROR] Lamp Error Exposure lamp error for scanner. See page P. replace the main PWB (See page P. Turn the power switch off and then back on again.1-5-24).1-5-29). replace the main PWB (See page P. Also check for continuity within the FFC. or improper connector insertion. The data transferred to the machine was too complex to print on a page.1-5sure lamp connector 31). If this message still remains. Turn the power switch off and slide shipping lock to unlock position (See page P.1-5-29. If none. Scanner home position sensor error for scanner.2G4 (2) Service error message Remarks Service error message [PRINTER ERROR] Service Call-#### Contents “####” means selfdiagnostic error code. Defective FFC between main PWB and CCD PWB.15-31). Poor contact in scanner home position connector terminals. replace the main PWB (See page P. Defective main PWB. Defective scanner home position sensor. replace the main PWB (See page P. Defective optical module unit. 1-4-3 . remedy or replace the FFC (See page P.1-5-35). Wait a while. If this message still remains. Turn the power switch off and then back on again. Replace the scanner home position sensor (See page P. Defective FFC between main PWB and CCD PWB. Also check for continuity within the FFC. Turn the power switch off and then back on again. Replace the exposure lamp (See page P.1-5-29. If this message still remains. or improper connector insertion. If this message still remains.1-5-24).1-5-29).1-5-28). Reinsert the connector (See page P. Defective main PWB. Defective main PWB. [PRINTER ERROR] Out of Memory On-line printer jobs are crowded. Memory error.1-2-4). Check procedures/corrective measures Turn the power switch off and then back on again. [SCANNER ERROR] AFE R/W Error [SCANNER ERROR] Home sensor AFE read/write error for scanner.1-535). Causes Self-diagnostic error occurred. If none. Reinsert the FFC.1-5-29). Replace the optical module unit (See page P. follow the self-diagnostic error code instruction. Replace the optical module unit (See page P.

1-5-28). Defective main PWB.1-5-29). Defective scanner unit. remedy or replace the FFC (See page P.1-536). Defective scanner motor. Defective toner container. Replace the main PWB (See page P. Reinsert the FFC.1-529).1-5-29. Check procedures/corrective measures Replace the scanner belt spring. P. Toner Low Toner low for printer. Reinsert the connector (See page P. Defective FFC between main PWB and CCD PWB.1-522) Replace the toner container.15-36). Please Replace Toner Toner empty for printer. 1-4-4 . Causes Defective scanner belt spring. Replace the toner container. If this message still remains. Replace the scanner unit (See page P. Turn the power switch off and then back on again.1-529). Replace the main PWB (See page P. Defective main PWB. or improper connector insertion. Also check for continuity within the FFC. Poor contact in scanner motor connector terminals. Defective main PWB. Toner has run out so Replace the toner container. Toner is running low. If none. Replace the scanner motor (See page P. Replace the toner container. Defective toner container. further copying or printing is impossible.2G4 Remarks Service error message [SCANNER ERROR] Motor Stall Contents Scanner motor stall for scanner. replace the main PWB (See page P.

Defective drive unit. then low. Remarks Check procedures/corrective measures Follow the flow chart. Yes Turn printer power off. Connect circuit tester to pin 5 (REMOTE) of YC5 connector on the engine/high voltage PWB.1-5-21. No 24 V DC at pin 1 of CN1 connector on the main motor? Yes Print status page. Replace engine/high voltage PWB. Defective harness between engine/ high voltage PWB and main motor. then on. Print status page. Does pin 3 (MMOTRDY) of CN1 connector on the main motor goes high. then on. within 2 seconds from pin 5 (REMOTE) goes low? Yes See page P. No OK? Yes Connect circuit tester to pin 1 of CN1 connector on the main motor. Turn printer power off. 1-4-5 . then low? No No Replace harness between engine/high voltage PWB and main motor. Defective main motor. check or replace drive unit.1-5-14. See page P. Replace the main motor. Start Reinsert the connector of harness between engine/high voltage PWB and main motor. Connect oscilloscope to pin 5 (REMOTE) and pin 3 (MMOTRDY) of CN1 connector on the main motor. Does pin 5 (REMOTE) of YC5 connector on the engine/high voltage PWB goes high. If not solved.2G4 (3) Service call codes Code 2000 Contents Causes Main motor error The main motor ready input is not given for two seconds during the main motor is driven. Defective engine/ high voltage PWB.

See page P.1-5-14. within 8 seconds after pin 5 (REMOTE) goes high. Replace harness between engine/high voltage PWB and laser scanner unit. See page P. then Replace engine/high low? voltage PWB. Replace laser scanner unit. See page P. Turn power switch on. then on. then low? Yes No Replace harness between engine/high voltage PWB and laser scanner unit. Turn power switch off.2G4 Remarks Causes 4000 Polygon motor (laser scanner unit) error The polygon motor ready input is not given for eight seconds during the polygon motor is driven. Connect oscilloscope to pin 2 (PLGDRY) and pin 3 (PLGON) of YC3 connector on the engine/high voltage PWB. Replace engine/high voltage PWB. OK? Turn power switch on.1-5-14. See page P. End.1-5-17. Code Contents Start +24 V DC at pin 5 of YC3 connector on the engine/high voltage PWB? Yes Connect oscilloscope to pin 1 (PLGCLK) and pin 3 (PLGON) of YC3 connector on the engine/high voltage PWB. Does pin 2 (PLGDRY) of YC3 connector on the Yes engine/high voltage PWB goes high.1-5-17. OK? Yes No Turn power switch off.1-5-14. Defective harness between engine/ high voltage PWB and laser scanner unit. then on. Does pin 3 (PLGON) of YC3 connector on the engine/high voltage PWB goes high. then low. Turn power switch on. No Yes End. See page P. No Replace laser scanner unit.1-5-14. Defective polygon motor (laser scanner unit). OK? No Replace engine/high voltage PWB. Check procedures/corrective measures Follow the flow chart. No Yes End. Does pin 1 *:1417 Hz (705 µs) (PLGCLK) of YC3 No connector on the engine/high voltage PWB output square-wave* signal? Yes Replace engine/high voltage PWB. 1-4-6 . See page P. Defective engine/ high voltage PWB.

Does pin 7 (PDN) of J7 connector on the main PWB output pulse signal*. then low? No (A) Continued to next page. Replace main PWB. Replace main PWB. Low level width: 10 µs) 1-4-7 .1-5-29. Turn power switch off. No OK? Yes No Replace harness between main PWB and engine/high voltage PWB.1-5-14. See page P.1 second after pin 3 (OUTPEN) goes high. Defective main PWB. Defective harness between main PWB and engine/ high voltage PWB. Turn power switch off. Check procedures/corrective measures Follow the flow chart. Turn power switch on.1-5-29. Code Contents Start 5 V DC at pin 5 of J7 connector on the main PWB? No Yes Connect oscilloscope to pin 3 (OUTPEN) of J7 connector on the main PWB. End. within 0. Replace engine/high voltage PWB. See page P.then on. Yes *: Pin photo diode sensor detect horizontal synchronization signal (Frequency: 1417 Hz. Turn power switch on. then before "4200" error? Yes Connect oscilloscope to pin 3 (OUTPEN) and pin 7 (PDN) of J7 connector on the main PWB. (B) Continued to next page. See page P.2G4 Remarks Causes 4200 PD (Pin photo diode) sensor (laser scanner unit) error The first BD input is not given for 10 seconds after power is turned on and the laser begins emitting. The first BD input is not given for 7 seconds during printing and after the laser begins emitting. Does pin 3 (OUTPEN) of J7 connector on the main PWB goes high. No OK? Yes End. Defective engine/ high voltage PWB.then on.

See page P. Yes OK? No End.1-5-17. End. Continued from previous page.2G4 Remarks Causes 4200 cont. Replace main PWB. See page P. (A) Code Contents Check procedures/corrective measures Continued from previous page. Turn power switch on. See page P. See page P. Yes No Yes End. Yes OK? No End. OK? OK? No Replace engine/high voltage PWB. Turn power switch on. Replace harness between main PWB and laser scanner unit. Replace harness between main PWB and engine/high voltage PWB. Yes OK? No Replace harness between main PWB and engine/high voltage PWB. End.1-5-29. Turn power switch on.1-5-29. Replace engine/high voltage PWB.1-5-14. End. (B) Replace laser scanner unit. Turn power switch on. See page P. Yes OK? No Replace harness between main PWB and laser scanner unit. 1-4-8 . Turn power switch on. Replace main PWB.1-5-14.

Detach YC7 connector on the engine/high voltage PWB. Code Contents Start Turn power switch off. See page P. Broken thermal cutout or heater lamp. Detach YC1 connector on the power source PWB. Check procedures/corrective measures Follow the flow chart. and remove power cord. Open (infinite)? No Yes Replace the fuser thermistor.2G4 Remarks Causes 6000 Broken heater lamp error The temperature won’t rise by 1 degree Celsius during warming up and the heater is turned on for 5 seconds. See page P. See page P.1-5-10.1-5-14.1-5-10. 1-4-9 . Replace the engine/high voltage PWB. Open (infinite)? No Yes Replace the thermal cutout or heater lamp. Defective fuser thermistor. Measure resistance between pins 1 and 2 of the detached connector. Defective engine/ high voltage PWB. Measure resistance between pins 1 and 2 of the detached connector. The temperature won’t rise by 1 degree Celsius during printing and the heater is turned on for 5 seconds with the duty cycle more than 60%.

Check procedures/corrective measures Follow the flow chart. End.1-5-14. Replace the engine/high voltage PWB. "6010" error shown? No Yes Replace the engine/high voltage PWB. Code Contents Start Check the installation condition of the fuser thermistor.then on. Defective the engine/high voltage PWB. the temperature at the upper fuser roller lower than 100 °C/212 °F continues for 30 s.2G4 Remarks Causes 6010 Fuser low temperature After the fuser heater lamp is turned on. 1-4-10 .1-5-14. Turn power switch off. See page P. See page P. OK? Yes No Remedy or replace the fuser thermistor. Defective the fuser thermistor.

Check procedures/corrective measures Follow the flow chart. Open (infinite)? Yes Replace the fuser thermistor. Defective the fuser thermistor. See page P. See page P. No OK? Yes Replace the engine/high voltage PWB. the zero-cross signal is not input within 3 s. 1-4-11 .2G4 Remarks Causes 6050 Broken fuser thermistor The thermistor AD value is less than 1 for 600 ms. Defective the power source PWB.1-5-14. End.1-5-14. Detach YC7 connector on the engine/high voltage PWB.1-5-10. No Replace the engine/high voltage PWB. Defective the engine/high voltage PWB. Start Replace the power source PWB. Follow the flow chart. Code Contents Start Turn power switch off. 6400 Zero cross signal error While fuser heater ON/OFF control is performed. See page P. See page P. and remove power cord.1-5-14. Measure resistance between pins 1 and 2 of the detached connector. Defective the engine/high voltage PWB.

Code Contents Start Shake the drum unit horizontally. See page P.1-5-6.2G4 Remarks Causes 7980 Waste toner full (Total page count less than 100. then on. Replace the waste toner full sensor or engine/high voltage PWB. Defective drum unit. "7980" error shown? Yes No End. Check procedures/corrective measures Follow the flow chart. then on. Turn power switch off. 1-4-12 .1-5-14.000 pages of printing) The toner-full sensor has detected that the waste toner is full before the total print page of less than 100. Defective engine/ high voltage PWB. Defective waste toner full sensor. "7980" error shown? Yes No Replace the drum unit.000 pages. Turn power switch off. See page P.

then on.1-5-6.000 pages of printing) The toner-full sensor has detected that the waste toner is full before the total print page of more than 100. F050 (E6) 1-4-13 .1-5-14) Replace the main PWB (See page P. "7990" error shown? Yes No Replace the drum unit. Turn power switch off. then on. See page P. Check procedures/corrective measures Follow the flow chart. Replace the engine/high voltage PWB (See page P.1-5-14). Defective engine/ high voltage PWB. F040 (E0) Main . Defective engine/ high voltage PWB. Turn power switch off. Defective engine/ high voltage PWB. Code Contents Start Shake the drum unit horizontally.1-5-14. Defective waste toner full sensor.000 pages.1-529). Defective main PWB. No End.2G4 Remarks Causes 7990 Waste toner full (Total page count more than 100. "7990" error shown? Yes Replace waste toner full sensor or engine/high voltage PWB. Replace the engine/high voltage PWB (See page P. Defective drum unit.Engine communication error The communication breakdown occurred between the main PWB and the engine/ high voltage PWB during the predetermined period in seconds. Engine checksum error Checksum result failed with the CPU and engine/high voltage PWB. See page P.

See page P. See page P. (5) Black horizontal streaks. See page P. (3) Dropouts. (1) Completely blank printout.1-4-15 (7) Unsharpness. ABC 123 ABC 123 ABC 123 This vertical line should be straight.1-4-18 1-4-14 .1-4-18 See page P. See page P.1-4-17 See page P. (4) Black dots.1-4-16 (10) Undulated printing at the right edge (scanning start position). ABC 123 ABC 123 ABC 123 See page P.1-4-17 See page P.1-4-16 (8) Gray background.1-4-16 (9) Dirt on the top edge or back of the paper.2G4 1-4-3 Image formation problems (2) All-black printout.1-4-18 See page P.1-4-15 (6) Black vertical streaks. See page P.

2G4 (1) Completely blank printout Copy example Causes Defective drum unit or developer unit. Defective transfer bias potential. Defective main PWB. Check procedures/corrective measures Open the printer top cover and check that the drum unit is correctly seated. Check the high voltage output on the engine/high voltage PWB. Check the transfer bias output on the engine/high voltage PWB. Replace the engine/high voltage PWB if high voltage potential is not available on the PWB (See page P.15-14). Check procedures/corrective measures Open the printer top cover and check that the drum unit and developer unit is correctly seated. Check for poor contact of the main charger terminal between the main charger unit and the drum unit. Defective main PWB. Replace the laser scanner unit (See page P.1-5-29). Replace the main PWB (See page P. This requires removal of the left cover and the test equipment. Defective laser scanner unit. Replace the engine/high voltage PWB if high voltage potential is not available on the PWB (See page P. The scanner components within the scanner may be disordered. Copy example Causes Defective main charger unit. Make sure the main charger high voltage output from the engine/high voltage PWB correctly arrives at the drum unit (main charger unit).1-5-29).1-5-17). Defective main charger high voltage output. Defective engine/high voltage PWB. Check for poor contact of the main charger terminal between the main charger unit and the drum unit. (2) No image appears (entirely black). Defective laser scanner unit control circuit in the main PWB (See page P. 1-4-15 .1-5-14).

apply a small amount of electro-conductive grease onto the tab. the problem may be the damaged drum (in the drum unit). Replace the developer unit (See page P.1-5-6). Replace the press roller or heat roller (See page P. Clean the bush to remove oil and debris. If the defects occur at random intervals.1-5-6). Replace the drum unit (See page P. ABC 123 Defective drum unit. If the defects occur at regular intervals of 94 mm/3 11/16". Defective paper specifications. Check procedures/corrective measures Defective drum unit’s ground. Paper with rugged surface or dump tends to cause dropouts. If necessary.15-14). ABC 123 (5) Black horizontal streaks Copy example Causes Defective drum unit’s ground. This requires removal of the left cover and the test equipment. Defective engine/high voltage PWB (transfer bias potential). Check procedures/corrective measures If the defects occur at regular intervals of 47. ABC 123 Defective fuser unit. Replace paper with the one that satisfies the paper specifications.1-5-6). 1-4-16 .1-5-10).1-5-5).2 mm/1 7/8". the problem may be the damaged fuser unit. Defective drum unit. Replace the drum unit (See page P.2G4 (3) Dropouts Copy example Causes Defective developing roller (in the developer unit). Replace drum unit (See page P. Defective paper specifications.1-56). If the defects occur at regular intervals of 63 mm/2 1/2" (heat roller or press roller). the grounding tab in the printer. Check procedures/corrective measures Defective drum unit. Replace the engine/high voltage PWB if high voltage potential is not available on the PWB (See page P. If the defects occur at regular intervals of 94 mm/3 11/16".1-5-6). (4) Black dots Copy example Causes 1. Defective fuser unit. Check the transfer bias output on the engine/high voltage PWB. the toner may be leaking from the developer unit and drum unit. the problem may be the damaged drum (in the drum unit). The drum axle in the drum unit and its counter part. Defective drum unit. The transfer roller must be supported by the bushes at the both ends. must be in a good contact. Defective transfer roller installation. Defective drum unit. Defective drum unit. Replace developer unit and drum unit (See page P. the problem may be the damaged developing roller (in the developer unit). Replace the transfer roller if necessary (See page P.

EcoPrint mode setting. Paper with rugged surface or dump tends to cause unsharp printing. Defective transfer bias potential. Defective transfer roller installation. Clean the bush to remove oil and debris. turn the EcoPrint mode off by using the operator panel. Defective magnet roller (in the developer unit). Defective drum surface. Replace the drum unit (See page P.1-5-14). ABC 123 Defective drum surface. Check procedures/corrective measures Defective paper specifications. For normal printing. The transfer roller must be supported by the bushes at the both ends. The EcoPrint mode can provides faint. Check procedures/corrective measures Contaminated main charger wire. Clean the main charger wire by sliding the green colored cleaning knob in and out several times. This requires removal of the left cover and the test equipment.15-6). For details refer to the operation guide. unsharp printing because it acts to conserve toner for draft printing purpose. EcoPrint mode setting. Defective transfer bias potential. Check the transfer bias output on the engine/high voltage PWB.2G4 (6) Black vertical streaks Copy example Causes Contaminated main charger wire. 1-4-17 . Replace the transfer roller if necessary (See page P. (7) Unsharpness Copy example Causes Defective paper specifications.1-5-6). A streak of toner remaining on drum after printing means that the cleaning blade (in the drum unit) is not working properly. Replace the developer unit (See page P.1-5-5). Defective magnet roller (in the developer unit). Defective transfer roller installation. Replace the engine/ high voltage PWB if high voltage potential is not available on the PWB (See page P.

Clean these areas and parts to remove toner. replace the developer unit with a new one (See page P. Defective polygon motor in the laser scanner unit. Defective drum surface potential. This may vary depending on production lots. Developing roller (in the developer unit). (10) Undulated printing at the right edge (scanning start position) Copy example Causes Defective laser scanner unit. Defective developing roller (in the developer unit). Try adjusting the print density. paper transportation paths. Check procedures/corrective measures Print density setting. Defective engine controller circuit in the engine/high voltage PWB. replace the current developer unit in the printer with the normal one. Defective main charger grid. Defective engine controller circuit in the engine/high voltage PWB. and the fuser unit inlet. If a developer unit which is known to work normally is available for check. This vertical line should be straight. The print density may be set too high. ABC 123 Defective transfer roller. (9) Dirt on the top edge or back of the paper Copy example Causes Toner contamination in various parts. Measurement is possible only by using the jig and tool specifically designed for this purpose. clean the transfer roller using a vacuum cleaner or by continuously printing a low-density page until the symptom has faded away. Clean the main charger grid. For details refer to the printer's operation guide. Check procedures/corrective measures Toner contamination in various parts. the bottom of the drum and developer. The drum unit will have to be replaced if it bears values far out of the allowable range. The drum surface potential should be approximately 470±15 V. Check procedures/corrective measures Defective laser scanner unit. 1-4-18 . If the transfer roller is contaminated with toner. ABC 123 Defective drum surface potential. Dirty edges and back of the paper can be caused by toner accumulated on such parts as the paper chute. If the symptom disappears. Defective transfer roller. Replace the engine/high voltage PWB (See page P. Defective main charger grid.15-14).1-56).2G4 (8) Gray background Copy example Causes Print density setting.1-5-17). Replace the laser scanner unit (See page P.

Defective engine/high voltage PWB. If none. Check for continuity across the coil.1-5-21). replace the power source PWB (See page P. (5)The registration clutch does not operate. Also check for continuity within the connector harness. Poor contact in power source fan motor connector terminals. replace the engine/high voltage PWB (See page P. Broken registration clutch coil. Replace the engine/high voltage PWB (See page P. YC6-1. replace the registration clutch. If none.2G4 1-4-4 Electric problems Problem Causes No electricity at the power outlet. If none. replace the charness. Check the contact between the power plug and the outlet. Broken cooling fan motor coil. Defective harness between connect PWB and engine/ high voltage PWB. YC7-2. replace the cord. replace the power source PWB or engine/high voltage PWB (See page P. (1)The machine does not operate when the power switch is turned on. Defective interlock switch. If none. 1-4-19 . check for 5 V DC at YC4-11.1-5-14). If none. If none. YC5-1 YC9-1 on the engine/high voltage PWB. (3)The cooling fan motor does not operate. With AC present.1-5-14). and 24 V DC at YCYC3-5. If none. If none. Broken main motor gear. If none. Poor contact in the registra. Check for continuity. remedy or replace the harness. Broken power source fan motor coil. Reinsert the connector. Broken power cord. Defective connect PWB. Check procedures/corrective measures Measure the input voltage. Defective main motor. Check visually and replace the main motor if necessary. Check for continuity. Reinsert the connector. Defective power switch. (2)The main motor does not operate (Self diagnostic code 2000). replace the power source fan motor. remove the cause of blowing and replace the fuse. Reinsert the connector. The power cord is not plugged in properly. Replace the engine/high voltage PWB (See page P. Defective power source PWB or engine/high voltage PWB. If none. Check for continuity across the coil. Blown fuse in the power source PWB. replace the cooling fan motor. Defective engine/high voltage PWB. Replace the connect PWB. YC3-6. Poor contact in cooling fan motor connector terminals. (4)The power source fan motor does not operate. Check for continuity across the coil. tion clutch connector terminals.Reinsert the connector. The top cover is not closed. Check for continuity across the contacts. Replace the main motor (See page P. YC10-1. completely.1-5-14).1-5-14). Check for continuity across the harness. Poor contact in the main motor connector terminals.1-5-14). Check for continuity across the contacts of interlock switch.Check the top cover.

Defective engine/high voltage PWB. Check for continuity.1-5-14).1-5-10).1-5-14). Poor contact in the eraser lamp (PWB) connector terminals. Broken fuser thermistor. replace the fuser thermistor (See page P. If none. Check for continuity across thermal cutout. (10)No main charging.1-5-14). (9)The heater lamp does not turn off. Check visually and clean the fuser thermistor sensor parts (See page P. Defective engine/high voltage PWB. replace the engine/high voltage PWB (See page P. remove the cause and replace the thermal cutout (See page P. Broken main charger wire. Defective eraser lamp (PWB). Defective connect PWB. If none. If none. P. (8)The heater lamp does not turn on. Dirty sensor part of the fuser thermistor. Thermal cutout triggered.1-5-19). (11)No developing bias is output. Causes Broken feed clutch coil. (See page P. Check for continuity across the harness. Poor contact of main charger terminal and high voltage output terminal on the engine/high voltage PWB.1-5-10). If the eraser lamp (PWB) turns on when YC8-2 on the engine/high voltage PWB is held low. Defective harness between connect PWB and engine/ high voltage PWB. Poor insertion developer unit. If none. Reinsert the connector. Defective engine/high voltage PWB. If none. replace the eraser lamp (PWB) (See page P. Check procedures/corrective measures Check for continuity across the coil. replace the feed clutch. (7)The eraser lamp (PWB) does not turn on. 1-4-20 . Defective engine/high voltage PWB. Replace the engine/high voltage PWB (See page P. Check for continuity across each heater lamp.1-4-15).2G4 Problem (6)The feed clutch does not operate. Measure the resistance. Replace the connect PWB. Broken wire in heater lamp.1-5-10). Poor contact of developing bias terminal spring and high voltage output terminal (TAB1) on the engine/ high voltage PWB. Poor contact in the feed clutch connector terminals. replace the heater lamp (See page P.1-5-10). If it is ∞Ω. replace the charness. (See page P.1-5-6. Reinsert the connector. Poor insertion main charger unit.

J2. 1-4-21 . Replace the power source PWB (See page P. paper is caught around registration sensor or exit sensor. If there is no continuity when the interlock switch is on.1-5-14).1-5-14). Replace the engine/high voltage PWB (See page P. (15)The indicator requesting cover to be closed is displayed when the top cover is closed. Defective interlock switch on the engine/high voltage PWB. Defective engine/high voltage PWB. Defective exit sensor on the power source PWB. (13)The message requesting paper to be loaded is shown when paper is present in the paper cassette. Check for continuity across the interlock switch. (14)A paper jam in the paper feeding/ conveying section or fuser section is indicated when the power switch is turned on. Defective registration sensor on the engine/high voltage PWB. J3) on the engine/high voltage PWB. replace the engine/high voltage PWB (See page P. Replace the engine/high voltage PWB (See page P.1-5-14).2G4 Problem (12)No transfer bias is output. Causes Poor contact of transfer bias terminal and transfer bias terminal (J1. A piece of paper torn from Check and remove if any.1-5-14). Check procedures/corrective measures (See page P.1-5-14). Defective paper sensor on the engine/high voltage PWB.

Check visually and remedy if necessary. Defective feed clutch installation. (5) Paper jams. Check if the contact between the upper and lower registration rollers is correct. Check if the surfaces of the upper and lower registration rollers are dirty with paper powder. Check visually and remedy if necessary. Paper width guide in a cassette installed incorrectly. 1-4-22 . Clean the drum unit or developer unit. Clean or replace the upper and lower fuser roller. Clean with isopropyl alcohol. Change the paper. (4) Multiple sheets of paper are fed at one time. Check if the contact between the FD roller and FD pulley is correct. Check visually and remedy if necessary. rollers and gears operate Abnormal noise is heard. Check visually and remedy if necessary. smoothly. (2) No secondary paper feed. Check if the drum unit or developer unit is extremely dirty. (7) Check if the pulleys. (1) No primary paper feed. Change the paper. Replace the separator pad if it is worn. Defective registration clutch installation. Grease the bearings and gears. Check if the paper is excessively curled. Check visually and replace any deformed paper feed roller. Check if the separator pad is worn. Check the paper width guide visually and correct or replace if necessary. Check if the paper is curled. See page 1-6-4. (6) Toner drops on the paper conveying path.2G4 1-4-5 Mechanical problems Problem Causes/check procedures Check if the surfaces of the feed roller is dirty with paper powder. Corrective measures Clean with isopropyl alcohol. Check if the following electromagnetic clutches are installed correctly: Feed clutch and registration clutch. (3) Skewed paper feed. Check if the paper feed roller is deformed. Check if the upper and lower fuser roller is extremely dirty or deformed. Check visually and remedy if necessary.

2G4 1-5 Assembly and Disassembly 1-5-1 Precautions for assembly and disassembly (1) Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly. Do not touch any PWB containing ICs with bare hands or any object prone to static charge. Never substitute electric wires. 1-5-1 . as the copier may be seriously damaged. When handling PWBs. do not touch connectors with bare hands or damage the board. Use only the specified parts to replace the fixing unit thermostat.

4. 2. Right cover Figure 1-5-1Removing the right cover 5. left cover and top cover <Procedure> 1. Unlatch the four latches and then remove the right cover. 3. Unlatch the six latches and then remove the left cover. Open the front cover. Open the scanner unit. Remove the paper cassette.2G4 1-5-2 Outer covers and scanner unit (1) Detaching and refitting the right cover. Left cover Figure 1-5-2Removing the left cover 1-5-2 .

hook hook Top cover Top cover Top cover Screw Screw Rear cover Figure 1-5-3 1-5-3 . While opening the rear cover and then remove the two screws. 8. Remove the scanner unit (See page P.2G4 6. While unhooking the two hooks and then remove the top cover. 7.1-522).

2. Paper feed roller Figure 1-5-4Removing the paper feed roller 1-5-4 .2G4 1-5-3 Paper feeding/conveying section (1) Detaching and refitting the paper feed roller <Procedure> 1. Remove the paper feed roller. Check or replace the paper feed roller and refit all the removed parts. 3. Remove the paper cassette.

1-5-6). Remove the developer unit and drum unit (See page P.2G4 (2) Detaching and refitting the transfer roller <Procedure> 1. Transfer roller Bush Paper passing direction Short Long Transfer roller gear Paper passing direction Bush (black) Spring (black) Transfer roller Bush Spring Figure 1-5-5Removing the transfer roller 1-5-5 . Check or replace the transfer roller and refit all the removed parts. Remove the transfer roller from bushes. 2. 3.

2. Open the front cover. Open the scanner unit. Front cover Developer unit Figure 1-5-6Removing the developer unit 4.2G4 1-5-4 Process section (1) Detaching and refitting the developer unit and drum unit <Procedure> 1. Remove the developer unit (with toner container. 3. Check or replace the developer or drum unit and refit all the removed parts. Drum unit Figure 1-5-7Removing the drum unit 1-5-6 . Remove the drum unit. 5.

slide the main charger unit (2). Drum unit Main charger unit Main charger unit Main charger terminal Figure 1-5-8 1-5-7 . 3.1-5-6). 4. 2. Remove the main charger unit (3) by lifting it.2G4 (2) Detaching and refitting the main charger unit <Procedure> 1. Check or replace the main charger unit and refit all the removed parts. While pushing on the main charger terminal (1). Remove the drum unit (See page P.

Pull out the rear cover axises (with springs) from the axis holes.2G4 1-5-5 Fuser unit (1) Detaching and refitting the fuser unit <Procedure> 1. Clamp Connector Wire Clamp Connector Figure 1-5-9 4. Remove the two connectors. Remove the outer covers (See page P. Axsis hole Spring Axsis Axsis hole Axsis Rear cover Spring Figure 1-5-10 1-5-8 . 2.1-52). 3. Remove the wire from two clamps.

Check or replace the fuser unit and refit all the removed parts. Remove the two screws and then separate the upper fuser frame and lower fuser frame. Screw Screw Fuser unit Figure 1-5-11 6.2G4 5. Lower fuser frame Screw Upper fuser frame Screw Figure 1-5-12 1-5-9 . 7. Remove the two screws and then remove the fuser unit.

Remove the fuser unit (See page P. thermal cutout. Remove the two screws and terminal.2G4 (2) Detaching and refitting the heater lamp. Screw Fuser gear Heater lamp Rating marking Screw Terminal Heater lamp Welding side Figure 1-5-13 1-5-10 .1-5-8). Remove the heater lamp. and press roller <Procedure> 1. 3. 2. fuser thermistor. * Seat the heater lamp aligning its wattage mark and welding mark faced with the correct direction and side. heat roller.

Gear Bush Heat roller Heat roller Heat roller Bush Bush Bush Upper fuser guide Figure 1-5-14 6. Screw Fuser thermistor Figure 1-5-15 1-5-11 . heat L bush and heat gear from the heat roller.2G4 4. 5. Remove the one screw and then remove the fuser thermistor. Pull the heat R bush and heat L bush (with heat roller) from the upper fuser guide. Remove the heat R bush.

Remove the two screws (nuts). and terminal. Remove the thermal cutout.2G4 7. plate cord. 8. Cord plate Screw Thermal cutout Screw Terminal Nut Nut Figure 1-5-16 1-5-12 .

10. heat roller. Check or replace the heater lamp. fuser thermistor. or press roller and refit all the removed parts.2G4 9. Remove the press roller from the bushes. Press roller Bush Bush Lower fuser frame Figure 1-5-17Removing the press roller 1-5-13 . thermal cutout.

* When seating the engine/high voltage PWB. Remove the paper cassette.1-522). 2. ensure that the developer bias terminal spring is correctly in contact with the developing bias terminal (TB1) on the engine/high voltage PWB.2G4 (3) Detaching and refitting the engine/high voltage PWB and power source PWB <Procedure> 1. Connector Connectors Developing bias terminal spring Engine/high voltage PWB Developing bias terminal (TB1) Figure 1-5-18 1-5-14 . Remove the six connectors. Remove the scanner unit (See page P. 4. 3.1-5-6). Remove the developer unit and drum unit (See page P.

6. Remove the five screws and then remove the bottom frame plate with PWBs (behind the plate).2G4 5. Screws Screws Bottom frame plate (Transfer bias terminal) Figure 1-5-19 1-5-15 . Turn the printer bottom side up.

Remove the two connectors from power source PWB. 13. Remove the three screws from power source PWB and power source fan motor. hook the grounding wire to the projection. * To replace the engine/high voltage PWB. Remove four screws from the engine/high voltage PWB. remove the EEPROM (U2) from the old engine/high voltage PWB and mount it to the new engine/high voltage PWB. Screw 12. EEPROM Socket Screw Screw Screw Screw Connector Connectors Screw Engine/high voltage PWB source fan motor Power source PWB Screw Terminal Bottom plate frame Power source PWB Projection Screw Terminal Grounding wire Figure 1-5-20 1-5-16 . * When securing the grounding terminal. 8. 11.2G4 7. Check or replace the power source PWB or engine/high voltage PWB and refit all the Power removed parts. 9. Check or replace the engine/high voltage PWB or power source PWB and then refit all the removed parts. 10. Remove the one screw and terminal from the bottom frame plate. Separate the engine/high voltage PWB and Connector power source PWB.

Remove the two screws and then remove the LSU lid.2G4 (4) Detaching and refitting the laser scanner unit <Procedure> 1.1-52). Screw LSU lid Screw Figure 1-5-21 1-5-17 . 2. Remove the outer covers (See page P.

Connector Screw Laser scanner unit Screw Screw Figure 1-5-22 1-5-18 . Remove the two connectors and then remove the laser scanner unit. 5. 4. Check or replace the laser scanner unit and refit all the removed parts. Remove the three screws.2G4 3.

Wire Eraser lamp (PWB) Clamp Eraser sheet Figure 1-5-24 1-5-19 . Remove the one connector.2G4 (5) Detaching and refitting the eraser lamp (PWB) <Procedure> 1. Clumps Wire Connector Figure 1-5-23 4. 6. Remove the eraser lamp (PWB). 3. 5. Remove the sheet eraser. Remove the wire from two clamps. Remove the laser scanner unit (See page P. Check or replace the eraser lamp (PWB) and refit all the removed parts. 7.1-5-17). 2. Remove the wire form clamp.

2. Remove the three connectors.1-5-2). Connectors Grounding plate Screw Stopper Clutch Stopper Screw Clutch (black) Grounding plate Figure 1-5-25 5. 4. Remove the two screws and then remove the two grounding plates. 3. Remove the two stoppers and then remove the two clutches. Screw Drive unit Screw Screw Figure 1-5-26 1-5-20 . Remove the right cover (See page P.2G4 (6) Detaching and refitting the drive unit <Procedure> 1. 6. Check or replace the drive unit and refit all the removed parts. Remove the three screws and then remove the drive unit.

1-524).2G4 (7) Detaching and refitting the main motor <Procedure> 1. 2. Remove the one connector from main motor. Check or replace the main motor and refit all the removed parts. 3. 4. Remove the four screws and then remove the main motor. Remove the right cover (See page P. Screw Connector Main motor Screw Figure 1-5-27 1-5-21 .

Open the scanner unit. Scanner unit (DP) Lift link L Lift link R Locks Figure 1-5-28 1-5-22 . 2.2G4 1-5-6 Scanner unit (1) Detaching and refitting the scanner unit <Procedure> 1. While pressing the locks and then remove the lift link L and lift link R. 3.1-5-2). Remove the right cover and left cover (See page P.

Remove the scanner unit (with DP). 6.2G4 4. Remove the two screws and then remove the two terminals. Remove the three connectors. 8. Pivot pin Scanner unit (with DP) Pivot pin Terminal Connector Connector Screw Connector Terminal Screw Figure 1-5-29 1-5-23 . 5. 7. Check or replace the scanner unit and refit all the removed parts. Remove the two pivot pins.

Remove the scanner unit (See page P. Screw Screw Screw Screw Main PWB cover Screw Screw Connector Connector Main PWB Scanner unit Figure 1-5-31 1-5-24 .2G4 (2) Detaching and refitting the optical module unit <Procedure> 1. Remove the ejection extension. Turn over the scanner unit. 2. 3. 6. 8. Unlatch the two latches and then remove the original table. Turn over the scanner unit. Original table Ejection extension Latches Figure 1-5-30 4.1-522). 7. Remove the main PWB cover. 5. Remove the two connectors. Remove the six screws.

2G4 9. 10. While pressing the hinge locks and then remove the hinges of DP. Remove the two screws and then remove the DP signal cable. Document processor (DP) Screws DP signal cable Hinge lock Hinge Figure 1-5-32 1-5-25 .

Remove the operation unit.2G4 11. 13. Remove the three screws. Remove the FFC form FFC connector. Screw Screw Operation unit Screw Figure 1-5-33 12. Operation unit FFC connector FFC Operation unit Figure 1-5-34 1-5-26 .

Screw Scanner upper housing Screw Screw Screw Screw Figure 1-5-35 15. Scanner bottom housing Sliding rod Optical module unit Sliding rod Figure 1-5-36 1-5-27 .2G4 14. Remove the sliding rod. Remove the four screws and then remove the scanner upper housing.

Check or replace the optical module unit and refit all the removed parts. 18. Remove the two FFCs. 17.2G4 16. Remove the optical module unit from the scanner belt. FFC connector Optical module unit FFC connector FFC FFC Scanner belt Bottom view Scanner belt Optical module unit Figure 1-5-37 1-5-28 .

Remove the six screws.1-5-24).1-522). 5. 2. Remove the four connectors and three FFCs from main PWB.2G4 (3) Detaching and refitting the main PWB <Procedure> 1. Screw Screw Screw Screw Main PWB cover Screw Screw Connectors Connector Scanner unit FFC FFC FFC Main PWB Figure 1-5-38 1-5-29 . 4. Remove the original table and ejection extension (See page P. 3. Remove the scanner unit (See page P. Remove the main PWB cover.

8.) 34 mm 1 5/16" 71 mm 2 13/16" 25 mm 1" Q9 80 mm 3 1/8" 105 mm 4 1/8" U14 Q6 Silicon rubbers install position Figure 1-5-39 1-5-30 .2G4 6. 7. Remove the main PWB. Remove the six screws and three terminals. Screw Screw Screw Screw Screw Screw Main PWB Terminals Scanner unit Silicon rubber (Q9) Silicon rubber (U14) Silicon rubber (Q6) 134 mm 5 1/4" (approx. Check or replace the main PWB and refit all the removed parts.

Remove the one connector.1-5-24). Remove the exposure lamp holder. 4. Remove the adhesive tape. Remove the optical module unit (See page P. Hook Exposure lamp holder Hook Hook Adhesive tape Connector Hook Figure 1-5-41 1-5-31 . 5. 2. Remove the CCD cover. Hook CCD cover Optical module unit Stopper Figure 1-5-40 3.2G4 (4) Detaching and refitting the exposure lamp <Procedure> 1.

2G4

6. Remove the wires from the exposure lamp holder. 7. Remove the exposure lamp. 8. Check or replace the exposure lamp and refit all the removed parts.

Wire

Exposure lamp

Wire

Exposure lamp holder

Figure 1-5-42

1-5-32

2G4 (5) Detaching and refitting the inverter PWB <Procedure> 1. Remove the optical module unit (See page P.1-5-24). 2. Cut the band.

Optical module unit

Band

Figure 1-5-43

3. Remove the CCD cover.

Hook

CCD cover

Optical module unit

Stopper

Figure 1-5-44

1-5-33

2G4

4. Remove the two connectors. 5. Remove the one screw and then remove the inverter PWB. 6. Check or replace the inverter PWB and refit all the removed parts.

Connector

Screw

Inverter PWB

Connector

Figure 1-5-45

1-5-34

2G4 (6) Detaching and refitting the scanner home position sensor <Procedure> 1. Remove the optical module unit (See page P.1-5-24). 2. Remove the CCD cover.

Hook

CCD cover

Optical module unit

Stopper

Figure 1-5-46

3. Remove the one connector. 4. Remove the one screw and then remove the scanner home position sensor. 5. Check or replace the scanner home position sensor and refit all the removed parts.

Screw Scanner home positon sensor

Connector

Optical module unit

Figure 1-5-47

1-5-35

2G4 (7) Detaching and refitting the scanner motor <Procedure> 1. 3. 6. Remove the two screws. Remove the scanner motor wire. Remove the one connector. Check or replace the scanner motor and refit all the removed parts. Hook Connector CCD cover Scanner motor wire Stopper Optical module unit Figure 1-5-48 4. Remove the scanner motor. Screw Screw Scanner motor Figure 1-5-49 1-5-36 .1-5-24). 2. Remove the optical module unit (See page P. 5.

2G4 1-5-7 Document processor (DP) (1) Detaching and refitting the document processor (DP) <Procedure> 1.1-522). Remove the six screws and then remove the main PWB cover. Remove the scanner unit (See page P. While unlocking the both hinge locks and then remove the document processor (DP). Remove the connector from main PWB. 6. Remove the original table (See page P. Document processor (DP) Screws DP signal cable Hinge lock Hinge Figure 1-5-51 1-5-37 . Screw Screw Screw Screw Main PWB cover Screw Screw Connector Main PWB Scanner unit Figure 1-5-50 5. 3. 7. 2. Remove the two screws and then remove the DP signal cable. Check or replace the document processor (DP) and refit all the removed parts. 4.1-524).

Pad assembly DP cover Figure 1-5-52 1-5-38 . Open the DP cover. 2. Check or replace the pad assembly and refit all the removed parts. Press both arms of the pad assembly inwardly with your fingers and then pull out the pad assembly. 3.2G4 (2) Detaching and refitting the pad assembly <Procedure> 1.

Remove the original feed roller. Open the shaft holder. 2. Open the DP front cover. 3. 4. Check or replace the original feed roller and refit all the removed parts.2G4 (3) Detaching and refitting the original feed roller <Procedure> 1. Shaft holder Original feed roller DP front cover Figure 1-5-53 1-5-39 .

1-5-40 .2G4 This page is intentionally left blank.

Updating firmware program folder Example: Extract Figure 1-6-1 2.exe] in the [Auto Update] updating firmware program folder. Double-click [FWUpdate. install the updating firmware folder (files) before firmware updating. The updating firmware program starts automatically. 3. 1.2G4 1-6 Firmware 1-6-1 Updating the firmware on the main PWB Procedure Note: Ensure the machine is plugged in and connected to the PC’s USB port. PC display Message display Reboot MFP Power off/on Figure 1-6-2 1-6-1 . When message is displayed to indicate downloading is finished. Turn printer power off and then turn on.

1-6-2 .2G4 This page is intentionally left blank.

manual feed tray. motor etc. The sensors. feeds it in the printer and delivers in the output tray. clutches.. are described in the following pages. (1) Paper feed section The figure below shows the components in the paper feeding/conveying section and the paths through which the paper travels.2G4 2-1 Mechanical construction 2-1-1 Paper feeding/conveying section The paper feeding/conveying system picks up paper from the paper cassette. Paper is feed at the precise timing in synchronization with data processing. Figure 2-1-1 Paper feeding/conveying section (1) (2) (3) (4) (5) (6) Feed roller Feed pulley Lower registration roller Upper registration roller Registration sensor (Actuator) Base plate (7) (8) (9) (10) (11) (12) Cassette bottom Bottom pad Paper separator Separator pad Manual feed tray Feed guide 2-1-1 .

2G4 Engine/high voltage PWB Connect PWB Feed clutch Registration clutch +24V3 YC403-1 FEDSOLON YC403-2 +24V3 YC402-1 REGDR YC402-2 YC401-8 YC401-3 YC401-2 YC401-1 GND YC3-13 FEDDOLON YC3-8 REGSOLON YC3-7 +24V3 YC3-6 Registration sensor CN1-1 CN1-2 CN1-3 CN1-4 CN1-5 Main motor +24V3 GND MMOTRDY MOTCLK REMOTE YC5-1 YC5-2 YC5-3 YC5-4 YC5-5 Paper sensor Figure 2-1-2 Paper feeding/conveying section block diagram 2-1-2 .

and development. organic solvent. etc. alcohol.2G4 2-1-2 Drum section (1) Drum unit The durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base. the drum (in the drum unit) must be handled with care. exposure. Figure 2-1-3 Drum unit (1) (2) (3) (4) (5) Drum frame Drum cover A Drum cover B Waste toner cover Drum (OPC) 2-1-3 . therefore. Substances like water. etc. . finger prints can cause deterioration of the OPC layer. resulting in a print quality problem. the electrostatic image is constituted over the OPC layer. Also. The OPC tend to reduce its own electrical conductance when exposed to light. If the drum (drum unit) remains removed form the printer.. the exposure to a strong light source for a prolonged period can cause a print quality problem. The limit is approximately 500 lux for less than five minutes. Since the OPC is materialized by resin. should be strictly avoided. it is susceptible to damage caused by sharp edges such as a screwdriver. As with all other OPC drums. After a cyclic process of charging.. it should be stored in a cool. dark place.

its photoconductive layer is given a uniform. positive (+) corona charge dispersed by the main charger wire. Cleaning the charging wire prevents print quality problems such as black streaks.2G4 (2) Main charger unit As the drum rotates in a “clean (neutral)” state. 2-1-4 . Due to high-voltage scorotron charging. Drum Figure 2-1-4Main charger unit (1) (2) (3) (4) Main charger shield Main charger wire Main charger grid Main charger wire cleaner Main charger output 250 .10 µA (default) + Main charger wire Shield Grid Engine/high voltage PWB Zener PWB Drum Drum surface potential 470 + 15 V DC - Figure 2-1-5Drum unit and main charger unit block diagram. the charging wire can get contaminated by oxidization after a long run.

adjust the diameter of the laser beam.2G4 2-1-3 Expose section (1) Laser scanner unit The charged surface of the drum is then scanned by the laser beam from the laser scanner unit. Various lenses and mirror are housed in the laser scanner unit. Laser beam Drum Figure 2-1-6Laser scanner unit (1) (2) (3) (4) (5) (6) Laser scanner unit MID frame LSU lid LSU shutter LSU mirror Polygon motor (mirror) 2-1-5 . and focalize it at the drum surface. The laser beam (780 nm wavelength) beam is dispersed as the polygon motor revolves (27959 rpm) to reflect the laser beam over the drum.

........ 4. Diverts the laser beam vertically onto the drum............. each mirror corresponding to one scanned line width on the drum when laser beam scans on it................. F-theta lens ................................................................................ this pin photo diode sensor generates a trigger signal for the engine controller to start activating the paper feeding system.. Collimator lens ...... Cylindrical lens................... When shone by the sensor mirror above............... 7............................................. 9... 3............2G4 Figure 2-1-7Laser scanner unit 1. Emits diffused............................. PD lens ................. Note the diffused laser beam finally pinpoints on the drum...................... Aligns the laser beam to the cylindrical lens.................. Laser diode ... 2-1-6 ..... Polygon mirror (motor) ... Has six mirror segments around its hexagonal circumference........ Condensing laser beam focus to the pin photo diode sensor.......................... 6.............. 8........ The f-theta lens equalizes focusing distortion on the far ends of the drum..................... Compensates the vertical angle at which the laser beam hits a polygon mirror segment.. 2....... LSU mirror........ 5..... Bends the very first shot of a laser scan towards the pin photo diode sensor ( ) Pin photo diode sensor .... visible laser....... Sensor mirror ..

magnetized by magnet. is positioned approximately 0. (The gap between the drum and the developing roller is 0.32 mm. The positively charged toner is then attracted to the areas of the drum which was exposed to the laser light.32 mm S2 250 Drum N1 93 S1 Figure 2-1-8Developer unit and toner container (1) (2) (3) (4) DLP case Magnet roller Developing sleeve DLP screw A (5) (6) (7) (8) DLP screw B Doctor blade DLP shutter Toner container 2-1-7 . 0. positive DC power source. Toner attracts to the developing roller since it is powdery ink made of black resin bound to iron particles. The developing roller is also AC-biased to ensure contrast in yielding by compensating the toner’s attraction and repelling action during development. Toner on the developing roller is given a positive charge.2G4 2-1-4 Developing section (1) Developer unit The latent image constituted on the drum is developed into a visible image.30 mm above the developing roller to constitute a smooth layer of toner in accordance with the roller revolution. The developing roller contains a 3-pole (S-NS) magnet core and an aluminum cylinder rotating around the magnet core.30 mm N S 0. Doctor blade.) The non-exposed areas of the drum repel the positively charged toner as these areas maintain the positive charge. The developing roller is applied with the AC-weighted.

5 V DC + AC + TB1 Figure 2-1-9Developing section block diagram 2-1-8 .2G4 Engine/high voltage PWB Developing roller Developing bias output 350 .

2G4

2-1-5

Transfer section

The image developed by toner on the drum is transferred onto the paper because of the electrical attraction between the toner itself and the transfer roller. The transfer roller is negatively biased so that the positively charged toner is attracted onto the paper while it is pinched by the drum and the transfer roller.

Transfer roller

Figure 2-1-10Transfer section

Transfer roller

Transfer bias output -2.3 kV/-9 µA -2.6 kV/-12 µA

Engine/high voltage PWB

J1/J2/J3

Switches output depending on media type and media size.

Figure 2-1-11Transfer section block diagram

2-1-9

2G4

2-1-6

Cleaning section

After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development process. The cleaning blade is constantly pressed against the drum and scrapes the residual toner off to the sweep roller. The waste toner is collected at the output end of the sweep roller and sent back to the toner container, into the waste toner reservoir. After the drum is physically cleaned, it then must be cleaned to the electrically neutral state. This is necessary to erase any residual positive charge, ready to accept the uniform charge for the next print process. The residual charge is canceled by exposing the drum to the light emitted from the eraser lamp (PWB). This lowers the electrical conductivity of the drum surface making the residual charge on the drum surface escape to the ground.

Laser scanner unit

Waste toner reservoir Drum

Figure 2-1-12Cleaning section (1) (2) (3) (4) (5) Eraser lamp (PWB) Cleaning blade Sweep roller Drum roller Sheet sweep

ERASER

YC8-2

Eraser lamp (PWB)

Drum

Engine/high voltage PWB

Figure 2-1-13Cleaning section block diagram

2-1-10

2G4

2-1-7

Fuser section

(1) Fuser unit The toner on the paper is molten and pressed into the paper as it passes between the heat roller and the press roller in the fuser unit. The heat roller has a heater lamp (750 W) inside which continuously turns on and off by the fuser thermistor to maintain the constant temperature onto the heat roller surface. The heat roller is resin coated by florin to prevent toner from accumulating on the roller after a long run. Care must be taken while handling the heat roller not to scratch the roller surface as doing so may result in print problems. The heat roller has four claws (separators) which are continuously in contact with its surface. These claws (separators) prevent the paper on which toner has been fused from being wound around the heat roller causing paper jam. The press roller is made of the heat-resistant silicon rubber. This roller is used to strongly press the paper towards the heat roller by means of coil springs. The temperature of the heat roller is constantly monitored by the engine/high voltage PWB using the fuser thermistor and triac. Should the temperature of the heat roller exceed the predetermined value, the thermal cutout is activated to effectively disconnect the heater lamp from power.

Figure 2-1-14Fuser unit (1) (2) (3) (4) Upper fuser frame Lower fuser frame Heat roller Press roller (5) (6) (7) (8) Heater lamp Thermal cutout Separators Fuser actuator

2-1-11

2G4 Fuser unit Thermal cutout Power source PWB Engine/high voltage PWB N L Fuser heater lamp Fuser thermistor CN1-1 CN1-3 YC2-6 YC2-7 YC2-9 HEATN SLEEP ZCROSS YC1-6 YC1-7 YC1-9 +5V THERM YC7-2 YC7-1 Figure 2-1-15Fuser section block diagram 2-1-12 .

The paper is delivered to the output tray by the rotation of the FD roller.2G4 2-1-8 Paper exit section (1) Paper exit section The paper exit section transports the paper which passed the fuser unit towards the output tray. finally reaching the FD roller. The paper which passed through the fuser unit turns on the exit sensor which is driven by the fuser actuator in the fuser unit. Figure 2-1-16Paper exit section (1) (2) (3) (4) (5) (6) Output tray FD pulley FD roller Rear cover Fuser actuator Exit sensor actuator 2-1-13 . and is led by the guide comprised of the rear cover and the frame.

2G4 Fuser unit Engine/high voltage PWB YC2-8 EXITN YC1-8 Exit sensor Power source PWB Figure 2-1-17Paper exit section block diagram 2-1-14 .

VOR_EVEN2 MS1. MS2. RESET HMSEN Exposure lamp Inserter PWB CCD image sensor OUT1A.2G4 2-1-9 Scanner section (1) Scanner unit Figure 2-1-18Scanner section (1) (2) (3) (4) (5) (6) (7) Scanner upper housing Scanner bottom housing Contact glass Size indicator Optical module unit housing Lamp housing CCD cover (8) (9) (10) (11) (12) (13) Exposure lamp Mirror Mirror Mirror Lens CCD PWB Original Platen Optical module unit Main PWB CCD PWB PHY1_A1. CP. PHY2_A2 SH1. SH3 RS. SW VOB_ODD. SLEEP. SETP. PHY1_A2 PHY2_A1. VOG_EVEN1. 2B Mirrors and lens Stepping motor driver Scanner motor Scanner home position sensor GND Scanner_open Scanner open/close switch Scanner unit Figure 2-1-19Scanner section block diagram 2-1-15 . DIR. 2A OUT1B. SH2.

converts it to electric signals. The operation described above is repeated for scanning the overall image of the original. a lens. a CCD PWB. The original on the contact glass is exposed to the light of the exposure lamp that is reflected by the reflector. The image is input through reflection by the three mirrors and through the lens to the CCD image sensor on the CCD PWB. the optical module unit stops at the position of the contact glass and scans sequentially one row of the image on the original in synchronization with the moving timing of the original in the sub scan direction by driving the DP. Sliding rod Figure 2-1-20Optical module unit (1) (2) (3) (4) (5) (6) (7) (8) (9) Exposure lamp Scanner motor Lens CCD PWB Scanner home position sensor Inverter PWB Mirror Mirror Mirror 2-1-16 . Also an inverter PWB for driving the exposure lamp and a scanner home position sensor for detecting the home position of the optical module unit are incorporated. Then the optical module unit is moved in the sub scan direction along the sliding rod. and the CCD image sensor scans the next row of the image in the main scan direction. The CCD image sensor scans one row of the image in the main scan direction.2G4 (2) Optical module unit The optical module unit consists of an exposure lamp. three mirrors. If a document processor (DP) is used. and outputs them to the main PWB. and so on.

2G4 2-1-10 Document processor (DP) section (1) Document processor (DP) Figure 2-1-21Document processor (DP) section (1) (2) (3) (4) (5) (6) Original feed roller Pad assembly Original conveying roller Original conveying pulley DP upper housing DP cover (7) (8) (9) (10) (11) (12) DP bottom housing DP frame DP contact plate Original exit roller Original exit pulley Original table Document processor (DP) Original feed sensor Original feed motor Original conveying sensor Motor driver PWB OUT1A. SLEEP. OUT2B PAPER_OUT_P PAPER_IN_P Stepping motor driver MS1. OUT1B. MS2 DIR. OUT2A. STEP. RESET Main PWB Figure 2-1-22Document processor (DP) section block diagram 2-1-17 .

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............... Adjusts the main charger grid electrostatic potential........................... Zener PWB ..................... Shuts off the power source to the heater lamp when the heat roller reaches extremely high temperature........ Registration sensor ..... 18............... Engine/high voltage PWB ................. 9... Power switch.............. After full-wave rectification of AC power source input. Drives the polygon mirror....... Drives the entire machine...................... Paper sensor..... Exit sensor ... Cools the interior of machine........ AC inlet ... Detects the timing of primary feeding and paper jam. switching for converting to 24 V DC and 5 V DC for output......... Energizes the heat roller.............. 22..................... Feed clutch ... Controls the input/output of electrical parts and generates the high voltage............. Eliminates the residual electrostatic charge on the drum... Fuser thermistor.. Cooling fan motor........ Turns ON/OFF the AC power source........ 21... Polygon motor................. Detects the waste toner reservoir (drum unit) being full.......................................... Toner empty sensor .. Connects the AC power source...... 6.......................................... 13........ Detects paper in the paper cassette................. 2.....................2G4 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) Electrical parts layout Fuser unit Drum unit Laser scanner unit Developer unit Figure 2-2-1 MFP main frame 1.... Consists the buzzer and wiring relay circuit......... 8. Main motor ..... 10......................... Thermal cutout ................ 3......... Power source PWB................ Controls the paper cassette paper feed. Controls the primary paper feed......... Cools the power source PWB..... Monitors whether the top cover is open and cuts off the 24 V DC powersource....... Measures toner in the toner container......... 14............................. 20.................... 2-2-1 ..... 7.................. Connect PWB ........ 17........... Power source fan motor........ Measures the heat roller temperature.. 15................................. 5....................................... Interlock switch ................................................ Detects paper jam in the fuser unit and paper exit section...... 4......................... Registration clutch ............................................................................. 11.... Waste toner full sensor ..................... 12............. Eraser lamp PWB ................................ 19..... 16.......................................... Heater lamp .....................

..... Controls the exposure lamp.... 7. Controls the DP unit........................................................... 3.... Exposure lamp ............................................ Indicates the LED indicators and controls key inputs.......... Detects when the scanner unit is opened or closed.............. 8..... Motor driver PWB... Exposes originals........... Drives the original feed section........ Document conveying sensor.................. CCD PWB .... 12............ 10... Scanner unit open/close switch .. 4.. Controls the software such as the print data processing and provides the interface with computer.... 5....2G4 DP Optical module unit Scanner unit Figure 2-2-2 Scanner unit and document processor (DP) Main PWB ........... 1...... Scanner motor ................... Operation panel PWB ............. Document feed motor .............. Document feed sensor................... Scanner home position sensor ................................... Inverter PWB......... 2. Detects the original scanning timing.......... Detects the presence of an original. Drives the optical module unit................. Reads the image off originals... 9......................................... 2-2-2 ......... 11......... Detects the optical module unit in the home position................................... 6...

switching control circuit. and the engine/ high voltage PWB outputs the heater lamp ON signal (HEATN) to the heater lamp control circuit based on the timing of zero cross signal (ZCROSS) and controls the AC power loading to the heater lamp. 2-3-1 . The switching regulator circuit consists of the noise filter circuit. other zero cross signal detection circuit and heater lamp control circuit. 5 V DC rectification/smoothing output circuit. 24 V DC rectification/smoothing output circuit and overvoltage detection circuit. rectification smoothing circuit. The zero cross signal detection circuit detects the 0 V point (zero cross) of the AC wave form and outputs to the engine/high voltage circuit.2G4 2-3 Operation of the PWBs 2-3-1 Power source PWB Power source PWB AC input Power switch SW1 F1 Noise F2 NTC1 filter circuit (L1) Rectification smoothing circuit D10-13 T1 24V1 24 V DC rectification/ smoothing output circuit C8 Q1 GND D31 D32 Switching control circuit 5 V DC rectification/ smoothing output circuit Overvoltage detection circuit (IC101) 5V Heater lamp control circuit TRA1 GND Zero cross signal detection circuit PC5 PC1 PC2 Pulse PC4 Exit sensor EXITN SLEEP ZCROSS 24V2 Thermal cutout Heater lamp PC3 HEATN Figure 2-3-1Power source PWB block diagram The power source PWB consists of the switching regulator section that is the main part. and this circuit converts the AC power input to the 5 V DC and 24 V DC power source by the switching operation and outputs it to the engine/high voltage PWB.

240 V AC 120 V AC 5 V DC 5 V DC 24 V DC 0/24 V DC 0/5 V DC 0/5 V DC 0/5 V DC (pulse) 24 V DC 24 V DC 24 V DC 5 V DC 5 V DC 0/5 V DC Description AC power input AC power input Power supply for heater lamp (On/Off) Power supply for heater lamp (On/Off) 5 V DC power output 5 V DC power output Ground Ground 24 V DC power input (via interlock switch) Heater lamp: On/Off Sleep mode: On/Off Exit sensor: On/Off Zero cross signal 24 V DC power output 24 V DC power output Ground 24 V DC power output Ground Ground 5 V DC power output 5 V DC power output Power source fan motor: On/Off YC3 Connected to the main PWB YC4 Connected to the power source fan motor 2-3-2 .240 V AC 120 V AC 220 . N N L N L 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 L N L +5V +5V GND GND +24V HEATN SLEEP EXITIN ZCROSS +24V +24V GND +24V4 GND GND +5V +5V FAN Signal I/O I I O O O O I I I O O O O O O O O Voltage 220 .240 V AC 120 V AC 220 .240 V AC 120 V AC 220 .2G4 CN1 N L YC1 1 YC3 1 1 YC2 1 YC4 Figure 2-3-2Power source PCB silk-screen diagram Connector CN1 Connected to the AC inlet YC1 Connected to the heater lamp YC2 Connected to the engine/high voltage PWB Pin No.

2-3-3 .2G4 2-3-2 Engine/high voltage PWB Engine/high voltage PWB Connect PWB EECLK EEDIO EEPROM (U2) BUZZ Buzzer Registration clutch Feed clutch RESETN Reset IC (U3) REGSOLON FEDSOLON FANH FANL MMOTON MOTCLK MMOTRDY CPU (U1) Registration sensor Paper sensor Cooling fan motor Toner empty sensor TONER Main motor Waste toner full sensor Eraser lamp (PWB) TNFULL ERASERON THERM PLGON PLGRDY PLGCLK Fuser temperature HEATN abnormal circuit Fuser thermistor Laser scanner unit HEAT SLEEPN ZCROSS EXITPAP Interlock switch Power source PWB OUTPEN PLGCLK Exit sensor 24V1 Main PWB RESETN EGIRN SDIR SBSY PDMASKN EGSI EGSO 24V2 24V1 24V2 5V ILOCK High voltage circuit Main charger Developing bias Transfer bias Figure 2-3-3Engine/high voltage PWB block diagram The engine/high voltage PWB consists mainly of CPU (U1) and it is primarily divided into the engine circuit section that controls the entire hardware such as the process and paper feeding/conveying mechanism and the high voltage circuit section that generates various high voltages to output during the process operation.

2G4 3 1 2 1 3 1 1 2 2 1 YC10 YC8 YC6 YC9 YC7 1 YC11 11 1 YC1 13 YC2 1 7 5 YC5 1 13 YC3 1 12 YC4 1 Figure 2-3-4Engine/high voltage PWB silk-screen diagram 2-3-4 .

394 V DC 2.544 to 2.798 V DC 1. YC1 1 Connected 2 to the power 3 source PWB 4 5 6 7 8 9 10 11 12 13 YC3 1 2 Connected to the laser 3 scanner unit 4 and con5 nect PWB 6 7 8 9 10 11 12 Signal +5 +5 GND GND +24V HEATN SLEEP EXITIN ZCROSS +24V +24V GND GND PLGCLK PLGRDY GND GND +24V3 +24V3 REGSOLON FEDDOLON BUZ FPLED2 FPLED1 FPSW I/O I I O O O I I I I O I O O O O O O O I Voltage 5 V DC 5 V DC 24 V DC 0/24 V DC 0/5 V DC 0/5 V DC 0/5 V DC (pulse) 24 V DC 24 V DC 5 V DC (pulse) 0/5 V DC 24 V DC 24 V DC 0/24 V DC 0/24 V DC 0/5 V DC (pulse) 0/5 V DC 0/5 V DC Analog 5V DC 3.160 to 3. SW2 On Ground Reset signal Engine interrupt signal Communication direction change signal Engine busy signal PD mask control signal Engine interface serial communication data Clock signal for engine interface Engine interface serial communication data Clock signal for polygon motor Laser output: On/Off Ground 24 V DC power output Ground Ground (power) Main motor clock signal Main motor: On/Off 5 V DC power output Waste toner full sensor detecting signal: Full/Not full Ground YC4 Connected to the main PWB YC5 Connected to the main motor YC6 Connected to the waste toner full sensor YC7 Connected to the fuser thermistor 13 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 1 2 3 GND RESETN EGIRN SDIR SBSY PDMASKN EGSI SCLKIN EGSO PLGCLK OUTPEN GND +23V3 GND MMOTRDY MOTCLK REMOTE +5V TNFULL GND O O O O O I I O I O O O O O I - 1 2 +5V THERM O I 5 V DC Analog 5 V DC power output Fuser thermistor detection voltage 2-3-5 .2G4 Connector Pin No. SW2 Off SW1: Off.193 V DC 0/5 V DC 0/5 V DC 0/5 V DC 0/5 V DC 0/5 V DC 0/5 V DC (pulse) 0/5 V DC (pulse) 0/5 V DC (pulse) 0/5 V DC (pulse) 0/5 V DC 24 V DC 0/5 V DC (pulse) 0/5 V DC 5 V DC 0/5 V DC Description 5 V DC power input 5 V DC power input Ground Ground 24 V DC power output (via interlock switch) Heater lamp: On/Off Sleep mode: On/Off Exit sensor: On/Off Zero cross signal 24 V DC power input 24 V DC power input Ground Ground Polygon motor clock signal Polygon motor: Ready/Not ready Ground Ground 24 V DC power output 24 V DC power output Registration clutch: On/Off Feed clutch: On/Off Buzzer: On (4 kHz) READY indicator: On/Off ATTENTION indicator: On/Off GO key (SW1) and CANCEL key (SW2) input: SW1: Off. SW2 On SW1: On.947 to 2. SW2 Off SW1: On.

Signal 1 ERASPW 2 ERASER I/O O O Voltage 24 V DC 0/24 V DC Description 24 V DC power output Eraser lamp (PWB): On/Off 1 2 +24V1 FAN O O 24 V DC 0/12/24 V DC 24 V DC power output Cooling fan motor: Full speed/Half speed/Off 1 2 3 +5V TONER GND O I - 5 V DC 0/5 V DC - 5 V DC power output Toner empty/Not Ground 2-3-6 .2G4 Connector YC8 Connected to the eraser lamp (PWB) YC9 Connected to the cooling fan motor YC10 Connected to the toner empty sensor Pin No.

8 V Over driver 24 V Normal 16 V PWM 12 V regulator 12 V regulator Lamp inverter 12 V 5 V 5 VA regulator Lamp heater Figure 2-3-5Main PWB block diagram 2-3-7 .3 V 1.0 System bus J9 Glue logic Operation panel PWB J5 Operation panel control circuit Flash-ROM 4 MB J3 PC J10 Engine/high voltage PWB Power source PWB Power 24 V 5V J1 Power tramsform Power 24 V 24 V 5V 3.2G4 2-3-3 Main PWB CCD PWB CCD image sensor Stepping motor driver IC J11 Vos Main PWB SDRAM 32 MB NVRAM 2 kbytes AFE VD [0:7] Scanner motor J6 CCD control Logic IC Motor control ASIC (CPU) Real time clock Video I/F Serial communication I/F Motor driver PWB Original feed motor Stepping motor driver IC USB 2.

2G4 J11 2 1 1 J10 20 19 1 J7 1 20 22 21 J8 1 7 J6 12 J5 2 1 J9 Figure 2-3-6Main PWB silk-screen diagram 2-3-8 2 1 J3 J12 J2 30 1 1 J1 8 17 J4 .

2-4 Appendixes AC inlet YC7 +5V THERM 1 1 2 2 CN1 Power switch Board to board connector Board to board connector YC2 1 LIVE Fuse Fuser thermistor Eraser lamp PWB Toner empty sensor 3 NEUTRAL YC8 ERASPW ERASERON 1 1 2 2 Power source PWB YC10 +5V TONER GND 1 1 2 2 3 3 Thermal cutout YC1 (1) Wiring diagram 1 HEATERLIVE 3 NEUTRAL +5V +5V 5VGND 5VGND +24V2 HEATN SLEEPN EXITIN ZCROSS +24V +24V 24VGND 24VGND 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 YC1 1 +5V 2 +5V 3 GND 4 GND 5 +24V2 6 HEATN 7 SLEEPN 8 EXITPAP 9 ZCROSS 10 +24V1 11 +24V1 12 GND 13 GND T2 TB1 +5V TNFULL GND 1 1 2 2 3 3 Heater lamp J1 YC4 YC3 FGND FGND FGND +24V1 FANL/FANH 1 1 2 2 Transfer roller Zener PWB Developing roller YC12 JP1 JP2 JP3 YC6 1 5V 2 FAN Exit sensor YC9 Drum Waste toner full sensor Cooling fan motor Power source fan motor J9 J3 +24V4 GND GND GND +5V +5V 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 24V_POWER P_GND P_GND P_GND +5V_POWER +5V_POWER 1 2 3 4 5 6 Document feed motor Registration sensor +24V3 GND MMOTRDY MOTCLK MMOTON 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 J2 J3 1 2 3 4 1 2 3 4 OUT2B OUT2A OUT1B OUT1A Main motor J1 Document conveying sensor USB connector Paper sensor Interlock switch YC4 YC3 J4 USBPWR USB_DM USB_DP USB_GND Feed clutch YC401 +24V3 FEDSOLON +24V3 REGDR 1 1 2 2 1 1 2 2 1 2 3 4 5 6 1 2 3 4 5 6 VCC5 GND PAPER_OUT_P VCC5 GND PAPER_IN_P Document feed sensor J4 5 V DC connector +5V_POWER P_GND P_GND 1 2 3 1 COVER_OPEN 2 GND STEP DIR MS1 PAPER_IN_P GND VREF_SW1 ADF_PLUG ADF_PLUG COVER_OPEN SLEEP RESET MS2 GND VREF_SW2 PAPER_OUT_P VCC5 GND GND MGND 24V_MOTOR_ADF GND N. GND 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 RESETN EGIRN SDIR SBSY PDMASKN EFSI EFSCK EFSO PLGCLK OUTPEN +5V GND 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 SPK VCC_5V J1 J7 GND VDATAN OUTPEN SAMPLEN +5V_POWER GND PDN 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 Engine/high voltage PWB Operation panel PWB J11 J6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 Laser scanner unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LCD_GND BVCC_5V /INTENSITY RS R/W LCDCS LCD0 LCD1 LCD2 LCD3 LCD4 LCD5 LCD6 LCD7 BACKLIGHT J2 +5VD_M HMSEN MGND 1 2 3 1 2 3 SD0 SD1 GND SD2 SD3 GND SD4 SD5 GND SD6 SD7 VCC_5V VCC_5V GND GND LCDCS RS GND /KBRD GND /KBWR SPKR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 UI_DATA0 UI_DATA1 GND UI_DATA2 UI_DATA3 GND UI_DATA4 UI_DATA5 GND UI_DATA6 UI_DATA7 VDD_UI VDD_UI GND GND LCDE LCDRS GND /KBRD GND /KBWR SPKR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Scanner home position sensor J3 12V_heater MGND 1 2 1 2 Operation panel PWB J2 J4 LAMP_GND 24V1 1 2 1 2 Exposure lamp J5 J1 OUT1B OUT1A OUT2A OUT2B 1 2 3 4 1 2 3 4 GND CCD_12VA GND VOR GND VOG GND VOB GND CCD_RS CCD_SW1 CCD_CP GND CCD_SH GND GND CCD_PHY2 CCD_PHY1 CCD_5VA CCD_5VA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 GND +12V GND VOR_EVEN2 GND VOG_EVEN1 GND VOB_ODD GND RS SW1 CP GND SH0 GND GND PH2 PH1 +5VD +5VD J6 Scanner motor HMSEN GND VREF_SW2 VREF_SW1 FB_MOTOR_SLEEP FB_Motor_REST FB_Motor_STEP VDD5 GND 24V_MOTOR 24V_MOTOR FB_Motor_DIR GND FB_Motor_MS1 FB_Motor_MS2 HEATER_PWR LAMP_GND 24V_LAMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 HMSEN MGND VREF_SW2 VREF_SW1 /SLEEP /RESET STEP +5VD_M MGND 24VM 24VM DIR MGND MS1 MS2 12V_heater LAMP_GND 24VI CCD PWB J12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 VDD5 SYSDATA4 SYSDATA3 SYSDATA5 SYSDATA2 SYSDATA6 SYSDATA1 SYSDATA7 SYSDATA0 GND GND GND SYSADR4 GND SYSADR3 SYS_WR SYSADR2 SYS_RD SYSADR1 GND SYSADR0 FAX_RING_DET GND FAX_CS2 FAXINT GND PHONE_LINE /RESET SPKR VCC33 Main PWB Scanner_open GND 1 1 2 2 2-4-1 Scanner unit open/close switch 2G4 .C. 2 3 4 5 6 7 8 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 ADF_Motor_STEP ADF_Motor_DIR ADF_Motor_MS1 PAPER_IN GND VREF_SW1 ADF_PLUG_in ADF_PLUG_out COVER_OPEN ADF_Motor_SLEEP ADF_Motor_REST ADF_Motor_MS2 GND VREF_SW2 PAPER_OUT VDD5 GND GND GND 24V_MOTOR_ADF GND N.C. +24V3 REGSOLON FEDSOLON BUZZ FPLED2 FPLED1 FPSW GND 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 +24V3 REGSOLON FEDSOLON BUZZ FPLED2 FPLED1 FPSW GND 2 3 4 5 6 7 8 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 2 3 4 5 6 7 8 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 2 3 4 5 6 7 8 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 Connect PWB Polygon motor Registration clutch 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Motor driver PWB J5 PLGCLK PLGRDY PLGON GND +24V3 J2 J3 J10 E_RSTN E_EGIRN E_SDIR E_SBSY E_PDMSKN E_EGSI E_SCKN E_EGSO E_PLGCLK OUTPEN N.C.

2G4 (2) Repetitive defects gauge First occurrence of defect 24 mm (15/16") [Upper registration roller] 38 mm (1 1/2") [Lower registration roller] 47.2 mm (1 7/8") [Developing roller] 48 mm (1 7/8") [Transfer roller] 63 mm (2 1/2") [Heat roller or press roller] 94 mm (3 11/16") [Drum] 2-4-2 .