Section |
Page |
Notices and Safety Information |
13 |
Laser Notices |
13 |
Safety Information |
24 |
1. General Information |
31 |
Maintenance Approach |
31 |
Tools Required for Service |
31 |
Serial Number |
32 |
Acronyms |
33 |
Standard Features |
34 |
Printer (Main) |
34 |
Printer Options |
41 |
Printer Identification |
42 |
Options Identification |
43 |
Printer Theory of Operation |
44 |
Printer Systems Description |
45 |
Basic Principles of Color Printing |
45 |
Mechanical and Electrical Structures |
45 |
Printer Component Systems |
47 |
Basic Process of Color Printing |
48 |
Print System and Transfer System |
49 |
Structure of OPC Belt (Photo Developer Cartridge) |
50 |
Basic Structure of the Print System |
51 |
Details of the Print System |
53 |
Charging Process |
53 |
Exposing Process |
55 |
Developing Process |
56 |
First Transfer (Drum) Process |
58 |
Belt Discharge (Erase Lamp) Process |
60 |
Belt Cleaning Process |
61 |
Details of the Transfer System |
62 |
Second Transfer (Paper) Process |
62 |
Paper Discharging Process |
63 |
Drum Cleaner Process |
64 |
Details of the Optical System |
65 |
Details of the Paper Transportation System |
67 |
Fusing Unit |
69 |
Fusing Process |
71 |
Control System Structure |
72 |
Electrical System and Function |
72 |
Control of Print Process |
73 |
Print Sequence Diagram |
74 |
Laser Drive Control Circuit |
75 |
Interface Control |
77 |
Lower Feed Unit Theory of Operation |
78 |
Duplex Theory of Operation |
79 |
2. Diagnostic Information |
81 |
Start |
81 |
Service Error Codes |
82 |
Operator Messages |
89 |
Paper Jam Messages |
107 |
Symptom Tables |
112 |
Printer Symptom Table |
112 |
Print Quality Symptom Table |
114 |
Optional Lower Feed Unit Symptom Table |
116 |
Optional Duplex Unit Symptom Table |
117 |
Printer Service Checks |
118 |
901—Yellow Developer Clutch Service Check |
118 |
902—Magenta Developer Clutch Service Check |
119 |
903—Cyan Developer Clutch Service Check |
120 |
904—Black Developer Clutch Service Check |
121 |
905—Yellow/Black Developer Solenoid Service Check |
122 |
906—Magenta/Cyan Developer Solenoid Service Check |
123 |
907—Toner Empty Sensor P.W.B. Board Service Check |
124 |
910—Developer Motor (DM) Drive Service Check |
125 |
911—Main Motor (MM) Service Check |
127 |
915—Control Cooling Fan Service Check |
130 |
916—Ozone Fan Service Check |
131 |
917—Fuser Heater Fan Service Check |
132 |
918—Erase Lamp Service Check |
133 |
920, 922, 923—Fuser Unit Service Check |
134 |
921—Fuser Thermistor Service Check |
135 |
981—Duplex Motor (DPM1, DPM2) Service Check |
136 |
982—Duplex Upper Solenoid (DSOL-U) Service Check |
138 |
983— Duplex Fan (D-FAN) Service Check |
139 |
984—Duplex Lower Solenoid (DSOL-L) Service Check |
140 |
990—Transfer Drum Encoder Sensor (HPSEN) Service Check |
141 |
991—Transfer Roller Cam Clutch (TRCM) Service Check |
143 |
992—Drum Cleaner Brush Cam Clutch (FBCM) Service Check |
144 |
993—Cleaner Clutch (FBCL) Service Check |
145 |
994—Fuser Clutch (FUCL) Service Check |
146 |
995—OPC Belt Cartridge, Belt Marker Sensor (PBS) Service Check |
147 |
997—High Voltage Power Supply Unit (HVU) Service Check |
149 |
OPC Belt (Photo Developer) Cartridge Drive Service Check |
150 |
Operator Panel Service Check |
150 |
Options No Power Service Check |
152 |
Paper Discharge Service Check |
153 |
Printer No Power Service Check |
154 |
Toner Feed Service Check |
155 |
Waste Toner Feed Service Check |
156 |
Paper Feed Service Checks |
157 |
Printer Paper Feed Service Check |
157 |
Lower Feed Unit Paper Feed Service Check |
159 |
Duplex Paper Feed Service Check |
161 |
Print Quality Service Checks |
163 |
Background Service Check |
163 |
Back Stain Service Check |
164 |
Banding Service Check |
165 |
Black Line Service Check |
166 |
Color Misregistration Service Check |
167 |
Insufficient Fusing Service Check |
168 |
Insufficient Gloss Service Check |
169 |
Jitter Service Check |
170 |
Missing Image at Edge Service Check |
171 |
Mixed Color Image Service Check |
172 |
Mottle Service Check |
173 |
Residual Image Service Check |
174 |
Ribbing Service Check |
175 |
Toner Drop Service Check |
176 |
Vertical Line Service Check |
177 |
Vertical Staggering Image Service Check |
178 |
Vertical White Band Service Check |
179 |
White Band Service Check |
180 |
White Line I Service Check |
181 |
White Line II Service Check |
182 |
White Spot / Black Spot Service Check |
183 |
White Print Service Check |
184 |
Wrinkle / Image Migration Service Check |
185 |
Spacing Table |
186 |
Roller Specifications |
186 |
3. Diagnostic Aids |
187 |
Disabling Download Emulations |
187 |
Paper Jam Sequence |
188 |
Diagnostic Mode |
191 |
Diagnostics Menu Structure |
192 |
Print Quality Test Pages |
192 |
Print Registration |
193 |
Setting Tray 2 Left Margin |
193 |
Setting Top Margin |
193 |
Print Tests |
194 |
Hardware Tests |
195 |
LCD Test |
195 |
Button Test |
195 |
Parallel Wrap Test |
196 |
ROM Memory Test |
196 |
DRAM Memory Test |
197 |
Serial Wrap Test |
198 |
Duplex Tests |
199 |
Duplex Left Margin |
199 |
Device Tests |
200 |
Quick Disk Test |
200 |
Disk Test/Clean |
200 |
Flash Test |
201 |
Printer Setup |
202 |
Setting the Page Count |
202 |
Viewing the Permanent Page Count |
202 |
Serial Number |
202 |
Setting Configuration ID |
203 |
Parallel Strobe Adjustment |
204 |
Resetting Counters |
205 |
Error Log |
205 |
Viewing the Error Log |
205 |
Clearing the Error Log |
206 |
Restore EP Factory Defaults |
206 |
Exiting Diagnostic Mode |
206 |
Examples of Print Quality Test Pages |
207 |
4. Repair Information |
211 |
Removal and Cleaning Precautions |
211 |
Handling the Printed Circuit Boards with MOS ICs |
212 |
During Transportation/Storage: |
212 |
During Replacement: |
212 |
During Inspection: |
212 |
Image Belt Cartridge/OPC |
213 |
During Transportation/Storage |
213 |
Handling |
213 |
Parts Not To Be Touched |
213 |
Adjustments |
214 |
Printer Removal Procedures |
215 |
Precautions to Take Before Maintenance Work |
215 |
Printer Covers |
216 |
Upper Side Cover (L) Removal |
217 |
Side Cover (R) Removal |
218 |
Side Cover (L) Removal |
220 |
Side F Cover (L) Removal |
221 |
Top Cover Assembly Removal |
222 |
Paper Exit Cover / Paper Exit Front Cover / Paper Exit Cover (U) Removal |
223 |
Transfer Cover Removal |
225 |
Rear Cover Removal |
226 |
Rear Cover (U) Removal |
227 |
Base Cover (R) Removal |
228 |
Base Cover (L) Removal |
230 |
Cleaner Cover Removal |
231 |
Front Cover Removal |
232 |
Printer Board Removals |
233 |
Printer Board Layout |
233 |
Main Engine (MCTL P.W.B.) Board Removal |
234 |
IOD1 P.W.B. Removal |
236 |
IOD2 P.W.B. Removal |
238 |
Panel P.W.B. (Operator Control) Removal |
239 |
Power Supply Unit (Low Voltage Power Supply - LVPS) Removal |
240 |
High Voltage Power Supply Unit (HVU) Removal |
243 |
Erase Lamp Removal |
245 |
Motor Removals |
247 |
Fan / Motor Layout |
247 |
Main Motor (MM) / BD Gear Assembly Removal |
248 |
Main Gear Unit Removal |
250 |
Developer Motor (DM) Removal |
251 |
Developer Drive Unit Removal |
252 |
Optical Unit (Printhead Scanner Motor Assembly) Removal |
254 |
Control Fan (3) (CTFAN) Removal |
257 |
Heater Fan (HTFAN) Removal |
259 |
Ozone Fan (OZFAN) / Ozone Duct Assembly Removal |
260 |
Clutch and Solenoid Removals |
262 |
Clutch (FUCL, FBCL, RECL) Removal |
263 |
Paper Feeder Clutch (PCLU) Removal |
264 |
Developer Clutch (DCLK, DCLY, DCLM, DCLC) Removal |
265 |
Cam Clutch (FBCM, TRCM) Removal |
267 |
Sensor Removals |
268 |
Interlock Switch (Front) Removal |
269 |
Interlock Switch (Top) Removal |
270 |
Interlock Switch (Rear) Removal |
271 |
Paper Sensor (Paper Feeding Sensor PT1) Removal |
273 |
Paper Exit Sensor (PT2) Removal |
274 |
Paper Empty Sensor (PEU) / OHP Sensor (OHP) Removal |
275 |
Paper Size Sensor (PSU) Removal |
277 |
Drum Jam Sensor (DPJ) Removal |
278 |
Oil Sensor (OIL) Removal |
279 |
Drum Encoder Sensor (HPSEN) Removal |
280 |
Belt Sensor (PBS) Removal |
282 |
Waste Toner Sensor (TBLE/TBFL) (Waste Toner Holder Assembly) Removal |
283 |
Toner Sensor Assembly (TPD) / (TTR) Removal |
284 |
Cleaning Roller Sensor (FCS) Removal |
286 |
Paper Full Sensor (PFUL) Removal |
287 |
Toner Key Sensor (TNK) Removal |
288 |
Transfer Unit (Rollers and Drum) Removal |
289 |
Transfer Unit Removal |
289 |
Registration Roller Removal |
290 |
Transfer Drum Removal |
291 |
Paper Feed Roller / Separator Pad Removal |
293 |
Front Cover Unit Removal |
294 |
Paper Exit Unit / Paper Exit Roller Removal |
296 |
Discharger Brush Removal |
298 |
Waste Toner Feeder (U) (Stay 'A' Assembly) Removal |
299 |
Fuser Connector Removal |
300 |
Waste Toner Feeder (L) Removal |
301 |
Fuser Unit Removal |
303 |
Lower Feeder Unit (LFU) Removals |
304 |
Lower Feeder Unit Top Cover (R) Removal |
305 |
Lower Feeder Unit Top Cover (L) Removal |
306 |
Lower Feeder Unit Front Top Cover Removal |
307 |
Lower Feeder Unit Base Cover (R) Removal |
308 |
Lower Feeder Unit Base Cover (L) Removal |
309 |
Lower Feeder Unit Paper Sensor Removal |
310 |
Lower Feeder Unit Paper Size Sensor (SL-PS -A57 P.W.B. Assembly) Removal |
311 |
Lower Feeder Unit Paper Feed Clutch (PKCLL) / LF Clutch (DPKCL) Removal |
312 |
Lower Feeder Unit Paper Feeder Rolling / Separator Pad Removal |
313 |
Duplex Cover and Paper Guide Removals |
314 |
Duplex Side Cover Low (R) Removal |
315 |
Duplex Side Cover Low (L) Removal |
316 |
Duplex Cover Top (R) Removal |
317 |
Duplex Cover Top (L) Removal |
318 |
Duplex Cover Top (B) Assembly Removal |
319 |
Duplex Cover Top (C) Assembly Removal |
321 |
Duplex Cover Low (B) Assembly Removal |
322 |
Duplex Bottom Cover Assembly Removal |
323 |
Duplex Paper Guide RVS Unit Removal |
325 |
Duplex Paper Guide RVS IN Removal |
327 |
Duplex Paper Guide Bottom Removal |
329 |
Duplex Paper Top Assembly (D-Top Unit and D-Lower Unit) Removal |
331 |
Duplex Paper Guide Top Assembly Removal |
333 |
Duplex Print P.W.B. Removal |
334 |
Duplex Relay P.W.B. Removal |
336 |
Duplex Motor 1 Removal |
338 |
Duplex Motor 2 Removal |
339 |
Duplex Fan Motor Removal |
341 |
Duplex Solenoid (U) Assembly Removal |
342 |
Duplex Solenoid (L) Assembly Removal |
343 |
Duplex Interlock Switch (D-SW1, D-SW2) Removal |
344 |
Duplex Interlock Switch (D-SW3, D-SW4) Removal |
345 |
Duplex D Paper Sensor (PT5) Removal |
346 |
Duplex Paper Sensor Low (PT4) Removal |
347 |
5. Locations |
349 |
Printer |
349 |
Options |
351 |
Electronic Components |
352 |
Sensor Locations |
352 |
Printer Circuit Board Locations |
354 |
Fan/Motor Locations |
356 |
Solenoid/Clutch Locations |
357 |
Symbol and Part Name Table |
359 |
Wiring Diagram / Cable Harness Reference |
361 |
Controller RIP Card |
363 |
Main Engine (MCTL P.W.B.) Board |
364 |
IOD1 P.W.B. Board |
365 |
IOD2 P.W.B. Board |
366 |
Low Voltage Power Supply (LVPS) Board |
367 |
High Voltage Unit (HVU) Board |
368 |
Fuser Unit (LVPS) Board |
369 |
Connector Locations for Options |
370 |
Lower Feed Unit Option |
370 |
Duplex Unit |
371 |
Connector Pin Assignments |
372 |
Location 1 |
372 |
Location 2 |
373 |
Location 3 |
373 |
Location 4 |
373 |
Location 5 |
374 |
Location 6 |
375 |
Location 7 |
376 |
Location 8 |
376 |
Location 9 |
377 |
Location 10 |
377 |
Location 11 |
378 |
Location 12 |
379 |
Location 13 |
379 |
Location 14 |
380 |
Location 15 |
380 |
Location 16 |
381 |
Location 17 |
381 |
Location 18 |
381 |
Location 19 |
382 |
Location 20 |
382 |
Location 21 |
383 |
Location 22 |
383 |
Location 23 |
383 |
Location 24 |
384 |
Location 25 |
384 |
Location 26 |
384 |
Location 27 |
385 |
Location 28 |
385 |
Location 29 |
386 |
Location 30 |
386 |
Location 31 |
387 |
Location 32 |
388 |
Location 33 |
388 |
Location 34 |
388 |
Location 35 |
389 |
Location 36 |
389 |
Location 37 |
390 |
Location 38 |
390 |
Location 39 |
391 |
Location 40 |
392 |
Location 41 |
392 |
Location 42 |
393 |
Printer Cables |
394 |
Cable 1 Connector Assignments |
394 |
Cable 2 Connector Assignments |
394 |
Cable 3 Connector Assignments |
395 |
Cable 4 Connector Assignments |
396 |
Cable 5 Connector Assignments |
397 |
Cable 6 Connector Assignments |
397 |
Cable 7 Connector Assignments |
397 |
Cable 8 Connector Assignments |
398 |
Cable 9 Connector Assignments |
398 |
Cable 10 Connector Assignments |
398 |
Cable 11 Connector Assignments |
399 |
Cable 12 Connector Assignments |
399 |
Cable 13 Connector Assignments |
399 |
6. Preventive Maintenance |
401 |
Safety Inspection Guide |
401 |
Service Precautions |
401 |
Cleaning Procedures |
401 |
Lubrication Specifications |
402 |
Printer Supplies and Maintenance Schedules |
403 |
Cleaning for Maintenance |
404 |
7. Parts Catalog |
405 |
How to Use this Parts Catalog |
405 |
Index |
437 |