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Kyocera DISCOVER FS-3830N, Service Manual

The Kyocera DISCOVER FS-3830N is a high-performance printer designed for professional use. To ensure smooth operation and maintenance, we provide a comprehensive Service Manual that you can easily download for free from manualshive.com. This manual offers step-by-step instructions and insights to help you maximize the functionality of your printer.

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2FP/2FY2FR

1-5-5 Mechanical problems ...........................................................................................................................  1-5-24

(1) No primary paper feed. ...................................................................................................................  1-5-24
(2) No secondary paper feed. ...............................................................................................................  1-5-24
(3) Skewed paper feed. ........................................................................................................................  1-5-24
(4) Multiple sheets of paper are fed at one time. ....................................................................................  1-5-24
(5) Paper jams. ....................................................................................................................................  1-5-24
(6) Abnormal noise is heard. ................................................................................................................  1-5-24

1-6 Assembly and Disassembly

1-6-1 Precautions for assembly and disassembly .........................................................................................  1-6-1

(1) Precautions .....................................................................................................................................  1-6-1

1-6-2 Removing the developer ......................................................................................................................  1-6-2

(1) Removing the developer .................................................................................................................  1-6-2

1-6-3 Removing the paper transfer unit .........................................................................................................  1-6-4
1-6-4 Removing the main charger unit ..........................................................................................................  1-6-5
1-6-5 Removing the operator panel and outer covers ...................................................................................  1-6-6

(1) Removing the operator panel .........................................................................................................  1-6-6
(2) Removing the top cover/face-down output tray ..............................................................................  1-6-7
(3) Removing the right cover ................................................................................................................  1-6-8
(4) Removing the left cover ..................................................................................................................  1-6-9

(1) Removing the MP tray paper feed unit ......................................................................................... 1-6-13
(2) Removing the MP tray feed roller ............................................................................................... 1-6-14
(3) Removing the retard holder (roller) .............................................................................................. 1-6-14

1-6-6 Removing the drum unit .....................................................................................................................  1-6-10
1-6-7 Removing the pickup roller and feed roller .........................................................................................  1-6-11
1-6-8 Removing the MP tray paper feed unit, MP tray feed roller and retard holder (roller) .......................  1-6-13

1-6-9 Removing the transfer roller ...............................................................................................................  1-6-15

1-6-10 Removing the controller unit and the principal circuit board ..............................................................  1-6-16

(1) Removing and opening the controller unit ....................................................................................  1-6-16
(2) Removing the engine board and power supply unit .....................................................................  1-6-20
(3) Removing the main board ............................................................................................................  1-6-22
(4) Removing the high voltage unit ....................................................................................................  1-6-23
(5) Removing the sensor board .........................................................................................................  1-6-24

1-6-11 Removing the drive unit and main motor ...........................................................................................  1-6-25
1-6-12 Removing and splitting the fuser unit .................................................................................................  1-6-27

(1) Removing the separators .............................................................................................................  1-6-30
(2) Removing the heater lamp ...........................................................................................................  1-6-31
(3) Removing the heat roller ..............................................................................................................  1-6-32
(4) Removing the thermistor and thermal cutout ................................................................................  1-6-33
(5) Removing the press roller .............................................................................................................  1-6-34

(1) Replacing the ozone filter B and ozone filter ...............................................................................  1-6-36

1-6-13 Removing the laser scanner unit ........................................................................................................  1-6-35
1-6-14 Replacing the ozone filter B and ozone filter ......................................................................................  1-6-36

1-7 Upgrading the Firmware

1-7-1 Upgrading the firmware on the main board ..........................................................................................  1-7-1

(1) Firmware program data format .......................................................................................................  1-7-2
(2) Downloading the firmware from the parallel interface ....................................................................  1-7-3
(3) Downloading the firmware from the memory card ..........................................................................  1-7-5
(4) Downloading errors ........................................................................................................................  1-7-7

2-1 Mechanical Construction

2-1-1 Paper feeding system ..........................................................................................................................  2-1-1

(1) Paper feeding system .....................................................................................................................  2-1-1
(2) Paper feed control ..........................................................................................................................  2-1-2
(3) Paper feeding mechanism ..............................................................................................................  2-1-3

Summary of Contents for DISCOVER FS-3830N

Page 1: ...SERVICE MANUAL Published in June 2006 842FR116 2FRSM066 Rev 6 FS 1920 FS 3820N FS 3830N ...

Page 2: ... 5 2 3 2 2 3 3 Revised all 2 4 1 to 2 4 14 1 1 5 1 1 1 1 1 3 1 1 5 1 4 1 1 5 2 1 5 3 1 5 11 1 5 13 1 5 20 1 5 21 1 6 24 1 6 25 2 1 11 2 3 5 2 3 6 1 4 1 1 4 9 1 6 13 1 6 14 1 6 36 6 23 June 2006 1 4 2 1 4 3 1 4 4 1 4 5 1 4 7 1 4 8 Address 5 9 May 2006 1 4 6 1 4 7 1 4 8 1 4 9 Address 3 7 January 2005 1 1 2 1 1 4 1 1 5 1 1 6 Corrected Product code 2FP 2FR Combined FS 3820N model 2FY ...

Page 3: ...rsonnel 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 ...

Page 4: ...ompliance with warning messages using this symbol WARNING Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol CAUTION Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol Symbols The triangle symbol indicates a warning includi...

Page 5: ...d or dusty place This may cause fire or electric shock Do not install the copier near a radiator heater other heat source or near flammable material This may cause fire Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool as possible Insufficient ventilation may cause heat buildup and poor copying performance Always handle the machine by the correct ...

Page 6: ...e clean Dirt on them can cause abnormally high temperatures Do not remove the ozone filter if any from the copier except for routine replacement 2 Precautions for Maintenance WARNING Always remove the power plug from the wall outlet before starting machine disassembly Always follow the procedures for maintenance described in the service manual and other related brochures Under no circumstances att...

Page 7: ...at all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling Replace with new ones if necessary Handle greases and solvents with care by following the instructions below Use only a small amount of solvent at a time being careful not to spill Wipe spills off completely Ventilate the room well while using grease or solvents Allow app...

Page 8: ...This page is intentionally left blank ...

Page 9: ...feed detection 1 5 1 1 Paper misfeed indication 1 5 1 2 Paper misfeed detection 1 5 1 1 5 2 Self diagnosis 1 5 2 1 Self diagnostic function 1 5 2 2 Self diagnostic indication 1 5 2 1 5 3 Image formation problems 1 5 15 1 Completely blank printout 1 5 16 2 No image appears entirely black 1 5 16 3 Dropouts 1 5 17 4 Black dots 1 5 17 5 Black horizontal streaks 1 5 18 6 Black vertical streaks 1 5 18 7...

Page 10: ...der roller 1 6 13 1 6 9 Removing the transfer roller 1 6 15 1 6 10 Removing the controller unit and the principal circuit board 1 6 16 1 Removing and opening the controller unit 1 6 16 2 Removing the engine board and power supply unit 1 6 20 3 Removing the main board 1 6 22 4 Removing the high voltage unit 1 6 23 5 Removing the sensor board 1 6 24 1 6 11 Removing the drive unit and main motor 1 6 ...

Page 11: ...N models 2 4 6 Timing chart No 7 Optional paper feeder feeding A4 size paper For FS 1920 3820N models 2 4 7 Timing chart No 8 Paper cassette feeding A4 size paper For FS 3830N model 2 4 8 Timing chart No 9 Paper cassette feeding Letter size paper For FS 3830N model 2 4 9 Timing chart No 10 Paper cassette feeding Legal size paper For FS 3830N model 2 4 10 Timing chart No 11 MP tray feeding A4 size ...

Page 12: ...2FP 2FY2FR This page is intentionally left blank This page is intentionally left blank ...

Page 13: ...p time Approx 10 s or less from sleep mode Approx 18 s or less from power on Paper feed system One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m2 0 11 µm MP tray 100 sheets 80 g m2 0 11 µm Paper eject system Face down 250 sheets 80 g m2 0 11 µm Face up 250 sheets 80 g m2 0 11 µm Face up 100 sheets 80 g m2 0 11 µm Optional paper tray PT 60 Standard memory 32 M...

Page 14: ...1E 10 Base TX 100 Base TX wireless LAN card IB 22 must be installed Optional serial interface RS 232C Max 115 2 Kbps Serial interface board IB 11 must be installed Dimensions 345 W 300 H 390 D mm 139 16 W 1113 16 H 181 4 D Weight Approx 13 2 kg 299 16 lbs Floor requirements 496 W 740 D mm 199 16 W 293 16 D Power source 120 V AC 60 Hz 8 0 A 220 240 V AC 50 60 Hz 3 9 A Power consumption Max 979 W 12...

Page 15: ...pprox 10 s or less from sleep mode Approx 18 s or less from power on Paper feed system One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m2 0 11 µm MP tray 100 sheets 80 g m2 0 11 µm Paper eject system Face down 250 sheets 80 g m2 0 11 µm Face up 250 sheets 80 g m2 0 11 µm Face up 100 sheets 80 g m2 0 11 µm Optional paper tray PT 60 Standard memory 64 MB expand...

Page 16: ...al interface KUIO LV 1 Network interface card IB 20 10 Base TX 100 Base TX 10 Base 2 IB 21E 10 Base TX 100 Base TX wireless LAN card IB 22 must be installed Optional serial interface RS 232C Max 115 2 Kbps Serial interface board IB 11 must be installed Dimensions 345 W 300 H 390 D mm 139 16 W 1113 16 H 181 4 D Weight Approx 13 2 kg 299 16 lbs Floor requirements 496 W 740 D mm 199 16 W 293 16 D Pow...

Page 17: ...15 s or less from sleep mode Approx 20 s or less from power on Paper feed system One universal cassette and one MP tray Paper loading capacity Cassette 500 sheets 80 g m2 0 11 µm MP tray 100 sheets 80 g m2 0 11 µm Paper eject system Face down 250 sheets 80 g m2 0 11 µm Face up 250 sheets 80 g m2 0 11 µm Face up 100 sheets 80 g m2 0 11 µm Optional paper tray PT 60 Standard memory 96 MB expandable u...

Page 18: ...l interface KUIO LV 1 Network interface card IB 20 10 Base TX 100 Base TX 10 Base 2 IB 21E 10 Base TX 100 Base TX wireless LAN card IB 22 must be installed Optional serial interface RS 232C Max 115 2 Kbps Serial interface board IB 11 must be installed Dimensions 345 W 300 H 390 D mm 139 16 W 1113 16 H 181 4 D Weight Approx 13 2 kg 299 16 lbs Floor requirements 496 W 740 D mm 199 16 W 293 16 D Powe...

Page 19: ...y 14 Memory card slot 15 Paper transfer unit 16 Paper transfer unit release lever 17 MP tray 18 Rear cover 19 AC inlet 20 Parallel interface connector 21 USB interface connector 22 Option unit connector 23 Network interface card option or serial interface board option 24 Network interface connector for FS 3820N 3830N models only 1 10 11 9 8 7 15 17 18 23 20 21 22 19 13 14 2 3 23 20 21 24 22 19 FS ...

Page 20: ... Data indicator 3 Attention indicator 4 GO key 5 CANCEL key 6 MENU key 7 U key 8 V key 9 Y key 10 Z key 11 ENTER key 12 TYPE indicator 13 SIZE indicator 14 INTERFACE indicator 15 Message display Figure 1 1 2 Message display 3 9 4 7 10 2 1 6 8 11 5 15 14 13 ...

Page 21: ... paper feeder PF 60 Optional paper feeder PF 60 Optional paper feeder PF 60 1 11 7 2 3 6 4 10 9 8 5 1 1 3 Machine cross section 1 Cassette 2 Paper feed unit 3 MP tray 4 MP tray paper feed unit 5 Process unit 6 Toner container 7 Transfer section 8 Fuser unit 9 Face down output tray 10 Laser scaner unit LSU 11 Controller unit Figure 1 1 3 ...

Page 22: ...2FP 2FY 2FR 1 1 10 This page is intentionally left blank ...

Page 23: ...ght or bright lighting Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams Avoid extremes of temperature and humidity abrupt ambient temperature changes and hot or cold air directed onto the machine Avoid dust and vibration Choose a surface capable of supporting the weight of the machine Place the machine on a level surface maximum a...

Page 24: ...2FP 2FY 2FR 1 2 2 This page is intentionally left blank ...

Page 25: ...llation procedure Unpacking Installing the toner container Installing the waste toner box Loading paper Installing the dust cover Start Connect the printer cable and power cord Initializing the printer and make test page Completion of the machine installation ...

Page 26: ...3 For U S A model only 8 7 5 6 4 Unpack 1 Printer 2 Waste toner box 3 Toner container 4 Power cord 5 CD ROMs 6 Installation guide and other printed matter 7 Plastic bag for developer 8 Dust cover For U S A model only Figure 1 3 1 Unpacking ...

Page 27: ...ow ten times or more to loosen and mix the toner inside Installing the toner container Figure 1 3 2 Figure 1 3 4 Toner container 2 Carefully remove the protective seal Protective seal Figure 1 3 3 Top cover Toner container 3 Open the printer top cover all the way 4 Install the toner container into the printer ...

Page 28: ...top cover Figure 1 3 6 Figure 1 3 7 Toner container Top cover Install the waste toner box Waste toner box Cap Left cover Waste toner box 1 Open the cap of the waste toner box 2 Open the left cover on the left side of the printer 3 Insert the waste toner box as shown in the figure The box will be locked when it fits into place ...

Page 29: ... cassette Figure 1 3 9 Load paper 1 If you have installed a paper cassette that can hold the legal size paper install the dust cover at the back of the printer The legal size cassette and the dust cover are supplied for U S A model only Dust cover Legal size cassette Installing the dust cover ...

Page 30: ...twork interface For FS 3820N 3830N models only Figure 1 3 11 Connect the printer cable and power cord Figure 1 3 10 Paprallel cable USB cable Network ether cable Parallel USB Network FS 3820N 3830N models only 2 Connect the power cord to AC inlet Power cord AC inlet ...

Page 31: ...tandard status page To print standard status page 1 Press the MENU key on the operator panel 2 Press the U or V key repeatedly until the message display shows Print Status Page 3 Press the ENTER key twice The message display indicates Processing during printing of the standard status page then returns to Ready To print service status page 1 Press the MENU key on the operator panel 2 Press the U or...

Page 32: ... shock WARNING Turn the printer s power switch off Unplug the printer s power cable Procedure 1 Remove the two screws and then pull the main board all the way out of the printer There are two DIMM sockets are provided on the FS 3830N model and one DIMM socket on the FS 1920 3820N models for expanding the printer s memory The extra 32 MB of DIMM memory that come standard with the FS 3830N model is ...

Page 33: ...en the clips on both ends of the DIMM socket 3 Insert the DIMM into the DIMM socket so that the notches on the DIMM align with the corresponding protrusions in the slot 4 Close the clips on the DIMM slot to secure the DIMM DIMM memory Clip Clip DIMM socket ...

Page 34: ...le and disconnect the printer from the computer or the network Never insert or remove a memory card while the printer power is ON Failure to turn the power switch OFF will immediately halt the printer with a Memory card err20 message this message may not always appear It also could result in any damage to the printer s electronic parts or the memory card Turn the power switch ON again to restart t...

Page 35: ...reign substances such as metal chips or liquid get inside the printer during the installation process Operation of the printer during the presence of a foreign substance may lead to fire or electric shock WARNING Turn the printer s power switch off Unplug the printer s power cable Procedure 1 Remove the two screws and then pull the main board all the way out of the printer See page 1 3 8 2 Install...

Page 36: ... the printer during the presence of a foreign substance may lead to fire or electric shock WARNING Turn the printer s power switch off Unplug the printer s power cable Procedure 1 Turn the power switch off 2 Remove the two screws then remove the option interface card slot cover 3 Insert the network interface card to the option interface card slot 4 Fix the network interface card by two screws 5 Co...

Page 37: ...until Others is displayed Print Menu Map Print Status Page Service mode items 3 Press the u key 5 Press the u key To performing a drum refreshing See page 1 4 11 DRUM CTRL 00 Print Event Log Developer To performing a automatic drum refreshing See page 1 4 11 To initial setting for the developer See page 1 4 10 To print an event log EVENT LOG Displayed when FRPO I1 is set to 1 See page 1 4 6 To res...

Page 38: ...Service information 0104 A103 C1 22 00AFUB 03 03 Total page 9690 t P00 S00 U00 F00 N00 D10 DM0301 DAN 0020 0020 1061 0811 0 0 0 0 0 0 0 0 0 0 0 0 0 0 AAAAAA AAAAAA AAAAAA AAAAAA AAAAAA AAAAAA AAAAAA 003D 0005 0005 0005 0005 0005 0005 0005 0000 RS2 FF 00 0003 0003 AI E 81 31 50 0 00 00 00 00 00 00 03030303 03030303 03030303 03000000 00000000 03030303 03030303 SPD1 0203040508090A0B0C0D0F101112131415...

Page 39: ...0005 0005 0005 0005 0005 0005 0005 0000 RS2 FF 00 0003 0003 AI E 81 31 50 0 03030303 03030303 03030303 03000000 00000000 03030303 03030303 SPD1 0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088808880808000 8088...

Page 40: ...d 02 Version error 03 Checksum error 04 NVRAM crush error 12 NVRAM downloading status 00 Normal downloaded Bit 7 Error occurred MSB Bit 6 Reserved Bit 5 OEM data Bit 4 Operator panel message data File name displayed Bit 3 Program data Bit 2 Macro data Bit 1 Host data Bit 0 Font data LSB 13 Printable area information Top offset Left offset Page length Page width 14 Left offset MP tray Cassette 1 Ca...

Page 41: ...Second 2 bytes Bit 0 Face up Bit 1 Face down Bit 2 Reserved Bit 3 Sorter Bit 4 to 15 Reserved 29 Average print density 2 digits of integer part and 1 digit of fraction part total print density from shipping from factory 30 Operation panel message language PMSG command setting value decimal 31 Current temperature 0 to 80 C Humidity temperature sensor is abnormal 32 Current humidity 5 to 100 RH in 1...

Page 42: ... 32 01 91 00 88 32 74 04 A8 C0 Paper jam Cassette 2 Number Page Count Code Event list Event log Total page 522 Figure 1 4 3 Details of event list Print Event Log Details of event list The event list includes the following information A Number Prints a list of error history 1 to 16 A smaller number means an older event B Page Count Number of pages printed when an error occurred C Code 1 02 fixed 2 ...

Page 43: ...ther than 01 and 02 11 Paper misfeed occurred when paper is being transported 91 Paper remains when power is turned on 99 Others Paper stopped due to external cause such as opening of a cover during printing 00 MP tray 04 Cassette 4 09 Duplexer 01 Cassette 1 in the printer 05 Reserved 99 Envelope feeder 02 Cassette 2 06 Reserved 03 Cassette 3 08 Bulk paper feeder Identification code Error type hex...

Page 44: ... paper feeder 3 feed sensor 51 Paper does not pass the paper feeder 3 feed sensor 52 Paper remains at the paper feeder 3 feed sensor when power is turned on 60 Reserved 61 Reserved 62 Reserved A1 Paper does not arrive at the vertical path sensor duplexer A2 Paper does not arrive at the switchback sensor duplexer A3 Paper does not pass the duplex refeed sensor duplexer A4 Paper does not arrive at t...

Page 45: ... 1 Remove the developer unit and drum unit See page 1 6 2 and 1 6 10 2 Replace the paper transfer unit See page 1 6 4 3 Replace the fuser unit See page 1 6 27 4 Replace the ozone filter B and ozone filter See page 1 6 36 5 Replace the MP tray feed roller and retard holder roller See page 1 6 14 Method 1 Enter the service mode Maintenance 2 Press the Enter key will be displayed 3 Press the ENTER ke...

Page 46: ...he developer unit has been replaced Method 1 Enter the service mode Developer 2 Press the Enter key will be displayed 3 Press the Enter key 4 Turn off and on the printer Self test Please wait Adding toner will displayed The printer continually engages in this mode for a period of approximately 8 minute after which the printer reverts to the Ready state Ready will displayed Developer initialization...

Page 47: ...e mode from 00 to 02 00 Mode turned OFF default setting 01 Refreshing operation time short 02 Refreshing operation time long 5 Press the Enter key The new value is set Drum surface refreshing drum cleaning mode Description This mode forces the printer to rotate the drum against the cleaning roller inside the drum unit for a predetermined period of time The printer automatically activates the drum ...

Page 48: ... and the paper ramp using the wiper cloth included in the toner kit CAUTIONS Do not touch the transfer roller black sponge roller when wiping the paper ramp Area A below is factory applied with lubricating oil When cleaning the paper transfer unit do not use alcohol to clean this area If the oil is completely removed an incorrect action of the MP tray paper sensor actuator will result Upper regist...

Page 49: ...ialized See page 1 4 10 Shipping the developer The printer is supplied with a plastic bag that should be retained for future shipment of the developer 1 To pack the developer in the packing carton first flap down the magnet roller protective cover 2 Put the developer into the supplied plastic bag 3 Put the developer on the developer install position of packing carton Magnet roller protective cover...

Page 50: ...2FP 2FY 2FR 1 4 14 This page is intentionally left blank ...

Page 51: ...printing and displays the paper misfeed message on the operator panel To remove paper misfeed in the printer pull out the paper cassette or rear cover paper transfer unit Figure 1 5 1 2 Paper misfeed detection Figure 1 5 2 Paper jam MP tray Paper misfeed location Paper misfeed message Paper full sensor Exit sensor Registration sensor ...

Page 52: ...ne board KP 1081 Improper installa tion between printer and op tional duplexer DU 61 Defective optional duplexer DU 61 Defective engine board KP 1081 Check EEPROM installation Remedy Replace engine board KP 1081 See page 1 6 20 Replace engine board KP 1081 See page 1 6 20 Follow installation instruction carefully again Replace optional paper feeder PF 60 Replace engine board KP 1081 See page 1 6 2...

Page 53: ...ersion is used on the main board in paper feeder PF 60 Wrong firmware version is used on the main board in paper feeder PF 60 or bulk paper feeder PF 8E Wrong firmware version is used on the main board in paper feeder PF 60 Defective gate array U7 on the engine board KP 1081 Improper installa tion between printer and op tional duplexer or each optional unit Defective har ness S03022 between engine...

Page 54: ...o Replace harness S03012 between engine board KP 1081 and engine relay board KP 1071 Replace engine relay board KP 1071 See page 1 6 13 OK START Remove and check harness S03012 between engine board KP 1081 and engine relay board KP 1071 or harness S02401 1 3 S03026 2 between engine relay board KP 1071 and main motor 24 V DC at 1 pin of YC802 on engine board KP 1081 Does pin 16 MMOTON of YC7 on eng...

Page 55: ...ctive harness S03022 between engine board and optional unit inter face connector Defective paper feeder PF 60 Defective gate array U7 on the engine board KP 1081 Defective harness S03022 between engine board and optional unit inter face connector Defective optional paper feeder PF 60 Defective gate array U7 on the engine board KP 1081 Defective harness S03022 between engine board and optional unit...

Page 56: ... 1 2 7165 KHz Print status page Print status page Print status page Remove and check harness between engine board KP 1081 and laser scanner unit Turn power switch off Turn power switch on 24 V DC at 33 pin of YC7 on engine board KP 1081 Yes Yes No Replace harness between engine board KP 1081 and laser scanner unit OK START Replace engine board KP 1081 See page 1 6 20 Replace engine board KP 1081 S...

Page 57: ...Remove and check harness between engine board KP 1081 and laser scanner unit 24 V DC at 1 pin of YC601 on APC board KP 1062 Yes Yes No Replace harness between engine board KP 1081 and laser scanner unit OK START Replace engine board KP 1081 See page 1 6 20 Replace engine board KP 1081 See page 1 6 20 Replace laser scanner unit See page 1 6 35 Does pin 4 LASER of YC601 on APC board KP 1062 goes hig...

Page 58: ...ly 14 to 15 5 V DC Approximately 24 V DC Remove and check harness S02412 between drum board KP 1064 and eraser lamp board KP 1067 Check deformation pins of connector YC702 on sensor board Yes Yes No No Replace harness S02412 between drum board KP 1064 and eraser lamp board KP 1067 OK OK START Turn power switch on and print status page Turn power switch off Measure voltage 1 pin ERASEDR pins of con...

Page 59: ...KP 1069 0 V DC at pin 6 THERM of YC831 on fuser board KP 1069 Yes Yes No Replace harness S02678 between fuser board KP 1069 and power supply unit OK 6000 shown End Turn power switch on Turn power switch off and remove power cable Turn power switch off Turn power switch on Detach connector CN2 A on power supply board Measure resistance between pins 1 and 3 of the detached connector Replace power su...

Page 60: ...elow 6020 No Remove and check harness S02678 between fuser board KP 1069 and power supply unit Yes Yes No Replace harness S02678 between fuser board KP 1069 and power supply unit OK STRAT Replace engine board KP 1081 See page 1 6 20 Replace fuser unit See page 1 6 27 CAUTION Fuser unit is fed directly by AC power from primary circuit on power supply board Be careful with electric shock Measure vol...

Page 61: ...030 disappeared End Turn power switch on Turn power switch on Replace the thermistor See page 1 6 33 Replace the power supply unit See page 1 6 20 Detach the thermistor connector YC834 of the fuser board KP 1069 connect the circuit tester and measure resistance between pins of the connector Replace the engine board KP 1081 See page 1 6 20 Open infinite Remove the fuser unit See page 1 6 27 START C...

Page 62: ...otor cir cuitry due to an excessive torque caused by hard ened toner Defective gate array U7 on the engine board Improper connec tor insertion Defective harness between devel oper and high voltage unit Defective harness between high volt age unit and en gine board Replace power supply unit See page 1 6 20 Replace engine board See page 1 6 20 Follow the flow chart below 6400 7001 Replace with a new...

Page 63: ... inserted in the printer Defective drum unit Defective engine board KP 1081 A non supported bulk paper stacker HS 8E is in stalled Defective system DIMM board KP 1059 1 893 2 3 Defective main board KP 1053 1 1033 2 3 LCD controller board KP 1079 Defective system DIMM board KP 1059 1 893 2 3 Improper system DIMM board KP 1059 1 893 2 3 insertion to sys tem DIMM slot on the main board KP 1053 1 1033...

Page 64: ...main board KP 1053 1 1033 2 3 Defective expand ing memory DIMM on the main board KP 1053 1 1033 2 3 Defective main board KP 1053 1 1033 2 3 Defective gate array U02 on the main board Connector failure between the en gine board KP 1081 and main board KP 1053 1 1033 2 3 Overrun in the engine system deactivating the program flash ROM U2 on the engine board KP 1081 Defective CPU U1 or gate array U7 or...

Page 65: ...BC 123 See page 1 1 6 17 5 Black horizontal streaks ABC 123 See page 1 1 6 18 6 Black vertical streaks ABC 123 See page 1 5 18 7 Unsharpness See page 1 5 19 8 Gray background ABC 123 See page 1 5 19 9 Dirt on the top edge or back of the paper ABC 123 See page 1 5 20 10 Undulated printing at the left edge scan ning start position This vertical line should be straight See page 1 5 20 ...

Page 66: ...n board KP 1053 1 1033 2 3 See page 1 6 22 Defective laser scanner unit control circuit in the main board KP 1053 1 1033 2 3 See page 1 6 22 2 No image appears entirely black Causes 1 Defective main charger unit 2 Defective drum bias 3 Defective high voltage unit 4 Defective main board Causes Check procedures corrective measures 1 Defective main charger unit 2 Defective drum bias 3 Defective high ...

Page 67: ...es the paper specifications The transfer roller must be supported by the bushes at the both ends Clean the bush to remove oil and debris Replace the transfer roller if necessary See page 1 6 15 Check the transfer bias output on the high voltage unit This requires removal of the left cover and the test equipment Replace the high voltage unit if high voltage potential is not available on the board S...

Page 68: ...e page 1 6 10 Replace the developer See page 1 6 2 6 Black vertical streaks Causes 1 Contaminated main charger wire 2 Defective drum surface 3 Defective magnet roller in the developer Causes Check procedures corrective measures 1 Defective drum unit s ground 2 Defective drum unit The drum axle in the drum unit and its counter part the grounding tab in the printer must be in a good contact If neces...

Page 69: ...ness Causes 1 Defective paper specifications 2 Defective transfer roller installation 3 Defective transfer bias potential 4 EcoPrint setting Causes Check procedures corrective measures 1 Print density setting 2 Defective drum surface potential 3 Grid 4 Developing roller in the developer The print density may be set too high Try adjusting the print density using the Remote operation panel utility F...

Page 70: ...procedures corrective measures 1 Toner contamination in various parts 2 Defective transfer roller Dirty edges and back of the paper can be caused by toner accumulated on such parts as the paper chute paper transportation paths the bottom of the drum and developer and the fuser unit inlet Clean these areas and parts to remove toner If the transfer roller is contaminated with toner clean the transfe...

Page 71: ...istration sensor or exit sensor Surface of the paper gauge sensor 1 PH702 and 2 PH703 on the sen sor board KP 754 are dirty with paper particles A piece of paper torn from a sheet is caught around paper gauge sensor 1 PH702 and 2 PH703 on the paper sensor board KP 754 Reflecting mirror has come off the actuator of paper gauge sensor 1 PH702 and 2 PH703 Defective paper gauge sensor 1 PH702 and 2 PH...

Page 72: ...nnection of harness S03012 between engine board KP 1081 and engine relay board KP 1071 Defective main board sys tem DIMM board KP 1059 1 893 2 3 Defective LCD controller board KP 1079 Defective engine board KP 1081 Improper connection of harness S02402 between LCD controller board KP 1079 and engine relay board KP 1071 Improper connection of harness S03012 between engine board KP 1081 and engine r...

Page 73: ...f connector YC832 and pin 2 of connector YC831 If none replace the face up down solenoid and fuser board KP 1069 at the same time Or replace fuser unit See page 1 6 27 Replace engine board KP 1081 or power supply unit See page 1 6 20 Measure voltage 12 pin of YC701 on sensor board KP 1077 Connect circuit tester to pin 20 of YC4 on engine board KP 1081 Yes Yes No No Replace engine board KP 1081 See...

Page 74: ...Check if the pulleys rollers and gears oper ate smoothly Check if the following electromagnetic clutches solenoid are installed correctly feed clutch registration clutch middle clutch and MP feed solenoid Problem Causes check procedures Corrective measures 1 5 5 Mechanical problems 1 No primary paper feed 2 No secondary paper feed 3 Skewed paper feed 4 Multiple sheets of paper are fed at one time ...

Page 75: ...atic charge Do not touch any PWB containing ICs with bare hands or any object prone to static charge Use only the specified parts to replace the fixing unit thermal cutout Never substitute electric wires as the printer may be seriously damaged Use the following circuit testers when measuring voltages Hioki 3200 Sanwa MD 180C Sanwa YX 360TR Beckman TECH300 Beckman DM45 Beckman 330 Beckman 3030 Beck...

Page 76: ...er do not let the magnet roller touch any part in the printer 1 Open the top cover 2 Remove the toner container 3 Disconnect the developer connector 4 Remove the developer from the printer while sliding the developer lock lever frontwards Figure 1 6 1 Removing the developer Developer connector Developer Developer Lock lever ...

Page 77: ...rotective cover NOTE After removing the developer seal it in the protective bag and place it on a flat surface Do not place the developer in a dusty area If you ship the developer pack it in the shipping container specifically supplied with the printer See page 1 4 13 Magnet roller protective cover Magnet roller ...

Page 78: ...2FY 2FR 1 6 4 1 6 3 Removing the paper transfer unit 1 Draw the paper transfer unit while pressing the buttons in the direction of arrow A Figure 1 6 3 Removing the paper transfer unit Paper transfer unit A ...

Page 79: ...g the main charger unit 1 Pull the main charger unit upwards while pushing main charger release lever Then pull the main charger unit frontwards Figure 1 6 4 Removing the main charger unit Main charger release lever Main charger unit ...

Page 80: ...operator panel and outer covers 1 Removing the operator panel 1 Open the top cover and MP tray 2 Unlatch two hooks 3 Pull the operator panel towards the front Figure 1 6 5 Removing the operator panel Operator panel MP tray Top cover Hooks ...

Page 81: ...t tray 1 Open the top cover 2 Remove two screws 3 Remove the top cover face down output tray while pressing it the direction arrows A backwards Figure 1 6 6 Removing the top cover face down output tray Screw Screw Top cover Top cover face down output tray A A ...

Page 82: ...8 3 Removing the right cover 1 Remove the operator panel See page 1 6 6 2 Unlatch the four snaps A and three hooks B on the chassis Remove the right cover Figure 1 6 7 Removing the right cover A A A B B B A Right cover ...

Page 83: ...2FP 2FY 2FR 1 6 9 4 Removing the left cover 1 Unlatch the four snaps A and three hooks B on the chassis Remove the left cover Figure 1 6 8 Removing the left cover A B B A A B Left cover A ...

Page 84: ...Remove the paper cassette and the paper transfer unit See page 1 6 4 2 Remove the developer unit See page 1 6 2 3 Remove the waste toner bottle 4 Remove the drum unit while pressing the drum lock Figure 1 6 9 Removing the drum unit Drum unit Drum lock ...

Page 85: ... 2 Turn the paper transfer unit over 3 Detach the release holder by sliding it while pressing the projections 4 Remove the feed roller assembly while pressing it in the direction of arrow A Figure 1 6 10 Removing the feed roller assembly Projection Projection Feed roller assembly Release holder A Paper transfer unit ...

Page 86: ...feed roller Figure 1 6 11 Remove the pickup roller and feed roller CAUTIONS Pickup gear Z32S is installed of the inside the one way clutch When refitting pickup gear Z32S face the one way clutch face to the feed bracket cover Feed bracket cover Snap Snap Snap Pickup gear Z32S One way clutch Pickup roller Feed roller ...

Page 87: ...2 Remove the developer See page 1 6 2 3 Remove the three connectors 4 Remove the engine relay board while 5 Pull the MP tray paper feed unit out while unlatching two latches off of points A unlatching the latches Figure 1 6 12 Removing the engine relay board Figure 1 6 13 Removing the MP tray paper feed unit Connectors Connector Latches Engine relay board MP tray paper feed unit Latch A A Latch ...

Page 88: ...3 Removing the retard holder roller 1 Remove the cassette from the printer 2 Unlatch the two latches and then remove the retard guide 3 Remove the retard holder roller Figure 1 6 13 a Removing the MP tray feed roller Figure 1 6 13 b Removing the retard holder roller Lever MP tray feed roller Retard guide Cassette Latch Latch Retard roller Retard holder MP feed roller holder MP feed roller holder ...

Page 89: ... surface Oil and dust particles of paper etc on the transfer roller can significantly deteriorate the print quality white spots etc 1 Draw the paper transfer unit from the printer 2 Remove the paper chute 3 Remove the transfer roller Figure 1 6 14 Removing the transfer roller Paper chute Transfer roller ...

Page 90: ...emove the right and left covers See page 1 6 8 and 1 6 9 3 Remove the four connectors and one tab from the controller unit left side Figure 1 6 15 Removing the connectors and tab from controller unit left side CAUTIONS Draw the connector straight to remove If you draw the connector while it is slanted the receptacle may be damaged Connector Receptacle Controller unit Connectors Tab Connectors ...

Page 91: ...2FP 2FY 2FR 1 6 17 4 Remove the two connectors from the controller unit right side Figure 1 6 16 Removing the connectors from controller unit right side Connector Receptacle Connectors Controller unit ...

Page 92: ...FR 1 6 18 5 Remove three screws 6 Remove frame unit while releasing the projections from the catches on the frame unit Figure 1 6 17 Removing the controller unit form the frame unit Frame unit Screw Screw Screw ...

Page 93: ...in board 9 Remove four screws 10 Remove the grounding terminal and controller unit lid from the controller unit Figure 1 6 18 Opening the controller unit Main board Screw Screw Controller unit Controller unit lid Screw Screw Grounding terminal Screw Screw ...

Page 94: ...e pages 1 6 19 2 Remove the connectors YC3 and YC6 from the engine board 3 Remove the connector YC10 from the engine board For FS 3820N 3830N models only 4 Remove five screws 5 Remove the engine board Figure 1 6 19 Removing the engine board Screws Screws Engine board Connector YC3 Connector YC6 Connector YC10 ...

Page 95: ...nding wire terminal and lock washer 8 Remove three screws 9 Remove the power supply unit from the power supply unit cover Screw Screws Lock washer Grounding wire terminal Power supply unit Power switch rod Power supply unit cover Figure 5 2 20 Removing the power supply unit ...

Page 96: ...ed or inserted while the printer is on damage could result in the printer s electronics as well as the memory card 1 Turn the power switch off 2 Remove the memory card that may be inserted in the memory card slot at the left side of the printer 3 Remove two screws 4 Pull the main board all the way out of the printer Main board Screw Screw Memory card slot Memory card Figure 1 6 21 Removing the mai...

Page 97: ... the top cover and left covers See pages 1 6 7 and 1 6 9 2 Remove the high voltage unit while unlatching two latches 3 Remove two connectors from the high voltage unit Figure 1 6 22 Removing the high voltage unit Connector Connector Latch Latch High voltage unit ...

Page 98: ...e damaged 1 Remove the drum unit See page 1 6 10 2 Remove the high voltage unit See previous page 3 Remove two connectors 4 Remove the high voltage unit cover 5 Remove the sensor board while unlatching two latches Figure 1 6 23 Removing the sensor board High voltage unit cover Sensor board Latch Latch Connector Connector Connector Connector Receptacle Receptacle ...

Page 99: ...nit See page 1 6 4 2 Remove the top cover face down output tray See page 1 6 7 3 Remove the left and right covers See pages 1 6 8 and 1 6 9 4 Remove two connectors 5 Remove three connectors of the drive unit 6 Remove five screws and the ground wire terminal 7 Remove the drive unit from the frame unit Figure 1 6 24 Removing drive unit Connector Connectors Connector Receptacle Receptacle Screw Groun...

Page 100: ...2FP 2FY 2FR 1 6 26 8 Remove four screws 9 Remove the main motor from the drive unit Figure 1 6 25 Removing the main motor Screws Screws Main motor Drive unit ...

Page 101: ...NING The fuser unit is hot after the printer was running Wait until it cools down 1 Remove three connectors and one tab 2 Remove two screws 3 Remove the fuser unit from the frame unit Figure 1 6 26 Removing the fuser unit Screw Screw Connector Connectors Tab Fuser unit ...

Page 102: ...ve the rear cover and the spring 5 Remove the solenoid actuator 6 Remove the change guide 7 Remove one connector Figure 1 6 27 Removing the rear cover and change guide Connector Solenoid actuator Rear cover Spring Change guide ...

Page 103: ...2FP 2FY 2FR 1 6 29 8 Remove two screws 9 Split the fuser unit Figure 1 6 28 Splitting the fuser unit Screw Screw Fuser unit ...

Page 104: ...l it cools down 1 Remove and split the fuser unit See page 1 6 27 2 Remove the upper exit guide while unlatching three latches 3 Remove the exit pulley 4 Hold the separator upright and remove the separator and the separator spring Figure 1 6 29 Removing the separators Step 1 Step 2 Separator Separator spring Separator Latch Latch Latch Upper exit guide Exit pulley ...

Page 105: ...heater lamp s outer surface can prevent proper fusing of toner on paper When holding the heater lamp hold the ceramic parts of heater lamp at both ends When refitting the heater lamp direct the wattage making side facing the heat gear Z36 side 1 Remove and split the fuser unit See page 1 6 27 2 Remove the lamp support 3 Remove two screws and heater wire terminal 4 Remove the heater lamp from the h...

Page 106: ... and split the fuser unit See page 1 6 27 2 Remove the heater lamp See the previous page 3 Remove the separators See page 1 6 30 4 Remove the two C rings 5 Pull up both bearings at the same time 6 Remove heat gear Z36 bearings heat R bush and heat L bush from the heat roller Figure 1 6 31 Removing the heat roller Heat gear Z36 Bearing Heat R bush Bearing Heat roller Heat L bush C ring C ring ...

Page 107: ...page 1 6 31 3 Remove the heat roller See previous page 4 Remove one screw 5 Remove the thermistor 6 Remove two screws and then remove cord plate 7 Remove one screw and the heater wire terminal 8 Remove the thermal cutout Figure 1 6 32 Removing the thermistor and thermal cutout Screws Screw Heater wire terminal Thermal cutout Thermistor Cord plate ...

Page 108: ... is extremely hot immediately after the printer was running Allow substantial period of time until it cools down 1 Remove and split the fuser unit See page 1 6 27 2 Remove the press roller from the fuser unit Figure 1 6 33 Removing the press roller Press roller Fuser unit ...

Page 109: ...move two connectors 3 Remove four screws 4 Remove the laser scanner unit from the frame unit CAUTIONS When refitting the laser scanner unit fix the four screws in the order indicated above Figure 1 6 34 Removing the laser scanner unit 2 3 4 Order of fixing the laser scanner unit 1 Screws Screws Laser scanner unit Connectors ...

Page 110: ...ce down output tray See page 1 6 7 2 Remove the right cover See page 1 6 8 3 Replace the ozone filter B 4 Remove the two screws and then remove the cooling fan motor 5 Replace the ozone filter Figure 1 6 35 Replacing the ozone filter B Figure 1 6 36 Figure 1 6 37 Replacing the ozone filter Ozone filter B Ozone filter Cooling fan motor Screw Screw ...

Page 111: ...operator panel message in different languages can also be downloaded through the parallel interface or through the memory card CompactFlash NOTE System DIMM Firmware update is possible only with a flash ROM type system DIMM board Masked type system DIMM board can not be overwritten Check the type of the system DIMM board currently used on the main board by service status page See page1 4 2 Figure ...

Page 112: ... spa jpn dan swe ita spa por rus pol cze Japanese Dutch Swedish Italian Spanish Portuguese Russian Polish Czech Compression Void Version code Version 84 00 Version code Version A002 Version code Version 01 ID code for engine firmware ID code for system firmware System firmware file name example Engine firmware file name example ID code for operator panel massage data Operator panel message data fi...

Page 113: ... parallel interface The computer must be connected to the printer with a parallel cable 1 Turn power switch on 2 At the DOS prompt send the command to the printer that engages the printer in the supervisor mode 3 Copy the firmware data to the printer See the flow chart below System firmware ex SB20KA8400 bcmp Engine firmware ex EB20KA002 x01 Operator panel message data ex dm2001 spa Message displa...

Page 114: ...on See page 1 4 2 If the message display indicates download error refer to section Downloading errors on page 1 7 7 data receiving BootROM erase write engine download message download DIMM erasing Ready Power switch Off On System firmware Engine firmware Operator panel message data Spanish 04 04 01 18 1234 2 B A B B G C E F E F E F D G G 20 A002 04 01 18 1234 2 84 00S 04 01 18 1234 2 A u Extractin...

Page 115: ...by an accidental power failure etc the system DIMM may have to be replaced NOTE The firmware program data must be stored to the root directory of the memory card CompactFlash 1 Turn power switch off 2 Insert the memory card in the printer s memory card slot 3 Turn power switch on 4 The printer is automatically engaged in the supervisor mode The parallel interface receives for the firmware data Mes...

Page 116: ... message display indicates download error refer to section Downloading errors on page 1 7 7 Supervisor mode CF CARD Reading BootROM erase write engine download message download DIMM erasing Ready Power switch Off Power switch On Spanish 04 04 01 18 1234 2 B A B B G C E F E F E F D G G 20 A002 04 01 18 1234 2 84 00S 04 01 18 1234 2 A u Extracting W Writing V Verifying B Version C Machine code D Lan...

Page 117: ...between PC and printer Defective parallel cable Improper connection of parallel cable between PC and printer Incompatibility of firmware and en gine board Improper connection of parallel cable between PC and printer Defective LCD controller board Obtain the correct firmware Confirm whether the firmware is applicable to this printer Replace the system DIMM board Check the contact between PC and the...

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Page 119: ...ws the components in the paper feeding system and the paths through which the paper travels The sensors clutches solenoids motor etc are described in the following pages Figure 2 1 1 Paper feeding components 5 6 8 7 9 10 11 12 13 14 16 17 18 19 20 4 3 2 1 Paper from optional paper feeder PF 60 or duplexer DU 61 15 1 Middle feed roller 2 MP tray feed roller 3 Guide pulley s 4 MP tray 5 Paper casset...

Page 120: ...it Drum unit Laser scanner unit Developer REGDR MIDDR MPFSOL FDDR REGPAP PVOLAN2 PVOLAN1 HANDS FDPFUL EXITPAP Fuser board Power supply unit MMOTON Power train FUDR FDDR YC2 3 YC2 4 YC2 2 YC2 6 YC4 17 YC4 22 YC4 18 YC7 16 YC7 15 YC5 13 YC7 11 YC7 5 YC7 3 Sensor board Engine relay board High voltage unit 6 11 0 3 9 8 7 2 4 5 Engine board 1 1 Main motor 2 MP tray paper sensor 3 Registration sensor 4 ...

Page 121: ...Figure 2 1 3 Drive and paper transfer unit To fuser unit Drive unit Paper transfer unit Power train 8 1 2 3 4 5 A B A B 6 7 1 Main motor 2 Registration clutch 3 Feed clutch 4 Pickup roller 5 Feed roller 6 Lower registration roller 7 Upper registration roller 8 Transfer roller ...

Page 122: ...feed unit Figure 2 1 4 MP tray paper feed unit Drive unit MP tray paper feed unit MP tray To paper transfer unit D Power train 9 11 C 12 10 C D 9 Middle feed clutch 10 MP tray feed solenoid 11 MP tray feed roller 12 Middle feed roller ...

Page 123: ... face up down output To face down output tray To face up output tray or option device 14 15 16 19 18 13 F Drive unit Power train Paper from paper transfer unit FD gear bracket Fuser unit F 13 Heat roller 14 Press roller 15 Exit roller 16 Exit pulley s 17 FD roller 18 Pinch roller s ...

Page 124: ...erforms a cyclic action made of six steps as follows Each step is technically explained in the following sections Figure 2 1 6 Electrophotographic cycle 2 Exposure 3 Developing 6 Cleaning 1 Main charging 4 Transfer 5 Fusing Drum unit Laser scanner unit Developer Paper transfer unit Fuser unit Drum ...

Page 125: ... 13 14 1 6 8 7 2 9 Drum unit Main charger unit 1 Eraser lamp board KP 1067 2 Zener board KP 1073 3 Drum board KP 1064 4 Waste toner full sensor board KP 1065 5 Waste toner full sensor receiver 6 Cleaning blade 7 Cleaning roller 8 Cleaner screw 9 Drum gear Z36H 10 Drum 11 Main charger shield 12 Grid 13 Main charger wire 14 Charger wire cleaner ...

Page 126: ...ectronically conductive when exposed to a laser light source to effectively ground electrons charged on its outer surface to the ground This layer is approximately 9 mm thick The carrier block layer lies between the amorphous silicon layer and the aluminum base cylinder and prevents the backward electron flow from the base cylinder to the drum s outer surface which might give adverse effect possib...

Page 127: ...wire The grid regulates the main charging potential so that it is evenly and stably dispersed over the drum at a constant voltage level Due to being high voltage scorotron charging the main charger wire can get contaminated by oxidization after a long run Therefore it must be cleaned periodically from time to time using the charger wire cleaner charger cleaning knob Cleaning the main charger wire ...

Page 128: ...tor with polygon mirrors revolves 27 165 rpm to reflect the laser beam over the drum Lenses and diversion mirror are housed in the laser scanner unit These lenses adjust the diameter of the laser beam 670 nm wavelength so that the laser beam effectively focalizes on the drum surface Drum Laser scanner unit Laser beam output Polygon motor Lens Lens Diversion mirror ...

Page 129: ...gth of line A B in the figure below the laser beam draws on the drum becomes longer as the laser beam hits closer to the drum edge In the figure 2 1 11 above distances represented by A and B are not the same A B until the f theta lenses are provided between the polygon mirror and the drum A B 7 Diversion mirror Diverts the laser beam vertically onto the drum Note the diffused laser beam finally pi...

Page 130: ...am the electrical resistance of the photoconductor is reduced and the potential on the photoconductor is also lowered Resulted on the drum surface is an electrostatic image which represents the data to print Note that the area to be printed black has the low potential constituting a positively exposed image Figure 2 1 12 Drum surface potential Aluminum base a Si layer Laser beam Charged surface po...

Page 131: ...FR 2 1 13 3 Development Figure 2 1 13 Developer mechanism 6 7 1 B A 5 3 2 4 Toner container Developer B A Power train 1 Toner motor 2 Toner sensor 3 Developing roller 4 DLP A screw 5 DLP B screw 6 Blade 7 Magnet ...

Page 132: ...veloping roller is applied with the AC weighted positive DC power source Toner on the developing roller is given a positive charge The positively charged toner is then attracted to the areas of the drum which was exposed to the laser light The gap between the drum and the developing roller is approximately 0 3 mm The non exposed areas of the drum repel the positively charged toner as these areas m...

Page 133: ...r container dwindles and the toner level lowers in the reservoir the sensor translates it into an electrical signal through its diaphragm urging the toner motor to feed more toner Figure 2 1 15 Toner sensor Toner Toner hopper Toner sensor Developer Diaphragm Sensible level Toner container Toner motor ...

Page 134: ...by the drum and the transfer roller Figure 2 1 16 Transfer The nominal transfer bias is set to approximately 2 3 kV limit Since the ideal potential of the transfer bias depends on the thickness of paper the bias is raised to approximately 2 6 kV for thicker paper On the other hand the bias current is reduced to 2 1 kV for thin paper S S N Transfer roller Drum Voltage Paper type Transfer bias outpu...

Page 135: ... Separators which are continuously in contact with its surface These claws 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 b...

Page 136: ...rom paper transfer unit transfer section 10 16 7 1 Face up down solenoid 2 Thermistor 3 Thermal cutout 4 Exit sensor 5 Fuser board KP 1069 6 Press roller 7 Heat roller 8 Exit roller 9 Exit pulley s 10 Heat gear Z36 11 Exit gear Z21 12 Idle gear Z18 13 Idle gear Z28 14 Separator s 15 Change guide 16 Heater lamp Figure 2 1 18 Fuser unit mechanism ...

Page 137: ... accept the next uniform charge The residual charge is canceled by exposing the drum to the light emitted from the eraser lamp board See figure 2 1 19 above in the similar manner as described on page 2 1 9 This lowers the electrical conductivity of the drum surface making the residual charge on the drum surface escape to the ground After the drum is physically cleaned it then must be cleaned to th...

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Page 139: ...supply unit 12 High voltage unit 13 Registration sensor PH701 14 Paper gauge sensor 1 PH702 15 Paper gauge sensor 2 PH703 16 Top cover paper transfer unit interlock switch SW702 17 Left cover interlock switch SW703 18 Top cover switch SW701 19 MP tray paper sensor PC502 20 Option feeder sensor PC501 21 Paper full sensor 22 Exit sensor 23 Temperature humidity sensors 24 Power switch 25 Paper size s...

Page 140: ...ing fan motor 4 Controller unit fan motor 5 Developer fan motor 6 CPU cooling fan motor 1 7 Face up down solenoid 8 MP feed solenoid 9 Middle feed clutch 10 Feed clutch 11 Registration clutch 12 Heater lamp 13 AC inlet 1 For FS 3820N 3830N models only 6 5 8 9 10 11 2 7 4 12 13 3 1 ...

Page 141: ... developer 1 Drum board KP 1064 2 Waste toner full sensor board KP 1065 3 Waste toner full sensor receiver 4 Eraser lamp board KP 1067 5 Zener board KP 1073 6 Toner sensor 7 Toner motor 7 6 3 4 2 1 Drum unit Developer 5 2 Drum and developer ...

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Page 143: ...PPDATA7 0 YC5 PDATA7 0 NSELIN PDATA7 0 Option serial I F P1284DIR DTR RTS TXD CTS DSR RXD RSSEL YC9 DBTXD DBRXD DBCLK Debugger connector YC10 TDO TDI TCK TMS HALTN RISC watch connector U13 3 3 V Regulator 5 V1 3 3 V1 SDRAM Data bus SDD31 0 SDD15 0 SDD31 16 SDCSN1 2 SDA12 0 SDCLK SDCLK SDD31 0 SDA12 0 SDA12 0 SDRAM Address bus YS02 Option SDRAM DIMM Slot U11 IIC EEPROM IICSCL IICSDA SDA12 0 SDCSN0 ...

Page 144: ...er I F P1284DIR DTR RTS TXD CTS DSR RXD RSSEL RISC watch connector U27 3 3 V Regulator 5 V 3 3 V U28 U03 2 5 V Regulator 5 V 2 5 V U29 1 8 V Regulator R128 R129 R130 R131 5VAR 1 8 V Resistor 5 V 5VAR SDRAM Data bus SDD31 0 SDD31 0 SDD31 0 SDD15 0 SDD31 16 SDA12 0 SDCLK3 4 SDCSN4 5 SDA12 0 SDA12 0 SDRAM Address bus YS2 YS3 Option SDRAM DIMM Slot 2 For FS 3830N model only SDD31 0 Option SDRAM DIMM S...

Page 145: ...S FPCLK FPDIR FPDATA 3 3V1 SIOUT VSEREQ SOOUT SCLKOUT RD WR ALE OPSCLK OPSDO BFANON OPTSDI OPSEL3 5 OPSDI OPRDY SYSRES SDIR VDFON1 PDOUT 20PTRIG SBSY EGIR VDFON1 SCLKIN SOIN OPSEL0 2 FRCS GAINT SYSCLK RESET RESET RESET HEATON AIRTEMP AIRWET WETCK1 WETCK2 FDPFUL EXITPAP FDON FUON FDDR FUDR FANDR DVFANDR FPRST DVFAN FANON DVFANSPD FANSPD Driver Driver Engine board ERASE ERDEAD POLCLK POLON POLRDY SA...

Page 146: ... supply 2 24V1 O 24 V DC 24 V DC power supply 3 24V1 O 24 V DC 24 V DC power supply 4 GND Ground Ground 5 GND Ground Ground 6 24V2 I 24 V DC 24 V DC power supply via interlock switches 7 24V2 I 24 V DC 24 V DC power supply via interlock switches 8 24V2 I 24 V DC 24 V DC power supply via interlock switches 9 ERASEDR O 0 24 V DC Eraser lamp On Off 10 WTNLED O 0 5 V DC pulse Waste toner full sensor L...

Page 147: ... DC Transfer charger output reverse voltage On Off 13 HANDS I 0 5 V DC MP tray paper sensor On Off 14 DLPTYPE I 0 5 V DC Developer identification signal Not installed Developer DV 63 15 5V2 O 5 V DC 5 V DC power supply 16 TMOTDR O 0 24 V DC Toner motor On Off 17 CONTYPE I 0 5 V DC Toner container identification signal for MICR Normal Not installed abnormal 18 24V3 O 24 V DC 24 V DC power supply 1 ...

Page 148: ... DC Registration clutch On Off 16 MMOTON O 0 5 V DC Main motor On Off 17 GND Ground Ground 18 MMOTRDY I 0 5 V DC Main motor READY signal Ready Not ready 19 5V3 O 5 V DC 5 V DC power supply 20 SAMPLE O 0 5 V DC Sample Hold signal laser power output 21 DVFANDR O 12 24 V DC Developer fan motor Low High speed 22 LASER O 0 5 V DC Laser output On Off 23 VD0 O 0 3 3V DC pulse Laser output data signal 24 ...

Page 149: ... B13 FPCLK O 0 3 3 V DC pulse Clock signal LCD control board A14 GND Ground Ground B14 FPDATA I O 0 3 3 V DC pulse Data signal LCD control board A15 20PSEL5 O 0 5 V DC Optional unit identification code 5 B15 GND Ground Ground A16 20PSEL3 O 0 5 V DC Optional unit identification code 3 B16 20PSEL4 O 0 5 V DC Optional unit identification code 4 A17 GND Ground Ground B17 20PTRIG O 0 5 V DC Optional so...

Page 150: ...l generation circuit Power switch Current fuse Noise filter circuit Transformer 24 V DC rectifier smoothing circuit Photo coupler Photo coupler Photo Triac Triac ZCROSS FDDR EXITPAP FDFUL THERM HEATON FUDR 24V1 24V3 5V1 GND GND Heater lamp AC input Rectifier circuit 5 V DC rectifier smoothing circuit Power supply unit Fuser board Interlock switches Thermal cutout Thermistor Paper full sensor Exit ...

Page 151: ...7 5V1 O 5 V DC 5 V DC power supply 8 GND Ground Ground 9 24V3 I 24 V DC 24 V DC power supply 10 SLEEP Not used 11 ZCROSS O 0 5 V DC pulse Zero cross signal 12 HEATON I 0 24 V DC Heater lamp On Off 13 5V1 O 5 V DC 5 V DC power supply 14 5V1 O 5 V DC 5 V DC power supply 15 5V1 O 5 V DC 5 V DC power supply 16 5V1 O 5 V DC 5 V DC power supply 17 GND Ground Ground 18 GND Ground Ground 19 GND Ground Gro...

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Page 153: ...7 7876 9602 Exit sensor EXITPAP 6029 8139 612 Middle feed clutch MIDDR 1542 4596 8487 5547 7657 Face up down solenoid FDON FUON 5715 7825 522 Main charger MCHON 8642 437 Eraser lamp ERASE 10680 4706 6819 Developing bias BIAS 6492 86002 4877 6991 Transfer bias TRCHON 6544 8658 0 Transfer bias reverse RTRCHON 10680 527 4598 5692 Feed clutch FEDDR 1542 5243 7356 1 2 3 4 0 6 7 8 9 5 11 12 10 1 2 3 4 0...

Page 154: ...9 10 11 12 0 Drum speed 176 mm s Paper feeding speed 176 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 YC7 11 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP...

Page 155: ... 9 5 11 12 10 Drum speed 176 mm s Paper feeding speed 176 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 YC7 11 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPA...

Page 156: ...Drum speed 176 mm s Paper feeding speed 176 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP Exit sensor EXITPAP...

Page 157: ...0 Drum speed 176 mm s Paper feeding speed 176 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP Exit sensor EXITP...

Page 158: ... Drum speed 176 mm s Paper feeding speed 176 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP Exit sensor EXITPA...

Page 159: ...8 9 5 11 12 10 Feed clutch Feed motor Drum speed 176 mm s Paper feeding speed 176 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registra...

Page 160: ...369 9740 11186 Exit sensor EXITPAP 8153 9972 930 Middle feed clutch MIDDR 1734 6955 10269 7749 9567 Face up down solenoid FDON FUON 7890 9708 494 Main charger MCHON 10400 424 Eraser lamp ERASE 12109 12109 7045 8866 Developing bias BIAS 8544 10365 7190 9009 Transfer bias TRCHON 8573 10392 0 Transfer bias reverse RTRCHON 859 Feed clutch FEDDR 1734 7908 8776 1 2 3 4 0 6 7 8 9 5 11 12 10 1 2 3 4 0 6 7...

Page 161: ...10 11 12 0 Drum speed 210 mm s Paper feeding speed 210 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 YC7 11 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP E...

Page 162: ... 5 11 12 10 Drum speed 210 mm s Paper feeding speed 210 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 YC7 11 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP ...

Page 163: ...10 Drum speed 210 mm s Paper feeding speed 210 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP Exit sensor EXIT...

Page 164: ... 12 10 Drum speed 210 mm s Paper feeding speed 210 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP Exit sensor ...

Page 165: ...2 10 Drum speed 210 mm s Paper feeding speed 210 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Registration sensor REGPAP Exit sensor EX...

Page 166: ...0 6 7 8 9 5 11 12 10 Feed clutch Feed motor Drum speed 210 mm s Paper feeding speed 210 mm s Detecting no presence of paper at this time indicates paper jam Detecting presence of paper in this period of time indicates paper jam Main motor MMOTON YC7 16 YC7 31 YC7 22 YC7 15 YC4 17 YC2 5 YC7 5 YC2 3 4 YC5 10 YC4 9 YC7 16 YC5 6 YC5 12 Polygon motor POLON Laser diode LASER Registration clutch REGDR Re...

Page 167: ...C1 24V3 CONTYPE TMOTDR 5V2 DLPTYPE HANDS RTRCHON HUNIT MCHON GND HVCLK TONSCAN TRCHON TNEMP TRVSEL3 5V1 TRVSEL1 TRVSEL2 24V1 24V1 24V1 24V2 24V2 24V2 ERASEDR WTNLED TNRFUL 5V2 GND EEDIO EECLK REGPAP PVOLAN1 TCPVP FCPVP CASIZE PVOLAN2 Sensor board KP 1077 4 3 2 1 N C GND ERASEDR N C GND WTNLED EECLK TNRFUL EEDIO N C 5V2 GND 5V2 Drum board KP 1064 YC741 YC743 YC742 YC771 YC761 1 2 2 1 1 2 2 1 2 1 Wa...

Page 168: ...34 YC833 YC832 24V3 YC1 24V3 CONTYPE TMOTDR 5V2 DLPTYPE HANDS RTRCHON HUNIT MCHON GND HVCLK TONSCAN TRCHON TNEMP TRVSEL3 5V1 TRVSEL1 TRVSEL2 24V1 24V1 24V1 24V2 24V2 24V2 ERASEDR WTNLED TNRFUL 5V2 GND EEDIO EECLK REGPAP PVOLAN1 TCPVP FCPVP CASIZE PVOLAN2 Sensor board KP 1077 4 3 2 1 N C GND ERASEDR N C GND WTNLED EECLK TNRFUL EEDIO N C 5V2 GND 5V2 Drum board KP 1064 YC741 YC743 YC742 YC771 YC761 1...

Page 169: ... 1 2 1 2 YC3 YC10 YC831 YC834 YC833 YC832 24V3 YC1 24V3 CONTYPE TMOTDR 5V2 DLPTYPE HANDS RTRCHON HUNIT MCHON GND HVCLK TONSCAN TRCHON TNEMP TRVSEL3 5V1 TRVSEL1 TRVSEL2 24V1 24V1 24V1 24V2 24V2 24V2 ERASEDR WTNLED TNRFUL 5V2 GND EEDIO EECLK REGPAP PVOLAN1 TCPVP FCPVP CASIZE PVOLAN2 Sensor board KP 1077 4 3 2 1 N C GND ERASEDR N C GND WTNLED EECLK TNRFUL EEDIO N C 5V2 GND 5V2 Drum board KP 1064 YC74...

Page 170: ...rrence of defect 63 mm Developing roller Process unit 25 mm Upper registration roller 38 mm Lower registration roller 61 mm Heat roller Press roller Fuser unit 94 mm Drum Process unit 50 mm Transfer roller Repetitive defects gauge ...

Page 171: ...2FP 2FY 2FR 2 4 19 This page is intentionally left blank ...

Page 172: ...MEMO ...

Page 173: ...MEMO ...

Page 174: ...MEMO ...

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