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MINOLTA-QMS PagePro 4100 Series, Service Manual

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MINOLTA-QMS PagePro 4100 Series Service Manual Download Page 71

56

4

M

A

IN

T

E

NANCE/DIS

A

S

S

EM

BL

Y

4-2. Maintenance Schedule List

The Imaging Cartridge is a user-replaceable item.

4-3. Required Service Tools

Parts (Unit)

Cleaning Cycle

Replacement Cycle

(Continuous Printing)

Replacement Cycle

(Single Printing)

Imaging Cartridge
(separately sold)

none

approximately 9,000 
simplex prints

approximately 7,200 
simplex prints

Imaging Cartridge
(provided with 
printer)

none

approximately 5,000 
simplex prints

approximately 4,000 
simplex prints

Imaging Transfer 
Roller

none

approximately 50,000 simplex prints

Fusing Unit

none

approximately 50,000 simplex prints

Paper Take-up 
Roller

at the time of 
trouble

approximately 150,000 simplex prints

2nd and 3rd Cassette 
Unit Paper Take-up 
Roller

at the time of 
trouble

approximately 150,000 simplex prints

Transfer Roller

at the time of 
trouble

approximately 150,000 simplex prints

Tools

Phillips screwdriver

(No. 1)

tool1

Phillips screwdriver

(No. 2)

tool1

Stubby screwdriver

(Phillips)

tool3

Flat screwdriver

tool9

Summary of Contents for PagePro 4100 Series

Page 1: ...www minolta qms com minolta qms com Service Manual 1750041 001B PagePro 4100 Series The essentials of imaging ...

Page 2: ......

Page 3: ... Inc MS DOS Microsoft and Windows are registered trademarks of Microsoft Corporation IBM is a registered trademark of International Business Machines Corporation Adobe and PostScript are trademarks of Adobe Systems Inc Centronics is a registered trademark of Centronics Inc All other brand or product names are trademarks or registered trademarks of their respective companies or organizations Copyri...

Page 4: ...neer attention to what is graphically represented inside the marking including a warning Used to prohibit the service engineer from doing what is graphically repre sented inside the marking Used to instruct the service engineer to do what is graphically represented inside the marking 1 Always observe precautions 2 Before starting the procedures be sure to unplug the power cord WARNING CAUTION WARN...

Page 5: ... a possible fire or electric shock Do not use a multiple outlet to which any other appliances or machines are connected Be sure the power outlet meets or exceeds the specified capacity A part marked with the symbol shown on the left carries a high voltage Touching it could result in an electric shock or burn Be sure to unplug the power cord before servicing this part or the parts near it Do not un...

Page 6: ...lectric shock or injury Take great care to avoid personal injury from possible burrs and sharp edges on the parts frames and chassis of this product When moving the product or removing an option use care not to injure your back or allow your hands to be caught in mechanisms Wherever possible keep all parts and covers mounted when energizing the product If energizing the product with a cover remove...

Page 7: ... Before installing a new battery make sure of the correct polarity of the installa tion or the battery could burst Dispose of used batteries according to the local regulations Never dispose of them at the user s premises or attempt to try to discharge one Removing the cover marked with the following caution label could lead to pos sible exposure to the laser beam resulting in eye damage or blindne...

Page 8: ...STRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs applicable only to the products using MOS ICs The PC Drum is a very delicate component Observe the precautions given in HAN DLING OF THE PC DRUM because mishandling may result in serious image prob lems Note that replacement of a circuit board may call for readjustments or resetting of particular items or software installation After completing a servic...

Page 9: ...onformément aux instructions du fabricant Denmark only ADVARSEL Lithiumbatteri Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med batteri af samme fabrikat og type Levér det brugte batteri tilbage til leverandøren Norway only ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten Brukte batterier k...

Page 10: ...alth CDRH of the U S Food and Drug Administration implemented regulations for laser products on August 2 1976 Compliance is mandatory for products marketed in the United States The label shown below indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States Internal Laser Radiation Maximum Radiation Power 1 03 mW at laser aperture of the pri...

Page 11: ...katso säteeseen VARNNING Om apparaten används på annat sätt än i denna bruksanvisning specificerats kan användaren utsättas för osynlig laserstrålning som överskrider gränsen för laser klass 1 VAROITUS Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteiylle ADVARSEL Dersom apparatet brukes på...

Page 12: ...ix WARNING LABEL ...

Page 13: ... Parts Function 15 2 6 1 Printer 15 2 6 2 2nd Paper Cassette Unit Option for 4100E 4100GN 3rd Paper Cassette Unit Option for 4100E 4100GN 4100W 17 2 6 3 Duplex Unit Option 17 2 7 Explanation of the Control Panel for 4100E 4100GN 18 2 7 1 Indicator Lights 18 2 7 2 Indicator Status 19 2 7 3 Control Panel Button Function 20 2 7 4 Test Print Function 21 2 8 Explanation of the Control Panel for 4100W 2...

Page 14: ...he Right Cover the Left Cover and the Front Cover 63 4 5 6 Removal of the Control Panel 64 4 5 7 Removal of the Controller Board PWB C P and the Mechanical Control Board PWB A 65 4 5 8 Removal of the Paper Take up Solenoid SL1 67 4 5 9 Replacing the Transfer Roller 68 4 5 10 Removal of the Top Cover 70 4 5 11 Removal of the Rear Cover 71 4 5 12 Removal of the Fusing Unit Cooling Fan M3 71 4 5 13 R...

Page 15: ...the paper take up section 94 6 3 3 Paper misfeed occurred at the paper exit section 95 6 3 4 Paper misfeed occurred at the Duplex Unit 95 6 4 Troubleshooting for Malfunctions 4100E 4100GN 96 6 4 1 No power 96 6 4 2 Engine error fusing unit 96 6 4 3 Engine error laser or main motor 97 6 4 4 Engine error polygon scanner 97 6 4 5 Engine error fan motor 97 6 4 6 Engine error jogging function 4100GN on...

Page 16: ...ile and flammable materials and curtains 1 2 Usage Environment In order to make sure the printer functions properly make sure the ambient environment satisfies the following requirements 1 3 Installing the Power Supply Do not plug the Power Cord into a power outlet via an extension cord supplying electricity to more than one unit Do not connect the printer to a power outlet used for other equipmen...

Page 17: ...INSTALLATION 1 4 Installation Space 1 4 1 Standard 1 4 2 With 2nd and 3rd Paper Cassette Units and Duplex Unit Options 511 mm 20 1 8 436 mm 17 1 8 369 mm 14 1 2 536 7 mm 21 1 8 436 mm 17 1 8 605 4 mm 23 7 8 ...

Page 18: ... paper 60 90 g m2 16 to 24 lbs Recycled paper 60 90 g m2 16 to 24 lbs Thick paper 90 163 g m2 24 to 43 lbs Transparencies Envelopes Letterhead Postcards Labels First printing time Simplex within 18 sec A4 or Letter Duplex within 28 5 sec A4 or Letter Multi print speed Simplex 18 prints min or more A4 or Letter Face down Duplex 9 prints min or more A4 or Letter Face down Warm up time Within 23 sec ...

Page 19: ...erage Power save mode 30 W or less average Acoustic noise 67 dB or less during printing 39 dB or less power saving mode Operating environment 10 35 C or 50 95 F Imaging Cartridge life 9 000 prints or more in continuous printing 7 200 prints or more in single printing Black White ratio 5 Imaging Cartridge life provided with printer 5 000 prints or more in continuous printing 4 000 prints or more in...

Page 20: ... Supply from main unit Dimensions 436 width x 351 depth x 120 height mm or 17 1 4 width x 13 3 4 depth x 4 3 4 height without Paper Cassette Weight Approx 4 5 kg 10 lbs Standard accessory Paper cassette A4 or Letter Option Paper cassette A4 B5 Legal Letter Executive Media Type Ordinary plain paper 64 90 g m2 17 to 24 lbs Recycled paper 64 90 g m2 17 to 24 lbs Media Size A5 A4 B5 Legal Letter Execu...

Page 21: ...ver Mode Function to regulate the toner consumption Emulation Compatible with PCL5e HP LaserJet5 Compatible with PCL6 HP LaserJet6P Adobe PostScript3 Option on for 4100E Printer Driver PCL Driver For Windows95 NT4 0 3 1 PS Driver Option For Windows95 NT4 0 3 1 CPU Hitachi Zenographics 20MHz Imaging Method Band Buffer method bitmap method Memory configuration Standard ROM 64KB Standard RAM 2MB 4100...

Page 22: ...nel 2 Face down Tray 3 Manual Feed Guide 4 Multi purpose Tray 5 Paper Cassette 6 3rd Paper Cassette Unit Option 7 2nd Paper Cassette Unit Standard for 4100GN 8 Power Switch 9 Top Cover Release Button 10 Imaging Cartridge 2 3 5 4 1 10 9 7 6 8 ...

Page 23: ...8 2 GENERAL INFORMATION 11 Duplex Unit Option 12 Power Cord Socket 13 Power Cord 14 Parallel Interface Connector 12 13 14 11 ...

Page 24: ...te Unit 6 Paper Size Guide 20 2nd Paper Cassette 7 Imaging Cartridge Guide 21 2nd Paper Take up Roller 8 Fusing Separator 22 2nd Paper Lift up Plate 9 Paper Exit Sensor PS3 23 2nd Paper Empty Detecting Lever 10 Backup Roller 24 3rd Paper Cassette Unit 11 Heat Roller 25 3rd Paper Cassette 12 PC Drum 26 3rd Paper Take up Roller 13 Image Transfer Roller 27 3rd Paper Lift up Plate 14 Paper Take up Sen...

Page 25: ...e flow fusing 9 PC Drum 2 Drive flow PC Drum 10 Fusing Roller 3 Drive flow developing 11 Paper Exit Roller 4 Drive flow paper take up 12 Duplex Unit Connection Gear 5 Main Motor M1 13 2nd Paper Take up Roller 6 Paper Take up Roller 14 2nd Paper Transfer Roller 7 Paper Transfer Roller 15 3rd Paper Take up Roller 8 Imaging Cartridge Connection Gear 16 3rd Paper Transfer Roller 11 10 9 7 14 12 1 4 2 ...

Page 26: ...ng Fan Motor PWB O Control Panel Board 4100W 4110W M4 Jog Motor 4100GN only PWB OP Control Panel Board 4100E 4100GN M5 Print Head Cooling Fan Motor PWB P Controller Board 4100W 4110W P_ENP1 Paper Empty Sensor S1 Power Switch PH Print Head Unit S2 Interlock Switch PS1 Paper Take up Sensor SL1 Paper Take up Solenoid PS3 Paper Exit Sensor TH1 Thermistor PU1 Power Unit TS1 Thermostat M1 SL1 S1 PU1 M3 ...

Page 27: ...2 5 3 Controller for 4100W 4110W NIC Network Interface Card 4100GN Standard 4100E Option PWB C Controller Board PWB RS PS ROM Board Option SIMM SIMM Option NIC Network Interface Option PWB P Controller Board SIMM SIMM Option PWB C NIC SIMM PWB RS PWB P NIC IMM ...

Page 28: ... Option for 4100E 4100W 4110W 3rd Paper Cassette Unit Option for 4100E 4100GN 4100W 4110W PI2 Paper Empty Sensor PWB A Connecting Board SL21 SL31 Paper Take up Solenoid SW21 SW31 Cassette Detecting Switch PWB A PI2 SW21 SW31 SL21 SL31 ...

Page 29: ... Option DUP_OPEN Duplex Cover Sensor DUP_PS1 Duplex Exit Sensor DUP_PSR Duplex Entrance Sensor M41 Switchback Motor M42 Transfer Motor PWB A Control Board for Duplex Unit SL41 Skew Correction Solenoid DUP_OPEN DUP_PSR PWB A SL41 M41 M42 DUP_PS1 ...

Page 30: ...Jog Motor 4100GN only Motor for jogging function Slides the Paper Exit Roller to right and left and sorts paper M5 Print Head Cooling Fan Motor Cooling Fan Motor for the Print Head Unit NIC Network Interface Card Communicates with the Personal Computer on the Network and controls all printer operation 4100E 4100W 4110W option 4100GN standard P_ENP1 Paper Empty Sensor Detects the presence of paper ...

Page 31: ...rd for 4100W 4110W Communicates with the Personal Computer and the Mechanical Control Board and controls all printer operation PWB RS PS_ROM Board option for 4100E 4100GN PS Font ROM Board of Adobe PostScript3 correspondence S1 Power Switch Turns ON or OFF the printer S2 Interlock switch Detects the opening or closing of the top cover Cuts output voltage except 5 VDC when the Top Cover is open SL1...

Page 32: ...pe according to the paper size Symbol Name Function DUP_OPEN Duplex Cover Sensor Checks the status of the cover and stops operation of the Duplex Unit when the cover is open DUP_PS1 Duplex Exit Sensor Detects that paper is discharged from the Duplex Unit The signal is low when paper is detected DUP_PSR Duplex Entrance Sensor Detects that paper is fed into the Duplex Unit The signal is low when pap...

Page 33: ...r lights and one button 2 7 1 Indicator Lights Different combinations of the three indicator lights indicate the current printer status and let the user know what the printer is doing The details of the current printer status appear on the host computer 1 Ready Green 3 Error Red 2 Paper Amber 4 Panel Button 1 2 3 4 ...

Page 34: ... in your printer You may notice a difference in image quality when compressed data is printed Off Off Blinking Memory overflow data received cannot be processed because it is too complex Off Blinking Blinking The wrong size or multiple sheets of paper are loaded On Blinking Off The printer is waiting for paper to be loaded manually On On Off The printer is waiting for paper to be loaded manually O...

Page 35: ...e cancel the current job 1 Hold down the control panel button for about five seconds 2 After all the indicator lights are lit release the control panel button to cancel the print job Print Configuration Use the following procedure whenever you want to print a sheet that shows the current printer settings Briefly press the control panel button to start printing the configuration page Form Feed When...

Page 36: ...21 2 7 4 Test Print Function Perform the following operation to print a test page showing the current printer settings Operation Briefly press the control panel button Configuration Page Sample ...

Page 37: ...cator lights indicate the current printer status and let the user know what the printer is doing The details of the current printer status appears on the host computer 2 8 2 Panel Button Press this key if an error should occur in order to have the current condition of the printer displayed through the indicator lights 1 Error Amber 4 Ready Green 2 Toner Amber 5 Panel Button 3 Paper Amber 1 2 3 5 4...

Page 38: ...r Save Mode Off Off Blinking On No Paper Cassette in Tray 2 or Tray 3 Press the Panel Button in the event of a No Paper Cassette Off Off Blinking Blinking Wait Action Press the Panel Button in the event of a paper size error or when operating in the manual mode Blinking Off On On Paper Empty Press the Panel Button in the event of a paper empty Blinking Off Off Off Operator Error Press the Panel Bu...

Page 39: ...supply of 2nd paper cassette is empty On On On On Tray 3 Paper Empty The paper supply of 3rd paper cassette is empty Indicate cause of Fatal Error Error Toner Paper Ready Printer Status Off Off Blinking On Press the Panel Button Off On On On No Cassette on Tray 2 The 2nd Paper Cassette is not present On On On On No Cassette on Tray 3 The 3rd Paper Cassette is not present Indicate cause of Fatal Er...

Page 40: ...eed at Paper Take up Section Manual feed Off On On On Wrong Media of Duplex Unit The wrong size of paper has been loaded into the duplex unit On Off Off Off Paper Misfeed at Paper Take up Section Multipurpose Tray On Off Off On Paper Misfeed at Paper Transport Section PC Drum On Off On On Paper Misfeed at Duplex Unit Paper switchback section On Off On Off Paper Misfeed at Paper Take up Section 3rd...

Page 41: ...Blinking Off Blinking On Engine error Fusing Unit warm up error Blinking Off Off On Engine error polygon scanner Off Blinking Blinking On Engine error Fusing Unit cooling fan error Off Blinking Off On Engine error main motor Off Off Blinking On Engine error Fusing Unit overheat Off Off Off On Engine error HSYNC Off On Off On Engine error Controller I F Off On On Off I O Error Network A Network por...

Page 42: ... 2 position PJ3 Connector Connector for Network Interface Card PJ4 Connector Parallel Connector Centronics IEEE1284 Nibble compatible mode Type B Connector S1 Dip switch 1 ON Inch PageWorks OFF Metric PagePro 2 ON OEM OFF OWN 3 Factory Use Only Normally OFF 4 Not used Normally OFF SIMM2 SIMM slot Slot for optional PostScript ROM SIMM3 SIMM4 SIMM slot Slot for optional DRAM SIMM up to max 104 MB RA...

Page 43: ... mode Type IC8 9 SRAM 64KB for mode setting and counters IC11 EPROM 64KB PJ3 Connector Parallel Connector Centronics IEEE1284 ECP EPP compatible mode Type B Connector PJ4 SIMM slot Slot for optional DRAM SIMM up to max 18 MB RAM 4100W up to max 66 MB RAM 4110W PJ5 Connector Connector for Network Interface Card Option XTAL1 Oscillator 20 MHz XTAL2 Oscillator 33 MHz XTAL3 Oscillator 96 59242 MHz IC3...

Page 44: ...in Refer to chapter 5 F1 Fuse Rating 8A 125V RV2 Dial for factory adjustment Available only at factory RV51 Dial for factory adjustment Available only at factory CN1 30P CN12 8P CN15 14P CN8 6P CN1 5P VR1 CN1 5P CN2 2P CN14 3P CN4 11P CN5 7P CN9 5P CN13 2P CN11 12P CN3 2P CN6 4P CN7 4P IC7 CN2 4P CN3 2P CN4 2P CN5 4P F1 RV2 RV51 ...

Page 45: ...ias terminal DC 1286V DC 800V B Developing Bias terminal DC 300V SS Toner Blade Bias terminal DC 550V BL Toner Blade Bias terminal DC 550V T Image Transfer Bias terminal DC3000V DC 1000V max VR2 Dial for factory adjustment Available only at factory CN1 11P VR2 T C B SS BL ...

Page 46: ...lt Position Settings 4110s019 OP7 OP5 OP4 OP3 OP2 OP6 OP1 OFF ON P4 P1 P2 S R P W CUST BYPASS TEST 10 100 Base T for 4100E 4100GN OP7 OP5 OP4 OP3 OP2 OP6 OP1 OFF ON P4 P1 P2 S R P W CUST BYPASS TEST 10 Base T 2 for 4100E 4100GN THIN JP4 JP3 10 BT MAN AUTO ...

Page 47: ...OP1 ON FACT P ACK T B BYPASS TEST ON CS2 JP2 CS1 10 100 Base T for 4100W 4110W The 4100W and 4110W NIC are different and each has a unique part number even though the graphic shown is identical for both The difference between the 2 NICs is chip based ...

Page 48: ...rry out the following functions The transfer of image data Mutual exchange and confirmation of data on the progress of the printing sequence Data about the Engine is given to the Controller Engine operation commands are sent PWB A Print Head Unit CPRDY CTBSY PRINT CMD SRCLK RESET EPRDY PRRDY TOD ETBSY STS HSYNC VIDEO Controller Board PWB P 4100W 4110W PWB C 4100E 4100GN Mechanical Controller Board...

Page 49: ... of the Engine SRCLK This signal is a serial synchronization clock for transmitting the CMD and STS signals RESET This signal is sent from the Controller to the Engine and initializes the Engine resets the CPU EPRDY This signal indicates that the Engine is ready for communication with the Controller following initialization of the CPU in the Engine after the main power is turned on The signal beco...

Page 50: ...Transfer signal Image Transfer output 40 0mm 10 30msec 6 0sec 2 23sec 0 3sec 0 34sec 0 3sec 2 47sec 2 23sec 0 3sec 0 3sec 0 7sec 20 0mm 29 0mm 24 0mm 66 0mm 0 8sec more than 100ºC or 212ºF 1200V 120V 2 4sec 0 8 2 6sec Polygon Motor M2 Paper Take Up Sensor PS1 Main Motor M1 Drum charge Laser exposure Development signal Image Transfer output Image Transfer signal 38 0mm 44 0mm 28 0mm 48 0mm 45 0mm 7...

Page 51: ...er Cassette Unit 500 sheets In addition duplex printing is possible when the Duplex Unit is installed Paper fed by the Paper Take up Roller is transported to the Image Transfer Roller Fusing Roller and Paper Exit Roller then discharged onto the printer tray When duplex printing the printer pulls the paper into the Duplex Unit and printing is performed on the back side of the paper A Paper Take up ...

Page 52: ...used for the paper separation system It prevents the second or later sheets of paper from being fed together with the top sheet As the Multipurpose Tray has no paper size detecting mechanism it recognizes the paper size by the paper length which is calculated from the time the paper passes over and activates the Paper Take up Sensor PS1 Therefore sheets of paper having differ ent widths are recogn...

Page 53: ...Tray determines whether paper is loaded in the tray When paper is present the actuator is lifted and the sensor is deactivated When the tray has run out of paper the actuator falls into the cutout in the tray and the sensor is activated Standing by Taking up the paper 1 Tray 2 Tray Lifting Plate 3 Depressing Cam 2 1 3 ...

Page 54: ...n claw in the paper cassette and the strength of paper itself corner separation system One sheet of paper is fed for each paper feed cycle The Paper Take up Solenoid SL21 is controlled by the printer via PWB A in the Second Paper Cassette Unit Paper Empty Detection The Paper Empty Sensor PE21 on the Connecting Board PWB A determines whether paper is loaded in the tray When paper is present the act...

Page 55: ... a set and the printer recognizes the cassette type paper size by the combination of ON OFF states of the switches The printer determines the cassette type paper size by the combination of ON OFF states of the switches The state of SW21 for each cassette type 1 Paper Cassette 3 Cassette Detecting Switch SW21 2 Projection Cassette Type SW21 1 SW21 2 SW21 3 A4 OFF OFF ON B5 ON ON OFF Letter OFF ON O...

Page 56: ...5 Cleaning blade Removes excess toner waste toner on the PC Drum after transferring the image to the paper 6 Image Transfer Roller Transfers the toner image on the PC Drum to the paper 7 PC Drum An invisible image is created on the surface by laser developing is performed by the resin sleeve and the developed image is transferred to the paper 8 Sleeve Roller Transfers toner to the surface of the P...

Page 57: ...r recognizes that the imaging cartridge is replaced and resets the toner empty command 10 Toner Transport Roller Transfers toner to the sleeve roller section 11 PC Drum protection cover Covers and protects the PC Drum when taking the imaging cartridge out of the printer 12 Toner Agitating blade Agitates the toner in the Toner Hopper and sends the toner to the Toner Transport Roller 13 LED penetrat...

Page 58: ...ause the charge is directly applied to the PC Drum the PC Drum can be charged by low voltage The PC Drum is charged evenlyacross it s entire surface The Pre charge Film supplies the charge to the PC Drum before being charged by the Rotating Charge Brush to improve charging efficiency The electric potential on the surface of the charged PC Drum is approximately 800 V 1 Rotating Charge Brush 3 Groun...

Page 59: ...r rotate and the paper is fed into the printer The printing in the sub scanning direction is started when PWB A sends the VIDEO signal to the Print Head a certain time after the leading edge of the paper activates the Paper Sensor TOD signal This process is controlled as follows in order to appropriately time image printing In the scanning direction horizontal direction The SOS sensor is installed...

Page 60: ...o the engine The controller determines the starting point of printing according to the TOD signal sub scanning direction sent from the engine PWB A and the HSYNC signal Laser exposure is started when the print head receives the VIDEO signal 1 Printing Area 4mm 4mm VIDEO HSYNC TOD VIDEO 1 ...

Page 61: ...nvisible static image on the PC Drum and a toner image is created on the drum surface 1 PC Drum 6 Ground PC Drum 2 Sleeve Roller 7 Developing Bias 3 Toner Transport Roller 8 Toner Blade Bias Terminal 4 Toner Blade 9 Lower Seal Bias 5 Lower Seal 8 7 9 6 6 7 8 9 1 2 3 5 4 ...

Page 62: ... there is little generation of ozone due to corona dis charge Also there is no blur of toner because the paper is always pressed by the PC Drum and the Image Transfer Roller When cleaning the Image Transfer Roller and before printing reverse bias is applied The residual electric potential on the paper is dissipated via a discharge needle 1 PC Drum 4 Discharge Needle 2 Imaging Transfer Roller 5 Rev...

Page 63: ...ing Section A heat roller system is used as the fusing system The toner is fused on the paper as it is pressed between the Backup Roller and Heat Roller heated by the Heater Lamp 1 Paper Separator 5 Heat Roller 2 Thermostat TS1 6 Paper 3 Thermistor TH1 7 Backup Roller 4 Heater Lamp H1 8 Fusing Entrance Guide Plate 2 1 3 4 5 8 7 6 ...

Page 64: ...er Lamp is not turned OFF even if the Thermistor detects a high temper ature malfunction if the surface temperature of the Fusing Heat Roller exceeds 245 C 473ºF the signal from IC1A 79 changes from low to high to turn OFF the Heater Lamp forcibly 1 2 1 2 CN1 CN2A 2 1 TH1 1 2 3 CN14A 1 2 3 CN3PU1 FAN N C HEATER Power Unit 1 2 CN14 HEAT_N HEAT_L H1 TS1 PU1 DC5V 78 IC1A PWB A Mechanical Control Boar...

Page 65: ...radually to about 190 C 374ºF from about 200 C 392ºF If this mode continues for 308 seconds it will shift to mode 3 Mode 3 The temperature is controlled to maintain about 124 C 255ºF during standby and about 190 C 374ºF during printing Unless an error occurs or the top cover is opened this mode is maintained Temperature immediately after temperature control starts The state before discontinuation ...

Page 66: ...tray function enables the Paper Exit Roller to slide to the left and right so that paper is sorted and discharged at different positions on the tray while printing The original discharging position when not using the jog tray function is regarded as jog position 1 The position where paper is discharged with the Paper Exit Roller changed by the jog tray function is regarded as jog position 2 Jog po...

Page 67: ...s forward when the Paper Exit Sensor PS3 is turned off The paper is discharged sliding to the side jog position 2 while the Paper Exit Roller is sliding When the paper is discharged the Jog Motor M4 rotates backward The roller stops sliding when the Jog Position Sensor JOG_POS1 is turned on 1 Jog Motor M4 3 Paper Exit Roller 2 Jog Position Sensor JOG_POS1 M4 1 2 3 ...

Page 68: ... the Paper Exit Roller until the paper passes the Paper Exit Sensor The Switch Back Motor M41 then rotates backward to feed the paper to the Duplex Unit The paper is transferred to the Register Roller by the Transfer Motor M42 Paper tilt is checked and corrected by the Paper Exit Sensor DUP_PS1 and the paper is fed to the Transfer Section by the Register Roller Printing is performed on the rear si...

Page 69: ... handling it Be sure to wait until it cools down before disassembling the printer Be sure to check that power is turned off before plugging in or unplugging the power cord Always hold the connector housing when plugging in or unplugging the power cord Faulty contact may result if the wire is held when unplugging the power cord Be sure to use the fuse of the specified rating Do not forget to reinst...

Page 70: ...ord from the power source before unplugging the connec tors from the circuit boards Never touch the terminals of the IC or the printed pattern when removing the circuit board from its conductive bag or case or when replacing the board Always hold the edge of the board During Inspection Avoid checking the IC directly with a multi meter use connectors on the board Never short terminals on the IC wit...

Page 71: ...none approximately 5 000 simplex prints approximately 4 000 simplex prints Imaging Transfer Roller none approximately 50 000 simplex prints Fusing Unit none approximately 50 000 simplex prints Paper Take up Roller at the time of trouble approximately 150 000 simplex prints 2nd and 3rd Cassette Unit Paper Take up Roller at the time of trouble approximately 150 000 simplex prints Transfer Roller at ...

Page 72: ...57 4 4 Screws Illust No D x L mm Illust No D x L mm Illust No D x L mm 1308 3x8 3501 3541 3541 3x6 3x8 3x6 3907 3923 3x8 3x10 1112 3x6 3704 3727 3x8 3x8 4012 3x6 3435 3x30 ...

Page 73: ...ng Unit Cooling Fan M3 4 5 12 Fusing Unit 4 5 13 Left Frame 4 5 20 Power Unit PU1 4 5 19 Paper Empty Sensor P_ENP1 Toner Empty Sensor PWB G 4 5 22 Paper Take up Sensor PS1 4 5 23 Backup Roller Heater Lamp H1 Heat Roller Fusing Paper Separators Thermistor TH1 Thermostat TS1 4 5 14 Controller Board PWB C P 4 5 7 Interlock Switch S2 4 5 17 Print Head Unit PH 4 5 16 High Voltage Board HV1 4 5 18 Mecha...

Page 74: ...bling the machine the following units need to be removed 1 Push the Top Cover Release Button and fully open the Top Cover 2 Remove the Imaging Cartridge 3 Remove the Paper Tray 1 Top Cover Release Button 3 Imaging Cartridge 2 Top Cover 4 Paper Tray 1 2 3 4 ...

Page 75: ...er approximately every 150 000 simplex prints 1 Open the Paper Take up Roller Cover and remove the Paper Take up Roller 1 screw NOTE When installing the roller fit the positioning pin on the back side of the roller into the hole of the shaft 1 Paper Take up Roller Cover 2 Paper Take up Roller 1308 1 2 ...

Page 76: ...e printing quality Carefully hold the roller by the shaft or bushings 1 Remove the Image Transfer Roller cover by using a Stubby Screwdriver 2 screws 2 Push down the lever of the bushings white of the Image Transfer Roller and remove the roller from the Image Transfer Roller holder NOTE Do not lose the holding springs for the Image Transfer Roller Holder 1 Image Transfer Roller Cover 3 Image Trans...

Page 77: ...he original Image Transfer Roller and attach them to the new one 4 Insert the new roller into the Transfer Roller holder and raise the lever of the bushings 5 Replace the Image Transfer Roller cover 2 screws 1 Imaging Transfer Roller 4 Gear 2 Bushing 5 Holding Screw 3 Roller Holder 3 2 1 3 4 2 3 5 ...

Page 78: ...e Right Cover 2 screws 2 Remove the Left Cover 2 screws 3 Remove the Front Cover 2 screws NOTE When reinstalling each cover securely insert the projections of the cover into the cutouts in the printer frame 1 Right Cover 3 Front Cover 2 Left Cover 3541 3541 3541 3541 1 3 2 3541 3541 ...

Page 79: ...TENANCE DISASSEMBLY 4 5 6 Removal of the Control Panel 1 Remove the Controller Cover 4 screws 2 Remove the Control Panel 2 screws 1 connector 1 Controller Cover 2 Control Panel 3544 3544 3544 3544 3541 3541 2 1 ...

Page 80: ...nical Control Board PWB A 1 Remove the Harness Cover 1 screw 2 Remove the Board Cover A 10 screws 3 Remove Board Cover B 5 screws 1 Harness Cover 2 Board Cover A 3 Board Cover B 3544 3727 3544 3544 3544 3544 3544 3544 3544 3544 3544 1 2 3544 1112 1112 3544 3544 3 ...

Page 81: ... P 4 screws 1 connector 5 After unplugging all connectors on the Mechanical Control Board PWB A remove the Mechanical Control Board PWB A 4 screws 4 Controller Board 4100E 4100GN PWB C 4100W PWB P 5 Mechanical Control Board PWB A 3541 3541 3541 3541 4 3541 3541 3541 3541 5 ...

Page 82: ...7 4 5 8 Removal of the Paper Take up Solenoid SL1 1 Remove the upper section of the printer 4 screws 1 connector 2 Remove the Paper Take up Solenoid SL1 1 screw 1 connector 3544 3544 3544 3544 3544 3727 ...

Page 83: ...5 9 Replacing the Transfer Roller Replace the Transfer Roller approximately every 150 000 sheets of print 1 Holding the Transfer Roller Holder move the Transfer Rolls apart to both sides 1 Transfer Rolls 2 Transfer Roller Holder 2 1 ...

Page 84: ... roller at the joint and remove it NOTE Attach the New Transfer Roller so that the guide film is placed upward Press the Transfer Roller Holder and the Paper Separator down when attaching the Transfer Rolls to the original positions 1 Transfer Roller 4 Paper Separator 2 Transfer Roller Holder 5 Guide Film 3 Joint 1 2 5 3 4 ...

Page 85: ...en the Top Cover and the printer 2 Remove the Shoulder Screw and washer from the Stopper Guide NOTE Hold the upper cover with your hand or the cover may fall when the screw is removed 3 Remove the screw between the Top Cover and Rear Cover 4 Remove the Top Cover 1 Top Cover 2 Shoulder Screw 2 1 3727 ...

Page 86: ...tor NOTE Do not lose the connector cover 4 5 12 Removal of the Fusing Unit Cooling Fan M3 1 Remove the Cooling Fan Cover 2 Remove the Fusing Unit Cooling Fan M3 1 Rear Cover 2 Connector Cover 1 Cooling Fan Cover 2 Fusing Unit Cooling Fan M3 3544 3544 3727 3727 3544 3544 2 1 2 1 ...

Page 87: ... Unit about every 50 000 sheets of print 1 Remove the Fusing Unit 3 screws Fixing Plate 3 connectors NOTE Once the Fusing Unit is removed use the following instructions to make repairs when image quality problems or parts failure occur 1 Fusing Unit 2 Fixing Plate 3544 3544 3544 1 2 ...

Page 88: ...nd separate the upper and lower fusing units 3 Remove the Backup roller 4 Slide the Front Fusing Guide Plate in direction 1 and pull it in direction 2 to remove one side of the plate Then pull the plate in direction 3 to remove it com pletely 1 Backup Roller 2 Fusing Entrance Guide Plate 3727 3727 1 1 2 2 3 ...

Page 89: ... Plate 2 screws 6 Pull out the Heater Lamp H1 NOTE When reinstalling the lamp position the voltage mark on the fusing drive gear side Be sure not to touch the lamp surface with bare hands 1 Terminal Plate 3 Voltage Mark 2 Heater Lamp H1 3727 3727 1 3 2 ...

Page 90: ...ection 2 to remove one side of the roller Then pull the roller in direction 3 to remove it completely NOTE In order not to scratch the surface of the Heat Roller with the Fusing Separators lift the Separators as much as possible when removing or installing the roller 1 Drive Gear 2 Heat Roller 1 3 2 2 1 ...

Page 91: ... the Thermistor TH1 1 screw NOTE Route the harness along the bottom of the Fusing unit when attaching the Thermistor as shown in the following figure 11 Remove the Thermostat TS1 2 screw 1 Fusing Paper Separators 3 Thermostat TS1 2 Thermistor TH1 4 Harness 3727 3727 3727 1 3 2 1 4 ...

Page 92: ...77 4 5 15 Removal of the Paper Exit Sensor PS3 1 Remove the Paper Exit Sensor PS3 from the Fusing Unit 1 Fusing Unit 2 Paper Exit Sensor PS3 1 2 2 ...

Page 93: ...ead Unit PH 1 Remove the Duct 1 screw 2 Remove the Cover 3 Unplug the two connectors from PWB A and remove the harness from the cord hold ers 4 Remove the Print Head Unit PH 6 screws 1 Duct 3 Print Head Unit PH 2 Cover 3704 3704 3544 3544 3544 3544 1 2 3 3544 ...

Page 94: ...nectors 4 5 18 Removal of the High Voltage Board HV1 1 Remove the High Voltage Board Cover with High Voltage Board 2 connectors 2 Remove the High Voltage Board HV1 from the Cover 2 screws 1 Interlock Switch S2 1 High Voltage Board Cover 2 High Voltage Board HV1 3520 3520 1 Red Orange 3727 3727 1 2 ...

Page 95: ... 2 Remove the Power Unit PU1 3 screws 6 connectors 4 5 20 Removal of the Left Frame 1 Remove the Cover Stay Guide 2 screws 2 Remove the Left Frame 6 screws 5 connectors 1 Duplex Connector Holder 2 Power Unit PU1 1 Cover Stay Guide 2 Left Frame 3727 3727 3727 3727 1 2 3544 3544 3541 3541 3544 3544 3544 3544 2 1 ...

Page 96: ... Removal of the Main Motor M1 the Print Head Cool ing Fan M5 and the Power Switch S1 1 Separate the Drive Unit Cover and the Left Frame 6 screws 1 Drive Unit Cover 2 Left Frame 3544 3544 3544 3544 3544 3544 2 1 ...

Page 97: ...BLY 2 Remove the Main Motor M1 4 screws 3 Remove the Print Head Cooling Fan M5 2 screws 4 Remove the Power Switch S1 2 connectors 1 Main Motor M1 3 Power Switch S1 2 Print Head Cooling Fan M5 1 2 3 4012 4012 4012 4012 3435 3435 ...

Page 98: ...ty Sensor PWB G 1 Remove the Imaging Cartridge Cover 2 Remove the Paper Empty Sensor P_ENP1 and unplug the connector 3 Remove the Toner Empty Sensor PWB G and unplug the connector 1 Imaging Cartridge Cover 1 Paper Empty Sensor P_ENP1 2 Toner Empty Sensor PWB G 1 1 2 ...

Page 99: ...ASSEMBLY 4 5 23 Removal of the Paper Take up Sensor PS1 1 Remove the Image Transfer Guide Assembly 2 Remove the Paper Take up Sensor PS1 and unplug a connector 1 Image Transfer Guide Assembly 1 Paper Take up Sensor PS1 1 1 ...

Page 100: ...100GN only 1 Remove the Jog Motor Cover from the Top Cover 3 screws 2 Remove the Jog Motor M4 2 screws 3 Remove the Jog Position Sensor JOG_POS1 and unplug the connector 1 Top Cover 2 Jog Motor Cover 1 Jog Motor M4 2 Jog Position Sensor JOG_POS1 3727 3501 3727 1 2 3541 3541 1 2 ...

Page 101: ...roximately every 150 000 sheets of print 1 Separate the printer and 2nd 3rd Paper Casette Unit 2 As shown in the figure remove the Paper Take up Rollers 1 Pull up on the lever of the roller 2 Pull it to the right 3 Lift out the roller 3 Install a new Paper Take up Rollers in the opposite way 1 Paper Take up Roller 1 2 3 1 1 ...

Page 102: ...M41 2 screws 1 connector 4 Remove the Transfer Motor M42 2 screws 1 connector 5 Remove the Skew Correction Solenoid 1 screw 1 connector 6 Remove the Sensor Bracket 1 screw 7 Remove the Duplex Entrance Sensor DUP_PSR and unplug the connector 1 Left Cover 5 Skew Correction Solenoid SL41 2 Board Cover 6 Sensor Bracket 3 Switchback Motor M41 7 Duplex Entrance Sensor DUP_PSR 4 Transfer Motor M42 3907 3...

Page 103: ...BLY 4 5 27 Removal of the Duplex Exit Sensor DUP_PS1 1 Open the Bottom Cover of the Duplex Unit 2 screws 2 Remove the Duplex Exit Sensor DUP_PS1 and unplug the connector 1 Bottom Cover 2 Duplex Exit Sensor DUP_PS1 1 2 3907 3907 ...

Page 104: ...ve the Rear Cover of the Duplex Unit 2 shoulder screws and 1 screw 2 Remove the Right Cover 1 screw 3 Remove the Duplex Cover Sensor DUP_OPEN and unplug the connector 1 Rear Cover 3 Right Cover 2 Shoulder Screw 4 Duplex Cover Sensor DUP_OPEN 3541 3907 2 1 3 2 4 ...

Page 105: ...y following one of the procedures described below 1 Remove the right cover so that VR1 of PWB A can be adjusted 2 Turning VR1 on PWB A in the clockwise direction makes the gap d greater and turning it in the counter clockwise direction makes the gap d smaller Adjustment by Voltage 1 Touch the positive and negative terminals of the tester to VR1 and frame GND respec tively with power turned on 2 Ad...

Page 106: ...h S1 is turned ON check and adjust the position of the Interlock Switch S2 following the procedure below 1 Remove the left cover right cover and front cover 2 After loosening the screw of the interlock switch S2 close the top cover carefully 3 Move the interlock switch S2 up and down and tighten the screw at the position where the switch turns on ...

Page 107: ... Roller in the printer or optional 2nd Cassette Unit or 3rd Cassette Unit starts turning 2 The Paper Take Up Sensor PS1 does not deactivate within 8 21 sec after the paper leading edge reaches the Paper Take Up Sensor PS1 3 The Paper Exit Sensor PS3 does not activate within 2 84 to 3 79 sec after the paper leading edge reaches the Paper Take Up Sensor PS1 4 The Paper Exit Sensor PS3 does not deact...

Page 108: ...r is adjusted LD_APC1 LD_APC2 These signals are to adjust the laser drive current 6 2 3 Main Motor Malfunction 1 The motor lock signal has not been ON within 1 0 sec after the Main Motor M1 is energized 2 When motor lock signal is continuously turned OFF for 0 1 seconds during main motor rotation 6 2 4 Polygon Motor Malfunction 1 The SSCAN signal has not been entered once within 0 8 sec after the ...

Page 109: ...Paper Take up roller of the 2nd Cassette unit and 3rd Cassette unit turn No Replace SL1 Replace SL21 Replace SL31 Yes Does the paper being used conform to the product specifications No Instruct the user to use the paper that conforms to the product specifications Yes Is the paper curled waved or damp Yes Change the paper Instruct the user to store the paper properly No Are the Paper take up roller...

Page 110: ...lace PWB A Replace PWB C 4100E 4100GN Replace PWB P 4100W Check Remedy Switchback Motor M4 rotates and the paper is sent into Duplex Unit No Replace M4 Replace PWB A of Duplex Unit Replace PWB A of Printer Yes Does the Duplex Entrance Sensor DUP_PSR lever move correctly No Correct the Sensor lever movement Yes Is the Paper Transfer Roller deformed worn or dirty with paper dust Yes Clean the Paper ...

Page 111: ...Interlock Switch S2 been turned ON No Adjust the Interlock Switch S2 position Yes Has the fuse in the Power Unit PU1 blown No Replace PU1 Replace PWB A Replace PWB C Yes Replace the fuse F1 Check Remedy Is an error shown after the printer has completed warming up Yes Replace the Thermistor TH1 or Fusing Unit Replace PWB A No Is the Fusing Unit warm Yes Replace the Thermistor TH1 or Fusing Unit Rep...

Page 112: ...edy Polygon Malfunction Replace the Print Head Unit Replace PWB A Replace PWB C Check Remedy Fusing Unit Cooling Fan Motor M3 rotates simultaneously with power supply ON No Replace M3 Replace PU1 Replace PWB A Yes P H Cooling Fan Motor M5 rotates simultaneously with power supply ON No Replace M5 Replace PWB A Yes Replace PWB A Replace PWB C Check Remedy The Jog Motor M4 rotates and Paper Exit roll...

Page 113: ...s Has the Interlock Switch S2 been turned ON No Adjust the Interlock Switch S2 position Yes Has the fuse in the Power Unit PU1 blown No Replace PU1 Replace PWB A Replace PWB P Yes Replace the fuse F1 Check Remedy Is an error shown after the printer has completed warming up Yes Replace the Thermistor TH1 or Fusing Unit Replace PWB A No Is the Fusing Unit warm Yes Replace the Thermistor TH1 or Fusin...

Page 114: ...place the Heater Lamp H1 Thermostat TS1 or Fusing Unit Yes Replace the Power Unit PU1 Replace PWB A Replace PWB P Check Remedy Is an error shown after the printer has completed warming up Yes Replace the Thermistor TH1 or Fusing Unit Replace PWB A No Is the Fusing Unit warm Yes Replace the Thermistor TH1 or Fusing Unit Replace PWB A No Is there electrical conduction between CN14 1 and CN14 2 of th...

Page 115: ...medy The Main Motor M1 rotates when the Power Switch S1 is turned ON No Replace M1 Replace PWB A Yes Replace PWB A Replace PWB P Check Remedy Polygon Malfunction Replace the Print Head Unit Replace PWB A Replace PWB P Check Remedy Fusing Unit Cooling Fan Motor M3 rotates simultaneously with power supply ON No Replace M3 Replace PWB A Yes Replace PWB A Replace PWB P Check Remedy P H Cooling Fan Mot...

Page 116: ...lel Network Fatal Error Remedy Controller Malfunction Replace optional SIMM Replace PWB A Replace PWB P Fatal Error Remedy Parallel Port Malfunction Replace Interface Cable Replace PWB P Network Port Malfunction Replace Network Cable Replace NIC Replace PWB P ...

Page 117: ...lem occurs with the printer please refer to the following chart to help determine the defective unit Pitch Defective Part diameter Defective Unit 26 0 mm or 1 1 32 Sleeve Roller φ 15 8 mm or 7 12 Imaging Cartridge 94 2 mm or 3 5 8 PC Drum φ 30 mm or 1 1 8 50 6 mm or 2 7 16 Imaging Transfer Roller φ 16 1 mm or 11 16 Image Transfer Roller 62 8 mm or 2 7 16 Heat Roller φ 20 mm or 13 16 Fusing Unit 67...

Page 118: ...ransfer Roller Replace HV1 Replace PWB A Replace PWB C 4100E 4100GN Replace PWB P 4100W Black print Improper laser exposure Replace Print Head Unit Replace PWB A Replace PWB C 4100E 4100GN Replace PWB P 4100W Improper charging Replace HV1 Replace PWB A Replace PWB C 4100E 4100GN Replace PWB P 4100W White spots The paper may have absorbed moisture due to high humidity Replace the paper Poor image t...

Page 119: ...ide of the printer Low Image density Toner empty in the Imaging Cartridge Replace the Imaging Cartridge Defective PC Drum end of life Replace the Imaging Cartridge Poor development Replace HV1 Replace PWB A Replace PWB C 4100E 4100GN Replace PWB P 4100W Foggy background Poor development Replace HV1 Replace PWB A Replace PWB C 4100E 4100GN Replace PWB P 4100W Defective PC Drum end of life Replace t...

Page 120: ...efective Print Head Unit Replace the Print Head Unit Replace PWB A Replace PWB C 4100E 4100GN Replace PWB P 4100W Offset image Defective Fusing Roller Replace the Fusing Unit or Fusing Roller Defective Image Transfer Roller Replace the Image Transfer Roller Symptom Possible Cause Remedy ...

Page 121: ...15 Electrical Service Parts on P W Boards 27 Engine error Controller 101 Engine error fan motor 97 Engine error Fusing Unit cooling fan 100 Engine error Fusing Unit low temperature error 98 Engine error Fusing Unit overheat 99 Engine error Fusing Unit warm up error 99 Engine error fusing unit 96 Engine error HSYNC 100 Engine error jogging function 18N only 97 Engine error laser or main motor 97 En...

Page 122: ...nction 93 Maintenance Schedule List 56 MAINTENANCE DISASSEMBLY 54 Malfunction Detection 93 MECHANICAL ELECTRICAL 36 Multi purpose Tray 37 N No power 96 98 O Offset image 105 P Panel Button 22 Paper Exit 51 Paper Misfeed Detecting Conditions 92 Paper Misfeed Detection 92 Paper misfeed occurred at the Duplex Unit 95 Paper misfeed occurred at the paper exit section 95 Paper misfeed occurred at the pa...

Page 123: ...WB G 83 Removal of the Paper Exit Sensor PS3 77 Removal of the Paper Take up Sensor PS1 84 Removal of the Paper Take up Solenoid SL1 67 Removal of the Power Unit PU1 80 Removal of the Print Head Unit PH 78 Removal of the Rear Cover 71 Removal of the Right Cover the Left Cover and the Front Cover 63 Removal of the Switchback Motor M41 the Transfer Motor M42 the Skew Correction Sole noid SL41 and th...

Page 124: ...U Usage Environment 1 V Video Interface Engine I F 33 W White spots 103 White Black lines and bands 105 ...

Page 125: ...Second Paper Cassette Unit 4100GN Standard 4100W 4110W 4100E Option ...

Page 126: ...PagePro 4100W 4110W 4100W 4110W ...

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