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SERVICE MANUAL

A610/A611 SER.

2014-01-22

Confidential

Summary of Contents for A610 Series

Page 1: ...SERVICE MANUAL A610 A611 SER CS 2014 01 22 CE Confidential...

Page 2: ...ponents 9 Installation 12 Environment Unpacking and Components 12 Option Tray 13 Image Cartridge 15 Cable Connection 16 Maintenance 17 Preventive Maintenance 17 Detailed Description 18 Image Process 1...

Page 3: ...Main Functions 66 System Card Components and Main Functions 74 LVPS Components and Main functions 87 HVPS Components and Main Functions 91 Replacement and Adjustment 97 External Cover 97 Left Cover 98...

Page 4: ...125 Disassembling Optional Tray Unit 127 Resist Guide A ssy 143 Removing the Resist Roller 144 Output Unit 145 Duplex Unit 146 Removing Duplex Unit 146 Front Part 156 Main Board OPU 156 PDU 157 Troub...

Page 5: ...vil A610SER SDAPL PCL5e 6 PS3 A610DN SDAPL Sindoh Advanced Print Language GDI Front No Name Remark 1 Tray 1 250 Sheets 75 g m 2 Tray 2 Optional Tray 250 Sheets 75 g m 3 Multipurpose Tray MPT 4 Front C...

Page 6: ...d Connector 10 Power Button 11 USB Port Connector 12 Wi Fi Connector 13 Ethernet Connector 14 Back Cover 15 Duplex Tray Capacity 1 Basic Configuration Tray 1 250 Sheets MPT 50 Sheets 2 Basic Configura...

Page 7: ...SDAPL PCL5e 6 PS3 A611DN SDAPL Sindoh Advanced Print Language GDI Front No Name Remark 1 Tray 1 500 Sheets 75 g m 2 Tray 2 Optional Tray 500 Sheets 75 g m 3 Multipurpose Tray MPT 4 Front Cover 5 Contr...

Page 8: ...d Connector 10 Power Button 11 USB Port Connector 12 Wi Fi Connector 13 Ethernet Connector 14 Back Cover 15 Duplex Tray Capacity 1 Basic Configuration Tray 1 500 Sheets MPT 50 Sheets 2 Basic Configura...

Page 9: ...rocessor 360MHz LCD Display 128X32 Graphic LCD Korean Available English Korean Interface Port 1USB Device host Ethernet 10 100Base T Wi Fi 801 21 BGN Optional Emulation SDAPL PCL5e 6 PS3 OS Windows XP...

Page 10: ...Processor 800MHz LCD Display 128X64 Graphic LCD Korean Available English Korean Interface Port 1USB Device host Ethernet 10 100 1000Base T Wi Fi 801 21 BGN Emulation SDAPL PCL5e 6 PS3 OS Windows XP V...

Page 11: ...ter Legal Executive Statement 60 120 g m 16 32lb Optional Tray A611 Standard 500 Sheets Thick Up to set height Marked by Label A4 A5 JIS B5 Folio Letter Legal Executive 60 163 g m 16 32lb MPT ALL Stan...

Page 12: ...rtridge A610 A611DN 6K 3K 6K 13K Drum Unit 45K Consecutive printing 30K 3page job 18K 1page Job Conditions 1 Life specified above is based on A4 and 5 charts 2 Standard temperature and humidity 3 Life...

Page 13: ...377mm Weight 3 5kg approx Feeder 1 Friction Pad A ssy 2 Center Align System 3 Incline plate 1 EA Incline spring 2 EA 4 2 step end fence 5 Feeder beam sensor Pickup Feed roll A ssy 1 Pickup roll A ssy...

Page 14: ...Gear Arm Pivot A ssy 1EA 6 BKT Accufeed PR 1EA Frame Exterior Unit 1 Frame A ssy 3EA MO 2 PR 1 2 Exterior Cover 4EA Feeding Tray Unit 1 Cassette Tray 1EA 2 Cover Tray 1EA 3 Side Fence _ Left 1EA 4 Si...

Page 15: ...S 45PPM KARA 40PPM Feeder Capacity 500 Sheets 75gsm 1 Paper Min A5 Max Legal Xerographic OR Business paper Paper Weight 16 90 lb 60 163gsm paper Dimension H W D 130 3 mm 383 mm 387 mm Weight 4 5kg app...

Page 16: ...r Printer operating temperature 15 6 C 32 2 C shipping and storage 40 0 C 60 0 C Installation Unpacking and Checking Components Unpacking 1 Take out the printer and all components from the box 2 Remov...

Page 17: ...rn the printer s power off Remove the power cord from the printer and remove all cables from the back 1 Remove all wrappings and tapes on the feeder 2 Pull the feeding unit out from the feeder 1 Tray1...

Page 18: ...ld both handles on the bottom sides lift it up and place it on the placing location Align the tab narrow hole and connector on the top of the feeder exactly with the bottom of printer Place it on the...

Page 19: ...ooves of the printer arrow stickers 3 Push in the cartridge until you hear a click inside the printer 4 Close front cover Check if both sides of the cover have been shut with a click Check if multipur...

Page 20: ...connected devices 2 Connect the USB cable Network Connection Connect the enclosed CORE to the cable before connecting the network cable Wi Fi Connection Wi Fi Module WN400 option Recognized automatica...

Page 21: ...r unit 120K Transfer roller 120K MPT separation pad 30K A610 A615 Pickup roller separation pad 120K A611 A616 Feeder Accufeed roller 120K Service life of this device is 400 000 sheets A610 600 000 she...

Page 22: ...18 Detailed Description IMAGE PROCESS Charging Voltage of 1540V is applied to charging roller from HVPS and the drum surface is charged with approximately 900V Exposure...

Page 23: ...potential of scanned area drops to about 300V to form Latent Image Development Images are formed on the drum surface by attaching the charging toner with approximately 550V via development roller and...

Page 24: ...icity applied to the transfer roller pulls the image forming toner particles on drum surface to form unsettled images on the paper Cleaning Remaining toner on the drum surface after transferred to pap...

Page 25: ...r 6 OPC Drum 7 Development roller 8 Doctor Blade 9 Add Roller 10 Paddle Roller 11 Mid Roller 12 Multipurpose Tray Feed Roller 13 Multipurpose Tray Friction Pad 14 Tray 1 Feed Roller 15 Tray 1 Friction...

Page 26: ...22 Paper Path 1 Output Bin 2 Multipurpose Tray 3 Main Feeder 4 Optional Feed Unit 5 Duplex Unit...

Page 27: ...SW1 Power Supplies power to the machine If this is turned off no power will be supplied to the machine Located on the bottom right on the back of the machine SW2 Front Cover Detects opening of front...

Page 28: ...Power supply unit Supplies AC power to Fusing lamp and optical heater and DC power to the system Solenoid SOL1 Multipurpose Tray feeding Controls multipurpose Tray s feeder roller operation SOL2 Duple...

Page 29: ...The machine has one main motor and the rotation of this motor is delivered to the train of gears composed with various gears to operate developer drum manual feeder fusing unit duplex unit resist rol...

Page 30: ...machine s front door is opened the link connected to the front door moves in the direction of 1 Lever no 2 moves consecutively by the moving link and the Oldham lever and dog bone lever each pull the...

Page 31: ...connecting to the cartridge Removing Fusing Paper Jam 1 Removing paper from back of fuser unit Gear link is pushed to the back disconnecting gear and allowing jammed paper to be removed 2 Removing pa...

Page 32: ...tor I Reflection Mirror E 1 F theta lens J OPC Drum Laser Diode Unit Generates laser beam Collimator lens Converts dispersed laser beams to straight beam Cylindrical Lens Concentrates sub scanning dir...

Page 33: ...acturer QSI LD Form No QL78F6DF LSU NOTICE This machine is approved by US for in compliance with DHHS21 CFR Subchapter J regulations for class 1 laser products and IEC 60825 1 regulations in other cou...

Page 34: ...d can be separated Drum cartridge does not have a separate chip but toner cartridge has a separate information chip to store toner counter and manufacturer information The machine refers to the inform...

Page 35: ...omponents A toner cartridge consists of a Development roller Add roller and a Doctor blade as shown above and has a Paddle roller carrying toner to add roller Doctor blade allows toner supplied to Dev...

Page 36: ...eration When the driving force of main motor A is delivered to development coupler driving gear B the Oldham type coupler C rotates As a result the driving force of the main motor is ultimately delive...

Page 37: ...roller again via charging roller spring G and conductive roller bushing H Drum surface gets charged with about 900V with this charged voltage Also 200V of core voltage is applied to drum and this vol...

Page 38: ...t with a new one you may be able to continue using the old drum cartridge but the printing quality cannot be guaranteed Toner Cartridge Like a drum cartridge a toner cartridge is calculated based on t...

Page 39: ...papers there is a load limit line indication Main Tray Components and Feeding and Separating Mechanism Main Tray consists of the following 6 components Role of each component is specified below 1 Bas...

Page 40: ...ar to the pickup roller 3 Pickup Roller Bushing Holds the pickup roller s position from both ends of picku p roller 4 Pickup Electromagnetic Clutch The electromagnetic clutch operates at the time of f...

Page 41: ...ed pressure between the pickup roller and the base plate is rubbed against the friction pad and by this paper is separated and fed one sheet at a time The front part of a paper is fed up to the transf...

Page 42: ...le paper can be categorized as Special Paper because of its curl Hold the rear fence lever to move the rear fence Legal paper in particular must have the rear fence wall expanded In this case set the...

Page 43: ...e pickup roller fails to turn on the input sensor after having rotated once it rotates one more time If paper fails to turn on the input sensor even after the pickup roller has rotated twice the print...

Page 44: ...hen loading paper in the tray for the 500 sheet option or in KARA S adjust the side and rear fences to fit the paper size in order to prevent gaps within the cassette Paper loading limits for thick or...

Page 45: ...r Supplies power for pickup roller rotation and adjusts feeding speed by setting the timing 7 Power transfer A ssy Accufeed arm A ssy Positioned between pickup motor and roller to transfer power from...

Page 46: ...after this process Feeding Transfer Mechanism When a feeding signal is entered from the main body the pickup motor of the selected tray begins to operate The pickup roller rotates picking up the top s...

Page 47: ...ray has fed all the paper inside the paper detection sensor operates and displays a Paper Low message Side Fence Rear Fence Operation Hold right side fence lever and right side fence to move the side...

Page 48: ...the fence To load paper hold the rear fence lever and push it back as far as possible align the front part of paper to the separation dam then hold the lever again and move it to fit the edge of the...

Page 49: ...t 3 statuses Paper Full Paper Low and Empty and display these messages on the LCD screen Sensor 1 Sensor 2 Stack Paper Full 10 100 Paper Low Near End under 10 Paper End 0 sheet Paper End Light Exposur...

Page 50: ...d to the paper size detection sensor Switch sensor 3EA enters the hole in the end fence for paper detection If the finger can enter the hole the sensor detects 0 If the finger cannot enter the hole th...

Page 51: ...xtension all the way and adjust side fences to the paper size to have no gaps Paper load limit lines are marked separately for postcards envelops labels and other special paper MPT Components The MPT...

Page 52: ...s the base plate rises by base plate spring to generate feeding force by contacting loaded paper with pickup roller and allows loaded paper to be fed in orders from top by pickup roller s rotation Whe...

Page 53: ...ition by torsion sprint for sensor flag to isolate the light and causing the sensor s output value to change The printer detects paper presence with this sensor s output value Paper Jam Detection If t...

Page 54: ...nts Role of each component is as follows 1 Upper Body Acts as upper ribs to allow paper to pass through easily A roller is installed to partially correct skews 2 Front Body Guides paper in the reverse...

Page 55: ...rtially correct skews 2 Front Body Guides paper in the reverse section bottom up to the EP frame upper and supports the base body with a spring fixture 3 Base Body Corrects skew to allow front part of...

Page 56: ...method The paper is re aligned to the left by a tilted roller in the reverse section Letter or A4 Paper Jam Detection A610DN When there is a paper jam in the reverse section of the duplex unit remove...

Page 57: ...x unit press down the handle on the jam remove cover in the center to remove paper with ease If you cannot see the paper when the jam remove cover is open open the rear cover and remove the jammed she...

Page 58: ...d reaches the output roller The forward backward bracket is activated by the solenoid operating in the output unit and the output roller rotates in reverse Paper is then transferred to the duplex sect...

Page 59: ...uide The paper then is delayed temporarily by the resist dams 4 Feeding has been delayed by the resist dams but the paper continues to be transferred by pickup roller rotation This and the delay by th...

Page 60: ...user Unit Components The fuser unit and paper exit area consist of the following parts 1 Fusing Roller 2 Pressure Roller 3 Heater 4 THERMOSTAT 5 THERMISTOR 6 Separator 7 Entrance Guide 8 Exit Guide 9...

Page 61: ...h paper type Fusing temperature is configured differently for each paper but may be changed within a certain range by the user Heater power is turned OFF when an error occurs or when printer enters Po...

Page 62: ...be smeared on paper Be sure to restore the pressure lifting lever after printing envelops Output Unit Overview The output unit is the last part of the printer that moves paper to the output bin It is...

Page 63: ...ge and small output gears and the forward reverse bracket 7 Screw 8 Output Shaft 4 rollers inserted in sum shaft assembled that are connected to the gear and rotate with the idle roller assembled in t...

Page 64: ...ses through the fusing roller and the middle output roller by the rotating output shaft before finally reaching the exit Each shaft always rotates when the main motor operates in order to give paper l...

Page 65: ...rive unit always rotates forward the forward reverse bracket is operated by solenoid operation in order to print 2 sides by reversing delivery unit The left image below shows that solenoid is turned o...

Page 66: ...62 Forward Rotation Reverse Rotation Fuser Driving Gear Solenoid Activated Fuser Driving Gear...

Page 67: ...nt Part Overview Operational Panel Unit OPU Components and Main Functions A610DN Block Diagram of Components Pin Array I F Connector PIN No Signal Description 1 VCC5V 5V POWER 2 GND GND 3 UICC_IRQ INT...

Page 68: ...sic components of OPU and their functions are as follows 1 R5F212A7SNFA of MCU uses 8 Mhz external clock to communicate with system card by SPI Communication standard is 32KHz SPI 2 OP consists of 7 k...

Page 69: ...anel Unit OPU Components and Main Functions A611DN Block Diagram of Components Pin Array I F Connector CN2 PIN No Signal Description 1 VCC5V 5V POWER 2 UICC_TXD UART TX Signal for sending data to SYST...

Page 70: ...ion 1 VBUS USB POWER 2 D USB D DATA 3 D USB D DATA 4 GND GND 5 SHIELD1 USB SHIELD GND 6 SHIELD2 USB SHIELD GND Components and Basic Functions OPU s basic components and their functions are as follows...

Page 71: ...tching element 4 SOC in the system card and the LCD controller in LCM LCD module exchange signals via 4 bit parallel method 5 LCD s backlight uses S8050 NPN TR as a switching element to control on and...

Page 72: ...68 2 LCM Connection Part...

Page 73: ...69 3 Button Input 4 LED Drive...

Page 74: ...70 5 Backlight Control 6 POWER BUTTON POWER LED...

Page 75: ...al and NAND flash System Main Clock uses 24MHz external and 360MHz internal SOC with each function module built in performs following functions Motor Control It controls BLDC motor to control the cont...

Page 76: ...ND 3 CN41 BLDC_M NO Signal Description 1 S GND SIGNAL GND 2 BLDC_FG F B signal for checking motor rotation standard 3 BLDC_CLK Standard clock for motor 4 BLDC_ST Motor ON signal 5 BLDC_LD Detects arri...

Page 77: ...ND GND 5 24V 24V Power 6 CN48 LSU_IF NO Signal Description 1 GND GND 2 nHSYNC_H Sync detection signal 3 GND GND 4 5V 5V Power 5 5V 5V Power 6 GND GND 7 DT1P Image LVDS Data 8 DT1N Image LVDS Data 9 GN...

Page 78: ...HR_PSU Fusing Heater ON signal 14 XZEROX Zero Cross Signal 15 PS_24V 24V Power Save Signal 8 CN25 MAIN FAN NO Signal Description 1 MAIN_FAN FAN ON Signal 2 MAIN_FAN_BACK Detects arrival of set RPM 3...

Page 79: ...signal from UI 5 UI_TXD1 UART TX Data signal to UI 6 GND GND 7 UI_SCK UI Communication control clock signal 8 UI_CS UI Select signal 9 POWER BUTTON UI POWER BUTTON Signal 10 5V 5V Power 11 POWER BUTT...

Page 80: ...MPT 5 GND GND 6 5V 5V Power 17 CN45 FULL STACK_S NO Signal Description 1 FULL STACK_S Detects full paper stack 2 GND GND 3 5V 5V Power 18 CN13 Fuser Exit_S NO Signal Description 1 THERMISTER Detects...

Page 81: ...the following functions Motor Control Controls BLDC motor to control the drive unit UICC Control unit I F Uses the built in UART I F module to control the control unit Optional Tray I F Uses the built...

Page 82: ...GND GND 3 CN41 BLDC_M NO Signal Description 1 S GND SIGNAL GND 2 BLDC_FG F B signal for checking motor rotation standard 3 BLDC_CLK Standard clock for motor 4 BLDC_ST Motor ON signal 5 BLDC_LD Detect...

Page 83: ...ND GND 5 24V 24V Power 6 CN48 LSU_IF NO Signal Description 1 GND GND 2 nHSYNC_H Sync detection signal 3 GND GND 4 5V 5V Power 5 5V 5V Power 6 GND GND 7 DT1P Image LVDS data 8 DT1N Image LVDS data 9 GN...

Page 84: ...SU Fuser heat ON signal 14 XZEROX Zero cross signal 15 PS_24V 24V Power save signal 8 CN25 MAIN FAN NO Signal Description 1 MAIN_FAN FAN ON signal 2 MAIN_FAN_BACK Detects arrival of set RPM 3 GND GND...

Page 85: ...scription 1 5V 5V Power 2 UI_RXD1 UART RX Data signal from UI 3 UI_TXD1 UART TX Data signal to UI 4 GND GND 5 GND GND 6 POWER BUTTON UI POWER BUTTON signal 7 GND GND 8 5V 5V Power 9 POWER BUTTON _LED...

Page 86: ...TY_MPT_S NO Signal Description 1 EMPTY_S Tray paper detection 2 GND GND 3 5V 5V Power 4 MPT_S MPT paper detection 5 GND GND 6 5V 5V Power 19 CN45 FULL STACK_S NO Signal Description 1 FULL STACK_S Full...

Page 87: ...aper Size Detect Switch NO Signal Description 1 Paper_Size_Detect_SW3 Paper size detection sensor 2 GND GND 3 Paper_Size_Detect_SW2 Paper size detection sensor 4 Paper_Size_Detect_SW1 Paper size detec...

Page 88: ...ain output constant voltage 6 Photo Triac Control the heater in the machine to turn on and off 7 Fuse 1st 2nd Protect rear circuit on over current lead in Pin Array 1 INLET AC SW Connector No Connecto...

Page 89: ...or Name Pin No Signal Name Image CN2 HEATER CONNECTOR 1744056 3 AMP Or Equivalent 1 HEATER_L 2 removed 3 HEATER_N Spacing for no 2 pin from total of 3 pins to secure isolation distance 3 DC Connector...

Page 90: ...Range nominal 220 240Vac Voltage min max 198 264Vac Nondestructive Voltage 187 276Vac Input Current AC DC 3 9A DC TBD Input Power Energy Saver Mode Over 55 efficiency on energy saver mode Rush Curren...

Page 91: ...ation for minimum of 30 min 3 5A Maintain operation for minimum of 30 min Peak Output Current 6 0A 2nd Rush Current Surge Current 20A 50uS min Total Max Output Power 10 0W 86W Static Mutual Load Varia...

Page 92: ...d Main Functions Block Diagram of Components Pin Array Refer to DC connector part from LVPS pin array Basic Functions 1 Channels HVPS is composed with 4 DC DC converters and with 7 channels of chargin...

Page 93: ...nel always maintains 200V versus GND using zener diode 9 DEV PWM It controls DEV TR and BL channel voltages TR and BL voltages use zener diode to always maintain DEV 120V and DEV 300V versus DEV outpu...

Page 94: ...90 2 AC DC Rectification Unit 3 24V Output Unit...

Page 95: ...91 4 5V Output Unit 5 AC Drive Section 6 Switching Unit...

Page 96: ...92...

Page 97: ...93 Circuit Diagram HVPS Input Section 1 PWM Input Section 2 RCC Control Drive Section...

Page 98: ...94 3 High Voltage Output 4 TX SENSING Unit...

Page 99: ...in power switch off and remove power cord and network cable from the machine Be careful not to lose bolts when disassembling and see harness path to handle paths identical when reassembling Assembly s...

Page 100: ...om the main body be careful not to damage 4 hooks inside the cover Left Cover 1 Remove rear door and cover from the main body 2 Open front cover and unlock the hook under the main body Pull cover up t...

Page 101: ...t to damage 8 hooks inside the cover when removing the left cover Right Cover 1 Remove rear door and cover from the main body 2 Unlock the 4 hooks under the main body and pull the cover to separate fr...

Page 102: ...98 Be careful not to damage the 7 hooks inside the cover when removing the right cover...

Page 103: ...cted to the CN30 connector on main board and remove Control Panel from the frame Be careful not to disconnect harness wires when removing the harness from the connector Be careful not to damage flat h...

Page 104: ...so to the left and remove it from the frame When reassembling push the left and right hinges to frame s right side to fixate it and connect 3 links Top Cover 1 Remove the rear cover and the left and r...

Page 105: ...side of the frame and lift the top cover up to remove it from the machine Output Cover 1 Remove the rear cover 2 Remove 2 bolts on the left and right side on the frame and pull it forward to remove t...

Page 106: ...eam Removing Laser Unit Please check if main power switch has turned off and power cable is pulled from outlet before disassembling or adjusting the laser unit 1 Open front door 2 Remove rear cover 3...

Page 107: ...unit from frame Laser unit removed Installing Laser Unit 1 Place laser unit on frame 2 Before tightening the laser unit with screws use skew JIG A to position the laser unit and tighten 4 screws B Sc...

Page 108: ...er unit s alignment and proceed with the Laser Unit Adjustment before installing the top cover Aligning Laser Optical Housing Unit When replacing the laser unit with a new one please proceed with foll...

Page 109: ...Put 1 hole on A to 1 EMBO shape on B 2 Put bump on C floor through 2 shape on A to 2 hole on B 3 Rotate C to circumferential direction to match the end of the arrow on the bottom of C with hole around...

Page 110: ...106 Main Driving A ssy Unit Removing Main Driving Gear Unit 1 Remove link with front cover towards machine 2 Remove MPT segment gear outward pushing hook 3 Remove motor harness connector motor Part...

Page 111: ...107 4 Remove MPT Solenoid connector mainboard part 5 Remove fixing bolts 5 from the mainboard BKT and push BKT to the left to reveal bolt heads...

Page 112: ...108 6 Remove bolts 8 on the left frame that connect the driving A ssy and remove entire A ssy away from the machine Be careful not to damage or change gear when extracting A ssy Proceed in reverse...

Page 113: ...109 order to reassemble Removing Main Motor 1 Remove 3 bolts that fix the big gear BKT and remove the big gear BKT A SSY 2 Remove the 4 bolts that fix the motor Reassemble in reverse order...

Page 114: ...cover of the machine 2 Hold the development unit handle and pull it upward to remove it Separating Drum Unit and Development unit 1 Press and hold the A development unit pressure release lever down a...

Page 115: ...t it up to remove the transfer roller Be careful not to touch the transfer roller while disassembling Fuser Unit Removing Fuser Unit Turn off main switch and wait until the fuser unit has cooled down...

Page 116: ...112 4 Separate 3 connectors marked by red circles...

Page 117: ...y from the machine Assemble in revers order Replacing the Fuser Lamp 1 Open the front door 2 Remove the rear cover 3 Remove fuser assembly from the machine 4 Remove the 3 screws A and remove the press...

Page 118: ...e the 2 removed fuser assembly side covers 6 Remove the cover and unscrew 2 screws fixing the fuser Lamp Replacing the Thermostat 1 Open front door and rear cover 2 Remove fuser assembly 3 Remove the...

Page 119: ...the Cleaning Roller 1 Open rear door 2 Press red circled parts A in the cleaning roller BKT and remove from the main body A 3 To assemble place the cleaning roller A SSY in the correct position and pr...

Page 120: ...Sub Fan 1 Open the front door and remove the right cover from the frame 2 Remove the 2 bolts tightened on the Sub Fan duct and remove from the right frame Be careful not to switch left and right when...

Page 121: ...117 MAIN FAN SUB FAN...

Page 122: ...Main Feed Roller A610DN 1 Open the front door and separate the link 2 Remove the left cover 3 Remove 3 screws to separate segment gear A and bypass solenoid A ssy 4 Remove the driving gear A ssy 5 Rem...

Page 123: ...119 6 Turn the bushing fixing the pickup shaft on the main body to remove 7 Press the frame on the left of the pickup roller to remove the bushing and remove the pickup roller...

Page 124: ...120 Paper Detection Sensor A610DN 1 Separate the feeder and remove one screw at the bottom of the machine to remove it Separating the Main Feeding Roller A611DN 1 Pull the tray 2 Press Accufeed A ssy...

Page 125: ...121 3 Press left and right hooks and remove the feeding roller A ssy 4 Pickup roller A ssy removed 5 Pickup tire removed...

Page 126: ...1 Open the front door and disconnect the link connected with the machine 2 Push the front door to the left to remove it from the machine 3 Remove 2 screws to separate door open shaft 4 Separate MPT f...

Page 127: ...2 Separate the harness connected to the left paper detection sensor 3 Separate MPT s bottom body A ssy to replace friction pad A ssy Removing the MPT Paper Detection Sensor 1 Separate MPT s bottom bo...

Page 128: ...and clutch A ssy 3 Remove the metal clamp A contacting with pick roll shaft 4 Remove the bush holding pickup roll shaft to the right 12 o clock direction and remove it 5 Separate the top body A ssy wh...

Page 129: ...125 6 Remove both caps on shaft ends and paper top guide and E ring to separate arm from the shaft 7 You can remove and replace the pickup roller and idle roller...

Page 130: ...d separate feeding unit from the machine Before removing the tray unit from the machine the machine s power must be turned off 2 Separate the tray unit and remove 4 screws 3 Separate the connector to...

Page 131: ...te right cover Be careful not to damage the hook inside of top right cover Removing the Optional Tray Pickup Roller A610DN 1 Flip the tray 2 Push down the plastic preventing bush separation and remove...

Page 132: ...Remove the bushing on the other side the same way 4 Disassembled pickup roller Removing Optional Tray Feeding Roller A610DN 1 Remove one E ring and 4 screws to separate left board and motor mounted br...

Page 133: ...129 2 Remove the segment gear A and gear B 3 Remove one screw to remove pickup shaft holder C 4 Rotate the pickup shaft bushing to right to remove pickup shaft and 2 screws...

Page 134: ...130 5 Remove 2 screws on the top right of pickup A ssy 6 Separate the pickup A ssy Lift the right side to remove harness through the frame hole...

Page 135: ...131 7 Remove E ring and bushing to remove feeding roller shaft...

Page 136: ...t Cover A611DN 1 Remove the tray cassette and remove the feeding unit from the main body Turn off the power of the machine before removing the feeding unit from the main body 2 Remove the tray and rem...

Page 137: ...133 Removing the Optional Tray Pickup Roller A611DN 1 Pull out the tray 2 Press Accufeed A ssy 3 Press left and right hooks and remove the feeding roller A ssy 4 Disassembled pickup roller A ssy...

Page 138: ...134 5 Disassembled Pickup Tire...

Page 139: ...ving the Optional Tray Return Unit A611DN 1 Remove 5 harnesses and unscrew A and B 2 Press the 2 hooks on the top cover and remove the top cover 3 Remove 4 screws B and separate the transport unit Har...

Page 140: ...136 4 Remove the 2 harnesses on the separated transport unit remove 2 screws B and remove the driving A ssy 5 Hold the E ring on the pickup shaft s right and remove the one way clutch B...

Page 141: ...137 6 Remove the E Ring and bushing and separate the feeding roller shaft...

Page 142: ...ove 5 screws A 2 Remove from the hole in the hook Accufeed BKT on the motor cover and remove the Accufeed BKT Handle the harness and spring carefully when separating 3 Remove the E ring on the left of...

Page 143: ...prings from the 7 holes from the Accufeed starting at the front Press the hook on the auto comp and remove the feeder 6 Remove the Accufeed unit and paper detection sensor from which the harness has b...

Page 144: ...140 7 Remove the E ring on the left and remove the shaft 7 Auto comp and arm A ssy disassembled from shaft 8 Remove 2 screws C and separate the motor 9 Separated auto comp and motor C...

Page 145: ...141...

Page 146: ...142 Resist Guide A ssy 1 Disconnect 2 springs A connected to the resist guide A ssy at the bottom of the machine 2 Tilt the resist guide A ssy 60 and pull forward to remove...

Page 147: ...Remove screw A and spring B from the bottom part of the machine and disconnect the spring C 2 Push the coupler D outward to remove 2 Hold and lift the cover from which the coupler has been removed and...

Page 148: ...e the rear cover 2 Remove the two screws fixing the output frame and press the fuser output guide down to separate the output frame 3 Remove 2 screws and replace the fuser driving gear You can remove...

Page 149: ...overs 5 Remove the top cover and replace the idle roller inside Duplex Unit A610DN Removing the Duplex Unit 1 Remove the main and optional trays from the main body 2 Press the base body of the duplex...

Page 150: ...to damage the hook 1 hook on either side 5 Tilt the machine upright and remove the base body of the duplex unit When removing press the unit to avoid being hooked by the cassette clip at the back of...

Page 151: ...147 7 Remove the right cover 8 Remove PDU and screw A 9 Remove the pickup roller A ssy 10 Remove screws A and B to remove the front guide of the duplex unit...

Page 152: ...the duplex unit after removing screws To install the duplex align the front body with the grooves in the frame 12 Replace with a front body that does not have a white holder and install on the main bo...

Page 153: ...plex Unit A611DN Removing the Duplex Unit 1 Turn off power and remove power and USB cables from device 2 Remove main tray IC and optional tray from the main body 3 Open rear cover and loosen bolts to...

Page 154: ...150 4 Loosen bolts on both sides and remove the exit frame 5 Undo the ground connecting harness bolt in the fuser frame...

Page 155: ...151 6 Stand machine on its side and remove 2 frame fixing Press BKT 4 bolts each 7 Remove 3 bolts fixing the Accufeed unit and base BKT...

Page 156: ...152 8 Remove the E ring holding the shaft 9 Remove Accufeed spring Use sharp tool...

Page 157: ...153 10 Push the Accufeed unit to the left to remove 11 Stand the jam removal cover horizontally and remove the right hinge first...

Page 158: ...sition Insert a screwdriver into the left of the base bracket seen from the rear Push driver in and remove 13 Stand device on its side again and loosen the bolts fixing the upper BKT and EP frame Rein...

Page 159: ...over 3 Separate 15 harnesses from the connector and 4 bolts and the main board Be careful not to disconnect harness wires when removing the harness from the connector When disassemble take caution on...

Page 160: ...from the connector Be careful not to damage flat harness on control panel Refer to the harness path to main board to reassemble When disassembling OPU make sure not to lose LED indicator below the but...

Page 161: ...ved replace the Fusing unit 301 Fuser under temperature while at standby OccursOccurs when Fusing temperature is lower than the set temperature for more than 10 seconds during stand by 1 Check the har...

Page 162: ...riving motor unit 2 If the problem is not solved replace the driving motor unit 330 Fan motor lock failure OccursOccurswhen fan motor does not reach target speed within the configured time 1 Check the...

Page 163: ...heck reoccurrence after POR 2 Replace the system card 202 Memory Full Occurs when memory is full 1 Check reoccurrence after POR 2 Replace the system card 211 Defective Flash Occurs when flash drive ca...

Page 164: ...s sent to Tray 2 while there s no paper option tray 1 Check the operation status of tray 2 empty sensor flag 2 Check if tray 2 empty sensor is operating Diagnosis Mode 3 If it does not operate replace...

Page 165: ...nsor within a certain time after pick up attempt from MPT Even if 102 paper jam occurs when pickup from MPT fails there might be a jammed paper on the paper path 1 Check if papers are loaded properly...

Page 166: ...Check if there s an obstacles on Duplex Unit s paper path 2 Check if duplex solenoid operates properly 3 If it does not operate replace the solenoid and test again 4 Check if entrance sensor works pro...

Page 167: ...h standby temperature Occurs when Fusing temperature does not reach stand by temperature within 90 seconds after POR 1 Check the harness between Fusing and power unit 2 Check the harness between syste...

Page 168: ...he fan unit 331 Sub Fan motor lock failure Occurs when drum fan motor fails to reach target speed in set time 1 Check the harness between system card and fan unit 2 If the problem is not solved replac...

Page 169: ...th than the length assigned from driver User Interactive Messages Paper Jam Messages 1xx Message Description Re Insert Cartridge Occurs when printer has failed to recognize cartridge or when cartridge...

Page 170: ...age is displayed if MPT has failed to pick up paper there may not be a paper jam in the path 1 Check whether paper has been properly loaded in the tray check tray guide condition 2 Check whether the t...

Page 171: ...Miss Feed Jam Occurs when paper fails to reach the entrance sensor within set time after being picked up from optional tray Although 103 Tray3 Miss Feed Jam message is displayed if the optional tray h...

Page 172: ...curs when paper s bottom does not get out the delivery sensor within a certain time 4 Check if there s an obstacle on paper delivery path after the delivery sensor 5 Check if delivery sensor works pro...

Page 173: ...ray option tray and bypass tray and paper discharge direction See the Paper Jam Message described above for details A610 615DN A611 616DN Slowly and softly pull the jammed paper to not to tear the jam...

Page 174: ...f file may be broken Solution If error has occurred while printing an image file check the file name and USB Disk Check if BMP or Gif files are read properly on your PC 01 xxx Engine related Errors Ty...

Page 175: ...d clean cartridge Check the condition of the spring in the connection unit Type Error Code 01 007 Client Description Media Size Mismatch Error Selected paper size does not match paper size in tray Sol...

Page 176: ...eed in Tray2 Optional Tray Solution Check for obstacles in Tray2 paper path torn paper etc Check condition of Pick up Roller or Tray Pad If Tray2 Empty Sensor is faulty paper pickup from empty tray ma...

Page 177: ...s in paper path Type Error Code 01 206 Client Description Engine Jam 106 Output Sensor failed to detect end of paper Occurs when the end of paper failed to leave Output Sensor Solution Check for obsta...

Page 178: ...his image file is unusable Type Error Code 05 003 Client Report Client Description Width Length ratio of image is smaller than 1 5 or larger than 5 Length of image is too large to be processed Solutio...

Page 179: ...sed Type Error Code 05 008 Client Report Client Description File data could not be read USB Memory may have been broken while printing Solution Check the file size Copy to a new USB and retry 06 xxx F...

Page 180: ...176 Type Error Code 06 681 Client Host Print GDI PDL Description MPT Empty Error Solution Load MPT and press Start on UI to proceed...

Page 181: ...as too big Wrong text value in Report Solution If an error has occurred while printing the file is not supported Report printing error Re update code and refresh file system Type Fatal Code 00 003 Cli...

Page 182: ...n Unknown S W memory error This error may include Printing Stop Solution Reboot and retry Type Fatal Code 00 008 Client Function Process Description Printer S W malfunctioned during operation Uncommon...

Page 183: ...n Page Print Solution Request for technical support Error while printing Report Skew Quality Reboot If problem recurs update code and refresh file system Type Fatal Code 00 100 Client Function Process...

Page 184: ...e 00 107 Client HostPrint OPL HostPrint PDL Description Not enough memory for printing This error does not occur in normal situations LIPP S W may have wrong calculation Not related to device Printing...

Page 185: ...erature drops while on standby Solution Reboot and retry Replace Fuser Unit if problem persists Type Fatal Code 01 412 Client Description Engine Fuser 302 Fatal Error Fuserfailed to reach standby temp...

Page 186: ...ccurs when device fails to detect LSU sync Solution Reboot and retry Replace LSU if problem persists Type Fatal Code 01 501 Client Description Engine Feed Motor Fatal Error Occurs when main motor fail...

Page 187: ...nit failed to reach fixed speed Solution Reboot and retry Replace Main Fan if problem persists Type Fatal Code 01 505 Client Description Engine Sub Fan Motor Fatal Error Occurs when Sub Fan small fan...

Page 188: ...d in this chapter you need to enter Diagnosis Mode The configurations and operations used for machine manufacturing and servicing are included in the Diagnosis Mode group Entering Diagnosis Mode 1 Tur...

Page 189: ...ack Top Margin Magnification Horizontal Vertical Print Skew Page Print Skew B Se Beam Adjust Drum Lock Enable Hardware Test Sensor Test Solenoid Test Quality Pages Printer Setup Page Count Perm Page C...

Page 190: ...or on Motor rotation time not including printing time sec REGISTRATION Margin Adjustment To print margin adjustment 1 Select REGISTRATION from Diagnosis Mode 2 Select Margin Adjust 3 Select a value to...

Page 191: ...value and press Select key Magnification ranges that can be configured are as the following 1 unit 0 5 Description Value Vertical Magnification 5 5 default 0 Horizontal Magnification 5 5 default 0 5...

Page 192: ...Life Page Count Default option is ON Drum Lock Error occurs when recommended drum usage has been exceeded and is Disabled HARDWARE TESTS Button Test 1 Select Button Test from diagnosis mode 2 To test...

Page 193: ...over open close message appears normally the status of cover switch is normal If message is not displayed properly there s a problem with cover switch status and it needs to be inspected Solenoid Test...

Page 194: ...age is a print quality checking page For checking skew For checking print quality PRINTER SETUP Page Count You can check and modify the page count value To modify the page count 1 Select Page Count fr...

Page 195: ...1 and oldest is on position 12 when 12 errors have occurred When the log is full and an error occurs the oldest error gets deleted To view error log 1 Select Display Log from Error Log menu Error log...

Page 196: ...mples of an error log 01 205 Engin jam on input output sensor See Error code list Error type Recoverable Non Recoverable Uptime 1 day 12 hour 03 min 25 sec Time after ON KARA No internal battery Time...

Page 197: ...enter Diagnosis Mode The configurations and operations used for machine manufacturing and servicing are included in the Diagnosis Mode group Entering Diagnosis Mode 7 Turn on the power 8 Press 1 0 and...

Page 198: ...argin Gap Beam Adjust Hardware Test Quality Pages Sensor Test Solenoid Test T1 motor test T2 motor test T3 motor test Printer Setup Page Count Perm Page Count Error Log Print Log Clear Log Port filter...

Page 199: ...r of pages printed compared to toner capacity Free motor on Motor rotation time not including printing time sec Margin Adjust Margin setting of device Magnification Magnification setting of device Bea...

Page 200: ...Select Magnification 8 Select a value from either Vertical or Horizontal 9 Press the arrow keys to set desired value and press Select key Magnification ranges that can be configured are as the follow...

Page 201: ...e for left margin for double sided Letter 2 Margins printed are as follows Margins can be modified to 1 unit 0 2mm Category Value Top Margin 25 25 Left Margin 25 25 Beam Adjust Adjust LSU Beam Power l...

Page 202: ...ng skew For checking print quality Page Count You can check and modify the page count value To modify the page count 4 Select Page Count from PRINTER SETUP menu 5 You can increase or decrease a 100 di...

Page 203: ...r test mode the status will be displayed on LCD For example if you press the MPT Empty Sensor during the sensor test mode and MPT On Off message appears normally the status of cover switch is normal I...

Page 204: ...RDWARE TEST in Diagnosis Mode 2 Select T1 motor test Entered Tray 1 Motor Test Mode Test begins Once Tray 1 Motor Test begins Tray1 Pickup DC motor is turned ON then OFF automatically after 1 second T...

Page 205: ...r Tray3 Transport motor To perform Tray 3 Motor Test 1 Select HARDWARE TEST in Diagnosis Mode 2 Select T3 motor test Entered Tray 3 Motor Test Mode Test begins Once Tray 3 Motor Test begins Tray3 Pick...

Page 206: ...enable filter This means you can no longer use this port Select Disable to disable filter This means you can use this port FTP 1 Enable Filter On Port Disabled 2 Disable Filter Off Port Enabled SSH 1...

Page 207: ...1 Enable Filter On Port Disabled 2 Disable Filter Off Port Enabled RAW 1 Enable Filter On Port Disabled 2 Disable Filter Off Port Enabled ALL 1 Enable Filter On Port Disabled 2 Disable Filter Off Port...

Page 208: ...r on your PC 1 Turn on printer 2 Set printer as default in Printer Fax 3 Run FirmwareDownload_log exe in Windows 4 The following download window will appear 5 Click Download Send reset Send data butto...

Page 209: ...Thumb Drive to the printer s USB port next to LCD 3 Click OK when the following message appears on the printer s screen 4 Wait for update to be completed 6 Check the following screen once update has...

Page 210: ...ng the download program 1 Turn the power off and plug Shunt on arrow to tray board as above figure 2 Connect 1 set of download cable as the figure and connect it to serial port on PC 3 When setting is...

Page 211: ...appears click Exit button 2 Turn the power off and remove the Shunt and download cable 1 set on tray board Step 1 Click OK Step 2 Click Refer and select and run ABBAbank mot file from the folder Step...

Page 212: ...208 from step 1...

Page 213: ...e printer on 2 Set the printer as default printer from Printer and Fax window 3 Run FirmwareDownload_log exe file from Windows 4 A download window appears as below 5 Click Download Using Send reset or...

Page 214: ...lick OK when the following message appears on the printer s screen 4 Wait for update to be completed 6 Check the following screen once update has been completed Remove USB Thumb Drive and turn on prin...

Page 215: ...before running the download program 4 Turn the power off and plug Shunt on arrow to tray board as above figure 5 Connect 1 set of download cable as the figure and connect it to serial port on PC 6 Wh...

Page 216: ...dow appears click Exit button 2 Turn the power off and remove the Shunt and download cable 1 set on tray board Step 1 Click OK Step 2 Click Refer and select and run ABBAbank mot file from the folder S...

Page 217: ...213 from step 1...

Page 218: ...214 Copyright Material SERVICE MANUAL A610 A611 Printed January 22 2014 Issued January 22 2014 Published by SINDOH Co Ltd...

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Sindoh A610 Series, Service Manual

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Summary of Contents for A610 Series

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