DP-2800

DP-2800

SERVICE
MANUAL
Published in June 98
5A270760

DP-2800 (MCA) S/M

SERVICE
MANUAL
DP-2800

Safety precautions

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

Safety warnings and precautions

Various symbols are used to protect our service personnel and
customers from physical danger and to prevent damage to their
property. These symbols are described below:

DANGER: High risk of serious bodily injury or death may result from
insufficient attention to or incorrect compliance with warning
messages using this symbol.
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 including
danger and caution. The specific point of attention is shown
inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is
shown inside the symbol.
General prohibited action.
Disassembly prohibited.

indicates that action is required. The specific action

required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.

1. Installation Precautions
WARNING
Do not use a power supply with a voltage other than that specified.
Avoid multiple connections to one outlet: they may cause fire or electric
shock. When using an extension cable, always check that it is
adequate for the rated current. ..............................................................
Connect the ground wire to a suitable grounding point. Not grounding
the copier may cause fire or electric shock. Connecting the earth wire
to an object not approved for the purpose may cause explosion or
electric shock. Never connect the ground cable to any of the following:
gas pipes, lightning rods, ground cables for telephone lines and water
pipes or faucets not approved by the proper authorities. ......................

CAUTION
Do not place the copier on an infirm or angled surface: the copier may
tip over, causing injury. ..........................................................................
Do not install the copier in a humid 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 locations when moving it. ...
Always use anti-toppling and locking devices on copiers so equipped.
Failure to do this may cause the copier to move unexpectedly or
topple, leading to injury. .........................................................................
Avoid inhaling toner or developer excessively. Protect the eyes. If toner
or developer is accidentally ingested, drink a lot of water to dilute it in
the stomach and obtain medical attention immediately. If it gets into the
eyes, rinse immediately with copious amounts of water and obtain
medical attention. ..................................................................................
Advice customers that they must always follow the safety warnings
and precautions in the copiers instruction handbook. ...........................

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 attempt to bypass or disable safety features
including safety mechanisms and protective circuits. ............................

Always use parts having the correct specifications. ..............................

Always use the thermostat or thermal fuse specified in the service
manual or other related brochure when replacing them. Using a piece
of wire, for example, could lead to fire or other serious accident. .........
When the service manual or other serious brochure specifies a
distance or gap for installation of a part, always use the correct scale
and measure carefully............................................................................
Always check that the copier is correctly connected to an outlet with a
ground connection. ................................................................................

Check that the power cable covering is free of damage. Check that the
power plug is dust-free. If it is dirty, clean it to remove the risk of fire or
electric shock. ........................................................................................
Never attempt to disassemble the optical unit in machines using lasers.
Leaking laser light may damage eyesight. ............................................
Handle the charger sections with care. They are charged to high
potentials and may cause electric shock if handled improperly. ............

CAUTION
Wear safe clothing. If wearing loose clothing or accessories such as
ties, make sure they are safely secured so they will not be caught in
rotating sections. ...................................................................................
Use utmost caution when working on a powered machine. Keep away
from chains and belts. ...........................................................................
Handle the fixing section with care to avoid burns as it can be
extremely hot. ........................................................................................
Check that the fixing unit thermistor, heat and press rollers are clean.
Dirt on them can cause abnormally high temperatures. ........................
Do not remove the ozone filter, if any, from the copier except for
routine replacement. ..............................................................................
Do not pull on the AC power cord or connector wires on high-voltage
components when removing them; always hold the plug itself. .............
Do not route the power cable where it may be stood on or trapped. If
necessary, protect it with a cable cover or other appropriate item. .......
Treat the ends of the wire carefully when installing a new charger wire
to avoid electric leaks. ...........................................................................

Remove toner completely from electronic components. ........................

Run wire harnesses carefully so that wires will not be trapped or
damaged. ...............................................................................................

 After maintenance, always check that all the parts, screws, connectors
and wires that were removed, have been refitted correctly. Special
attention should be paid to any forgotten connector, trapped wire and
missing screws. .....................................................................................
Check that 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 applied solvents to evaporate completely before refitting the
covers or turning the main switch on.
Always wash hands afterwards.
Never dispose of toner or toner bottles in fire. Toner may cause
sparks when exposed directly to fire in a furnace, etc. ..........................
Should smoke be seen coming from the copier, remove the power
plug from the wall outlet immediately. ....................................................

3. Miscellaneous
WARNING
Never attempt to heat the drum or expose it to any organic solvents
such as alcohol, other than the specified refiner; it may generate toxic
gas. ........................................................................................................

5A2

CONTENTS
Chapter 1

PRODUCT INFORMATION

Printer identification labeling ........................................................................ 1-1

Printer Specifications ................................................................................... 1-2
Front and rear views .................................................................................... 1-5
Options ......................................................................................................... 1-7
Environmental requirements ........................................................................ 1-8
About the toner .......................................................................................... 1-11

Chapter 2

INSTALLATION/OPERATION

Unpacking ................................................................................................... 2-1

Installing the printer ..................................................................................... 2-3
Expanding memory ..................................................................................... 2-8
Installing KPDL .......................................................................................... 2-13
Using the Control Panel ............................................................................ 2-14

Chapter 3

MAINTENANCE/ADJUSTMENTS

Life expectancy of modules ......................................................................... 3-1

Toner container ............................................................................................ 3-2
Cleaning the printer ...................................................................................... 3-4
Replacing the developer unit ........................................................................ 3-9
Updating the firmware ................................................................................ 3-12
Adjusting the transfer bias .......................................................................... 3-16

Chapter 4

OPERATION OVERVIEW

Electrophotographics system ...................................................................... 4-1

Paper feeding system ............................................................................... 4-18
Print timing charts ..................................................................................... 4-29
Basic engine functions .............................................................................. 4-32
Engine controller system ........................................................................... 4-33
Logic controller system ............................................................................. 4-43

Chapter 5

DISASSEMBLY

General Instructions ..................................................................................... 5-1

Before starting disassembly ......................................................................... 5-2
Disassembly ................................................................................................. 5-3

1-1-1

5A2

Chapter 6 TROUBLESHOOTING
Board layouts .............................................................................................. 6-1
Diagnostic ................................................................................................... 6-2
General error handling ................................................................................ 6-7
Error messages ........................................................................................... 6-8
Call-Service person errors ........................................................................ 6-13
Print quality problems ................................................................................ 6-33
Correcting a paper jam .............................................................................. 6-41
Correcting paper jams ............................................................................... 6-43

Appendix A PRINTER INTERFACE

Parallel interface ......................................................................................... A-1
Serial interface ............................................................................................ A-3

Appendix B STATUS PAGE

Status page .................................................................................................. B-1

1-1-2

5A2

CONTENTS
Chapter 1

PRODUCT INFORMATION

Printer identification labeling ................................................................................... 1-1

US/Canada version ...................................................................................................... 1-1
Printer Specifications ................................................................................................ 1-2
Recommended flash cards .......................................................................................... 1-4
Front and rear views .................................................................................................. 1-5
Front view .................................................................................................................... 1-5
Internal assemblies ...................................................................................................... 1-6
Rear view ..................................................................................................................... 1-6
Options ....................................................................................................................... 1-7
Environmental requirements .................................................................................... 1-8
Environmental conditions ............................................................................................. 1-8
Clearance ..................................................................................................................... 1-9
Places to avoid ........................................................................................................... 1-10
Note on power ............................................................................................................ 1-10
About the toner ........................................................................................................ 1-11
Toner container handling ........................................................................................... 1-11
Toner storage ............................................................................................................. 1-12

1-1-5

5A2

Printer identification labelling

The printer has a label bearing its model and serial number at its back. This label also
contains other safety precautions.
US/Canada version

DP-2800
PRINTER
MANUFACTURED

60Hz

120V

Tested To Comply
With FCC Standards

10A

THIS LASER PRODUCT CONFIRMS TO THE APPLICABLE

REQUIREMENTS OF FEDERAL REGULATIONS 21 CFR
CHAPTER 1, SUBCHAPTER J.

8J68
UL1950

FOR HOME OR OFFICE USE

YM

MITA INDUSTRIAL CO.,LTD.

2-28 1-CHOME TAMATSUKURI CHUO-KU OSAKA JAPAN

MADE IN JAPAN

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference
that may cause undesired operation.
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numrique de la classe B est conforme la norme NMB-003 du Canada.

CAUTION

REMOVE POWER CORD

BEFORE SERVICE AND
FUSE REPLACEMENT.

PRECAUCION

RETIRE EL CORDON ELECTRICO ANTES

DE REALIZAR SERVICIO O REEMPLAZAR
EL FUSIBLE.

ATTENTION

POUR PRVENIR LES CHOCS

,
LECTRIQUES, COUPER L ALIMENTATION
AVANT DE REMPLACER LE FUSIBLE.

1-1

5A2

Printer Specifications
Engine
Specification
Print method Electrophotography laser scan
Print speed (when printing
multiple copies of the
same page) A4/11" 81/2": 28 pages/min., B4 (257 364 mm):
18 pages/min., A3/11" 17": 16 pages/min.
Resolution (dpi) 600 horizontal/600 vertical
Smoothing KIR 2 (2400 horizontal/600 vertical)
First print (A4/11" 81/ 2" or letter,
23C), depends on input data 10 seconds or less (75 seconds or less with sleep
mode on)
Warm-up time at 23 65 seconds or less
Maximum duty cycle (A4) 100,000 pages/month
Laser diode Visible laser
Main charger Scorotron wire
Transferring Biased roller
Separation DC
Drum cleaning Blade
Drum discharging LED array
Fuser Heat and pressure
Paper Plain paper (as specified separately)
Capacity of paper feed tray
(80 g/m2 [0.11 mm thickness]) Cassette: 500 sheets, MP tray: 100 sheets
Capacity of output trays
(80 g/m2 [0.11 mm thickness]) 500 sheets
Controller
Specification
CPU
System ROM size
Resident font ROM size
Option fonts ROM
Main RAM
Additional RAM (SIMM)
Memory card

PowerPC603e/100 MHz
4 MB, flash DIMM or masked DIMM
4 MB
2 MB (PK-4)
4 MB
64 MB maximum (72-pin SIMM 2)
SRAM or flush, JEIDA 4.2/PCMCIA 2.1
See Recommended flash cards in this chapter.
Host interface Parallel: High-speed, bi-directional (IEEE1284),
Serial: RS-232C/RS-422A, Option, KCIO (HDD).
Page description language Prescribe II
Standard emulation modes HP LaserJet 5Si, IBM Proprinter X24E, Diablo 630,
Epson LQ-850

1-2

5A2
Weight and dimensions
Specification
Main unit

Width:
Height:
Depth:
Weight:
Paper feeder Width:
Height:
Depth:
Weight:

56 cm (22")
34.5 cm (13.6")
56.6 cm (22.3")
41.5 kg (18.7 lb.)
56 cm (22")
24.7 cm (9.7")
56.6 cm (22.3")
19.5 kg (8.8 lb.)

Power requirements
Specification
Voltage requirements US/Canada: 120 V AC 10%, 60 Hz 2%.
Watts Maximum:
1200 W
Normal operation: 677 W
Standby:
215 W
Sleeping:
34 W
Environmental requirements
Specification
Operating temperature and
humidity 10 to 32.5C (50 to 90.5F), 20 to 80% RH
Maximum altitude 2,000 m (6,500 feet)
Noise emission (Excluding
peaks, measured at 1m from
printer, as per ISO7779) 50 dB (A) maximum/38 dB (A) at standby/
unmeasurably low at sleeping)

1-3

5A2

Recommended flash cards

The printer provide support for a JEIDA/PCMCIA category of memory card in both SRAM
and flush types of up to 32 MB. Following is a list of makes and models of flush cards
recommended for use with the printers.
Note that the flush card to be used should be operable on 5 V DC.
Model
AMD

AmC001CFLKA
AmC002CFLKA
AmC004CFLKA
AmC010CFLKA
AmC004DFLKA
AmC008DFLKA
AmC020DFLKA

1 MB
2 MB
4 MB
10 MB
4 MB
8 MB
20 MB

Fujitsu

MB98A81063
MB98A81183
MB98A81273
MB98A81373
MB98A81473

1 MB
2 MB
4 MB
8 MB
16 MB

Panasonic

1-4

Capacity

BN-02MHF4C (CC)

2 MB

BN-04MHF4C (CC)

4 MB

Centennial

FL01M-20-11114-03
FL02M-20-11114-03
FL04M-20-11114-03
FL08M-20-11114-03

1 MB
2 MB
4 MB
8 MB

Maxell

EF-2M-TB (DC)
EF-4M-TB (DC)
EF-8M-TB (DC)
EF-16M-TB (DC)

2 MB
4 MB
8 MB
16 MB

5A2

Front and rear views

Front view
Paper-full sensor
Vent

Option feeder
connector
MP (multipurpose) tray

Front control panel

Front cover

Upper paper cassette

Paper feeder side cover

Lower paper cassette

Paper feeder

Left side view

Face-down tray

Power switch

Left side cover

Face-up paper tray

1-5

5A2
Internal assemblies
Toner container release lever
(Green colored)

Toner container
Drum unit

Drum release lever

(Green colored)

Fuser unit
Fuser release
lever

Feed unit handle

Developer release lever

Developer

Feed unit

Rear view

Harddisk
drive slot
Memory card slot
Parallel interface
connector

Power receptacle
Rear panel

Serial interface
connector
Paper cassette
access door
Option interface
slot cover

1-6

5A2

Options
The example option units are shown below. The instruction handbook come with the printer
has more information regarding the accessories available for this model.

Inboard duplexer

Paper feeder
supplied as
standard

Bulk paper
stacker

First optional
paper feeder

Second optional
paper feeder

Wheels (Caster kit)

1-7

5A2

Environmental requirements
Environmental conditions
The Environmental requirements section on page Chapter 1-2 should be observed to
ensure the optimum operation of the printer. The use of the printer in a location which does
not satisfy the requirements may result in troubles and risk shortening its service life.
The printer will work best if it is installed in a location that is:
Level and well supported (Place the printer on a sturdy table or desk.)
Not exposed to sunlight or other bright light (not next to an uncurtained window). Do not
place the printer on an unstable cart, stand, or table.
Near an AC wall outlet, preferably one that can be used for the printer alone. The outlet
should have a ground slot, or an adapter should be used. If you use an extension cord,
the total length of the power cord plus extension cord should be 17 feet or 5 meters or less.
Well ventilated, not too hot or cold, and not too damp or dry (See section Environmental
requirements on page Chapter 1-2). If you install the printer where the temperature or
humidity is outside the requirements in section Environmental requirements in chapter 1,
the best print quality may not be expected and there will be an increased chance of paper
jams.
Provide a sufficient clearances around the printer to ensure ventilation and ease of
access.

1-8

5A2
Clearance
Allow the necessary minimum clearance on all sides of the printer (below). A total space of
92 by 138 cm (36 by 54") is needed.

1
3
2

Clearance

Dimensions

Left 1

45 cm (17.7"), or 30 cm (12") if the face-up tray is not used.

Front 2

60 cm (24")

Right 3

45 cm (17.7")

Back 4

20 cm (8")

Above 5

30 cm (12")

1-9

5A2
Places to avoid
Avoid installing the printer in locations exposed to:
Direct drafts of hot or cold air.
Direct drafts of outside air. (Avoid locations next to outside doors.)
Sudden temperature or humidity changes.
Any source of high heat, such as a radiator or stove.
Excessive dust. Dust and smoke may cause contamination on the laser scanner window,
causing print quality problem.
Vibration.
Ammonia fumes or other harmful fumes. (In case of humigating the room or saturate it with
insecticide, remove the printer first.)
Avoid greenhouse-like rooms. (Because of sunlight and humidity.)
Avoid enclosed spaces that block ventilation.
Avoid sites more than 6500 feet or 2000 meters above sea level.

Note on power
Use only the power source voltage conforming to the printers rated power voltage. Do not
use other power sources.
Disconnect the printer from the power source before attempting removal or re-placement
of an electrical component or a printed-circuit board.
The printer should not be connected to a power source until the instruction is given to do
so when performing tests described in this handbook.
In connecting the printer power, exercise an extreme care in handling the power supply
or any other electric parts which may give an electric shock.
Before performing maintenance or repair, power from both the power source and the
associated peripheral devices (computer, sorter, etc.) should be disconnected, unless
otherwise specified.
To avoid possible electrical shock, extreme caution must be exercised in handling the
power cord and any other electrical part.
An easily accessible socket outlet must be provided near the equipment.

1-10

5A2

About the toner

The printer should use the proprietary toner kit. To ensure the high print quality and long
service life, the following handling precautions should apply.
Caution: As the printers are designed to ensure the optimum print quality when used with
the proprietary toner, we do not recommend to use any refilled toner containers
that may be available commercially. This is because we have no means for
control over how such refilled toner could affect the print quality and the reliability
of the printer.

Toner container handling

To loosen and mix the toner inside before use, with the label side down, thoroughly shake
the toner container (in the direction of the arrow) 5 times or more.

Caution: Do not attempt to disassemble or refill the toner container.

1-11

5A2
Toner storage
The toner contained in the container is susceptible to temperature and humidity. To ensure
the high print quality, store the toner container in a place that satisfy the following
environmental conditions:
Temperature: 20 to 40C (4 to 104F)
Humidity:
15 to 90% RH
Note: If the toner container is removed from the printers developer unit, put it in a
protective bag and keep it in a dark place.
Caution: If the printer is shipped for return, etc., do not ship it with the toner container
installed. Otherwise, toner may leak and contamination may result in the printer.

1-12

5A2

CONTENTS
Chapter 2

INSTALLATION/OPERATION

Unpacking .................................................................................................................. 2-1

Unpacking the paper feeder ........................................................................................ 2-1
Unpacking the printer .................................................................................................. 2-2
Installing the printer .................................................................................................. 2-3
Connecting the printer and the paper feeder .............................................................. 2-3
Installing toner ............................................................................................................. 2-4
Developer initialization ................................................................................................ 2-7
Expanding memory ................................................................................................... 2-8
Minimum memory requirements .................................................................................. 2-8
SIMM specifications .................................................................................................... 2-8
Notes on handling SIMM ............................................................................................. 2-9
Getting access to the memory sockets ..................................................................... 2-10
Installing SIMM .......................................................................................................... 2-12
Testing the expansion memory ................................................................................. 2-12
Installing KPDL ........................................................................................................ 2-13
Installing the KPDL ROM .......................................................................................... 2-13
Getting access to the KPDL ROM socket ................................................................. 2-14
Using the Control Panel ......................................................................................... 2-14
Front control panel .................................................................................................... 2-14
Control panel view ..................................................................................................... 2-14
Basic key operation ................................................................................................... 2-14
Indicators ................................................................................................................... 2-15
Mode selection menu ................................................................................................ 2-15
Service mode ............................................................................................................ 2-15

1-1-7

5A2

Unpacking
The printer is delivered in two cartonsthe printer carton and the paper feeder carton. Since
the paper feeder is installed under the printer, begin unpacking and installing with the paper
feeder.
Unpacking the paper feeder
To unpack the paper feeder, proceed as diagrammed below.
Warning: The paper feeder weighs approximately 20 kg (9 lb.).

Place the paper feeder on a stable, level surface (table, floor, etc.). Note that wheels are
available for the printer as the Caster kit.

2-1

5A2
Unpacking the printer
To unpack the printer, proceed as shown in the diagrams below. Check that the listed parts
are all present.
Warning: The printer weighs approximately 41 kg (18 lb.). Lift it using two or more people.

Do not cut tapes

as they are
reusable for
future packing.

1
Take out the
accessories:
1 Power cable,
2 Drum unit
cover,
3 Toner kit
4 Documents
incl. CD-ROM.

2-2

5A2

Installing the printer

Installing the printer requires several steps. Proceed as follows in sequence.
If the printer is used with casters, fit them now before proceeding.
Connecting the printer and the paper feeder
The printer should be mounted over the paper feeder as shown below. Align the pins 1 and
the connector 2 on the paper feeder with the matching holes and the connector located at
the bottom of the printer, then slowly lower the printer onto the paper feeder.

2-3

5A2
Installing toner
First open the top cover 1 atop the printer. Slide the toner container release levers 2 to
the right side position. (This is the open position in which the toner container becomes
removable.)

2
1

2-4

5A2
Take the toner container from the toner kit supplied with the printer. With its label side facing
down, give it a good shake (5 to 6 times).

Label side

Peel off the seal 1 on the bottom of the toner container by carefully pulling off.

2-5

5A2
Insert the toner container in the printer as below. Align the two locating keys at the sides of
the container with the mating slots in the printer.

Caution: To avoid trouble, the toner container must be correctly seated and locked in the
printer. To do this, press the far side of the container 1 at the PUSH HERE
marks.

Making sure that the toner container is seated correctly on the developer, press the two
PUSH HERE markings on the toner container using both hands.

2-6

5A2
When the toner container is inserted in the printer properly, slide the toner container release
levers to the left side position until it stops. After installing the toner container, close the top
cover down firmly.

Developer initialization
The printer is shipped from the factory with no toner supplied in its developer unit. When the
printer is first switched on after the toner container is installed in the manner above, there
will be a delay of several minutes before the printer gets ready to print a job.
This delay is necessary for the printer to fill the developer reservoir with a sufficient amount
of toner to continuously support a print job. The period of time for this delay varies depending
on model: approximately 5 minutes.
Since the automatic implementation of the developer initialization is done only once at first
switching power on, if a new developer is installed in the printer, the developer must be
initialized manually using the service mode on the front panel. Refer to the section Feeding
toner into the new developer in chapter 3.

2-7

5A2

Expanding memory
Expanded printer memory is required particularly when a memory error occurred. It enables
the printer to print more complex pages, download more fonts, and define more macros.
Since expanding memory requires removal of the main circuit board from the printer and
handling of SIMM (single in-line memory module), the following procedures should be
followed only by a qualified service technician.
Minimum memory requirements
By default, the printer is equipped with 4 MB of memory at the shipment which is expandable
up to a maximum of 68 MB (two 32 MB SIMMs). The minimum memory requirements for
the printer with various options installed are listed in the table below. Refer to this table for
obtaining a rough approximation on how much memory is required for a particular need.
Resolution
Printing environment

300 dpi

600 dpi

HP emulation

2 MB

2 MB

HP+duplex (using duplexer)

2 MB

3 MB

HP+KPDL

2 MB

3 MB

HP+KPDL+duplex

3 MB

5 MB

HP+KPDL+resource protection

n/a

10 MB

HP+KPDL+resource protection+duplex

n/a

14 MB

SIMM specifications
Memory size in MB
Number of pins
Access speed
Parity
Bus width

2-8

1, 2, 4, 8, 16, 32
72
80 ns or faster
With/without
32 bits

5A2
Notes on handling SIMM
Before proceeding to install SIMM, read the following notes for handling the main circuit
board and SIMMs.
Protect the electronics by taking these precautions:
Before touching the main circuit board, touch a water pipe or other large metal object to
discharge yourself of static electricity. While doing the work, it is recommended that you
wear an antistatic wrist strap.
Touch the main circuit board and SIMM only by the edges, not in the middle. See below.

Yes

No

Follow the instructions the SIMM manufacturer should provide.

2-9

5A2
Getting access to the memory sockets
The main circuit board of the printer is equipped with two sockets for memory expansion.
Expansion memory is available in the form of a SIMM. To gain access to the main board,
the printers rear panel should be removed.
Warning: Turn the printers power off. Unplug the printers power cable and disconnect the
printer from the computer or the network.

Turn the power switch off. Remove the main board access panel 1 by removing 6 (plated)
screws. The main controller board 2 is exposed for inserting SIMMs.

Caution: When the main board is open, use care to avoid foreign objets from entering the
main board area. Otherwise, a serious damage to the printer could result.

2-10

5A2
Locate the sockets for the SIMMs on the main controller board by referring to the diagram
on the next page. Locate the sockets for memory expansion on the main board. These
sockets have 72 pins and are symbolized as YS1 and YS2.

Expansion SIMM sockets

KPDL ROM socket

2-11

5A2
Installing SIMM
Insert the SIMM 1 into the socket 2 as shown. Carefully push the board upright until it
snaps into place. Make sure that the catches at the ends of the socket fit into the holes 3
at the ends of the SIMM board.

3
1

Testing the expansion memory

After installing SIMMs in the printer, test the printer to see if the installation has been
successful. To test the expansion memory, turn printer power on and print a status page.
If the installation has been successful, the Total memory (Memory Allocation) of the status
page will show the expanded memory size corresponding to the amount of memory added.

2-12

5A2

Installing KPDL
KPDL is an upgrade for adding implementation of the PostScript page description language.
Upgrade is done by inserting a KPDL FONT ROM into an empty socket on the printers main
circuit board.
For details on KPDL, refer to the KPDL Upgrade Kit instruction handbook supplied with
KPDL FONT ROM.
Installing the KPDL ROM
Before installing the KPDL ROM delivered, carefully straighten the pins as follows.

Make sure that none of the pins are bent.

To insert the ROM into its socket, position the ROM in the socket as shown. Make sure that
the U-shaped indentation at the end of the ROM is oriented in the same direction as the
U-shaped indentation at the end of the socket. Align all pins of the ROM properly with their
socket holes.
ROM

U indentations

Socket

Getting access to the KPDL ROM socket

Refer to the previous section Expanding memory, page Chapter 2-8, and remove the
printers rear panel.
Locate the socket for inserting the KPDL ROM. Refer to the diagram on page Chapter 2-11.
This socket is marked as U13, adjacent to another (shorter) empty socket (U13).

2-13

5A2

Using the control panel

This section provides explanation on how to use the printers control panel. This is more fully
detailed in the instruction handbook.
Front control panel
The printers control panel has the LED indicators and a quartz message display to provide
a quick access to the printers conditions. It also features the control keys for adjusting the
various conditions on the fly. Note that the adjustments made using these keys may be
overridden by the settings made from within an application software.

Control panel view

o
ON LINE

DATA

CANCEL

STACK

FORM FEED

ATTENTION

INTERFACE

RESOLUTION

SIZE

COPIES

FEED

EXIT

ENTER

MODE

STATUS

Basic key operation

The control keys are used to configure the printer as follows. For more detailed explanations
on these keys, refer to the printers instruction handbook.
Key

Function

ON LINE

Switches the printer online and offline.

CANCEL

Abandons a printing job, resets numeric values or cancels a

setting procedure.

STACK

Selects whether printed pages are delivered to the face-down or

face-up tray.

FEED

Selects the cassette feed or manual (MP tray) feed.

CONTINUE

Resumes printing when the message display indicates a memory

error. Also, enters in a submenu item during mode selection.

Cycles forward through the item selections or enters numeric

values.

FORM FEED

Prints and feeds out one page. Also, exits a submenu item during
mode selection.

MODE/EXIT

Enters/exits the mode selection for changing the printers

configuration.

2-14

5A2

Cycles reverse through the item selections or enters numeric

values.

ENTER/STATUS

Prints a page of status information. During mode selection, this

key finalizes numeric values and other selections for changing
the printers configuration.

Indicators
Indicator
1ONLINE/Green

2DATA/Green

Status

Function

Steady

The printer is on-line and ready to prints received

data.

Off

The printer is off-line. The printer stores but not prints

received data.

Flashing The printer is receiving data from the host computer.

Steady

3ATTENTION/Red

The printer is processing the data for printing or for

writing on a memory card.

Flashing (1) The printer is warming up. (2) The printer was
stopped because of an error such as the insufficient
memory, memory card errors, etc. (See chapter 6.)
Steady

(1) The printer needs attention for a problem that can

be cleared by the user such as an open cover,
missing toner kit, paper-full stack, etc. (2) The printer
was stopped because of a problem that needs
servicing provided by a service technician.

Mode selection menu

The MODE key on the control panel allows to set or change the printer environment such
as the number of copies to make, emulation, etc., and to print a font list, manipulating a
memory card, etc.
During operating in the mode selection, several front panel keys serve exclusively for its
secondary function as labeled beside them (EXIT, +, , ENTER, , ). The diagram on
the next page gives a full load map to the full options and the sequence of mode selection
as well as usage of these secondary keys.

Service mode
Within Others option, the Service mode can be accessed by authorized service personnel.
This mode provides the following three treatments for service purpose:
printing a service information (a service status page)
cleaning on the drum surface
accelerating initial toner replenishment for a new developer
The service mode is available only when the printer is ready. To activate these features, see
chapter 3. While in service mode, the printer accepts print data but does not print it.

2-15

5A2

CONTENTS
Chapter 3

MAINTENANCE/ADJUSTMENTS

Life expectancy of modules ..................................................................................... 3-1

Toner container .......................................................................................................... 3-2
When to replace the toner container ........................................................................... 3-2
Toner container replacement ....................................................................................... 3-3
Toner saver mode (EcoPrint ) ....................................................................................... 3-3
Cleaning the printer ................................................................................................... 3-4
Main charger unit ......................................................................................................... 3-4
Cleaning the paper feed unit ........................................................................................ 3-7
Replacing the developer unit .................................................................................... 3-9
Replacement ................................................................................................................ 3-9
Installing a new developer ......................................................................................... 3-10
Feeding toner into the new developer ........................................................................ 3-11
Updating the firmware ............................................................................................. 3-12
Firmware data format ................................................................................................. 3-12
Downloading engine firmware data ............................................................................ 3-13
Downloading controller firmware data ........................................................................ 3-13
Downloading data from a memory card ..................................................................... 3-14
Errors during downloading ......................................................................................... 3-15
Adjusting the transfer bias ..................................................................................... 3-16

1-1-9

5A2

Life expectancy of modules

The table below shows the nominal life expectancy for modules. Detailed part information
for each module (except toner containers) can be found in Parts List.
For refurbishment purpose, the modules are available as a kit after 350,000 pages have
been printed. The contents of this kit is also shown in this table.

Module

Nominal life
(pages)

Toner
container

25,000

Drum unit

350,000

Developer unit

350,000

Fuser unit

350,000

Transfer roller

350,000

Refurbishment
(Maintenance) kit*1

350,000

Remarks
User-replaceable (20,000 for the initially supplied
container)

Includes a drum unit, a developer unit, a fuser

unit, a transfer roller, and a waste toner conveyer.

*1 To install the kit, refer to the instruction handbook included in the kit.

3-1

5A2

Toner container
The toner container is the only consumable that the printer requests (until it has printed
350,000 pages) to replace periodically during normal operation (user-replaceable). The
following toner container is available for use with model.
Model

Life in pages*2

Toner kit

25,000 (1,100 g)

*2 Based on letter or A4 size paper; average print density of 5%.

When to replace the toner container

The printer gives two steps of user attention for toner replacement as explained below:
Step 1The toner is almost run out. The message display indicates:

Replace Toner Clean printer

The printer will print approximately 2,500 pages (A4 or letter/5% coverage) until step 2. This
is the earliest chance to replace the toner container and clean various parts inside the printer
(See Cleaning the printer on page Chapter 3-4).
Step 2The toner is run out. The printer halts printing and the message display indicates:

Replace Toner Clean printer

This instructs the user to install a new toner kit to bring the printer back in normal operation.
Cleaning various parts inside must be also done in this occasion (See Cleaning the printer
on page Chapter 3-4).
Observe the following cautions when replacing the toner container:
Do not attempt to disassemble the toner container and reuse the waste toner inside.
Keep magnetic media such as floppy disks away from the toner container.
Be sure to clean the parts as instructed in this section at the same timing of replacing toner
container.
Use of the toner kit is highly recommended for the optimum operation of the printer.

3-2

5A2
Toner container replacement
To replace the toner container, open the top cover 1. Pull the toner container release levers
2 to the right position as shown. Lift and pull out the toner container 3.

Then, refer to section Installing toner in chapter 2 to install the new toner container. After
installing the new toner container, several parts in the printer must be cleaned as instructed
in section Cleaning the printer on page Chapter 3-4.
If the toner container has been replaced when the message

Replace Toner Clean printer

was displayed, then, the message

Clean printer press CONTINUE

will be displayed after replacement. After cleaning the inside of the printer following the
procedure shown below, press the CONTINUE key; the message will disappear and the
printer will be ready for printing.

Toner saver mode (EcoPrint)

The EcoPrint enables to reduce the amount of toner consumed on the page so as to save
printing costs by drastically extending the toner container life. EcoPrint mode is factory-set
to off and turned on by the printers front control panel (also accessible through the
application software with the assistance of the printer driver). See details in the printers
instruction handbook.

3-3

5A2

Cleaning the printer

To avoid print quality problems, the following printer parts must be cleaned with every toner
container replacement.
Main charger unit
The main charger unit should be cleaned in its two partsthe charger wire and grid (See
the picture below.)whenever the toner container is changed. Cleaning of the main charger
can be done without needing any tools thanks to its self-cleaning system.

Grid

Charger wire

3-4

5A2
To clean the charger wire, first open the front cover 1. Pull the cleaning knob (green) 2
slowly in and out a few times. This pulls a cleaning pad inside the drum unit along the wire.

Then, clean the grid using the grid cleaner supplied with the toner kit.

Take the grid cleaner 3 from protective bag in the new toner kit, and remove the cap 4.

Pad (impregnated with water)

The grid cleaner pad is impregnated with water. Perform the following cleaning procedure
before the pad dries.

3-5

5A2
Attach the grid cleaner 3 to the drum unit as shown in the diagram below. Insert the fixture
pin on the cleaner into the hole on the drum unit with the pad facing up.

3
Hold and pull up the main charger, then draw it out until it stops. Then, push it all the way
in. Repeat this procedure for 5 times or more.
To release the
main charger
unit for pulling,
first pull it up

Then, pull it
horizontally
out.

After cleaning is done, pull the main charger unit in place using the reverse manner of the
above. Close the front cover.

3-6

5A2
Cleaning the paper feed unit
The paper feed unit must be cleaned of paper dust whenever the toner container is
replaced. To gain access to the paper feed unit, first, open the front cover. Draw out the
paper feed unit by the handle (green) 5 on its front side.
Cleaning the paper feed unit should be done on several partsthe separation charger,
registration rollers, paper ramp, etc. as follows.
Caution: Do not touch the transfer roller (black sponge roller) 6 during the cleaning
procedure.

Take out the cleaning brush 7 recessed in the front of the paper feed unit. Cleaning the
separation charger (saw-toothed) 8 by sweeping with the brush.

The printer can get ready for printing approximately 15 seconds after replacing the toner
container.

3-7

5A2
Obtain the cleaning cloth (Locate in a new toner kit). Wipe the registration rollers 9 and
paper ramp 0 as shown below.

When cleaning is done, set the paper feed unit back in place by pushing on the handle. Make
sure that the paper feed unit has been correctly seated, close the front cover.

3-8

5A2

Replacing the developer unit

In case that the developer unit is to be removed from the printer for shipment or replacing
to a new one, it should be handled following the instructions below.
Also, a new developer unit, after installing, needs a special treatment that replenishes the
developer with toner for printing. This can be done by using the front control panel (See
section Feeding toner into the new developer on page Chapter 3-11).
Replacement
To replace the developer unit currently installed in the printer, first turn the printer power off.
Open the toner container access door. Refer to section Toner container replacement on
page Chapter 3-3 and remove the toner container. Open the front cover. Locate the
developer unit release lever 1 and turn it clockwise to the upper position. Grasp the
developers front end as shown below and slowly draw the developer 2 out from the printer.

Caution: If you ship the developer unit removed from the printer for repair, etc., pack the
developer in the container package designed for this purpose.

3-9

5A2
Installing a new developer
To install a new developer, use the reverse manner as above. Note that the new developer
is shipped from the factory with a protective cover 1 installed. Leave the protective cover
installed with the developer until the developer has been installed in the printer.
When the developer has been installed in the printer, grasp and pull the protective cover all
the way out, as shown below. Latch in the developer release lever.

Caution: Push in the developer unit slow and gently. If the developer contains toner,
pushing in the developer unit rudely can cause the distribution of toner to become
uneven in the far side of the developer. Also, it may risk damaging the connector
at the far end of the developer (and the mating connector in the printer).

3-10

5A2
Feeding toner into the new developer
The new developer unit is shipped from the factory with no toner contained. The developer
can be automatically replenished with toner when a toner container is installed onto it and
the printer is turned on. However, because the toner reservoir in the developer has a large
capacity, it requires a lengthy period of time until a substantial amount of toner has been fed
to get the printer ready.
A great many seconds of time for this is greatly deducted by using the service menu in the
printers mode select routine as accessed by its front control panel. Follow these steps to
use this feature, top to bottom. (For details on using the front control panel keys, refer to the
printers instruction handbook.)
Key to press:

Relevant display:

MODE
(repeatedly)

Others>

(repeatedly)

>Service>

>>Developer

ENTER

>>Developer?

ENTER

Turn printer power off, then on.

When printer power is turned on again, the printer continually engages in this mode for
several minutes after which the printer reverts to the ready state.

3-11

5A2

Updating the firmware

The printer accepts update of the engine and system firmware as well as the front panel
message data through the parallel interface. A PC that is connected to the printers parallel
interface and capable of running in DOS mode is required for this purpose.
Updating using these data is implemented by directly downloading the new firmware data
for rewriting the flush memory chips in the printer. The printer must enter to the supervisor
mode (See page Chapter 3-12) to update the engine firmware using Prescribe commands
as explained in this section.
The engine firmware and controller (system) firmware must be updated separately. We
supply three types of data for updating the printers firmware as follows:
Engine firmware data
Controller (system) firmware data
Front panel message data
These data may be stored in a memory card for field use. To store (write) data in a memory
card, and reread them into the printer through the slot, refer to the printers instruction
handbook.
Each single data must be written on a memory card. Do not write more than one data on
a memory card.
Firmware data format
The firmware data to be downloaded is identified using the following file specification:

de0330.dat
1

Identifies

3-12

de: Engine firmware data

ds: Controller (system) firmware data
dm: Front panel message data

03: This machine

Version of data (2 to 4 digits)

dat: Engine/controller firmware data

dan: Panel message data for Danish
swe: Panel message data for Swedish
ita: Panel message data for Italian
spa: Panel message data for Spanish

5A2
Downloading engine firmware data
To download engine firmware or panel message data, use Prescribe BOOT command.
Perform in sequence:

Relevant display

Turn printer power on. Make sure the printer is Ready.

Ready

At the DOS prompt, send the following command to the

printer.

Supervisor mode

!R! BOOT "SPR";

Note: Do not add an EXIT; command in the above.
The display indicates Supervisor mode when the
above command is sent to the printer.
DOS COPY (/b) the data to download from the host
computer. The display shows Downloading while
downloading data.

Downloading

When downloading finishes, the display reverts to

Supervisor mode. In this state, turn power off.

Supervisor mode

Turn power on again. Check the display shows Ready.

Ready

Caution: Do not turn off printer power while data are being downloaded (approximately
one minute).
Confirm the status page shows the new engine version. If the message display indicates
Call service person Dn ( n=0, 1, ), refer to section Errors during downloading on page
Chapter 3-14.

Downloading controller firmware data

To download controller firmware data, use Prescribe UPGR command as follows.
Perform in sequence:

Relevant display

Turn printer power on. Make sure the printer is Ready.

Ready

At the DOS prompt, send the following command to the

printer:

Supervisor mode

!R! UPGR "SYS";

Note: Do not add an EXIT; command in the above.
The display should indicate Supervisor Mode when the
above command is sent to the printer.
DOS COPY (/b) the data to download from the host
computer. The display shows Downloading while
downloading data.

Downloading

3-13

5A2
When downloading finishes, the display reverts to
Supervisor mode. In this state, turn power off.
Turn power on again. Check the display shows Ready.
If not, refer to section Errors during downloading on page
Chapter 3-14.

Supervisor mode

Ready

Caution: Downloading controller firmware takes several minutes (depending on the

processing speed of the computer used). Do not turn power off during downloading.
Confirm the status page shows the new firmware version (See Appendix B, page B-4). If the
message display indicates Call service person Dn (n=0, 1, ), refer to section Errors during
downloading on page Chapter 3-14.

Downloading data from a memory card

To download data written in a memory card to the printer, proceed as follows. Data in a
memory card can be selectively downloaded when the Prescribe RWER command is used.
Refer to the Prescribe Command Reference Handbook in the CD-ROM purchased with the
printer for details about the RWER command.
Perform in sequence:

Relevant display

Insert the memory card in the printers memory card slot

of the printer.
Turn printer power on. The printer automatically reads
data in the memory card, indicating Downloading on
the message panel during downloading.

Downloading

When the data is successfully read, the message display

indicates Supervisor mode.

Supervisor mode

Turn printer power off.

Remove the memory card from the printer.
Turn printer power on again. Check the display shows
Ready.

Ready

Confirm the status page shows the new firmware version (See Appendix B, page B-2). If the
message display indicates Call service person Dn (n=0, 1, ), refer to section Errors during
downloading below.

3-14

5A2
Errors during downloading
The following messages may be indicated on the message display when an error occurred
during downloading firmware data. Take the appropriate corrective action. If the corrective
action does not terminate the error, contact the manufacturer.
Error message

Meaning

Corrective action

Call service person

D0 - Checksum error

Checksum error occurred

during downloading. The
engine ROM is empty.

Turn printer power off

once, then on again.
Try downloading again.

Call service person

D1 - Machine compatibility
error

The data to be downloaded is

not compatible with the
printer.

Obtain correct data for

the printer model.

Call service person

D2 - Version compatibility
error

The version of the data does

not match the current engine
version.

Obtain the correct

version of data.

Call service person

D3 - Data error

The data to be downloaded is

corrupted.

Obtain the correct data.

3-15

5A2

Adjusting the transfer bias

Printing on paper with extra thickness of 91 to 200 g/m2, such as postcards, OHP,
envelopes, etc., tend to result in faint printing because of insufficient penetration of transfer
bias developer at the transfer roller. Whereas, for thin paper types, the regular transfer bias
may be so strong that the paper cannot effectively leave the drum surface after transferring,
causing paper jam.
For the satisfactory transferring process on different paper thickness, the transfer bias is
user-switchable in three degrees between 1.7 and 3.4 kV.
To select the transfer bias for different paper thickness, perform the following steps.
Steps

Display

Press MODE key.

Press key repeatedly until Paper
Normal is displayed.

type/

Press ENTER key. The question mark begins

flashing besides Normal.

Paper type
Normal
Paper type
Normal ?

Press key. Press ENTER key to select the thick

paper type.

Paper type

Or, to select the thin paper type to press key.

Press ENTER to select the thin paper type.

Paper type

3-16

Thick ?

Thin ?

5A2

CONTENTS
Chapter 4

OPERATION OVERVIEW

Electrophotographics system .................................................................................. 4-1

Electrophotographic cycle ........................................................................................... 4-1
Amorphous-silicon drum ............................................................................................. 4-2
Charging the drum ...................................................................................................... 4-3
Toner ........................................................................................................................... 4-4
Exposure ..................................................................................................................... 4-5
Scanner unit ................................................................................................................ 4-6
Laser scanning ............................................................................................................ 4-9
Development ............................................................................................................. 4-10
Developing roller bias ................................................................................................ 4-11
Image transfer ........................................................................................................... 4-13
Fusing ....................................................................................................................... 4-14
Drum cleaning and erasing static charge .................................................................. 4-16
Typical photo process timing chart ............................................................................ 4-17
Paper feeding system ............................................................................................. 4-18
Paper control signals ................................................................................................. 4-19
Paper feeding components ....................................................................................... 4-20
Control devices ......................................................................................................... 4-21
Paper feeder control devices .................................................................................... 4-22
Printing from paper feeder cassettes ........................................................................ 4-23
Printing from the MP tray .......................................................................................... 4-24
Printing from the optional envelope feeder ............................................................... 4-25
Paper jam detection .................................................................................................. 4-26
Message display at a paper jam ............................................................................... 4-28
Print timing charts .................................................................................................. 4-29
Basic engine functions ........................................................................................... 4-32
Engine controller system ....................................................................................... 4-33
Configuration memory ............................................................................................... 4-33
High-voltage generator .............................................................................................. 4-33
Laser scanner control ................................................................................................ 4-33
Polygon motor control ............................................................................................... 4-33
Safety interlock .......................................................................................................... 4-34
The engine gate arrays ............................................................................................. 4-35
Pin assignment .......................................................................................................... 4-36
GATE ARRAY B ........................................................................................................ 4-37
Power supply ............................................................................................................. 4-40
Power distribution ...................................................................................................... 4-42

1-1-11

5A2
Logic controller system .......................................................................................... 4-43
Main logic controller overview ................................................................................... 4-43
Controller block diagram ........................................................................................... 4-44
Printing data processing ............................................................................................ 4-45
Main logic component ............................................................................................... 4-46
API ROM socket (U09) .............................................................................................. 4-46
API ROM socket pin assignment .............................................................................. 4-47
System DiMM (YS3) .................................................................................................. 4-48
RAM (U11 and U12) .................................................................................................. 4-48
Memory card slot interface (YC4) ............................................................................. 4-48
Option interface (YC5) .............................................................................................. 4-49
Option interface pin assignment - Continued ............................................................ 4-49
KUIO interface (YC6) ................................................................................................ 4-50
Parallel interface ....................................................................................................... 4-51
Serial interface .......................................................................................................... 4-51
Engine interface ........................................................................................................ 4-52
Engine interface connector assignment .................................................................... 4-52
Signals used for the engine interface ........................................................................ 4-53

1-1-12

5A2

Electrophotographics system
Electrophotography is the technology used in laser printing which transfers data representing
texts or graphics objects into a visible image which is developed on the photosensitive drum,
finally fusing on paper, using light beam generated by a laser diode.
The key features for the electrophotography system of the printer are:
Real 600 dpi resolution (equivalent to 2400 dpi resolution thanks to KIR smoothing
technique)
Ultra long life amorphous silicon drum (non-heating)
Paper support for up to A3 (Ledger) size
Microfine mono component toner

Electrophotographic cycle
The electrophotography system of the printer performs a cyclic action made of seven steps
as follows. Each step is technically explained in the following sections.

2 Exposure

1 Main Charging

3 Developing

7 Erasing

6 Cleaning

4 Transfer

5 Fusing

4-1

5A2
Amorphous-silicon drum
The printer uses the long lasting amorphous silicon (a-Si) drum. The photoconductive layer
is coated over the aluminum cylinder base as shown below. The aluminum base is
electrically grounded to the ground.
The photoconductive layer is charged evenly over its surface by positive high voltage
charging (corona charging) given by the main charger unit (the wire and grid). The area on
the charged drum surface which is exposed to the laser beam, as the print image is
statistically drawn over the drum, loses the charge as it is escaped through the ground. The
resultant electrostatic latent (negative) image is then developed by toner and transfer to the
medium like paper.

The amorphous silicon photo conductor is extremely hard, non-toxic, and highly resistive
against chemical substances. These characteristics of the amorphous material make itself
up to a most durable, stable photoconductor for the electrophotography printer.

Photoconductive layer

Aluminum base cylinder

4-2

5A2
Charging the drum
Figure below is a simplified diagram of the electrophotographics components. Charging the
drum is done by the main charger unit marked A in the diagram.

As the drum B rotates in a clean (neutral) state, its photoconductive layer is given a
uniform, positive (+) corona charge dispersed by the main charger wire A.
Due to high-voltage scorotron charging, the charging wire can get contaminated by
oxidization and therefore must be cleaned periodically from time to time using the method
explained in chapter 3. Cleaning the charging wire prevents print quality problems such as
black streaks caused by the oxide ac-cumulated around the charging wire.

4-3

5A2
Toner
The toner is fed from toner kit. The toner is of dry mono component type and comprised of
the following substances as depicted below.

Single component toner

A Resin
B Ferrite
C Silica
D Polisher

B
C

4-4

5A2
Exposure
The charged surface of the drum B is then scanned by the laser beam from the scanner
unit A.

The laser beam is switched on for a black dot and off for a white (blank) dot according to
the print data. Whenever it is illuminated by the laser beam, the electrical resistance of the
photoconductor is reduced, the potential on the photoconductor is also lowered from
approximately 250 V to 20 V, effectively driving the charge through the a-Si layer down to
the aluminum base.
LASER BEAM

LASER BEAM

+ + + + +

+ + + +

250 V

a-Si LAYER

ALUMINUM

+ + + +

20 V
0V

4-5

5A2
Scanner unit
The 600 dpi scanner unit includes the laser diode that produces the 670 nm wavelength
laser beam. This wavelength is specifically designed to match the photoconductive
response of amorphous silicon.
The diagrams below show the components inside the scanner unit in two viewshorizontal
and vertical. The function of each component is described in the following pages. Note that
the directive arrows indicate the laser beam paths.

TOP VIEW

3
2

5
6
1

4-6

5A2
SIDE VIEW

Drum

1 Laser diode ...................................... emits diffused, visible laser.

2 Collimeter lens ................................. aligns the laser beam to the cylindrical lens.
3 Cylindrical lens ................................. compensates the slant angle at which the laser
beam hits a polygon mirror segment.
4 Polygon mirror (motor) ..................... has ten mirror segments around its octagonal
circumference; each mirror corresponding to one
scanned line width on the drum when laser beam
scans on it.
5 Primary f-theta lens .......................... See below.
6 Secondary f-theta lens ..................... The primary (above) and secondary f-theta lenses
equalize focusing distortion on the drum edges.
The effective length of line (A, B below) the
laser beam draws on the drum becomes longer as
the laser beam hits closer to the drum edges. In
the figure below, 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).

4-7

5A2

Secondary f-theta lens

A A

Primary f-theta lens

Polygon mirror

Laser diode

7 Diversion mirror ................................ diverts the laser beam vertically onto the drum.
Note the diffused laser beam finally pin-points on
the drum.
8 Protective glass ................................ prevents dust, debris, etc., from entering the
scanner assembly.
9 Sensor mirror ................................... bends the very first shot of a laser scan towards
the beam detection sensor (See next.).
0 Beam detector sensor ...................... when shone by the sensor mirror above, this
photosensor generates a trigger signal for the
engine controller to start activating the paper
feeding system.

4-8

5A2
Laser scanning
The laser beam hits one of ten polygonal mirrors. As the mirror revolves (at the nominal
revolution of 17,700 rpm), the laser beam reflects off of it and reaches the charged drum
surface in a lengthwise manner.
A pair of (plastic) lenses provides focusing the horizontally sweeping laser beam onto the
drum. As the drum rotates, the laser beam sweeps the entire length of the drum so that the
drums entire circumference is exposed to the laser beam. The revolution of the polygon
mirror motor and the drum itself is timing-controlled so that each successive sweeping of
the laser beam produces a 1/600 inch offset. The printers controller system continuously
turns the laser beam on and off to put a dot at every 1/600 inch distance horizontally.
Synchronizing the output data with one scanning line is achieved by the photo sensor
provided next to the first mirror. At the beginning of each laser sweeping, the beam hits the
photo sensor which in turn sends a command to the logic controller for synchronization.

4-9

5A2
Development
The latent image constituted on the drum is developed into a visible image. The developing
roller contains a magnet core and an aluminum cylinder rotating around the magnet core
at a speed twice faster than that of the drum. Toner attracts to the developing roller since
it is magnetic. A magnetized blade above the developing roller constitutes a smooth layer
of toner in accordance with the roller revolution.
Blade

Magnetism
0.1 mm

Drum

0.3 0.4 mm

Magnet

Developing roller

4-10

5A2
Developing roller bias
The developing bias is adjusted so that the toner, charged positive while each particle is
rubbing each other in the developer, is selectively developed onto the area of low potential
by adhering. The bias is AC weighted, positive DC power source.
Since the gap between the developing roller and the drum is wider than the average
diameter of the toner, the toner should fly over to the drum surface to accomplish
development. This method is known as the non-contact development method.

Blade
Toner

Develop. roller

Drum
Toner sensor

AC + DC

Toner

Drum

Develop. roller

4-11

5A2

Area not exposed by laser

Surface
potential =
250 V

Area exposed by laser

Developing roller bias

160 V DC + 1.8 kV AC

Developing

20 V

Toner

A toner replenishment sensor is provided within the developer. As the toner supply from the
toner container dwindles and the toner level lowers in the reservoir, the sensor translates
it through its sensing plate, urging the toner motor to feed more toner.
Sensing plate

Toner sensor
Sensable level

Toner

Developer unit

4-12

5A2
Image transfer
The image developed by toner on the drum (A below) is transferred onto the paper using
the electric charge attraction given by the toner itself and the transfer roller (B below). The
transfer roller is negatively biased so that the positively charged toner is attracted onto the
paper while it is pinched by the drum and the transfer roller.

The nominal transfer bias is set to approximately 1.7 kV (limit) with the 55 A current. Since
the ideal potential of the transfer bias varies depending on the thickness of paper, the bias
is raised to approximately 2.2 kV/55 A for thicker paper (91 to 200 g/m2). Double-sided
printing using a duplexer automatically increases the transfer bias to the above value. On
the other hand, the bias current is reduced to 40 A (1.7 kV) for thin paper. The bias is
switched automatically as the printer detects the thickness of the paper, and also switchable
manually on the printers control panel. For details on switching the transfer bias, refer to
the printers instruction handbook.
Paper separation
After the image transfer process, the paper is forcibly peeled off the drum by means of the
separation electrode. The separation electrode is located next to the transfer roller, giving
the positive charge to attract paper downwards.

4-13

5A2
Fusing
The toner on the paper is permanently fused onto the paper as it passes between the florinfinished heat roller (A below) and the pressure roller (B below) in the fuser unit. The toner
is molten and pressed into the paper.

B
The heat roller has two halogen lamps, turning alternatively on depending on the size of the
paper passing through to maintain the preheat temperature at approximately 185C/365F.
This ensures the even temperature dispersal over the long heat roller. See the picture and
table below.
Thermistor

Thermo-cut

Engine
Controller

Heat distribution

4-14

5A2
Heater(s) activated
Paper size

Idle
A3, A4 landscape
B4
Letter landscape
Letter, A4, A5
Ledger

Middle heater

Edge heater

Off
On
On+
On+
On
On

On
On
On
On
Off
On

The heat roller temperature is constantly monitored by the engine control circuit using the
a thermistor. In the above table, each eater is turned On as commanded by the thermistor.
The On+ status for paper sizes of B4 and letter (landscape) mean that the heater is turned
on a couple of seconds longer than that commanded by the thermistor.

4-15

5A2
Drum cleaning and erasing static charge
The drum needs to be physically cleaned of toner which is remaining on its surface in the
development process. The cleaning blade (A below) is constantly pressed against the
drum and scrapes the residual toner on the drum off to the refresher roller (B below). The
refresher roller drives the toner to the spiral (fins) roller (C below). The waste toner is
collected at the output end of the spiral roller and sent back to the toner container, into the
waste toner reservoir.

D
A

C B

After the drum is physically cleaned, it then must be cleaned to an electrically neutral state.
This is necessary to erase any residual positive charges, ready to accept the next uniform
charge. The residual charge is canceled by exposing the drum to the light emitted from the
eraser LED (D above). This lowers the electrical conductivity of the drum surface making
the residual charge on the drum surface escape to the ground.

4-16

5A2
Typical photo process timing chart
The following chart shows the signals used for photo processing. These signals activate the
corresponding device in the following timing sequences. A simple description for these
signals follow.
Page 1

Page 2

MOTOR
PAPER

MHVDR

ERASER

A
BIAS

B
THVDR

SHVDR

MHVDR (Main High Voltage Drive) turns on the main charger bias for charging the
toner. This signal is kept on during the job is being processed.
ERASER turns on the eraser (LED array) as soon as the motor begins to rotate revolving.
BIAS turns on the developer bias on the magnet roller. The duration of this signal is
dependent on the current paper size. The bias is reduced to approx. 100 V between paper
A. This avoids gray background effect by attracting excessive toner on the magnet roller
onto the drum (which will subsequently be collected back in the drum unit by means of the
cleaning blade).
THVDR (Transfer High Voltage Drive) turns on the transfer bias. Note that the transfer
bias is weakened (from 12 kV to 600 V) while paper is not present between the transfer
roller and the drum unit. This avoids contamination on the back side of paper B.
SHVDR (Separation-charger High Voltage Drive) turns on the separator to scrape the
paper off of the drum unit.

4-17

5A2

Paper feeding system

The paper feeder providing two paper cassettes is fitted to the printer externally at the
bottom of the printer. The printer can be installed with up to 6 cassettes by adding up to two
more paper feeder options (basically the same paper feeder fitted as the standard paper
feeder).
The paper feeding system picks up paper from the cassette or the MP tray. At a precise
timing, it feeds it to the electrophotography system. It finally delivers the printed page to
either the face-down or face-up tray, or to the optional stacker/finisher.
The figure below shows the components in the paper path within the printer. The sensors,
solenoids, etc., are also described in the following pages.

PAPER FEEDING DIAGRAM

1
2
3
4
5
6
7

4-18

Paper cassette
Paper feed rollers
Registration rollers+clutch
Drum
Transfer roller
Fuser rollers
Manual feed roller

5A2
Paper control signals
The following diagram shows the control signals that control the sensors and the rollers for
guiding paper. The engine controller provides these signals in conjunction with the
electrophotography process that is driven by the main controller system.

Stack
solenoid

EMOT*

Face-down
jam sensor

Heat Roller
Drum

Face-up
jam sensor
Pressure Roller

MPFPAP*

MFEED*

ENVPASS*

SUBCL*

JAMR*

REGCL*

THVDR*

Face-down
paper-full
sensor

RHVDR*

MMOT*

PAPFL*

JAMFD*

FDWSD*/FUPSD*

Engine Controller

Regist.
clutch

Regist.
jam
sensor
Regist roller

Separation
charger

Transfer roller

Paper feeder

Envel.
pass
sensor

Subclutch

Manual
feed
clutch

MP
feed
sensor
MP tray

Paper
sensor

Clutches

Paper Cassette
Paper
sensor

Paper Cassette

Sensors
Rollers

4-19

5A2
Paper feeding components
The figure below shows the locations of the sensors, clutches, microswitches, and fans.
Each number corresponds to the description in the table on the next page. The board Ids
accompany those parts mounted on the board.

3 6

1 @* ^ &

0
4
5

#
$

%
(

fi

4-20

fl

5A2
Control devices
Symbol

Title

Location

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Controller box fan (FAN3)

Printer side cover switch
Face-down paper-full sensor
Face-down jam sensor
Face-up jam sensor
Face-up/down solenoid
Scanner fan (FAN4)
Interlock switchfront
Drum/fuser fan
Tower sensor
Power supply fan (FAN2)
Main motor
Registration clutch
Intermediate clutch
Registration jam sensor
Interlock switchtop
Top cover switch
Toner container sensor

Controller box
Face-down unit
Face-down unit
Face-down unit
Face-down unit
Face-down unit
Top cover
Front frame
Rear frame
Rear frame
Shield box
Drive unit
Drive unit
Drive unit
Rear frame
MP feed unit
MP feed unit
MP feed unit

19
20
21
22

MPF paper sensor

MPF paper size sensors 1 and 2
MPF solenoid
Envelope feeder sensor

MP feed unit
MP feed unit
MP feed unit
MP feed unit

23

Toner container switch

Rear frame

Board
KP-552

KP-556
KP-574

KP-603
KP-576

4-21

5A2
Paper feeder control devices
Symbol

Location

Board

Upper cassette

KP-583

Upper cassette
Upper cassette
Upper cassette
Lower cassette

KP-581
KP-585

29
30
31
32
33
34
35
36
37
38
39

Upper cassette paper sensor/bottom limit

sensor
Upper cassette paper size sensors 1/2/3
Upper cassette LED
Upper cassette paper level switch
Lower cassette paper sensor/bottom limit
sensor
Lower cassette paper size sensors 1/2/3
Lower cassette LED
Lower cassette paper level switch
Upper cassette switch
Lower cassette switch
Upper jam sensor
Lower jam sensor
Right side cover switch
Upper cassette base elevation motor
Lower cassette base elevation motor
Intermediate stepping motor

Lower cassette
Lower cassette
Lower cassette
Drive plate
Drive plate

KP-581
KP-585

40

Feed stepping motor

Drive plate

24
25
26
27
28

4-22

Title

Drive plate
MP feed unit
Drive plate

KP-583

5A2
Printing from paper feeder cassettes
At the moment the logic controller finishes data processing, the logic controller passes
PRINTN signal to the engine controller. The engine controller then activates the clutch for
the feed roller of the currently selected cassette (in the paper feeder) and the sub clutch in
the printer to start feeding paper. As the paper kicks the registration jam sensor, it
momentarily stops there before the print data starts laser scanning on the drum.
Pick-up roller
Sensor 1

Feed roller

One-way clutch

Solenoid

Feed mechanism

Paper

Sensor 2

Bottom plate
Arm

Retard roller
Torque limiter

When the laser scanner and the fuser are ready, the engine controller sends VSREQN
signal to the logic controller to verify the readiness of data. When the logic controller finishes
data processing, it sends VSYNCN and VDATA to the engine controller. Now the paper is
released from the registration rollers and through under the drum unit, starting the image
development, transferring, and fusing. The paper having passed through the fuser unit kicks
the face-down or face-up paper jam sensor (and the paper-full sensor at the face-down
outlet, if the paper was destined to the face-down stack). When the paper is not detected
by these sensors in the expected time of period, depending on the current paper size, the
engine controller halts printing and report the occurrence of a paper jam.
The size of the paper currently in the selected cassette is acknowledged to the engine
controller by means of the on-off status of the photosensors PT1, PT2, and PT3 in the paper
feeder, at the end of the paper cassette. The table below summarizes the on-off status of
these photosensors in accordance with the supported paper sizes.

4-23

5A2
PAPER SIZE SENSING
Paper size

PT1

PT2

PT3

Ledger (portrait)
A3 (portrait)
B4 (portrait)
Legal (portrait)
B5 (portrait)
Letter (landscape)
A4 (landscape)
A5 (landscape)

Off
On
Off
Off
Off
On
On
On

On
On
Off
Off
On
On
Off
Off

On
On
Off
On
Off
Off
On
Off

Off=high/On=low

Printing from the MP tray

The presence of paper in the MP tray is detected by the MP feed sensor (See page Chapter
4-19). When the controller is ready to print, the engine controller activates the clutch for the
manual feed roller. The manual feed roller pulls the paper on the MP tray and sends it
forward to the registration roller after the envelope pass sensor is cleared. The rest of the
printing process is the same as that of the paper feeder explained on page Chapter 4-23.
The size of the paper currently on the MP tray is detected by two sensors (See page Chapter
4-20). Photosensors PT1 and PT2 are activated in accordance with the setting of the paper
guides (adjusted manually). The table below summarizes the on-off status of these
photosensors.

4-24

5A2
MP TRAY SIZE SENSING
Paper size

PT1

PT2

A3
Ledger
A4 (landscape)
Letter (landscape)
B4
8" width
Letter (portrait)
Legal
A4 (portrait)
8" width (portrait)
B5 (portrait)
A5 (portrait)
Hagaki
5" width

On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off

On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off

Printing from the optional envelope feeder

The envelope feeder (or universal feeder) is electrically connected to the printer via a
connector at the right side panel. This connector provides connection of the paper presence
and the envelope feeder motor to the printers engine system.
The envelope feeder motor sends the paper towards the registration roller after the
envelope pass sensor is cleared. The rest of the printing process is the same as that of the
paper feeder explained on page Chapter 4-23.

4-25

5A2
Paper jam detection
The sensors illustrated in the following diagram are used to track the paper while it is moving
through the printer. More detailed sensor information can be found from the diagrams in
section Paper feeding components on page Chapter 4-20.

H
A
B

1
C
2
F
3
D

4
5
E
6

4-26

5A2
Each sensor coded above represents the following locations. When a paper jam occurs, the
code(s) is actually indicated on the message display in order for the user to easily know
where to remove the jammed paper.
Code
A
B
C
D
E
F
G
H
I
1
2
3
4
5
6

Suggested jam location

Envelope feeder (optional)
MP tray
Top paper feeder jam door
Middle paper feeder jam door
Bottom paper feeder jam door
Optional stacker
Face-up stack outlet/Printer side cover
Paper feed unit/Fuser unit
Duplexer (optional)
First paper cassette
Second paper cassette
Third paper cassette (optional)
Fourth paper cassette (optional)
Fifth paper cassette (optional)
Sixth paper cassette (optional)

4-27

5A2
Message display at a paper jam
When paper jammed within the printer system, the sensor(s) triggers the signal to the
engine controller, which indicates the jam position. At the same time, the engine controller
causes the message display to show Open front cover. This urges the user to refer to the
instructions that is affixed at the back side of the front cover of the printer.
A sample of the display transition when a jam occurred follows. Read through from top to
bottom.
When a paper jam occurs, the display shows:

Paper jam
Open front cover

After opening the front cover, the actual jam

positions are indicated:

Paper jam
C, F, G, H, I, 6

As the paper is removed in order of the display,

the specific position code will go out.

Paper jam
F, G, H, I, 6

When all jam locations are cleared of jam, the

display shows:

Front cover
Open

Close the front cover. The printer starts

warming up.

Please wait

When the printer reverts to normalcy, the

printing job resumes.

4-28

Processing
PAR 600 A4 001

100

MHVDR

ERASE

BIAS

100

PSEN2_3

PSEN1_3

PSEN2_2

PSEN1_2

PSEN2_1

515

105

STML_3

PSEN1_1

55

100

0 (ms)

SUBM_3

SUBM_2

SUBM_1

FDWSD

SUBCL

PAPFUL

JAMFD

JAMR

REGCL

LASER

SCRDY

SCANER

MMOT

880

1740

2658

3800

3518

4878

4513

4500

4018

4648

5013

5133

6628

6340

6643

6353

6353

6353

6208
5843

5488

6443

6343
6428

7370

6443
VSREQ

6443
6172
6060

6198
5788
5820

5448

4300
VSREQ

4293

4300

4300

3883

3653

3730

3875

3865

3720

3365

3023

2735

2370

2988
2870

2990

2990

2505

2248

2150

1875

1510

1375

845

1155

8483

9092
9070

8983

8983

8488

8983

8983

8771

8571

7548
8273

7931
7963

8315

11

11235
9691
10416 11213
10068
10611
10003

9513

10

12515

12211
12146

12515

12

13

14

15

16

(S)

5A2

Print timing charts

Line speed=125 mm/s; feed speed=263 mm/s [paper feeder], 125 mm/s [MP tray]

A4 landscape feed [210 mm]/28 ppm/Cass 6

4-29

4-30

100

ERASE

BIAS

100

MHVDR

PSEN2_3

PSEN1_3

PSEN2_2

PSEN1_2

PSEN2_1

515

105

STML_3

PSEN1_1

55

100

SUBM_3

SUBM_2

SUBM_1

FDWSD

SUBCL

PAPFUL

JAMFD

JAMR

REGCL

LASER

SCRDY

SCANER

MMOT

0 (ms)

880

845

2173

2538

4500

4338

4703

4528
4163

6813

6813

6693

6361

6328

5996

7128

7326

7691

7148

8686

8020

8323

8321

8033

8033

8033

8023

8468

8123
7878

7852
7740

8123
VSREQ

8123

7468
7500
7370
7548
8273

6628 7148

6428

5973

5698
5333

4300
VSREQ

4668

4300

4300

3928

3875

3865

3720

3800

3533

3168

2870

2990

2990

2505

2150

1875

1510

1155

10451

11

11875

12343

12343

12

11843

12343

12343

11291
11323
11193
11371
12096
11744
12291
11883

10772
10750

10251

10

13

14595
14573

14

16

15875

15875

15571
15506

15

(S)

5A2

A3 [420 mm]/16 ppm/Cass 6

BIAS

ERASE

MHVDR

MPSIZE

MPFBCL

FDWSD

SUBCL

PAPFUL

JAMFD

JAMR

REGCL

LASER

SCRDY

SCANER

MMOT

500
525

100

100

175

175

100

0(ms)

1497

1190

4300

4300

5212

5080

4300
VSREQ

4500

4300

3800

5580
5605

5788
5820

6677

6340

9217

9092
9070

8717

9217

9217

9005

8805

8273

9217

8468

8549

8165
8197
7548

7589

7370

6677
VSREQ

6877

6628

6577
6428

6677

6677
6270

6172
6060

9925
10650
10068
10003

9747

10

10845

11469
11447

11

12749

12749

12749

12445
12380

12

13

14

15

16

(S)

5A2

A4 [210 mm]/26 ppm/MP tray [Cassette mode]

4-31

5A2

CONTENTS
Chapter 5

DISASSEMBLY

General Instructions .................................................................................................. 5-1

Before starting disassembly ..................................................................................... 5-2
Disassembly ............................................................................................................... 5-3
Developer unit .............................................................................................................. 5-3
Removing the paper feed unit ...................................................................................... 5-6
Removing the transfer roller unit .................................................................................. 5-7
Removing the drum unit ............................................................................................... 5-9
Main charger unit ....................................................................................................... 5-10
Removing the controller cover ................................................................................... 5-11
Removing the controller box ...................................................................................... 5-13
Right side cover/Feeder unit ...................................................................................... 5-15
Removing the face-down unit .................................................................................... 5-17
Removing the manual feed roller/Separator .............................................................. 5-19
Drive gears assembly ................................................................................................ 5-20
Removing the fuser unit ............................................................................................. 5-22
Removing the laser scanner ...................................................................................... 5-26

1-1-15

5A2

General Instructions
This chapter provides procedures for removal and replacement of field replacement
components. For other components not shown in this chapter, the diagrams in the Parts List
attached with this handbook will help locate the component.
For replacement of a component, use the reverse of the removal procedures explained in
this chapter.
Before proceeding, make sure printer power is switched off and the power cord is unplugged
from the printer. See Warning below.
Warning: To avoid injury to human bodies, make sure that AC power is removed and the
power cord is unplugged from both the power line and the printer.
Caution: To secure a self-tapping screws, align it with the thread carefully. First turn it
counterclockwise, then slowly clockwise. Do not over-tighten. In case the
selftapped thread is damaged, the affected part must be replaced with a new
part.

5-1

5A2

Before starting disassembly

Warning: Before proceeding, unplug the power cord from the printer and the power
supply.
Warning: Never attempt to operate the printer with a component removed.
Caution: The printer uses electrostatic-sensitive parts inside (on boards, laser scanner,
etc.). Provide an antistatic (discharging) device, such as a wrist strap, that can
effectively discharge your body before touching boards, laser scanner, etc.

5-2

5A2

Disassembly
Developer unit
First, the toner container must be removed.
Open the top cover. The toner container 1 must be removed first: Pull the toner container
release lever 2 as below. Pull the toner container 3 slowly up, keeping it as level as
possible.

5-3

5A2
Open the front cover. Locate the developer unit release lever 1 and turn it clockwise to the
upper position. Grasp the developers front end as shown below and slowly draw the
developer 2 out from the printer.

Notes:
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.
Do not place floppy disks near the developer.

5-4

5A2
REPLACING THE DEVELOPER UNIT
To replace the developer unit into the printer, be sure to align the guides and rails on the
drum unit with each other. Do not force to slide the drum unit in unless they are properly
aligned with each other.

When the developer unit has been fully seated, remove the protective cover.

Caution: Do not rush the developer unit into the printer. It may cause damaging the
developer unit connector and an uneven toner distribution inside the developer
unit which may result in a printing problem.

5-5

5A2
Removing the paper feed unit
The paper feed unit can be removed from the printer without using a tool.
Note: If duplexer is installed in the printer, uninstall it before proceeding.
While holding and pushing the locking tab 1 at the left side of the paper feed unit, draw the
paper feed unit all the way out.

5-6

5A2
Removing the transfer roller unit
Before removing the transfer roller unit, remove the paper feed unit out of the printer. Then,
the transfer roller comes out without needing a tool.
Caution: Do not touch the transfer roller (sponge) surface. Oil and dust (particles of paper,
etc.) on the transfer roller can significantly deteriorate the print quality (white
spots, etc.).
The transfer roller unit 1 is held in place by two joints at both ends. To remove the transfer
roller unit: Hold the tab at both left and left sides of the transfer roller unit first. When
removing, tilt the transfer roller unit upward so that the joints are aligned to free the transfer
roller unit.

5-7

5A2
INSTALLING THE TRANSFER ROLLER UNIT
To install the (new) transfer roller unit, align the mounting holes 1 of the transfer roller unit
with the joints 2 of the paper feed unit.

1
2

CLEANING THE TRANSFER ROLLER UNIT

To clean the transfer roller, remove the transfer roller unit out from the feed unit as shown
on page 5-7. Use a vacuum cleaner, moving nozzle along the roller, but do not let the nozzle
directly touch on the roller, while rotating the transfer roller by the gear. Thoroughly clean
the entire surface of the roller.

5-8

5A2
Removing the drum unit
Caution: Removing or reinstalling the drum unit requires the drum protective cover
supplied with the new drum kit package. Do not forcibly attempt to remove the
drum without following the procedures provided below, using the drum protective
cover.
Caution: Store the drum unit in a clear, clean place, not exposed to a strong light source.
Seal it in a protective bag. Avoid bump the drum surface onto hard objects.
To remove the drum unit 1, first insert the drum unit protective cover 2 as shown below.
This unlatches the drum unit for removal. Be sure to install the protective cover firmly in.

While pressing the drum release lever 3 at the left side of the printer, as shown below, pull
the drum unit all the way out. It should come off with the protective cover. When the drum
unit is halfway out, hold the handle at the top of the drum unit.

5-9

5A2
Main charger unit
Pull the main charger 1 until it stops. While pushing the (white) locking button 2 the printer,
pull the main charger unit all the way out.

The main charger unit is technically explained in chapter 4, Operation.

5-10

5A2
Removing the controller cover
Remove the controller cover by removing the screws 1 below.

1
1

Disconnect the two connectors 2 on CONN1 board at the back.

5-11

5A2
Open the front cover and remove the screws 3 below.

Remove the screws 4 and 5. All these are self-tapping screws of the same type. Then,
remove the top cover.

5-12

5A2
Removing the controller box
Remove the middle bracket by removing four screws 1.

Remove the connectors 2.

5-13

5A2
Remove two screws 3 to remove the controller box.

5-14

5A2
Right side cover/Feeder unit
Remove four screws, 1 and 2, and remove the right side cover.

2
1

Remove three screws 3.

3
3

5-15

5A2
Remove the screw 4 at the front side.

Remove the controller box (Refer to Removing the controller box , the previous section.),
then remove the screw 5 below to remove the ground wire (black) 6 of the feeder
assembly.

After removing the above screw, set the drum unit release lever to the left (down) position.
Then, carefully remove the feeder assembly.

5-16

5A2
Removing the face-down unit
Remove the face-up tray by pulling the left and right arms of the tray while pushing in the
locking tab 1 for each arm.

Remove six screws 2 and remove the left cover.

2
2
2

5-17

5A2
Remove the screw 3 on the front side (below). Then, remove the one on the rear side.

5-18

5A2
Removing the manual feed roller/Separator
While pressing the locking tab 1 in, remove the manual feed roller.

To remove the separator 2, use a small flat blade screwdriver in the manner shown below.

5-19

5A2
Drive gears assembly
Begin removing the driver gear assembly by first removing the sub gears assembly C. This
assembly mounts gears for driving the toner container and the waste toner conveyer. To
remove this assembly, remove two screws 1.

Sub gears
assembly C

Then, remove the waste toner conveyer housing. To remove this part, remove three screws
2. The right side cover must be removed first. Remove five screws. Detach two connectors.
Then remove the drive assembly from the printer.

Waste toner
conveyer housing

5-20

5A2
To remove the main motor assembly, remove all screws indicated as 3 below.

Main motor
assembly

To remove the drive gears assembly, remove three screws 4 as shown below.

5-21

5A2
Removing the fuser unit
The fuser unit can be detached from the feed unit without needing a tool. To remove the
fuser unit, first, open the feed unit. To open the feed unit, raise and hold the (green) handle
and pull the feed unit frontwards gently.
Warning: The fuser is hot after the printer was running. Wait until it cools down.
Fuser unit

Feed unit

5-22

5A2
To remove the fuser unit, unlatch the fuser unit from the feed unit. This is done by releasing
the latch at both sides of the fuser unit in the manner shown below.

Latches: Move to the

arrowed direction
to release the
fuser unit.

Fuser unit

Then, hold the fuser unit using both hands and lift gently. Remove as shown below.

5-23

5A2
Removing heater lamps
The fuser unit includes two heater lamps which are different in function and shape (length).
To gain access to the heater lamps in the fuser, first, remove the cover (on the connector
side) as shown below, by removing two screws 1.
Fuser unit

1
1

Remove the screw 2 shown below and remove the terminal.

5-24

5A2
Remove the appropriate screw 3 to remove the lamp.

Warning: The heater is extremely hot immediately after the printer was running. Allow
substantial period of time until it cools down. Also, the heater is fragile: Handle
it with great care.
Cautions:
The heater lamps are fragile. Use extreme care when handling not to drop or break.
Do not directly touch on the heater lamp. Finger prints on the heaters outer surface can
prevent proper fusing of toner on paper.

5-25

5A2
Removing the laser scanner
To remove the laser scanner, the top cover and the face-down unit must be removed first.
For details, see page 5-12.

Warning: The laser scanner contains electrostatic-sensitive parts inside (laser diode, etc.).
Before touching the laser scanner, provide an antistatic (discharging) device,
such as a wrist strap, that can effectively discharge your body.
To remove the laser scanner, remove screws 1 and 2. Detach connectors as needed.
After removing the scanner, handle it carefully.

5-26

5A2

CONTENTS
Chapter 6

TROUBLESHOOTING

Board layouts ............................................................................................................ 6-1

Overall boards layout (Rear view) ............................................................................... 6-1
Diagnostic .................................................................................................................. 6-2
Engine diagnostics flow ............................................................................................... 6-3
Logic controller diagnostics flow ................................................................................. 6-6
General error handling ............................................................................................. 6-7
Panel indicator ............................................................................................................ 6-7
Error messages ......................................................................................................... 6-8
Memory card errors ................................................................................................... 6-11
Call-Service person errors ..................................................................................... 6-13
A1: Uninstalled waste toner conveyer ....................................................................... 6-13
A2: Fuser overheating ............................................................................................... 6-15
A3: Fuser heater disconnection ................................................................................ 6-16
A4: Developer unit life-fuse error .............................................................................. 6-17
B1 B6: Feed cassette bottom plate motor error ..................................................... 6-18
C1: Duplex communication error ............................................................................... 6-19
C2: Duplex printing registration error ........................................................................ 6-19
C3: Void .................................................................................................................... 6-19
C4: Document finisher IPC communication error ...................................................... 6-19
C5: Document finisher backup RAM error ................................................................ 6-20
C6: Document finisher sensor error .......................................................................... 6-20
C7: Void .................................................................................................................... 6-20
C8: Document finisher staple unit movement motor error ......................................... 6-20
C9: Document finisher staple motor error ................................................................. 6-20
CA: Document finisher alignment motor error ........................................................... 6-20
CB: Document finisher tray motor error .................................................................... 6-21
CC: Document finisher paper feed motor error ......................................................... 6-21
CD: Document finisher paper exit motor error/Sorter error ....................................... 6-21
D0 D4: Firmware program errors ........................................................................... 6-21
E0: Communication failure ........................................................................................ 6-22
E1: Main motor error ................................................................................................. 6-23
E2: Laser scanner motor error .................................................................................. 6-25
E3: Laser beam detection error ................................................................................. 6-25
E4: Fuser heater error ............................................................................................... 6-27
E5: Eraser error ......................................................................................................... 6-28
E8: Fuser unit life fuse error ...................................................................................... 6-29
E9: Toner motor error ................................................................................................ 6-29
F0: Controller system lock error ................................................................................ 6-30
F1: Main controller ROM checksum error ................................................................. 6-30
F2: RAM read/write error ........................................................................................... 6-30

1-1-17

5A2
F3: Controller system error ....................................................................................... 6-30
Other errors relating to the controller board .............................................................. 6-31
Option harddisk errors ............................................................................................... 6-32
Print quality problems ............................................................................................ 6-33
Completely blank printout .......................................................................................... 6-33
All-black printout ........................................................................................................ 6-33
Dropouts .................................................................................................................... 6-34
Black dots .................................................................................................................. 6-35
Horizontal streaks ..................................................................................................... 6-35
Black vertical streaks ................................................................................................ 6-35
Unsharp printing ........................................................................................................ 6-36
Gray background ....................................................................................................... 6-37
Dirt on the top edge or back of the paper .................................................................. 6-38
Repetitive defects gauge ........................................................................................... 6-39
Drum cleaning ........................................................................................................... 6-40
Correcting a paper jam ........................................................................................... 6-41
Locating and correcting paper jams .......................................................................... 6-42
Correcting paper jams ............................................................................................ 6-43
Paper jam removal diagrams .................................................................................... 6-46

1-1-18

5A2

Board layouts
Overall boards layout (Rear view)

Symbol
(above)

Board No.

KP-536

Main logic board

KP-537

System ROM (Flash DIMM)

KP-544

Engine board

KP-564

Wiring liaison board (CON1)

Description

Power supply

6-1

5A2

Diagnostic
The printer automatically executes its self-diagnostic test when it is powered up. The
sequence and the items to be diagnosed are explained below.
When the printer locates the error with a specific item, it calls for operators attention by
showing the appropriate Call service person message on the operator panel display. The
Call service person message is followed by one of the following codes:
A, Development component
B, Paper cassettes
C, Duplexer, stacker, finisher
D, Firmware downloading
E, Engine controller
F, Main controller
Flowcharts on the following pages show the order and the items diagnosed in each system.
Note: Diagnostic test is canceled if one of the user-accessible covers is opened during the
test.

6-2

5A2
Engine diagnostics flow

Power
on

Engine ROM
checksum OK?

No

D0: Firmware program error

Yes

Fuser heater
temp. normal?

No

A2: Fuser overheating

Yes

Fuser heater
normal?

No

A3: Fuser heater disconnection

Yes

Is fuser new?
Yes

Fuser life fuse

blown?

No

E8: Fuser unit life fuse error

Yes

6-3

5A2

Is developer new?
Yes

Developer life fuse

blown?

No

A4: Developer unit life-fuse error

Yes

Fuser thermistor
normal?

No

E4: Fuser heater error

Yes

Polygon motor
normal?

No

E2: Laser scanner motor error

Yes

Laser pin-photo
detects laser?

No

E3: Laser beam detection error

Yes

Main motor normal?

Yes

6-4

No

E1: Main motor error

5A2

Toner being fed?

Yes

Toner motor normal?

No

E9: Toner motor error

Yes
Waste toner
conveyer normal?

No

A1: Uninstalled waste toner

conveyer

Yes

Fuser temp. rises

in normal time?

No

E4: Fuser heater error

Yes
Engine
ready

6-5

5A2
Logic controller diagnostics flow

Power on

System ROM
checksum OK?

No

F1: System ROM error

Yes

Communication
established between
engine and main
CPUs?

No

E0: Communication error

Yes

System memory OK?

Yes
Controller is ready.

6-6

No

F2: System memory error

5A2

General error handling

This section provides how to handle general errors as indicated on the message display.
Refer to the section starting on page for errors calling for service person assistance.
Panel indicator
The symbol mark on the front panel provides following user-handling errors. Proceed with
Corrective actions indicated below.
Indicator

Indication

The printer has run low on toner. The toner

should be replaced as soon as possible.
Clean the printer after replacement.

Lit

Toner is low or has run out. Replace with a

new toner container.

Fast flashing

Paper is jammed in the location flashing.

Slow flashing

The paper has run out in the paper cassette

or multi-purpose tray. Add paper to the
paper feed source.

Lit

This indicates either the current paper feeder

or the paper output point.

Flashing

A paper jam has occurred in the optional

duplexer. Remove the paper jam in the
duplexer.

Lit

An optional duplexer has been attached,

and the printer is printing in duplex printing
mode.

Flashing

The printer is warming up (Please wait) or

the printer has insufficient memory available.
Confirm the message indicated on the
message display.

Lit

A message will be displayed in the message

display. Take corrective action according to
the message displayed. The table on the
following pages lists the corrective action to
take in response to each message.

Low toner

Paper feeding

Duplexer
ATTENTION

Corrective action

Flashing

6-7

5A2

Error messages
The printer indicates on its front control panel various messages ranging from userrecoverable errors to call-service person errors. The instructions below indicate how to
respond to all those problems indicated by the error messages. For call-service person
errors, further reference to the descriptions including flowcharts may be required as
instructed in Corrective action below.
Message

Corrective action

Top cover
Open

The top cover is open. Close it tightly.

Front cover
Open

The front cover is open. Close it tightly.

Side cover
Open

The printers side cover is open. Close it tightly.

Paper feeder 1
side cover Open

The paper feeders side cover is open. Close it tightly. If an

optional paper feeder is installed, the paper feeder having the
problem will be indicated number in the message. If the
maximum of three feeders are installed, the upper feeder is 1,
the middle feeder is 2, and the bottom feeder is 3.

Face-down tray
paper full

The face-down tray has become full. You must remove all
printed pages from the face-down tray. The face-down tray
can hold approximately 500 sheets.

Add paper

The paper source is out of paper. Add paper to the paper

cassette or multi-purpose tray.

Set paper
Press CONTINUE

Add a sheet of paper to the multi-purpose, and press the

CONTINUE key. Printing will start. This message appears
when the multi-purpose tray is in manual mode.

Load paper
(paper size)

The paper size does not match. The size of the paper in the
cassette is different to the size specified by the application
software or by PRESCRIBE II command. Put paper of the
specified size into the cassette.
If the CONTINUE key is pressed, printing will be resumed.
However, if more than one sheet is to be printed, the same
message will again be displayed from the second sheet
onward.
You can abandon printing by pressing the CANCEL key.

Cassette
not loaded

The cassette is not closed securely, Close it tightly.

Paper jam
Open front cover

Paper has become jammed. Open the front cover. The location of the paper jam is displayed in the message display.

6-8

5A2
Message
Paper jam
##############

Corrective action
This message appears when the front cover is open during a
paper jam.
Letters A through I and numbers 1 through 6 will appear in
place of the #s. For details on the meaning of the text
displayed, see page Chapter 6-34. A label displaying these
number indications is also attached to the back of the front
panel. The indicator on the front panel also flashes the
location of the paper jam.

Warning
Low memory

The printers internal memory is running low. Remove any

unnecessary download fonts and/or macros. You can check
the amount of user memory currently available by printing a
status page.

Replace Toner
Clean printer

There is not enough toner inside the toner container. Be sure

to promptly replace with a new toner as the printer will stop
printing before long. Clean the printer after replacement.

Replace Toner
Clean printer

There is no more toner in the toner container. The printer has

stopped because there is no more toner. Replace with a new
toner kit. After replacing, be sure to clean the printer.

Clean printer
Press CONTINUE

Please clean the inside of the printer. After cleaning the inside
of the printer, press the CONTINUE key and the printer will be
ready for printing. This message will be displayed when
replacing the toner container after the message Replace
Toner Clean printer has been displayed.

Missing
Toner kit

No toner container is installed. Install the toner container. The

printer does not operate when this message is displayed.

Install MK

The maintenance kit needs to be replaced. Replace the

maintenance kit since the total number of printed pages has
reached 350,000. Contact the licensed dealer from which you
purchased the printer or service outlet. The maintenance kit
includes a drum unit, developer unit and so on.

Call service
person##:#######

A failure requiring the attention of service personnel has

occurred. A failure requiring the attention of service personnel
has occurred and the printer has stopped. The corresponding
error code and total printed pages are displayed in the
message display (part indicated by #s).

Memory overflow
Press CONTINUE

Current print processing cannot continue due to insufficient

memory. Check available user memory by printing a status
page, and either remove unnecessary download fonts and/or
macros or expand the printers memory.
Press the CONTINUE key to print data as far as it was stored.
You can abandon printing by the CANCEL key.

6-9

5A2
Message
Print overrun
Press CONTINUE

Corrective action
Current print processing cannot continue due to insufficient
memory. The data transferred to the printer was too complex
to print on a page.
Check available user memory by printing a status page, and
either remove unnecessary download fonts and/or macros or
expand the printers memory.
Note: After this message has been displayed, Page protect
mode will be on. To maintain optimum use of memory
during printing, display >Page protect from the mode
select menu, and re-select Auto.
Press the CONTINUE key to print data as far as it was stored.
You can abandon printing by the CANCEL key.

MEMORY CARD err

Insert again

The memory card is missing. This message appears when

the memory card has been removed from the memory card
slot during memory card operations. Re-insert the same
memory card in the same slot. the printer will continue with
memory card processing.

Insert the same

MEMORY CARD

Insert the same memory card. This message appears when

the memory card has been removed from the memory card slot
during memory card operations and replaced with a different
memory card. Re-insert the same memory card in the same
slot. the printer will continue with memory card processing.

Warning battery
MEMORY CARD

The memory cards battery is low. This message appears

when the printer is in the ready state and the battery of the
memory card installed in the printer is low. You can still enter
the memory card mode, but the battery should be changed as
soon as possible.

Battery error
MEMORY CARD

Insert a new battery in the memory card. This message

appears when the printer is in the ready state and the battery
in the memory card is missing or completely dead. Memory
card operations are not possible. Insert a new battery in the
memory card.

Format error
MEMORY CARD

The memory card requires formatting. This message appears

when the printer is in the ready state and the memory card is
not formatted. Be sure to format the memory card. (See the
instruction handbook.)

MEMORYCARD err ##
Press CONTINUE

This message appears when an error occurs during access

to the memory card using the PRESCRIBE ICCD command
or from the printers control panel. Look at the error code
given in place of ## and refer to the corresponding description
given below. Note that only error codes 09 and 11 are
displayed due to memory card operations made from the
control panel.
For details, see Memory card errors which follows on page
Chapter 6-11.

6-10

5A2
Message
I/F occupied

Corrective action
The interface selected is currently being used. This message
only appears if an optional interface is installed.
The interface is secured while the interface name displayed
in the message display is flashing even if the printer is in the
ready state. How long this takes depends on the interface
release timeout (FRPO J2) setting.
This message appears, and then the ATTENTION indicator
lights, when an attempt is made to select a secured interface
from the control panel or when an attempt is made to perform
memory card operations while the interface indicator is flashing.
Repeat operations after releasing the interface.

Processing
PAR FIT A4

Compressed data is printed due to insufficient memory.

Compressed data is printed due to insufficient memory when
FIT flashes in the resolution indicator. The quality of printed
data is reduced when this occurs. FIT will continue flashing
even after printing is finished. The resolution indicator will
automatically return to reading 600 dpi when any key is
pressed, when a timeout occurs, or when subsequent data is
received. Expand printer memory to avoid this error.

Processing
PAR 600 A4

600 dpi processing cannot be performed due to insufficient

memory. When 300 flashes in the resolution indicator even
though the printer was set to 600 dpi, the printer automatically
set resolution to 300 dpi due to insufficient memory and
continued printing. The resolution indicator will automatically
return to reading 600 dpi when any key is pressed, when a
timeout occurs, or when subsequent data is received.
Expand printer memory to avoid this error.

Processing
PAR 300 A4

Memory card errors

Error
code

Applicable
card type

Meaning

01

SRAM

Card size error (An attempt was made to write data of greater
than 32 MB in size.). Reduce the size of the data to be written from
the host computer to 16 MB or less; or, a file name could not be
found in the memory card.
No memory card inserted. Insert a proper memory card.

02

SRAM

03
04

SRAM/flush
SRAM

Non PCMCIA card. Replace the card with a PCMCIA card.

Not RAM card. Use a SRAM-type card if you want to write data
to an memory card.

05

SRAM

Memory card battery error. Replace the memory cards internal

battery with a new one.

6-11

5A2
Error
code

Applicable
card type

Meaning

06

SRAM

07

SRAM

08

SRAM

09

SRAM

10

SRAM

Reserved
Data name full (An attempt was made to write more than 127
destination data names). Press CONTINUE key (Ready).

Flush

Reserved
Erase logic error with flash memory card. Try replacing the
memory card.

14

15

Flash

Reserved
Non PCMCIA flush card. Replace the card with a PCMCIA flush
card.

11
12
13

16

17

Flush

18

Flush

19

Memory card protect error. Release the write protection on the

memory card when you write data to the memory card.
Non format. Reformat the memory card using MODE SELECT
(See the printers instruction handbook).
Partition name error. Follow instructions given attempt in Chapter
2 to properly name the destination.
Memory card data full error (An attempt was made to write data
exceeding the capacity of the memory card). Abandon the writing
operation on the host computer first. Press CONTINUE key;
when the message turns to Waiting, press FORM FEED key
(Ready).

Reserved
Unable to write to the flash memory card due to insufficient printer
memory. Either delete unnecessary macros or fonts stored in the
printer, or extend the printers available memory.
Writing error. Try replacing the memory card.
Reserved

For details on memory card availability, see section Printer specifications in chapter 1.

6-12

5A2

Call-Service person errors

The printer does not operate when a message beginning with Call service person (A, B, C,
D, E, F) is displayed. The message is categorized by an alphanumeric code. Proceed with
this section for taking a corrective action depending on the code.
The Corrective action may be useful for on-site service. Follow the flowchart if one is
provided in that item for further analysis of the problem.
A1: Uninstalled waste toner conveyer
Meaning

Suggested causes

Corrective action

The waste toner con- Waste toner converyer is not

veyer is not installed,
installed.
or the conveyer is The belt is not rotating in the
clogged inside with
conveyer unit.
waste toner.
Connection failure between the
CON1 board and the conveyer
board

Install a waste toner

conveyer or replace the
conveyer and belt.
Replace KP-544 or
KP-546. Check cable
S02070 for possible
disconnection. [If not
corrected, replace the
Engine gate arrays (U2/U6) failure cable.]
Defective LED driving circuit on the
engine board. Defective LED on
the conveyer board. Connection
failure between the waste toner
conveyer board and the photo
transistor. Defective photo
transistor.
Contaminated waste toner
conveyer housing or photo
receptor.
The waste toner driving system in
the toner container is not working
properly.

6-13

5A2

A1

Waste toner
conveyer installed?

No

Install conveyer.

Turn power off, then on.

Yes
Remove conveyer.

A1 shown?

Replace conveyer and

tower-guide assembly.

No

End

Yes

Can sweep
roller in toner container
be manual
rotated?

No

Replace with a new toner container.

Yes
Open waste toner outlet of
drum and manipulate to turn.

Is waste toner
emitted through the waste
toner outlet?

No

Replace with a new drum unit.

Yes
Turn power off, then on.

Still A1?
Yes
Replace KP-544. If not
recovered, replace KP-564.
If not recovered, replace
cable S02070 between
KP-564 and KP-574.

6-14

No

End

5A2
A2: Fuser overheating
Meaning

Suggested causes

The fuser unit is Defective photo-coupler (low

voltage) for heaters
overheating.
Defective engine gate array U2
Defective heater control circuit
(engine board) or heater temperature detector

Corrective action
Replace KP-544./Replace the switching
regulator./Check or
replace S02069 cable
KP-544 and the switching
regulator./Replace fuser.

A2

Remove fuse unit.

Temp adj pot.

meter on fuser board at
fully clockwise
position?

No

Replace fuser unit.

Yes

Thermistor fit tightly?

No

Replace fuser unit.

Yes
Replace KP-544. Replace
the switching regulator.
Check or replace S02069
cable KP-544 and the
switching regulator.
Replace fuser.

6-15

5A2
A3: Fuser heater disconnection
Meaning

Suggested causes

Either or both heater Blown-out heater lamp(s)

lamp(s) is blown out. Defective connection between the
engine board and the low voltage
supply.
Malfunctioning engine CPU

Corrective action
Replace KP-544. Replace KP-564. Check/
replace S02054 cable.
Replace fuser unit.

Defective heater disconnection

sensor circuit in the low voltage
supply
Defective thermo-cut (Replace the
fuser unit.)

A3

Remove fuser unit.

Measure the resistance

across primary terminals
(See right fig.) of fuser
connector.

2
Less than 10?

No

Yes
Replace KP-544. If not recovered,
replace KP-564, power supply,
S02069 cable between KP-544 and
power supply, or S02054 cable
between KP-544 and power supply,
in the order of the above.

6-16

Replace fuser unit.

5A2
A4: Developer unit life-fuse error
Meaning

Suggested causes

The life fuse wont cut Defective engine gate array

in the developer unit. Defective fuse cut circuit on the
engine board

Corrective action
Try turning the printer off
and on several times.
Replace developer unit.
Replace KP-544.

6-17

5A2
B1 B6: Feed cassette bottom plate motor error
Meaning

Suggested causes

The feed cassette Excessive torque on the motor

bottom plate motor (activating the current protection
circuit)
wont revolve.
Stuck motor
Defective feed board PU (U1)
Defective motor driver circuit
(transistors) or over-current
detector circuit

Corrective action
Replace the motor.
Check/replace S02088/
S02089 cables. Try
replacing with other
cassette to see if that
cassette is faulty.
Replace KP-546.

B1 B6

Change cassette to other

cassette. Turn printer power
off, then on.

Error still happens?

No

Replace the cassette.

Yes
Connect ckt tester to pin 5
of KP-546/U1. Measure
voltage.

High level (>3.5 V)?

Yes
Replace KP-546.

6-18

No

Replace motor. If not recovered,

S02088 between KP-546 and
cassette. If not recovered, replace
cassette or KP-546.

5A2
C1: Duplex communication error
Meaning

Suggested causes

Communication error Defective engine gate array (U6)

between the duplexer Defective engine CPU (U1)
and the printer.
Duplexer CPU (U1) malfunction
Defective U2, U5, U6 on duplexer
board
Defective connection between
KP-544 (YC4) and KP-568 (YC1),
KP-568 (YC3) and liaison
connector, liaison connector and
KP-587 (YC1), or defective liaison
connector

Corrective action
Try reinstalling duplexer.
Check/replace cable
between printer and
duplexer. Replace KP587. Replace KP-544.
Replace
duplexer.
Replace KP-568.

C2: Duplex printing registration error

Meaning

Suggested causes

The duplexers regis- Defective registration motor

tration boards are not Defective home position sensor
in the home position. Malfunctioning motor driving circuit
(U2/U6/U7) on duplexer board
Defective duplxer CPU (U1)
Connection error between the
registration motor and KP-587
(YC5), or home position sensor
and KP-587 (YC7)

Corrective action
Check foreign objects or
fractions of paper in
duplexer. Try manipulating adjusters to check
for smooth move. Check
photo sensor for normal
connection. Check/
replace S02100 cable.
Replace home position
sensor. Replace KP-587.
Replace duplexer.

C3: Void

C4: Document finisher IPC communication error

Meaning

Suggested causes

Communication error Defective IPC (intelligent protocol

with the document
controller) LSI (communication
finisher
chip)
Defective interface connector/cable

Corrective action
Check interface cable
between document finisher and printer.
Replace KP-544 (engine)
or KP-568 (CON3) in the
printer. Replace S02053
cable.

6-19

5A2
C5: Document finisher backup RAM error
Meaning

Suggested causes

Backup RAM error in Defective backup RAM

the document finisher

Corrective action
Replace
finisher.

document

C6: Document finisher sensor error

This error means any of the following sensors in the document finisher is defective:
Input sensor
Exit path sensor
Inversion sensor
Printer connection sensor
Stack height limit sensor
Stack home position sensor
Offset sensor
Cover sensor
Stacker full sensor

C7: Void

C8: Document finisher staple unit movement motor error

Meaning

Suggested causes

The staple unit move- The driver circuit for the motor is
ment motor does not defective.
rotate.
The staple unit is defective.
The motor is defective.

Corrective action
Check connector J8 for
the driver board. If not
corrected, replace document finisher.

C9: Document finisher staple motor error

Perform the same procedure as C8 for the document finishers staple motor.

CA: Document finisher alignment motor error

Perform the same procedure as C8 for the document finishers alignment motor except
making check on connector J11.

6-20

5A2
CB: Document finisher tray motor error
Perform the same procedure as C8 for the document finishers tray motor except making
check on connector J7.

CC: Document finisher paper feed motor error

Perform the same procedure as C8 for the document finishers feed motor except making
check on connector J11.

CD: Document finisher paper exit motor error/Sorter error

Perform the same procedure as C8 for the document finishers exit motor except making
check on connector J10.
The CD error also suggests that the bulk paper stacker is defective.

D0 D4: Firmware program errors

These errors are explained in chapter 3, Downloading firmware programs.

6-21

5A2
E0: Communication failure
Meaning

Suggested causes

Corrective action

The engine controller Error with CPU and gate arrays of

does not respond to either the engine or main controller
the main controller.
Connection error between the
engine board and the main controller board
Program overrun in the engine or
main controller

Check/replace S02051
cable. Replace KP-544.
Replace KP-536.

E0

Cable S02051
between KP-544 and
KP-536 wired
properly?
Yes
Replace KP-544. If not
cured, replace KP-536.

6-22

No

Reconnect
properly.

5A2
E1: Main motor error
Meaning

Suggested causes

The main motor wont Error with CPU and gate arrays of
revolve, or will revolve either the engine or main controller
too slow.
The motor brake circuit is activated
because of an abnormal torque of
the motor.
Overheating protection circuit is
activated because of the overheating main motor IC

Corrective action
Replace KP-544. Replace main motor. Check/
replace S02056 cable.
Replace drive unit.

Defective engine gate array (U2)

Defective main motor driving circuit
(transistor arrays, etc.) on the
engine board
Defective buffer IC for FG signal
detection on the engine board

6-23

5A2

E1

Turn power on and off.

Does motor rotate

5 seconds or more?

No

Can main motor

be manipulated
to turn?

Yes

No
Replace motor. If not
recovered, replace
S02056 cable between
motor and KP-544. If not
recovered KP-544.
Can drive
gears for fuser,
drum, and developer be
manipulated
to turn?

Turn printer power off, then on.

No

End

Yes
Replace DRIVE ASSY.
Turn printer power off, then on.

E1 shown again?
Yes

6-24

No

Locate the unit

preventing the
motor to rotate.

Replace the unit.

Replace main motor. If not cured,

replace cable S02056 between
main motor and KP-544.

No

Yes

E1 shown again?

Yes

End

5A2
E2: Laser scanner motor error
Meaning

Suggested causes

The revolution of the Defective scanner motor (e.g., at

polygon motor does
its axle holder)
not reach the prede- Connection error between polygon
termined revolution.
motor and liaison connector, or
liaison connector and KP-570 (YC3)
Defective engine gate array (U2/
U6)

Corrective action
Check/replace cables.
Replace KP-544. Replace
KP-564. Replace KP-570.
Replace scanner unit.

Defective scanner motor driver

transistor

E3: Laser beam detection error

Meaning

Suggested causes

Beam detection is Laser diode does not emit.

failed. The photo de- Connectionerror between KP-578
tector failed to detect
(YC2) and KP-579 (YC101 [within
laser beam.
scanner]), KP-578 (YC1) and
KP-570 (YC2), KP-578 (YC1) and
KP-564 (YC3), KP-570 (YC1) and
KP-564 (YC3), or KP-572 (YC1)
and KP-564 (YC3)

Corrective action
Check/replace cables.
Replace KP-544. Replace
KP-564. Replace KP-570.
Replace scanner unit.

Defective or contaminated pinphoto IC

Malfunctioning interlock detection
circuit on the ending board
Defective engine gate array U2

6-25

5A2

E3

Connect ckt tester to pin 3

of KP-564/YC3.
Turn power off, then on.

No

Is pin 3 low?

Connect ckt tester to

pin 45 of KP-544/U2.

Turn power off, then on.

Yes
Connect ckt tester to pin 10
of KP-564/YC3.
Is pin 3 low?
Turn power off, then on.

No

Replace KP-544.

Yes
Replace KP-564.

Is pin low for

approx. 900 s?
Is pin 10 low?

No

Replace S2108 cable.

Connect ckt tester to pin 45

of KP-544/YC2.

Replace scanner unit.

Turn power off, then on.

Yes
Replace KP-544.

6-26

End

Yes

Yes

Is pin 10 low?

No

E3?

E3?
No

Yes
Replace KP-564.

Replace KP-570.

No

End

5A2
E4: Fuser heater error
Meaning

Suggested causes

The fuser heater does Connection error between the

not turn on. [E4 is indi- engine board and the fuser unit
cated immediately Defective engine gate array U2
after power is on.]
Defective comparators on the
engine board

Corrective action
Replace KP-544. Replace fuser (temp.
adjustment is required.)
Check/replace S02054
cable.

Defective thermistor (cut)

Connection error between the fuser
board and the thermistor

The fuser heater does

not turn on. [E4 is indicated several minutes
after power is on.]

Connection error between the

engine board and the low-voltage
power supply
Defective engine gate array U2
Defective transistors, logic gate ICs,
comparators, etc. on the engine
board

Defective thermistor (showing high

resistance even at heating)

E4

E4 shown
within 30 seconds since
power is on?

No

Replace KP-544.
If not recovered,
replace fuser unit.

Yes
Measure resistance
between pins 4 and 5 of
KP-550/YC1.

Less than 1M ?

No

Replace fuser unit

(req. Temperature
adjustment).

Yes
Replace KP-544. If not
recovered, replace cable
between KP-544 and
fuser unit.

6-27

5A2
E5: Eraser error
Meaning

Suggested causes

Corrective action

The eraser does not Connector error between CON1

board and the drum liaison board
turn on.
Defective connector between the
drum liaison board and the drum
board
Defective transistors and logic gate
ICs in the eraser controller circuit
on the engine board

Replace KP-544. Replace

KP-564. Replace drum
unit.
Check/replace
S02070 cable.

Connection error between drum

unit board and eraser lamp
Broken eraser lamp

E5

Remove drum unit.

Measure resistance
between pins 1 and 7 of
KP-562.

R=?

Yes
Replace drum unit.

No

Install drum unit.

Measure resistance
between pins 2 and 6 of
KP-564/YC7.

R=?

No

Yes
Replace KP-558. If not
recovered replace S02070
cable between KP-564 and
KP-568.

6-28

Replace KP-544.
If not recovered,
replace KP-564.

5A2
E8: Fuser unit life fuse error
Meaning

Suggested causes

Corrective action

The fuser unit life fuse Defective gate array U6

Turn printer power off and
wont blow out.
Defective fuse cut circuit on the off several times. Replace fuser unit. Replace
engine board
KP-544.

E9: Toner motor error

Meaning

Suggested causes

Corrective action

Replace toner container.*

Replace developer unit.
Replace KP-544. Replace KP-599. Check/
replace S02052 and
Defective toner motor driver S02076.
transistor or overcurrent detector

The toner motor does Overcurrent in the toner motor

circuitry due to an excessive torque
not revolve, or the
current protection Toner motor locked
circuit is activated.
Defective gate array U2

* Also, try rotating the toner kit gear (feed gear). Compare the torque with a new toner kit.
Replace the toner kit if the torque is abnormal. Replace developer unit if the toner kit is
normal.

E9

Turn printer off, then on.

Damaged
toner container
gears?

No

Yes

Replace developer.

Turn printer off, then on.

Replace toner container.

E9 shown?

No

End

Yes
Replace KP-544. If not recovered,
replace KP-599, KP-560, S02076
cable between KP-599 and KP-560 or
S02052 cable between KP-544 and
KP-599, in the order of priority.

6-29

5A2
F0: Controller system lock error
Meaning
Main controller can not
communicate with
control panel [shown
approx. 30 seconds
since OS fails to
continue operating.]

Suggested causes
Connection error between main
controller board and engine controller board, engine board and
CON1 board, or CON1 board and
front panel board.

Corrective action
Replace KP-536 (main
cont.). Check/replace
S02051. Replace KP-544
(engine). Replace KP-564
(CON1).

F1: Main controller ROM checksum error

Meaning

Suggested causes

Checksum is failed
with the system ROM

Corrective action
Replace KP-537
(cont. ROM).

F2: RAM read/write error

Meaning

Suggested causes

Checksum is failed
with the RAM on the
main controller board.

Corrective action
Replace option SIMMs.
Replace KP-536.

F3: Controller system error

Meaning

Suggested causes

Error other than F0,

F1, and F2. [privilege
violation, bus error,
etc.]

6-30

Corrective action
Turn printer power off,
then on again. If not
solved, replace the main
controller board.

5A2
Other errors relating to the controller board
Symptom

Suggested causes

Corrective action

Display freezes while

indicating Processing.

A situation in which OS is not

able to run is occurred.

Turn power on and off. Or,

replace the main controller
board.

Printed characters
garbled.

Wrong printer driver is used.

Wrong emulation is used.
Parameters are incorrect on the
parallel interface. The surge
protection devices on the main
controller is defective.

If the parallel interface is being

used, investigate for the
adequate length of the
parallel cable. Also, check
that the cable is properly
shielded. Or, replace the main
controller board.

Harddisk error occurred.

No display on the
message display.

Defective wiring around the front

panel. Defective front panel
board.

See Option harddisk errors

on page Chapter 6-32.
Check wiring between the
main board and engine board;
between the engine board
and CON1 board; and CON1
board and front panel board.
Replace the front panel board
and/or main board.

6-31

5A2
Option harddisk errors
The printer indicates Harddisk error messages on the message display when it detects
errors with the option harddisk (if installed). This message is followed by a two-digit code
which provides the following meaning and corrective action to the specific error.
To clear the error message and continue operating the printer, press the CONTINUE key.
Harddisk
error code

Meaning

Corrective action

01

Format error or the harddisk is

damaged.

Turn printer power off then on again. If

not recovered, consider reformatting the
harddisk.*
[WarningFormatting erases all data
existing in the harddisk.]

02

No harddisk installed.

03

Harddisk is write-protected.

Ensure that the harddisk is installed

properly in the printer. For instructions,
refer to the handbook accompanying
the harddisk unit.
Unlock the write-protection state by
KPDL or PJL. Consult the system administrator if required.

04

Insufficient capacaity on harddisk,

or the number of files stored has
exceeded 10,000.

Free harddisk space by removing

unnecessary file in the harddisk.

05

The specified file does not exist.

Ensure whether a file with the specified

name exists on the harddisk. If the file
exists, ensure that correctly matching
file name is called, i.e. case. Print out a
partition list from the printer to obtain a
list of the included partition names in the
harddisk. (See the printers handbook.)

06

The memory available for use by

the file system is insufficient.

Install more memory in the printer. (See

the printers handbook.)
* For instruction on how to format the harddisk, refer to the instruction handbook for the
printer or the harddisk.

6-32

5A2

Print quality problems

Print quality problems range from uneven tone to completely blank output. The troubleshooting
procedure for each type of problem is given below.
Completely blank printout
Check the developer unit.

Check that the developer unit is inserted correctly

Check that the developers connector is connected
properly.
Check that toner is adhered around the developing
roller. If no toner appears to be on the roller, try feeding
toner into the developer using the manner described in
chapter 3 (See page 3-9).

Check main charging potential.

Check the main charging output on the HV board. This

requires removal of the left side cover and the test
equipment. Replace the HV board if high voltage
potential is not available on the board.

Check the laser scanner.

The scanner components within the scanner may be

disordered. Note that the laser scanner is concealed to
protect the components which are susceptible to dust.
It should not be disassembled except within a dust-free
chamber. Replace the scanner unit if necessary.

All-black printout
Check the main charger unit
installation.

Open the printer side cover and check that the main
charger unit is correctly seated. To do this, take out the
main charger unit from the printer; then reinstall it
carefully.

Check the grid plate (the

mesh metal bottom part of the
charger unit).

The grid plate must be flat and fit horizontally in place.

Replace the main charger unit if necessary.

Check the drum bias.

Make sure the bias from the HV board is correctly

arrived at the drum unit.

Check high voltage potential

at the HV board.

Check the high-voltage output on the HV board. This

requires removal of the left side cover and the test
equipment. Replace the HV board if high voltage
potential is not available on the board.

6-33

5A2
Dropouts

ABC
123

Note the spacing of the

defects. Use the Repetitive
defect gauge on page 6-39.

If the defects occur at regular intervals of 63 mm, the

problem may be a dirty transfer roller. Clean or replace
the transfer roller.
If the defects occur at regular intervals of 94 mm, the
problem may be a damaged drum unit or fuser roller.
Replace the drum unit or fuser unit accordingly.

Try changing the transfer

bias potential (Normal or
Thick).

Use the MODE SELECT key on the printers control

panel. For details, refer to the instruction handbook
accompanying the printer.

Check paper for property.

Paper with rugged surface or dump tends to cause this

type of failure.

Check the paper chute

installation.

The paper chute (the metallic fixture provided between

the transfer roller and the fuser unit for antistatic
purpose) must not be fit loose. Press the paper chute
down firmly if necessary.

Check the transfer roller

installation.

The transfer roller must be supported by the axle holder

at the both ends. Clean the axle holder to remove oil
and debris. Replace the transfer roller if necessary.

Check the transfer bias

potential.

Check the transfer bias output on the HV board. This

requires removal of the left side cover and the test
equipment. Replace the HV board if high voltage
potential is not available on the board.

6-34

5A2
Black dots
Note the spacing of the
defects. Use the Repetitive
defects gauge on page 6-39.

If the defects occur at regular intervals of 94 mm, the

problem may be a damaged drum unit or fuser roller.
Replace the drum unit or fuser unit accordingly.
If the defects occur at random intervals, the toner may
be leaking from the drum unit. Replace the drum unit.
If the defects occur at regular intervals of 38 mm, the
problem may be a toner lump on the developing roller.
Remove the lump using a soft brush. Note that the
developing roller surface is fragile: Contact the
manufacturer for type of the brush to use.

Horizontal streaks
Check drum ground.

The drum axle and its counter partdrum grounding

tab in the printer must be in a good contact. If necessary,
apply a small amount of electro-conductive grease
onto the tab. See the manufacturer for which type of
grease to use.

Check main charger contacts.

Take out the main charger unit; check the electric

terminals to see if they are clean.

The drum unit may be

defective.

Replace the drum unit.

Black vertical streaks

ABC
123

Contaminated main charger

wire.

Clean the main charger wire by pulling the green

colored cleaning knob in and out several times.

Check the drum surface for

a streak of toner laying
lengthwise.

A streak of toner remaining on drum after printing

means that the cleaning blade in the drum unit is not
working properly. Replace the cleaning blade; or replace
the drum unit.

Defective developer unit.

Replace the developer unit.

6-35

5A2
Unsharp printing

Check contamination on
the main charger wire and
the grid.

Clean the main charger wire by pulling the green color

main charger wire cleaner know in and out several
times.

Check paper for property.

Paper with rugged surface or dump tends to cause this

type of failure.

Check the paper chute

installation.

The paper chute (the metallic fixture provided between

the transfer roller and the fuser unit for antistatic
purpose) must not be fit loose. Press the paper chute
down firmly if necessary.

Try changing the transfer bias

potential (Normal or Thick).

Use the MODE SELECT key on the printers control

panel. For details, refer to the instruction handbook
accompanying the printer.

Check the transfer roller

installation.

The transfer roller must be supported by the axle holder

at the both ends. Clean the axle holder to remove oil
and debris. Replace the transfer roller if necessary.

Check the transfer bias

potential.

Check contamination on the main charger wire and the

grid.

Check EcoPrint setting.

The EcoPrint mode can provides faint, unsharp printing

because it acts to conserve toner for draft printing
purpose. For normal printing, turn the EcoPrint mode
off by using the MODE SELECT key on the printers
control panel.

Refresh drum.

Try cleaning the drum surface using the printers builtin cleaning system specifically provided for this purpose.
For details, refer to page 6-40.

6-36

5A2
Gray background

ABC
123

Check contamination on the

main charger wire and the grid.

Clean the main charger wire by pulling the green color

main charger wire cleaner know in and out several
times.

Check the grid plate (the

mesh metal bottom part of
the charger unit).

The grid plate must be flat and fit horizontally in place.

Replace the main charger unit if necessary.

Check the print density setting.

The print density may be set too high. Try adjusting the
print density using the MODE SELECT key. For details
refer to the printers instruction handbook.

Check the surface potential of

the drum.

The drum potential values may vary depending on

production lots and the measurement is possible only
by using the jig and tool specifically designed for this
purpose. The drum unit will have to be replaced if it will
bear the values far out of the allowable range.

The developer unit may be

defective.

If a developer unit which is known to work normally is

available for check, replace the developer currently
used in the printer with it. If the symptom disappears,
replace the developer unit with a new one.

6-37

5A2
Dirt on the top edge or back of the paper

ABC
123

Check toner contamination in

various parts.

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 developer
unit, and the fuser inlet. Clean these areas and parts to
remove toner.

Check the transfer roller.

If the transfer roller is contaminated with toner, clean

the transfer roller using a vacuum cleaner; or by
continuously printing a low-density page until the
symptom has faded away.

6-38

5A2
Repetitive defects gauge
Use the following measurements for checking repetitive occurrences on the printed page.
See the above section for details.
FIRST OCCURRENCE OF DEFECT

32 mm:

DEVELOPING ROLLER

37.5 mm: UPPER REGISTRATION

ROLLER
50 mm:

LOWER REGISTRATION
ROLLER

66 mm:

TRANSFER ROLLER/
DEVELOPING PULLEY

94.3 mm: FUSER PRESSURE

ROLLER

116.3 mm: FUSER HEAT ROLLER

128.3 mm: DRUM UNIT

6-39

5A2
Drum cleaning
This mode is meant to provide a manual means of drum cleaning in addition to the regular
cleaning procedure made automatically in a photographic cycle. In this mode, the drum
turns for the period of approximately three minutes with no main charging dispersed over
the drum. Since the cleaning blade in the drum continuously attempt to scrape soils and
paper dust on its surface, the drum can be brought in a clean state.

To clean the drum using this feature, perform the following, top to bottom:
press
MODE
then,
press
repeatedly until:
Others>
press
then,
repeatedly until:
, the display should show:
, the display should show:
ENTER, the display should show:
ENTER

press
press
press
press
press

>Service>
>>Developer
>>Drum
?

The drum then starts turning and stops after approx. 3 minutes. The printer reverts to Ready.

6-40

5A2

Correcting a paper jam

This section describes how to remove paper when it jams in the printer. The printer will stop
whenever paper jams in the printer or paper is not fed from a cassette. The printer will go
offline and the message Paper jam Open front cover will appear in the message
display.

Paper jam
Open front cover
Opening the printers front cover will cause the message display to change. It will now
indicate the coded location (A through I and 1 through 6) of the paper jam.

Example:

Paper jam
C, H, 1
In this example, paper is jammed in the paper feeder (C), paper feed unit (H), and in the
upper cassette (1). The corrective action to take in cases like this is explained using actual
examples beginning from page 6-45.
The meanings of symbols appearing on the message display and the corresponding
locations of paper jams are given in the table on the next page. Be sure to correct paper
jams according to the procedure given on the following pages.

6-41

5A2
Locating and correcting paper jams
MESSAGE DISPLAY INDICATOR AND PAPER JAM LOCATION
Ind.

Meaning of Indicator

Optional paper feeder

(Envelope feeder or Universal
feeder)

Multi-purpose tray

Paper feeder included with

printer

Optional paper feeder

Optional paper feeder

Optional paper stacker

(Document finisher or Bulk
paper stacker)

Corresponding Printer Location

A
H
G
1
2
F

Face-up output tray

Paper feed unit

Optional duplex printing unit

(Duplexer)

Cassette 1

Cassette 2

Cassette 3

Cassette 4

Cassette 5

Cassette 6

6-42

5A2

Correcting paper jams

Warning: Pull out the paper feed unit (See below.) and wait a while to allow the fuser unit
to cool. Do not touch the fuser unit as this may result in a burn injury.

Fuser unit

Warning: Take care not to leave any small pieces of paper in the printer when removing
paper jams as this may result in fire.
Note: Data remaining in the printer will be lost if power is turned off while correcting a paper
jam.
After checking the location of the paper jam using the table on the previous page, take
corrective action according to the table on the next page. After removing all jammed paper,
the printer will automatically resume printing.

6-43

5A2
Ind.

Meaning of indicator

Corresponding printer location

Check the optional paper feeder

(Envelope feeder or Universal
feeder).

When a paper jam occurs in the optional

feeder, pull it out carefully. (For details,
read the instruction handbook for each
separate option.)

Check the multi-purpose tray.

When a paper jam occurs in the multipurpose tray, first completely remove all
jammed paper and then open and close
the front cover.

C, D, E Check the optional paper feeder. (D

and E are only displayed when an
optional paper feeder is installed.)

Open the side cover of the paper feeder

indicated and remove the jammed paper.
See page Chapter 6-47.

Check the optional paper stacker

Document finisher or Bulk paper
stacker.

Remove the paper jammed in the paper

stacker. (For details, read the paper
stacker instruction handbook.)

Check the face-up output tray.

If printing stops before a page is

completely output, carefully remove that
sheet of paper. See Chapter 6-48.

Check the face-down output tray.

If printing stops before a page is

completely output, carefully remove that
sheet of paper.

Check the paper feed unit.

Open the front cover and carefully pull

out the paper feed unit as far as it will go.
If paper is jammed in the registration
rollers, remove it by the easiest means
possible. See page Chapter 6-49. Pull
jammed paper out of the fuser unit in the
same manner. See page Chapter 6-49.
After all paper has been completely
removed, return the paper feed unit.

Check the fuser unit.

Open the front cover and carefully pull

out the paper feed unit as far as it will go.
Open the fuser unit cover (grasp the tab
[green]) and check inside the fuser unit.
Jammed paper may sometimes be left
inside the fuser unit. See page Chapter
6-51.

Check the optional duplex printing

unit (Duplexer).
(Only when installed)

Open the front cover, pull out the duplex

printing unit and remove the jammed
paper. (For details, read the duplex
printing unit instruction handbook.)

Check the cassette indicated.

Pull out the cassette indicated and

remove the jammed paper. After all paper
has been completely removed, open and
close the front cover.

16

6-44

5A2

Example: Understanding the paper jam indication

In the example below, paper is jammed in the paper feeder (C), the upper cassette (1), and
the paper feed unit (H).

Paper jam
C, H, 1
1. When paper jams in multiple locations such as in this example, begin taking corrective
action from the location displayed at left. After the paper jam in the paper feeder (C) is
corrected, the display will change as follows.

Paper jam
H, 1
2. Next, pull out the paper feed unit and remove the jammed paper. After removing the
paper the display will change as follows.

Front cover
Open
3. Close the front cover. This completes removal of this paper jam.
The page on which the paper jam occurred may not be re-printed depending on the location
of the paper jam.
Frequent occurrence of paper jams may indicate you are using a paper specification which
does not suit the printer. If this appears to be the case, try switching to a different type of
paper.

6-45

5A2
Paper jam removal diagrams
These diagrams are for assistance in following instructions on page Chapter 6-41.
DIAGRAM 1: PAPER FEEDER

6-46

5A2
DIAGRAM 2: FACE-UP STACK
Step 1

Step 2

6-47

5A2
Step 3

6-48

5A2
DIAGRAM 3: TRANSFER UNIT
Step 1

Step 2

6-49

5A2
DIAGRAM 4: FUSER UNIT

6-50

5A2

6-51

5A2

CONTENTS
Appendix A PRINTER INTERFACE
Parallel interface ....................................................................................................... A-1
Port pin assignment .................................................................................................... A-1
Parallel interface connection ....................................................................................... A-2
Serial interface .......................................................................................................... A-3
Serial interface specifications ...................................................................................... A-3
Data error information (Snn) ....................................................................................... A-4
Changing the serial interface configuraion .................................................................. A-4
Serial port pin assignment ........................................................................................... A-6
Serial interface connection .......................................................................................... A-7
RS-232C interface voltage levels ................................................................................ A-7
Connector configurations ............................................................................................ A-8
RS-232C protocol ........................................................................................................ A-9

1-1-21

5A2

Parallel interface
The printer uses a bi-directional parallel interface for high-speed data transmission for the
host computer. This interface includes the buffers which are compatible with the IEEE 1284
standards. The parallel interface provides support for the ECP and nibble modes in this
standards.

Port pin assignment

The pins of the parallel interface connector carry the signals listed below.
No.

Terminal

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

nStrobe
Data1
Data2
Data3
Data4
Data5
Data6
Data7
Data8
nAck
Busy
PError
Select
nAutoFd
Not defined
Logic ground
Chassis ground
Peri-logic power

Signal
(STBIN1/2*)
(PAD0)
(PAD1)
(PAD2)
(PAD3)
(PAD4)
(PAD5)
(PAD6)
(PAD7)
(ACKOUT)
(BUSYOUT)
(PERROR)
(SELECT)
(AUTOFD*)
NC
GND
(GND)
(VCC)

No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Terminal
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
nInit
nFault
Not defined
Not defined
Not defined
nSelect In

Signal
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
(INIT*)
(FAULT*)
Pull-up (1kW)
NC
Pull-up (1kW)
(SELECTI*)

*: Negative logic
**: Maximum rated current for pin 18 is 0.25A (fused).
***: Pin 17 is grounded through a chip bead or a chip resistor.

A-1

5A2
Parallel interface connection
Detailed descriptions of the parallel interface signals follow.
Signal

Meaning

Strobe* [nStrobe] (Pin 1)

A negative-going Strobe* pulse causes the printer to

read and latch the data on the Data 0 [1] to Data 7 [8]
signal lines.

Data 0 [1] to Data 7 [8]

(Pins 2 to 9)

These eight signals form the data byte sent from the host
computer to the printer. Data 7 [8] is the most significant
bit.

Acknowledge* [nAck]
(Pin 10)

This negative-going pulse acknowledges the previous

character received by the printer. Acknowledge* pulses
are sent only when Busy is low.

Busy [Busy] (Pin 11)

This signal is high when the printer is busy and low when
it is able to accept more data. Every high-to-low transition
is followed by an Acknowledge* pulse.

Paper Empty [PError]

(Pin 12)

This signal goes high when the printer runs out of paper.

On-Line [Select] (Pin 13)

This signal is high when the printer is on-line and low

when the printer is off-line. It goes low when the upper
unit is raised, or when the ON LINE key is pressed to set
the printer off-line.

Note: The Paper Empty and On-Line signals are not

used unless enabled by the FRPO command (O2
parameter).
Auto-Feed [nAutoFd]
(Pin 14)

This signal is used in the Epson version of the Centronics

interface to receive a carriage return. In high-speed
mode, it is used as an interrupt.

+5 V DC (pin 18)

This line is connected to the printers +5 V DC line

(+5 V 0.5 V, 250 mA maximum [serial and parallel
total], fused).

Prime [nInit] (Pin 31)

This signal is used in the standard Centronics interface

to enable the computer to reset the printer. It is ignored
by the printer.

Error* [nFault] (Pin 32)

When the high-speed parallel line control is on (FRPO

O2 = 2), this line returns error status.

Auxiliary output 1 (Pin 33)

This signal line is not used.

Power Ready (Pin 35)

This signal is high when the printers power is on.

Select In [NSelectIn]
(Pin 36)

This signal is used in some versions of the Centronics

interface to enable the computer to force the printer online. In high-speed mode, it is used as an interrupt.

A-2

5A2

Serial interface
The printer is equipped with a serial port whose circuitry duplicates the option interface card.
The device responsible for controlling the serial interface is integrated in the gate array in the
controller system. The serial interface supports both protocols of RS-232C and RS-422A.
In the RS-232C protocol, CTS and DSR signals are included to support SNMP (Simple
Network Management Protocol) protocol (used typically for Windows 95s plug-and-play
function). Toggling the protocol between RS-232C and RS-422A is made by a shorting
jumper socket that is accessible on the controller board. (The jumper wire arrangement, that
used to be provided for the succeeding models to switch the DTR polarity is not used with
these models.) To change the serial interface protocol, refer to Changing the serial interface
configuration section which follows.
A 25-pin D-sub connector is used for the serial interface. The extra signals used for
RS-422A are assigned to these pins that are not used for RS-232C according to the IBM
pin assignment scheme.
Serial interface specifications
The table below summarizes the specifications for the serial interface used in the printer.
The parameter options can be selected using either the printers front panel or Prescribe
FRPO command.
Selection

Default

Interface mode*1 RS-232C or RS-422C

Item

By changing hardware
jumper (See the next
section)

RS-232C
(factory
setting)

Baud rate

Front panel or FRPO

H1 command

9600 (96)

Front panel or FRPO

H2 command

Front panel or FRPO

H4 command

None (0)

Data bit length

Option parameters

300, 600, 1200, 2400,

4800, 9600, 19200,
38400, 57600, 115200
7, 8

Parity bit length

None (0), odd (1), even (2),

ignore (3)

Protocol*2

DTR [pos] & Xflow [buf] (0), Front panel [(1) through
DTR [pos] (1), DTR [neg]
(4) only] or FRPO H5
(2), Xflow [buf] (3), ETX
command
[nobuf] (4), Xflow [nobuf]
(5), ETX [buf] (6), Xflow
[buf] & ETX [nobuf] (7)

DTR [pos]
& Xflow
[buf] (0)

Error robust
control*3

Robust On (0), Robust

Off (1), Error Control &
Robust Off (10), Error
Control & Robust On (11)
^C, ^T, Esc.B, Esc.

Robust On
(0)

Status send

FRPO D0 command

*1 The serial interface mode currently engaged is indicated at the bottom of the service
status page as: RS2 = RS-232C mode, RS4 = RS-422C mode.
*2 In the protocols that do not use DTR, DTR is fixed to be positive.
*3 Robust: Xon is sent every 3 to 5 seconds during ready or waiting. Error Control: Sets
the printer off line when an error occurs or at off line state.

A-3

5A2
Data error information (Snn)
A data error occurred on the serial interface is indicated on the service status page. The Snn
code in the same row as Service information on the status page shows various error
conditions as follows:
S code

Meaning

S00
S01
S02
S03
S04
S05
S06
S07

No error
Framing error
Overrun error
Overrun error and framing error
Parity error
Parity error and framing error
Parity error and overrun error
Parity error, overrun error, and framing error

Changing the serial interface configuration

To change the serial interface protocol from RS-232C to RS-422A, or vice versa, the main
controller board must be taken out of the printer. Protect the electronics by taking these
precautions:
Before touching the main circuit board, touch a water pipe or other large metal object to
discharge yourself of static electricity. While doing the work, it is recommended that you
wear an antistatic wrist strap.
Touch the main circuit board only by the edge.

Refer to the diagram below and remove the rear panel cover.

Rear panel cover

A-4

5A2
To change the serial protocol from RS-232C to RS-422A, for example, carefully remove the
jumper connector from the main circuit board, and reconnect to the pin position shown in
the diagram.

RS-232C position

RS-422A position

After finishing the above procedure, replace the rear panel cover back by referring the
diagram above into the printer. Secure the panel cover by the six screws.

A-5

5A2
Serial port pin assignment
The pins of the parallel interface connector carry the signals listed below. The RS-422A
specific signals are noted in the Definition.
No.
1
2
3
4
5
6
7
9
10
11
18
20
Others

A-6

Signal
FG
TxD
RxD/RDA
RTS
CTS
DSR
SG
SDA
SDB
+5 V DC
RDB
DTR
Not connected

Flow

Definition

Printer host
Host Printer
Printer host
Host printer
Host printer

Frame ground
Transmit data: RS-232C
Receive data/receive data (Reversed)
Transmit request
Transmit permitted
Data-set-ready
Signal ground
Transmit data (Reversed): RS-422A
Transmit data: RS-422A
Peri-logic power
Receive data: RS-422A
Data-terminal-ready
Undefined

Printer host
Printer host

Host printer
Printer host

5A2
Serial interface connection
Detailed descriptions of the serial interface signals follow.
Signal

Meaning

FG (Pin 1)

This pin is connected directly to the printer frame.

TxD (Pin 2)

RS-232C only: This output carries asynchronous data

sent by the printer to the computer. It is used mainly in
handshaking protocols.

RxD/RDA (Pin 3)

This input carries serial asynchronous data sent by the

computer to the printer. In RS-422A, this carries the
inversed differential data (RDA).

RTS (Pin 4)

This output is always held high (above 3 V).

CTS (Pin 5)/DSR (Pin 6)

Unused.

SG (Pin 7)

All signals can transmit between the printer and the host
computer to send each signals with a signal ground.

SDA (Pin 89)

This output transmits asynchronous inversed form of

differential data from the printer to the computer.

SDB (Pin 810)

This output carries asynchronous non-inversed form of

differential data from the computercmputer to the printer.

+5 V DC (Pin 11)

This line is connected to the printers +5 V DC line (+5 V

0.5 V, 250 mA maximum [serial and parallel total],
fused).

DTR Data Terminal

Ready (Pin 20)

This output is used as a buffer nearly-full handshake line.

It is held high (above 3 V) when the buffer can accept
more data.

RS-232C interface voltage levels

The voltage levels of the RS-232C signals conform to EIA RS-232C specifications. FALSE
is from 3 volts to 15 volts. TRUE is from -3 volts to -15 volts. Voltages between -3 volts and
3 volts are undefined. The voltage levels of the RS-422A signals are equivalent to those of
the RS-232C signals except the signals used for transmission and reception.

A-7

5A2
Connector configurations
The printer uses a DB-25 connector for the serial interface. Depending on the computer
configuration for serial interface, use either of the appropriate configurations. A special
cable must be prepared or obtained for the RS-422A configuration by referring to the
diagram (last) below.
RS-232C FOR COMPUTERS WITH A DB-9 CONNECTOR:
Computer
serial port
(DB-9)

RXD-2
TXD-3
DTR-4
GND-5
DSR-6
RTS-7
CTS-8

Printer
serial port
(DB-25)

2-TXD
3-RXD
4-RTS
5-CTS
6-DSR
7-SG
20-DTR

RS-232C FOR COMPUTERS WITH A DB-25 CONNECTOR:

Computer
serial port
(DB-25)

GND-1
TXD-2
RXD-3
RTS-4
CTS-5
DSR-6
GND-7
DTR-20

A-8

Printer
serial port
(DB-25)

1-FG
2-TXD
3-RXD
4-RTS
5-CTS
6-DSR
7-SG
20-DTR

5A2
RS-422A
Computer
serial
interface

Frame gr.
Signal gr.
Rx term.
Tx term.

Printer
serial port
(DB-25)

1-FG
3-RD7-SF
9-SD10-SD+
18-RD+

On the computer serial port, investigate pin assignments depending on the computer
manufacturers instruction. Since the RS-422A configuration does not employ control lines
except for data transmission/reception, select a mode in which signals such as DTR are not
used.

RS-232C protocol
The serial interface supports the full baud rates of: 300, 600, 1,200, 2,400, 4,800, 9,600, and
19,200, 38,400, 57,600, and 115.2k (bps). For adjusting serial interface parameters
including baud rate, parity, etc., refer to chapter 7 in the printers instruction handbook.

A-9

5A2

Status page
The printer can print different types of the status pagethe user status page and the service
status page. This section exclusively describes the service status page. For information on
the user status page, refer to the printers instruction handbook.
Information obtainable on the service page include various settings for the printer, service
statistics, etc. To print a service status page, proceed as follows:
1 Ensure that the message display is indicating
Ready.
2 Press the MODE SELECT key.
3 Press until the message display indicates
Others>.

4 Press

Others>

>Service>

7 Press ENTER. The question mark (?)

appears at the end.

>>Print status page?

5 Press repeatedly until the message display

indicates >Service>.
6 Press . Press until the message display
indicates >>Print status page.

>>Print status page>

8 Press ENTER again. The service status

page is printed.

Service information on the status page

An example of the service status page is shown below. (Note the details born by a status
page may differ from a firmware version to another.) Most of the service information is
located under Service information.

B-1

5A2
Example of the service status page

PAGE PRINTER STATUS PAGE

Software version:

Released: dd/month/yyyy

Service information [A2/48-03][07] /P00/S00/F01/E01/N02/D10:DM0301.DAN

/0078/0033/1061/0811/AAAAAEI/AAAAAAA/AAAEJDJ/
0/
0/
0/
0/
0/
DN:SPL7400084/AAEJIJ/AAEFBE/AAEFBE/AA/DF/RS2

0/

Total page 3464

0/
0/
0/
SN:SPL6500004

/ is the separator.

Most of these service information on the status page are alphannumerically-coded. Each
item is explained below.

B-2

5A2
Service information on the service status page
Example

Meaning

Top of the page

Software version:

Controller firmware version*

Released:

Rreeased date of the

firmware (above)

Description

dd/month /yyyy

Bottom of the page, Upper line

[A2/48-03]
Engine ROM version/flush ROM version-product ID

[07]

Front panel ROM mask version

/P00

Parallel interface mode

00=Unidirectional, 04=Nibble
(Normal), 05=Nibble (Hispeed),
07=ECP

/S00

Serial interface error

00=Normal, bit 0=Framing error,

bit 1=Overrun, bit 2=Parity error

/F01

Front control panel

01=Locked, 02=Fully locked

/E01

Option interface error

01=Diagnostics error, 02=Board

error, 03=Board power-up,
04=Board disconnection

/N02

NVRAM error (Shown only

if error occurred)

01=ID error, 02=Version error,

03=Checksum error,
04=NVRAM error

/D10:DM301.DAN

NVRAM download
information

00=None downloaded, bit 4=Front

panel message data name,
bit 7=Error

Total page 3464

Total page count

(Also see below.)

Bottom of page, middle line

/0078
Top margin

Inches+1/ 100 inches (FRPO L1/L2)

/0033

Left margin

Inches+1/ 100 inches (FRPO L3/L4)

/1061

Page length

Inches+1/ 100 inches (FRPO L5/L6)

/0811

Page width

Inches+1/ 100 inches (FRPO L7/L8)

/0(9)

Left margin offset for paper

sources (Manual feed tray,
printers cassette, paper
feeders cassette (if
installed), from left to right)

in 1/600 inch

The firmware information also appear on the normal status page.

B-3

5A2
Example

Meaning

Description

Bottom of page, lower line

/DN:SPL6X40262 Serial number for the drum unit
/AA

Internal use

/DF

Internal use

/RS2

Serial interface mode

SN:SPL6500004

Serial number for the printer

B-4

RS2=RS-232C, RS4=RS-422A

5A2

General wiring diagram

ETON PWB
YC1
(KP-603)

Inter
Lock
Switch

3
S02056
4
S02052

32
YC1
YC6
YC2
YC3
1 VCC
2 EToNLED*
3 EToNPTR

S02075

1
2
3
4
5
6
7

5
1
2
3
4
5

1 LAMPMoN
2 PHSTRIG
3 GND

S02073

S02109

S02064

S02069

Fan2

CN6

CN1

Power SW

S02063

CN5

FAN24

S02072

CN2

S02071
4

DRRLY PWB HTON PWB

(KP-574)
(KP-558)

Switching PS
PWB

CN4

YC5

HT1 (C)
HT2,(S)
FAN2D*
+24V2

YC6

1
2
3
4

CN3

FCoP
FCoP

FAN24

FAN4D*

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Fan1

AC Inlet

S02054
Thermo Cut Out
S02095

Fuser Unit
S02085
Thermistor

S02080

B
M

Fuser PWB (KP-550)

YC1
F1
125V
2A
+5V

YC5

SEL0
SEL1
SEL2
SoUT
SCK*
SID
oP5V
oP5V

1
2
3
4

S02081
FG

Duplexer
(Option)

14

S02083

S02084

S02078

1
2
3
4
5
6
7
8

CON3 PWB
(KP-568)

YC3

HV PWB

YC4
F2
125V
3.15A
+24V

YC2

Drive Unit

Bulk paper stacker

or
Document stacker
(Option)

15

S02053

1
2
3
4
5
6
7
8
9
10
11
12
13
14

oP24V
oP24V
GND
GND

Regjam
Photo Sensor

1 GND
2 JAMRG*
3 VCC

GND
GND
GND
GND
VCC
VCC

S02055

Sub Cluch

SUBCLD*

1
2
3
4
5
6

14

Regist Cluch

+24V2

SWITCHING PS BOX

YC1

Heater

FUUNIT*
GNDFS
FHIT
THERMI
VCCFS

YC10 YC11

LCoP
GND
VCC
PAFL*
GND
VCC
JAMFDW*
GND
VCC
JAMFUP*
GND
FUPSDD*
+24V2
FDWSDD*

+24V2
LoNBo*
LASERo*
GND
SCANCK
SCRDYI*
SCAN*
GND
GND
PDI*
VCC
N.C
VDo+
VDoGND
N.C
GND
ERASED*
EEDATA
EESCLK
EECSo
GND
DRUNIT*
VCC
GND
ToWER
HTLD*
VCC

Drum PWB
(KP-562)

YC2

S02102

YC8

YC12

S02070

YC2

CN1 Main Motor

PWB

REGCLD*

CON1 PWB
(KP-564)

S02066

Fan4

YC4

S02077

+24V2
+24V2
+24V2
+24V2
GND
MMoTDR*
FG

1
2
3
4
5
6
7
8
9
10
11
12

Eraser

+24V2

YC4

YC6

3
3

Zener PWB
(KP-605)

+24V2
+24V2
+24V2
N.C
+24V
+24V
+24V

S02067

3
2

YC7
Drum Unit

1
2
3
4
5
6
7

5VSAFE
LoNBo*
LASERo
GND

YC3

28

YC3

YC1

+24V2
+24V2
+24V2
+24V2
VCC
VCC
VCC
VCC
SEL2
GND
SEL1
GND
SEL0
GND
SID
GND
SoUT
GND
SCK*
GND
FINTX
GND
FINTX
GND
FINRX
GND
GND
GND

FAN1D*

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

YC7

YC9

YC2
YC3
Apcrelay PWB
(KP-570)
YC1

YC1

MPFBSD*
MPPSIZE2
DEVHITD*
MPFPAPR
EToNLED*
JAMRG*
TCoP
TBoTLE*
ETNEMP*
TNMoTD*
TNMoTR*
TNENDI*

1
2
3
4

VCC
DRUNIT*
GND
EESCo
EESCLK
EEDATA
ERASED*
GND
GND
GND
GND
GND
GND

21
22
23
24
25
26
27
28
29
30
31
32

YC2
YC1

YC1 YC1

S02059

1
2
3
4
5
6
7
8
9
10
11
12
13

+24V2
+24V2
+24V2
DVUNIT*
ENVPASI*
VCC
MPPSIZE1
VCC
GND
GND
GND
GND
GND
ENVPAPI*
ENVUNTI*
HANDSI*
PF7UNTI*
REGCLD*
EMoTD*
SUBCLD*

TVSENSI
TISENSI
THPIDRD*
THVRDRD*
THVDRD*
HVoLT
TISET
RISET
RHVDRD*
HVCLK
MHVDRD*
GND
+24V2
BSEL

YC5

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

YC2

YC10

KUIO
Interface

1
2
3
4
5
6
7
8
9
10
11
12
13
14

APC-A PWB
(KP-578)
YC1

S02060

Engine PWB
(KP-544)
Dimm PWB
(KP-537)

YC1

YC1

YC2

S02057

VCC
PD
LD
GND

Inter Lock
PWB
(KP-556)

FDFUL
Left
FUP/FDW
Photo FDW FUP
Cover
Solenoid
Sensor Photo Photo
PWB
Sensor Sensor
(KP-552)

GND
SCK*
GND
GND
SoUT
SID
+24V2
+24V2
VCC
VCC
GND
SEL0
SEL1
SEL2

Release Brush

MPFPAP
YC1
Photo Sensor
YC1

S02051

S02062

Transfer Roller

TCOV SW

34

+24V

MPFPAP
YC1
PWB (KP-576)

YC1

60

S02068

YC1

1
2
3
4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

F100E
125V/0.5A
+5V

(KP-599)

PD PWB
(KP-572)

YC2

Simm

Option
Interface

K/B PWB
(KP-539)

YC1

Serial
Interface

APC-B PWB
(KP-579)

YC1

S02061

YC8

F1 125V/2A

ENVPAS
Photo Sensor YC1

VCC
FPDT
VCC
FPDIRo
GND
FPCLKo
GND

SCANCK
SCRDYI*
SCAN*
GND
+24V2

Paper
feeder

ENV
PWB
(KP-502)

YC781

YC782

Envelope feeder
or
Universal feeder

1
2
3
4
5
6
7

Main PWB
(KP-536)

+24V2
MPFSD*

1
2
3
4
5

Fan3

TBoTLE*
GND YC5

MPF
Solenoid

YC1

CONTOROLLER BOX

Parallel
Interface
Memory
Card

S02074
2

Toner Bottle PWB

YC1
(KP-552)

Poligon
Motor

Paper
feeder
(Option)

Laser Di

ERASED*
EESCLK
FPDIRo
FPCLKo
PDI*
FPDT
SCAN*
SCANCK
N.C.
SCRDYI*
N.C.
N.C.
LoNBo*
LASERo
GND
GND
GND
VDATA
GND
GND

S02058

A1 PF7UNTI*
A2 HANDSI*
S02098 S02097
A3 GND
A4 ENVPAPI*
A5 ENVUNTI*
Deve Unit
A6 EMoTD*
A7 oP24V
Dvrly PWB
3
Toner Sensor
A8 GND
Deve PWB 50 YC1 (KP-560)
A9 ENVPASI*
2
2
Toner Motor
(KP-548)
A10 VCC
B1 GND
YC2
Mag. Roller
B2 MPFSIZE2
B3 MPFSIZE1
S02076 B4 VCC
B5 N.C
B6 GND
8
B7 MPFPAPR
S02082
B8 VCC
1 GND
B9 GND
B
2 TNENDI*
TCoP
B10
3 VCC
YC8
4 DVUNIT*
5 DEVHITD*
6 TNMoTR*
7 TNMoTR*
CON2 PWB
8 TNMoTD

41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

YC7

TNMoTD
TNMoTR*
TNMoTR*
DEVHITD*
DVUNIT*
VCC
TNENDI*
GND
GND
GND
GND
GND
GND

TOWER*
HTLD*
N.C.
N.C.
DRUNIT*
JAMFUP*
HT2 (S)
TCoUNTD*
N.C.
HT1 (C)
FAN1DR*
FAN2D*
LCoP*
JAMFDW*
PAFL
FCoP*
FUPSDD*
FDWSDD*
EESCSo
EEDATA

YC4

1
2
3
4
5
6
7
8
9
10
11
12
13

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

GND
GND
GND
GND
GND
GND
VCC
VCC
VCC
VCC
VCC
VCC
+24V2
+24V2
+24V2
+24V2
+24V2
+24V2
+24V2
+24V2

Paper
feeder
(Option)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

+24V2

GND
GND
SCLKI
GND
SCD
VCC
VCC
VCC
VCC
VCC
CBSYI*
SBSYo*
CINHo*
EGIRo*
RESET*
CPRDYI
PToUTo
FPDATA
FPDIR
FPCLK
N.C
RDYo*
VSREQo*
VSYNCI*
Pdo
N.C
PRINTI*
oUTPEo*
N.C
GND
VIDEo*
GND
GND
GND

FAN3DR*

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

YC1

YC1

YC1

FG

FG

1
2
3
4
5
6
7
8
9
10
11
12
13
14
14

GND
SCK*
GND
SoUT
GND
SID
SEL0
SEL1
SEL2
FINTX
GND
FINRX
GND
FINLIFE
N.C

A03 BLOCK DIAGRAM

MITA COPYSTAR AMERICA, INC.

Headquarters:
225 Sand Road, P.O. Box 40008
Fairfield, New Jersey 07004-0008
TEL : (973) 808-8444
FAX : (973) 882-6000
New York Show Room:
149 West 51st street,
New York, NY 10019
TEL : (212) 554-2679
FAX : (212) 554-2625
Northeastern Region:
225 Sand Road, P.O. Box 40008
Fairfield, New Jersey 07004-0008
TEL : (973) 808-8444
FAX : (973) 882-4401
Midwestern Region:
225 Spring Lake Drive,
Itasca, Illinois 60143
TEL : (630) 250-7447
FAX : (630) 250-8787

Western Region:
14101 Alton Parkway,
P.O.Box 57006, Irvine,
California 92618-7006
TEL : (714) 457-9000
FAX : (714) 457-9119
Southeastern Region:
1500 Oakbrook Drive,
Norcross, Georgia 30093
TEL : (770) 729-9786
FAX : (770) 729-9873
Southwestern Region:
2825 West Story Road,
Irving, Texas 75038-5299
TEL : (972) 550-8987
FAX : (972) 570-4704
Dallas Parts Distribution Center
& National Training Center:
2825 West Story Road,
Irving, Texas 75038-5299
TEL : (972) 659-0055
FAX : (972) 570-5816

MITA COPYSTAR CANADA, LTD.

6120 Kestrel Road,
Mississauga, Ontario L5T 1S8
TEL : (905) 670-4425
FAX : (905) 670-8116

MITA COPYSTAR MEXICO, S.A. DE C.V.

Av. 16 de Septiembre #407
Col. Santa Ins,
Delegacin Azcapotzalco
Mxico, D.F. C.P. 02130
TEL : 3-83-27-41
FAX : 3-83-78-04

1997 MITA INDUSTRIAL CO., LTD.

MITA and
are registered trademarks of MITA INDUSTRIAL CO., LTD.
Printed in U.S.A.

5A2

1-1-22

5A2

CONTENTS
Appendix B STATUS PAGE
Status page ................................................................................................................ B-1
Service information on the status page ........................................................................ B-1
Example of the service status page ............................................................................. B-2
Service information on the service status page ........................................................... B-3

1-1-23

5A2

Printer identification labelling

The printer has a label bearing its model and serial number at its back. This label also
contains other safety precautions.
US/Canada version

DP-2800
PRINTER
MANUFACTURED

60Hz

120V

Tested To Comply
With FCC Standards

10A

THIS LASER PRODUCT CONFIRMS TO THE APPLICABLE

REQUIREMENTS OF FEDERAL REGULATIONS 21 CFR
CHAPTER 1, SUBCHAPTER J.

8J68
UL1950

FOR HOME OR OFFICE USE

YM

MITA INDUSTRIAL CO.,LTD.

2-28 1-CHOME TAMATSUKURI CHUO-KU OSAKA JAPAN

MADE IN JAPAN

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference
that may cause undesired operation.
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numrique de la classe B est conforme la norme NMB-003 du Canada.

CAUTION

REMOVE POWER CORD

BEFORE SERVICE AND
FUSE REPLACEMENT.

PRECAUCION

RETIRE EL CORDON ELECTRICO ANTES

DE REALIZAR SERVICIO O REEMPLAZAR
EL FUSIBLE.

ATTENTION

POUR PRVENIR LES CHOCS

,
LECTRIQUES, COUPER L ALIMENTATION
AVANT DE REMPLACER LE FUSIBLE.

1-1

5A2

Printer Specifications
Engine
Specification
Print method Electrophotography laser scan
Print speed (when printing
multiple copies of the
same page) A4/11" 81/2": 28 pages/min., B4 (257 364 mm):
18 pages/min., A3/11" 17": 16 pages/min.
Resolution (dpi) 600 horizontal/600 vertical
Smoothing KIR 2 (2400 horizontal/600 vertical)
First print (A4/11" 81/ 2" or letter,
23C), depends on input data 10 seconds or less (75 seconds or less with sleep
mode on)
Warm-up time at 23 65 seconds or less
Maximum duty cycle (A4) 100,000 pages/month
Laser diode Visible laser
Main charger Scorotron wire
Transferring Biased roller
Separation DC
Drum cleaning Blade
Drum discharging LED array
Fuser Heat and pressure
Paper Plain paper (as specified separately)
Capacity of paper feed tray
(80 g/m2 [0.11 mm thickness]) Cassette: 500 sheets, MP tray: 100 sheets
Capacity of output trays
(80 g/m2 [0.11 mm thickness]) 500 sheets
Controller
Specification
CPU
System ROM size
Resident font ROM size
Option fonts ROM
Main RAM
Additional RAM (SIMM)
Memory card

PowerPC603e/100 MHz
4 MB, flash DIMM or masked DIMM
4 MB
2 MB (PK-4)
4 MB
64 MB maximum (72-pin SIMM 2)
SRAM or flush, JEIDA 4.2/PCMCIA 2.1
See Recommended flash cards in this chapter.
Host interface Parallel: High-speed, bi-directional (IEEE1284),
Serial: RS-232C/RS-422A, Option, KCIO (HDD).
Page description language Prescribe II
Standard emulation modes HP LaserJet 5Si, IBM Proprinter X24E, Diablo 630,
Epson LQ-850

1-2

5A2
Weight and dimensions
Specification
Main unit

Width:
Height:
Depth:
Weight:
Paper feeder Width:
Height:
Depth:
Weight:

56 cm (22")
34.5 cm (13.6")
56.6 cm (22.3")
41.5 kg (18.7 lb.)
56 cm (22")
24.7 cm (9.7")
56.6 cm (22.3")
19.5 kg (8.8 lb.)

Power requirements
Specification
Voltage requirements US/Canada: 120 V AC 10%, 60 Hz 2%.
Watts Maximum:
1200 W
Normal operation: 677 W
Standby:
215 W
Sleeping:
34 W
Environmental requirements
Specification
Operating temperature and
humidity 10 to 32.5C (50 to 90.5F), 20 to 80% RH
Maximum altitude 2,000 m (6,500 feet)
Noise emission (Excluding
peaks, measured at 1m from
printer, as per ISO7779) 50 dB (A) maximum/38 dB (A) at standby/
unmeasurably low at sleeping)

1-3

5A2

Recommended flash cards

The printer provide support for a JEIDA/PCMCIA category of memory card in both SRAM
and flush types of up to 32 MB. Following is a list of makes and models of flush cards
recommended for use with the printers.
Note that the flush card to be used should be operable on 5 V DC.
Model
AMD

AmC001CFLKA
AmC002CFLKA
AmC004CFLKA
AmC010CFLKA
AmC004DFLKA
AmC008DFLKA
AmC020DFLKA

1 MB
2 MB
4 MB
10 MB
4 MB
8 MB
20 MB

Fujitsu

MB98A81063
MB98A81183
MB98A81273
MB98A81373
MB98A81473

1 MB
2 MB
4 MB
8 MB
16 MB

Panasonic

1-4

Capacity

BN-02MHF4C (CC)

2 MB

BN-04MHF4C (CC)

4 MB

Centennial

FL01M-20-11114-03
FL02M-20-11114-03
FL04M-20-11114-03
FL08M-20-11114-03

1 MB
2 MB
4 MB
8 MB

Maxell

EF-2M-TB (DC)
EF-4M-TB (DC)
EF-8M-TB (DC)
EF-16M-TB (DC)

2 MB
4 MB
8 MB
16 MB

5A2

Front and rear views

Front view
Paper-full sensor
Vent

Option feeder
connector
MP (multipurpose) tray

Front control panel

Front cover

Upper paper cassette

Paper feeder side cover

Lower paper cassette

Paper feeder

Left side view

Face-down tray

Power switch

Left side cover

Face-up paper tray

1-5

5A2
Internal assemblies
Toner container release lever
(Green colored)

Toner container
Drum unit

Drum release lever

(Green colored)

Fuser unit
Fuser release
lever

Feed unit handle

Developer release lever

Developer

Feed unit

Rear view

Harddisk
drive slot
Memory card slot
Parallel interface
connector

Power receptacle
Rear panel

Serial interface
connector
Paper cassette
access door
Option interface
slot cover

1-6

5A2

Options
The example option units are shown below. The instruction handbook come with the printer
has more information regarding the accessories available for this model.

Inboard duplexer

Paper feeder
supplied as
standard

Bulk paper
stacker

First optional
paper feeder

Second optional
paper feeder

Wheels (Caster kit)

1-7

5A2

Environmental requirements
Environmental conditions
The Environmental requirements section on page Chapter 1-2 should be observed to
ensure the optimum operation of the printer. The use of the printer in a location which does
not satisfy the requirements may result in troubles and risk shortening its service life.
The printer will work best if it is installed in a location that is:
Level and well supported (Place the printer on a sturdy table or desk.)
Not exposed to sunlight or other bright light (not next to an uncurtained window). Do not
place the printer on an unstable cart, stand, or table.
Near an AC wall outlet, preferably one that can be used for the printer alone. The outlet
should have a ground slot, or an adapter should be used. If you use an extension cord,
the total length of the power cord plus extension cord should be 17 feet or 5 meters or less.
Well ventilated, not too hot or cold, and not too damp or dry (See section Environmental
requirements on page Chapter 1-2). If you install the printer where the temperature or
humidity is outside the requirements in section Environmental requirements in chapter 1,
the best print quality may not be expected and there will be an increased chance of paper
jams.
Provide a sufficient clearances around the printer to ensure ventilation and ease of
access.

1-8

5A2
Clearance
Allow the necessary minimum clearance on all sides of the printer (below). A total space of
92 by 138 cm (36 by 54") is needed.

1
3
2

Clearance

Dimensions

Left 1

45 cm (17.7"), or 30 cm (12") if the face-up tray is not used.

Front 2

60 cm (24")

Right 3

45 cm (17.7")

Back 4

20 cm (8")

Above 5

30 cm (12")

1-9

5A2
Places to avoid
Avoid installing the printer in locations exposed to:
Direct drafts of hot or cold air.
Direct drafts of outside air. (Avoid locations next to outside doors.)
Sudden temperature or humidity changes.
Any source of high heat, such as a radiator or stove.
Excessive dust. Dust and smoke may cause contamination on the laser scanner window,
causing print quality problem.
Vibration.
Ammonia fumes or other harmful fumes. (In case of humigating the room or saturate it with
insecticide, remove the printer first.)
Avoid greenhouse-like rooms. (Because of sunlight and humidity.)
Avoid enclosed spaces that block ventilation.
Avoid sites more than 6500 feet or 2000 meters above sea level.

Note on power
Use only the power source voltage conforming to the printers rated power voltage. Do not
use other power sources.
Disconnect the printer from the power source before attempting removal or re-placement
of an electrical component or a printed-circuit board.
The printer should not be connected to a power source until the instruction is given to do
so when performing tests described in this handbook.
In connecting the printer power, exercise an extreme care in handling the power supply
or any other electric parts which may give an electric shock.
Before performing maintenance or repair, power from both the power source and the
associated peripheral devices (computer, sorter, etc.) should be disconnected, unless
otherwise specified.
To avoid possible electrical shock, extreme caution must be exercised in handling the
power cord and any other electrical part.
An easily accessible socket outlet must be provided near the equipment.

1-10

5A2

About the toner

The printer should use the proprietary toner kit. To ensure the high print quality and long
service life, the following handling precautions should apply.
Caution: As the printers are designed to ensure the optimum print quality when used with
the proprietary toner, we do not recommend to use any refilled toner containers
that may be available commercially. This is because we have no means for
control over how such refilled toner could affect the print quality and the reliability
of the printer.

Toner container handling

To loosen and mix the toner inside before use, with the label side down, thoroughly shake
the toner container (in the direction of the arrow) 5 times or more.

Caution: Do not attempt to disassemble or refill the toner container.

1-11

5A2
Toner storage
The toner contained in the container is susceptible to temperature and humidity. To ensure
the high print quality, store the toner container in a place that satisfy the following
environmental conditions:
Temperature: 20 to 40C (4 to 104F)
Humidity:
15 to 90% RH
Note: If the toner container is removed from the printers developer unit, put it in a
protective bag and keep it in a dark place.
Caution: If the printer is shipped for return, etc., do not ship it with the toner container
installed. Otherwise, toner may leak and contamination may result in the printer.

1-12