1.19 Tray Sensor Holder.... IV-17 1.20 Roller Holder.... IV-18 1.21 Paper Pick-up Roller Assy, Bearing... IV-18 1.22 Paper Pick-up Solenoid... IV-20 1.23 Paper Feed Motor Assy.... IV-20 1.24 MP Tray Cover.... IV-21 1.25 MP Tray Assy..... IV-22 1.26 Paper Path Separation Plate, Paper Path Separation Film.. IV-23 1.27 Latch.... IV-23 1.28 Fixing Unit (for both 120V and 230V, the only difference is the halogen heater). IV-24 1.29 Transfer Unit.... IV-27 1.30 DC Gear Holder Assy.... IV-28 1.31 PS Switch Wire, Remote Switch... IV-29 1.32 High-Voltage Power Supply PCB Assy... IV-29 1.33 Low-Voltage Power Supply PCB Assy... IV-30 1.34 Toner Cartridge (EP-ED HC Cartridge)... IV-31 1.35 Paper Tray.... IV-32
CHAPTER V MAINTENANCE AND SERVICING..V-1
1. PERIODICAL REPLACEMENT PARTS... V-1 2. CONSUMABLE PARTS STANDARD ENDURANCE TABLE. V-1 3. LIST OF STANDARD TOOLS.. V-2 4. LIST OF LUBRICANTS AND CLEANERS... V-3
CHAPTER VI TROUBLESHOOTING...VI-1

1. INTRODUCTION... VI-1

1.1 Initial Check.... VI-1 1.2 Basic Procedure..... VI-2
2. TEST PRINTING AND MECHANICAL CHECK.. VI-2
2.1 Test Printing.... VI-2
3. IMAGE DEFECTS.... VI-3
3.1 Image Defect Examples.... VI-3 3.2 Troubleshooting Image Defects.... VI-4
4. TROUBLESHOOTING OF MALFUNCTIONS.. VI-11 5. TROUBLESHOOTING PAPER TRANSPORT PROBLEMS.. VI-18
5.1 Paper Jams..... VI-18 5.2 Incomplete Paper Feed.... VI-21

6. OPERATION... VI-23

6.1 Line Inspection Mode Procedure... VI-23 6.2 DRAM Test.... VI-25
7. STATUS MESSAGE LIST... VI-26
CHAPTER VII TROUBLESHOOTING..VII-1
1. HIDDEN FUNCTIONS... VII-1
1.1 Holding down Specified key(s) at Power on... VII-1 1.2 Off-line and Hold down Mode + FF CONT keys... VII-2 1.3 Off-line and Hold down CONT + SEL keys... VII-17

APPENDIX A

1. Engine Block Diagram.... A-1 2. Paper Feed/Size-SW PCB Circuitry Diagram (1/1).. A-2 3. Main PCB Circuitry Diagram (1/7)... A-3 4. Main PCB Circuitry Diagram (2/7)... A-4 5. Main PCB Circuitry Diagram (3/7)... A-5 6. Main PCB Circuitry Diagram (4/7)... A-6 7. Main PCB Circuitry Diagram (5/7)... A-7 8. Main PCB Circuitry Diagram (6/7)... A-8 9. Main PCB Circuitry Diagram (7/7)... A-9 10. Control Panel PCB Circuitry Diagram (1/1).. A-10 11. Laser LD PCB Circuitry Diagram (1/1)... A-11 12. Serial NO. Description... A-12

CHAPTER I GENERAL

1. FEATURES
A. This high-speed, non-impact (low-noise) printer is based on electrophotography, electronics and laser technology. The printer is compact and easy to carry. The internally-storable, front-loading paper cassette enables you to save an occupation space for the machine; the printer can now be installed in a smaller place. The charging roller, developing cylinder, photosensitive drum and cleaner of the printer are combined into a single assembly called an EP-ED HC cartridge. The cartridge can be replaced by the user when necessary without a need of service call. High printing quality is maintained by a simple cleaning procedure. Laser beam safety is designed into the printer. The printer is approved by the US Center for Devices and Radiological Health (CDRH). Paper can be fed in two ways, by the multi-purpose paper feed tray and paper cassette. Maintenance is easy with print component units which are directly detachable, and they require no adjustment after reassembly.

SPECIFICATIONS

(1) (2) (3) Type Printing method Printing speed Cassette feed Desktop page printer Electrophotography (single-component dry toner)
20 ppm (600 x 600 dpi or 300 x 300 dpi, A4 size) 21 ppm (600 x 600 dpi or 300 x 300 dpi, Letter size) 10 ppm (1,200 x 1,200 dpi, A4 & Letter size) 16 seconds or less (A4 size by face-down print delivery from the paper cassette) Prestart by software command for 10 second first print

First print time

(5) (6)
Warm-up (WAIT) time Max. 1 minute at 20C (68F) Optical system Laser
Scanning system (7) Resolution Horizontal Vertical
Semiconductor laser Output power : 5mW max. Wave length : 780 nm Rotating six-faced polygon mirror
600 dots/inch and 1,200 dots/inch 600 raster lines/inch and 1,200 raster lines/inch
Printing system Photosensitive drum Charging Exposure Development Paper feed Image transfer Separation Fixing Toner supply Life expectancy
OPC Charging Roller Laser scanning system Toner projection development system Cassette or manual feed Roller method Natural(utilizing a small drum radius), Static charge eliminator Heated fixing roller Included in the replaceable EP-ED HC cartridge 9,000 pages/cartridge

Paper Cassette feed

Plain paper for Letter, Legal, A4 (A4 or letter size paper with the print density set at level 8 with 5% coverage, recommended: 60 g/m - 105 g/m ) Plain paper of 95 x 148 mm - 216 x 356 mm (recommended: 60g/m - 200 g/m , overhead projector (OHP) film, postcards, label stock and envelopes (specified sizes)

Multi-purpose Tray

Cassette (Tray 1) Paper cassette
A4 Letter / Legal Universal (Option) :
Maximum load height Feedable paper type (11) (12) Print delivery Print delivery tray capacity Face-down Face-up
A4, Letter, Legal, Executive, ISO B5, A5, ISO B6, A6 and approx. 20 envelopes. 2 A4: 55 mm (500 sheets of 80 g/m paper) 2 Letter / Legal: 52 mm (500 sheets of 75 g/m paper) - 105 g/m Face-down or (face-up)
Approx. 500 sheets (80 g/m ) Discharge only

Effective printing area

E A C E

Printable area

Figure 1.1 Printable Area Effective printable area is referred to as a area within which is guaranteed the printing of all interface signal data on a hard copy without any omission. The tables below shows the effective printable area for each paper size.
Table 1.1 Plain Paper SIZE A4 Letter Legal B5 (ISO) Executive A5 B6(ISO) A6 A (mm) 210.0 215.9 215.9 176.0 184.2 148.0 125.0 105.0 B (mm) 297.0 279.4 355.6 250.0 266.7 210.0 176.0 148.0 C (mm) 203.2 207.4 207.4 167.5 175.7 139.5 116.5 96.5 D (mm) 288.5 270.9 347.1 241.5 258.2 201.5 167.5 139.5 E (mm) 3.39 1.0 4.23 1.0 4.23 1.0 4.23 1.0 4.23 1.0 4.23 1.0 4.23 1.0 4.23 1.0
Table 1.2 Envelope SIZE COM-10 MONARCH DL C5 B5 (ISO) A (mm) 104.8 98.4 110.1 162.2 176.0 B (mm) 241.3 190.5 221.0 228.6 250.0 C (mm) 96.3 89.9 101.6 154.1 167.5 D (mm) 232.8 182.0 212.5 220.1 241.5 E (mm) 4.23 1.0 4.23 1.0 4.23 1.0 4.23 1.0 4.23 1.0

Figure 1.3

PARTS OF THE PRINTER

External Views

Upper cover Control panel MP tray Tray 1 Power switch PCMCIA card slots Fan outlet port
Face-up print delivery port Centronics interface connector RS-232C interface connector USB port Duplex unit, Lower tray unit connector Rating label AC inlet

Figure 1.4

Cross Sectional View
Control panel EP-ED HC cartridge Photosensitive drum Laser unit Transfer unit Face-down tray Print-delivery path Fixing unit
Low-voltage power supply assy High-voltage power supply assy Paper cassette (Tray 1) Pick-up rollers MP tray Registration rollers

Figure 1.5

STORAGE AND HANDLING OF EP-ED HC CARTRIDGES
An EP-ED HC cartridge is influenced by the storage conditions even if it is sealed in its package, so its life depends on the way in which it is used or stored. EP-ED HC cartridges should be handled carefully.
Storage of Sealed EP-ED HC Cartridges When storing sealed EP-ED HC cartridges in a warehouse or workshop, the storage conditions shown in (25) Environmental conditions on Page 1-5 must be met. Follow the instructions below: 1) 2) 3) 4) Avoid direct sunlight. Do not store cartridges on a surface that is subject to vibration. Do not hit or drop the packages containing cartridges. The cartridges should be stored horizontal when they are removed from the body (with their label side upside). 5) Avoid putting the cartridges near a CRT screen, a disk or a floppy disk (to keep their data from being destroyed).
Storage of Unsealed EP-ED HC Cartridges Each EP-ED HC cartridge contains a photosensitive drum that has an organic photoconductor (OPC) which deteriorates when exposed to strong light. It also contains toner. The user, therefore, should be fully informed about the correct storage and handling of EP-ED HC cartridges. (1) Storage requirements 1) Avoid places exposed to direct sunlight or near a window. Do not leave an EP-ED HC cartridge in a car in warm or hot weather even if it is in its storage box. 2) Avoid places with a too-high or too-cool temperature and/or humidity. Also avoid places exposed to sudden temperature or humidity changes (such as near an air conditioner outlet). 3) Avoid dusty places or places exposed to ammonia fumes or other harmful fumes. 4) Do not store an EP-ED HC cartridge in a temperature above 40C. (2) EP-ED HC cartridge life The effective life of an EP-ED HC cartridge is 2.5 years from the date of manufacture (printed on the cartridge.) The expiry year and month (date of manufacture plus 2.5 years) is shown on the EP-ED HC cartridge box. An EP-ED HC cartridge used after the expiry may produce low-quality printing, so a cartridge should be used within the stated period.

When the laser beam scans the drum surface, it causes the charge to be neutralized in the areas struck by the beam. Areas on the drum with no charge form the electrostatic latent image.
Developing stage Development places particles of toner onto the areas of the drum that have been cleared of charge by the laser beam. This makes a visible image. This printer uses the toner projection development method with a single-component toner.

Step 3 Development

Stirrer

AC bias DC bias

Developing cylinder Cylinder Magnet

Figure 2.11

The charges on the light areas on the photosensitive drum are shown as positive in this figure. Actually they are negative, but they are more positive than the developing cylinder and explanation is simplified by regarding them as positive.
As shown in Figure 2.11, the developing unit consists of a developing cylinder and rubber blade. The developing cylinder rotates around a fixed internal magnet. The singlecomponent toner consists of magnetite and a resin binder, and is held to the cylinder by magnetic attraction. The toner is an insulator, and acquires a negative charge by friction due to the rotation of the cylinder. The areas on the drum that were exposed to the laser beam have a higher potential (are less negative) than the negatively charged toner particles on the developing cylinder. When these areas approach the cylinder, the potential difference projects the toner particles onto them. This is called toner projection, and the latent image on the drum becomes visible.
Developing cylinder surface potential +V

Voltage (V)

Drum surface potential (exposed area) DC bias

-V Time t

Drum surface potential (unexposed area)
Figure 2.12 An AC bias is applied to the developing cylinder to help project the toner particles to the drum surface and improve the contrast of the printed image. The center voltage of the AC bias (1600 Vp-p) varies with the DC bias voltage. The IMAGE DENSITY ADJUSTMENT signal (sent from the Engine CPU to the highvoltage power supply) changes the DC bias, and thus the potential difference between the cylinder and drum. This changes the density of the print. This printer has a stirring mechanism to supply toner in the cartridge smoothly to the cylinder.
Transfer stage In the transfer stage, the toner image is transferred from the drum surface to the paper.

Step 4 Transfer

Transfer charging roller
Figure 2.13 A positive charge applied to the back of the paper attracts the negatively charged toner particles to the paper. The printer accomplishes transfer by using the charging roller method. Advantages compared with the corona transfer method are as follows: Low transfer voltage that is less than half that for corona transfer. Less ozone generation. The paper is supported by the transfer charging roller and photosensitive drum, so feed is more stable. Reference: If the image on the photosensitive drum is not completely transferred to the paper due to jamming, etc., the toner may adhere to the transfer charging roller. The printer removes the toner from the transfer charging roller by switching the transfer voltage between positive and negative in sequence. During wait, initial rotation, and last rotation, the printer sets the primary DC voltage to zero, and sets the charge on the drum to zero. In this case, the transfer voltage is made negative to remove the negatively-charged toner on the transfer charging roller to the drum. The transfer charging roller is thus cleaned. Step 5 Separation

0.12 sec 0.12 sec 0.65 sec

Figure 2.20

Paper Jam Detection The printer has a registration sensor and a paper eject sensor at the paper outlet to detect whether the printed paper has been fed correctly. A paper jam is detected by whether the paper is present at the sensor at the check periods programmed in the engine CPU memory. If the engine CPU detects a paper jam, the main motor, paper feed motor and scanner motor is turned off immediately and the jam status is transmitted to the video controller circuit. A paper jam is detected in any of following conditions: 1) Paper exists at the paper ejection sensor or the registration sensor when power is switched on. (JAM REAR or JAM INSIDE) 2) Paper has not reached the registration sensor within a specified time (JAM TRAYS). 3) Printed paper has not passed through the registration sensor within a specified time (JAM INSIDE (1) ). 4) Printed paper has not reached the paper ejection sensor within a specified time (JAM INSIDE (2) ). 5) Printed paper has not passed through the paper ejection sensor within a specified time (JAM REAR). Jam tray

STBY PRINT

Main motor Pick-up solenoid Registration sensor

3.00 sec 3.00 sec

Jam check

Normal

Figure 2.21 Jam inside (1)
Main motor Paper feed motor Registration sensor

2.94 sec

Figure 2.22

Jam inside (2)

Main motor Paper feed motor Paper ejection sensor

1.50 sec 1.50 sec

Figure 2.23

Jam rear

5.74 sec 5.74 sec
Figure 2.24 If the stuck-full sensor detects a status that the paper is inside the printer for 20 seconds, it sends out the full signal.
CHAPTER III ELECTRICAL SYSTEM
Electric signal levels are expressed by High (approximate the supply voltage) or Low (approximate 0V). Signals with hyphen or slash, such as -FSRD or FSRD/, are low-active and signals without hyphen or slash, such as FSRD, are high-active signals.

MAIN PCB

Outline The Main PCB consists of the Video Controller Circuit and the Engine Controller Circuit. The Video Controller Circuit performs the following functions. (1) Converts data received from an external device, such as a personal computer, through Centronics parallel interface or RS-232C serial interface into video data and transfers it to the Engine controller circuit. (2) Displays the current printer status in LED and LCD, and enables settings from the control panel. The operation sequence of the printer controlled by a microprocessor in the Engine Controller Circuit. The Engine Controller Circuit outputs signals to drive the various loads on the laser diode, laser unit motor, main motor, etc. according to the print commands and image data from the external device.

Fast page type and EDO type can be used together although it is not recommended.
1) The SIMMs have its printed marking on the PCB by silk screen: SLOT1 and SLOT2, respectively. 2) The attached Printer SIMM map shows the memory map for 4 SIMMs combined.
ROM block ROMs store the CPU control program and font data. ROMs are two 32Mbit masked ROMs. Optional sockets are available for two 8Mbit EPROM (PD27C8000DZ-120 - NEC or equivalent) for expansion. ROM access time should be less than 120nsec. DRAM block DRAMs are used for receiving buffer or working area of the CPU. The DRAM block contains four 16Mbit DRAMs, thus having 8MB memory capacity in total. The refreshing method is CBR (Cas Before Ras). DRAM access time should be less than 80nsec.
0000_0000 0040_0000 0080_0000 ROM (4 bunk)
There are 4 CS terminals for CSROM#0 - CSROM#3. 2MB or 4MB is selectable from CSROM#0 - CSROM#2. If the both are selected, it will become one memory space and ROM#0 supports upto 16MB. CSROM#3 is a rest of the memory space with 256MB

0100_0000

Font card 1 (64MB) Font card 2 (16MB) $5E00_0000 Memory wait setting Memory structure setting FC control setting $5E40_0000 ROM3 (128MB) $5E60_0000 Soft support function Mediation level setting Interruption External interruption

0200_0000

$5E20_0000

0400_0000 $5E80_0000

SDRAM mode setting DRAM transfer Ghost for CS1# $5EA0_0000 LSB setting HRC/GS setting $5EC0_0000 BD $5EE0_0000 CPU $5F00_0000 Timer Engine CDCC Write to LSB

0600_0000

0800_0000 DRAM (MAX 128MB) 64MB x 8 bunk 0B00_0000 0C00_0000 Reverved (16MB x 4) MIO / EOT $5F80_0000 ASIC $5FA0_0000 $5F60_0000 $5F20_0000

Easy serial 1

16550 $5F40_0000 Switching clock Default setting

0E00_0000 Ghost for CS4#

$5FE0_0000

$5FC0_0000

0FC0_0000 0FD0_0000 (256MB)

$5FFF_FFFF

Figure 3.2 Memory map

Option I/F Connector

Option ROM Socket

Centronics I/F

CPU (VIDEO) ASIC MB87F1611

USB I/F

RS232C I/F

SIMM Block

DRAM Block

MASK ROM (Flat package)

Control Panel Connector ASIC MPD65632GC PCMCIA Card Connector CPU (ENGINE)

Figure 3.4 Main PCB

Engine Controller Circuit

Laser Unit

Transfer roller High-Voltage Power Supply Assy

Developing cylinder

Toner sensor

Pick-up Solenoid

MP Tray Pick-up Solenoid Paper Feeder PCB Pick-up Motor Detectors

s Notes

Printer body
Upper cover Font cover ASSY Front cover Side cover R Side cover L Paper feed chassis unit PS switch wire Remote switch
Control panel unit Side cover L

Toner cartridge lid

Upper cover ASSY
*Toner cartridge Paper tray Separation pad ASSY MP PE sub actuator MP tray cover MP tray ASSY
s PRINTER DISASSEMBLING PROCEDURE

Rear cover ASSY

DC fan motor P feed/size-SW PCB ASSY Size -switch spring Paper path separation plate Latch DC gear holder ASSY Main PCB Regist sensor actuator PE sensor actuator Tray sensor holder
Font cover ASSY Side cover R

Transfer unit

Cartridge stopper ASSY
High-voltage power supply unit
Low-voltage power supply unit

Roller holder

Paper pick-up roller

Paper feed motor ASSY

PRINTER BODY

1.1 Configuration

Upper cover ASSY Control panel unit Toner cartridge lid
Paper tray Side cover L Font cover ASSY Rear cover ASSY Side cover R

Figure 4.1

Control Panel Unit (1) Release the Stopper. (2) Remove the Lead wire cover. (3) Remove the 3 screws from the bottom of the Control panel unit, and remove the 3 screws from the Interlock actuator. (4) Pull out the Harness connector.
Carefully remove the Panel cover from the rib.
Control panel unit (Bottom)

Interlock actuator Screw

Lead wire cover

Figure 4.2

Toner Cartridge Lid (1) (2) (3) (4) (5) Remove the supporter from the Toner cartridge lid. Push the right side of the Toner cartridge lid to release the boss. Hold the right side of the Toner cartridge lid and Move it towords the left side. Push the left side of the Toner cartridge lid to release the boss. Remove the Toner cartridge lid from the Upper cover.
Open the Toner cartridge lid Toner cartridge lid

Supporter

Figure 4.3
Side Cover L (1) Release the lock by pinching the lever on the left top surface ( A ) and remove the cover by pulling it rearward ( B ).

Cleaner brush

Hook lever

Side cover L

Figure 4.4
Font Cover ASSY (1) Remove the font cover ASSY by loosening the screw on the top and releasing the hooks on the bottom.

Font cover ASSY

Figure 4.5

1.6 1.6.1

Upper Cover ASSY, Rear Cover ASSY Upper cover ASSY, Rear cover ASSY Loosen the top left screw and 2 screws at the top of the Rear cover ASSY. Release the hook at the right side of the Upper cover ASSY and lift it upwards to remove. Note: Pay attention to the Paper sensor actuator when removeing the Upper cover ASSY. The hook is released automatically by removing the Upper cover ASSY in the direction of the arrow.

Fixing unit cover Hooks

Fixing unit chassis

Figure 4.51

Spring

Thermistor cleaner ASSY

Figure 4.52
Loosen a screw and remove the Fixing PCB ASSY.

Connector (2P)

Fixing PCB ASSY
Figure 4.53 (9) Release the left hook and take off the Paper delivery actuator.
Paper delivery actuator Thermistor

Fixing unit cover

Figure 4.54 (10) 1) Remove the retaining rings (on both sides). 2) Remove the HR gear, loosen the screw and remove the spring washer, remove the left and right HR bearings and the heat roller by sliding it.
Screw Spring washer Heat roller
Retaining ring HR bearing

HR gear Retaining ring

HR bearing

Figure 4.55

3) Remove the Pressure roller spring and Pressure roller bearing on both sides, and the Pressure roller.
Do not use the electric driver to loosen/secure the screw as the plastic bush is easy to break.

Pressure roller bearing

Pressure roller Pressure roller spring
Figure 4.56 < Reassembly > Using the Release spacer L & R may help to assemble springs.
Transfer Unit (1) (2) Loosen a screw. Release the 3 right hooks, (see Figure 4.57) lift the right part of the unit ( A ) and slide it to the right ( B ) (See Figure 4.56)to take off the left part from the main chassis L. Remove the transfer unit from the body by lifting the former.

Screw Transfer unit

Main chassis L

<Right>

Figure 4.57
Open the transfer base hook and take off the left bearing (white) from the hook ( A ). Lift the left side ( B ), slide it to the left ( C ) and take off the roller shaft from the right bearing (black) ( D ). Remove the transfer roller ASSY.
Do not touch the sponge rubber roller when replacing the transfer roller (the roller with hand grease or clasped too strongly may result in poor printing quality).

3 Hooks

Transfer base ASSY

Transfer roller ASSY

Figure 4.58 1.30 DC Gear Holder ASSY (1) (2) (3) (4) Remove the DC motor connector, then remove the Paper delivery holder spring. Loosen the 4 screws and remove the DC gear unit from the chassis. Remove the Paper delivery gear ASSY, the gears, the Gear 48 spring, and the washer. Loosen the 3 screws and remove the DC motor ASSY from the gear holder.

Paper Tray (1) (2) (3) Release the roller holder fixing pawl and remove the roller holder by pulling it out upward. Remove the roller. Remove the Separation pad ASSY (pull it out by turning it).

Paper tray (A4 size)

Roller
Roller holder fixing pawl
Separation pad ASSY and spring

Figure 4.68

Paper stopper Paper tray (legal / letter size)

Earth spring

Figure 4.69

PR98191

CHAPTER V MAINTENANCE AND SERVICING
1. PERIODICAL REPLACEMENT PARTS
Periodical replacement parts are the parts to be replaced periodically to maintain product quality at same level (in other words the parts which would affect the product greatly if they lost their function even if they are not damaged or there is no change in their appearance.) It is recommended to replace such parts on the occasion of a periodical service which is carried out before or after the specified number of sheets are printed, whichever more immediate to that time.
CONSUMABLE PARTS STANDARD ENDURANCE TABLE
The table below shows the suspected mean life (in terms of number of sheets) of the consumable parts, that is the parts which subject to deterioration or damage, should be replaced at least once during the period of warranty of the product only when the parts have such a failure.
Table 5.1 No. 5 Description Fixing unit Fixing unit Paper pick-up roller ASSY 3 Paper pick-up roller ASSY 5 Separation pad ASSY Separation pad ASSY W Transfer roller ASSY A Laser unit Part No. UH1886001 UH1887001 UH2821001 UH1494001 UH2393001 UH1500001 UH1834001 UH1885001 Qty Service life 100,000 pages 100,000 pages 100,000 pages 100,000 pages 100,000 pages 200,000 pages Remarks 115V 230V
PART LIFE=100K PART LIFE=100K PART LIFE=100K PART LIFE=100K PART LIFE=100K PART LIFE=200K
The above table shows only estimated value, so these value are subject to change without prior notice.
When every 100,000 pages are printed, the printer prompts 73 MAINTENANCE 1 on the LCD panel for the replacement of the Fixing unit, the Paper pick-up roller ASSY, the Separation pad ASSY and the Transfer roller ASSY A. When every 200,000 pages are printed, the printer prompts 73 MAINTENANCE 2 on the LCD panel for the replacement of the Laser unit. After replacing the periodical replacement parts, the parts life counter for them MUST BE RESET with the following procedure. [ Reset procedure ] (1) Take the printer off-line. (2) Press CONT + SEL key. (3) Press or to get PART LIFE 100K RESET, or PART LIFE 200K RESET. (4) Press SET key to reset the parts life counter.

Replace the high-voltage power supply PCB assy.
Replace the HV harness. Replace the main PCB assy.
"13 JAM XXXXXX" is not displayed even if a paper jam has occurred (or is displayed even if a paper jam has not occurred) XXXXXX is TRAYS/INSIDE/REAR/DUPLEX.

Possible cause Actuator

Check Does the actuator of the paper delivery sensor or the registration sensor operate smoothly?
Paper delivery sensor Regist sensor
Fuser harness Feed flat cable
Does the voltage of P2-1 in the fixing PCB connector rise from 0V to 5V when the eject sensor is covered, or the voltage of P5-5 in the paper feeder PCB connector rise from 0V to 5V when the registration sensor is covered? Does the voltage of P11-1 in the main PCB connector rise from 0V to 5V when the eject sensor is covered, or the voltage of P3-5 in the main PCB connector rise from 0V to 5V?
Remedy Reassemble or replace the paper delivery actuator and regist sensor actuator. Replace the fixing PCB assy or the paper feed/size-sw PCB assy.
Replace the fuser harness or the feed flat cable. Replace the main PCB assy.
"54 MOTOR MALF" is displayed (The main motor rotation disabled )
Possible cause Low-voltage power supply PCB LV harness Main PCB DC motor harness DC motor assy
Check Is the voltage of P7-1 in the main PCB connector +24V?
Remedy Replace the main PCB assy low-voltage power supply PCB assy, or the LV harness. Replace the main PCB assy. Replace the DC motor harness or the DC motor assy.
Does the voltage of P7-4 in the main PCB connector drop from 5V to 0V after dropping the voltage of P7-3 from 5V to 0V?
No paper pick-up from cassette (or MP tray)
Possible cause Mis-operation Main PCB
Check Is the paper feed mode set correctly? Does the voltage of P3-20 (or 19) in the main PCB connector rise from 0V to 5V and is a pulses having about 11ms period generated at P3-6, 7, 8 ,9 pin? Does the voltage of P5-20 (or 19) in the paper feeder PCB. Connector rise from 0V to 5V and is the pulses having about 11ms period generated at P3-6, 7, 8 ,9 pin? Does the voltage of P3-1 (or P4-1) in the paper feeder PCB connector drop from 24V to 0V and is the chopping pulses generated at P1-1, 2, 5 ,6 pin? Does the pick-up (or MP Pick) solenoid operate? Does the pick-up motor rotate?

Result No No

Remedy Set paper feed mode correctly. Replace the main PCB assy.

Feed flat cable

Replace the feed flat cable.

Paper feeder PCB

Replace the Paper feed/size-SW PCB assy.

32 BUFFER ERROR

Input buffer overflow

34 MEMORY FULL

Work memory overflow

40 LINE ERROR

Error in the communications circuit

41 PRINT CHECK

Error in communication with the engine controller
Error Message 42 CARD 1 FULL CARD 2 FULL 43 CARD 1 W ERROR CARD 2 W ERROR

Meaning Card overflow

Action Delete unnecessary macros or fonts, or use a new card. Set the write protect switch of the card to OFF if it has been set to ON. Use a new card. If the same error occurs, consult your dealer or service personal. Install the MIO card correctly.

Card write error

45 MIO ERROR
Error in communication with the MIO card. Connection error with optional feeders and duplex unit.

46 OPT IO ERROR

Check the interface cable connection between the printer and the fitted option. Use a new card, If the same error occurs, consult your dealer or service personal. Set the correct size of paper in T2 or for duplex printing. Press the RESET switch.

47 CARD R ERROR

Card read error

48 XX SIZE ERROR

Paper of incorrect size is loaded into XX. XX is T2/DX. Data is ignored because of an error in the Post Script program. The lower tray unit for HL1260 / 1260e / 1660 / 1660e is installed. The duplex unit for HL-1260 / 1260e / 1660 / 1660e is installed. Notice for replacing the periodical replacement parts.
IGNORE DATA (BR- Script 2 mode only)

48 INCORRECT LT

Install the lower tray unit LT2000.

49 INCORRECT DX

Install the duplex unit DX2000.

73 MAINTENANCE 1

Replace the following parts of and reset the parts life counter. (See Page V-1) Fixing unit Paper pick-up roller ASSY 3 Paper pick-up roller ASSY 5 Separation pad ASSY Separation pad ASSY W Transfer roller ASSY A
Error Message 73 MAINTENANCE 2
Meaning Notice for replacing the periodical replacement parts.
Action Replace the following parts of and reset the parts life counter. (See Page V-1) Laser unit Remove the output paper.

MP FEED=500msec

FLASH CARD CHECK

FLASH CARD CHK2

Flash card test mode
FIRST PRINT Set the first print speed. Not rotate a laser unit at power on for the less of laser unit noise. This is chosen by default. Rotate a laser unit at power on. The first print time will reduced.

SPEED=NORMAL

SPEED=MIDDLE

VII-13

SPEED=HIGH

PRINT SPEED

Always keep a laser unit rotating. The first print time will be reduced by 2 sec. *As the laser unit life is 3000h, it would necessary to replace the laser unit periodically. Adjust the interval of the paper feeding A4 size paper is fed with an interval to achieve 20ppm print speed. This is chosen by default.

SPEED=20.0ppm

SPEED=21.0ppm
HUMIDITY Countermeasure of the print quality problem which is likely appear as it is high humidity. This is chosen by default.

HUMIDITY=LOW

HUMIDITY=HIGH Change the handling of data which comes in through CDCC and RS232C. Handle the data as ASCII. Cntl-T, Cntl-C etc. are handled as the control codes This is chosen by default. Binary data can be printed. Cntl-T, Cntl-C etc. does not work.

PS BINARY SELECT

PS BINARY=ASCII

PS BINARY=BIN

PS QUOTE BINARY Not accept the binary data even with special codes. This is chosen by default. Accept the binary data with special codes. This setting is for the faster print speed with a OS/2 driver. This is chosen by default.

PS QUOTEBIN=ON

PS IMAGE MASK

PS IMAGEMSK=OFF

PS IMAGEMSK=ON

VII-14

BOISE ID MODE
To support Windows 95 Plug & Play.
BOISE ID=WIN95 This is chosen by default.

BOISE ID=IEEE

ECP RLE MODE Not use the ranlength decompression. This is chosen by default. Use the ranlength decompression on software side. To support some MIO with a firmware download function and unknown timeout for restarting.

ECP RLE = OFF

ECP RLE = ON

MIO RESTART MODE

MIO RESTART = OFF Restart MIO after the 10 min.timeout. This is chosen by default. Some UNIX systems leave a printer with MIO in open connection and do not put it close connection. Due to this, the data received by the other interfaces is not processed.

MIO RESTART = ON

MIO TIMEOUT MODE
MIO TIMEOUT = OFF Even if a printer stays in open connection, it is able to process the data received by parallel and serial I/F.This is chosen by default.

MIO TIMEOUT = ON

DPX MODE Process 2 pages data at a time.

DPX MODE = SLOW

DPX MODE = FAST

PRO.OFF=NORMAL Reset a printer with ESC E. This is chosen by default. Carry out form feed with ESC E.

HP ESC E COMMAND

HP ESC E=RESET

HP ESC E =F/F

DPX FF SUP. MODE

DPX FF SUP. =NORMAL

This is chosen by default. Not eject paper if both the 1st and 2nd faces are blank. This is chosen by default.

DPX FF SUP. =SPEC.

PS300RESO

PS300RESO =NO

PS300RESO =IF 2M

PS300RESO =FORCE

When the total memory is 2MB, 300 dpi is automatically selected in PS for less memory full. Use 300 dpi only in PS.

JAM CHECK LEVEL

JAM CHECK=TIGHT
This setting delays paper jam error detection. This is chosen by default.
JAM CHECK=LOOSE This is chosen by default.

COPY PAGES

COPY PAGES=ON

COPY PAGES=OFF

1 page is fixed for the copy page number. Settings made on the panel are reset job by job. This is chosen by default.

PANEL RESET MODE

RESET=JOB

RESET=NORMAL

USB SETTING

USB=ENABLE

Turn ON USB function. This is chosen by default. Turn OFF USB function.

USB=DISABLE

VII-19

A5 FEED SETTING

A5 FEED=PORT

A5 FEED=LAND

JAM RECOVER MODE

JAM RECOVER=ON

A5 paper size in portrate can be printed. To protect the fixing unit from overheat, printing speed will slow down. This is chosen by default. A5 paper size in landscape can be printed. Printing speed will be maintained as A5 paper width in landscape is the same as A4 paper widht in portrate. For faster print after paper jam occurs. It is very depending on memory status. This is chosen by default.
JAM RECOVER=OFF Clear NV-RAM Page counter cannot be cleared without a password. LINE TEST ENGINE TEST TONER EMPTY TEST SENSOR TEST exit ENGINE TEST SINGLE TESTPRINT REPEAT TESTPRINT DRAM CHECK START FLASH CARD CHECK FLASH CARD CHK2 exit TEST MENU BUZZER SETTING BUZZER =OFF This is chosen by default.

TEST MENU

BUZZER =ON

PARTS LIFE

PART 100K=0K

PART 100K=RESET

Display the number of the life counter for the periodical replacement parts with 100,000 pages life. See page V-1. Reset the life counter for the periodical replacement parts with 100,000 pages life.

VII-20

PART 200K=0K

PART 200K=RESET

Display the number of the life counter for the periodical replacement parts with 200,000 pages life. See page V-1. Reset the life counter for the periodical replacement parts with 200,000 pages life.

VII-21

Appendix A 1. Engine Block Diagram

HL - 6 0

E n g i n e

B l o c k

Di a g r a m

P I CK UP

E J E CT

MOT OR

P A NE L

E J E CT 2 S E NS OR

LASER PRINTER

PARTS REFERENCE LIST

HL-2060
NOTE FOR USING THIS PARTS REFERENCE LIST
1. In the case of ordering parts, it needs mentioning the following items: (1) Code (2) Q'ty (3) Description (4) Symbol ( PCB No., Revision , and Parts location mounted on the PCB.)
Note : No orders without Parts Code or Tool No. can be accepted.

< Example >

(1) REF.NO. CODE

(2) QTY

(3) DESCRIPTION

(4) SYMBOL REMARK

Revision No.: marked on the printed circuit board.

B48K056 - 201A

Design change indication Specification No. Pattern alteration No. Circuit board No.
2. Design-changed parts : If the parts are changed, any one of the following symbols is indicated in the REMARKS column. #A : compatible between old and new #B : replaceable from old to new #D : incompatible # : newly established
3. The original of this list was made based on the information available in November, 1997.
4. Parts are subject to change in design without prior notice.

CONTENTS

1. 2. 3. 4. 5. 6. 7. 8. 9. POWER CORDS & HARNESSES... 1 MAIN PCB... 1 HIGH-VOLTAGE POWER SUPPLY... 3 LOW-VOLTAGE POWER SUPPLY.. 3 COVERS.... 5 PCB ATTACHMENTS... 7 TRANSFER... 7 CHASSIS.... 9 PAPER FEEDER... 11
10. PAPER TRAY A4, LRT/LGL... 13 11. LASER UNIT.... 13 12. FIXING UNIT, 115V/230V.. 15 13. DOCUMENTS... 15 14. PACKING MATERIALS... 17 15. ADJUSTMENT TOOL KIT.. 19
1. POWER CORDS & HARNESSES
1A 1B 1C 1D 1E 1F 1G 1H 1I 2 3
MODEL HL-2060 54T-U04-050/070

2. MAIN PCB

MODEL HL-2060 54T-U04-103
REF.NO. 1A 1B 1C 1D 1E 1F 1G 1H 1I 6 7
CODE UH1052001 UH1053001 UH1055001 UH1054001 UH1051001 U34320001 UK4094001 U34322001 U34342001 UK2502001 UK4100000 UK2506001 UK2507001 UK4072001 UK4166001

Q'TY 1

1. POWER CORDS & HARNESSES DESCRIPTION AC CORD, VDE AC CORD, SEV AC CORD, SAA AC CORD, BS AC CORD, UL/CSA AC CORD #4, BS AC CORD, DEMKO AC CORD #6, ISRAEL AC CORD #8, BS/SINGAPORE HV HARNESS 16P PAPER FEED FFC 21P LV HARNESS 8P FUSER HARNESS 4P DC MOTOR HARNESS 3P PAPER EJECT SENSOR HARNESS 3P

REMARK

MODEL HL2060 54T-U04-050/070

REF.NO. 1-4 5

CODE UK4051001 UK4215000 UK4216000 UK087320616

Q'TY 8 1

2. MAIN PCB DESCRIPTION MAIN PCB ASSY, HL-2060 MROM23C32000-01 EVEN MROM23C32000-02 ODD MIO CONNECTOR PCB ASSY TAPTITE, CUP S M3X6 TAPTITE, CUP S M3X6
SYMBOL B512006-2 B512013-2
3. HIGH-VOLTAGE POWER SUPPLY

HL-2060 54T-U04-200

4. LOW-VOLTAGE POWER SUPPLY

REF.NO. 1 2

CODE UK3750001 087320616
3. HIGH-VOLTAGE POWER SUPPLY Q'TY DESCRIPTION 1 HV PS PCB ASSY HL-TAPTITE, CUP S M3X6

SYMBOL B48K297-2

MODEL HL-2060 54T-U04-200

REF.NO. 2

CODE UK4150001 UK4151001 UH2036001
4. LOW VOLTAGE POWER SUPPLY Q'TY DESCRIPTION 1 LV PS PCB ASSY 115V HL-LV PS PCB ASSY 230V HL-TAPTITE, PAN S(WASHER) M3X8

SYMBOL

MODEL HL-2060 54T-U04-300

5. COVERS

17 17-4

26 4-5

HL-2060 54T-U04-400

REF.NO. 1-4-17-30

CODE UH1526001 UH1533001 UH1534001 UH1535001 UH1538001 UH1540001 UH1541001 UH1893001 UK4068001 UH1589001 UHUH1572001 UH2076001 UH2077001 UH2027001 UH1531001 UL7978001 UH1542001 UH2085001 UH1548001 UK4083001 UH1511001 UH1512001 UH1514001 UH085311015 UH1509001
5. COVERS DESCRIPTION UPPER COVER ASSY M COVER A M COVER B M COVER C TONER CARTRIDGE LID PAPER STOPPER PAPER STOPPER GUIDE SW PANEL ASSY (SP) SW PANEL HARNESS ASSY PANEL SHEET HL-2060 INTERLOCK ACTUATOR TAPTITE, BIND B M3X10 FONT CARD COVER CLEANER BRUSH SIDE COVER L, GRAY1227 SIDE COVER R2 ASSY SWING PAPER TRAY PLATE SPRING REAR COVER ASSY CHANGEOVER GUIDE, GRAY1227 JAM REMOVE COVER PAPER EJECT SENSOR PCB ASSY LEAD WIRE COVER FRONT COVER NAME PLATE PAPER SENSOR ACTUATOR TAPTITE, CUP S M3X6 TAPTITE, CUP S M3X6 TAPTITE, CUP S M3X6 TAPTITE, CUP S M3X10 TAPTITE, BIND B M3X10 TAPTITE, BIND B M3X8 LIGHT GUIDE

B512005-1

B512002-1
MODEL HL-2060 54T-U04-400

6. PCB ATTACHMENTS

MODEL HL-2060 54T-U04-450

7. TRANSFER

HL-2060 54T-U04-600

REF.NO. 9 10

CODE UH2121001 UH2122000 UHUH2144000 UK2826000 UK3213000 UK3214000 UK3215000 UH2030000

Q'TY 1 1

6. PCB ATTACHMENT DESCRIPTION REMOTE SWITCH PS SWITCH WIRE DC FAN MOTOR2 TAPTITE, PAN B M3X35 HOLDER SPACER CORE:RI-12-15-8.5 CORE:FPC-16-12 CORE:ZCAT1518 CABLE CLAMP DC FAN SPONGE

REF.NO. 1-2

CODE UH2787001 UH1834001 087321016
7. TRANSFER Q'TY DESCRIPTION 1 TRANSFER BASE ASSY (SP) 1 TRANSFER ROLLER ASSY A (SP) 1 TAPTITE, CUP S M3X10
MODEL HL-2060 54T-U04-600

8. CHASSIS

HL-2060 54T-U04-500

REF.NO. 19 20

CODE UHT31242001 UH2229001 UH2233001 UHUH2250001 UH2252000 UH2254000 UH087320616 UH1516001 UH1515001 UH1518001 UHUK3215000 UH1830001
8. CHASSIS DESCRIPTION LV FAN MOTOR TAPTITE, CUP S M3X30 PCB SPACER F CARTRIDGE STOPPER ASSY DC GEAR HOLDER ASSY DC MOTOR ASSY 3 (SP) TAPTITE, CUP S M3X6 PAPER DELIVERY HOLDER SPRING SPACER 2 SPACER 1 SCANNER FAN MOTOR TAPTITE, PAN B M3X30 TAPTITE, CUP S M3X6 M HOLDER B M HOLDER A M HOLDER D M HOLDER C TAPTITE, BIND B M3X6 CABLE CLAMP CABLE TIE
MODEL HL-2060 54T-U04-500

- 10 -

9. PAPER FEEDER

HL-2060 54T-U04-630

REF.NO. 1-46
CODE UH1835001 UH085310815 UH2821001 UH1487001 UH1477001 UHUH1488001 UH1488001 UL0633000 UHUHUH2428000 UH2379000 UH2380000 UH2381000 UH2382000 UH2383000 UH2384000 UH2136001 UH1891001 UH2393001 UH2433001 UH2397001 UH2400000 UH2401000 UH2402000 UH2403000 UH2404000 UH2406000 UH2407000 UH2821001 UH1487001 UH1477001 UH1494001 UHUHUH1837001 UHUH1898001
9. PAPER FEEDER DESCRIPTION PAPER FEED UNIT (SP) PAPER FEED MOTOR ASSY TAPTITE, CUP S M3X6 TAPTITE, BIND B M3X8 PAPER PICK-UP ROLLER ASSY 3 PAPER PICK-UP COLLAR LOW COLLAR STOPPER BEARING TAPTITE, BIND S M3X6 PAPER FEED ROLLER ASSY 72 PAPER FEED ROLLER ASSY 72 WASHER, PLAIN BEARING TAPTITE, BIND S M3X6 PAPER PICK-UP SOLENOID TAPTITE, BIND S M3X4 BEARING CALLOR TRAY SENSOR HOLDER PE SENSOR ACTUATOR TRAY PE ACTUATOR LINK DU DETECTION ACTUATOR PE SENSOR ACTUATOR MP REGIST SENSOR ACTUATOR LATCH MP PAPER FEED UNIT (SP) SEPARATION PAD ASSY SEPARATION PAD SPRING MP MP TRAY ASSY MP PE SUB ACTUATOR MP PAPER GUIDE MP RELEASE PLATE MP RELEASE SUPPORTER MP PUSH UP SPRING MP TRAY COVER MP EXTENSION TRAY PAPER PICK-UP ROLLER ASSY 3 PAPER PICK-UP COLLAR LOW COLLAR STOPPER PAPER PICK-UP ROLLER ASSY 5 BEARING TAPTITE, BIND S M3X6 BEARING R TAPTITE, BIND S M3X6 PAPER FEED PCB ASSY (SP) SIZE SWITCH SPRING TAPTITE, CUP S M3X6 PAPER FEED EARTH SPRING 1

B512011-2

MODEL HL-2060 54T-U04-630

- 12 -

10. PAPER TRAY A4, LTR/LGL

54T-U02-650/651

11. LASER UNIT

54T-U02-700

REF.NO. 5 6
CODE UH1500001 UH1582001 UH1583001 UH2360000 UH2459000 UH2472001
10. PAPER TRAY A4, LTR/LGL DESCRIPTION SEPARATION PAD ASSY W SEPARATION PAD SPRING 100 SEPARATION PAD SPRING 50 ROLLER ROLLER HOLDER TRAY GUIDE PLATE 1

MODEL HL-2060 54T-U04-650/651

REF.NO. 7

CODE UH1885001 UK3773000 UK4158000 UHUK3254001 UH1597001

Q'TY 3

11. LASER UNIT DESCRIPTION LASER UNIT (SP) LSR FLAT CABLE 14P LSR FLAT CABLE 6P POLYGON CONTROL PCB ASSY TAPTITE, CUP S M3X16 POLYGON HARNESS 5P LOCK SPACER
MODEL HL-2060 54T-U04-700

- 14 -

12. FIXING UNIT, 115V/230V

1-18 14

MODEL HL-2060 54T-U04-770/771

13. DOCUMENTS

HL-2060 54T-U04-920

REF.NO. 1-18 1-17 18

CODE UH3607001 UH3608001 UH3609001 UH028030245 UH1861001 UH2627001 UHUH1865001 UH1868001 UH1871001 UKUHUH1888001 UH1889001 UH2627001 087421015

Q'TY 2

12. FIXING UNIT120V/230V DESCRIPTION FIXING UNIT 115VT (SP) FIXING UNIT 230VT (SP) HEAT ROLLER 30T (SP) HEAT ROLLER STOP RING TAPTITE, BIND B M3X10 WASHER, SPRING 2-3 AC PLATE SCREW, CUP M3X6 THERMISTOR ASSY TAPTITE, CUP B M3X12 CLEANER ASSY 1 CLEANER ASSY 2 CLEANER SPRING FIXING UNIT PCB ASSY TAPTITE, BIND B M3X10 PAPER EJECT ACTUATOR TAPTITE, CUP B M3X12 HL HEATER 115V ASSY (SP) HL HEATER 230V ASSY (SP) SCREW, CUP M3X6 TAPTITE, CUP S M4X10

PR98316 REMARK

B512046-2

REF.NO. 5

CODE UK3881001 UK3883001 UK4329001 UH3588001 UH3589001 UH3590001 UH3591001 UH3592001 UH3593001 UH3594001 UH3595001 UH3596001 UH3597001 UH3598001 UH3599001
13. DOCUMENTS DESCRIPTION P-DRIVER DISK#1 P-DRIVER DISK#2 CD-ROM ASSY (HL-1070/1660E/2060) USER'S GUIDE ENG USER'S GUIDE GER USER'S GUIDE FRA USER'S GUIDE HOL USER'S GUIDE NOR USER'S GUIDE ITA SETUP GUIDE ENG SETUP GUIDE GER SETUP GUIDE FRA SETUP GUIDE HOL SETUP GUIDE NOR SETUP GUIDE ITA
CHNG VER.#D CHNG VER.#D CHNG VER.#C
MODEL HL-2060 54T-U04-920
T/I NO. PR98263 / PR98279 / PR98291 / PR98316

- 16 -

14. PACKING MATERIALS

HL-2040 54T-U04-930

REF.NO. 11
CODE UE0700000 UE0701000 UE0702000 UE0374000 UE0707000 UH2735001 UH2736001 UE0396000 UE0741000 UE0742000 UUE0713000 UE0714000 UE0425001
14. PACKING MATERIALS DESCRIPTION CARTON, HL-2060 US CARTON, HL-2060 EU STYROFOAM, HL-2060 CARTON ,TNR CARTRIDGE PLATE HOLDER SF RELEASE SPACER R RELEASE SPACER L PANEL HOLDER PAD D BAG 900X900 BAG 900X900 GB CAUTION LABEL 24 ,US SUFFOCATION CAUTION LABEL ,BS LTR HOLD PAD D A4 HOLD PAD D POSITION FIXING SPONGE