SERVICE MANUAL
A4 Full Color Laser Printer
EPSON AcuLaser C4200
SEPG05001
Notice:
All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.
The contents of this manual are subject to change without notice.
All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.
The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof.
EPSON is a registered trademark of SEIKO EPSON CORPORATION.
General Notice:
Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their respective owners. EPSON disclaims any and all rights in those marks.
Copyright © 2005 SEIKO EPSON CORPORATION. I&I CS/Quality Management & PL Department
PRECAUTIONS Precautionary notations throughout the text are categorized relative to 1)Personal injury and 2) damage to equipment.
DANGER
Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by DANGER Headings.
WARNING
Signals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.
DANGER 1. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURES. 2. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK. 3. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
WARNING 1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. 2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE. 3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS. 4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS. 5. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF SECONDSOURCE ICs OR OTHER NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
About This Manual This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the printer. The instructions and procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page.
Manual Configuration This manual consists of six chapters and Appendix. CHAPTER 1.PRODUCT DESCRIPTIONS Provides a general overview and specifications of the product. CHAPTER 2.OPERATING PRINCIPLES Describes the theory of electrical and mechanical operations of the product. CHAPTER 3.TROUBLESHOOTING Describes the step-by-step procedures for the troubleshooting. CHAPTER 4.DISASSEMBLY / ASSEMBLY Describes the step-by-step procedures for disassembling and assembling the product. CHAPTER 5.ADJUSTMENT Provides Epson-approved methods for adjustment. CHAPTER 6.MAINTENANCE Provides preventive maintenance procedures and the lists of Epsonapproved lubricants and adhesives required for servicing the product. APPENDIX Provides the following additional information for reference: • Connector pin assignments • Electric circuit boards components layout • Electrical circuit boards schematics • Exploded diagram & Parts List
Symbols Used in this Manual Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Be aware of all symbols when they are used, and always read NOTE, CAUTION, or WARNING messages. A D J U S T M E N T R E Q U IR E D
Indicates an operating or maintenance procedure, practice or condition that is necessary to keep the product’s quality.
C A U T IO N
Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.
C H E C K P O IN T
May indicate an operating or maintenance procedure, practice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.
W A R N IN G
Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.
Abbreviations A lot of abbreviations are used throughout this manual. Some of them are common ones and the others are original ones. The list below includes the most of the major abbreviations and may include those which are not used in this manual as this is intended to be used in every quarter.
[A] ADC........................................ Auto Density Control ALM ................................................................Alarm Assy ........................................................... Assembly Aux. ............................................................Auxiliary [B] B/W................................................. Black and White BCR ............................................... Bias Charge Roll Bk .....................................................................Black BCR ............................................... Bias Charge Roll BRKT ............................................................Bracket BTR ............................................. Bias Transfer Roll BUR ..................................................... Back Up Roll [C] C ........................................................................Cyan CCW ........................................... Counter Clockwise Cl. ................................................................... Clutch Clk ................................................................... Clock CHK.................................................................Check CK....................................................................Check Conpane...............................................Control Panel Cont ...........................................................Controller CR...........................................................Charge Roll CRU...............................Customer Replaceable Unit CRUM ................................................ CRU Memory CST...............................................................Cassette CVR ................................................................. Cover CW............................................................ Clockwise
[D] DB ...................................................Developing Bias Deve ..........................................................Developer Diag .......................................................... Diagnostic dpi..........................................................dots per inch DTS ........................................................ Detack Saw Dup.................................................................Duplex [E] Elec................................................................Electric EP ............................................. Electro Photography ESS............................................Electric Sub System [F] F ........................................................................Front FDR ................................................................ Feeder FG....................................................... Frame Ground FIP .....................................Fault Isolation Procedure FRU ...................................... Field Replaceable Unit FX............................................................. Fuji Xerox [G] GG ........................................................ Guide Gauge GND .............................................................. Ground [H] H........................................................................ High H/R .............................................................Heat Roll HCF ........................................ High Capacity Feeder HCS ....................................... High Capacity Stacker Hex ....................................................... Hexadecimal HVPS ........................... High Voltage Power Supply
[I] I/F.................................................................Interface I/L ............................................................... Interlock ID ....................................................... Image Density [J] Jxx..................................................................Jack xx [K] [L] L.......................................................................... Left L......................................................................... Low L/H............................................................ Left Hand L/P ........................................................... Low Paper LD .......................................................... Laser Diode LEF ................................................. Long Edge Feed LVPS ............................ Low Voltage Power Supply [M] M..................................................................Magenta M/N.................................................... Multi National Mag .............................................................Magnetic MCU ...................................... Machine Control Unit Mech ....................................................... Mechanical MOT ................................................................Motor MSI ............................................Multi Sheet Inserter [N] N/F ...................................................... Normal Force N/P ..............................................................No Paper NPS ................................................. No Paper Sensor NV ........................................................ Non Volatile NVM ...................................... Non Volatile Memory (to continue to next page)
[O] OHP ............................................Overhead Projector OPC ..................................Organic Photo Conductor OPT.................................................................Option [P] Pyy .................................................................Plug yy P/J ........................................................Plug and Jack P/H .................................................... Paper Handling P/R ........................................................Pressure Roll PL ...................................................................... Plate PLT .................................................................... Plate PPM ................................................ Print Per Minute PV ........................................................ Print Volume PWB ....................................... Printed Wiring Board PWBA.............................................. PWB Assembly [Q] [R] R ....................................................................... Right R ........................................................................ Rear R/H ......................................................... Right Hand RDY.................................................................Ready Regi........................................................ Registration ROS .......................................Raster Output Scanner RRP................Removal and Replacement Procedure RTN ................................................................ Return [S] SEF ................................................. Short Edge Feed SG .......................................................Signal Ground SNR ................................................................ Sensor SNS................................................................. Sensor Sol................................................................Solenoid SOS...................................................... Start Of Scan SPI .......................................................Scan Per Inch STD..............................................................Standard STK................................................................ Stacker STND...........................................................Standard SW ..................................................................Switch Sync ...................................................... Synchronous
[T] T ..........................................Tooth (number of Gear) Temp ..................................................... Temperature TR.................................................................Transfer TTL ............................... Transistor-Transistor Logic [U] [V] [W] [X] Xero....................................................... Xerographic [Y] Y.....................................................................Yellow YMCBk ...................... Yellow/Magenta/Cyan/Black YMCK........................ Yellow/Magenta/Cyan/Black [Z]
Safety Information To prevent possible accidents during maintenance work, strictly observe the WARNINGs and CAUTIONs described in this manual. Never attempt to perform dangerous operations or any other operations which depart from the descriptions and procedures in this manual. Other than the cautions and warnings stated below, there are many other situations and circumstances that could result in serious bodily injury. Always pay enough attention to secure safety when working with the printer.
Power Supply
Mechanical Components
Before starting any service procedure, turn the printer power off and unplug the power cord from the wall outlet.When the power supply cable must be connected, be aware of the potential for electrical shock and do all tasks by following the procedures in this manual.
When servicing any driving assembly (e.g., gears), first turn the power off and unplug the power cord, and then manually rotate the assembly.
W A R N IN G
Do not touch any live parts other than the required parts while the printer is on. As the LVPS ASSY (power supply section) is live even when the power is off, never touch the live parts. Do not touch any live parts unless instructed to do so.
W A R N IN G
Do not touch the driving part (e.g., gears) while the assembly (printer) is operating.
High Temperature Assembly When working with hot parts (FUSER etc.) make sure to turn the power off, unplug the power cable, and leave the printer until it cools down sufficiently to work with to prevent burn injury. W A R N IN G
Ida_00_002A
As the inside of the printer is high-temperature state immediately after the operation, leave it more than 40 minutes before working.
Laser Beam W A R N IN G
C H E C K P O IN T
Letting a laser beam get directly into your eyes could result in loss of vision. Never open the Cover where the Warning Label about Laser Beam is affixed. Before disassembling or assembling, be sure to turn the power off. If you need to work on the printer with power applied, strictly follow the instructions in this manual. Understand hazardous nature of the laser beam, use extreme caution to avoid injury of yourself and anyone around you.
ROS ASSY
Since the laser beam has a narrower frequency band and more coherent phases than any other light (sunlight, electric light), the beam has excellent monochromaticity and convergence, thus it reaches long distances. Because of these characteristics, the laser beam converges into one point, causing high density and high temperature, which is harmful to the human body. Reference: The laser beam in this printer is invisible.
Ida_00_003A
Caution Label for Toner Cartridges
Warning/Caution Labels Warning labels and caution labels are attached on the corresponding locations on or in the printer. C H E C K P O IN T
In maintenance work, check that the labels are free from peeling and soiling.
Caution Label for High-temperature Surface
Ida_Sec00_010GA
Ida_00_004A
Caution Label about PHD ASSY and BTR ASSY
Caution Label about MSI and Paper Tray
Ida_Sec00_005FA
Ida_00_006A Ida_00_009A
Caution Label about FRAME ASSY DEVE
Caution Label about ROS ASSY
Ida_Sec00_007GA
Ida_Sec00_008GA
Cautions relating to Toner cleaning
Storage of Paper
To prevent ignition, explosion, burn, injury, etc., do not use a general vacuum cleaner for cleaning dropped toner. (To do so may cause the toner to catch fire by sparks in the vacuum cleaner.)
Damp papers could cause printing quality troubles. To keep papers in their best condition, store them wrapping tightly with packing material or putting them into a plastic bag.
W A R N IN G
Do not pick up dropped toner with a general vacuum cleaner. To do so may cause ignition.
Leg_Sec001_014EA
Revision Status Revision
Date of Issue
A
JUN 24, 2005
Description
First release
EPSON AcuLaser C4200
Revision A
Contents Chapter 1 PRODUCT DESCRIPTION 1.1 Overview ............................................................................................................... 7 1.1.1 Engine Features ............................................................................................ 7 1.1.2 Controller Features ....................................................................................... 7 1.1.3 Software Features ......................................................................................... 8 1.2 Basic Specifications.............................................................................................. 9 1.2.1 Process Specifications & System.................................................................. 9 1.2.2 Printer Basic Specifications.......................................................................... 9 1.3 Paper Specifications ............................................................................................ 19 1.3.1 Paper Type .................................................................................................. 19 1.3.2 Paper that may cause printing defects, paper jams or printer malfunction. 19 1.3.3 Available Paper by Feeder.......................................................................... 20 1.3.4 Printing Area............................................................................................... 20 1.4 Reliability and Serviceability .............................................................................. 21 1.4.1 Reliability ................................................................................................... 21 1.4.2 Durability.................................................................................................... 22 1.4.3 Serviceability .............................................................................................. 22 1.5 Service Conditions............................................................................................... 23 1.6 Conditions for Storage and Transport ................................................................. 24 1.7 Electrical Characteristics ..................................................................................... 25 1.8 Compatible Specification .................................................................................... 26 1.9 Consumables/Periodic Replacement Unit ........................................................... 27 1.9.1 Specifications.............................................................................................. 27 1.9.2 Conditions for Storage and Transport......................................................... 28 1.10 External Appearance and Unit Names .............................................................. 29 1.10.1 Unit Names ............................................................................................... 29 1.11 Engine Restrictions............................................................................................ 31 1.11.1 Controls that Restrict Print Speed............................................................. 31 1.11.2 Controls that Restrict Print Start............................................................... 31 1.11.3 Toner Duty Limiting Value ...................................................................... 31 1.12 Notes When Replacing Consumables and Installing Optional Products........... 32 1.12.1 Consumables............................................................................................. 32
1.12.2 Optional Products ..................................................................................... 1.13 Life Details ........................................................................................................ 1.14 Engine Control (Appendix) ............................................................................... 1.15 Controller Specifications................................................................................... 1.15.1 Controller Basic Specifications ................................................................ 1.15.2 Controller Configuration .......................................................................... 1.15.3 External Interface Specifications.............................................................. 1.16 Control Panel..................................................................................................... 1.16.1 External Appearance and Names.............................................................. 1.16.2 Panel Settings List .................................................................................... 1.16.3 Explanation of Menu and Settings............................................................ 1.16.4 Special Operations.................................................................................... 1.17 Printer Status ..................................................................................................... 1.17.1 List of Printer Messages ........................................................................... 1.17.2 Status Messages and Troubleshooting...................................................... 1.17.3 Warning Messages and Troubleshooting ................................................. 1.17.4 Error Messages and Troubleshooting ...................................................... 1.17.5 Service Call Error Messages..................................................................... 1.18 Expanding the RAM.......................................................................................... 1.19 Handling Precautions ........................................................................................ 1.20 Status Sheet ....................................................................................................... 1.21 Engine Status Sheet/Print Log Report............................................................... 1.22 Color Registration Sheet ................................................................................... 1.23 Form Overlay List ............................................................................................. 1.24 Paper Handling Algorithm ................................................................................
32 33 34 36 36 37 37 40 40 42 53 59 60 60 62 63 65 68 70 71 72 76 77 78 79
Chapter 2 OPERATING PRINCIPLES 2.1 Print Process ........................................................................................................ 2.1.1 Print Process Overview .............................................................................. 2.1.2 Print Process Diagram ................................................................................ 2.1.3 Technical Explanation of Print Process......................................................
82 82 83 84
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EPSON AcuLaser C4200 2.2 Flow of Print Data ............................................................................................... 92 2.2.1 Data Flow.................................................................................................... 92 2.3 Drive Transmission Path ..................................................................................... 93 2.3.1 DRIVE ASSY MAIN ................................................................................. 93 2.3.2 DRIVE ASSY DEVE ................................................................................. 94 2.3.3 DISPENSER ASSY (Y, M, C, K) .............................................................. 96 2.3.4 DRIVE ASSY FUSER ............................................................................... 97 2.3.5 MOTOR ASSY DUP 17PM....................................................................... 98 2.3.6 DRIVE ASSY (550-sheet Paper Cassette Unit) ......................................... 99 2.3.7 DRIVE ASSY 2ND (1,100-sheet Paper Cassette Unit) ........................... 100 2.4 Feeding Paper .................................................................................................... 101 2.4.1 Paper Feed Path (When options are not installed).................................... 101 2.4.2 Paper Feed Path (When the 550-sheet Paper Cassette is installed) .......... 102 2.4.3 Paper Feed Path (When the 1100-sheet Paper Cassette is installed) ........ 103 2.5 Main Structure and Function ............................................................................. 104 2.5.1 Paper Cassette........................................................................................... 104 2.5.2 Paper Feeder ............................................................................................. 105 2.5.3 Optional Feeder (550-sheet Paper Cassette)............................................. 106 2.5.4 Optional Feeder (1100-sheet Paper Cassette)........................................... 108 2.5.5 Retard & Regi Assy .................................................................................. 110 2.5.6 Front Assy In ............................................................................................ 111 2.5.7 Chute Assy Out......................................................................................... 112 2.5.8 BTR Assy & Fuser Assy........................................................................... 114 2.5.9 Xerographics............................................................................................. 116 2.5.10 Toner Cartridge....................................................................................... 117 2.5.11 Frame & Drive........................................................................................ 119 2.5.12 Electrical ................................................................................................. 120 2.6 Switch and Sensor ............................................................................................. 122 2.7 Mode.................................................................................................................. 123 2.7.1 Printing Mode ........................................................................................... 123 2.7.2 Operating Modes ...................................................................................... 123 2.8 Control ............................................................................................................... 124 2.8.1 Paper Size Control .................................................................................... 124 2.8.2 Paper Feeder Selection Control ................................................................ 124 2.8.3 ROS Light Intensity Control..................................................................... 124 2.8.4 Process Control......................................................................................... 125 2.8.5 Color Registration Control ....................................................................... 128 2.8.6 BTR ASSY Control .................................................................................. 129 2.8.7 Toner Control............................................................................................ 130
Revision A 2.8.8 Fuser Control ............................................................................................ 2.9 Detection Mechanisms ...................................................................................... 2.10 Features of the Controller................................................................................ 2.10.1 Power Supply..........................................................................................
131 132 134 136
Chapter 3 TROUBLESHOOTING 3.1 Procedure for Troubleshooting.......................................................................... 3.1.1 Procedure for Troubleshooting................................................................. 3.1.2 Preliminary Check .................................................................................... 3.1.3 Precautions in Performing Troubleshooting Work................................... 3.1.4 Notes on Using FIP................................................................................... 3.2 Paper Jam .......................................................................................................... 3.2.1 Paper Transferring Path and The Main Components ............................... 3.2.2 Paper Jam Handling (FIP) ........................................................................ 3.2.3 Check Points for Frequent Paper Jam....................................................... 3.3 Level 1 FIP ........................................................................................................ 3.3.1 Level 1 FIP ............................................................................................... 3.3.2 The flow of Level 1 FIP ........................................................................... 3.4 Level 2 FIP ........................................................................................................ 3.4.1 List of Warnings and Errors ..................................................................... 3.4.2 List of Service Request............................................................................. 3.4.3 Engine-related Trouble FIP ...................................................................... 3.4.4 Controller-related Trouble FIP ................................................................. 3.4.5 Print Quality Trouble FIP ......................................................................... 3.4.6 Other FIP .................................................................................................. 3.5 Abnormal Noise-related Trouble....................................................................... 3.5.1 Abnormal Noise-related Troubleshooting Entry Chart ............................ 3.5.2 Abnormal Noise-related FIP..................................................................... 3.6 Test Print ...........................................................................................................
138 138 138 139 140 141 142 144 151 152 152 152 153 153 158 163 209 211 225 228 228 229 233
Chapter 4 DISASSEMBLY/REASSEMBLY 4.1 Overview ........................................................................................................... 4.1.1 Precautions................................................................................................ 4.1.2 Before starting work ................................................................................. 4.1.3 Screws....................................................................................................... 4.1.4 Tools ......................................................................................................... 4.1.5 Conventions used in descriptions of procedures ......................................
236 236 238 239 240 241
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EPSON AcuLaser C4200 4.2 COVERS ........................................................................................................... 4.2.1 COVER TOP MAIN................................................................................. 4.2.2 CONSOLE PANEL .................................................................................. 4.2.3 COVER ASSY FRONT HEAD ............................................................... 4.2.4 COVER ASSY TOP PHD ........................................................................ 4.2.5 COVER REAR ASSY.............................................................................. 4.2.6 FAN REAR............................................................................................... 4.2.7 COVER SIDE R ASSY ............................................................................ 4.2.8 COVER FRONT R ................................................................................... 4.2.9 TRAY ASSY MSI BASE......................................................................... 4.2.10 COVER ASSY MSI ............................................................................... 4.2.11 COVER FRONT L ASSY ...................................................................... 4.2.12 COVER SIDE L ASSY .......................................................................... 4.2.13 COVER ASSY TOP, COVER TOP STOPPER..................................... 4.3 PAPER CASSETTE .......................................................................................... 4.3.1 ROLL ASSY RETARD............................................................................ 4.3.2 HOLDER ASSY RETARD...................................................................... 4.3.3 KIT GUIDE SIDE L, KIT GUIDE SIDE R ............................................. 4.3.4 KIT GUIDE END ..................................................................................... 4.4 PAPER FEEDER............................................................................................... 4.4.1 CHUTE ASSY FEEDER.......................................................................... 4.4.2 COVER CST ............................................................................................ 4.4.3 FEEDER ASSY (REFERENCE ONLY) ................................................. 4.4.4 SWITCH ASSY SIZE .............................................................................. 4.4.5 SWITCH ................................................................................................... 4.4.6 HARNESS ASSY OPFPLG ..................................................................... 4.4.7 PICK UP ASSY........................................................................................ 4.4.8 ROLL ASSY TURN, BEARING SLEEVE, PLASTIC ........................... 4.4.9 SENSOR NO PAPER............................................................................... 4.4.10 SENSOR LOW PAPER ......................................................................... 4.4.11 SOLENOID FEED ................................................................................. 4.4.12 ACTUATOR LOW PAPER ................................................................... 4.4.13 CHUTE UPPER (REFERENCE ONLY) ............................................... 4.4.14 ROLL ASSY FEED................................................................................ 4.4.15 ACTUATOR NO PAPER ...................................................................... 4.5 RETARD & REGI ASSY ................................................................................. 4.5.1 ACTUATOR REGI .................................................................................. 4.5.2 SENSOR REGI......................................................................................... 4.5.3 CHUTE ASSY REGI IN .......................................................................... 4.5.4 SENSOR OHP ..........................................................................................
Revision A 242 242 243 244 245 246 247 248 249 250 251 252 253 254 255 255 256 257 259 261 261 262 263 266 267 268 269 270 271 272 273 274 275 276 277 278 278 279 280 281
4.5.5 ROLL ASSY RETARD............................................................................ 4.5.6 CHUTE ASSY REGI ............................................................................... 4.5.7 ROLL REGI METAL............................................................................... 4.5.8 ROLL REGI RUBBER ............................................................................ 4.5.9 CLUTCH REGI........................................................................................ 4.5.10 CLUTCH TURN .................................................................................... 4.5.11 ROLL TURN MSI.................................................................................. 4.6 CHUTE ASSY IN & OUT ................................................................................ 4.6.1 FUSER ASSY........................................................................................... 4.6.2 BTR ASSY ............................................................................................... 4.6.3 HOLDER ASSY CTD.............................................................................. 4.6.4 SENSOR TNR FULL............................................................................... 4.6.5 DRIVE ASSY FUSER ............................................................................. 4.6.6 SOLENOID FEED MSI ........................................................................... 4.6.7 SENSOR NO PAPER............................................................................... 4.6.8 ACTUATOR NO PAPER MSI ................................................................ 4.6.9 ROLL ASSY FEED.................................................................................. 4.6.10 SENSOR FULL STACK........................................................................ 4.6.11 SENSOR DUP JAM............................................................................... 4.6.12 ACTUATOR FULL STACK ................................................................. 4.6.13 MOTOR ASSY DUP 17PM................................................................... 4.6.14 ACTUATOR DUP ................................................................................. 4.6.15 ROLL DUP............................................................................................. 4.6.16 ROLL EXIT............................................................................................ 4.6.17 CHUTE ASSY DUP IN ......................................................................... 4.6.18 CHUTE ASSY DUP OUT ..................................................................... 4.6.19 FAN FRONT .......................................................................................... 4.7 XEROGRAPHICS ............................................................................................ 4.7.1 ROS ASSY ............................................................................................... 4.7.2 HSG ASSY BIAS..................................................................................... 4.8 DEVELOPMENT ............................................................................................. 4.8.1 FRAME ASSY DEVE.............................................................................. 4.8.2 CONN_ASSY_CRUM_MC..................................................................... 4.8.3 DEVE ASSY (Y), (M), (C), (K)............................................................... 4.8.4 DISPENSER ASSY-4 (REFERENCE ONLY)........................................ 4.8.5 DISPENSER ASSY (Y) ........................................................................... 4.8.6 DISPENSER ASSY (M) .......................................................................... 4.8.7 DISPENSER ASSY (C) ........................................................................... 4.8.8 DISPENSER ASSY (K) ........................................................................... 4.8.9 SENSOR NO TNR (Y), (M), (C) .............................................................
282 283 284 285 286 287 288 289 289 290 291 292 294 296 299 300 302 304 305 307 308 309 310 311 312 315 319 320 320 321 322 322 324 325 326 329 331 333 335 337
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EPSON AcuLaser C4200 4.8.10 SENSOR NO TNR (K)........................................................................... 4.8.11 ACTUATOR SENSOR 2 ....................................................................... 4.8.12 BOX ASSY CRUM READER ............................................................... 4.9 DRIVE ............................................................................................................... 4.9.1 DRIVE ASSY DEVE ............................................................................... 4.9.2 DRIVE ASSY MAIN ............................................................................... 4.10 ELECTRICAL................................................................................................. 4.10.1 LVPS ASSY (REFERENCE ONLY)..................................................... 4.10.2 LVPS....................................................................................................... 4.10.3 HARNESS ASSY AC INLET................................................................ 4.10.4 HARNESS ASSY INTERLOCK ........................................................... 4.10.5 PWBA EEPROM.................................................................................... 4.10.6 PWBA MCU IDTN ................................................................................ 4.10.7 SENSOR HUM....................................................................................... 4.10.8 HVPS ...................................................................................................... 4.10.9 ESS BOX (REFERENCE ONLY) ......................................................... 4.10.10 PWBA ESS MAIN ............................................................................... 4.10.11 PWBA ESS ROM................................................................................. 4.10.12 PWBA NIC C533 ................................................................................. 4.11 ONE TRAY OPTION FEEDER ..................................................................... 4.11.1 1 TRAY OPTION FEEDER ASSY ....................................................... 4.11.2 HARNESS ASSY OPFREC................................................................... 4.11.3 PWBA OPTFDR 1T ............................................................................... 4.11.4 COVER RIGHT...................................................................................... 4.11.5 HARNESS ASSY OPFPLG2 ................................................................. 4.11.6 CHUTE ASSY FEEDER........................................................................ 4.11.7 COVER LEFT ........................................................................................ 4.11.8 SWITCH ASSY SIZE ............................................................................ 4.11.9 PICK UP ASSY ...................................................................................... 4.11.10 ROLL ASSY TURN............................................................................. 4.11.11 CLUTCH ELECTRO MAGNETIC ..................................................... 4.11.12 SENSOR NO PAPER........................................................................... 4.11.13 SENSOR LOW PAPER ....................................................................... 4.11.14 SOLENOID FEED ............................................................................... 4.11.15 DRIVE ASSY....................................................................................... 4.11.16 ACTUATOR LOW PAPER ................................................................. 4.11.17 CHUTE UPPER (REFERENCE ONLY) ............................................. 4.11.18 ROLL ASSY FEED.............................................................................. 4.11.19 ACTUATOR NO PAPER .................................................................... 4.11.20 ROLL ASSY RETARD........................................................................
Revision A 338 339 340 342 342 344 345 345 347 348 349 350 351 355 356 356 358 360 361 362 362 363 365 366 367 369 370 371 373 376 377 378 379 381 382 383 384 385 386 387
4.11.21 HOLDER ASSY RETARD.................................................................. 4.11.22 KIT GUIDE SIDE L, KIT GUIDE SIDE R ......................................... 4.11.23 KIT GUIDE END ................................................................................. 4.12 TWO TRAY OPTION FEEDER .................................................................... 4.12.1 2 TRAY OPTION FEEDER ASSY ....................................................... 4.12.2 COVER ASSY LEFT............................................................................. 4.12.3 COVER ASSY RIGHT .......................................................................... 4.12.4 COVER ASSY FRONT ......................................................................... 4.12.5 COVER CST .......................................................................................... 4.12.6 FEEDER ASSY LEFT ........................................................................... 4.12.7 FEEDER ASSY RIGHT......................................................................... 4.12.8 SWITCH ASSY SIZE ............................................................................ 4.12.9 CHUTE ASSY FEEDER........................................................................ 4.12.10 HARNESS ASSY OPFREC2............................................................... 4.12.11 PWBA OPTFDR 2T............................................................................. 4.12.12 DRIVE ASSY 2ND .............................................................................. 4.12.13 PICK UP ASSY 3RD ........................................................................... 4.12.14 ROLL ASSY TURN............................................................................. 4.12.15 CLUTCH ASSY ................................................................................... 4.12.16 SENSOR NO PAPER........................................................................... 4.12.17 SENSOR LOW PAPER ....................................................................... 4.12.18 SOLENOID FEED ............................................................................... 4.12.19 ACTUATOR LOW PAPER ................................................................. 4.12.20 CHUTE UPPER (REFERENCE ONLY)............................................. 4.12.21 ROLL ASSY FEED.............................................................................. 4.12.22 ACTUATOR NO PAPER .................................................................... 4.12.23 PICK UP ASSY 4TH ........................................................................... 4.12.24 ROLL ASSY TURN............................................................................. 4.12.25 CLUTCH ELECTRO MAGNETIC ..................................................... 4.12.26 SENSOR NO PAPER........................................................................... 4.12.27 SENSOR LOW PAPER ....................................................................... 4.12.28 SOLENOID FEED ............................................................................... 4.12.29 ACTUATOR LOW PAPER ................................................................. 4.12.30 CHUTE UPPER (REFERENCE ONLY)............................................. 4.12.31 ROLL ASSY FEED.............................................................................. 4.12.32 ACTUATOR NO PAPER .................................................................... 4.12.33 ROLL ASSY RETARD........................................................................ 4.12.34 HOLDER ASSY RETARD.................................................................. 4.12.35 KIT GUIDE SIDE L, KIT GUIDE SIDE R ......................................... 4.12.36 KIT GUIDE END .................................................................................
388 389 391 393 393 394 395 396 397 398 399 400 401 402 403 404 405 408 409 410 411 412 413 414 415 416 418 421 422 423 424 425 426 427 428 429 431 432 433 435
4
EPSON AcuLaser C4200
Revision A
4.12.37 FOOT ASSY A, FOOT ASSY B ......................................................... 437
7.7 Circuit Diagram ................................................................................................. 551
Chapter 5 ADJUSTMENT 5.1 Overview ........................................................................................................... 5.1.1 Precautions................................................................................................ 5.1.2 Adjustment Execution Timing.................................................................. 5.2 Adjustment/Action ............................................................................................ 5.2.1 Adjusting Color Registration Alignment.................................................. 5.2.2 Writing USB ID........................................................................................ 5.2.3 Firmware Update ......................................................................................
439 439 440 441 441 442 444
Chapter 6 MAINTENANCE 6.1 Overview ........................................................................................................... 6.2 Cleaning............................................................................................................. 6.3 Maintenance Menu ............................................................................................ 6.3.1 Entry into Maintenance Mode .................................................................. 6.3.2 Maintenance Menu Items ......................................................................... 6.4 Sheet for Servicing ............................................................................................ 6.4.1 Engine Status Sheet .................................................................................. 6.4.2 Print Log Report ....................................................................................... 6.5 Consumables and Components That Need Periodic Replacement.................... 6.5.1 Consumables............................................................................................. 6.5.2 Regular Replacement Parts.......................................................................
452 454 458 458 459 460 460 464 466 466 468
Chapter 7 APPENDIX 7.1 Connectors......................................................................................................... 7.1.1 The List of Plugs and Jacks ...................................................................... 7.1.2 P/J Layout Diagram .................................................................................. 7.2 Wire Net ............................................................................................................ 7.3 Wiring Connection Diagrams............................................................................ 7.3.1 Marks used in the Diagram....................................................................... 7.4 Wiring Connection Diagram between Parts ...................................................... 7.4.1 Configurations .......................................................................................... 7.4.2 Marks used in the Wiring Connection Diagram between Parts................ 7.5 Service Parts List ............................................................................................... 7.6 Exploded diagram..............................................................................................
471 471 474 479 482 482 485 485 488 516 520
5
CHAPTER
1 PRODUCT DESCRIPTION
EPSON AcuLaser C4200
Revision A
1.1 Overview
1.1.2 Controller Features
This printer is a non-impact color page printer that takes advantage of a laser and electrophotographic technologies. It provides 1200/600 dpi of resolution, and the printing speed is 25 pages per minute (ppm) for color single-side printing, or 35 ppm for monochrome single-side printing.
High-speed controller for latest tandem 64-bit RISC CPU:
64-bit high-speed memory:DDR333 200 pin SO DIMM (compatible with the RAM for AcuLaser C9100)
Standard RAM:
128MB By installing additional RAM, the memory can be expanded up to 640MB (128MB + 512MB). (The extended RAM must be installed to slot-1. Changing the initial state of slot-0 is prohibited.)
1.1.1 Engine Features High-speed A4 tandem engine Color
Monochrome
Simplex printing
25.0 ppm
35.0 ppm
Duplex printing
14.8 ppm
20.4 ppm
Enhanced ASIC (FMV-FAIO) The color management technologies are incorporated into the hardware to achieve high-speed processing.
Three Built-in interfaces
Note : When printing on A4-sized paper
Duplex print unit equipped as standard
Parallel interface (IEEE 1284 compliant, Supports ECP)
(Duplex printing is not available on extra thick paper, OHP sheet (transparency), labels, and envelopes.)
USB interface (Rev. 2.0 HS) Ethernet interface (100 Base-TX/10 Base-T)
Compatible with high quality plain paper that enables higher quality printing
Functions described below can be enhanced and increased in speed by expanding
Printable on thick paper and transparency for laser printer
memory with RAM DIMMs
This product is designed so that users can replace all the consumables. • • • •
CPGI drawing area
Toner cartridges (C, M, Y and K) Photoconductor Unit Transfer Unit Fuser Unit
Image creating speed Resolution Receive buffer
High-capacity paper supply
Option
Print buffer for collate printing Paper Feeder
Capacity
MP tray
up to 150 sheets
Lower cassette
up to 550 sheets
550-sheet paper cassette unit
up to 550 sheets
1,100-sheet paper cassette unit
up to 1100 sheets
Standard
Power PC 750FX 600 MHz
Maximum
Updating firmware is available (RCC compatible) when a Flash ROM DIMM is installed
Large capacity HDD such as 40GB can be installed
2,350 sheets with 5 bins
Paper eject capacity is 250 sheets, face-down only
PRODUCT DESCRIPTION
Overview
7
EPSON AcuLaser C4200
Revision A
1.1.3 Software Features Color technologies Smooth expanding of color images by ESC/Page-Color Color/Monochrome auto-detect function Supports 1200 dpi Monitors printer status and printer environment by bi-directional EJL and MIB Adobe PostScript3 is equipped as standard Supports PCL5c with optional DIMM (1200 dpi not supported) Engine controller ROM (only for Flash) can be upgraded Panel display Supports the new wide panel Displays remaining amount of C, M, Y, and K toner on the panel Displays toner cartridge presence, paper size, and remaining amount of papers Help function Supports 14 languages: English, French, Italian, German, Spanish, Portuguese, Dutch, Swedish, Danish, Finnish, Norse, Chinese Simplified, Chinese Traditional, and Korean
Supports EPSON Status Monitor 3 Employs new user interface suitable for business use
PRODUCT DESCRIPTION
Overview
8
EPSON AcuLaser C4200
Revision A
1.2 Basic Specifications
PRINTING SPEED MODE Table 1-1. Printing Speed Mode
1.2.1 Process Specifications & System Printing method:
Printing Speed Mode
Semiconductor laser beam scan and electro photography with dry double component non-electromagnetic toner
Light source:
Semiconductor laser
Photoconductor:
Negative organic photoconductor
Charging:
Roller charger
Development:
Exposed area development
Toner:
Chemical toner
Primary transfer:
Roller transfer method
Fixing:
Heated roller method and flexible belt nip method
Standard 1
The resolution is set to 600 dpi. Suitable for plain paper.
Low speed 1
The resolution is set to 600 dpi. Suitable for plain paper, thick paper, and envelopes.
Monochrome Low speed 1 mode (B/W) Low speed 2
The resolution is set to 600 dpi. Suitable for plain paper, thick paper, extra thick paper*, and labels.
Low speed 3
The resolution is set to 600 dpi. Suitable for plain paper (high gross), and transparency.
Standard 2
The resolution is set to 600 dpi. Suitable for plain paper
Low speed 1
The resolution is set to 600 dpi. Suitable for plain paper, thick paper, and envelopes.
Color mode Low speed 1 (F/C)
The resolution is set to 1200 dpi. Suitable for plain paper, thick paper, and envelopes.
1.2.2 Printer Basic Specifications RESOLUTION 600 dpi, 1200 dpi
Low speed 2
The resolution is set to 600 dpi. Suitable for plain paper, extra thick paper*, and labels.
Low speed 3
The resolution is set to 600 dpi. Suitable for plain paper (high gross), and transparency.
WARMING UP TIME
35 seconds or less: 25 seconds or less:
From turning the power on to ready-to-print status. (at: 22°C, 55% RH, rated voltage, memory standard)
The resolution is set to 1200 dpi. Suitable for plain paper, thick paper, and envelopes.
Note *: 164-216 g/m2
From standby mode to ready-to-print status. (at 22°C, 55% RH, rated voltage, memory standard)
PRINT MODE
Color mode:
Use four toners (CMYK) to print in full color.
Monochrome mode: Use only black toner (K) and the highest print speed is available.
PRODUCT DESCRIPTION
Basic Specifications
9
EPSON AcuLaser C4200
Revision A
PRINTING MODE BY PAPER TYPE
FIRST PRINT TIME
Table 1-2. Printing Mode by Paper Type
Paper Type