Olivetti d-Color MF1600 User manual

MULTIFUNCTIONAL COLOUR PRINTER
d-color MF1600/MF2000
SERVICE MANUAL
code Y108500-4

PUBLICATION ISSUED BY:
Olivetti S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2007, Olivetti
All rights reserved

Preface
This manual explains the maintenance methods of d-Color MF1600/2000
This manual is prepared for the maintenance person. In regard to the handling methods of d-Color
MF1600/2000, please refer to the User’s Manual.
Note! • Contents of this manual is subject to change without notice.
• While all reasonable efforts have been made to make this document as ac-
curate and helpful as possible, we make no warranty of any kind, expressed
or implied, as to the accuracy of the information contained herein. Oki Data
assumes no responsibility to the damages caused or claimed to have been
caused by the user as a result of repair, adjustment and/or change using this
manual.
• Parts of this product are delicate and can be damaged unless properly handled.
We strongly recommend the user to maintain the product at the hand of the
registered maintenance person of our company
• Before starting the maintenance work, please neutralize the static electricity.
Y108500-4 Service Manual 3

Table of contents
1 CONFIGURATION ................................................................................................7
1.1 System Configuration ...........................................................................................................7
1.2 Structure of MFP ...................................................................................................................9
1.3 Offer of Options...................................................................................................................10
1.4 Specifications...................................................................................................................... 11
1.5 Interface Specification.........................................................................................................14
1.5.1 USB Interface Specification...................................................................................14
1.5.1.1 Outline of USB Interface ............................................................................14
1.5.1.2 USB Interface Connector and Cable.........................................................14
1.5.1.3 UBS Interface Signal.................................................................................14
1.5.2 Network Interface Specification.............................................................................15
1.5.2.1 Outline of Network Interface .....................................................................15
1.5.2.2 Network Interface Connector and Cable ..................................................15
1.5.2.3 Network Interface Signal...........................................................................15
2. OPERATION DESCRIPTION..............................................................................16
2.1 Electrophotographic Process Mechanism...........................................................................16
2.2 Printing Process ..................................................................................................................21
3. MFP INSTALLATION ..........................................................................................31
3.1 Precautions and Prohibition ................................................................................................31
3.2 MFP Unpacking Procedure.................................................................................................33
3.3 MFP Installation Instructions...............................................................................................34
3.4 Packed Units and Attachments ...........................................................................................35
3.5 Assembly Procedure ...........................................................................................................36
3.5.1 MFP Main Body .....................................................................................................36
3.5.2 Power Cable Connection.......................................................................................43
3.5.3 Installation of Optional Components .....................................................................45
3.5.4 Confirm the Recognition of Option ........................................................................49
3.6 Configuration Page Print .....................................................................................................50
3.7 Network Information Print....................................................................................................52
3.8 Connection Procedures.......................................................................................................53
3.9 Checking of User Paper ......................................................................................................56
4. REPLACEMENT OF PARTS ..............................................................................57
4.1 Precautions on the replacement of parts ............................................................................57
4.2 Part replacement methods..................................................................................................58
4.2.1 Detachment methods of the scanner and printer ..................................................58
4.2.2 Scanner .................................................................................................................59
4.2.2.1 Detachment of the paper tray.................................................................59
4.2.2.2 Detachment of Pad.................................................................................60
4.2.2.3 Removing ADF PCBA ............................................................................61
4.2.2.4 Removing operation panel .....................................................................62
4.2.2.5 Removing MPCBA..................................................................................63
4.2.2.6 Removing ADF Assembly ......................................................................64
4.2.2.7 Removing USB board.............................................................................66
4Service Manual Y108500-4

4.2.3 Printer ....................................................................................................................67
4.2.3.1 Left side cover ........................................................................................67
4.2.3.2 Right side cover......................................................................................68
4.2.3.3 Rear cover (Top/Bottom)........................................................................69
4.2.3.4 Front cover..............................................................................................70
4.2.3.5 Top cover assembly................................................................................71
4.2.3.6 Top cover................................................................................................72
4.2.3.7 LED assembly/ LED assembly spring ....................................................73
4.2.3.8 RFID assembly .......................................................................................74
4.2.3.9 OP frame assembly ...............................................................................75
4.2.3.10 Lever lock ...............................................................................................76
4.2.3.11 Feeder unit ............................................................................................77
4.2.3.12 Manual feeder unit..................................................................................78
4.2.3.13 Face up tray............................................................................................79
4.2.3.14 Guide eject assembly.............................................................................80
4.2.3.15 Eject roller...............................................................................................81
4.2.3.16 Plate shield front.....................................................................................82
4.2.3.17 Color registration assembly ...................................................................83
4.2.3.18 Plate shield rear......................................................................................84
4.2.3.19 PRE board (toner sensor board)/ Gear idle dram ..................................85
4.2.3.20 Main motor/ Solenoid .............................................................................86
4.2.3.21 Belt motor/ High voltage board/ Cover open switch ..............................88
4.2.3.22 Low voltage power supply/ Low voltage fan ..........................................89
4.2.3.23 M32 Board (Main Board)........................................................................90
4.2.3.24 Remove the Stay-Guide-L-Assy .............................................................91
4.2.3.25 Disassembly of the Stay-Guide-L-Assy..................................................92
4.3 Lubricating points................................................................................................................93
5. REGULAR MAINTENANCE ............................................................................. 108
5.1 Recommended substitutes ............................................................................................. 108
5.2 Cleaning ............................................................................................................................ 108
5.3Cleaning LED lens array .................................................................................................. 108
5.4 Cleaning the pick-up roller ...............................................................................................110
5.5 Cleaning the inside of the MFP.........................................................................................111
5.6 Cleaning the papaer path in the ADF ...............................................................................113
5.7 Cleaning the underside of the ADF...................................................................................114
5.8 Cleaning the Flatbed glass................................................................................................114
Y108500-4 Service Manual 5

6. TROUBLESHOOTING PROCEDURES............................................................115
6.1 Precautions prior to repair...............................................................................................115
6.2Items to be checked prior to taking action on abnormal images.....................................115
6.3 Precautions when taking action on abnormal images ....................................................115
6.4 Preparations for troubleshooting .....................................................................................115
6.5 Troubleshooting method..................................................................................................115
6.5.1 LCD Message List ..............................................................................................116
6.5.2 Preparing for troubleshooting.............................................................................. 161
6.5.2.(1) LCD Display Malfunction.......................................................................163
6.5.2.(2) Irregular Operation of the device after turning on the power................ 164
6.5.2.(3) Paper Feed Jam (1st tray).....................................................................174
6.5.2.(4) Paper Feed Jam (Multipurpose tray) ....................................................176
6.5.2.(5) Paper transport jam ..............................................................................178
6.5.2.(6) Paper Exit Jam .....................................................................................183
6.5.2.(7) Paper Size Error....................................................................................186
6.5.2.(8) ID Unit Up-Down Error (Service Call 140-143) ..................................... 187
6.5.2.(9) Fuser Error (Service call 170-177) ........................................................188
6.5.2.(10) Motor Fan Error(Service call 127) ........................................................189
6.5.2.(11) Print Speed is Slow (Low Performance)...............................................190
6.5.2.(12) LED head is not recognized(Error 131,132,133,134) ............................190
6.5.2.(13) Toner cartridge is not recognized (Error 540, 541, 542, 543) ..............191
6.5.2.(14) Fuse Cut Error (Service call 150-155)..................................................192
6.5.2.(15) Dew Condensation Errors (Service call 123).......................................192
6.5.2.(16) RFID Related Error...............................................................................193
6.5.3 Image Problem Troubleshooting..........................................................................194
6.5.3.(1) Color is totally pale (Figure 7.2 A)........................................................195
6.5.3.(2) Background is dirty (Figure 7.2 B) .......................................................196
6.5.3.(3) Blank Print (Figure 7.2 C).....................................................................197
6.5.3.(4) Vertical lines are printed .......................................................................198
6.5.3.(5) Cyclic Print Trouble (Refer to Figure 7.2 E) .........................................199
6.5.3.(6) Color drift is wide. ................................................................................. 200
6.5.3.(7) Solid Black Print.................................................................................... 201
6.5.4 Response after Flash compulsive initialization...................................................202
6.5.5 Network Troubleshooting ....................................................................................203
6.6 Fuse Checking ..................................................................................................................204
6Service Manual Y108500-4

Figure 1-1-1
1 Configuration
1.1 System Configuration
d-Color MF2000
The system configuration of this product is shown in Figure 1-1-1.
2
2
3
2 2 2 2
3 3 3 3
610 8
Fax Board
ELC12
ELC12
ELC24
ELC24
24
12
ELC24
ELC24
24
ELC24
ELC24
24
ELC24
ELC24
24
ELC17
JST17
JST4 MOLEX6
17
4
AMP4 AMP4
4
AMP4 AMP4
4
AMP5
JST6 JST10
JST20
JST11
30V. GND
AMP5
5
AMP5 AMP4
4
AMP10
DCON I/F
LSYNIC
LEISUS
Command I/F HEADSEL
AMP10
10
JST2 2
3 4 1
JST5
ELC5
RFID
5
12
4
14
2
10 5 3
2
2
2
2
ELC10
ELC10
ELC12
AMP2
JST12
JST3 JST3
JST3
HRS2-10 HRS2-10
MOLEX10 MOLEX5
MOLEX5
AMP3
AMP3
JST14
10
USB MEMORY I/F
Drawer Connector (Iriso30)
Drawer Connector (Iriso30)
USB HOST
Scanner PCB
Scanner Unit
CCD Unit ADF PCB
FAN
FB
Motor
ADF
Motor
Operation Panel PCB
LCD
Network I/F
USB2.0
K LED HEAD
Y LED HEAD
M LED HEAD
C LED HEAD
K-Tag
Y-Tag
M-Tag
C-Tag
K Toner
Sensor
Y Toner
Sensor
Toner Sensor PCB
ID Fuse-Cut terminal
LED
FUSE
LED
FUSE
LED
FUSE
LED
FUSE
K-ID
UP/DOWN High Voltage Power Unit ENV Sensor
Belt Unit
BELT
FUSE
Cover Open
SW
BOURBON
DCON ASIC
(Spilytas)
ASIC(ARMORED)
Low Voltage Power Unit
AC
Front Sensor PCB
Rear Sensor Relay PCB
FAN AC-SW AC Inlet
Fuser Unit
LOW-TH
FRM-TH
UP-TH
SIDE-TH
Temperature
Sensor
FUSE
: CABLE
: FFC
: TERMINAL XXX
Density
Sensor
Reg-LSensor
HOP
Motor
IN1
Sensor
IN2
Sensor
WR
Sensor
ID
Motor
HOP
Solenoid
IDUP
Motor
BELT
Motor
HEAT
Motor
Heater Thermistor x 4
Consumable Fuse
Reg-R Sensor
EXIT
Sensor
EEPROM
Belt Consumable Fuse
75?5V?3.3V
OVL, OVP
5V, 24V
Color Blur,
Density
Thermistor signal
5V?1.5V
Regulator
OPTION
RAM
33MHz
20MHz
1st P.E
FLASH
8M
CU
PU
Sensor
Y-ID M-ID C-ID
M Toner
Sensor
C Toner
Sensor
Environment Temoerature
Humdity
High Pressure I/F, Cover Open
Y108500-4 Service Manual 7

d-Color MF1600
System configuration of this product is shown in Figure 1-1-2.
Figure 1-1-2
2
2
3
2 2 2 2
3 3 3 3
6
10 8
ELC24
ELC24
24
ELC24
ELC24
24
ELC24
ELC24
24
ELC24
ELC24
24
ELC17
JST17
JST4 MOLEX6
17
4
AMP4 AMP4
4
AMP4 AMP4
4
AMP5
JST6 JST10
JST20
JST11
30V. GND
AMP5
5
AMP5 AMP4
4
AMP10
DCON I/F
LSYNIC
LEISUS
Command I/F HEADSEL
AMP10
10
JST2 2
3 4 1
JST5
ELC5
RFID
5
12
4
14
2
10 5 3
2
2
2
2
ELC10
ELC10
ELC12
AMP2
JST12
JST3 JST3
JST3
HRS2-10 HRS2-10
MOLEX10 MOLEX5
MOLEX5
AMP3
AMP3
JST14
10
USB MEMORY I/F
Drawer Connector (Iriso30)
Drawer Connector (Iriso30)
USB HOST
Scanner PCB
Scanner Unit
CCD Unit ADF PCB
FAN
FB
Motor
ADF
Motor
Operation Panel PCB
LCD
Network I/F
USB2.0
K LED HEAD
Y LED HEAD
M LED HEAD
C LED HEAD
K-Tag
Y-Tag
M-Tag
C-Tag
K Toner
Sensor
Y Toner
Sensor
Toner Sensor PCB
ID Fuse-Cut terminal
LED
FUSE
LED
FUSE
LED
FUSE
LED
FUSE
K-ID
UP/DOWN High Voltage Power Unit ENV Sensor
Belt Unit
BELT
FUSE
Cover Open
SW
BOURBON
DCON ASIC
(Spilytas)
ASIC(ARMORED)
Low Voltage Power Unit
AC
Front Sensor PCB
Rear Sensor Relay PCB
FAN AC-SW AC Inlet
Fuser Unit
LOW-TH
FRM-TH
UP-TH
SIDE-TH
Temperature
Sensor
FUSE
: CABLE
: FFC
: TERMINAL XXX
Density
Sensor
Reg-LSensor
HOP
Motor
IN1
Sensor
IN2
Sensor
WR
Sensor
ID
Motor
HOP
Solenoid
IDUP
Motor
BELT
Motor
HEAT
Motor
Heater Thermistor x 4
Consumable Fuse
Reg-R Sensor
EXIT
Sensor
EEPROM
Belt Consumable Fuse
75?5V?3.3V
OVL, OVP
5V, 24V
Color Blur,
Density
Thermistor signal
5V?1.5V
Regulator
OPTION
RAM
33MHz
20MHz
1st P.E
FLASH
8M
CU
PU
Sensor
Y-ID M-ID C-ID
M Toner
Sensor
C Toner
Sensor
Environment Temoerature
Humdity
High Pressure I/F, Cover Open
8Service Manual Y108500-4

Figure 1-2
1.2 Structure of MFP
The insides of d-Color MF1600/2000 printers are composed of the following parts.
• Scanner part
• Electronic photography process part
• Paper path
• Control part (CU part/PU part)
• Operation panel
• Power supply parts (high voltage part/low voltage part)
Figure 1-2 shows the composition of the MFP.
Y108500-4 Service Manual 9

1.3 Offer of Options
This product can be installed with the following option.
(1) Additional memory board 256MB
10 Service Manual Y108500-4

1.4 Specifications
Category Item C3520MFP C3530MFP
Exterior
Dimension
Width 447mm
Height 521mm
Weight about 29kg
Width of print Width of print A4
Engine speed
(A4)
Monochrome 12ppm 20ppm
Color 12ppm 16ppm 10ppm 16ppm
Fast print time
(A4)
Monochrome 12sec 10sec
Color 15sec 12sec
Warm-up time 60sec
Low noise mode Unavailable
Resolution LED head 600dpi
Maximum input resolution 600 x 1200dpi
Output resolution True 600 x 1200dpi
True 600 x 600dpi
Step 4 step 600 x 600dpi
Economic mode toner saving by lowering light
CPU Core PowerPC405
I-cash 16KB
D-cash 16KB
Clock 266MHz
Bus width 32bit
RAM Resident 128MB
Option 256MB
ROM Program total capacity 8MB
Power
Consumption
Power input 110-127VAC (Range 99-140VAC)/
220-240VAC (Range 198-264VAC)
Power saving mode Below 30W
Idle 110W
Normal operation 400W
Peak 980W
Operation
Environment
(temperature)
In operation 10 -32 , 17 -27
(temperature at full color printing with quality guaranteed)
At stand-by 0 -43 , power off
In storage (1 year max.) -10 -43 , with drum and toner
At transport (1 month max.) -29 -50 , with drum and without toner
At transport (1 month max.) -29 -50 , with drum and toner
Operation
Environment
(humidity)
In operation 20%-80%, 50%-70%
(humidity at fullcolor printing with quality guaranteed)
Max. wet bulb temperature : 25
At stand-by 10%-90%, Max. wet bulb temperature : 26.8 with power off
In storage 10%-90%, Max. wet bulb temperature : 35
At transport 10%-90%, Max. wet bulb temperature : 40
Y108500-4 Service Manual 11

Category Item C3520MFP C3530MFP
In operation (ISO 7779 front)
Printing on one side 6.38B (A) 6.5B (A)
At stand-by 3.7B (A)
Operation
noise
Power saving mode back grand level
Paper feeding capacity (1st
tray) legal/universal cassette 250 sheets (_0kg)
Paper feeding capacity
(manual feeder) 1 sheet
Paper handling
Paper output 150 sheets (70kg) face down/ one sheet (10 postcards) face up
tray
Legal/universal or A4
cassette/ Universal cassette
1st cassette:legal13/13.5/14, letter, executive, A4, A5, B5, A6,
postcard
Paper size
Manual feeder
legal 13/13.5/14, letter,
ezecutive, A4, A5, B5, A6, C5,
DL, Com-9, com-10, monarch,
custom size, government
postcard, reply paid postcard,
end-opening envelope
legal 13/13.5/14, letter,
ezecutive, A4, A5, B5, A6, C5,
DL, Com-9, com-10, monarch,
custom size, government
postcard, reply paid postcard,
end-opening envelope, banner
up to 1200mm (In case length
is over 356, width would be up
to 210 to 215.9)
1st tray 100mm x 14 mm
Min. paper size
Manual feeder 100mm x 14 mm
1st tray 64-120gsm
Manual feeder 64-203gsm
Paper
thickness
duplex (manual) 64-105gsm
Paper tray empty Available
Paper low N/A
Toner low Available (Y.M.C.K)
Cover open Available
Fuser temp Available
Paper size N/A
Status switch/
Sensor
Stacker full N/A
Standard (on circuit board) Hi-Speed USB
Ethernet
N/A FAX
Communication
Interface
On/off switch Automatic
Standard Hiper-C
Emulation
Emulation switch N/A
12 Service Manual Y108500-4

Category Item C3520MFP C3530MFP
Bit map
Type face N/A
Scalable 1
Type face N/A
Scalable 2
Type face N/A
Scalable 3
Type face N/A
Luster riser N/A
Bar code N/A
OCR N/A
Japanese PCL font N/A
Font
Japanese PS font N/A
Option
(Removable)
RAM set 256MB
USB-IF logo Available
Windows logo Available
Others
Operation by UPS Operation by UPS (outage free power supply) is not
guaranteed. (Do not use UPS)
Y108500-4 Service Manual 13

2
3 4
1
1.5 Interface Specification
1.5.1 USB Interface Specification
1.5.1.1 Outline of USB Interface
(1) Basic Specification
USB
(2) Transmission Mode
Hi speed (480Mbps±0.05% max.)
(3) Power Control
Self power device
1.5.1.2 USB Interface Connector and Cable
(1) Connector
• Printer side: B receptacle
Upstream port
Equivalent of UBR24-4K5C00 (made by ACON)
Connector pin arrangement
• Cable side: B plug (off)
(2) Cable
Cable length: Specification Cable of USB2.0 spec. of less than 5m.(less than 2m is
recommended)
(Shielded cable is used here.)
1.5.1.3 UBS Interface Signal
Name of Single Function
1 Vbus Power Supply (+5V)(red)
2 D - Data transmission (white)
3 D + Data transmission (green)
4 GND Single ground (black)
Shell Shield
14 Service Manual Y108500-4

1 8
1.5.2 Network Interface Specification
1.5.2.1 Outline of Network Interface
Table 1.5.2 Basic Specification of Network Interface
Protocol Family Network Protocol Application
TCP/IP IPz4, TCP, ICMP, UDP LPR, RAW
SNMPv1
DHCP/BOOTP
HTTP
1.5.2.2 Network Interface Connector and Cable
(1) Connector
100 BASE-TX/10 BASE-T (automatic switch, no simultaneous use)
Connector pin arrangement
(2) Cable
Unshielded twist pair cable with RJ-45 connector (Category 5 is recommended.)
1.5.2.3 Network Interface Signal
Pin No. Singles Single Direction Functions
1 TXD+ FROM PRINTER Send Data +
2 TXD- FROM PRINTER Send Data -
3 RXD+ TO PRINTER Received Data +
4 - - Unassigned
5 - - Unassigned
6 RXD- TO PRINTER Received Data -
7 - - Unassigned
8 - - Unassigned
Y108500-4 Service Manual 15

-
-
-
--
-
Electrification roller
OPC drum
Power
supply
unit
2. OperatiOn DescriptiOn
2.1 Electrophotographic Process Mechanism
(1) Electronic photography Process
Electronic photography process is outlined as follows:
1. Electrification
Electric voltage is impressed on CH roller and the surface of CPC drum is electrified.
2. Exposure
LED head radiates light on the electrified surface of OPC drum following the image
signal. Electric charge on the radiated OPC drum surface abates depending on the
intensity of light and static latent image is formed on the OPC drum surface.
3. Development
Electrified toner is adhered to the static latent image on the OPC drum by static
electricity and a visible image is formed on the OPC drum surface.
4. Transcript
A sheet of paper is put upon the OPC drum surface and the toner image is transferred
on the paper by impressing electric charge on its back side by the transcript roller.
5. Drum Cleaning
Drum cleaning blade eliminates the remaining toner on the OPC drum after transfer.
6. Belt Cleaning
Belt cleaning blade eliminates the remaining toner on the belt.
7. Fusing
The toner image on the paper is fused by adding heat and pressure.
(2) Electrification
Electric voltage is impressed on electrification roller touching on the OPC drum surface and
thus the OPC drum surface is electrified.
16 Service Manual Y108500-4

-
-
-
--
---
-
LED head
Electrified roller
OPC drum
OPC drum
Paper
Power
supply
unit
LED head
-
-
-
--
---
-
-
-
-
Electrified roller
Development roller
Sponge roller
OPC drum
(3) Exposure
The light emanated from the LED head is radiated on the OPC drum surface. The electric
charge on the radiated portion of the OPC drum surface abates by intensity of the light and
a static latent image is formed on the OPC drum surface.
(4) Development
Adhere the toner to the static latent image on the drum surface and change it to the toner
image.
1. The sponge roller let the toner adhere to the development roller.
2. The static latent image on the OPC drum surface is changed to a visible image by the
toner.
Y108500-4 Service Manual 17

-
-
-
--
---
-
-
-
-
-
-
-
+
-
+
-
+
-
+
-
+
-
+- +- +- +- +- +
-
+- +
-
+- +
-
+- +
OPC drum
Transcript roller
Paper
Transport belt
Power
supply
unit
(5) Transcript
A sheet of paper is placed under the OPC drum surface and is given electric charge from
the back side by the transcript roller. When a high voltage is impressed on the transcript
roller, the electric charge generated by the transcript roller moves over to the paper surface
at the interfacing part of the transcript roller and the toner is absorbed to the paper surface
from the OPC drum surface.
18 Service Manual Y108500-4

C3400 (belt fusing method)
Thermostat
Thermistor
Heat roller
Halogen lamp
Paper
Pad
Thermistor
Backup roller
Belt
Backup roller
Thermistor
Heat roller
Thermostat
Thermistor
Halogen lamp
Paper
C3300 (roller fusing method)
Paper Type Setting
Light
Medium
Heavy
U.Heavy
Paper Thickness
Thin
Thick
Temperature Setting
Middle temp.
High temp.
Middle temp.
Low temp.
Setting of Fusing Temperature
(6) Fusing
The toner image transferred on the paper is impressed with heat and pressure and is fused
to the paper when the paper passes through the heat roller and the back-up roller.
Further, a thermostat is equipped for the safety’s sake and if the temperature of the heat
roller rises above a certain degree, the thermostat opens and shuts the power supply to the
heater.
Y108500-4 Service Manual 19

Waste toner area
Drum cleaning blade
ID unit
Toner cartridge
Belt waste toner box
Belt cleaning blade
Transport belt
(7) Drum Cleaning
The toner not transferred and remaining on the OPC drum is scraped away by the drum
cleaning blade and is collected in the waste toner area of the toner cartridge.
(8) Belt Cleaning
The toner remaining on the transcript belt is scraped away by the belt cleaning blade and is
collected in the waste toner box of the transcript belt unit.
20 Service Manual Y108500-4