Star Micronics WinType 4000 User manual

WinType 4000
T ECHNICAL MANUAL
[ SECOND EDITION ]
LASER PRINTER

NOTICE
•Allrightsreserved.Reproductionofanypartofthismanualinany
form whatsoever, without STAR’s express permission, is forbid-
den.
•The contents of this manual are subject to change without notice.
•All efforts have been made to ensure the accuracy of the contents
of this manual at the time of going to press. However, should any
errors be detected, STAR would greatly appreciate being in-
formed of them.
•The above notwithstanding, STAR can assume no responsibility
for any errors in this manual.
Trademark acknowledgments
Windows : Microsoft Corporation
© Copyright 1996 Star Micronics Co.,Ltd.

INTRODUCTION
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3
4
5
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This manual describes the WinType 4000 laser printer.
It is intended for use as a reference when performing maintenance procedures.
This manual is prepared for use at a technical level and is not for the general user.
This manual is divided into the following sections:
Chapter 1 General Specifications
Specifications, safety information
Chapter 2 Theory of Operation
A description of the principles of the electrical and mechanical systems and their functions
Chapter 3 Parts Replacement and Adjustments
Explanation of disassembly, reassembly, and adjustment procedures
Chapter 4 Maintenance Guide
Contains an overview of steps for recovering from a breakdown, connector layout diagrams, wiring
connections, and other information useful in maintenance operations.
Chapter 5 Troubleshooting
Contains breakdown analysis procedures used when repairing breakdowns.
Chapter 6 Parts List
Illustrations showing disassembly diagrams, part numbers and part names
* In this manual, MCU PWB is the abbreviation for Main Control Unit Printed Wiring Board.

1
CHAPTER 1
GENERAL SPECIFICATIONS
1. GENERAL SPECIFICATIONS................................................................................3
2. SAFETY INFORMATION........................................................................................6
2-1. Power Supply .......................................................................................................... 6
2-2. Drive Parts............................................................................................................... 6
2-3. Safety Devices ........................................................................................................ 6
2-4. Laser safety............................................................................................................. 7
3. PRINTER COMPONENTS......................................................................................8

– 2 –
GENERAL SPECIFICATIONS

– 3 –
GENERAL SPECIFICATIONS
1. GENERAL SPECIFICATIONS
Engine Printing process Electro-photographic
Resolution 300 x 300 dpi (Smoothing off)
600 dpi class (Smoothing on)
Exposure Semi-conductor laser beam scanning
Fixing Thermal fusing using heated rollers
Printing speed
Warm-up time 45 seconds or less after power on at 22°C (72°F)
(115 volts or 220 volts)
Time for first print 20.5 seconds for Letter paper
21.1 seconds for A4 paper
Continuous printing speed Min. 4 pages per minute for Letter or A 4 size paper
Printable area 4mm in from the edge of the paper on all sides
Paper feed Input tray Capacity: 100 sheets of standard paper, 30 overhead (OHP) trans-
parencies, 30 label sheets or 10 envelopes
Paper weight: From 60 g/m2(16 lb.) – 135 g/m2(36 lb.)
Output tray Face down
Capacity: Approximately 50 sheets
Printing materials
Standard paper XEROX 4024 DP 20 lb 8.5" x 11" cut sheet paper (US)
Special printing OHP film: 8.5" x 11" XEROX, PN 3R2780 (US)
materials A4 XEROX, PN 3R91330 (Europe)
Label: 8.5" x 11" XEROX, PN 3R4469 (US)
A4 XEROX, PN 3R97408 (Europe)
Envelope: Com-10 Monroe Brand, Monarch Monroe Brand

– 4 –
GENERAL SPECIFICATIONS
Toner cartridge ThetonercartridgeconsistsofanOPCdrum,developingrollerandblades,
primary charge roller, drum cleaner and high definition black toner.
Toner save mode Off/Dark/Medium/Light
Mode Yield
Off Approx. 4000 pages
Dark Approx. 5000 pages
Medium Approx. 5700 pages
Light Approx. 8000 pages
Mean printing life Starter cartridge: 4000 sheets at 5% paper coverage
Replacement cartridge: 4000 sheets at 5% paper coverage
Power specifications
Input line voltage/ For US Voltage Frequency
frequency Min.: 90V 47Hz
Normal: 100/120V 50/60Hz
Max.: 132V 63Hz
For Europe and Asia/Pacific
Voltage Frequency
Min.: 198V 4 7Hz
Normal: 220/240V 50/60Hz
Max.: 264V 63Hz
Power consumption Maximum power consumption when warming-up and printing is as
follows
100/120V Less than 400W (less than 3A)
220/240V Less than 400W (less than 2A)
Environmental specifications Energy Star Compliant
Temperature, humidity Print engine with toner cartridge:
and altitude Operating: 5 – 35°C (41 – 95°F) at 15 – 85% RH (no conden-
sation)
Non-operating: 20 – 40°C (60 – 104°F) at 5 – 95% RH (no conden-
sation)
0 – 2,500 meters (0 – 8,200 feet)
Print engine without toner cartridge:
Non-operating: 20 – 40°C (60 – 104°F) at 5 – 95% RH (no conden-
sation)
0 – 15,000 meters (0 – 49,200 feet)
Acoustic noise Printing: 48 dB (A) or less
Warm up: 38 dB (A) or less
In accordance with ISO 7779
Dust emission Less than 0.1mg/m3
concentration: Measured in accordance with Mass Measurements Method

– 5 –
GENERAL SPECIFICATIONS
Reliability specifications
MPBF Recommended usage: Average 2,000 pages per month
Maximum 10,000 in any one month
MPBF: 60,000 pages
MTTR Within 30 minutes
Jam ratio 1/1000 using recommended paper
1/100 using special printing materials
Double feed ratio 1/1000 using recommended paper
1/100 using special printing materials
Life 100,000 pages or 5 years
Dimensions 330mm x 235mm x 265mm
(13.0 in. x 9.25 in. x 10.4 in.)
Weight 6.5 kg. (14.3 lbs.) without toner cartridge
7.5 kg. (16.5 lbs.) with toner cartridge
Controller I/F High speed bi-directional parallel interface
Panel 2 LED lamps (Ready and Error)
Software Windows Direct (GDI) mode Provides fast, WYSIWYG output from Windows (GDI) mode applica-
tions
PCL mode Provides compatibility with the popular printer languages used in the
LaserJet II series. Both Windows applications and DOS applications
running under Windows can use PCL emulation mode for printing.
PostScript mode Provides compatibility with the sophisticated PostScript language. Both
WindowsapplicationsandDOSapplicationsrunningunderWindowscan
use PostScript emulation mode for printing.
Paper size Paper sizes available A4, Letter, Legal, A5, Executive, B5, Com 10, C5, DL, Monarch
in GDI mode
Paper sizes available in A4, Letter, Legal, Executive, Com 10, C5, DL, Monarch
PCL4 emulation
Paper sizes available in A4, Letter, Legal, A5, Executive, B5, Com 10, C5, DL, Monarch
PostScript emulation

– 6 –
GENERAL SPECIFICATIONS
2. SAFETY INFORMATION
Inorder to prevent accidentsfrom occurring while maintenanceis being carried out,all warnings and precautionsshould
bestrictly observed whilework is being carriedout. Never attempt any kind of dangerous procedure when servicing this
machine.
The precautions noted below only cover a few of the situations which could foreseeably occur during maintenance
operations. Please make sure every safety precaution is observed while work is being carried out.
2-1. Power Supply
In order to prevent electrical shock, burns, damage to the equipment and other problems, always make sure the power
supply is turned off and the power supply cable has been unplugged before maintenance work is carried out.
If the power must be left on in order to measure voltage or for other reasons, make sure sufficient precautions are taken
to prevent electrical shock, and follow the procedures laid down in this manual.
2-2. Drive Parts
Inspection of drive section parts such as sprockets and gears should be carried out using a hand crank.
DANGER: Never inspect these parts while the equipment is in operation!
2-3. Safety Devices
Thorough consideration should be given to safety devices designed to prevent accidents (fuses, interlock switches, etc.)
as well as those handled by the user in the course of operating the equipment (covers, panels, etc.), in order to make sure
they fulfill their function as safety equipment.
DANGER: In order to prevent exposure to the laser beam contained in the printer, the following precautions must
always be strictly observed.
Exposure to the laser beam can result in blindness.
• Never open a cover (ROS assembly) that has the label shown in figure 1-3 on it.
• When disassembling and adjusting the equipment, always make sure the power supply has been
turned off first.
• This equipment is provided with a two-stage safety switch function, so that it can be operated even
withthecoversremoved,bypressingtheinterlockswitch.Whenusingthismethodofoperation,never
short the other switch at the same time (the second switch is pressed when the actuator at the back of
the EP toner cartridge attachment section is pressed).
• When servicing the printer’s optical system, be careful not to place screwdrivers or other reflective
objects in the path of the laser beam.
Be sure to take off accessories, such as watches and rings, before working on the printer. A reflected
beam, though invisible, can permanently damage your eyes.
Because the laser beam is invisible, be especially careful when servicing the optical system.
Figure 1-1 Itnerlock switch location
Itnerlock switch

– 7 –
GENERAL SPECIFICATIONS
2-4. Laser safety
This printer is certified as a Class 1 laser product. This means that this laser product does not emit harmful laser beams.
Thisprinter emits a Class 3Blaser beam, but thebeam is entirely enclosed withina protective case and anexternal cover,
and cannot escape from the printer while the printer is in use.
CLASS 1 LASER PRODUCT.
LUOKAN1LASERLAITE.
KLASS1LASERAPPARAT.
CLASS3BLASER
WAVE LENGTH 780nm(INVISIBLE)
RATED POWER 5mW
LUOKAN 3B LASER
AALLONPITUUS 780nm(NÄKYMÄTÖN)
TEHO 5mW
Figure 1-3 Caution Label
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso
säteeseen.
VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.
Laser Klasse 1
Laser de Classe 1
Láser Clase 1
Laser Luokan 1
Laser Klass 1
Figure 1-2 Class 1 Label

– 8 –
GENERAL SPECIFICATIONS
3. PRINTER COMPONENTS
Figure 1-4 External Dimensions Figure 1-5 Rear View
Figure 1-6 Front View
Power release lever
Power switch
Extension bar and
paper support extender
Upper paper tray
330 mm 235 mm
265 mm
Ventillation fan outlet
Front cover
Output paper
extender
Output tray
Ready LED lamp
(Green)
Error LED lamp
(Orange)
Power switch Power card socket
Parallel interface
connector

2
CHAPTER 2
THEORY OF OPERATION
1. PRINTING PROCESS...........................................................................................11
2. PAPER TRANSPORTATION ...............................................................................14
3. FUNCTIONS OF THE MAIN PARTS....................................................................15
3.1 Covers.................................................................................................................... 15
3.2 Feeder & Drive ...................................................................................................... 15
3.3 Fuser & Paper Exit................................................................................................ 17
3.4 Photographics & ROS .......................................................................................... 19
3.5 Electrical................................................................................................................ 21

– 10 –
THEORY OF OPERATION

– 11 –
THEORY OF OPERATION
1. PRINTING PROCESS
The printing process for this system consists of the repetition of the following five basic steps:
Charging Scanning exposure Developing FusingTransfer
(Separation) (Cleaning)
CM blade
Heat roller
Fuser assembly
Pressure roller
BTR
Drum
Magnetic roller
Ros assembly
BCR
Figure 2-1 Printing Process
: Laser beam
: Paper path

– 12 –
THEORY OF OPERATION
• Description of the Printing Process
Step Details
Charging The surface of the rotating drum in the EP toner cartridge is uniformly negatively charged
by the electric charge from the BCR (Bias Charge Roller).
TheROSassemblyscanstheexposurebyconvertingtheimagesignalfromtheMCUPWB
into an optical signal (laser beam) and directs the laser beam onto the drum.
Scanning Exposure Whenanimageispresent,alaserisemittedandthelaserbeamisirradiatedontothesurface
of the drum causing the irradiated area to be set to a neutral charge, thus enabling an
invisible latent electrostatic image to be formed on the drum’s surface.
The latent electrostatic image on the drum’s surface attracts toner from the surface of the
magnetic roller in the EP toner cartridge, forming a visible image on the surface of the drum.
Developing Themagnetinsidethemagneticrollercausesthetoner,whichalsohasmagneticproperties,
to adhere to the roller while the friction between the rotating magnetic roller and the CM
blade (Charge Metal Blade) negatively charges the toner, so that a thin layer of toner is n
the surface of the magnetic roller.
Transfer
A positive charge is applied to the back of the paper by the BTR (Bias Transfer Roller)
causing the toner on the drum’s surface to be transferred to the paper.
Applying a positive charge to the back of the paper causes the paper itself to be positively
charged, so that the paper adheres to the drum
(Separation) The firmness of the paper causes the paper with the toner affixed to it to be separated from
the drum.
Fusing Theheatfromtheheatrollerheatedbytheheatrodandthepressurefromthepressureroller
causes the toner to be fused to the paper in the fuser assembly.
(Cleaning) Any residual toner remaining on the drum after the transfer step is scraped off by the
cleaning blade which is in contact with the drum’s surface.
–350V
0
–V
–350V
0
–V
–350V
0
–V
–210V
(Developing bias)
Laser beam
Scanning Exposure DevelopingCharging
Toner image
(Visible image)
Electrostatic latent
image (Invisible image)
Drum’s surface
Voltage
Figure 2-2 Printing Process (Drum’s Surface)

– 13 –
THEORY OF OPERATION
Cleaning blade
BCR
AC Bias: 1.6kVp-p
(f=2.4kHz)
DC Bias: –210V
Laser beam
Toner
DC Bias
(+): 250V~2600V
(0.5µA~1.6µA)
(–): –700V
Magnetic roll
AC Bias: 200µA
(f=160Hz)
DC Bias: –350V
Paper
Eliminator
Pressure roll
BTR
Drum
(30mm)
CM blade
Toner
17.28
Heat roll
17
Transfer
Scanning Exposure
152˚C 140˚C
158˚C 150˚C
Separation
While the lamp
flashes
six times
After the lamp
flashes
the sixth time Developing
Charging
Heat roll
Figure 2-3 Printing Process (Seven Steps)

– 14 –
THEORY OF OPERATION
- - - : Transport path of the paper
Input tray assembly
Feeder assembly
Heat roller
Pinch roller
Exit roller
Delivery tray assembly Fuser assembly
Pressure roller
Drum BTR
Feed roller
Figure 2-4 Paper Transportation
2. PAPER TRANSPORTATION
The following diagram shows the order in which paper passes over the rollers.
Paper that is inserted is automatically fed.
Paper is supplied and transported by the feed roller.
Paper is transported by the drum and BTR assembly.
Paper is transported by the heat roller and pressure roller.
Paper is discharged by the exit roller in the fuser assembly and the pinch roller in the
fuser top cover assembly.

– 15 –
THEORY OF OPERATION
3. FUNCTIONS OF THE MAIN PARTS
The main parts are briefly described and illustrated as follows. In order to remain consistent with the parts list, parts are
divided into the following five sections based on their type.
1 Covers
2 Feeder & Drive
3 Fuser & Paper Exit
4 Photographics & ROS
5 Electrical
3.1 Covers
This consists of the printer, four covers and two trays.
(Refer to Chapter 6, Parts List)
3.2 Feeder & Drive
• Input Tray Assembly
Regular (cut sheet) paper, envelopes can be fed into the printer from this tray.
Slide the left and right paper guides to hold the paper in place.
• Feed Roller Assembly
This assembly consists of the feed roller and the feed clutch. After the spring clutch in the feed clutch has been set by
the movement of the feed solenoid, the feed roller assembly rotates driven by the drive assembly and the feed rollers
feed the paper into the printer from the input tray assembly.
One full rotation of the feed roller assembly causes the spring clutch to be released by the feed solenoid and disables
the drive assembly from transmitting a driving signal.
• Feed Solenoid
The feed solenoid controls the operations (rotation and stop) of the feed roller assembly.
• Pre-regi. Sensor
This sensor detects whether paper is sent by the paper set lever based on changes in the position of the regi. actuator
and sends a signal to the MCU PWB.
• MCU PWB
The MCU PWB controls the regi. solenoid, rotates the feed roller assembly and feeds the paper into the printer with
the paper set lever. After receiving the signal from the regi. sensor, the MCU PWB instructs the EP toner cartridge to
generate the image.
(Refer to section 3.5 Electrical System. Illustrations of the parts described above are shown in Chapter 6, Parts List
PL5.)
• Drive Assembly
The drive assembly consists of the main motor and the gear that transmits the driving force. This assembly transmits
a driving force by rotating the main motor.

– 16 –
THEORY OF OPERATION
Feed clutch
Feed solenoid Feed roller assembly
Paper set lever
Retard pad
Pre-regi. sensor
Figure 2-5 Feeder & Drive
Drive assembly
Main motor
Paper set lever
Input tray assembly
Feed roller