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Chapter 3 Removal and Replacement Procedures

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Main Page Page Page Page Cautions for operation 1. Marks giving caution 2. Related documents 3. Safety 3.1 Power source Page 3.2 Driving units 3.3 High-temperature units 3.4 Laser beams Page x 4. List of Abbreviations Page Page Page Page Chapter 2 Operation of Diagnostics........................................................... 2-95 Chapter 3 Removal and Replacement Procedures ................................. 3-119 Page Page Chapter 4 Plug/Jack (P/J) Connector Locations...................................... 4-271 Chapter 6 Principles of Operation............................................................ 6-313 Chapter 7 Wiring Diagrams and Signal Information................................. 7-369 Page Page Page Page 1. Progressing with the Troubleshooting 1.1 Flow of Troubleshooting 1.2 Preparatory Requirements 1.3 Cautions for Service Operations 1.4 Cautions for FIP Use Page 2. Level 1 FIP 2.1 Level 1 FIP 2.2 Flow of Level 1 FIP 3. Level 2 FIP 3.1 Level 2 FIP 3.2 Error / Status Code List Page Page 3.3 Operating / Clearing the Error Page Page 3.4 Error Code FIP FIP-1 Yellow Toner Cartridge Detached (Yellow Toner Cartridge Missing) FIP-2 Magenta Toner Cartridge Detached (Magenta Toner Cartridge Missing) FIP-3 Cyan Toner Cartridge Detached (Cyan Toner Cartridge Missing) FIP-4 Black Toner Cartridge Detached (Black Toner Cartridge Missing) FIP-5 PHD Detached (Imaging Unit Missing) FIP-6 BTR Detached (Transfer Unit Missing) FIP-7 Fuser Detached (Fuser Unit Missing) FIP-8 CRUM ID Error (Call for Service CRUM ID Error) FIP-9 CRUM ID Error (Invalid Imaging Unit) FIP-10 Media Type Mismatch (Media Type Mismatch) FIP-11 Feed Jam (Media Jam Feed) Page Page FIP-12 Regi Jam (Media Jam Registration) FIP-13 Fuser Jam (Media Jam Fuser) FIP-14 Duplex Jam (Media Jam Duplex) Page FIP-15 ROS Failure (Call for Service ROS Motor) FIP-16 Fuser Failure (Call for Service Fuser Failure) Page FIP-18 ADC Sensor Error (ADC Sensor Dustiness Warning) FIP-19 Fan Motor Failure (Call for Service Fan Motor Error) Page FIP-20 Low Density Error (Call for Service Low Density) Page FIP-22 Environment Sensor Error (Call for Service ENV Sensor Error) FIP-23 Yellow Toner Empty (Yellow Toner Low) FIP-24 Magenta Toner Empty (Magenta Toner Low) FIP-25 Cyan Toner Empty (Cyan Toner Low) FIP-26 Black Toner Empty (Black Toner Low) FIP-27 PHD Life Over (Replace Imaging Unit) FIP-28 BTR Life Over (Replace Transfer Unit) Page FIP-30 ADC Sensor Dustiness (ADC Sensor Dustiness Error) FIP-31 Front Cover (Front Cover Open) FIP-32 BTR Life Warning (Transfer Unit Life Low) Page FIP-34 Paper Empty (Put %s in %s Bin) FIP-35 Upper Cassette Detached (Adjust Input Bin) FIP-36 Full Stack (Output Bin Full) FIP-37 Yellow Toner Empty 2 (Yellow Toner Empty) FIP-38 Magenta Toner Empty 2 (Magenta Toner Empty) FIP-39 Cyan Toner Empty 2 (Cyan Toner Empty) FIP-40 Black Toner Empty 2 (Black Toner Empty) 3.5 Image Trouble FIP 3.6 Roller Circumferences FIP-P1 Light (Undertoned) Prints FIP-P2 Blank Prints FIP-P3 Black Prints FIP-P4 Vertical Band Deletions FIP-P5 Horizontal Band Deletions FIP-P6 Black (color) spots FIP-P7 Background FIP-P8 Skewed Image FIP-P9 Crease FIP-P10 Unfused Image or Image Easily Rubs off of Page 3.7 Other FIPs FIP-AC FIP-DC 4. Preventive Maintenance Page Page 1. Diagnostics for a Standalone Printer 1.1 General 1.2 Printing Method 1.3 Test Print Pattern 2. Diagnostics Using the MINOLTA- QMS magicolor 3100 Diagnostics (Hanabi Service Commander) 2.1 General 2.2 Preparation 2.3 Operation of magicolor 3100 Diagnostics Page 2.4 Test Print 2.5 Input Test Page Page 2.6 Output Test Page Page 2.7 Operation of EEPROM Page Page Page Page Page Page Page Page Page Page 1. Removal and Replacement Procedures 1.1 Before starting service work 1.2 Description of procedures RRP1. COVERS RRP1.1 CONSOLE PANEL HANABI (PL1.1.1) RRP1.2 COVER ASSY FRONT HEAD (PL1.1.2) Page Page Page RRP1.4 COVER TOP MAIN (PL1.1.9) RRP1.5 COVER ASSY TOP PHD (PL1.1.10) RRP1.6 COVER REAR (PL1.1.20) RRP1.7 LINK:L (PL1.1.23) RRP1.8 LINK:R (PL1.1.23) RRP1.9 COVER SIDE R (PL1.1.24) Page Page RRP1.11 COVER MSI (PL1.1.26) RRP1.12 TRAY ASSY MSI (PL1.1.28) Page Page RRP1.14 COVER SIDE L (PL1.1.30) RRP2. PAPER CASSETTE RRP2.1 ROLL ASSY (PL2.1.1) Page Page RRP2.3 CASSETTE ASSY FRONT (REFERENCE ONLY) Page Page Page Page Page Page Page Page Page Page Page RRP3.6 SENSOR HUM TEMP (PL3.2.2) RRP3.7 HARNESS ASSY OPFREC (PL3.2.3) RRP3.8 SWITCH ASSY SIZE (PL3.2.4) Page Page Page RRP3.10 INDICATOR (PL3.2.8) Page Page Page RRP3.12 PICKUP ASSY (PL3.3.1) Page Page Page RRP3.14 SENSOR PHOTO:NO PAPER (PL3.3.3) RIGHT LEFT RRP3.15 SENSOR PHOTO:LOW PAPER (PL3.3.3) RRP3.16 ACTUATOR NO PAPER (PL3.3.4) RRP3.17 LINK ACTUATOR (PL3.3.5) RRP3.18 SOLENOID FEED (PL3.3.16) RRP3.19 CLUTCH ASSY TURN (PL3.3.17) RRP3.20 ROLL ASSY TURN (PL3.3.19) RRP3.21 ROLL ASSY (PL3.3.22) RRP4. HOUSING ASSY RETARD RRP4.1 HOUSING ASSY RETARD (PL4.1.1) RRP4.2 ROLL TURN (PL4.1.2) Page Page RRP4.4 CLUTCH TURN (PL4.1.9) RRP4.5 STUD RTD (PL4.1.10) Page Page Page RRP5.2 SENSOR ADC ASSY (PL5.1.11) RRP5.3 SENSOR TNR FULL (PL5.1.13) Page Page Page RRP5.5 LATCH R (PL5.1.21) RRP5.6 LATCH L (PL5.1.30) Page Page Page RRP6.2 SENSOR PHOTO:FULL STACK (PL6.1.4) RRP6.3 ACTUATOR FULL (PL6.1.5) RRP6.4 SENSOR PHOTO:DUP (PL6.1.4) RRP6.5 SENSOR PHOTO:MSI (PL6.1.4) RRP6.6 ELIMINATOR ASSY (PL6.1.9) RRP6.7 ROLL DUP (PL6.1.12) Page Page Page RRP6.9 LATCH OUT (PL6.1.18) RRP6.10 ROLL ASSY FEED (PL6.1.27) RRP6.11 ACTUATOR MSI (PL6.1.37) RRP6.12 SOLENOID FEED MSI (PL6.1.40) Page Page RRP6.14 PLATE ASSY BOTTOM MSI (PL6.1.42) RRP7. CHUTE ASSY EXIT RRP7.1 CHUTE ASSY EXIT (PL7.1.1) RRP7.2 ROLL EXIT (PL7.1.4) RRP7.3 ROLL MID (PL7.1.5) RRP7.4 MOTOR ASSY DUP (PL7.1.8) RRP8. BTR ASSY & FUSER RRP8.1 FUSER ASSY (PL8.1.1) Page Page RRP8.3 ACTUATOR EXIT (PL8.1.7) RRP8.4 BTR UNIT ASSY (PL8.1.12) RRP8.5 STRAP (PL8.1.13) Page RRP9. XEROGRAPHICS RRP9.1 ROS ASSY (PL9.1.1) Page RRP9.2 HSG ASSY BIAS (PL9.1.4) Page Page Page RRP9.4 SENSOR PHOTO:REGI (PL9.1.8) RRP9.5 ACTUATOR REGI (PL9.1.9) Page Page Page Page Page Page Page RRP10.2 HOLDER TCRU ASSY (1) (PL10.1.1) RRP10.3 HOLDER TCRU ASSY (2) (PL10.1.2) RRP10.4 HOLDER TCRU ASSY (3) (PL10.1.3) RRP10.5 HOLDER TCRU ASSY (4) (PL10.1.4) RRP10.6 SWITCH TCRU ASSY (PL10.1.18) RRP10.7 SENSOR TONER LOW (PL10.1.8) RRP10.8 PWBA EEPROM STD (PL10.1.16) RRP10.9 S-HVPS (PL10.1.17) Page Page Page Page Page Page RRP11.3 ACTUATOR I/R (PL11.1.8) RRP11.4 DEVE DRIVE ASSY (PL11.1.13) RRP11.5 MAIN DRIVE ASSY (PL11.1.14) RRP11.6 PWBA ASSY EARTH (PL11.1.16) Page Page Page RRP12.2 FAN REAR (PL12.1.2) RRP12.3 CONTROLLER BOARD (PL12.1.4)(TBD) Page Page RRP12.5 HARNESS ASSY AC SW (PL12.1.11) RRP12.6 PWBA HNB DRV (PL12.1.12) Page Page RRP12.8 HOUSING ASSY CONTACT (PL12.1.14) Page Page Page Page 1. Connector [P (plug) / J (jack)] 1.1 List of P/J Page Page Page Page Page Page Page 1. Parts List 1.1 Caution for use of parts list Page PL 1.1 Cover [List] Page PL 2.1 Paper Cassette [List] Page Page Page PL 3.2 Paper Feeder II [List] Page PL 3.3 Paper Feeder III [List] Page PL 4.1 Housing Assy Retard [List] Page PL 5.1 Chute Assy In [List] Page PL 6.1 Chute Assy Out [List] Page PL 7.1 Chute Assy Exit [List] Page PL 8.1 BTR Assy & Fuser [List] Page PL 9.1 Xerographics [List] Page PL 10.1 TCRU Assy [List] Page PL 11.1 Frame & Drive [List] Page PL 12.1 Electrical [List] Page PL 13.1 Harness [List] Page Page Page 1. Printing Process 1.1 Summary of Printing Process 1.2 Schematic Diagram for Printing Processes Outline of printing processes is shown in the figures below. PHD ASSY is integrated major units of printing processes. It is compose d as follows. Page Page Electrostatic latent image (Laser beams) (Laser beams) Drum surface -V 0 Page Page Page Page Page IDT1 surface IDT2 surface IDT1 surface Page Page Page Page 2. Flow of Print Data PWBA HNB MCU 3. Drive Transmission Route 3.1 MAIN DRIVE ASSY Rotary power of the MAIN DRIVE ASSY is transmitted through the route below. Page 3.4 FUSER DRIVE ASSY Rotary power of the FUSER DRIVE ASSY drives the FUSER ASSY. Rotary power of the MOTOR ASSY DUP is transmitted through the route below. 3.5 MOTOR ASSY DUP 3.6 Gear Layout 4. Paper Transport 4.1 Paper Transport Route (without option) 4.2 Layout of Paper Transport Route 5. Functions of Major Functional Components 5.1 Paper Cassette Page 5.2 Paper Feeder Page Page Page 5.4 Front Assy In Page 5.5 Chute Assy Out Page 5.6 Chute Assy Exit Page 5.7 BTR Assy & Fuser Page 5.8 Xerographics Page 5.9 TCRU Assy Page 5.10 Frame & Drive Page 5.11 Electrical Page 6. MODES 6.1 Print Mode 6.2 Operation Modes 7. Control 7.1 Control of Paper Size 7.2 Selective Control on Paper Pick-up Unit 7.3 ROS Light Quantity Control 7.4 Process Control Y M C K Page Page 7.5 Color Registration Control 7.6 BTR UNIT ASSY Control 7.7 Toner Control 7.8 Fuser Control Page Page 1. General Wiring Diagram Page 1. Wiring Diagram between Parts 1.1 Configuration Page 1.2 Notes on Using the Wiring Diagram between Parts Page Page 1 Power supply section Page 2 Cassette section Page 3 Drive section Page Page Page 4 Developer section 1 Page 5 Developer section 2 Page 6 Fuser section 7 ROS section PWBA HNB MCU Page 8 Xerographics 1 Page 9 Xerographics 2 RTC Page 10 Paper Feed Section Page 11 Controller Section PWBAHNB MCU Page Page Page 2. Electrical Properties 2.1 Power Source 2.2 Power Consumption 3. Mechanical Properties 3.1 Dimensions/Mass of Printer 3.2 Dimensions/Mass of Universal Paper Tray (standard paper supply - 500 sheets) 3.3 Dimensions/Mass of Consumables (CRU) 3.4 Installation Space (min. installation space) 4. Functions 4.7 Speed Mode 4.8 Print Mode 4.9 Paper Mode 4.10 Warm-up Time 4.11 FPOT (First Print Output Time) 4.12 Continuous Printing Speed 4.13 Printing Area 4.14 Input Properties 4.15 Output Properties 4.16 Paper 5. Consumables 5.1 Items of Consumables 5.2 Consumable Life 6. Operating Environment 7. Safety / Environment Conditions 7.4 Noise 8. Print image Quality 8.1 Image Quality Guarantee Conditions 9. Option Page Page Page A B C D E F G H I L M N O P R S T U W X Y