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ADVARSEL
VARNING
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INVISIBLE LASER RADIATION WHEN OPEN AND INTERLOCK DEFEATED.

AVOID DIRECT EXPOSURE TO BEAM. CLASS 3B LASER PRODUCT.

ADVARSEL
ATTENTION
VORSICHT

USYNLIG LASERSTRLING.UNNG DIREKTE KONTAKT MED LASERENHETEN

NR TOPPDEKSELET ER PENT. KLASSE 3B LASERPRODUKT.

ATENCIN

RADIACIN LASER INVISIBLE CUANDO SE ABRE

LA TAPA Y EL INTERRUPTOR INTERNO EST
ATASCADO. EVITE LA EXPOSICIN DIRECTA
DE LOS OJOS. PRODUCTO LASER CLASE 3B.

USYNLIG LASER STRLING NR KABINETLGET STR BENT.

UNGD DIREKTE UDSTTELSE FOR STRLING. KLASSE 3B LASER.
OSYNLIG LASERSTRLNING NR DENNA DEL R PPNAD OCH SPRRAR
R URKOPPLADE. STRLEN R FARLIG. KLASS 3B LASER APPARAT.
AVATTAESSA JA SUOJALUKITUS OHITETTAESSA OLET ALTTIINA
NKYMTTMLLE LASERSTEILYLLE. L KATSO STEESEEN. LUOKAN
3B LASERLAITE.

RADIATIONS LASER INVISIBLES QUANDOUVERT ET VERROUILLAGE ENLEVE.

EVITER EXPOSITIONS DIRECTES AU FAISCEAU. PRODUIT LASER CLASSE 3B.
UNSICHTBARE LASERSTRAHLUNG WENN ABDECKUNG
GEFFENT UND SICHERHEITSVERRIEGELUNG
BERBRCKT. NICHT DEM STRAHL AUSSETZEN.
SICHERHEITSKLASSE 3B.

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SAFETY INFORMATION

DEFINITIONS OF WARNINGS, CAUTIONS AND NOTES

The following conventions are used in this service manual:

WARNING
Indicates warnings that must be observed to prevent possible personal injury.

CAUTION:

Indicates cautions that must be observed to service the printer properly or prevent damage
to the printer.
NOTE:
Indicates notes and useful tips to remember when servicing the printer.

**Listed below are the various kinds of WARNING messages included in this manual.

WARNING
Always turn off the power switch and unplug the power cord from the power outlet
before accessing any parts inside the printer.

WARNING
Some parts inside the printer are extremely hot immediately after the printer is used.
When opening the front cover or rear cover to access any parts inside the printer,
never touch the red colored parts shown in the following figures.

WARNING
If you analyze malfunctions with the power plug inserted into the power outlet,
special caution should be exercised even if the power switch is OFF because it is a
single pole switch.

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CHAPTER 1 GENERAL

3.5

Paper

3.5.1

Feedable paper
(1) Paper type
Upper
paper
tray

Multipurpose
tray

Optional
lower
tray

Duplex
printin
g

60 g/m2 to 105 g/m2

(16 to 28 lbs.)

Plain paper

Recycled paper

Plain paper

Paper type

Select the paper

type from the
printer driver

Plain paper

Bond paper

Bond paper

Thick paper
or thicker paper

Thick paper
105 g/m2 to 161 g/m2
(28 to 43 lbs.)

Transparency

Up to 10
sheets

Label

Only A4
or Letter
size

Transparency

Only A4
or Letter
size

Plain paper

Envelope

Envelope

Card

Thick paper
or thicker paper

(2) Paper size

Upper
paper tray
A4, Letter, Legal,
8.5x13 in., B5 (JIS),
B5 (ISO), Executive,
Paper size A5, A6, B6

Multi-purpose
tray
Width:
70 to 216 mm
(215 to 8.5 in.)
Length:
116 to 356 mm
(4.57 to 14.0 in.)

(3) Other paper specifications

<Paper cassette>
Cut sheet
Basis weight

60 to 105 g/m2 (16 to 28 lb.)

Caliper

0.08 to 0.13 mm (0.003 to 0.005

in.)

1-8

Optional lower
tray

Duplex
printing

A4, Letter,
Legal, B5 (JIS),
B5 (ISO),
Executive, A5

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2

CHAPTER 1 GENERAL

3.5.2

Paper cassette capacity

Upper
paper tray
250 sheet
2

Paper
Capacity

3.5.3

(80 g/m or 20 lbs.)

Multi-purpose
tray
100 sheets
(80 g/m2 or 20 lbs.)
Legal: 30
8.5x13 in.: 30
Label stock: 10

Optional lower tray

250 sheets
(80 g/m2 or 20 lbs.)

Print delivery
(1) Face down output tray
capacity:
Maximum 150 sheets (80 g/m2)
face down only
(2) Face up output tray
capacity:
NOTE:
Face-down:
Face-up:

Maximum 50 sheets (80 g/m2)

face up only

Delivery with the printed face of the paper downwards.

Delivery with the printed face of the paper upwards.

(3) We recommend the following print methods (output tray) for each paper media type.

Media type
Plain paper

Paper output
Face down

Face up

Thick paper
Recycled paper

Transparency

Label

Envelope

Card

1-10

HL-1650/1670N SERVICE MANUAL

3.6

Printable Area

3.6.1

PCL5e/EPSON/IBM emulation
The figure below shows the printable area each emulation guarantees when printing on Portrait
and Landscape.

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HL-1650/1670N SERVICE MANUAL

4.3

Printing to the Face up Output Tray (Face up Printing)

When the face up output tray is open, the printer has a straight paper path from the paper
cassette or multi-purpose tray to the rear of the printer. Use this output method when printing
on special media that is thick or should not be bent, such as heavy paper, labels,
transparencies, card stock or envelopes.
When printing to the face up output tray, follow the steps below;
(1) Open the face up output tray.
(2) Unfold the face up output tray extension.
(3) Place the paper into the paper cassette or multi-purpose tray.

Fig. 2-29

Fig. 2-30

(4) After the printer ejects all the printed pages, remove them and close the face up output
tray.

4.4

Printing on Both Sides of the Paper (Duplex Printing)

The supplied printer drivers for Windows 95/98/Me, Windows NT 4.0, Windows 2000 supports
automatic duplex printing.
Guidelines for duplex printing:

If the paper is thin, it may wrinkle.

If paper is curled, straighten it, and then place it in the paper cassette.

Use A4, Letter or Legal size plain paper (60 to 105 g/m2 or 16 to 28 lb.). Do not use bond
paper.

If the paper is not feeding correctly, it may be curled. Remove the paper and straighten it.

When printing on both sides of the paper, follow the steps below;
(1) Load paper into the paper cassette or multi-purpose tray
(2) When using A4 or Letter size paper, set the
paper adjustment lever for duplex printing to
match the paper size.

Fig. 2-31

NOTE:
If the paper adjustment lever for duplex printing is not correctly set for the paper size, paper
jams may occur and the printing will be out of position on the paper.

2-17


 


 


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CHAPTER 2 INSTALLATION AND BASIC OPERATION

5.4

How to Use the Control Panel

The followings are the basic steps when operating the switches; Menu, +, , Set, and Back.

If no control panel operations are performed for 30 seconds, the LCD automatically
returns to READY.

When pressing the Set switch to select a setting, an asterisk briefly appears at the end of
display. After that, the display returns to the previous menu level.

After changing the status or number, pressing the Back switch before pressing the Set
switch will cause the display to return to the previous menu with the original setting
unchanged.

Numbers can be input by scrolling through the available range (000 to 999) or by setting
digits one at a time. When setting digits one at a time, the blinking digit is the
changeable digit.

An example for operation: When turning the MP FIRST setting on

Choose this setting to load paper from the multi-purpose tray first.
READY
Press the + switch.
Press the + or switch to scroll forward or backward
through the Menu selections.
INFORMATION
Press the Set switch.
Press the Set switch to enter the next level of the selected menu.
PAPER
Press the Set switch to proceed to the next menu level.
SOURCE
Press the + switch.
MP FIRST
Press the Set switch.
=OFF

Press the + switch.

=ON
Press the Set switch.
An asterisk * briefly appears at the end of the display.
The default setting is indicated by an *.
=ON

2-28


 


 


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5.5.8

5.5.9

Reset menu
Setting Menu

Description

RESET PRINTER

Resets the printer and restores all printer settings including

command settings to settings you have previously made with
the control panel switches.

FACTORY RESET

Resets the printer and restores all printer settings including

command settings to the factory settings. See subsection
5.5.11 List of factory settings in this Chapter.

Set IP address

INFORMATION
Press the + or switch to select the NETWORK menu.

NETWORK
Press the Set switch.

TCP/IP
Press the Set switch.

TCP/IP ENABLE
Press the + switch.

IP ADDRESS=
Press the Set switch.

192.0.0.192

*
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123.0.0.192
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123.45.67.89
Press the Set switch to complete the IP address.

123.45.67.89

An asterisk appears at the end of the display.

2-37


 


 


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HL-1650/1670N SERVICE MANUAL

6.2

Functions

6.2.1

LED functions

L-LED
(Green)

F-LED

(Orange)

A-LED
(Green)

Fig. 2-38

L-LED (Green): Link activity

This LED is on if there is a valid connection to the network (either 10BaseT or 100BaseTX). It
is off if no network is detected.
F-LED (Orange): Fast Ethernet
This LED will be on if the print server is connected to a 100BaseTX Fast Ethernet network. It
is off if the print server is connected to a 10BaseT network.
A-LED (Green): Transmission activity
This LED will blink as the print server receives or transmits data.
6.2.2

Factory default setting

If you wish to reset the print server back to its default factory settings (resetting all information
such as the password and IP address information), hold down the Network Test button for
more than 5 seconds.

2-45


 
  


 








 
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Network board

Optional RAM (DIMM)

(max. 128Mbytes)

External device

(Standard for HL-1670N

Option for HL-1650)
Ethernet
10/100 Base TX

Control system
Expansion
memory I/O

PCI bus
External device

Low-voltage power
supply block

RAM 8MB

Interface block
(Parallel / USB)

Video control block

Engine control block

High-voltage power
supply block



Operation block
(Control panel)

Drive block
(DC motor)

Laser unit

Paper tray unit

Paper cassette
MP tray

Drum unit
Transfer block

Fixing unit
Charging
block

Paper dust
cleaner block

Drum

Duplex
printing unit

Paper eject block

Developing
block

Paper feed system

Toner cartridge
Image generation system

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A S I C

CPU Core
Reset Circuit

(MB86834)
BUS

Oscillator (48MHz)

INT

Address Decoder
DRAM Control

Program + Font ROM

10 Mbytes

Timer
Network Program
(2.0 Mbytes)
FIFO

RAM
CDCC Parallel I/O

(HL-1650: 8.0 Mbytes)

To PC

(HL-1670N: 16 Mbytes)

USB I/O
Option RAM (DIMM)
(max. 128Mbytes)

Soft Support

EEPROM (8192 x 8 bits)

EEPROM I/O

Engine Control I/O

Oscillator 33.3MHz
To Engine PCB
To PC
or Hub

Network Board
(Option for HL-1650)

PCI Bus Control

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Fuse
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Lamp

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Feedback

Line
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24V
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8V

3.3V
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Q63

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Q82

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Laser Unit H
Network
Board
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Laser
Polygon Motor
Drum Unit
Primary Charger (Corona Wire)
Primary Charger (Grid)

Main PCB

Engine PCB
Front
Registration
Sensor

Low-Voltage
Power Supply
PCB

HighVoltage
Power
Supply
PCB

Rear
Registration
Sensor

LT Front
Connector

LT PCB (Option)

60 mm sq Fan Motor

Main Motor
FAN
Relay
PCB

DX Sensor PCB
DX Tray Sensor

80 mm sq Fan Motor
Toner Sensor PCB (Light reception)
Rear Cover Sensor
Panel Back Light PCB

DX Paper
Size Sensor

DX Solenoid
Casette Sensor PCB

LT Paper
Empty Sensor

Transfer Roller

60 mm sq Fan Motor A

LT Solenoid
LT Paper
Registration Sensor

Supply Roller

Paper Dust Cleaner

Fixing Unit
Halogen
Lamp

Development Roller

MP Solenoid
SOL
Relay
PCB

Casette Sensor
Paper Empty
Sensor

Casette Solenoid
Registration Solenoid
Toner Sensor PCB (Light emission)

Thermister
Relay PCB
Jam Clear
Cover Sensor

 



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Paper Eject Sensor


 
 






 




  
 



 

  

 

        
    

  
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Paper cover
Heat roller
Photosensitive drum
Paper outer guide

Paper feed
pinch roller

Paper guide

First eject roller

Pressure roller

Duplex Tray

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sensor lever
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Aluminum drum sleeve

Organic Photoconductor layer

Photosensitive
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Grid

HVPS

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Primary charging

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Transfer the image to paper

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 DISASSEMBLY AND RE-ASSEMBLY

1.

SAFETY PRECAUTIONS
To avoid creating secondary problems by mishandling, follow the warnings and precautions
below during maintenance work.

WARNING
(1) Always turn off the power switch and unplug the power cord from the power outlet
before accessing any parts inside the printer.
(2) Some parts inside the printer are extremely hot immediately after the printer is
used. When opening the front cover or rear cover to access any parts inside the
printer, never touch the red colored parts shown in the following figures.

CAUTION:

(1) Be careful not to lose screws, washers, or other parts removed.

(2) Be sure to apply grease to the gears and applicable positions specified in this chapter.
(3) When using soldering irons or other heat-generating tools, take care not to accidentally
damage parts such as wires, PCBs and covers.
(4) Before handling any PCBs, touch a metal portion of the equipment to discharge any static
electricity charge on your body, or the electronic parts or components may be damaged.
(5) When transporting PCBs, be sure to wrap them in the correct protective packaging.
(6) Be sure to replace self-tapping screws correctly, if removed. Unless otherwise specified,
tighten screws to the following torque values.
TAPTITE, BIND or CUP B
M3: 70N ! cm
M4: 80N ! cm
TAPTITE, CUP S
M3: 80N ! cm
SCREW
M3: 70N ! cm
M4: 80N ! cm
(7) When connecting or disconnecting cable connectors, hold the connector body, not the
cables. If the connector has a lock, release the connector lock first to release it.
(8) After a repair, check not only the repaired portion but also all connectors. Also check that
other related portions are functioning properly before operational checks.

4-1

2.

DISASSEMBLY FLOW

1
AC CORD

11

19
BASE PLATE

LASER UNIT

DRUM UNIT

20

12

PAPER CASSETTE

ENGINE PCB ASSY

/ HIGH-VOLTAGE
PS PCB ASSY

FIXING UNIT

13
NETWORK BOARD

(A)

PAPER PICK-UP
ROLLER ASSY

26
TOP COVER

EXIT ROLLER UNIT

21

14

DX SENSOR
PCB ASSY

FEED MP UNIT

(A)

6
DX FEED ASSY

15

24
PAPER FEED
ROLLER ASSY

DRIVE UNIT

7
REAR COVER

22

25

TONER SENSOR
PCB UNIT

FIRST FEED
ROLLER ASSY

8
REAR COVER R / L
SIDE COVER R / L

16

9
MP COVER ASSY

17
LOW-VOLTAGE
PS PCB ASSY

MAIN PCB ASSY

18

10
PROCESS UNIT
COVER ASSY

FAN MOTOR
FAN MOTOR 60

4-2

23
TONER LED
PCB UNIT


  
 
 

3.

DISASSEMBLY PROCEDURE
NOTE:
Refer to the subsection 3.27 Harness Winding Form in this Chapter when re-assembling
printer parts.

3.1

AC Cord
(1) Disconnect the AC cord from the printer AC inlet.

Printer

AC cord

AC inlet

Fig. 4-1

3.2

Drum Unit
(1) Press the cover release button, and open the process unit cover ASSY and remove the
drum unit from the printer.
Drum unit

Process unit cover ASSY

Fig. 4-2

4-3

Cover release button


 
 
 

3.3

Paper Cassette
(1) Close the MP cover and pull out the paper cassette from the printer and remove the paper
from the cassette.

MP cover

Paper cassette
Fig. 4-3

(2) Remove the pad holder ZLh ASSY by pulling it upwards, then remove the separation pad
spring 300 from the paper cassette.

Pad holder ZLh ASSY

Separation pad spring 300

Paper cassette

Fig. 4-4

4-4

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

PR2001135

NOTE:

When replacing/re-assembling the pad holder ZLh ASSY, remove the old grease and apply a
suitable amount of grease referring to the figure below;
Paper pick-up roller

Paper cassette

Grease: Molykote PG-662

(1 rice-grain size)

Fig. 4-5

(3) Turn the paper cassette upside down, then remove the tray cover film by peeling it
carefully from the underside of the cassette.
(4) Remove the TORX pan B M3x8 Taptite screw and remove the paper tray cover from the
front of the cassette.

Tray cover film

Taptite, TORX pan B M3x8

Paper cassette

Paper tray cover

Fig. 4-6

NOTE:
The cover film must not be reused after it has been removed. Always replace it with a new
one.
The screw securing the paper cassette cover indicated RED in the figure above is very
special. When disassembling/re-assembling the screw, you need a special screw driver.
Refer to the parts reference list.

4-6


 
 
 

(5) Keeping the paper cassette upside down, release the pressure roller holder assembly
from the cassette by releasing the metal mounting plate from the plastic retaining boss.
Use a flat screwdriver to press the metal plate forwards until it clears the boss and then
remove the pressure roller holder assembly downwards from the cassette.
(6) Remove the cassette pressure roller from the assembly, then remove the pressure roller
shaft from the pressure roller collar.
(7) Remove the sponge holder ASSY from the holder. The two sponge holder springs will
also come off.
Pressure roller shaft
Sponge holder ASSY

Pressure roller collar

Sponge holder springs

Pressure roller holder

Paper cassette

Flat screwdriver
Pressure roller holder
Fig. 4-7

(8) Keeping the paper cassette upside down, remove the two cup B M2.6x5 Taptite screws.
(9) Unhook the catches of each side guide, then press the lock lever towards the front of the
cassette to release the pressure plate.
Side guide L

Step (9)

Taptite, cup B M2.6x5

Side guide rack

Taptite, cup B M2.6x5

(catches)

Lock lever
Side guide L
Side guide rack

Paper cassette
(Back side)
Fig. 4-8

4-6


  
 
 

(10) Turn the cassette the correct way up and slide the two paper guides to the center of the
cassette.
(11) Remove the side guides Right and Left from the paper cassette.

Side guide L

Side guide R

Paper cassette

Fig. 4-9

(12) Unhook the two catches (A) of the pressure plate while pulling the plastic frame outwards,
then unhook the other two catches (B) of the plate while pulling the plastic frame outwards
to remove the pressure plate ASSY.
(13) Unhook the pressure plate spring from the plastic hook to remove the two pressure plate
springs.
Step (12)

(catches (A))

Pressure plate ASSY

Paper cassette

Step (12)

(hook)

(catch (B))
Plastic frame

Step (13)
Pressure
plate spring

Fig. 4-10

4-7


 
 
 

NOTE:
When re-assembling the pressure plate ASSY, ensure that the paper indicator arm is under the
pressure plate.

CAUTION:

When unhooking the catches to remove the pressure plate, do not bend the pressure plate,
gently ease the plastic cover. If the pressure plate is deformed, paper feeding problems may
occur.
(14) Remove the release lever extension spring.
(15) Unhook the two catches and rotate the lock lever to remove it downwards from the
cassette.
Paper cassette

Release lever
extension spring

Lock lever
Fig. 4-11

NOTE:
When re-assembling the lock lever, insert it upwards from underneath the cassette and rotate
it until the two catches lock into place..
(16) Slide the rear paper guide fully forwards in the cassette and remove it from the slot.
Paper cassette

2
1
3

Rear paper guide

Fig. 4-12

4-8


  
 
 

(17) Turn the cassette upside down and remove the one cup B M3x8 Taptite screw to remove
the side guide gear. Then remove the one friction spring.
(18) Remove the two side guide racks.
(19) Remove the paper indicator.
Taptite, cup B M3x8

Side guide gear

Side guide rack

Friction spring

Side guide rack

Step (19)
1
2

Paper indicator
Fig. 4-13

NOTE:
When re-assembling the side guide racks, they should both be aligned so that the wide end
of the racks are in line with the inside edge of the paper guide release slots in the cassette
before refitting the spring and gear.
When replacing/re-assembling the paper cassette, remove the old grease and apply a
suitable amount of grease onto both sides of the paper cassette referring to the figure
below;

Grease: Molykote PG-662

(1 sesame size)

Grease: Molykote PG-662

(1 sesame size)

Fig. 4-14

4-9

Paper cassette


 
 
 

(20) Remove the pan B M3x8 Taptite screw to remove the tray lock lever from the paper
cassette.
(21) Unhook the four catches to remove the paper tray rear from the paper cassette.
Taptite,pan B M3x8
Tray lock lever
Paper tray rear

(catch)

(catches)

(catch)
Paper cassette
Fig. 4-15

4-10


  
 
 

3.4

Network Board (For HL-1670N only)

(1) Open the access cover by sliding it to the backward.
(2) Loosen the two bind S M3x8 Taptite screws to remove the PCB access plate.
PCB access plate

Access cover

Taptite, bind S M3x8

Printer
Fig. 4-16

(3) Remove the two bind S M3x8 Taptite screws to remove the network board cover plate.
(4) Disconnect the connector connected with the main PCB and remove the network board.

Taptite, bind S M3x8

Printer

Main PCB
Network board

Fig. 4-17

4-11


 
 
 

3.5

Top Cover
(1) Open the Process unit cover ASSY.
(2) Remove the four shoulder screws from the side cover R and L.
(3) Open the rear cover and disconnect the two harnesses for the panel PCB ASSY.
(4) Remove the top cover from the printer.
Shoulder screws

Top cover

Shoulder screws

Side cover R

Rear cover

Process unit cover ASSY

Side cover L
Fig. 4-18

(5) Remove the paper stopper and the paper stopper S from the top cover.
Top cover

Paper stopper S

Paper stopper

Fig. 4-19

4-12


  
 
 

!#  

(6) Turn the top cover upside down and remove the three cup B M3x8 Taptite screws from
the top cover.
(7) Turn the top cover the correct way up to remove the panel cover ASSY from the top cover.
Taptite,cup B M3x8

Panel cover ASSY

Top cover (Back side)

Fig. 4-20

(8) Disconnect the connector and the harness connected with the panel PCB ASSY.
(9) Remove the three cup B M3x10 Taptite screws to remove the panel PCB ASSY from the
panel cover ASSY.
Taptite,cup B M3x10

Panel PCB ASSY

Taptite,cup B M3x10

LCD holder

Panel cover ASSY

Fig. 4-21

4-13


 
 
 

(10) Remove the LCD holder from the panel cover ASSY and remove the back light PCB
ASSY by releasing two hooks from ASSY.
(11) Remove the LCD from the panel PCB ASSY by releasing two hooks and then remove the
diffusion film from the ASSY.

(hooks)

LCD holder

Panel cover ASSY

Fig. 4-22

Back light PCB

(hooks)
LCD holder
Diffusion film

LCD

Fig. 4-23

4-14


  
 
 

(12) Remove the panel light guide, and then remove the key from the panel cover.

Panel light guide

Panel cover

key

Fig. 4-24

(13) Remove the key top A and the key top B form the key.

Key top A
Key top B

Key

Fig. 4-25

4-15


 
 
 

3.6

DX Feed ASSY
(1) Close the rear cover and remove the DX feed ASSY from the printer.
Rear cover

DX feed ASSY
Fig. 4-26

(2) Remove the bind M3x4 screw to remove the ground wire cover and the ground wire from
the paper guide upper ASSY, and then remove the ground wire from the ground wire
cover.
(3) Remove the bind B M3x7.5 Taptite shoulder screw, the washer and the bind B M3x8
Taptite screw to remove the paper guide upper ASSY from the DX feed ASSY.

Ground wire cover

Bind M3x4

Ground wire
Taptite,bind B M3x8

Paper guide upper ASSY

Shoulder Taptite,
bind B M3x7.5A

DX feed ASSY

Fig. 4-27

4-16


  
 
 

(4) Remove the roller holder using a pair of tweezers from the paper guide upper ASSY while
pushing the pressure roller slightly down to assist the roller holder being released.

(boss)

Roller holder

Pressure roller
Paper guide upper ASSY
Fig. 4-28

(5) Turn the DX feed ASSY upside down and remove the bind B M3x5 Taptite screw from the
DX feed ASSY.
(6) Turn the DX feed ASSY the correct way up and remove the side regist roller holder and
the pressure rollers using a pair of tweezers by releasing the boss from the left guide plate
ASSY. Remove the two pressure rollers from the side regist roller holder.

Pressure rollers

Taptite,bind B M3x5

Side regist roller holder

Left guide plate ASSY

DX feed ASSY (Back side)

(boss)

DX feed ASSY
Fig. 4-29

4-17

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

PR2001114
(7) Remove the bind B M3x8 Taptite screw from the guide plate stopper and remove the left
guide spring 2.
(8) Remove the side regist guide from the DX feed ASSY by releasing the hook at the bottom
side of the ASSY using a pair of long nose pliers.
NOTE:
ERROR 41 may occur if the left guide springs are not fitted correctly. See subsection 2.2
Service Calls in CHAPTER 6 for more information on ERROR 41.

Taptite, bind B M3x8

Guide plate stopper

(hook)

DX feed ASSY (Back side)

Left guide springs 2

2
1

DX feed ASSY

Side regist guide

Fig. 4-30

(9) Remove the left guide plate from the DX feed ASSY while pushing down the DX paper
actuator forward and then release the Drive gear 14 to remove the DX feed roller ASSY.
DX feed roller ASSY

Drive gear 14
DX paper actuator

DX feed ASSY

Left guide plate

4-18


  
 
 

(10) Remove the side regist roller from the DX feed ASSY and then remove the T-belt
B40S2M142 and the T-belt B40S2M224.
DX feed ASSY

Side regist roller

T-belt B40S2M224

T-belt B40S2M142
Fig. 4-32

(11) Remove the DX paper actuator and the guide actuator from the DX feed ASSY, and then
remove the paper actuator spring and the guide actuator spring from the each actuator.
DX paper actuator
Paper actuator spring
Guide actuator
Guide actuator spring

DX feed ASSY

(hooks)

Fig. 4-33

4-19


 
 
 

3.7

Rear Cover
(1) Open the rear cover.
(2) Release the hooks on the right and left sides of the DX rear chute to release the DX outer
chute ASSY from the rear cover.
(hook)

Printer
Rear cover R

DX rear chute
DX outer chute ASSY

Rear cover
Rear cover L
Fig. 4-34

(3) Remove the DX outer chute ASSY from the printer by releasing the hooks at the right and
left sides of the printer.
(hook)

Printer

2
DX outer chute ASSY

Fig. 4-35

4-20


  
 
 

(4) Remove the frap 2 spring from the flap 2 and then remove the flap 2 from the DX outer
chute.

Flap 2

Frap 2 spring

DX outer chute

(hook)

Fig. 4-36

(5) Remove rear cover from the printer by releasing the hooks at the right and left sides of the
printer and then remove the DX rear chute from the rear cover C.

DX rear chute

Rear cover C

Fig. 4-37

4-21


 
 
 

3.8

Rear Cover R & L / Side Cover R & L

(1) Remove the two shoulder screws to remove the rear cover R and rear cover L from the
printer.
Rear cover R
Printer

Rear cover L
Shoulder screws
Fig. 4-38

(2) Remove the three shoulder screws at the side and the back of the side cover R.
(3) Hold slightly up the back side of the side cover R while releasing the hook and remove the
side cover R from the printer while pulling outward, taking care not to break the cover.
(4) Remove the shoulder screw to remove the side cover L from the printer by releasing the
hook at the bottom of the cover.

CAUTION:

Use caution not to bend the hooks of the interface when handling the side cover R.
Side cover L

Side cover R

Shoulder screw

Shoulder screws

(hook)

Fig. 4-39

4-22


  
 
 

3.9

MP Cover ASSY
(1) Open the MP cover ASSY. Remove the MP paper guide 1 ASSY from the front cover by
releasing two hooks and pulling slightly upward.
Printer

MP paper guide 1 ASSY

MP cover ASSY

(hook)
Fig. 4-40

(2) Remove the cup B M3x6 Taptite screw to remove the side guide gear from the MP pager
guide 1 ASSY.
(3) Remove the MP side guide R and MP side guide L from the ASSY.

2
MP side guide R

Taptite, cup B M3x6

Side guide gear

MP paper guide 1 ASSY

MP side guide L
Fig. 4-41

4-23


 
 
 

(4) Remove the MP cover ASSY from the printer.

(hook)

(hook)

Printer

(hook)

MP cover ASSY

Fig. 4-42

(5) Remove the MP side guide 2 from the MP cover and then MP side guide 3 from the MP
side guide 2.

MP side guide 3

MP side guide 2

MP cover

Fig. 4-43

4-24


  
 
 

3.10

Process Unit Cover ASSY

(1) Release the hooks while pushing the process unit cover ASSY slightly inward to remove
the cover by pulling it forward.
(hook)

Printer

Process unit cover ASSY

Fig. 4-44

(2) Remove the two cup B M3x8 Taptite screws to remove the process unit cover from the
process unit cover ASSY.
(3) Remove the lock lever spring from the process unit cover ASSY and then the P cover lock
lever R and P cover lock lever L from the cover.

Taptite, cup B M3x8

Process unit cover

P cover lock lever R

Lock lever spring

2
1

P cover lock lever L

Process unit cover ASSY

Fig. 4-45

4-25


 
 
 

3.11

Laser Unit
(1) Loosen the cup S tite 3x6 screw to release the fan relay PCB ASSY and the harness on
the fan relay PCB ASSY from the main unit.
Screw, cup S tite 3x6

Fan relay PCB ASSY

Main unit

Fig. 4-46

(2) Remove the three cup S M3x16 Taptite screws.

(3) Push the P harness cover to the right to release it from the hook and remove the P
harness cover.
(4) Disconnect the LD harness and the polygon motor connector.
(5) Taking care not to touch the lens and mirror, remove the laser unit.

LD harness
Taptite, cup S M3x16

Laser unit

Polygon motor
connector

Polygon motor connector

(hook)
Fig. 4-47

4-26

P harness cover


  
 
 

CAUTION:

Never touch the reflect mirror and lens inside the laser unit. If there is any dirt or dust on
the mirror or lens, blow it off using an air gun.
Never touch the scanner window on the printer body. If there is any dirt or dust on the
window, blow it off using an air gun. If cleaning the underside of the scanner window, wipe
off dirt or dust with soft clean paper. Refer to subsection 3.3 Cleaning the Scanner
Window in CHAPTER 5.
Laser unit

Printer body

Reflect mirror

Scanner window

Lens
Fig. 4-48

3.12

Fixing Unit
(1) Place the main frame on its base so that the rear side is facing you.
(2) Disconnect the two connectors of the heater harness and release the harness from the
hooks on the right side of the fixing unit.
(3) Remove the shoulder screw and the cup S M3x8 Taptite screw securing the fixing unit.
(4) Remove the fixing unit from the main frame.
Main frame
Fixing unit

Shoulder screw

Heater harness

Taptite, cup S M 3x8

Thermistor connector
Fig. 4-49

4-27


 
 
 

(5) Remove the three bind B tite 3x10 screws to remove the FU front paper guide from the
fixing unit .
Pin

Fixing unit

FU front paper guide

Screw, bind B tite 3x10

Fig. 4-50

(6) Remove the two cup B M3x20 Taptite screws from the top of the fixing unit frame.
(7) Release the thermistor harness from the hooks.
Taptite, cup B M3x20

Taptite, cup B M3x20

Thermistor harness

Fixing unit

(hooks)
Fig. 4-51

4-28


  
 
 

(8) Remove the FU frame upper from the FU frame lower by releasing hooks as shown in the
figure below.
(hook)
(hook)

(hook)

FU frame lower

FU frame upper

(hook)
(hook)

(hook)
Fig. 4-52

(9) Remove the one pan B M3x10 Taptite screw securing the halogen lamp connector plate at
the drive unit side of the FU frame upper and then loosen the cup M3x6 screw at the other
side.
(10) Disconnect the halogen lamp connector from the FU frame upper.
(11) Lift the right hand end of the heat roller 25 and remove the halogen heater lamp from the
heat roller 25.
Screw, cup M3x6
Heat roller 25

Halogen heater lamp

Colored side
115V: Red
230V: Blue

Taptite, pan B M3x10

Halogen lamp
connector plate

Heat roller 25

FU frame upper

Halogen heater lamp

Fig. 4-53

NOTE:
When re-assembling the halogen heater lamp, ensure that the direction of the halogen heater
lamp is correct referring to the figure above.

4-29


 
 
 

CAUTION:

Never touch the surface of the halogen heater lamp.

When securing the screw to assemble the halogen lamp connector plate, ensure you use
the plastic jig as shown in the figure below to avoid damaging the edge of the halogen
heater lamp.
Halogen lamp
connector plate

Screw, cup M 3x6

Plastic jig
Halogen heater lamp

Fig. 4-54

(12) Lift and remove the heat roller 25. The HR gear 34 will also come off.
(13) Remove the HR bearing 25 from the left hand end of the heat roller 25. To remove the
HR bearing 25 at the gear side, first remove the two washers, then remove the bearing.
Heat roller bearing 25

HR bearing 25
Heat roller 25

Washer

Washer
Heat roller gear 34
Fig. 4-55

CAUTION:

Never touch the surface of the heat roller.

4-30


  
 
 

NOTE:
When re-assembling the heat roller 25 to the FU frame upper, place the two projections at
the right hand side of the roller onto the bosses on the frame as shown in the figure below.
Heat roller gear 34

(projection)
HR bearing 25

Heat roller 25

(boss)

Fig. 4-56

When re-assembling the heat roller 25 to the FU frame upper, ensure you do not damage
the heat roller 25 with the four pick off fingers on the FU frame upper.
Heat roller 25

Pick off fingers

Pick off fingers

FU frame upper

Fig. 4-57

4-31


 
 
 

(14) Remove the cleaner ASSY H complete with the cleaner spring 30 from the FU frame
upper by lifting it upwards until the spring releases from the frame.
(15) Remove the cleaner spring 30 from the cleaner ASSY H.
Cleaner ASSY H

Cleaner spring 30

FU frame upper

Fig. 4-58

NOTE:
When re-assembling the cleaner ASSY H complete with the cleaner spring 30 onto the FU
frame upper, ensure
that the direction of the roller is correct referring to the figure above.
that the spring is seated correctly in the locating channel and does not protrude from either
end.
to push down the cleaner ASSY H to hook it onto the FU frame upper, and then fit the heat
roller 25 and release the hook of the cleaner ASSY H so that the cleaner ASSY H contacts
the surface of the heat roller 25.

4-32


  
 
 

(16) Remove the pressure roller 25 from the FU frame lower by gently levering the right hand
side upwards to release it from the PR bearing and then sliding it to the right to remove it.
(17) Remove the five cleaner pinch roller ASSY complete with the pick off finger cleaner spring
and the thermistor cleaner spring for each from the FU frame lower by lifting it upwards
until the spring releases from the cover.
(18) Remove the pick off finger cleaner spring and the thermistor cleaner spring from the each
cleaner pinch roller ASSY.
pressure roller 25

Thermistor
cleaner spring
Cleaner pinch
roller ASSY

PR bearing

Pick off finger

cleaner spring

FU frame lower

PR spring

Cleaner pinch roller ASSY

Fig. 4-59

NOTE:
When re-assembling the cleaner pinch roller ASSY complete with the cleaner spring onto
the FU frame lower, ensure the direction of the roller is correct referring to the figure above.
Ensure that the both springs are seated correctly in the locating channel and does not
protrude from either end.
Ensure also that the proper spring is fixed to the each cleaner pinch roller ASSY because
the both springs are NOT identical with each other.

4-33


 
 
 

(19) Remove the bind B tite 3x10 screw to remove the eject sensor PCB ASSY.
(20) Disconnect the connector for the thermistor relay PCB ASSY.
(21) Remove the bind B tite 3x10 screw to remove the thermistor relay PCB ASSY from the FU
frame lower.
Screw, bind B tite 3x10

Thermistor relay
PCB ASSY

Eject sensor PCB ASSY

FU frame lower

Screw, bind B tite 3x10

Fig. 4-60

(21) Release the paper eject actuator from the hook on the FU frame lower, and then slide the
paper eject actuator to the right direction to remove the paper eject actuator and the eject
actuator spring from the FU frame lower.

Eject paper spring

Paper eject actuator

(hook)

FU frame lower

Fig. 4-61

4-34


  
 
 

NOTE:
When re-assembling the paper eject actuator and the eject actuator spring to the FU frame
lower, ensure the paper eject actuator is seated correctly in the locating channel referring to
the figure below;
FU frame lower

Eject actuator spring

Paper eject actuator
Fig. 4-62

(22) Release the thermistor harness from the hooks on the FU frame upper and then remove
the one cup B M3x12 Taptite screw and remove the thermistor ASSY.
FU frame upper

(hooks)

Thermistor ASSY

Taptite, cup B M3x12

(hook)
Fig. 4-63

4-35


 
 
 

NOTE:
When re-assembling the thermistor to the FU frame upper, ensure the direction of the
thermistor is correct referring to the figure below;
FU frame upper
Thermistor

Thermistor

Taptite, cup B M3x12

Fig. 4-64

(23) Remove the B 2.6x10 Taptite screw to remove the idle gear 13H. Hold slightly up the
right end of the eject roller and then remove the left end of the roller from the hook first,
then remove the eject roller from the FU frame upper.
NOTE:
When removing the left end of the eject roller, align the protrusion of the hook of the frame with
the concave part of the roller, and then pull the roller through underneath the protrusion.

FU frame upper

Eject roller

Idle gear 13H

Taptite, B 2.6x10
Concave part of the roller
Fig. 4-65

4-36


  
 
 

(24) Remove the eject pinch roller F (8pcs.) with the eject pinch roller holder R (2pcs.) and the
eject pinch roller holder L (2pcs.) from the FU frame upper, and then remove the eject
pinch spring (4pcs.).
Eject pinch roller F with
eject pinch roller holder R

Eject pinch roller F with

eject pinch roller holder L

FU frame upper

Eject pinch springs

Eject pinch springs

Fig. 4-66

(25) Remove the four eject pinch roller F from the two eject pinch roller holder R and the four
eject pinch roller F from the two eject pinch roller holder L.

Eject pinch roller F

Eject pinch roller F

Eject pinch roller holder R

Eject pinch roller holder L

Fig. 4-67

4-37


 
 
 

(26) Release the harness from the hooks on the FU frame upper. Turn the frame up-side
down. Remove the cup B M3x6 Taptite screw to remove the pick off finger holder plate
and then remove the pick off finger using a piece of tweezers.
Taptite,cup B M3x6
Pick off finger
Pick off finger holder plate

Pick off finger

Tweezers

FU frame upper

Fig. 4-68

4-38


  
 
 

3.13

Paper Pick-up Roller ASSY

NOTE:
Be sure to remove all the covers before removing the paper pick-up roller ASSY.
(1) Place the main frame upside down.
(2) Remove the bearing R from the front chute ASSY.
(3) Shift the paper pick-up roller ASSY with two roller collars to the left (the bearing R side) to
release from the paper pick-up roller shaft.
(4) Remove the paper pick-up roller ASSY and the roller collars from the front chute ASSY.
(5) Remove the bearing L from the front chute ASSY.
Paper pick-up
roller ASSY

Roller collar
Bearing L

Roller collar

Main frame

Bearing R

Front chute ASSY

3
1
Bearing L
Paper pick-up roller ASSY
Bearing R
Fig. 4-69

4-39


 
 
 

3.14

Feed MP Unit
(1) Turn the main frame the right way up.
(2) Open the MP roller cover.
(2) Remove the bearing R from the MP chute ASSY.
(3) Shift the paper pick-up roller ASSY with two roller collars to the left (the bearing R side) to
release from the MP paper pick-up roller shaft.
(4) Remove the paper pick-up roller ASSY and the roller collars from the MP chute ASSY.
(5) Remove the bearing L from the MP chute ASSY.

Paper pick-up
roller ASSY

Roller collar
Bearing R

Roller collar

Bearing L

MP roller cover

2
1

MP chute ASSY

3
Paper pick-up roller

Bearing L

Fig. 4-70

4-40

Bearing R


  
 
 

(6) Remove the separation plate ASSY.

(7) Remove the two MP pressure spring 25.
(8) Remove the two bind B tite 3x10 screws from the MP chute cover.
(9) Release the two bosses at the both ends of the MP pressure plate ASSY using a flat
screwdriver, and then remove it from the main frame.
MP pressure spring 25
Separation plate ASSY

Screw, bind B tite 3x10

Screw, bind B tite 3x10

MP pressure spring 25

(boss)

MP pressure plate ASSY

MP chute cover
(boss)
Fig. 4-71

4-41


 
 
 

3.15

Drive Unit
(1) Place the printer body carefully on its left hand side so that the drive unit is at the top.
(2) Remove the three cup S tite 3x6 screws securing the reversing drive frame unit.
(3) Disconnect the harness connector and remove the bind M3x4 screw to remove the
reversing switch solenoid from the reversing drive frame unit.

Screw, cup S tite 3x6

Printer body

Drive unit

Reversing drive frame unit

Fig. 4-72

Reversing switch solenoid

Reversing drive frame unit

Screw, bind M3x4

Fig. 4-73

4-42


  
 
 

(4) Release the hook of the gear to remove the switch arm ASSY and then remove the T-belt
by releasing the hook of the two gears.
Switch arm ASSY
(hook)

Gear

Gear

(hook)

(hook)
T-belt

Drive unit

Fig. 4-74

(5) Remove the two cup S tite 3x6 screws to remove the gear pressure plate from the gear
plate.
(6) Shift the pendulum gear 30 to the arrow direction and release the hook from the gear 21 to
remove the gear 21 by pulling upward through the opening space of the gear plate.
Screw, cup S tite 3x6
Gear pressure plate

Gear plate

Pendulum gear 30

(hook)

Gear 21

Fig. 4-75

4-43


 
 
 

(7) Remove the three tapes on the harnesses and release the harness from the hooks.
(8) Remove the four cup S tite 3x6 screws from the drive sub ASSY A and remove the spring,
extension P/R from the gear 60 P/R.
(9) Disconnect the connectors for the main motor ASSY and the toner LED PCB unit.
(10) Remove the drive sub ASSY A from the main frame.

Gear 60 P/R

Spring, extension P/R

Screw, cup S tite M3x6

Screw, cup S tite M3x6

Tapes

Lock lever
springs

Main motor
ASSY

Drive sub ASSY A

(hooks)

Main frame
Fig. 4-76

CAUTION:

Be sure to hold the pendulum gear 30 when removing the drive sub ASSY A in order not to
lose the friction spring fitted under the gear (name).
Be careful not to lose the joint spring on the develop joint when removing the drive sub
ASSY A.

4-44

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

PR2001114
(11) Remove the four cup S tite 3x6 screws and disconnect the harness to remove the main
motor ASSY from the drive sub ASSY A.
Screw, cup S tite 3x6
Screw, cup S tite 3x6
Drive sub ASSY A

Fuser drive gear

Main motor ASSY

Fig. 4-77

(8) Place the main frame so that the drive unit side is at the right as the figure shown below.
(9) Remove the two bind B M4x10 Taptite screws.

Solenoid unit

Main frame

Taptite, bind B M4x10

Fig. 4-78

4-52


 
 
 

(10) Disconnect the two connectors for the solenoid relay PCB to remove the solenoid unit
from the drive unit.
(11) Release the two hooks and remove the solenoid ASSY P/R (red) and the solenoid ASSY
MP (black) from the unit.
Clutch lever P/R

Clutch lever MP

Solenoid release
spring P/R

Solenoid ASSY P/R (red)

(hook)
Plunger
Solenoid unit
(hook)
Solenoid release
spring P/R

Solenoid ASSYMP (black)

Fig. 4-79

(12) Place the main frame so that the drive unit side is at the right as the figure shown below.
(13) Remove the bind M3x4 screw to remove the feed solenoid ASSY from the main frame L.

CAUTION:

Be sure not to lose the solenoid return spring F/R when removing the clutch lever F/R.
(15) Remove the clutch lever F/R from the main frame.
Plunger

Clutch lever F/R

Solenoid return
spring F/R

Feed solenoid ASSY

Main frame

DX guide rail L

Screw,bind M3x4

Screw,bind M3x4
Fig. 4-80

4-46


  
 
 

(16) Remove the gear 60 P/R and gear 72 MP from the conductor bearing 5, and remove the
middle roller gear from the conductor bearing H.
(17) Remove the two conductor bearing 5.
(18) Turn the knob of the conductor bearing H as the figure shown below, and remove the
conductor bearing H from the main frame L.
Gear 72 MP

Gear 60 P/R

Middle roller gear

Conductor bearing 5

Conductor bearing 5

Conductor bearing H

Conductor bearing H

(knob)

Fig. 4-81

3.16

Low-voltage Power Supply PCB ASSY

(1) Remove the eight cup S tite 3x6 screws and the pan M3.5x6 screw with washer and the
lead wire FG, and then disconnect the engine PCB connector.
(2) Remove the PS PCB ASSY from the main frame.

Main frame
Screw, cup S tite 3x6
Screw, cup S tite 3x6
Screw, pan M3.5x6
with washer
Lead wire FG

Screw, cup S tite 3x6

PS PCB
Screw, cup S tite 3x6
PS PCB ASSY

Fig. 4-82

4-47


 
 
 

3.17

Main PCB ASSY

(1) Remove the two pan M3x6 screws and the six cup S tite 3x6 screws from the main PCB
ASSY.
(2) Disconnect the four connectors for the low-voltage power supply, engine PCB, the panel
PCB and the scanner unit.
(3) Remove the main PCB ASSY from the frame.
Main PCB ASSY
Screw, pan M3x6

Screw, cup S tite M3x6

Screw, cup S tite M3x6

Main frame
Fig. 4-83

3.18

Fan Motor / Fan Motor 60

NOTE:
Be sure to disconnect the fan motor connector on the fan relay PCB before removing the fan
motor and fan motor 60.
(1) Release the two hooks and remove the fan motor from the fan duct by pulling slightly
forward.
(2) Remove the fan motor 60 from the main frame by pulling upward.
Fan motor

(hook)
Fan duct
(hook)

Fan motor 60
Fig. 4-84

NOTE:
When re-assembling the fan motor and the fan motor 60, fit the both motors with the labeled
surface facing the printer.

4-48


  
 
 

3.19

Base Plate
(1) Turn the main frame upside down.
(2) Remove the five bind B M4x10 Taptie screws and four cup S tite 3x6 screws from the
base plate.
(3) Slide the base plate to the rear of the printer to remove it.
Taptite, bind B M4x10

Screw, cup S tite 3x6

Base plate

Main frame

Screw, cup S tite 3x6

Fig. 4-85

3.20

Engine PCB ASSY / High-voltage Power Supply PCB ASSY

(1) Remove the two bind B M4x10 Taptite screws to remove the PCB insulation sheet.
Taptite, bind B M4x10
PCB insulation sheet

Main frame

Fig. 4-86

4-49


 
 
 

(2) Remove the two bind B M4x10 Taptite screws, one from the high-voltage PS PCB ASSY
and the other from the engine PCB ASSY.
(3) Shift the engine PCB ASSY slightly and remove the central connector, which connects the
engine PCB ASSY, and the high-voltage PS PCB ASSY.
(4) Remove the high-voltage PS PCB ASSY first by lifting up straight upward.
(5) Disconnect the 12 (twelve) connectors from the engine PCB to remove the engine PCB
ASSY.
Screws

Engine PCB ASSY

High-voltage PS PCB ASSY

Main frame

Fig. 4-87

NOTE:
When re-assembling the the engine PCB ASSY and the high-voltage PS PCB ASSY, fit the
engine PCB ASSY on the frame, then connect the both PCB ASSY with each other by the
central connector. And then fit the high-voltage PS PCB ASSY straight downward onto the
frame. Fix the both PCB ASSY with the two screws.

CAUTION:
Even if you want to remove only one of either the engine and high-voltage power supply
PCBs, ensure you remove all screws securing both PCBs and disconnect the central
connector while lifting both of them up. Failure to do so may damage the PCBs.
When re-assembling the engine PCB, ensure it is aligned with the positioning boss first.
Be careful the main motor harness is not caught between the engine PCB and the frame.
When re-assembling the engine PCB or high-voltage PS PCB, ensure the central
connector is connected correctly.

4-50


  
 
 

3.21

DX Sensor PCB ASSY

NOTE:
Be sure to disconnect the DX sensor connector on the engine PCB before removing the DX
sensor PCB ASSY.
(1) Remove the two cup S tite 3x6 screws to remove the DX guide rail L with DX sensor PCB
ASSY from the main frame.
Main frame

DX guide rail L

Screw, cup S tite 3x6

DX sensor PCB ASSY

Fig. 4-88

(2) Remove the bind B M3x8 Taptite screw to remove the DX sensor PCB ASSY from the DX
guide rail L.
Taptite, bind B M3x8

DX sensor PCB ASSY

DX guide rail L

Fig. 4-89

4-51


 
 
 

3.22

Toner Sensor PCB Unit (Light Reception)

NOTE:
Be sure to disconnect the toner sensor (light reception) connector on the engine PCB before
removing the toner sensor PCB ASSY (light reception).
(1) Remove the harness from the hooks on the fan duct.
(2) Release the three hooks, and then lift up slightly and slide the fan duct to remove it.
(3) Remove the cup S tite 3x6 screw to remove the toner sensor PCB unit.
(hook)

Toner Sensor PCB Unit

(hook)

Toner Sensor PCB Unit

Screw, cup S tite 3x6

Fan duct

(hook)

Main frame R

Fig. 4-90

3.23

Toner LED PCB Unit (Light Emission)

NOTE:
Be sure to disconnect the toner LED (light emission) connector on the engine PCB before
removing the toner sensor PCB ASSY (light emission).
Release the two hooks from the LED holder and remove the toner LED PCB unit (light
emission) by pulling upward.
Toner LED PCB unit

(hooks)
Main frame
Fig. 4-91

4-52


  
 
 

3.24

Paper Feed Roller ASSY

NOTE:
Be sure to remove all the covers and the gear 21 before removing the paper feed roller ASSY.
(1) Unhook the catch to remove the bearing 5 from the front chute ASSY.
(2) Remove the paper feed roller ASSY from the front chute ASSY by sliding to the left, then
lifting upward.
(3) Remove the joint 5 from the paper feed roller ASSY.
Joint 5

Paper feed roller ASSY

(catch)

Front chute ASSY

Fig. 4-92

3.25

Bearing 5

First Feed Roller ASSY

NOTE:
Be sure to disconnect the engine PCB connector on the cassette sensor PCB ASSY and
remove the tape on the engine PCB connector before removing the cassette sensor PCB
ASSY.
(1) Place the frame upside down.
(2) Remove the bind B tite 3x10 screw to remove the PE sensor cover and the cassette
sensor PCB ASSY from the front chute ASSY.
Screw, bind B tite 3x10
PE sensor cover

Tape

Cassette sensor PCB ASSY

Fig. 4-93

4-53


 
 
 

(3) Remove the paper pick-up roller shaft and the first feed roller shaft from the front chute
ASSY.
(4) Remove the four bind B M4x10 Taptite screws to remove the front chute ASSY.
CA actuator
PE actuator
Taptite, bind B M4x10

Paper pick-up roller shaft

Taptite, bind B M4x10

First feed roller shaft

Front chute ASSY

Fig. 4-94

(5) Turn the front chute ASSY upside-down, and then remove the bearing 5 and the joint 5 to
remove the first feed roller from the front chute ASSY.
(hook)

Bearing 5

First feed roller

Joint 5

Front chute ASSY

Fig. 4-95

4-54


  
 
 

3.26

Exit Roller Unit

NOTE:
Be sure to disconnect all the connectors on the fan relay PCB before removing the exit roller
unit.
(1) Remove the two shoulder screws to remove the exit roller unit from the printer.
Shoulder screws

Exit roller unit

Fig. 4-96

(2) Remove the two bind B M4x10 Taptite screws to remove the exit roller holder from the exit
roller unit.
(3) Lift up and remove the pinch roller ASSY from the exit roller unit, and then remove the
pinch roller spring from the pinch roller ASSY.
(4) Remove the cup B M3x8 Taptite screw to remove the rear cover sensor PCB ASSY from
the unit.
Exit roller holder

Taptite, bind B M4x10

Pinch roller ASSY

Exit roller ASSY ZLh

Taptite, cup B M3x8

Pinch
roller spring

Rear cover sensor PCB ASSY

Exit roller unit

Adhesive tape
Pinch roller ASSY
Adhesive tape
Fig. 4-97

4-55


 
 
 

(5) Remove the fan motor 60A unit from the exit roller holder.

Fan motor 60A unit

Exit roller holder

Fig. 4-98

4-56

3.27 Harness Winding Form

4-57


 
 
 

4.

PACKING

AC Cords

Accessory Bag
Accessory Carton

Pad
Drum Unit
(with Toner Cartridge included)

Pad

Printer

Carton

Fig. 4-99

4-58


 
  


 


 



   
  
    
 
   





  
   

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2.1 'Operator Calls'

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Turn off and on the printer

power switch.

6 'Image Defects'

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3.1 'Paper Loading Problems'

7 'Incorrect Printout'

5. 'Malfunctions'
Paper jam occurs.

3.2 'Paper Jams'

The printer does

not start printing.

4. 'Software Setting Problems'

8. 'Network Problem'




 
 



 
 








  
 

 
 




 


  
 

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I-2 Dark

I-3 Completely blank

I-4 All black

I-5 Dirt on back of paper

I-6 Black vertical

streaks

I-6 Black vertical

streaks

I-7 Black horizontal

stripes

I-8 Black vertical

streaks

I-9 White vertical

streaks

I-10 White horizontal

streaks

I-11 Faulty
registration

I-12 Poor fixing

I-13 Image distortion

I-15 White spots

I-16 Black spots

I-17 Black band

I-18 Gray background

I-20 Downward fogging

of solid black

I-21 Horizontal lines

I-22 Light rain

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I-14 Faint print

I-19 Hollow print

I-24 Toner specks


 
 



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HL-1650/1670N SERVICE MANUAL

I-6

Black and blurred vertical streaks

User Check
(1) Clean the corona wire in the drum unit.
(2) Check that the corona wire cleaner is at the home position.
(3) Check that the toner cartridge is not empty.
(4) The drum unit may be damaged. Install a new drum unit.
(5) The toner cartridge may be damaged. Install a new toner cartridge.

Possible cause

Step

Check

Result

Remedy

Corona failure

Is the vertical block streak

about 10mm wide?
(Check if the wire cleaner is at
its home position.)

Yes

Return the wire cleaner to its

home position.

Dirt in the paper

feed system

Is the paper cassette or feed

system on the drum unit dirty
with toner?

Yes

Clean the toner off.

Scratch on the
drum

Is the drum surface scratched?

Yes

Replace the drum unit.

Cleaning failure

Is the drum surface dirty with

toner in streaks?

Yes

Replace the drum unit.

Scratch on the
heat roller

Is the surface of the heat roller

scratched?

Yes

Replace the fixing unit.

NOTE:
If you print the same pattern (especially vertical streaks) continuously, electrostatic charge
performance of the drum will decrease temporarily and black vertical streaks may appear
on the paper.
This problem may occur with noise due to the corona wire being dirty. In that case, clean
the corona wire with the wire cleaner.

6-37


 
 



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CHAPTER 6 TROUBLESHOOTING

I-11

Faulty registration

Possible cause

Step

Excessive paper
load

Is the paper loaded in the

paper cassette more than
27mm high?

Yes

Instruct the user to keep paper

loads below 27mm in depth.

Print paper

Is the specified weight of the

recommended paper being
used?

No

Recommend to use the

specified types of paper.

Is the first printing position

within 1mm of the tolerance
specification?

Yes

Adjust the Y offset by using the

utility software supplied.

Is the rear registration sensor

off from the correct position?

Yes

Reposition the sensor to the

correct position.

Rear regist
sensor position
incorrect

I-12

Check

Result

Remedy

Poor fixing

Possible cause

Step

Check

Result

Remedy

Print paper

Is thick paper of more than

43lb being used?

Yes

Recommend to use the

specified types of paper.

Toner sensing
failure
(When printing
is faint.)

Is the problem solved by

replacing the drum unit or the
toner cartridge?

Yes

1) Toner is empty.
2) The toner sensing is
defective. Clean the toner
sensor.
3) If the wiper in the toner
cartridge is broken, replace
the toner cartridge with a new
one.

Fixing unit
thermistor
failure

Is the thermistor fitted

correctly?

No

Fit the thermistor correctly.

Low-voltage
power supply
PCB failure

Is the problem solved by

replacing the low-voltage
power supply PCB?

Yes

Replace the low-voltage power

supply PCB.

6-40

   
 

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I-20

Downward fogging of solid black

Possible cause

Step

Check

Result

Remedy

Toner cartridge
failure

Is the problem solved after

replacing the toner cartridge?

Yes

Replace the toner cartridge.

High-voltage
power supply
PCB failure

Is the problem solved after

replacing the high-voltage
power supply PCB?

Yes

Replace the high-voltage power

supply PCB.

I-21

Horizontal lines

Possible cause
Paper cassette
contacts

Step

Check

Result

Are the ground contacts on the

back side of the paper
cassette connecting correctly?

No

6-47

Remedy
Clean the contacts.

Ground
contacts

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IBM CHR SET MODE

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DLFNT Bd/It=NO*
DLFNT Bd/It=YES

B PROD ON/OFF

B PROD=OFF*
B PROD=ON

CONDENCE SELECT

CONDENC=16.66p*
CONDENC=17.14p

OEM FONT SELECT

OEMFONT=DISABLE*
OEMFONT=ENABLE

ISR FONT SELECT

ISRFONT=DISABLE*
ISRFONT=ENABLE

BRO FONT SELECT

BROBITM=DISABLE*
BROBITM=ENABLE



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AUTO HRC=OFF*

* 6!  6!  

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DEMO PAGE=ON*
DEMO PAGE=OFF

APPLETALK AT/PS

PS BINARY SELECT

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PS IMAGE MASK

APPLE TALK=PS*

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BOISE ID=IEEE*
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B6 PAGE

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COM10 PAGE

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07 

DL PAGE

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ERROR HISTORY

1:#######
2:#######
3:#######

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 .*&(2#%&)&&&&6 (* '+ 

%)# !()1))#( *&(2#%&)4* 
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L

HL-1650/1670N SERVICE MANUAL

PR2001022

4.
4.1

OTHER HIDDEN FUNCTION MENUS

Hidden Function Menus Enabled by Pressing Switch(es) When Turning the
Machine on
The following settings and function will be available by holding down the specified switch(es)
while turning the machine on.

Switch(es)

Display

Description

Go

DEMO MODE=ON*
DEMO MODE=OFF

Enables and disables DEMO MODE. If

this function is ON (default setting), the
user can set a printer to work as a demo
machine. It turns OFF automatically
when the printing data is sent to the
printer.
Continuously print the test pattern sheet.

Reprint

4.2

Back

LANG.=ENGLISH*

Selects a local language for display.

HEX DUMP MODE

Hex dump mode. Printer reset is

needed to exit this function.

Displays information about program/font

ROMs by pressing Set switch.

Set

Clear NVRAM.
This function is not normally used.

Go & +

DRAM CHECK MODE

Check DRAM.

Go & Set

GO TEST MODE

Enters the inspection mode. See

section 9. Inspection Mode in
CHAPTER 6.

&+

LINE TEST MODE

Printer test mode. For factory use.

& Set with

cover open

ZLH HV CHECK

For factory use.

Drum Life Reset Function

This function is used by the user when changing the new drum unit to clear the drum life
counter.
To operate this function, hold down the Go switch while the front cover (process unit cover)
is open until the message >>>>DRUM CLEAR appears on the LCD display.

4.3

Parts Life Reset Function

This function is used by service specialists only when changing the periodical replacement
parts to clear the life counter.
To operate this function, press the Go and + switches together until the menu RESET
PARTS LIFE appears on the LCD display. Select the required item (part name) using the
+/ switches, then press the Set switch. See subsection 2. PERIODICAL
REPLACEMENT PARTS in CHAPTER 5 for more information about the periodical
replacement parts.

7-9

Appendix 1. Connection Diagram, HL-1650/1670N

A-1

Appendix 2. Main PCB Circuit Diagram, HL-1650/1670N (1/6)

CODE

LJ8453001

NAME

B512078CIR (1/6)

A-2

Appendix 3. Main PCB Circuit Diagram, HL-1650/1670N (2/6)

CODE

LJ8453001

NAME

B512078CIR (2/6)

A-3

Appendix 4. Main PCB Circuit Diagram, HL-1650/1670N (3/6)

CODE

LJ8453001

NAME

B512078CIR (3/6)

A-4

Appendix 5. Main PCB Circuit Diagram, HL-1650/1670N (4/6)

CODE

LJ8453001

NAME

B512078CIR (4/6)

A-5

Appendix 6. Main PCB Circuit Diagram, HL-1650/1670N (5/6)

CODE

LJ8453001

NAME

B512078CIR (5/6)

A-6

Appendix 7. Main PCB Circuit Diagram, HL-1650/1670N (6/6)

CODE

LJ8453001

NAME

B512078CIR (6/6)

A-7

Appendix 8. Engine PCB Circuit Diagram, HL-1650/1670N (1/2)

Red 5 Pin PH
Right Angle

Black 6 Pin PH
Right Angle

Straight
White 2 Pin PH
Right Angle
White 3 Pin PH
Right Angle
White 5 Pin PH

Right Angle
White 4 Pin PH

Right Angle
Red 6 Pin PH

Right Angle
Red 4 Pin PH

Right Angle
White 6 Pin

Straight
Red 3 Pin PH

CODE

LJ8439001

NAME

B512079CIR (1/2)

A-8

Appendix 9. Engine PCB Circuit Diagram, HL-1650/1670N (2/2)

Straight
White 9 Pin PH

Red 9 Pin PH
Right Angle

Straight
Black 5 Pin PH

CODE

LJ8439001

NAME

B512079CIR (2/2)

A-9

Appendix 10. Network Board PCB Circuit Diagram, HL-1650/1670N

CODE

LJ8439001

NAME

B512058CIR

A - 10

Appendix 11. Low-voltage Power Supply PCB Circuit Diagram (100V)

NAME

Low-voltage PS Circuit
(100V)
A - 11

Appendix 12. Low-voltage Power Supply PCB Circuit Diagram (200V)

NAME

Low-voltage PS Circuit
(200V)
A - 12

Appendix 13. High-voltage Power Supply PCB Circuit Diagram

NAME

High-voltage PS Circuit

A - 13

APPENDIX

APPENDIX 14.

SERIAL NO. DESCRIPTIONS

The descriptions below show how to understand the meanings of the numbers printed on the
labels or bag of the printer and printer parts:
< ID for production month >
A:
E:
J:

January
May
September

B:
F:
K:

February
June
October

1:

2001

C:
G:
L:

March
July
November

D:
H:
M:

April
August
December

< ID for year >

0:

2000

< ID for factory >

9:
J:

Kariya Plant
A:
Buji Nan Ling Factory

Mie Brother

C:

BIUK

(1) Printer: Printed on the label attached on the rear of the main body
<MODEL NO.>

< SERIAL NO. >

U52682M0J111101
SEQUENTIAL NO.
FACTORY ID NO.
YEAR
MONTH

(2) Process unit: Imprinted on the aluminum bag

(Drum unit with toner cartridge)

0M11
YEAR
MONTH

JA
PRODUCTION
LINE NO.

DATE
FACTORY ID NO.

(3) Drum unit: Printed on the bar code label attached inside the drum unit

F095100104A
MONTH
YEAR

SERIAL NO.
TONER VOLUME
FACTORY ID NO.

A-14

PRODUCTION
LINE NO.

DR/TN REUSE
The first time: M
The second time: N
The third time: P

APPENDIX

(4) Toner cartridge: Imprinted on the aluminum bag

0M30

YEAR
MONTH

DATE
FACTORY ID NO.

Printed on the bar code label attached on the toner cartridge

CARTRIDGE
PRODUCTION INFO.

M99A600199A
MONTH
YEAR

SERIAL NO.
TONER VOLUME
FACTORY ID NO.

PRODUCTION LINE NO.

DR/TN REUSE
The first time: M
The second time: N
The third time: P

(5) Laser unit: On the laser unit

1 9 0 0 1
PRODUCTION LOT NO.
LASER UNIT NO. 9: LJ5120001 Laser Unit H
FACTORY ID NO. 1: Kariya Plant
2: Buji Nan Ling Factory

A-15




 
     

   
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APPENDIX

APPENDIX 19.

NVRAM DEFAULT VALUE

The default values for the main items to be set in NVRAM are as follows;
Items

Descriptions

Timing of Drum LED ON

16,000 page
(Counted from the drum unit life.)

Development switching
timing

The developing bias is switched from 400V to 300V when

5,000 pages are printed.
It is switched to 400V again when the toner cartridge is
replaced following the TONER EMPTY error message
(Counted from the number of the drum rotation in noncontinuous printing)

Fixing temperature

Transparency: 170C
Thin paper: 185C
Regular paper: 208C (195C when printing using duplex
function)
Thick paper: 220C
Thicker/Bond paper: 220C (in non-continuous printing)

Smaller size mode

See APPENDIX 16 PRINT SPEEDS WITH VARIOUS

SETTINGS.

<The Developing Bias Reset Function>

This function makes a counter reset for initializing the developing bias function when changing
the new toner cartridge before the previous one gets empty for any reason.
With the following settings, the developing bias reset function operates.
1.
2.
3.
4.
5.

Open the front cover, and take the drum unit out.
Press the GO switch once when keeping the front cover open.
Install the drum unit into the printer.
Press the GO switch again when keeping the front cover open.
Close the front cover.

A-27





 
 
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APPENDIX

PR2002109

APPENDIX 21.

TONER CARTRIDGE WEIGHT INFORMATION

Toner Cartridge Weight (approx weight)

TN7600/TN560
Brand new Toner Cartridge Weight
827.5g
Toner Weight at Brand New Toner Cartridge
197.52.5g
Toner Cartridge Weight at Toner Near Empty
720-725g
Remain Toner Weight at Toner Near Empty
90-95g
Toner Cartridge Weight at Toner Empty
710-715g
Remain Toner Weight at Toner Empty
80-85g
You can print 500 to 600 pages with 10g toner.
*Without yellow protector
*Toner cartridge weight may vary within 2 to 3g depending on the cartridge weight

A-29

APPENDIX

APPENDIX 22.

HOW TO REWRITE HL-1650/1670N FLASH ROM

The ROM composition of each PCB is as follows.

Main PCB
ROM 0 (64 Mbit x 2)
ROM 1 (8 Mbit x 2)
Production
MASK
FLASH
Spares
FLASH
FLASH
Working contents
1) Rewrite a Main firmware / Network firmware
2) Set up by country.
Object parts
LJ9349001

MAIN PCB ASSY ZLH FLASH

Preparation tool
1) PC (Windows 98)
Create the folder ZLH in C drive.
2) 1 HL-1650/1670N printer
3) 1 parallel cable
4) FLS-PRG.EXE or FILEDG32.EXE *1
Download FLS-PRG.EXE or FILEDG32.EXE from Utility DB, then copy it to ZLH folder
in C drive. (PrUt000008, PrUt030003)
5) PIT2LZSP.EXE
Create the folder PIT2 in C drive. Download PIT2LZSP.EXE from Utility DB, then copy it
to PIT2 folder in C drive. Extract the EXE file. (PrUt020038)
6) Firmware: VERxxx.AVA or ZLHxxx.BLF *2
VERxxx.AVA >Main firmware
ZLHxxx.BLF > Network firmware
*1
File Type

Software tool

AVA

FLS-PRG.EXE

BLF

FILEDG32.EXE

*2
xxx expresses the version.
Download and extract the firmware from ROM/Firmware DB, then copy it to folder ZLH in C
drive.

A-30

APPENDIX

1.

Controller Firmware (ROM 0)

Rewriting procedure (For AVA file)
(1) Choose Start>Program>MS-DOS
Since the DOS window is opened, move the ZLH folder. Type c:\ + ENTER, CD Zlh +
ENTER.
(2) Connect the parallel cable to the printer, then turn the printer power switch ON. Wait until
the printer LCD display turn green and READY message appears.
(3) Type fls-prg verXXX.ava in DOS window, then press ENTER key.
(XXX expresses a version.)
Data is sent to the printer via parallel cable.
(4) After finishing rewriting, the system will be rebooted. Wait until READY message
appears on the LCD display of printer.
After you have done (1) to (4) written above, follow the procedures below;
<PIT2>
(5) Go to PIT2 folder in DOS window and type PIT2, then press ENTER key. PIT2
(software tool) will start.
(6) Input /CS1650 or /CS1670N in PIT2 control window, then press ENTER. CS1650 or
CS1670N (SCRPTY.YY) message appears in the model section of PIT2 control window.
(Y,YY expresses a version of script)
(7) Input .VVVVV, then press ENTER.(.VVVVV expresses a country code. See the detail
below.)
ex. If you Input .00101 (USA version) , 00101 (USA / USA) message appears in the
specification section of PIT2 control window, and READY message appears in the PIT2
status window.
(8) Input 9 digit serial number in the PIT2 control window, then press ENTER. PIT2 will be
started, RUNNING message appears in the PIT2 status window accordingly.
(9) SER:VVVVVVVVVVVVVVVVVV message appears in the PIT2 control window, and
PASS message appears in ERR CODE section. READY message appears in the PIT2
status window. (READY is displayed in about 3 seconds.)
<When the error occurs>
The error generated step appears in the PIT2 control window, error code appears in ERR
CODE section, ERROR message appears in the PIT2 status window. To release the
error, Input check, then press ENTER.
Please carry out (8) again at the time of error generating. If the error message still
appears, please judge that there is something wrong with PCB.
(10) Turn the printer power switch OFF, then disconnect the parallel cable.
(11) In case of performing the rewriting work to other printers, repeat from the step 2. To finish
working, Input quit in the PIT2 control window, then press ENTER key.

A-31

APPENDIX

2.

Patch Area (ROM 1)

(1) Install the printer driver to the PC. Make a short-cut icon for FILEDG32 on the Desktop.
(2) Connect the parallel cable to the printer.
(3) Double click the FILEDG32 icon, and drag and drop the ROM1 data to the printer icon in
the FILEDG32.
(4) After finishing rewriting, the system will be rebooted. Wait until READY message
appears on the LCD display of the printer.

Country code
00101
00102
00103
00104
00105
00106
00107
00108
00109
00110
00112
00113
00115
00116
00117
00124
00126
00136
00146
00147

USA
CANADA
GERMAN
UK
FRANCE
AUSTRALIA
NORWAY
BELGIUM
NETHERLANDS
SWITZERLAND
FINLAND
DENMARK
SPAIN
ITALY
ISRAEL
SOUTH AFRICA
SWEDEN
CHILE
MEXICO
JAPAN

A-32


 
  



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