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magicolor 6100 Series Service Manual

1750039-001C

The essentials of imaging
www.minolta-qms.com

Safety and Revision Information

magicolor 6100 Series Service Manual

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magicolor 6100 Series Service Manual

Revision Control Table No. 1 2 3 4 5 6 7 Date of Revision July, 1999 August, 1999 October, 1999 October, 1999 March 2000 July 2000 June 2001 Revision Code First Edition "A" Edition "A" Edition QMS REV. 001 Description of Revision First edition. Reviewed to cover the mass-production unit. Reviewed following pages: 3-3, 7-34, 7-42, 7-60, 9-1 and 9-5 Internal manual revision. Duplexer and LFU information added.

QMS REV. 001A Final OEM information included. Format revision. Minolta-QMS Rev. 001B Minolta-QMS Rev. 001C Added LFU wiring diagram. Error message corrections included New OEM information included.

Note:Some pages found within this manual are 11" x 17". If you print out the Acrobat files, please note these pages should be printed seperately. FCC NOTICE WARNING This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. A shielded cable is required to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. Caution: Any modifications or changes to this product not expressly approved in writing by the manufacturer responsible for compliance to Federal Regulations could void the user's authority to operate this product within the Laws and Regulations of the Federal Communications Commission. Canadian Compliance

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This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. "Le presnt appareil numerique n'emet pas de bruits radioelectriques depassant les limites applicables aux appareils numeriques (de la Class A) prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada."

Product Safety Laser Product This engine is certified as a Class 1 laser product and complies with CDRH Laser-Radiation Standards, 21 CFR Chapter 1, Subchapter J.

WARNING Use of controls, adjustments or performances of procedures other than those specified in this manual may result in hazardous radiation exposure. Ozone Gas WARNING This engine is provided with the ozone filter in order to reduce exhaust ozone in compliance with Product Safety Standards. The ozone filter must be replaced yearly; otherwise, it may cause a strong odor, which will likely have ill effects on bronchial tubes.
Page iv magicolor 6100 Series Service Manual

Documentation Disclaimer QMS MAKES NO REPRESENTATION OR WARRANTIES OF ANY KIND WHATSOEVER WITH RESPECT TO THE CONTENTS HEREOF AND SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. i Safety Instructions i.i Safety Principles i.i.i Before starting any procedure, read this manual thoroughly. Read and understand the safety instructions found in this section. When handling any P.W.B. use all necessary ESD precautions. Perform all the operations by following the procedures described in this manual. Follow all the cautions and warnings set out in the procedures and on safety labels affixed to the machine. Failure to do so may result in personal injuries or equipment damage. Perform only the procedures explained in this manual. Refrain from opening or touching any portions that are not related with your operation. Repair and replacement of parts should be performed by trained and qualified service personnel only. Operators should not attempt to do such repair or replacement. It must be understood that the above-mentioned cautions and warnings do not cover everything, because it is impossible to guess at or evaluate all the circumstances beforehand.

i.i.ii i.i.iii

i.i.iv

i.i.v

i.i.vi

i.ii

Special Safety Information i.ii.i Introductory Information The warnings and cautions are made clear by "Signal Words" such as DANGER, WARNING and CAUTION.

i.ii.i.i

Definition of Signal Words

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DANGER is used to indicate the presence of a hazard which will cause severe human injuries or a fatal accident if ignored. WARNING is used to indicate the presence of a hazard or unsafe practices which may cause severe human injuries or a fatal accident if ignored. CAUTION is used to indicate the presence of a hazard or unsafe practices which may cause minor human injuries if ignored. CAUTION also calls attention to safety messages in this manual. i.ii.i.ii Follow Safety Instructions Carefully read all the safety messages set out in this manual and also in the safety signs placed on your equipment. Do not remove safety labels from products. Replace the safety labels if they become smeared or damaged. Learn how to operate the equipment and how to use the controls properly. Do not let anyone operate the equipment without reading the instructions. Keep the equipment in proper working condition. Unauthorized modification to the equipment may impair product function and safety, and affect the life of equipment. The following are the various kinds of "WARNINGs" contained in this manual. WARNING HAZARDOUS VOLTAGE It may cause serious injuries or fatal accidents. Voltage is now applied from the power supply of printer. There is the danger of electric shock if you touch the active area inside the printer. Make sure to turn the power supply switch OFF and pull out the plug from the outlet before starting the maintenance work on the printer. WARNING HARMFUL OZONE GAS Inhalation of an excessive amount of ozone gas may adversely affect the respiratory organs. The ozone filter is provided in this printer to reduce the exhaust ozone. This filter must be replaced with a new filter periodically in accordance with the manual for this printer.

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magicolor 6100 Series Service Manual

The following are the various kinds of "CAUTIONs" contained in this Manual. CAUTION HOT SURFACE Can cause serious burns. The fusing unit is approximately 150°C, therefore, the areas around the fuser are also very hot. When you need to change the cleaning pad or remove jammed paper, wait about 20 minutes after opening up the paper exit unit and confirm that the unit is well cooled down. CAUTION ROTATING PARTS Be aware of the danger of getting your fingers or hand caught in the printer or associated rollers causing serious injuries. Note that the exit roller is rotating while printing. Be careful not to get your hair, fingers, hands, sleeves or neckties caught in the printer while operating the machine. CAUTION HAZARDOUS POWDER Toner is a fine powder known to cause a powder explosion if dumped into open fire. Strictly refrain from dumping toner into the fire for disposal. Toner is a fine powder known to cause problems with eyes, and problems with respiratory organs if inhaled. Handle the toner cartridge, waste toner pack, and developing unit carefully. CAUTION POWER CORD AND PLUG This printer is equipped with a 3-wire power cord and 3-pronged plug (bipolar plug with grounding) for user safety.

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Connect the power cord to a properly grounded electrical receptacle to avoid an electric shock. CAUTION SAFETY INTERLOCK Cover and paper delivery unit of this printer have electric safety interlocks to turn the power off whenever they are opened. Do not attempt to circumvent these safety interlocks. CAUTION Do not step on or lean against the paper cassette. Failure to follow this guideline may cause the printer to tip over. This may cause injuries or it may damage the printer.

Do not step on or lean against the printer door. Failure to follow this guideline may cause the printer to tip over. This may cause injuries or it may damage the printer.

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magicolor 6100 Series Service Manual

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magicolor 6100 Series Service Manual

i Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v i.i Safety Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v i.ii Special Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi 1.0 Outline of Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Name and Function of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Name and Function of Duplexer Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Name and Function of LFU Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Internal Structure of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Internal Structure of the Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Description of The Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Conditions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-3 1-4 1-5 1-6 1-7 1-8 2-3 2-3 2-4 2-8 3-3 3-3 3-4 3-9

4.0 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.1 Basic Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.2 Print System and Transfer/Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.3 Optical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 4.4 Paper Transportation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 4.5 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 4.6 Structure of the Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 5.0 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.2 Cleaning for Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.3 Periodic Maintenance Cycles and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 6.0 Operation of and Adjustments through the Operator Panel. . . . . . . . . . . . . . . . . . . . . . 6-3 6.1 Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.2 Display Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.3 Operation of Normal Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.4 Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 6.5 Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 7.0 Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.1 Replacement of Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.2 Replacement of Printed Wire Boards (P.W.B) . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
magicolor 6100 Series Service Manual

7.3 Replacement of Motor Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 7.4 Replacement of Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 7.5 Replacement of Switches and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 7.6 Replacement of Rollers, Drums, and Other Components. . . . . . . . . . . . . . . . . 7-69 7.7 Replacement of the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80 7.8 Duplexer Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 7.9 Replacement of Lower Feed Unit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107 8.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.1 Troubleshooting Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.2 Operator Call Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.3 Paper Transport Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34 8.4 Printer Errors (non-Operator Call Errors). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37 8.5 Imaging Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72 9.0 Spare Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3

magicolor 6100 Series Service Manual

Section 1: Outline of Product

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1.0

Outline of Product 1.1 Name and Function of Components

1

3

4 6 2 5
Fig. 1-1

7

Number 1 2 3 4 5 6 7

Name of Part Operator Panel Front Door Paper Exit Unit Main Switch Power Connection Transfer Unit Door Interface Connector Panel

Function of Part Displays a status of printer operation. Acts as a front enclosure. Open when replacing toner cartridges or waste toner packs. Acts as an enclosure for the paper exit and output paper tray. Powers On/Off the printer. Connects to a power supply cable. Acts as a rear enclosure. Open when clearing an internal jam or performing maintenance. Video controller PWB installation location.

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1.2

Name and Function of Duplexer Components

1

5

4 3 2 6

Fig. 1-2

Number 1 2 3 4 5 6

Name of Part Top Unit Lower Unit Lower-rear Cover Reverse Paper Guide Unit Reverse Input Paper Guide Paper Guide FU

Function of Part Transports the front side of the page to the duplexer. Reverses the front page for printing on the back page. Open for clearing an inner jam or performing maintenance. Rear enclosure. Open for clearing inner jams or performing maintenance. Paper reverse and transport unit. Open for clearing inner jams or performing maintenance. Paper reverse and transport guide. Open for clearing "DUPLEX JAM." Paper transportation guide in D-top unit.

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magicolor 6100 Series Service Manual

1.3

Name and Function of LFU Components

5 2

4

3 1

Fig. 1-3

Number 1 2 3 4 5

Name of Component Paper Cassette Paper Guide Tray Latch Connector Pin Signal Connector Holds paper.

Function of Component

Guides paper from paper cassette to printer. Secures LFU to printer. Aligns the printer engine with the lower feeder unit. Activates lower feeder unit through electrical signal.

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1.4

Internal Structure of the Printer
4 3 1 2

K Y M C

10 6 7 8

5 9

Fig. 1-4

Number 1 2 3 4 5 6 7 8 9 10
Page 1-6

Name of Component Toner Cartridge OPC Belt Cartridge Drum Cleaner Fuser Transfer Drum Paper Discharger Transfer Roller Paper Cassette Pick-up Roller Optical Unit

Function of Component Contains the independent toner cartridges (K, Y, M, C) used during the development process. Holds the latent image for development. After development of each color layer, the image is transferred to the drum. Cleans and collects waste toner left adhering to the transfer drum. Fuses toner images on the paper using heat and pressure. Receives each color layer from the OPC.Holds the completed image to be transfered to the paper. Separates a sheet of paper from the transfer drum. Transfers the toner image from the transfer drum to paper. Holds paper to be fed into the printer. Feeds paper automatically from the paper cassette. Creates a latent image on the OPC belt.
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1.5

Internal Structure of the Duplexer
4

D1 2 D2 2

D3 2 7 D4 2

3

6 1

5

Fig. 1-5

Number 1 2 3 4 5 6 7

Name of Component Lower Feed Unit (LFU) Transport Rollers (D1 - D4) Registration Roller Shutter AS (U) Shutter AS (L) Sensor PT4 Sensor PT5

Function of Component Feeds paper to printer. Required for duplex operation. Transports paper. Performs registration for back side of paper. Switches paper to the duplexer. Switches paper from the duplexer. Senses paper. Senses paper.

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1.6

Description of The Operator Panel

'a b c d e f g h i j k l m n o PQRSTUVWXYZ1

1 3

2 5 7 8

MESSAGE

ONLINE

READY

4 6
DATA MENU ONLINE MEDIA CANCEL

9 11

10
SELECT

12

Number 1 2 3 4 5 6 7 8 9 10 11 12

Description LCD: 16 characters by 2 lines Message LED Online LED Ready LED Online Key Cancel Key Data LED (Red) Menu Key Media Key Select Key Scroll Key (Left) Scroll Key (Right)

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magicolor 6100 Series Service Manual

Section 2: Product Specifications

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2.0

Specifications 2.1 Rating WARNING Use the power supply cord provided, or a similar cord complying with following specifications: 3-wire power cord with grounding. Using a cord that does not adhere to these specifications may result in an electric shock. Printer Version United States Europe Japan Voltage (V) 120 220 - 240 100 Frequency (Hz) 50/60 50/60 50/60 Input Current (A) 11 6 13 Power Cord 1 (Standard) Not included. *1 1 (Standard)

*1:European customers must purchase and use a power cord complying with the following specifications. Figure A B Model Name H05VV-F3G0.75 H05VV-F3-0.75 Rating 250VAC, 6A 250VAC, 6A Approval Agency VDE, OVE, SEMKO, CEBEC, NEMKO, DEMKO, FIMKO BS Applicable Area Europe (Continent) UK

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Fig. A: Power Cord for Europe

2.5m

Fig. B: Power Cord for UK

2.5m

2.2

Printer Specifications

Number 1 2 3 4 5 6

Item Printing Method Scanning Method Recording Method Processing Method Fusing Method Print Speed a). Monochrome b). Two-Color c). Three-Color d). Four-Color Warm-Up Time (Ambient Temperature 68° F or 20° C) Resolution Feeding Method

Description/Specification Semiconductor laser and electrophotographic print. Semiconductor laser with rotating mirror. Black writing electrophotographic. Cyan, Magenta, Yellow, and Black toner image transfer to print media. Heated rollers. a). 24 Letter/A4; 12 Tabloid/A3 b). 12 Letter/A4; 6 Tabloid/A3 c). 8 Letter/A4; 4 Tabloid/A3 d). 6 Letter/A4; 3 Tabloid/A3 210 seconds maximum

37

84 9

600 dpi (base unit) Cassette Feed

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magicolor 6100 Series Service Manual

Number 10

Item Cassette Capacity

Description/Specification Standard Paper: 250 sheets, OHP: 50 sheets, Envelope: 30 envelopes (15 envelopes under humid conditions), Post Card: 50 Letter, Legal, Executive (A4), OHP, Label, Envelope, A3 Nobi, A3 Face Down, 250 sheets 24.2" (W) x 21.3" (D) x 16.5" (H) 615 mm (W) x 540 mm (D) x 420 mm (H) Standby: 48dB (A) Printing: 55dB (A), 60dB (A) at maximum Without Consumables: Approx. 101 lbs/46kg With Consumables: Approx. 119 lbs/54kg

11 12 13 14 15

Media Paper Exit External Dimension Acoustic Noise Weight of Printer

2.2.1

Lower Feed Unit Specifications

Number 1 2 3 4 5

Item Lower Feed Unit Cassette Capacity Media Sizes Dimensions Weight

Description/Specification Option for printer Paper: 500 sheets Letter, Legal, A4, Executive, B5, Label, Ledger 19.5" (W) x 19" (D) x 4.5" (H) 500mm (W) x 484mm (D) x 116mm (H) Approximately 17.6 lbs (11kg)

2.2.2

Duplexer Specifications

Number 1

Item Duplexer Option for printer

Description/Specification

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Number 2 3 4 5 6

Item Mandatory Option Media Sizes Cassette Capacity Rated Voltage Dimensions Lower Feeder Unit

Description/Specification

Letter, Legal, A3 Nobi, A3, A4 Face-Down Output Tray: 250 sheets Lower Feed Unit: 500 sheets 24VDC to be supplied from Printer Duplexer: 19.1" (W) x 7.8" (D) x 23.1" (H) 485mm (W) x 198mm (D) x 588mm (H). Printer with Duplexer: 24.2" (W) x 24.4" (D) x 24" (H) 615mm (W) x 620mm (D) x 610mm (H) Duplexer: Approx. 26.5 lbs. (12kg) Printer with Duplexer and Lower Feed Unit: Approx. 169.9 lbs. (77kg)

7

Weight

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magicolor 6100 Series Service Manual

Table 2-1: Characteristics of OEM Paper
Item Basis Weight (g/m2) Thickness (µm) Smoothness (Bekk) Stiffness (Clark) Brightness (%) Surface Resistance (¾) Grain Direction Description 82 ± 5 95 ± 6 90 ± 20 100 ± 15 85 ± 2 1010 ~ 1011 Long

Table 2-2: Characteristics of OEM Recommended Paper and Other Media
Paper Xerox 4024 Paper Weight (g/m2) Thickness (µ/m) Smoothness (Bekk) Stiffness (Clark) Surface Resistance x 109 (¾) CIE LAB L*a*b* Brightness (%) Grain Direction a. Printed side. b. Back side. Measurement Conditions: 63.5 to 81°F (17.5 ~ 27.0°C) and 50 ~ 70% RH Note: Keep the paper sealed. Do not open the paper until using it. L* a* b* 75 ± 4 102 ± 6 35 ± 4 100 ± 15 10 ~ 100 Paper Hammermil l Laserprint 90 ± 4 105 ± 6 120 ± 20 90 ± 15 10 ~ 100 Label Avery 5260 163 ± 7 184 ± 7 20 ± 6 65 ± 15 1 ~ 100 OHP Sheet 142 ± 4 110 ± 6 500 ± 100 56 ± 15 10 ~ 1000a 10 ~ 1000b SPHINX Auto Fil #1914 90 ± 4 125 ± 10 22 ± 10 70 ± 20 1 ~ 100

94 ± 2 0.4 ± 1 1.6 ± 1 80 ± 2 Long

94 ± 2 -0.5 ± 1 2.2 ±1 85 ± 2 Long

94 ± 2 -0.2 ± 1 4.5 ±1 77 ± 3 Long ----82 ± 5 --S 80% (Transmittance)

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2.3

Environmental Conditions 2.3.1 Ambient Temperature / Humidity / Altitude: 2.3.1.1 Operating: 10.0 ~ 32.5°C, 20 ~ 80% RH

(See the figure below.)
80

Humidity (%RH)

70 60 50 40 Recommended Conditions 63.5 ~ 81° F (17.5 ~ 27.0° 50 ~ 70% RH

Ambient

20

0

10 17.5 20 27 30 Ambient Temperature ( C)

32.5 40

2.3.1.2

Idle: 41~95°F (5.0~35.0°C), 10 ~ 80% RH

(See the figure below.)
80

Ambient Humidity (%RH)

60

40 30 20 10 0 5 10 20 Ambient Temperature( C ) 30 35 40

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magicolor 6100 Series Service Manual

2.3.1.3

Storage and Transportation Environment of Printer The following defines storage and transportation environment specifications for printers that have been packed according to the OEM manufacturer's specifications. However, this section does not address belt cartridges and toner cartridges. Consumables such as toner are individually packaged. The following guidelines should be followed. During transportation, strictly refrain from leaving the printer and consumables on the ground, in extreme heat, or in direct sunlight.

Description Temperature, Normal Conditions Severe Conditions, High Temperature Severe Conditions, Low Temperature Humidity Period of Storage Other Atmosphere

Parameters 32°F ~ 95°F (0°C ~ 35°C) 95°F ~ 104°F (35°C ~ 40°C) 14°F ~ 32°F (-10°C ~ 0°C) 10% ~ 90%RH One Year No Condensation 613 ~ 1,067 hpa (460 ~ 800 mm Hg)

Notes: The length of time the printer is exposed to the noted severe conditions must not exceed 48 hours. The printer must be stored under normal conditions for S90 percent of the storage period. Severe conditions must make up ð10 percent of total storage time.

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magicolor 6100 Series Service Manual

Section 3: Installation

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3.0

Installation 3.1 Conditions for Installation A laser beam printer will be influenced by its environment. If the printer is set up in an inappropriate location, it may not perform as expected. Therefore, the following factors must be taken into consideration prior to deciding where to set up the printer.

3.1.1

Environmental Conditions
The printer should not be set up in the locations referred to by the following items. · Exposed to direct sunlight or similar light. · Areas prone to wide fluctuations in temperature and humidity between the maximum and minimum levels. Normal operation environment is within 50° ~ 95° F (10° C ~ 35° C), 20 ~ 80% RH and without any condensation. · Areas prone to receive cold air from an air conditioner or warm air from a heater, or to receive direct radiant heat. · Areas with high levels of humidity, dust, smoke, oil mist, or ammonia gas. · Areas with poor ventilation. · Unstable surfaces (table, etc.). · Unlevel/uneven surfaces (greater than ±1°). CAUTION

If the printer is installed on a table, make sure that the paper cassette does not protrude beyond the table edge. Protrusion of the paper cassette may cause the printer to tip over if the user leans against, or applies excessive force to, the paper cassette. Fig. 3-1 shows the basic layout of the printer set up location suitable for the smooth operation and maintenance of printer.

Stable Surface

20" (50cm) 8" (20cm) 6.4" (16cm)

8" (20cm)

28" (70cm)

Paper Exit Side

28" (70cm)

32" (80cm)

4" (10cm)

Front Side

Fig. 3-1

magicolor 6100 Series Service Manual

Page 3-3

3.2

Unpacking
WARNING The shipping package is too heavy for one person to carry (143.2 lbs./65 kg). At least two adults are needed to move the printer. Because this printer is a precision machine, carry it carefully, making sure not to bump or jar it excessively. Do not attempt to lift the printer by the vinyl bag. The bag is not designed to hold the weight of the printer. Additionally, the bag is very slippery and if you drop the printer it will be damaged. 3.2.1 Printer Unpacking Procedures

(see Fig. 3-2)
1. 2. 3. 4. 5. 6. 7. 8. Cut two bands (17) around the packing box. Remove the tape (16). Open the upper flap and pull the outer box (1) straight up. Remove the starter kit (6). Remove the upper packing (3) from the four noted locations. Remove the power cord (18). Remove the vinyl bag (5) wrapping the printer. Using at least two people, lift and position the printer on a stable surface.

Page 3-4

magicolor 6100 Series Service Manual

7

8

1
11 12

magicolor 6100 Series Service Manual
9
15 13
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 NAME OF PARTS OUTER BOX BASE UPPER PACKING SILICA GEL VINYL BAG (EN) VINYL BAG (ST) STARTER PACKING SLEEVE STARTER KIT PACKING (U) STARTER KIT PACKING (M) STARTER KIT PACKING (L) VINYL BAG (CASET) VINYL BAG (T) VINYL BAG (OPC) VINYL BAG (CL) VINYL BAG (OIL) TAPE BAND POWER CORD Q'TY 1 1 4 1 1 1 1 1 1 1 1 4 1 1 1 1 2 1

STARTER KIT

6

Fig. 3-2
14

12
Band

3 18
10
POWER CORD (US and JAPAN only)

17 16

5

2 4
BASE PALLET

Page 3-5

3.2.2

Starter Kit Unpacking Procedures

(see Fig. 3-2)
1. Open the vinyl bag covering the starter kit (6). 2. Confirm that all of the following items are contained in the starter kit packing box.

Component Name

Diagram
Y (Yellow)

Toner Cartridges Yellow Magenta Cyan Black

M (Magenta) C (Cyan) K (Black)

OPC Belt Cartridge

Oil Bottle

Cleaning Roller

Cleaning Roller
Siphon

Envelope Adapter

Cassette

Paper Cassette with Envelope Adapter

Page 3-6

magicolor 6100 Series Service Manual

3.2.3

Lower Feed Unit Unpacking Procedures 1. 2. 3. 4. 5. Remove the tape from the top of the carton. Open the box (as shown in Fig. 3-3). Take out the side covers right (5) and left (6). Remove the upper packing material. Take out all lower feeder unit components.

Packing List
6 5

No.

Name of Parts

Quantity 1 1 1 1 1 1

1 Lower Feeder Unit
Upper Packing

2 Paper Cassette
3

3 Set-Up Guide (R) 4 Set-Up Guide (L)

4 1

5 Right Side Cover 6 Left Side Cover

Base

2

23

.5"

23"

9.5"

Fig. 3-3

magicolor 6100 Series Service Manual

Page 3-7

3.2.4

Unpacking the Duplexer 1. 2. 3. 4. 5. Remove the tape from the top of the box. Open the top of the box. Remove the upper packing. Remove the duplex unit. Remove the vinyl bag.
Upper Packing

Vinyl Bag Tape

Weight: Approx. 44 lbs. (20 kg)

Base

Packing Box

Fig. 3-4

Page 3-8

magicolor 6100 Series Service Manual

3.3

Installation Note: Install the unit parts of the starter kit to the printer according to the following procedures: 3.3.1 Procedures for Installation of Cleaning Roller and Oil Bottle

(see Fig. 3-5 to Fig. 3-8).
Note: If a duplexer is installed, open the top cover of the duplexer first. 1. Open the paper exit unit.
Paper Exit Unit Fuser

Fig. 3-5 2. Open the oil bottle and cleaning roller lock levers. Move the tension-release levers (left and right) to the normal operating position (center).
Fuser Oil Bottle

Fig. 3-6 3. Install the oil bottle into the fusing unit.
Cleaning Roller Tension-Release Lever

Lock Lever

Fig. 3-7 4. Close the retainer lock lever. 5. Install the cleaning roller in the fusing unit. 6. Close the cleaning roller retainer lock lever. 7. Close the paper exit unit.
Cleaning Roller Lock Lever

Oil Bottle Lock Lever

Fig. 3-8

magicolor 6100 Series Service Manual

Page 3-9

3.3.2

Procedures for Installation of the OPC Belt Cartridge

(see Fig. 3-9 to Fig. 3-12)
CAUTION Do not touch the OPC belt. Do not expose the OPC belt to direct light because the belt may be ruined. 1. Open the front cover. 2. Open the paper exit unit.

Paper Exit Unit

Front Cover

Fig. 3-9

3. Open the belt cartridge lock levers.

Belt Cartridge Lock Lever (Left)

Belt Cartridge Lock Lever (Right)

Guide

Belt Cartridge Lock Lever

Fig. 3-10

4. Pull and remove the tension release pins from both sides (left and right) from the belt cartridge. 5. Remove the protective sheet from the belt cartridge.

Protective Sheet

Tension Release Pins

Fig. 3-11

Page 3-10

magicolor 6100 Series Service Manual

6. Gently slide the new belt cartridge along the guides into the printer. 7. Close the two belt cartridge lock levers. 8. Close the top door. 9. Close the front door.

Belt Cartridge Lock Lever Guide

Fig. 3-12

3.3.3

Procedures for installation of the toner cartridges

(see Fig. 3-13 to Fig. 3-15)
CAUTION Holding a toner cartridge vertically will adversely affect the print quality. 1. Open the front door. 2. Holding the toner cartridge horizontally, shake it left and right three to four times.

Front Door

Fig. 3-13
Protective Cover

3. Remove the tape from around the protective cover. Remove the protective cover.
Toner Cartridge

Fig. 3-14

4. Install the toner cartridges in this order: Cyan (C), Magenta (M), Yellow (Y), and Black (K). 5. Push each toner cartridge along the guides into the printer until you feel resistance. 6. Close the front door.

K Y M C

Fig. 3-15

magicolor 6100 Series Service Manual

Page 3-11

3.3.4

Procedures for installation of paper cassette and adapter

(see Fig. 3-16 to Fig. 3-19).
3.3.4.1 Paper Cassette
Cassette Cover

1. Remove the cassette cover.

Paper Cassette

Fig.3-16 2. Set the side plate according to the paper size. For the horizontal direction, move the green side plate to meet the paper size position (see Fig. 3-17). For the vertical direction, move the green lever to adjust the end plate to meet the appropriate paper-size position (see Fig. 318).

Fig. 3-17

Fig. 3-18 3. Load paper into the cassette.
PAPER LABEL OHP FILM

Fig. 3-19 CAUTION The capacity of the cassette is dependent upon the type of media used. Keep the volume below the upper limit marked on the label. Overloading media will result in paper feed jams or print quality failure. 4. Install the cassette cover and slide the cassette into the printer.
Page 3-12 magicolor 6100 Series Service Manual

3.3.4.2

Installation procedures for the envelope adapter

(see Fig. 3-20 to Fig. 3-21)
3.3.4.2.1 Specifications of adapter.

Envelope Capacity 15 (7 High Humidity) DL, #10

Optional Post Card 50

Size

10 x 148 mm

Installation: 1. Put the adapter on the cassette base, and latch the hook onto the cassette base. 2. Move the side plate to meet the adapter base. 3. Move the end plate to the desired envelope size. If you have a postcard adapter, move the end plate until it contacts the adapter base. 4. Move the adapter plates to meet the desired envelope size.

Optional Post Card Adapter Japanese Version Only

Envelope Adapter

Side Plate End Plate

CAUTION Do not load the media in the adapter above the specified capacity limit. It may result in a paper feed jam or bad print quality. 5. Load the envelopes in the adapter. 6. Slide the paper cassette into the printer.

Fig. 3-20

magicolor 6100 Series Service Manual

Page 3-13

3.3.4.3

Procedures for removal of the envelope adapter:

1. Remove the paper cassette from the printer. 2. Move the end and side plates out to release the adapter. 3. Lift up the trailing edge of the adapter approximately 10 mm and pull the adapter toward you. 4. Remove the adapter. Fig. 3-21 CAUTION Do not lift up the trailing edge of the envelope adapter forcefully, otherwise, it may result in damaging the hook at the leading edge of the adapter.

Adapter

Cassette Base

Hook

Cassette Base

Fig. 3-22

Page 3-14

magicolor 6100 Series Service Manual

3.3.5

LFU Installation 1. Lay the Lower Feeder Unit (LFU) on a flat and stable surface. Adjust the anchor feet all the way up.

Anchor Feet

Fig. 3-23 2. Pull out the LFU connector cable from the rear left of LFU.

LFU Cable

Fig. 3-24

3. Orient the LFU and the position of the adjuster pins. Verify the position of the claw of the tray latch (see Fig. 3-25).

Adjuster pins Tray Latch

Fig. 3-25 CAUTION The printer weighs approximately 143.2 lbs. (65kg) which is too heavy for one person to carry. At least two adults are needed to move the printer. Because this printer is a precision machine, carry it carefully, making sure not to bump or jar it excessively.

magicolor 6100 Series Service Manual

Page 3-15

4. Lift up the printer with assistance, and mount it on the LFU. A. Slowly lower the printer so its bottom hole meets the adjuster pin of the LFU. B. After placing the printer on the LFU, confirm that all parts meet properly. 5. Couple the printer with the LFU. A. The metal coupler is fixed to the rear left area by a thumbscrew (see Fig. 3-27). B. Loosen the thumbscrew, and hook the leading edge of metal coupler onto the engine base (see Fig. 3-27). C. Tighten the thumbscrew to secure the metal coupler. D. Look into the entrance of the cassette slot for the tray latch at the right front side of the LFU. The tray latch can be pivoted on its set screw.

Printer Engine

LFU

Fig. 3-26

Metal Coupler

Fig. 3-27

Claw

Fig. 3-28 E. Pivot the tray latch so that it is hooked to the engine base.
Claw

Tray Latch

Fig. 3-29

Page 3-16

magicolor 6100 Series Service Manual

6. Connect the LFU interface cable to the printer connection.

Printer Side

Duplexer Connector (Upper, Black)

LFU Connector (Lower, White)

Fig. 3-30

LFU Cable

7. Install the right side cover. Pop in the right side cover (back to front); no mounting hardware is necessary.

Right Side Cover

Fig. 3-31 8. Install the left side cover. Pop in the left side cover; no mounting hardware is necessary.

Left Side Cover

Fig. 3-32

Left Side Cover

Fig. 3-33 9. Adjust the anchor feet for stability. Rotate each anchor foot to move it down, and stop the adjustment when the anchor foot reaches the level surface. 10. Turn the locking nut upward and fix the anchor bolt. CAUTION When lifting the printer, make sure that the connector of the LFU connector cable and tray latch are disconnected before lifting.

Stopper Anchor Foot

Fig. 3-34

magicolor 6100 Series Service Manual

Page 3-17

3.3.6

Installation of the Duplex Unit 3.3.6.1 Preparation of the Printer and Lower Feed Unit

1. Assemble the lower feeder unit on the printer. See the installation instructions for the lower feeder unit

(see section 3.3.5).
3.3.6.2 Preparation of the Printer

1. Remove the paper exit upper cover (see Fig. 3-35).
2. Remove the two caps from the upper rear cover (see Fig. 3-36). 3. Remove left and right LFU side covers (see Fig. 3-37 and Fig. 3-38). 4. Remove the LFU left and right access plates (Fig. 3-39 and Fig. 3-40).

Paper Exit Upper Cover

Caps

Left Side Cover

Fig. 3-35

Fig. 3-36

Fig. 3-37

Right Access Plate

LFU Side Cover

Left Access Plate

Fig. 3-38

Fig. 3-39

Fig. 3-40

Page 3-18

magicolor 6100 Series Service Manual

3.3.6.3

Installation of Duplex Unit. CAUTION Confirm that the jam cover of LFU is securely closed (see Fig. 3-41).

Fig. 3-41 1. While holding the handle, lift up the duplex unit (see Fig. 3-42). CAUTION Pay attention to the duplex top cover because it may be folded in the middle. Pay attention not to get your fingers caught between the hinges of the upper and lower unit. 2. Insert the fixing pins into the sockets of the LFU (see Fig. 3-43 and Fig. 3-44).

Duplexer Handle
Fixing Pin
Fixing Pin

Fig. 3-42

Fig. 3-43

Fig. 3-44

magicolor 6100 Series Service Manual

Page 3-19

3. Attach the hooks (located on each side of the DPU) to the holes of the printer. Install the duplexer (see Fig. 3-44).
Hook

Hole

Fig. 3-45 4. Slowly open the upper unit. 5. Secure the duplexer to the printer with the thumb screws (see Fig. 3-46).
Thumbscrews

Fig. 3-46 6. Close the upper unit. 7. Connect the interface connectors between the DPU and the printer

(see Fig. 3-47 and Fig. 3-48).

Fig. 3-47

Connector Cable

Fig. 3-48

Page 3-20

magicolor 6100 Series Service Manual

8. Install the LFU left side cover (see Fig. 3-49).

LFU Left Side Cover

Fig. 3-49

magicolor 6100 Series Service Manual

Page 3-21

3.3.7

Test Run and Test Print 3.3.7.1 Test Print 3.3.7.1.1 Test Print Details

Operation Test Print See section 3.3.7.1.2 "Test Print Procedures" for details.

Details of Operation Printer has the following built-in print patterns for test printing. 1). Grid Pattern: Available in mono-color print of Y, M, C, K, and two-color print of R, G, and/or B.

GRID

2). Stripe Pattern: Available in color print of Y, M, C, K, R, G, and B.
STRIPE

Page 3-22

magicolor 6100 Series Service Manual

3.3.7.1.2

Test Print Procedures Perform the test print according to the following procedures.

Procedure 1. Turn off the printer. Holding down both scroll keys (Left and Right) and the MENU Key, turn on the printer. 2. Press the SELECT key so that the display changes from screen A) to B). 3. Select "GRID" with the SCROLL keys. Note that you could select the option of printing a "STRIPE" here. 4. Press the SELECT key so that the display changes from screen B) to screen C). 5. Select the color "R" (red) with the SCROLL keys. Note that you could select the option of printing yellow, magenta, cyan, black, red, green, or blue here. 6. Press the SELECT key so that the display changes from screen C) to screen D). This screen will only appear when the optional duplexer is attached. 7. Press the SELECT key so that the display changes from screen D) to screen E). 8. Press the MEDIA key to stop the test print. 9. Repower the printer to bring it back to normal printing mode.
B)

Operator Panel
SERVICE MODE TEST PRINT / NEXT

A)

31 GRID PRT GRID / STRIPE

C)

31 GRID PRT Y/M/C/K/R/G/B

31 GRID PRT D) DUP 1 / 2 / 3 / SIMP

E)

31 GRID PRT YM

F)

MEDIA KEY

3.3.7.1.3

Selection of Media Press the MEDIA key on the operator panel, which selects the media to be used. Select the tray which will hold the media. Operator Call When "Operator Call" is displayed on the operator panel, see the "Operator Call" information in section 8.2.1, and take the necessary actions.

3.3.7.1.4

magicolor 6100 Series Service Manual

Page 3-23

Page 3-24

magicolor 6100 Series Service Manual

Section 4: Theory of Operation

magicolor 6100 Series Service Manual

Page 1-1

Page 1-2

magicolor 6100 Series Service Manual

4.0

Theory of Operation 4.1 Basic Structure 4.1.1 Mechanical and Electrical Structures This laser beam printer consists of five individual systems including: Print, Optical, Transfer, Paper Transport, and Control. See Fig. 4-1 for the sequence of operations. 4.1.1.1 Print System Print system consists of the following six functional subsystems located around the OPC Belt, which form a toner image on the OPC Belt. · Charge · Expose · Development · First Transfer · Discharge · Clean Optical System The optical system consists of the following two functional subsystems. The optical system forms an electrostatic latent images on the OPC belt by scanning the OPC belt with a laser beam. · Optical Unit · Scanner Motor (SCM) Transfer System The transfer system consists of the following three functional subsystems, which transfer the toner image formed on the transfer drum to the paper. · Transfer Drum · Second Transfer · Drum Cleaner Paper Transport System The paper transport system consists of the following five functional subsystems, which pick up a page from the paper cassette, separate the paper from the transfer drum, and feed it from the printer after fusing the toner image on the transported paper. · Paper Cassette · Transport · Paper Discharger · Fuser · Paper Exit

4.1.1.2

4.1.1.3

4.1.1.4

magicolor 6100 Series Service Manual

Page 1-3

Main Motor MM Developer Motor Paper Exit Drum Cleaner Paper Exit DM Toner Cartridge Drum Cleaning Operation OPC Belt K Development Transfer Unit AC Discharger Unit Transfer Roller Second Transfer Discharge Resistration Roller Transport Roller Erase Lamp Clean Paper Feed Paper Cassette Charge DC Charger Paper Discharger Transfer Drum First Transfer Expose Optical Unit LD Laser Diode SCM Y M C

Video Controller

Fuser Fix

MCTL I/F Control

Sequence Control

Laser Control

Scanner Moter

Fig. 4-1

Page 1-4

magicolor 6100 Series Service Manual

4.1.1.5

Control System The control system consists of the following four control logic functions which run the printer by processing the interface signals transmitted from the host and each subsystem such as the print, transfer, optical, transport system. · · · · Sequence Control Laser Control Fusing Temperature Control Interface Control

4.1.2

Basic Mechanism of Color Printing 4.1.2.1 Principle of Color Printing Color printing uses the subtractive color theory process by combining three primary colors, yellow, magenta, and cyan (Fig. 4-2 shows the three primary colors and subtractive process).

C G K M R Y
Y: Yellow M: Magenta C: Cyan R: Red G: Green B: Blue K: Black

B

Fig. 4-2 4.1.2.2 Basic Process of Color Printing · The printer has a yellow, magenta, cyan, and black toner cartridge (see Fig. 4-3). · The toner image is developed by cyan, yellow, and magenta toner. Combinations of toner, moved to the transfer drum, develops different colors (see Fig. 4-4).

OPC Belt Toner Cartridge Transfer Drum K Y M C

Fig. 4-3

magicolor 6100 Series Service Manual

Page 1-5

· The toner image formed on the transfer drum is transferred to paper (see Fig. 4-4). · The toner is fused to the paper by the fuser unit. This process fixes the toner image onto the paper (see Fig. 4-4).

First Transfer

Toner

MMM C C C Y YY C C Y YY Transfer Drum

Second Transfer
Y Y Y YY Y MMM C C C C C Paper

Fusing
Red R Cyan C Green G

Paper

Fig. 4-4

4.1.3

Structure of the OPC Belt The OPC belt consists of a surface layer of photoconductor OPC/organic material, an inner layer of an insulator material (PET), and the aluminum deposit layer in between (see Fig. 4-5). The OPC belt is a main part of the print system (see Fig. 46).
Electrode Photoconductor(OPC)

Aluminum Deposit Layer Insulator Material (PET)

Fig. 4-5
Belt Cartridge Toner Cartridges OPC Belt

K Transfer Drum Y M C

Fig. 4-6

Optical Unit

Page 1-6

magicolor 6100 Series Service Manual

4.2

Print System and Transfer/Transport System Fig. 4-7 shows the basic systems of the printer.

1 Charging

2 Exposing
Print System

KCMY

6

OPC Belt Cleaning

3 Developing

KCMY

5

Belt Discharge

KCMY OPC Belt 4 Transfer Drum (First Transfer) Transfer Drum K C M Y

Transfer System

7 Second Transfer (Paper)

9

Transfer Drum Cleaning

8

Paper Discharge

10 Fusing
Transport System

11 Paper Exit
Fig. 4-7

magicolor 6100 Series Service Manual

Page 1-7

4.2.1

Structure of Printer

Name of Component Charger Optical Unit Toner Cartridge Belt Cartridge Transfer Drum Belt Discharger Erase Lamp Cleaning Blade Transfer Roller Paper Discharger Drum Cleaner Fuser Unit Paper Exit Unit

Function Charges the OPC. Exposes the OPC. Develops the latent image on the OPC. Receives Latent Images and transfers developed images to the Drum. Transfers Image to Paper. Discharges the OPC Belt. Cleans the OPC Belt. Transfers Toner Image to the Paper from the Drum. Separates the Paper from the Drum. Cleans the Drum. Fuses the Toner to the Paper. Ejects Paper into the Paper Exit Tray.

Drum Cleaner Belt Cartridge Paper Exit Unit

Toner Cartridges

K Y M

Fuser Paper Discharger Transfer Roller

C

Transfer Drum Cleaning Blade Erase Lamp
Fig. 4-8

Charger Optical Unit

Page 1-8

magicolor 6100 Series Service Manual

4.2.2

Basic Structure of the Printing System The toner image is formed by the potential of the OPC belt varying with each of the processes. They are charging, exposing, development, transfer, and cleaning. 4.2.2.1 Processes of the Print System

(see Fig. 4-9)
The OPC belt is biased to the voltage of -CBV by the HVPS (CBV). The negative high voltage is applied to the charger unit by the HVPS (CBV), and an electrostatic charge is generated. The developer Roller of the toner cartridge is biased to -DBV by the HVPS (DBV). The frame potential of the transfer drum is GND.
Cleaning Unit FCBV Fuser Unit Toner OPC Belt
Toner Cartridge

K Develop Paper Discharger

Transfer Drum

Y

M ACHV Transfer Roller THV (+) THV ( - ) Cleaning Paper Erase Lamp
Brade

DBV C CBV Optical Unit Charger CHV ZDV Po

Fig. 4-9

magicolor 6100 Series Service Manual

Page 1-9

4.2.2.2

Variation of the OPC Belt's Potential

(see Fig. 4-10).
The OPC belt is biased to -CBV. The OPC belt's surface is evenly charged to V0 in the process of charging. The potential of the OPC belt is discharged to -VR as it is exposed to the laser beam. An electrostatic latent image is formed on the OPC belt. Negatively charged toner is attracted to the OPC belt in the development process due to the difference of potential between -VR and -DBV, and the visible image is now formed. Negatively charged toner on the OPC belt is moved to the transfer drum in the transfer process because the potential GND of the transfer drum is greater than -VR(V) of OPC belt. The OPC belt is discharged by the erase lamp shining on the OPC belt.

Process

1

2

3

4
Transfer Drum GND

5

OV - CBV - VR Toner Toner Dev. Roller 1 Charging Process 2 Exposing Process Charger 3 Developing Process 4 Transferring Process 5 Cleaning (Erasing Process) CBV CHV DBV CBV Voltage for OPC Belt Bias CHV Voltage for Charging DBV Voltage for Dev. Roller Bias VR Remaining Voltage on the OPC Belt

OPC Belt
- VO

DBV

Fig. 4-10

Page 1-10

magicolor 6100 Series Service Manual

4.2.3

Details of Each Process 4.2.3.1 Charging The charging process means that the OPC belt is evenly charged by the charger. 4.2.3.1.1 Structure of the Charger Unit (see Fig. 4-11). The charger unit is located as shown in Fig. 4-11. The charger unit consists of the case, corona wire and grid (see Fig. 4-11). The grid is constructed to allow for uniform charging. The charger unit charges the OPC belt surface to the potential -V0.
Grid Corona Wire

ZD Case CBV CHV

Fig. 4-11 4.2.3.1.2 Process of Charging (see Fig. 4-12) The OPC belt is biased to -CBV. The charger unit generates a negative charge and uniformly charges the surface of the OPC belt.

-V0

Cleaning (Blade)

Charging

Fig. 4-12

magicolor 6100 Series Service Manual

Page 1-11

4.2.3.2

Exposing During the exposing process, the OPC belt surface is exposed by a laser beam, which forms an electrostatic latent image. 4.2.3.2.1 Structure of the Optical Unit The optical unit is located as shown in Fig. 4-8. The source of the laser beam is a semiconductor laser. The laser beam is transformed into a beam of light by the optical unit. Scanning over the OPC belt creates an electrostatic latent image. Process of Exposing (see Fig. 4-12) The OPC belt surface has been charged to the potential -V0. The laser beam scans across the OPC belt as the belt moves in its forward direction. The image data transmitted from the host switches the laser on and off. The areas exposed to the laser are discharged to the potential of -VR. An invisible electrostatic latent image is formed on the OPC belt (see Fig. 4-12).

4.2.3.2.2

-V R -V O

Charging

Exposing

Fig. 4-13

Page 1-12

magicolor 6100 Series Service Manual

4.2.3.3

Developing Developing is defined as a process to develop the electrostatic latent images that have been transferred onto the OPC belt by using toner. 4.2.3.3.1 Structure of the Toner Cartridge (see Fig. 4-8) Toner cartridge is located as shown in Fig. 4-8. Four toner cartridges are used. The order of the toner cartridges from top to bottom is black, yellow, magenta and cyan. Process of Developing (see Fig. 4-8, and Fig. 4-14 to Fig. 4-16) Toner adheres to the developer roller of the toner cartridge. Development occurs when the developer roller contacts the OPC belt surface. The developer roller has been biased to the potential -DBV. Fig. 4-14 shows the relationship established between the potential of the toner, the potential -Vo at the non-exposed area of OPC belt and the potential -VR at the exposed area of OPC belt. Potential of the exposed area is positive relative to the potential of the toner. Therefore, toner is attracted to the OPC belt, where the development takes place. Potential of the unexposed area has the same polarity as the toner. Therefore, the toner is repelled by the surface of the OPC belt, where no development takes place.
Dev.roller (-CBV)+(-DBV)

4.2.3.3.2

Toner (-CBV)

O PC Be l t

DBV

CBV

Fig. 4-14

magicolor 6100 Series Service Manual

Page 1-13

OPC Belt Dev. roller

Toner Cartridge

Toner

Toner

Toner

Fig. 4-15

Toner(M)

Y
Exposing

M
Fig. 4-16

C

K

Developing

Page 1-14

magicolor 6100 Series Service Manual

4.2.3.4

First Transfer (Drum) First transfer is defined as the process which moves the toner images from the OPC belt to the transfer drum. 4.2.3.4.1 Structure of the Drum Transfer (see Fig. 4-8 and Fig. 4-17) The drum transfer components are shown in Figure 4.8. The drum is made of aluminum. The drum surface is coated with rubber as shown in Fig. 4-17. The transfer drum rotates, synchronously maintaining contact with the OPC belt.

Transfer Drum

Aluminum

Rubber

Fig. 4-17

magicolor 6100 Series Service Manual

Page 1-15

4.2.3.4.2

Process of First Transfer (see Fig. 4-18) The OPC belt comes in contact with the transfer drum, and rotates synchronously with the transfer drum. The OPC belt is biased to the potential of -CBV. The potential of the transfer drum is near ground. The toner on the OPC belt is moved to the transfer drum due to the difference of potential between the OPC belt and the transfer drum. Each color toner is developed and transferred onto the transfer drum. Two toner images are overlapped on the transfer drum. After the drum transfer process is complete, the toner images are transferred onto the paper.

OPC Belt

Residual Charge Residual Toner

Belt Belt Cleaning Discharging (Brade) DrumTransferring (Erase Lamp) Fig. 4-18

Page 1-16

magicolor 6100 Series Service Manual

4.2.3.5

Belt Discharging (Erase Lamp) Belt discharging is defined as a process in which the erase lamp shines LED light onto the OPC belt, and discharges the residual charge for the electrical cleaning. 4.2.3.5.1 Structure of the Erase Lamp The erase lamp to be used in the belt discharging process (see Fig. 4-8). The light source of the erase lamp consists of 24 light emitting diodes (LED). Process of Discharging (see Fig. 4-19) The toner image on the OPC belt is transferred onto the transfer drum; however, residual toner and residual electric charge still remain on the OPC belt. The residual electric charge is discharged by shining LED light onto the OPC belt prior to proceeding to the next process.

4.2.3.5.2

Drum Transferring

Belt Discharging (Erase Lamp)

Belt Cleaning (Brade)

Fig. 4-19

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4.2.3.6

Belt Cleaning Belt cleaning is defined as process to remove the residual toner attached to the surface of the OPC belt. 4.2.3.6.1 Structure of Belt Cleaning The blade for the belt cleaning is located on the belt cartridge (see Fig. 4-8). Process of Belt Cleaning (see Fig. 4-19) Residual toner is defined as the remaining toner on the OPC belt that has not been transferred through the drum transfer process. The belt cleaning blade is used to mechanically scavenge the residual toner from the surface of the OPC belt. Scavenged residual toner is collected and sent to the waste toner pack by the waste toner auger.

4.2.3.6.2

Drum Transferring

Belt Cleaning B Erase Lamp

Fig. 4-20

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magicolor 6100 Series Service Manual

4.2.3.7

Second Transfer (Paper) Second transfer (paper) is defined as a process to transfer toner images from the transfer drum onto paper. 4.2.3.7.1 Structure of Second Transfer The transfer roller for the second transfer is located as shown in Fig. 4-8. The transfer roller is normally separated from the transfer drum. The transfer roller is positively biased by the power supply THV. The transfer roller contacts the transfer drum during the paper transfer process. Transported paper passes between the transfer roller and the transfer drum. Process of Second Transfer (see Fig. 4-21) Paper is transported in synchronization with the transfer drum. The transfer roller contacts the transfer drum. Transported paper passes between the transfer roller and transfer drum. In this instance, positive high voltage (THV) is applied to the transfer roller. Negatively charged toner is attracted to the positively charged paper. After of the paper transfer, the transfer roller moves away from the transfer drum.

4.2.3.7.2

Paper Discharger

Transfer Roller

Transfer Drum VAC: Power Supply for Paper discharging THV: Power Supply for Transfer Roller Bias

Toner Image VAC THV Paper

Fig. 4-21

magicolor 6100 Series Service Manual

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4.2.3.8

Paper Discharging Paper discharging is defined as the process of applying an AC charge to the paper to separate it from the transfer drum. 4.2.3.8.1 Structure of Paper Discharge (see Fig. 4-21) The AC charger unit for discharge of paper is located as shown in Fig. 4-8. The AC charger unit consists of the case and charger wire. The high AC voltage (VAC) is applied to the AC charger unit. 4.2.3.8.2 Process of Paper Discharge (see Fig. 4-22) In the transfer process, the paper tends to stick to the transfer drum due to the potential of the transfer drum. An AC charge generated by the AC charger unit is applied to the transported paper which neutralizes or discharges the paper. The transported paper is separated from the transfer drum and transported to the fuser.

Paper Discharger

Transfer Roller

Transfer Drum

Toner VAC THV
Fig. 4-22

Paper

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magicolor 6100 Series Service Manual

4.2.3.9

Drum Cleaning Drum cleaning is defined as a process to remove residual toner from the surface of the transfer drum. 4.2.3.9.1 Structure of Drum Cleaning (see Fig. 4-23) The drum cleaning unit is located as shown in Fig. 4-8. A conductive cleaning brush rotates and cleans the surface of the transfer drum. The drum cleaning roller is positively biased by the positive voltage FCBV. FCBV is injected into the cleaning brush as well, and the cleaning brush is self-biased by the resistance of the brush. The cleaning roller rotates in contact with the brush. Process of Drum Cleaning (see Fig. 4-23) Residual toner remains on the surface of the transfer drum after the paper transfer process. As the cleaning brush is biased to +FBBV, the brush attracts and removes the residual toner from the surface of the transfer drum while it is rotating. As the cleaning roller is biased as +FCBV > +FBBV, the residual toner attracted into the brush is attracted to the cleaning roller. The residual toner attracted to the surface of the cleaning roller is removed by the cleaning blade and moved to the waste toner bottle by the waste toner auger.

4.2.3.9.2

Cleaning Brush

Cleaning Roller

Waste Toner Feeder Residual Toner FCBV Drum Cleaning Unit Transfer Drum

FCBV: Cleaning Roller Power Supply for cleaning Roller Bias

Fig. 4-23

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4.3

Optical System The printer uses a semiconductor laser diode as a light source. The laser diode is controlled on the basis of image data (video signal) through high-speed switching. The emitted laser beam is scanned over the OPC belt through a polygon mirror and lens. An electrostatic latent image is formed on the OPC belt. 4.3.1 Structure of the Optical System

(see Fig. 4-24)
The optical unit consists of following parts.

Number 1 2 3 4 5 6 7 8 9

Name of Component Laser Unit Cylinder Lens Polygon Mirror F-Ø Lens Scanner Motor Mirror LDC (Laser Diode Control) PD (Photodetector Sensor) BTD Mirror (Beam Timing Detect) Emits a laser beam. Condenses the laser beam.

Function

Scans the laser beam across the OPC. Focuses the laser beam. Rotates the polygon mirror. Reflects the laser beam. Controls circuitry for the laser diode Used to detect laser beam start position. Guides the laser beam to the PD.

Optical unit box 8 6 4 2 Dust-proof glass 9

5 3 Developer belt

2 1 7

Fig. 4-24
Page 1-22 magicolor 6100 Series Service Manual

4.3.2

Specifications of the Optical Unit The specifications of the optical unit are described as follows:

Component Rated Output of Laser Diode Wave Length of Laser Beam Scanning Density Scanning Width Rotations Per Minutes of Scanner Motor Number of Polygon Mirror Faces

Specification 5 mW Approximately 785 nm. 600 dpi. 310 mm. 24,072 rpm. 6

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4.4

Paper Transportation System 4.4.1 Outline The printer employs an automatic paper-feeding feature with the paper cassette. When toner images are formed on the transfer drum through the print system and the transfer system, a page is fed by the pick-up roller and transported to the registration roller. The registration roller carries the transported page to each unit in the proper order (the transfer unit, fuser, and paper exit unit) while synchronizing with the rotation of the transfer drum. Structure of the Paper Transportation System

4.4.2

(see Fig. 4-25)
The paper transportation system consists of the following parts.

Number 1 2 3 4 5 6 7

Name of Component Paper Cassette Pick-Up Roller Registration Roller Transfer Paper Discharger Unit Fuser Unit Paper Exit Roller Holds paper

Function

Separates and feeds paper one sheet at a time. Transports paper while synchronizing with the transfer drum. Carries out the print process by transferring toner images onto the pages. Consists of the transfer drum and roller. Separates the attached paper from the transfer drum by charging the AC corona. Melts the toner images on the paper with the heat roller. The process fuses these toner images onto the paper. Ejects the page from the printer after the paper fusing process is complete.

7

6

5 4 3

2

1

Fig. 4-25
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4.5

Fuser The Fuser employs a thermal fusing system - a heater in the roller. Paper carrying the toner images passes between the heat rollers. A combination of heat and pressure is applied to a page when it passes between the heat rollers so that the toner image is melted and fused on the paper (see Fig. 4-26). 4.5.1 Structure The Fuser consists of the following components:

Number 1 2 3 4 5 6 7

Name of Component Fusing Roller Back-Up Roller Fusing Heater Thermistor Thermal Fuse Oil Bottle Cleaning Roller

Function Heats toner with a quartz halogen lamp. Applies pressure and also contains a heater. Heated by the halogen lamp. Detects the temperature of the fuser roller's surface. Prevents the fuser roller from being overheated. Houses the silicone oil for fusing. Cleans the fuser roller.
7 4 1

6 2

5

Fig. 4-26

3

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4.5.2

Process of Fusing

(see Fig. 4-27)
Silicone oil, supplied from the oil bottle, is applied to the surface of the fuser roller and back-up roller. The toner image is transferred onto the paper, but is not yet fused to the paper. The transported paper passes between the fuser roller and back-up roller. Each roller is heated up to approximately 150° C, and receives approximately 156N from the opposite heat roller. When the paper carrying the toner image passes between the two rollers, the toner image is melted and fused on the paper. The paper carrying the fused image is separated from the heat rollers and ejected from the printer.
M: Magenta toner Y : Yellow toner C : Cyan toner

Before Fusing

Toner Image

M Y M

C Y
Paper

R : Red M: Magenta G: Green Fixed Toner

After Fusing

R

M
Fig. 4-27

G

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magicolor 6100 Series Service Manual

4.6

Structure of the Control System 4.6.1 Electrical System and Function Most of the main electrical components of this printer are controlled by the MCTL P.W.B. 4.6.1.1 Overview of the Structure of the Sequence Control The basic structure of the sequence control is shown in Fig. 4-28.

Number 1 2 3 4 5 6 7

Control Component Print Process Control Laser Output Control Fuser Temperature Control Toner Sensing Control Interface Control Operator/Control Panel Error Control

Function Controls the print process through the paper feeding, printing, and transport. Automatically controls the laser output. Controls the fusing heater so that the fuser roller and backup roller maintain the set temperature. Senses the absence or presence of toner. Processes I/O signals to and from the external controller (host). Displays the printer operation status on the panel. Stops the printer safely, and displays the status of the defects if any error occurs with the printer.

magicolor 6100 Series Service Manual

Page 1-27

Operator Panel Host Computer Belt Sensor Drum Sensor

Main Motor Cooling Fan DM Cooling Fan

Scanner Motor

Y

M

C

K

LDU

PD

I/F Sequence Control I/F Controller Control Temperature Control Toner Empty Sensing Control Operator Panel Control Error Processing Control CPU

Laser Control

Cleaning Roller Sensor High Voltage Unit Oil Sensor Fusing Unit DC Power Supply Unit Interlock Switch

Paper Sensor Paper Feed Sensor Paper Empty Sensor Paper Size Sensor Paper Exit Sensor OHP Sensor Drum Jam Sensor Cleaning Roller Sensor

Drum Encoder

Belt Sensor

Oil Sensor

Paper Full Sensor

Waste Toner Sensor

Toner CG Sensor

Developer Sensor

Page 1-28

Paper Full Sensor

Fig. 4-28

magicolor 6100 Series Service Manual

4.6.1.2

Layout and Function of Electrical Components 4.6.1.2.1 Print P.W.B. (see Fig. 4-29)

Number 1

Component MCTL P.W.B.

Function Controls a series of processes of the Printer: Fuser Temperature Control, Laser Output Control, Operator Panel Indication, Toner Empty Sensing Control, Error Processing Control, Interface Control. Displays the Printer's operation status. Controls the drive and output of the laser diode. Detects the laser diode emission and the position of its beam (included in the optical unit). Discharges the OPC belt by shining the LED beam onto the OPC belt (included in the optical unit). Relays the signals between the controlled parts and MCTL P.W.B., and drives the controlled parts. Relays the signals between the controlled parts and MCTL P.W.B., and drives the controlled parts. Provides the printer with the power for the printer control. Provides the printer with the high-voltage power necessary for the printing process.

2 3 4 5 6 7 8 9

Panel P.W.B. LDU P.W.B. PDU P.W.B. Erase Lamp IOD1 P.W.B. IOD2 P.W.B. Lo