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IP-304
SERVICE HANDBOOK
February, 2001
Ver. 1.0
KONICA CORPORATION
TECHNOLOGY SUPPORT CENTER
TOKYO JAPAN
KCSI30410
COPYRIGHT ©2001
KONICA CORPORATION
All rights reserved
MF13MP0650
Safety and Important Warning Items
SAFETY AND IMPORTANT WARNING ITEMS
Read carefully the Safety and Important Warning Items described below to understand them before
doing service work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this equipment, as well as the
risk of damage to the equipment, Konica Corporation, strongly recommends that all servicing be
performed only by Konica-trained service technicians.
Changes may have been made to this equipment to improve its performance after this service
handbook was printed. Accordingly, Konica Corporation, makes no representations or warranties,
either expressed or implied, that the information contained in this service handbook is complete or
accurate. It is understood that the user of this service handbook must assume all risks or personal
injury and/or damage to the equipment while servicing the equipment for which this service hand-
book is intended.
Therefore, this Service Handbook must be read carefully before doing service work both in the
course of the technical training and even after that, for keeping the correct maintenance and control
of the copying machine. Keep the Service Handbook also for the future service. When it is impos-
sible to read the description about safety and warning (due to contamination or tear), the relevant
page should be replaced.
DESCRIPTION ITEMS FOR Danger, Warning AND Caution
In this Service Handbook, each of three expressions, " Danger, Warning and Caution" is
defined as follows together with a symbol mark to be used in a limited meaning.
When servicing, the relevant works (disassembling, assembling, adjustment, repair and mainte-
nance) need to be conducted with utmost care.
Danger: Actions having a high possibility of suffering death or serious
wound
Warning: Actions having a possibility of suffering death or serious wound
Caution: Actions having a possibility of suffering a slight wound, medium
trouble and material damage
C-1 PRINT CONTROLLER
Safety and Important Warning Items
SAFETY WARNINGS
q MODIFICATIONS NOT AUTHORIZED BY Konica
Konica copiers are renowned for their high reliability. This reliability is achieved through high-quality
design and a solid service network.
Photocopier design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving at
proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk
of degrading performance and safety. Such modifications are therefore strictly prohibited. The points
listed below are not exhaustive, but they illustrate the reasoning behind this policy.
Prohibited Actions :
(1) Using extension cables or a different power cord than specified by Konica.
(2) Using other fuses than specified by Konica. Safety will not be assured, lead-
ing to a risk of fire and injury.
(3) Disabling fuses or bridging fuse terminals with wire, metal clips, solder or
similar. (This applies also to thermal fuses.)
(4) Removing air filters (except for replacement).
(5) Disabling relay functions (such as wedging paper between relay contacts,
etc.).
(6) Disabling safety functions (interlocks, safety circuits, etc.). Safety will not be
assured, leading to a risk of fire and injury.
(7) Performing actions to copier not described in the instruction manual or the
service handbook.
(8) Using parts other than specified by Konica.
q CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE
Konica copiers are extensively tested before shipping, to ensure that all applicable safety stan-
dards are met, in order to protect the customer and customer engineer from the risk of injury.
However, in daily use, any electrical equipment will be subject to parts wear and eventual failure. In
order to maintain safety and reliability, the customer engineer must perform regular safety checks.
Caution :
(1) Wear clothing that facilitates work and is designed for safety.
(2) Carry out all procedures carefully to prevent injury.
(3) Be sure to disconnect the power cord of the copier and all optional equip-
ment from the AC outlet.
Simply turning off the power switch is not sufficient, because paper feed
units or other electrical equipment may be powered also when the power
switch is turned off.
(4) Proceed with special care when performing operation checks or adjustment
while the unit is powered. When carrying out operation checks or adjust-
ment while external covers are removed, the risk of electrical shock exists
when touching parts which carry high voltage or electrical charge. The risk
of injury exists when touching moving parts such as gears or chains.
C-2 PRINT CONTROLLER
Safety and Important Warning Items
The following list is not exhaustive, but it includes actions which must be carried out at every ser-
vice call.
Caution :
(1) Check external covers and the frame for sharp edges, burrs, or nicks.
(2) Check external covers and hinges for loosening or damage.
(3) Check wiring for squeezing or damage.
(4) Check power cord for insulation problems (conductor must not be exposed).
(5) Check that power cord is properly connected.
Warning :
(1) Verify that the copier is properly grounded. If a problem is detected, estab-
lish a proper ground connection.
(2) Connecting the ground lead to an improper point such as listed below re-
sults in a risk of explosion and electric shock.
Unsuitable ground points:
- Gas pipe
- Lightning rod
- Telephone line ground
- Plastic water pipe or water pipe or faucet that has not been approved by
authorities for grounding use
q PRECAUTIONS FOR ON-SITE SERVICE
Caution :
(1) Before performing maintenance work, read all relevant documentation (ser-
vice handbook, technical notices, etc.) and proceed according to the pre-
scribed procedure, using only the prescribed tools. Do not carry out any
adjustments not described in the documentation.
(2) If the power cord is damaged, replace it only with the specified power cord.
If the power cord insulation has been damaged and there are exposed sec-
tions, short-circuits and overheating may occur, leading to a serious fire risk.
(3) Do not route the power cord so that it can be stepped on or pinched. Other-
wise overheating may occur, leading to a serious fire risk.
(4) When disconnecting any cables, always grasp the connector and not the
cable (especially in the case of AC and high-voltage leads).
(5) Carefully remove all toner remnants from electrical parts, electrodes, etc.
(6) Make sure that wiring cannot come into contact with sharp edges, burrs, or
other pointed parts.
(7) Double-check to make sure that all screws, components, wiring, connec-
tors, etc. that were removed for maintenance have been reinstalled in the
original location. (Pay special attention to forgotten connectors, pinched
cables, forgotten screws, etc.)
(8) When installation and preventive maintenance, verify that the power cord
has been securely plugged into the AC outlet. Contact problems may lead
to increased resistance, overheating, and the risk of fire.
Warning :
(1) Before disassembling or adjusting the optical unit or any parts that use a
laser, make sure that the power cord has been disconnected.
C-3 PRINT CONTROLLER
Safety and Important Warning Items
(2) Do not remove the main cover of the write unit. Direct exposure of the eye to
laser beams may lead to blindness.
(3) Do not turn the copier on while the write unit is not installed in its normal
position.
(4) Danger of explosion if battery is incorrectly replaced, replace only with the
same or equivalent recommended by the manufacturer. Discard used bat-
teries according to the manufacture's instructions.
Vorsicht :
(4) Expiosionsgefahr dei unsachegemäßem Austausch der Battetie. Ersatz nur
durch denselben oder einen vom. Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
q HANDLING OF MATERIALS FOR SERVICING
Caution: Drum cleaner (alcohol-based) and roller cleaner (acetone- based) are
highly flammable and must be handled with care.
When using these materials for cleaning of copier parts, observe the
following precautions.
(1) Disconnect the power cord from the AC outlet.
(2) Use only a small amount of cleaner at a time and take care not to spill any
liquid. If this happens, immediately wipe it off.
(3) Perform cleaning only in an environment where sufficient ventilation is assured.
Breathing large quantities of organic solvents can lead to discomfort.
(4) Do not replace the cover or turn the unit on before any solvent remnants on
the cleaned parts have fully evaporated.
Caution: Toner and developer are not harmful substances, but care must be
taken not to breathe excessive amounts or let the substances come
into contact with eyes etc.
If this happens, immediately rinse with eye wash and plenty of water,
and consult a physician.
q MEASURES TO TAKE IN CASE OF AN ACCIDENT
(1) If an accident has occurred, the distributor who has been notified first must
immediately take emergency measures to provide relief to affected persons
and to prevent further damage.
(2) If a report of a serious accident has been received from a customer, an on-
site evaluation must be carried out quickly and Konica Corporation must be
notified.
(3) To determine the cause of the accident, conditions and materials must be
recorded through direct on-site checks, in accordance with instructions is-
sued by Konica Corporation.
q CONCLUSION
Safety of users and customer engineers has topmost priority, ranking even higher than operability.
Safety depends on a appropriate maintenance work and is maintained by proper daily service work
conducted by customer engineers. When performing service, each copier on the site must be
tested for safety. The customer engineer must verify the safety of parts and ensure appropriate
management of the equipment.
C-4 PRINT CONTROLLER
Contents
CONTENTS
1. Overview
s Product Specifications ................................................................................ 1-1
s Product Overview ......................................................................................... 1-3
q Features of the IP-304 ....................................................................................................... 1-3
q Setup Sequence of the Main Body Printer and the Print Controller ............................ 1-4
q Data Flow ........................................................................................................................... 1-5
q Expanding the Print Controller's Memory ...................................................................... 1-6
2. Assembly / Disassembly
s Overall Construction .................................................................................... 2-1
s Disassembly/Assembly Workflow ............................................................... 2-2
s Disassembly/Assembly Procedures ........................................................... 2-3
[1] Removing the Left and Right Side Covers .................................................................... 2-3
[2] Removing Cards .............................................................................................................. 2-5
[3] Removing the Power Supply Unit .................................................................................. 2-8
[4] Removing/Installing the Memory DIMM ....................................................................... 2-14
[5] Removing the Disk Drives ............................................................................................ 2-16
[6] Removing the CPU and the Heat Sink ......................................................................... 2-19
[7] Removing/Installing the Motherboard ......................................................................... 2-21
[8] Removing the Front Cover ............................................................................................ 2-25
[9] Removing the Fan ......................................................................................................... 2-26
3. Troubleshooting
s Troubleshooting............................................................................................ 3-1
[1] Troubleshooting the Print Controller and the Main Body Printer ................................ 3-1
4. Diagnosis of Print Controller
s Corrective Diagnostics Program ................................................................ 4-1
s Using Corrective Diagnostics Program ..................................................... 4-1
[1] Basic Operations of Corrective Diagnostics Program ................................................. 4-1
[2] Diagnostic Test Screen and Diagnostic Test-Interrupted Screen ................................ 4-2
[3] Starting Corrective Diagnostics Program ..................................................................... 4-3
[4] Ending Corrective Diagnostics Program ...................................................................... 4-3
PRINT CONTROLLER C-5
Contents
s Workflow for Print Controller Diagnostics ................................................. 4-4
s Checking System Profile ............................................................................. 4-5
s Hardware Diagnostics .................................................................................. 4-6
[1] Memory Diagnostics ....................................................................................................... 4-6
[2] Floppy Disk Drive Diagnostics ....................................................................................... 4-9
[3] CPU Diagnostics ............................................................................................................ 4-10
[4] Hard Disk Drive Diagnostics ........................................................................................ 4-10
s Diagnostics on Other Hardware ................................................................ 4-11
[1] Display Diagnostics (with a resolution of lower than 640*480) ................................. 4-11
[2] Display Diagnostics (with a resolution of 640*480 or higher) ................................... 4-12
[3] Motherboard Diagnostics ............................................................................................. 4-13
s Error Identification and Countermeasures .............................................. 4-14
[1] LOG UTILITIES ............................................................................................................... 4-14
[2] Error Status and Countermeasures ............................................................................. 4-16
s Other Features ............................................................................................ 4-20
[1] RUNNING TEST .............................................................................................................. 4-20
[2] Programming RUNNING TEST ...................................................................................... 4-22
[3] CHILD PROCESS ........................................................................................................... 4-27
[4] DISK UTILITIES .............................................................................................................. 4-29
s Corrective Diagnostics Program Menus List........................................... 4-30
Appendix
[1] Guide for Installing the Print Controller Software .......................................... Appendix-1
[2] Jumper on the Motherboard ............................................................................. Appendix-6
[3] Beep Codes ........................................................................................................ Appendix-7
[4] Limitation ........................................................................................................... Appendix-7
[5] 25 Mode .............................................................................................................. Appendix-8
[6] Handling Motherboard of the Print Controller ................................................ Appendix-9
INDEX ............................................................................................................. Index-1
C-6 PRINT CONTROLLER
1
Overview
Blank Page
Chapter 1 Overview
s Product Specifications
Type: External type for the Konica 7065/7055 printer/copier
Paper: 5.5" x 8.5" / 8.5" x 11" / 8.5" x 14" / 11" x 17" / A3 / A4 / A5 / B4 /
B5 / B6 / F4
Paper Feeding and
Amount of Feeding Paper: The same as the copier
Load Output Paper: The same as the copier
Mode: Dual operation of the Copier and the Printer is available.
(2 jobs can be processed at the maximum.)
Special Printing: Duplex, Offset, Staple, Punch, Combination (Booklet, 2-in-1),
Fold & Stitch, Trim, Front/Back Cover, Wait Mode,
Layout (pages per sheet), Password Print, etc.
Orientation: Portrait, Landscape
Resolution: 400 x 400 dpi, 600 x 600 dpi
Gradation: 1 bit
Printable Area: Normal paper size:
Head / Foot / Right / Left Margins: 2.5 mm
No. of Print: 1 to 999
Printing Speed: 65 ppm / A4, 8.5" x 11" (Konica 7065: 400 x 400 dpi)
55 ppm / A4, 8.5" x 11" (Konica 7065: 600 x 600 dpi)
55 ppm / A4, 8.5" x 11" (Konica 7055: 400 x 400 dpi)
55 ppm / A4, 8.5" x 11" (Konica 7055: 600 x 600 dpi)
Warm-up time: The same as the copier
Fast print time: The same as the copier
Basic Configuration
Control Board
CPU: Pentium Celeron 600 MHz
System Memory: 64 MB SD-RAM (Standard),
Expandable up to 256 MB (option: MU-401)
Interface: Parallel port Centronics (IEEE 1284)
amphenol 25 pin male connector
Network Interface (option): KN302A: Ethernet (100BaseTX / 10BaseT)
Protocol: IPX/SPX (NetWare)
TCP/IP (LPD/LPR, Peer to Peer)
AppleTalk (EtherTalk)
PRINT CONTROLLER 1-1
Chapter 1 Overview
Printer Language: PCL5e
Adobe PS3 (option: PS-332)
Built-in fonts: Agfa Microtype fonts
Compliant OS: Windows 95/98/Me
Windows NT 4.0/2000
Mac OS 7.1 or more (optional PS3 kit required)
Printer Driver: Printer driver for Windows 95/98/Me
Printer driver for Windows NT 4.0/2000
PS printer driver for Windows (optional PS3 kit required)
PS printer driver for Macintosh (optional PS3 kit required)
Compliant Host Computer: A Windows-based computer
Macintosh (optional PS3 kit required)
Option: PS-332 (PostScript3 option)
MU-401 (DIMM 64 MB)
Dimension: 200 mm (W) x 415 mm (D) x 350 mm (H)
7.9" (W) x 17" (D) x 13.8" (H)
Weight: Approx. 11 kg
Approx. 242.5 lb
Power: AC 100-120/220-240 V 50/60 Hz
Working Environment: Temperature: 10 degree °C to 30 degree °C
50 degree °F to 86 degree °F
Humidity: 20 % to 80 %RH (non-condensing)
Restrictive Conditions
· In the Printer mode, the EKC (Electric Key Counter) of the main body printer is not avail-
able.
· Although the Weekly Timer function of the main body printer is available in the Printer
mode, the power is not turned Off until the data output is finished when print data remains
in the E-RDH.
Notice: Specifications are subject to change without notice.
1-2 PRINT CONTROLLER
Chapter 1 Overview
s Product Overview
q Features of the IP-304
The Konica IP-304 (referred to as "print controller" in the following) is a print controller designed for the purpose
of making the Konica 7065/7055 copier (referred to as "main body printer" in the following) possible to be con-
nected to computers or networks and is used as a printer.
The print controller receives files from computers and translates them into graphics data for them to be printed
out using the main body printer.
The print controller can also be used as a network printer by installing an optional KN-302A network interface
card (referred to as "network interface card" in the following) into it.
This service handbook provides information about product configuration, disassembly and assembly procedures,
troubleshooting and diagnosis of print controller; its appendix describes software installation, jumper position on
the mother board, beep codes, and 25 mode, etc.
Print Controller
For use as a local printer
For use as a networked printer
Main Body Printer (Optional network interface card required)
PRINT CONTROLLER 1-3
Chapter 1 Overview
q Setup Sequence of the Main Body Printer and the Print Controller
To power up the print controller and the printer itself, you can choose either to "Power Up the Print Controller
First", or to "Power Up the Main Body Printer First".
To power up the print controller first, follow these steps:
1. Switch on power to the print controller.
The CIC (Copier Interface Card) starts which will serve as the interface to the printer itself.
The CIC tells the printer itself that the CIC is up and is waiting for the printer itself to be
switched on. In addition, the IP-304's CPU checks the system memory, and the system
program starts running.
2. Switch on power to the main body printer.
The main body printer enters printer mode after checking that the print controller is con-
nected and is powered up.
3. The link between the CIC and printer itself is established, and the CIC sends information
about settings to the printer itself.
4. When the print controller's system memory is fully checked (this takes about 2 or 3 minutes),
its OS boots up and the system software is read in.
5. When the system setting is finish, a controller icon appears in the LCD touch screen on the
operation panel of the printer itself. (If the printer mode is selected, the message "Ready to
Print" appears.)
1-4 PRINT CONTROLLER
Chapter 1 Overview
q Data Flow
Computer Application Browser HTML
Print Commands
Printer Driver
Spooler
Parallel I/F Ethernet Network I/F
( IEEE 1284 ) ( TCP/IP, IPX/SPX, AppleTalk )
Interface Nework Interface Card
( Option )
Print Controller
Parallel I/F PCI bus
Input Buffer
Hard Disk
PDL Processing ( Rasterization ) / Interpreter
Page memory
CIC ( Copier Interface Card )
Interface 8 bit parallel
Main body VIC ( Video Interface Card )
printer
E-RDH memory
Print Engine ( Print )
PDL command Rasterized image data Printer status
PRINT CONTROLLER 1-5
Chapter 1 Overview
q Expanding the Print Controller's Memory
The print controller has the base memory of 64 MB. This memory can be expanded up to 256 MB by inserting a
DIMM into a slot in the mother board.
Caution: Adding memory makes more complex print tasks possible.
Combination of additional memories
64 MB --- --- --- 64 MB
64 MB 64 MB --- --- 128 MB
64 MB 64 MB 64 MB --- 192 MB
64 MB 64 MB 64 MB 64 MB 256 MB
1-6 PRINT CONTROLLER
2
Assembly / Disassembly
Blank Page
Chapter 2 Assembly / Disassembly
s Overall Construction
Rear View
Memory DIMM
ATX Power Supply Unit
Hard Disk Drive
Host Interface Card
Power Switch
Copier Interface Card (CIC)
Floppy Disk Drive
Network Interface Card (Optional)
Reset Button
Motherboard
Front View
Tools required: Use a Phillips head screwdriver and a Long-nose pliers.
Caution: Before you go on to the disassembly/assembly process, be sure to discon-
nect the power cable. Having the equipment off is not enough.
Caution: · Before you go on to the disassembly/assembly process, check to see that all of the
cables are disconnected from the print controller.
· To prevent the hard disk from being affected, only use non-magnetized tools for the
disassembly/assembly tasks.
· Take, in advance, appropriate grounding measures by wearing a wrist strap for ex-
ample. Otherwise, there is a risk that circuit boards can be damaged.
· The disassembly/assembly tasks should be performed on cushioning materials.
PRINT CONTROLLER 2-1
Chapter 2 Assembly / Disassembly
s Disassembly/Assembly Workflow
The disassembly/assembly tasks are performed in the following sequence.
The assembly task is performed in reverse order of disassembly, unless otherwise noted.
Before going on to the disassembly/assembly of the targeted part, identify all other parts to be disassembled or
assembled.
[8] [1]
Front Cover Side Covers
[9] [2]
Fan Cards
1 CIC Card
Host
2
Interface Card
3 Network
Interface Card
[3] Power Supply
Unit
[5]
Disk Drives
[4]
Memory DIMM
1 Hard Disk
2 Floppy Disk [6]
CPU
[7]
Motherboard
2-2 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
s Disassembly/Assembly Procedures
The assembly task is performed in reverse order of disassembly, unless otherwise noted.
[1] Removing the Left and Right Side Covers
Caution: Check to make sure that the power cable is disconnected.
Caution: When connecting the power cable to the print controller:
Check to be sure that the voltage setting switch situated next to the power
cable connector is set to the correct local voltage. The wrong setting might
damage the power supply.
115
100-120V
Applicable Power Voltages Switch Setting 115
100 V - 120 V 115 V 230 220-240V
220 V - 240 V 230 V
Only the left side cover needs to be removed if you intend to remove or install the copier interface card
(CIC), the host interface card, the network interface card or the fan, and not any other parts.
Both the left and right covers need to be removed to remove or install parts other than the above ones.
(1) Remove the four screws on the rear of the print controller.
two screws
two screws
PRINT CONTROLLER 2-3
Chapter 2 Assembly / Disassembly
(2) Slightly slide the left and right side covers and remove them.
2-4 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
[2] Removing Cards
1 Removing the copier interface card (CIC)
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left side cover of the print controller. (See [1] Removing the Left and Right Side
Covers.)
(3) Remove the screw that fastens the copier interface card (CIC) to the chassis.
(4) Remove the copier interface card (CIC) by pulling it toward you.
Copier Interface Card (CIC)
one screw
Caution: Installation
When installing the card, be sure to insert it into the slot securely.
PRINT CONTROLLER 2-5
Chapter 2 Assembly / Disassembly
2 Removing the host interface card
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left side cover of the print controller. (See [1] Removing the Left and Right Side
Covers.)
(3) Remove the screw that fastens the host interface card to the chassis.
(4) Remove the host interface card by pulling it toward you.
Host Interface Card
one screw
Caution: Installation
When installing the card, be sure to insert it in the slot securely.
2-6 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
3 Removing the Network Interface Card
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left side cover of the print controller. (See [1] Removing the Left and Right Side
Covers.)
(3) Remove the screw that fastens the network interface card to the chassis.
(4) Remove the network card by pulling it toward you.
Network Interface Card
one screw
Caution: Installation
When installing the network card, be sure to insert it into the slot securely.
PRINT CONTROLLER 2-7
Chapter 2 Assembly / Disassembly
[3] Removing the Power Supply Unit
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left and right side covers. (See [1] Removing the Left and Right Side Covers.)
(3) Remove the cards. (See [2] Removing Cards.)
(4) Remove the two screws that fasten the power supply support plate C to the 5-inch bay, and
then remove the power supply support plate C.
Power Supply
Support Plate C two screws
Remove the power supply
support plate C forward.
Caution: Installation
The power supply support plate C is a
piece acting as a buffer against dropping
impact, so you need to press it in the
direction of the power source when in-
stalling it.
(5) Disconnect the cables from the power connectors on the floppy disk and the hard disk drives.
Caution: Installation
The P7 connector needs to be connected to the floppy disk drive, and the P6 connector
to the hard disk drive.
(6) Turn over the print controller itself with the upper panel down and the bottom panel up.
2-8 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
(7) Remove the two screws that fasten the earth band to the rear of the power supply unit.
PCI Slot Support Plate
Earth band to be fastened too
two screws
Power Supply Unit
Print Controller's Left-side View (Upside Down)
Caution: Removal Installation
The screws on the upper panel are used to fasten the earth band that is fastened to the
motherboard plate, and the screws on the bottom plate are used to fasten the earth
band that is fastened on the motherboard (next to the memory slot). Be careful not to
bend the terminal part of the earth bands during the work. (If the terminal part is bent,
there is a risk of fissure and of break.)
Caution: Installation
Tighten two screws so as to fasten the earth band too.
(8) Remove the four screws that fasten the power supply unit to the chassis, and then remove the
power supply unit.
four screws
Power Supply Unit
Rear of Print Controller (Upside Down) Print Controller's Left-side View (Upside Down)
PRINT CONTROLLER 2-9
Chapter 2 Assembly / Disassembly
Removal Installation
Caution: · Be sure to remove the screws on the upper panel first. If you remove the screws on
the bottom panel first, the power supply unit may slant, making it difficult to remove
the screws on the upper panel.
· At this stage, the power supply unit connector and the power supply unit of the
motherboard are not yet disconnected, so, when removing the power supply unit, do
not force it out.
(9) Remove the five screws that fasten the PCI support plate to the 3.5-inch bay at four points on
the middle section (two screws each side) and at one point on the uppermost section of the
PCI slot, and remove the PCI slot support plate.
four screws
one screw
PCI Slot Support Plate
Print Controller's Left-side View (Upside Down)
Caution: Removal
· After removing the screws at four points on the middle section of the 3.5-inch bay
(two screws each side), hold the PCI slot support plate with the hand when removing
the screw on the uppermost section of the PCI slot.
· Remove the PCI slot support plate by slanting it and pulling its end toward the PCI
from the opening in the power supply unit.
Let the end on the PCI
PCI Slot Support Plate out of the opening in the
power supply unit.
Pull toward the front and remove.
2-10 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
Caution: Installation
When installing the PCI slot support plate, install it by inserting it into the opening in the
power supply unit.
(10) Remove the three screws that fasten the power supply support plate B to the power supply
support plate A, and remove the power supply support plate B.
three screws Power Supply
Support Plate B
Earth band to be
fastened
Power Supply
Support Plate A
Print Controller's Left-side View (Upside Down)
Caution: Removal Installation
The screw on the side of the opening in the power supply unit is used to fasten the earth
band on the motherboard (next to the keyboard/mouse connector). Be careful not to
bend the terminal part of the earth band during the work. (If the terminal part is bent,
there is a risk of fissure and of break.)
Caution: Installation
Tighten the screw on the side of the opening in the power supply unit so as to fasten the
earth band too.
Power Supply Support Plate B
Remove the power supply
support plate B.
PRINT CONTROLLER 2-11
Chapter 2 Assembly / Disassembly
Caution: Installation
When installing the power supply support plate B, tighten the screw on the side of the
opening in the power supply unit before any other screws. And this while pressing the
power supply support plate A against the back and the motherboard and, at the same
time, pressing the power supply support plate B against the 5-inch bay and the forward
plate.
Power Supply Press the power supply
Support Plate A support plate A against
the back and the
motherboard.
Power Supply
Support Plate B
5-inch bay
Press the power supply support plate B against the 5-inch bay and the forward plate.
(11) Disconnect the P1 connector on the motherboard's power supply unit connector (ATX POWER
connector): the connector that is connected the power supply unit.
P1 connector
Power Supply Unit Connector on Motherboard
2-12 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
Caution: Removal
When turning over the print controller back to its normal position for the purpose of other
works after the above removal process is finish, first place it on its side with the
motherboard side down, and then raise it up to normal position. (If you place the print
controller on its side with the motherboard side up, the print controller is likely to get
unstable because the power supply support plate A may displace in the opposite direc-
tion.) If there is a compelling reason to place the print controller with the motherboard
side up, be sure to temporarily screw the power supply support plate A or hold it firmly
with the hand.
PRINT CONTROLLER 2-13
Chapter 2 Assembly / Disassembly
[4] Removing/Installing the Memory DIMM
Removal
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left and right side covers of the print controller. (See [1] Removing the Left and
Right Side Covers.)
(3) Remove the cards. (See [2] Removing Cards.)
(4) Remove the power supply unit. (See [5] Removing the Power Supply Unit.)
(5) Place the print controller on its side with the motherboard down.
Caution: Removal Installation
When placing the print controller on its side, be sure to temporarily screw the power
supply support plate A or hold it firmly with the hand to prevent the power supply support
plate A from displacing, which may cause the print controller to get unstable.
(6) If the DIMM needs to be replaced, push the levers on both sides of the socket, and push the
DIMM out and remove it from the socket straight.
Installation
(1) Hold the DIMM connector faced down.
(2) Insert the DIMM into the socket straight, and fasten it using the levers on both sides of the
socket.
Lever
Socket
Check to see that the cut-out edge is downward. Lever
Caution: Installation
· The DIMM can be inserted only in the appropriate direction. Install it so that the two
cutouts in the DIMM's lower edge fit the notches in the socket.
· When installing the power supply unit after having installed the DIMM, place the print
controller with its upper panel down and its bottom panel up. If you need to place the
print controller in normal position for the purpose of subsequent other works, tempo-
rarily screw the power supply support plate A or hold it with hand firmly.
2-14 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
Memory DIMM Installation Position
DIMM 1
DIMM 2
DIMM 3
DIMM 4
Caution: Installation
· When installing an additional DIMM, be aware that a DIMM with parity cannot coex-
ist with a DIMM without parity.
· Check to see the marks on the motherboard, DIMM 1/ DIMM 2 / DIMM 3 / DIMM 4,
and install the memory modules in this order.
PRINT CONTROLLER 2-15
Chapter 2 Assembly / Disassembly
[5] Removing the Disk Drives
1 Removing the hard disk drive
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left and right side covers. (See [1] Removing the Left and Right Side Covers.)
(3) Remove the cards. (See [2] Removing Cards.)
(4) Remove the power supply unit. (See [5] Removing the Power Supply Unit.
(5) Remove the memory. (See [4] Removing/Installing the Memory DIMM.)
(6) Either temporarily screw the power supply support plate A or hold it with the hand firmly and
place the print controller in its normal position.
(7) From the hard disk drive, disconnect the ribbon cable (the flat cable whose pin 1's lead is red).
(8) From the hard disk drive, disconnect the ribbon cable (the flat cable whose pin 1's lead is red).
Caution: Removal
When removing the hard disk unit, great care is needed so that it does not touch the
CPU and other parts on the motherboard.
Hard Disk Drive two screws
two screws
Print Controller's Left-side View (Normal Position)
Caution: Installation
When installing the hard disk unit, push it toward the front cover as far as it will go, and
fasten it there.
2-16 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
(9) Remove the four screws on the back of the hard disk unit which fasten the hard disk drive, and
remove the hard disk drive.
two screws two screws
Back of the hard disk unit
Caution: Installation
· Connect the ribbon cable in such a way that its pin 1 (red lead) is on the left, viewed
from the front of the print controller.
· When installing the hard disk drive, check to see that the jumper setting is at "Master".
Jumper
Jumper Setting of the Hard Disk
· When mounting the hard disk drive in the hard disk unit, fasten them in place while
aligning the connector side of the hard disk drive to the edge of the hard disk unit
(right side in the illustration).
Hard Disk Unit
Hard Disk
Connector Side Hard Disk's Side View
PRINT CONTROLLER 2-17
Chapter 2 Assembly / Disassembly
2 Removing the Floppy Disk Drive
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left and right side covers of the print controller. (See [1] Removing the Left and
Right Side Covers.)
(3) Remove the cards. (See [2] Removing Cards.)
(4) Remove the power supply unit. (See [5] Removing the Power Supply Unit.)
(5) Remove the memory. (See [4] Removing/Installing the Memory DIMM.)
(6) Either temporarily screw the power supply support plate A or firmly hold it with the hand, place
the print controller in its normal position.
(7) From the floppy disk drive, disconnect the ribbon cable (the flat cable whose pin 1's lead is
red).
(8) Remove the four screws that fasten the floppy disk drive to the front of the chassis, and slowly
remove the floppy disk drive.
Caution: Removal
When removing the floppy disk drive, great care is needed to prevent it from touching the
CPU and other parts on the motherboard.
two screws
Floppy Disk Drive
two screws
Print Controller's Left-side View (Normal Position)
Caution: Installation
· Connect the ribbon cable in such a way that its pin 1 (red lead) is on the right, viewed
from the front of the print controller.
· Check to see that a green LED does not light on the front panel. (It lights up solid if
the ribbon cable for floppy disk drive is connected upside down.).
· Do not fully tighten the screws unless the floppy disk drive is mounted on the chassis
and is correctly aligned to the front cover.
· When installing the floppy disk drive, insert it so that its edge flushes with the front
cover, and then fasten it there.
2-18 PRINT CONTROLLER
Setscrew locations
Chapter 2 Assembly / Disassembly
[6] Removing the CPU and the Heat Sink
(1) Disconnect the cable running out the rear of the print controller.
(2) Remove the left and right side covers of the print controller. (See [1] Removing the Left and
Right Side Covers.)
(3) Remove the cards. (See [2] Removing Cards.)
(4) Remove the power supply unit. (See [5] Removing the Power Supply Unit.)
(5) Remove the memory. (See [4] Removing/Installing the Memory DIMM.)
(6) From the motherboard, disconnect the DC cable whose other end is running out the heat sink.
DC cable connector
for CPU cooler
Heat Sink and CPU
CPU and Motherboard
(7) Peel off the glass tape attached to the flank of the heat sink and CPU.
Caution: Installation
The glass tape attached to the heat sink, about 4 cm long from the edge (DC cable side)
is for use in transportation. You don't need to replace it to the original place after com-
pleting these steps.
(8) Push down and remove heat sink bracket A that hangs on a detent in the CPU socket (left
illustration), then remove bracket B by tilting the heat sink (right illustration), and finally re-
move the heat sink by slowly lifting it up.
PRINT CONTROLLER 2-19
Chapter 2 Assembly / Disassembly
Bracket A
Bracket B
Caution: Removal Installation
When removing/installing the heat sink brackets, great care is needed so that it does not
touch the pattern on the motherboard.
Caution: Installation
Mounting the heat sink is the reverse of removing it: bracket B must be mounted before
bracket A.
(9) Lift up the lock lever of the CPU socket and take the CPU out of the socket.
Rock Lever
Caution: Installation
· When installing the CPU, be aware of the guide pin that prevents you from installing
it wrong way round.
· When changing the CPU, you need to change the heat sink too.
· When changing the CPU, it is necessary to rewrite the CMOS data. Refer to
"Appendix" in this service handbook for upgrading the CMOS data.
2-20 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
[7] Removing/Installing the Motherboard
Caution: Removal Installation
Be sure to rewrite the CMOS data after changing the motherboard. Refer to "Appendix" in
this service handbook for rewriting the CMOS data.
Removal
(1) Disconnect the cable running out the rear of the print controller, and remove the connector
cap.
(2) Remove the screw that fasten the motherboard mounting plate on the rear of the print control-
ler.
Motherboard Mounting Plate
Screw that fasten the
motherboard mounting
plate
Rear of Print Controller
(3) Remove the left and right side covers of the print controller. (See [1] Removing the Left and
Right Side Covers.)
(4) Remove the cards. (See [2] Removing Cards.)
(5) Remove the power supply unit. (See [5] Removing the Power Supply Unit.)
(6) Remove the memory. (See [4] Removing/Installing the Memory DIMM.)
(7) Remove the CPU and the heat sink. (See [6] Removing the CPU and the Heat Sink.)
(8) Disconnect and remove all of the connectors and cards that are connected to the motherboard.
(9) Either temporarily screw the power supply support plate A or firmly hold it with the hand, turn
over the print controller back to its normal position.
PRINT CONTROLLER 2-21
Chapter 2 Assembly / Disassembly
(10) Slightly slide the motherboard mounting plate toward the front cover, and pull it outward to
remove it.
Rear of Print Controller
(11) Remove the six screws that fasten the motherboard to the motherboard mounting plate, and
remove the motherboard.
Earth band to be fastened together
two screws
Earth band to be
fastened together four screws
Motherboard Mounting Plate and Motherboard
Caution: Removal
· Two of the six screws are used to fasten the earth band that is fixed to the motherboard
plate. During the work, be careful not to bend the terminal part of the earth band. (If
it is bent, there is a risk of fissure and of break.)
· Care should be taken that the earth band does not touch and short-circuit any parts
on the motherboard.
· When working on the motherboard, you should place insulation cushioning materials
beneath to prevent the pins on the back of the board from damaging and static
buildup.
Caution: Installation
Tighten two screws so as to fasten the earth band too.
2-22 PRINT CONTROLLER
Chapter 2 Assembly / Disassembly
Installation
(1) Mount a new motherboard on the motherboard mounting plate, and firmly tighten the screws.
Caution: Installation
· Be sure to fasten the earth band in place together with the motherboard. During the
work, care should be taken that the terminal part of the earth band is not bent. (If it is
bent, there is a risk of fissure and of break.)
· Care should be taken that the earth band does not touch and short-circuit any parts
on the motherboard.
· When working on the motherboard, you should place insulation cushioning materials
beneath to prevent the pins on the back of the board from damaging and static
buildup.
· Check to make sure that each of the screws is fully tightened.
(2) Mount the motherboard mounting plate in the case, and tighten it in place with screws.
Caution: Installation
When mounting the motherboard mounting plate, slide it while holding down the pin on the
mouse port.
(3) On the motherboard, mount the connectors, cards, memory, CPU, and heat sink. Compare the
jumper setting on the new motherboard to that on the old motherboard, and, if necessary,
tweak the jumper setting.
For guide in setting the jumpers, refer to Appendices of this service handbook.
Caution: Installation
Be sure to rewrite the CMOS after changing the mother board. Refer to "Appendix" in this
service ha