Page 3 - PREFACE; This service manual covers the HL-1060 laser printer.
PREFACE This service manual contains basic information required for after-sales service of the laser printer(here- in-after referred to as "this machine" or "the printer"). This information is vital to the servicetechnician to maintain the high printing quality and performance of the...
Page 4 - CONTENTS
i CONTENTS CHAPTER I FEATURES AND SPECIFICATIONS ..........................................I-1 1. FEATURES .........................................................................................................................I-1 2. SPECIFICATIONS .....................................................
Page 5 - ii; CHAPTER
ii 2.3 Sensors................................................................................................................................... II-19 2.3.1 Cover Sensor ............................................................................................................ II-19 2.3.2 Toner Em...
Page 6 - iii
iii CHAPTER IV MAINTENANCE AND TROUBLESHOOTING.......................... IV-1 1. INTRODUCTION .............................................................................................................. IV-1 1.1 Initial Check ...........................................................................
Page 7 - CHAPTER I FEATURES AND SPECIFICATIONS; FEATURES; This printer has the following features:; 200dpi Resolution and 10ppm Printing Speed; The dedicated printer driver and TrueType; -compatible fonts for; Printer Status Monitor with Bi-directional Parallel Interface
CHAPTER I -1 CHAPTER I FEATURES AND SPECIFICATIONS 1. FEATURES This printer has the following features: 1200dpi Resolution and 10ppm Printing Speed 600 dots per inch (dpi) with microfine toner and ten pages per minute(ppm) printing speed (A4 or Letter size paper). The printer alsosupports 1200 (H) x...
Page 9 - SPECIFICATIONS; Printing
CHAPTER I -3 2. SPECIFICATIONS 2.1 Printing Print method Electrophotography by semiconductor laser beam scanning Resolution 600 x 600dpi (for Windows/DOS)300 x 300dpi (under Apple Macintosh using optional RS-100M)1200 x 600dpi (Horizontal x Vertical)(for Windows DIB graphics) Print speed 10 page/min...
Page 10 - Electrical and Mechanical
CHAPTER I -4 2.3 Electrical and Mechanical Power source U.S.A. and Canada: AC 110 to 120V, 60Hz Europe and Australia: AC 220 to 240V, 50Hz/60Hz Power consumption Printing: 280W or less Standing by: 60W or less Sleep: 13W or less Noise Printing: 49dB A or less Standing by: 38dB A or less Temperature ...
Page 11 - Paper Specification; Feedable paper weight:; Feedable paper weight:
CHAPTER I -5 2.4 Paper Specification (1) Multi-purpose sheet feeder loading< Sheet Feeder 1 (Front)> Paper size: A4, Letter, Legal, B5, A5, A6, and Executive, and other sizes of mediathat can be handled by the feed mechanism, can be loaded. 69.8 to 229 mm 105 to 406mm (face down) Feeding direc...
Page 12 - Print Delivery; With the output tray opened; Deliver the printed face of the paper downward.; Types of paper
CHAPTER I -6 2.5 Print Delivery (1) With the output tray opened Tray capacity : Maximum 100 sheets (80g/m 2 ), face-down only (2) With the output tray closed Tray capacity : 1 sheet (80g/m 2 ), face-down only Note: Face down: Deliver the printed face of the paper downward. Environment : 23°C 2.6 Pap...
Page 13 - Effective Printing Area
CHAPTER I -7 (2) Paper feed conditions Type Name Feeder Manual feed Feeder 1 Feeder 2 60 to 80 g/m 2 { (200 sheets) { (200 sheets) { Normal paper (cut sheet) 80 g/m 2 paper (Legal) { (100 sheets) { (100 sheets) { 157 g/m 2 { (30 sheets) { (30 sheets) { Labels { (50 sheets) ✕ { Special paper (cut she...
Page 15 - SAFETY INFORMATION; The label for Japanese manufactured products
CHAPTER I -9 3. SAFETY INFORMATION 3.1 Laser Safety (110 - 120V Model only) This printer is certified as a Class 1 laser product under the US Department of Health andHuman Services (DHHS) Radiation Performance Standard according to the RadiationControl for Health and Safety Act of 1968. This means t...
Page 16 - Caution for Laser Product (Warnhinweis für Laserdrucker); Location of the laser beam window.
CHAPTER I -10 3.3 Caution for Laser Product (Warnhinweis für Laserdrucker) CAUTION: When the machine during servicing is operated with the cover open, the regulations of VBG 93 and the performance instructions for VBG 93 are valid. CAUTION: In case of any trouble with the laser unit, please replace ...
Page 17 - CHAPTER II THEORY OF OPERATION; ELECTRONICS; General Block Diagram
CHAPTER II -1 CHAPTER II THEORY OF OPERATION 1. ELECTRONICS 1.1 General Block Diagram Fig. 2.1 shows a general block diagram of the HL-1060 printer. Optional RAM(SIMM) (Max. 32Mbytes) Optional ROM (Max. 4Mbytes) Optional I/F Board ( RS-232C) Expansion Memory I/O Expansion I/O Expansion ROM I/O Paral...
Page 18 - Main PCB Block Diagram
CHAPTER II -2 1.2 Main PCB Block Diagram Fig. 2.2 shows the block diagram of the main PCB. Reset Circuit Program + Font ROM (4Mbytes) RAM (2Mbytes) Option RAM (SIMM) (Max. 32Mbytes) Optional ROM (Max. 4Mbytes) Option Serial I/O (RS232C & RS422A) EEPROM (512 x 8bits) CPU Core R3041 A S I C Oscill...
Page 20 - ASIC
CHAPTER II -4 1.3.2 ASIC The ASIC is composed of a Cell Based IC that contains the following functional blocks. (1) Oscillator circuitGenerates the main clock for the CPU by dividing the source clock frequency by two. (2) Address GeneratorGenerates the address bus by latching the AD bus with the ALE...
Page 21 - Nibble
CHAPTER II -5 (8) Parallel I/O<Data receive Mode>There are two modes in this unit. One is the CPU receive mode and the other is theDMA receive mode. In the CPU receive mode the CPU receives the command datafrom the PC, and after the CPU is switched to the DMA mode, it receives the imagedata an...
Page 24 - DRAM
CHAPTER II -8 1.3.5 DRAM Four 4Mbit DRAM (x 8bit) are used as the printer memory. Fig. 2.7
Page 25 - Optional RAM
CHAPTER II -9 1.3.6 Optional RAM A 32bit SIMM (72 pin) can be fitted as optional RAM. The main PCB has one slot and itscapacity is for SIMM from 1Mbytes to 32Mbytes. Fig. 2.8
Page 26 - EEPROM
CHAPTER II -10 1.3.7 Optional Serial I/O The interrupt of the serial I/O is input to the EXINT terminal of the ASIC, and recognized bythe CPU. A 32-byte space for a register is provided for this I/O, which is read and written toby the CPU. Fig. 2.9 1.3.8 EEPROM The EEPROM is an X24C04F two-wire type...
Page 27 - Reset Circuit
CHAPTER II -11 1.3.9 Reset Circuit The reset IC is a PST591DMT. The reset voltage is 4.2V (typ.) and the LOW period of thereset signal is 50ms (typ.). Fig. 2.11 1.3.10 Parallel I/O Fig. 2.12 shows the parallel interface circuit. Fig. 2.12
Page 29 - Paper Feed Motor Drive Circuit; A DC motor is used for paper feeding.; Driver PCB; laser, polygon motor, connector for main PCB; SW Panel PCB
CHAPTER II -13 1.3.12 Paper Feed Motor Drive Circuit A DC motor is used for paper feeding. Fig. 2.14 1.4 Driver PCB The following parts are mounted on the driver PCB.• Connectors ..................Low-voltage, high-voltage, solenoid, main motor, toner sensor, laser, polygon motor, connector for main...
Page 32 - MECHANICS; Overview of Printing Mechanism
CHAPTER II -16 2. MECHANICS 2.1 Overview of Printing Mechanism Fig. 2.17 EL PCB Main Motor Fan Motor TonerEmptySensorPCB High-VoltagePowerSupply Primary Charger (Corona Wire) Primary Charger (Grid) Developer Roller Transfer Roller Toner Empty Sensor SW Panel PCB Scanner Unit Solenoid Resist Main Cot...
Page 34 - Paper Eject
CHAPTER II -18 2.2.3 Paper Eject The completion of paper eject is detected in the following manner:(a) When the leading edge of the paper pushes down the eject sensor actuator located in the fixing unit, the photo sensor (photo interrupter) is opened and detects the start ofpaper eject.(b) When the ...
Page 35 - Detects opening and closing of the top cover.; Toner Empty Sensor
CHAPTER II -19 2.3 Sensors 2.3.1 Cover Sensor Detects opening and closing of the top cover. Fig. 2.23 2.3.2 Toner Empty Sensor Detects if there is toner in the toner cartridge. It also detects whether or not the drum unit isinstalled. (The toner cartridge is installed in the drum unit). Fig. 2.24 To...
Page 37 - Exposure Stage
CHAPTER II -21 2.5.2 Exposure Stage After the drum is positively charged, it is exposed to the light emitted from the laser unit. Fig. 2.26 The area exposed to the laser beam is the image to be printed. The surface potential of theexposed area is reduced forming the electrostatic image to be printed...
Page 40 - CHAPTER III DISASSEMBLY AND REASSEMBLY; SAFETY PRECAUTIONS; Be careful not to lose screws, washers, or other parts removed.
III-1 CHAPTER III DISASSEMBLY AND REASSEMBLY 1. SAFETY PRECAUTIONS To avoid creating secondary problems by mishandling, be careful to follow the followingprecautions during maintenance work. (1) Always turn off the power switch and unplug the power cord from the power outletbefore accessing any part...
Page 41 - DISASSEMBLY FLOW; BOTTOM
III-2 2. DISASSEMBLY FLOW DRUM UNIT MP SHEET FEEDER ASSY TOP COVER FIXING UNIT SR PCB / RELAY PCB SCANNER UNIT PAPER SUPPORT EXTENSION SUPPORT WIRE MAIN PCB ASSY BASE PLATE ASSY DRIVER PCB LOW-VOLTAGE PS PCB ASSY B B C C A A 1 3 5 7 10 11 20 UNDER SHOOT ASSY 6 OUTPUT TRAY ASSY 2 4 DRIVE UNIT MAIN MO...
Page 42 - DISASSEMBLY PROCEDURE; Drum Unit; Lift out the drum unit.; Output Tray ASSY
III-3 3. DISASSEMBLY PROCEDURE 3.1 Drum Unit (1) Open the top cover. (2) Lift out the drum unit. Fig. 3.1 3.2 Output Tray ASSY (1) Press the hinges at the left and right ends of the output tray inwards to release theoutput tray from the main cover. Fig. 3.2 Drum unit Top cover Main cover Main cover ...
Page 44 - Remove the MP feeder cover (; by using a screwdriver.
III-5 (2) Raise the pick-up roller cover ( ) and remove it ( ). (3) Remove the MP feeder cover ( ). Fig. 3.5 (4) Remove the tray side covers R and L by releasing the three hooks inside each ofthe covers as the following order. Fig. 3.6 MP feeder cover Pick-uproller cover Top side cover L Tray side c...
Page 45 - ) while pulling the side of the sheet feeder (
III-6 (5) After removing the sector gear, paper feed bearing, and bearing 6, take off thepaper pick-up roller unit. Fig. 3.7 (6) Raise the pressure plate toward you and press both sides of the pad inward torelease it by pressing the separation pad holder. Then take off the spring. Note: If it is imp...
Page 46 - MP Sheet Feeder 2 ASSY; Remove the four screws.; Under Shoot ASSY; Disconnect the two cable harnesses from the relay PCB.
III-7 3.5 MP Sheet Feeder 2 ASSY (1) Remove the four screws. (2) Disassemble any other parts of MP sheet feeder 2 in the same way as describedfor MP sheet feeder 1. Fig. 3.9 3.6 Under Shoot ASSY (1) Disconnect the two cable harnesses from the relay PCB. Fig. 3.10 Screws MP sheet feeder 2 Screw Main ...
Page 47 - Follow the number above in order when assembling.
III-8 (2) Remove the two screws. (3) Lift the rear portion of the under shoot assy to remove it. Fig. 3.11 Note: Follow the number above in order when assembling. Fig. 3.11.1 Main cover Under shoot ASSY Plate spring Feed shaft roller
Page 49 - Fixing Unit; Remove the two screws.
III-10 3.8 Fixing Unit (1) Remove the two screws. (2) Lifting the fixing unit, disconnect the two heater harnesses and the thermistorconnector on the EL PCB. Fig. 3.14 (3) Unhook the harness of the thermistor ASSY from the hook of the fixing unit. (4) Remove the screw. (5) Remove the thermistor ASSY...
Page 52 - Remove the bind B tight 3 x 10 screw securing the connector plate.; Never touch the surface of the halogen heater lamp.
III-13 Note: Follow instructions below when installing the cleaner ASSY HR.• Put the cleaner ASSY HR on the heat roller.• Rotate the hook of the cleaner ASSY HR as shown in the figure to fit it into thefixing unit frame.• Insert the cleaner lock into the fixing unit frame. , ,, ,,,, ,, ,, ,,,, ,, , ...
Page 53 - Scanner Unit; Remove the three screws.
III-14 3.9 Scanner Unit (1) Remove the three screws. (2) Lift out the scanner unit. Fig. 3.21 (3) Disconnect the three connectors from the driver PCB. (4) Remove the screw and the tape, and lift the toner sensor PCB from the scannerunit. Note: Never touch the inside of the scanner unit or the mirror...
Page 54 - Main PCB ASSY
III-15 (5) Turn the scanner unit upside down and remove the screw to release the tonersensor harness. Fig. 3.22-1 3.10 Main PCB ASSY (1) Remove the four screws. (2) Hold the hooks at left and right to pull out the main PCB ASSY. Fig. 3.23 Screw Screw Scanner unit Hook Toner sensor harness Screws Hoo...
Page 55 - Base Plate ASSY; Turn the printer upside down.
III-16 3.11 Base Plate ASSY Note: Prior to turning the printer upside-down, ensure that the drum unit has beenremoved from the printer. (1) Turn the printer upside down. (2) Remove the five M4 and four M3 self tapping screws and one screw. Fig. 3.24 (3) Lift the base plate ASSY and remove the ground...
Page 56 - Driver PCB ASSY
III-17 Note: See the Fig. 3.26 about the position installing the dumping material and thesoundproof sponge A,B. Fig. 3.26 3.12 Driver PCB ASSY (1) Remove the screw securing the driver PCB ASSY. (Slide the PCB A fromunderneath the main shield.) Fig. 3.27 Screw Driver PCB ASSY Main shield Driver PCB A...
Page 57 - Remove the screw securing the low-voltage power supply PCB ASSY.
III-18 97-P-56 (2) Disconnect the eleven connectors from the PCB. (Three connectors have alreadybeen disconnected when removing the scanner unit.) (Name of the harnesses) 1. SW panel harness 2. Scan motor harness 3. Toner harness 4. Laser harness 5. Fan motor harness 7. Main connector 8. High-voltag...
Page 58 - High-voltage Power Supply PCB ASSY; Remove the screw securing the high-voltage power supply PCB ASSY.; Fan Motor ASSY; Remove the screw securing the fan motor ASSY.
III-19 3.14 High-voltage Power Supply PCB ASSY (1) Remove the screw securing the high-voltage power supply PCB ASSY. (2) Disconnect the HV flat cable from the PCB. Fig. 3.30 Note: When reassembling, the flat side of the density dial shaft must be aligned with theflat side of the density dial plastic...
Page 59 - Remove the two screws securing the fan motor.; Drive Unit; Unhook the heater harness from the drive unit.
III-20 (3) Remove the two screws securing the fan motor. Fig. 3.32 3.16 Drive Unit (1) Unhook the heater harness from the drive unit. Fig. 3.33 SW panel PCB Fan motor holder Fan motor Screws Heater harness Drive unit Hook
Page 60 - Release the hook to remove the gear cover.; Main Motor ASSY; Remove the four screws securing the main motor ASSY.
III-21 (2) Release the hook to remove the gear cover. (3) Remove the six screws securing the drive unit. Lift the drive unit while pressingand releasing the static removal plate spring on the drive unit. Fig. 3.34 3.17 Main Motor ASSY (1) Remove the four screws securing the main motor ASSY. Fig. 3.3...
Page 61 - Gears and Solenoid; Apply grease to the points shown below.
III-22 3.18 Gears and Solenoid (1) Apply grease to the points shown below. J J A N N N F D F N K A E G G EE E G E K A B A B D C A H M L N H C A A A H A H A A E B H F M, L F Fig. 3.36
Page 62 - Follow instructions below when applying the grease.
III-23 Note: Follow instructions below when applying the grease. Sign When applying the grease Grease Application amount A Before installing the gear. Dow Corning LTD. EM-30L 1 rice-grain size B After installing the bendingwasher, and before installingthe gear. Dow Corning LTD. EM-30L 1 rice-grain s...
Page 64 - PACKING
III-25 4. PACKING Fig. 3.39 Documents Carton, SF assy Dust cover Pad Pad PE sheet Bag Pad Pad Carton
Page 65 - CHAPTER IV MAINTENANCE AND TROUBLESHOOTING; INTRODUCTION; Initial Check; Operating environment
CHAPTER IV -1 CHAPTER IV MAINTENANCE AND TROUBLESHOOTING 1. INTRODUCTION 1.1 Initial Check (1) Operating environment Check if :• The source voltage stays within ±10% from the rated voltage shown on the rating plate. • The printer is installed on a solid, level surface. • The room temperature is main...
Page 66 - Basic Procedure; CONSUMABLE PARTS; The Drum lamp is on when the drum unit is nearly at the end of its life.; Toner Cartridge; The Data and Alarm lamps blink once every five seconds.
CHAPTER IV -2 If condensation has occurred, wipe the effected units or parts with a dry cloth. If the drum unit is unpacked soon after it is moved from a cold room to a warm room,condensation may occur inside the unit, which may cause incorrect images. Instruct theuser to allow the unit to come to r...
Page 67 - Periodical Replacement Parts
CHAPTER IV -3 2.3 Periodical Replacement Parts No. Description Part No. Qty service life (number of print) Remarks 1 Fixing Unit Y (Cleaner ASSY HR) UH3308001 (UH3310001) 1 1 (100,000) 120V Fixing Unit Y (Cleaner ASSY HR) UH3309001 (UH3310001) 1 1 (100,000) 230V 2 Scanner Unit Y 1 (100,000) 3 MP she...
Page 68 - IMAGE DEFECTS; Image Defect Examples
CHAPTER IV -4 3. IMAGE DEFECTS 3.1 Image Defect Examples I-2 Dark I-1 Light I-2 Dark I-3 Completely blank I-4 All black I-5 Dirt on back of paper I-6 Black vertical streaks I-6 Black vertical streaks I-7 Black horizontal stripes I-9 White vertical streaks I-8 Black vertical streaks I-10 Faulty regis...
Page 69 - Troubleshooting Image Defects; Light
CHAPTER IV -5 3.2 Troubleshooting Image Defects The following procedures should be followed in the event of specific image defects.See subsection 3.3 for information about the location of the high-voltage contacts andgrounding contacts. I-1 Light Possible cause Step Check Result Remedy HV.GND contac...
Page 70 - Dark
CHAPTER IV -6 I-2 Dark Possible cause Step Check Result Remedy HV.GND contacts(Fig.4-5) Density dial 1 Is the density dial at the centerclick position? No Set it to the centerclick position orreasonable position. Corona failure(soiled wire) 2 Is the corona wire dirty? Yes Clean the corona wireby usi...
Page 71 - Completely blank
CHAPTER IV -7 I-3 Completely blank Possible cause Step Check Result Remedy HV.GND contacts(Fig.4-5) Developing biascontact failure 1 Are the developing biascontacts between the printerbody and drum unit dirty? Yes Clean the electrodesat both sides. i Drum unit 2 Are the drum shaft and drumelectrode ...
Page 72 - All black
CHAPTER IV -8 I-4 All black Possible cause Step Check Result Remedy HV.GND contacts(Fig.4-5) Corona failure 1 Is the corona wire of the drumunit broken? Yes Replace the drumunit. 2 Are the electric terminal springsin the printer body and theelectrode on the bottom face ofthe drum unit dirty? Yes Cle...
Page 73 - Dirt on the back of paper; Cleaning of the pressure roller
CHAPTER IV -9 I-5 Dirt on the back of paper Possible cause Step Check Result Remedy Fixing unit 1 Is the pressure roller dirty?Is any other area in the printerdirty? Yes Clean the pressure roller.(See the following note.) Dirt in the drumunit 2 Is the transfer roller dirty?is the problem solved afte...
Page 78 - Black spots; Clean the drum unit as follows:
CHAPTER IV -14 I-15 Black spots Possible cause Step Check Result Remedy Drum unit 1 Are the spots at 94mmintervals?The problem is not solved afterprinting a few pages. Yes If toner remains stuck, wipe itoff gently with a cotton swab.Replace the drum unit if theOPC drum is scratched ordeteriorated (e...
Page 79 - or paper powder on the surface toner lamp comes off.
CHAPTER IV -15 (3) Wipe the surface of the photosensitive drum with a cotton swab until the dust or paper powder on the surface toner lamp comes off. Fig. 4.4 Caution: Don't wipe the surface of the photosensitive drum with something sharp. (ball- point pen etc.) Use the cleaning liquid which is mixe...
Page 80 - The following cases raise the possibility of this problem.
CHAPTER IV -16 I-16 Black bank Possible cause Step Check Result Remedy Drum unit 1 Is the wire cleaner positioned atits home position? No Return the wire cleaner to itshome position. Yes Replace the drum unit. I-17 Gray background Possible cause Step Check Result Remedy Density dial 1 Is the problem...
Page 83 - Location of High-voltage Contacts and Grounding Contacts; Grounding contacts; Drum unit
CHAPTER IV -19 3.3 Location of High-voltage Contacts and Grounding Contacts Fig. 4.5 Fig. 4.6 Grounding contacts d Grounding wire c Drum shaft High-voltage contacts e For transfer roller Drum unit f For cleaning roller g For grid j Wire cleaner h For corona wire i For development roller k For supply...
Page 84 - Location of Feed Roller Shaft and Grounding Contacts
CHAPTER IV -20 3.4 Location of Feed Roller Shaft and Grounding Contacts Fig. 4.7 Feed shaft roller For feed roller
Page 85 - No paper The paper feed; How to make the sensors
IV-21 4. PAPER JAM Problem Type of jam Cause Temp measureJam at power on Paper stuck The paper feed sensor of paper ejectsensor is turned on. Remove the paper insidethe printer. If there is nopaper exist, checksuspected sensorsreferring to note andclear the problem. Top of paper stoppedat 20mm from ...
Page 86 - TROUBLESHOOTING MALFUNCTIONS; No AC power supplied
CHAPTER IV -22 5. TROUBLESHOOTING MALFUNCTIONS When carrying out countermeasures for malfunctions as described in this section, checkconnectors for contact failure before measuring the voltage at the specified connector pins. M-1 No AC power supplied Possible cause Step Check Result Remedy Supply vo...
Page 91 - INSPECTION MODE; Incorporated Inspection Modes
CHAPTER IV -27 6. INSPECTION MODE 6.1 Incorporated Inspection Modes The printer incorporates various inspection modes such as the factory inspection modeand the test print mode. The inspection mode varies depending on the model of the printer. This printer supports a factory inspection mode, continu...
Page 93 - Codes; * Refer to the further description of those errors as follows; HOW THE LED INDICATE AN ERROR; FUSER MALFUNCTION
CHAPTER IV -29 6.2 Error Codes In the event of a printer failure, error codes will be indicated as shown below. All the lampsand the specific lamps are turned ON alternately. The specific combination of lamps thatare ON indicates the type of the error. Type of error Data Ready Alarm Drum Feeder Fuse...
Page 94 - N B
V-1 APPENDIX 1. SERIAL NO. DESCRIPTIONS The descriptions as below shows how to read labels on each place. < ID for production month > A: January E: May J: September B: February F: June K: October C: March G: July L: November D: April H: August M: December (1) Printer .........................o...
Page 102 - NAME; FG
Appendix 9. Low-voltage Power Supply PCB Circuit Diagram (110 - 120V) Low-voltage PS Circuit (110 - 240V) NAME A B B F1 F2 Z1 Z2 C16 T1 C1 L1 L SW1 NTC1 BEA1 D12 D13 D14 D11 C5 C22 R23 R2 R5 R9 C8 PC2 R22 TRA1 R20 R21 CN2 R101 D110 Q101 R106 PC1 R104 R105 VR101 R103 C110 R102 Q2 Q1 R19 R13 R11 C9 R8...
