Engineer’s Guide to the
Intec CP2020
- 1-
Update information
First release 20th March 2009
Yield update 13th July 2010
- 2-
Contents
Page
Specifications 4
Stripdown 5
Covers
Rear Cover 5
Rear Side Cover 5
RH Side Cover 6
Cover Assembly (front) 6
PCB Cover (rear) 7
Cover Assembly (top) 7
Consumables
Drums 8
Belt 8
Fuser 8
Waste Toner Bottle 9
Printer
Eject Assembly 10
Belt Motor 11
Registration Assembly 12
Multi Purpose Tray 13
FDR Assembly 14
Waste Toner Duct Assembly 15
HV Power Supply 16
Low Voltage Power Supply 16
CU Board 17
PU Board 18
Drum, Fuser and Toner Replenishment motors 18
Tray 1 Paper Lift Motor 19
Operator Panel Assembly 20
Duplex Unit 21
LED Heads 22
Front Panel Operation 23
Print Statistics 25
Diagnostic Mode 26
Switch Scan 26
Motor and Clutch Test 30
Error Codes 31
Part Numbers 32
Consumable Part Numbers 32
Paper Feed Jam Errors 33
Cyclic Errors 33
- 3-
Specifications
Print Speed
36 pages per minute Colour / 40 pages per minute mono
Print Technology
LED
Print Resolution
600dpi x 1200dpi
Paper tray weights
MP Tray (std) 55 – 512 gsm
Tray 1 (std) 55 – 220 gsm
Tray 2 (optional) 55 – 220 gsm
Tray 3 (optional) 55 – 220 gsm
Tray 4 (optional) 55 – 220 gsm
Tray 5 (optional) 55 – 220 gsm
Consumable Life
Toner (K) 18,500 pages @ 5% coverage
Toner (CMY) 16,500 pages @ 5% coverage
Image Drum 42,000 pages @ optimal conditions
Fuser 100,000 pages
Belt 100,000 pages
Waste toner box 30,000 pages at 3 pages per job
Feed rollers
Tray 1 to 5 Around 120,000 pages
MP Tray Around 120,000 pages
NB Drum, Fuser and to a lesser extent belt lives are shortened by the use of heavy stock
Interfaces Parallel / USB 2.0 / 10/100 Base T network card
Memory
768Mb upgradeable to 1Gb max.
Options
2nd / 3rd Paper Tray
High Capacity Unit
Memory 128 / 256 / 512Mb
Wireless LAN card
Finisher
Finisher Punch unit (2 hole or 4 hole)
Firmware PU 00.05.06
CU 1.03 M
Image Drum Revision G0 H0
Toner Revision 4 / 22
Note: Toner revision is the 7th digit from the left (5) and the 2 digits
on the right (22). Do not use the 7C11.
- 4-
Stripdown
Note: Some photographs may have more parts taken off than is required as the printer was
stripped down.
Covers
Rear Cover (Gives access to the low voltage PSU)
Remove 5 screws and remove the rear cover
Rear side cover (right)
Open Top Cover
Remove 2 silver screws and remove the side rear
cover
- 5-
RH Side Cover
Remove rear cover
Remove 2 screws and unclip the 5 clips (being careful not to break them) and remove side
cover..
Cover Assembly (front)
Open Front cover. Remove waste toner box, press blue lever on RHS and lift out Remove 2
(silver) screws and slide the cover towards the right and remove.
- 6-
PCB Covers (rear)
Remove the 2 thumb screws and
remove by hinging out and lifting
vertically.
Unscrew the 2 screws and remove cover.
Cover Assembly Top
Remove screw
Remove cover to reveal another top cover screw
Remove 9 other screws and
remove top cover.
- 7-
Consumables
Drums
Open top cover
Lift Out the Drum Unit vertically complete with toner cartridge. Remove the other 3 the same
way.
Belt
Open top cover
Remove drums
Lift the 2 levers and remove the belt unit from the RH side of the machine using the blue
handle.
Fuser
Open top cover
Unlock the lock lever on the
fuser and lift out
- 8-
Waste Toner Bottle
Lift up the operator panel
Open the front cover.
Push the blue button down and pivot the waste
bottle towards the front.
Lift out.
- 9-
Printer Unit
Eject Assembly
Pivot point
Remove face up stacker, Unclip from the chassis and remove from the pivot point.
Unclip cover.
Remove the 13 pin connector and remove cabling from assembly through the hole at the rear.
- 10-
Eject Assembly (cont).
Remove 2 screws 1 on each side of the unit, unclip 2 clips
Lift out Eject Assembly
Note: On replacement, make sure that the 2 clips are inside the chassis as shown above. If
not the clips will catch on the fuser and will not allow the fuser to be removed.
Belt Motor
Open the front cover.
Remove the waste bottle.
Remove the 2 screws and connector from the motor.
Remove the motor.
- 11-
Registration Assembly
Open the front cover
Remove the waste bottle
Remove the belt motor.
Note: Remove the cover to get to
3rd connector. The cable is in a
clamp at the rear of the
assembly.
Remove the belt motor and hidden screw.
Remove 8 screws and 3 connectors.
Remove the registration assembly
Note: You will need to spread the chassis
apart slightly to remove the registration
assembly.
- 12-
Multi Purpose Tray assembly
Open top cover
Remove drums and toners
Remove belt unit
Remove cover plate
Remove 2 connectors
Open MP Tray assembly
Remove 2 screws, 1 from the LH side and 1 from the RH side.
Remove the 2 metal brackets.
Pivot the MP tray downwards and pull off from the front, then the rear.
Remove the 2 cables, disconnected previously, through the hole in the chassis, maybe fiddly,
and lift off MP Tray.
- 13-
FDR Assembly
Remove drums/toners and belt unit.
Remove the MP Tray
Remove the MP Tray lock, 5 screws.
Open side cover
Remove 1 screw
Lift out FDR assembly
- 14-
Waste Toner Duct Assembly
Open top cover
Remove drum units and belt
Remove black plastic cover. Unclip and lift out.
Remove black plastic tube guide
Remove 4 black self tapping screws (below)
Remove the motor 4 screws and 1 connector.
Use the white connector rather than the brown
one on the board.
Remove 8 silver screws and remove as 1 piece
Note a: When removing the screws in the chassis
some of the screws have black plastic protection
pieces underneath. These will land on the duplex unit
if fitted. Replace on reassembly.
Note b: When replacing the screws make sure that
they are the shorter of the silver screws as long
screws can inhibit the insertion of the duplex unit.
Note c: When replacing the assembly, make sure
that no wires are trapped.
- 15-
HV PSU
Open top cover
Remove drum units and belt unit
Remove the middle cover by unclipping and lifting out
Remove 2 screws and unclip cables around the cover. Remove the clips at the rear of the
cover and lift off.
Remove 2 screws and 4 connectors and lift out HV PSU
LV PSU
Remove rear cover.
Remove 15 screws and pull LV PSU out slightly.
Unclip switch bar from RHS
Remove 4 connectors
Remove LV PSU
- 16-
CU Board
Remove rear covers.
Remove the
network
card, 2
screws and
pull off of
the CU
board.
Remove 2 screws holding the fan bracket.
- 17-
PU Board
Remove rear covers
Remove the bracket holding the 4 LED cables (2 screws), and RFID flat cable
Remove 17 connectors and 4 screws, one in each of the corners of the board and remove the
PU board.
Drum, Fuser and Toner Replenishment Motors
Remove the CU and PU boards
Remove the fan shroud.
Remove the chassis plate, 12 screws, this then gives access to the motors. On this side of
the chassis plate there should be 17 wires to connect into the engine board.
Toner Replenishment motors x 2
Drum motors x 4
Fuser motor
- 18-
Note: the 4 drum motors only have 2
screws in them.
The wiring for the motor unplugs from
the motor board which sits underneath
the 4 drum motors. The K drum motor
sits at 90 degrees to the other 3 to give
more access to the connections on the
driver board.
The 4 drum motors are all the same so can be swapped for fault finding. The fuser motor is
different to the drum motors.
The 2 toner replenishment motors just unclip from their plastic chassis and connect to the
driver board. The drum motors plug into the driver board in the same order as they are fitted
in the chassis as the connectors are all the same also.
Tray 1 Paper Lift Motor
Remove the rear cover
Remove the low voltage PSU
This gives access to the motor.
Remove 2 screws and 1 cable and remove the motor
- 19-
Operator Panel Assembly
Open top cover
Remove drum units
Lift Basket assembly
Remove 2 screws and 3 clips and remove cover guard left
Remove 3 screws and remove cover guard front
Unclip the top of the operator panel from below giving access to the flat cable. (6 clips).
Remove the screw and the flat cable
- 20-
Remove the 2 screws holding the operator panel to the chassis
Duplex Unit
To remove the duplex unit, pull the lever
on the RH side of the duplex unit and pull
out.
- 21-
LED Heads
Unclip the LED head from the cradle by pushing down from the top and releasing the lug
Unclip the power cable from the top of the LED head
Remove the data cable from the bottom of the
LED head
Remove the LED head
Note: All 4 LED heads are the same so can be swapped for fault finding.
Note: When replacing the data cable the pins are very fine both on the LED head end and the
engine board end, do no bend as this may result in an LED head missing error.
Note: When replacing the LED head make sure that the spring on the cradle is seated in the
LED head and is straight.
- 22-
Front Panel Operation
Note: As the CP2020 relies on its HDD to boot up the machine, use the Shutdown / Restart
button to shutdown the printer then either switch off or restart using the same button.
Configuration Page
Press the “d” twice, “Print Information”, displayed
Press the “Enter” button, “Configuration” displayed
Press the “Enter” button, “Execute” displayed
Press the “Enter” button to print
- 23-
“Execute” displayed
Press the “Enter” button
ID check Pattern (Maintenance Print)
To print the ID check Pattern it first requires
Enabling within the printers Menu. To do this:
Hold down “d” “c” and “Help” buttons and
power the printer on
“System Maintenance” displayed.
“d” until “Maintenance Print Menu” highlighted
“Enter” button, “Disable” highlighted with the
“*”
“c” to highlight “Enable”
“Enter” to move the “*”
“Back” button twice to exit
To print
“d” until “Print Information” highlighted
“Enter” button
“d” to “ID Check Pattern” highlighted
“Enter” button
“Execute” displayed
“Enter” button to print
- 24-
Print Statistics
Print statistics allows you to keep a record of the pages printed through the printer so that the
user can be billed..
Print Statistics first needs to be Enabled.
How to turn Print Statistics on
“d” until “Print Statistics” displayed
“Enter” button
“Enter Password” displayed. Password is a 4 digit number.
0000 is the factory default.
“c” to display 0 “Enter” button
“c” to display 0 “Enter” button
“c” to display 0 “Enter” button
“c” to display 0 “Enter” button, Enter button
“Statistics Log” displayed “Enter” button
Enable
* Disable displayed
“c” to highlight “Enable”, “Enter button
The printer will reboot and go back to “Ready to Print” displayed on the front panel.
Note: Until the printer has printed any pages there will be no jobs logged in the Usage report.
How to print the Usage Menu
“d” to display “Print Information”
“Enter” button
“d” to display “Usage Report”
“Execute” displayed “Enter” button
“Copies *1” displayed. “c” or “d” to change no. of copies (up to 100)
“Enter” button
- 25-
Diagnostics Mode
Diagnostic Mode is mainly used for checking functionality of switches, motors, clutches and
fans
To enter Diagnostics Mode power the printer on, when the printer displays Please wait……..
hold down MENU+, MENU- and HELP buttons. System Maintenance Mode is displayed.
Press the MENU+ or MENU- button until DIAGNOSTIC MODE XX.XX.XX appears.
Note: XX.XX.XX is the PU firmware revision.
Using the “d” “c” takes you through the Diagnostics settings See following pages for Switch
Scan and the Motor and Clutch tests.
To enter switch scan use the “d” “c” until Switch Scan is displayed. See charts on page 26
Press the ENTER button.
Is displayed.
Use the “d” “c” until the switch section to be tested is displayed and press the ENTER
button.
These are the 4 switches available to be tested in the chart below.
Moving the relevant sensor arm will make the displayed switch change from H to L or L to H.
If this does not happen then the switch, wiring or board could be faulty.
- 26-
Switch Scan Chart
- 27-
Switch Scan Chart (cont)
- 28-
Switch Scan
Position of switches
- 29-
Motor and Clutch test
When in Diagnostics Mode use the “d” or “c” until Motor & Clutch Test is displayed.
Press ENTER button and the below is displayed. Pressing ENTER will drive the K drum motor
for 10 secs. If the test requires to be cancelled press the CANCEL button.
Using the “d” or “c” will move through the motors, clutches and fans. If a finisher is fitted and
powered on, motors can be driven from the printer.
Motor and Clutch Test
Position of motors, clutches and fans.
- 30-
Error Codes
Fatal Error Code Description
051 CU fan error
120 PU board fan error
122 LV PSU fan error
127 Fuser fan error
131 Yellow LED head missing
132 Magenta LED head missing
133 Cyan LED head missing
134 Black LED head missing
140 Yellow drum lift error
141 Magenta drum lift error
142 Cyan drum lift error
160 Yellow toner sensor error
161 Magenta toner sensor error
162 Cyan toner sensor error
163 Black toner sensor error
167 - 177 Fuser temperature related
220 Print statistics HDD error
230 - 231 RFID related
For Paper Jam code refer to page 33.
- 31-
Part Numbers
Boards Part Number
CU board INT42867001
PU board INT42868011
Fans
CU fan(s) INT4286201
Low voltage PSU INT43163302
High Voltage PSU INT43130502
Motors
ID motor INT 42985001
Fuser motor INT 42629401
Belt motor INT42756901
Toner Motor INT42863902
Rollers
Tray 1 rollers Feed Roller upper INT43000601 Pick Up Roller INT42699401
Feed Roller lower INT41766501
MP Tray rollers Feed Roller INT42701302 Pick Up Roller INT42954401
LED Heads INT42580201
Consumables
Ultra Heavy Fuser INT12284112
Belt INT12284212
Waste Toner Box INT12284012
Drum
C INT01233203 M INT01233202 Y INT01233201 K INT01233204
Toner
C INT43837123 M INT43837122 Y INT43837121 K INT43837124
- 32-
Paper Feed Jam Error codes
Cyclic Errors
- 33-
- 34-
- 35-
Intec Printing Solutions
Unit 11B
Dawkins Road Industrial Estate
Hamworthy
Poole
Dorset
BH15 4JP
United Kingdom
Tel: +44 (0)1202 845960
Fax: +44 (0)1202 845961 Issue 1 - 20/03/09
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